APMEN April 2015

3D MEASUREMENT: A MULTIFACETED ENDEAVOUR EVENT REVIEW: TIMTOS 2015 April 2015

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2015 CONTENTS 28

METAL CUTTING 26 Case Study: Quicker Returns With Smart Systems

Good toolhandling systems and planning can improve ROI on new machines. Contributed

by Erica Lee, marketing communications & Andrew Sim, engineering (machine investment), Sandvik Coromant

28

Tool Balancing

Case Study: A balanced tool can contribute to a healthy manufacturing process. By Peter and Wolfgang Klingauf, k+k-PR, for Haimer

GREAT GEAR & SYSTEM 30 Platform-Based Design For Modern CNC Applications

Machine builders are starting to face limitations with the traditional CNC control, opening the door for platform-based approach to CNC as they allow higher performance, flexibility and cost management. By David Chia, MD of Beckhoff Automation

32

CNC Case Study: A New Lease Of Life

While it is possible to extend the life cycle of production lines at an engine manufacturer with just a CNC upgrade, it requires a fair amount of thought in order to do so without interrupting production in a big way.

By Steven Schilling, GM, Num Corporation

IN DESIGN 36

3D Measurement: A Multifaceted Endeavour

32 38

Developments in multisensory 3D metrology systems promise much for businesses who are looking to maximise the potential of their equipment. By Khoo Chin Hock, product line manager at Hexagon Metrology Asia Pacific

38

Take A Quick Scan

Mobile and accurate 3D measurements play an important role in the manufacturing of complex castings. By Annick Giesen, regional marketing manager EMEA, Creaform Deutschland

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APR

2015 CONTENTS ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

40

Production Snippet: Intelligent 3D Digitalisation

Fringe projection systems are limited when different areas of the surface to be digitised exhibit stark differences in reflexive properties. A sensor takes a new approach in this regard by automatically adapting the amount of light projected based on the local reflexive properties of the measured object. By Christian Thamm & Sebastian Oberndorfner, Development 3D Digitization, Steinbichler Optotechnik

SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/ Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: nurulhuda@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION

FAST FAB 42

FEATURES 56

Asia Pacific Metalworking Equipment News spoke with Georg Scheiba, product manager (waterjet) at Bystronic to get his view on waterjet cutting technology.

Production figures are looking up after a weak 2014.

Waterjet: A Clear Cut Solution

SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

INDUSTRY Endorsements Singapore Precision Engineering and Tooling Association (SPETA)

44

60

One company swapped their plasma table for a waterjet system to improve quality and increase productivity. By Nancy Lauseng, marketing manager, Jet Edge.

Auto suppliers must improve their network optimisation efforts to balance the competing demands of cost reduction and the desire to carry out manufacturing close to the customer.

By The Boston Consulting Group

Federation of Malaysian Foundry & Engineering Industry Associations

EVENTS & EXHIBITIONS 62

Indian Machine Tool Manufacturing Association (IMTMA)

66

China Machine Tool & Tool Builders' Association (CMTBA)

68

Machine Tool Club (MTC)

Case Study: New Opportunities With New Solutions

FOCUS 46

Aerospace Focus: Measure Up To The Standard

To remain competitive, aerospace manufacturers and suppliers must effectively manage compliance to the standards that drive their business. By Andy Reese, manager, IHS

50

Supply Chain Opportunities In Aerospace Manufacturing

With rising demands in the aerospace industry come greater opportunities for aircraft part suppliers. By Scott Walker, president of Mitsui Seiki USA

52

Forming An opinion On The Aerospace Industry

Christof Merten, aerospace product manager at Schuler Pressen looks at the aerospace industry from a forming viewpoint.

6

German Machine Tool Industry Expects Higher Production Output In 2015: VDW

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asia pacific metalworking equipment news April 2015

Federation of Asian Die & Mould Associations (FADMA)

Auto Suppliers Facing A Tight Squeeze

Event Review: TIMTOS 2015 Event Preview: MetalTech 2015 Event Preview: EMO Milano 2015 Press Conference

Taiwan Association of Machinery Industry (TAMI)

70

Event Preview: Intermach & Subcon Thailand 2015

REGULARS 10 Business News 75 Product Finder 79 Exhibition Programmes 80A Product Enquiry Card

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PT. Delcam Indonesia Perkantoran Pulomas satu Gedung-1, Lt-3 Room 12A Jl.A Yani No2, JAKARTA, Indonesia Tel: (62)-21-4894964

Delcam S.E.A. Pte. Ltd. 6001 Beach Road, #18-01 Golden Mile Tower, Singapore 199589 Tel : +65 97233095 & +65 64511124

Delcam Vietnam Representative Office Office 602, 159 Dien Bien Phu, Binh Thanh Dist, Ho Chi Minh City, Vietnam Tel : +84 8 35144078

Beijing Delcam Integrated System Co., Ltd. Rm. A411, Jinyu Jiahua Building, No.9, 3rd Street , Shangdi, Haidian District, Beijing 100085, China Tel +8610 6298 5591

Delcam (Thailand) Co.,Ltd. 11 Rama II Road Soi 54 Lane 4-3, Samaedam, Bangkhuntien, Bangkok 10150, Thailand Tel: +66 2 899 1182-4 ENQUIRY NO 075

EDITOR’S NOTE Published by:

Adapt Evolve

EASTERN TRADE MEDIA PTE LTD (a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

senior editor Syed Shah

syedshah@epl.com.sg

business development manager Randy Teo randyteo@epl.com.sg

The nation of Singapore recently lost one of its chief architects who helped propel an already budding state into economic superstardom within a few decades. Yet amidst the nationwide gloom that ensued, few dared to ask the question: So what exactly did the late former Prime Minister of Singapore, Harry Lee Kuan Yew (can’t assume everybody knows who I am referring to – or should I?) do for his country?

Everybody seems to think they know exactly what his “contributions” were.

Or do they?

Look I’m sure there are wonderful contributions but I wouldn’t want to risk pointing each of them specifically because let’s say, I might do it, an “injustice”. There surely are a million takeaways from a man like him. So here’s mine – his ability to adapt and evolve. A certain someone pointed out to me recently that Harry took a certain savings idea from a predecessor party and together with his team formulated and took the concept to the next level in what is now known as the Central Provident Fund. Almost immediately, the Microsoft Windows success story comes to mind. Xerox comes up with the Graphical User Interface (GUI) but Microsoft eventually capitalised on the idea and well, long story short, made the biggest bucks out of it. Brilliant stuff on both accounts.

So can the manufacturing industry adapt to new styles and trends?

Recently I had attended a trade event – always an industry gathering of sorts. These things are always a good opportunity to get yourself up to speed about the markets or technology. Along the way, I tried to gauge where the focus for various manufacturing sectors was

8

asia pacific metalworking equipment news April 2015

turning towards. First off, ever reeling Europe was a major talking point, and although this was balanced off by trade especially in China, we look set for another slow year of growth. Then came the press conference.

The reactions latest industry standards like Industry 4.0 or 3D Printing were lukewarm, at best, to which the latter got the most flak as being still untried and “not proven to be marketable”. But then the truth is that it has been tested and is marketable across industries.

The key consideration is still the reduction in costs and achieving the greatest ROI according to the press addresses by the various machine tooling association presidents. True, there is no silver bullet for innovation that revolutionises the production process but the path has been opened with new technologies that could lead to new business opportunities and still the market on this side of the world wants to “play it safe”?

I’d like to see someone in this part of the world take the reins of technology bandwagon in Europe and North America and prove that it is alright not to play safe. That it is alright not to be original and adapt accordingly. The one who does that right could just be manufacturing’s “next big thing”.

Would Harry approve the taking of such a risk? I suppose he would, no?

Rest well Harry.

writer Michelle Cheong michellecheong@epl.com.sg

editorial assistant Sharifah Zainon

sharifah@epl.com.sg

graphic designer Jef Pimentel

jeffreypimentel@epl.com.sg

circulation executive Nurulhuda binte Suhaimi nurulhuda@epl.com.sg

assistant circulation manager Chiang Hui chianghui@epl.com.sg

contributors Erica Lee Andrew Sim Wolfgang Klingauf Peter Klingauf Steven Schilling Khoo Chin Hock Annick Giesen Christian Thamm Sebastian Oberndorfner Georg Scheiba Nancy Lauseng Andy Reese Scott Walker Christof Merten

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.

Printed in Singapore by Fabulous Printers Pte Ltd MCI (P) No. 037/06/2014 PPS 840/09/2012 (022818) ISSN 0129/5519

EASTERN HOLDINGS LTD EXECUTIVE BOARD

chairman Kenneth Tan executive director Lum Kum Kuen

etm Syed Shah Senior Editor

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Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806

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BUSINESS NEWS Thailand Set For 2015 Growth Thailand: The Bank of Thailand (BoT) has revised its economic growth projection to 3.8 percent, down 0.2 percent from four percent earlier, after the country faced slow growth in the fourth quarter last year.

According to the bank, the GDP forecast cut is based on a slower-than-expected growth in the fourth quarter of 2014, news sources in Thailand said.

The Thai economy is proje c te d to re cove r more slowly than previously assessed a s a re sult of we a ker- tha n expected domestic spending while inflationary pressure is projected to decrea se from previous forecast mainly from lower world oil prices. Major developments contributing to the MPC’s ( Monetar y Policy Committee) forecast revision include: 1. Slower-than-expected global economic recovery due to growth moderation in China and Asia, 2. L o w e r - t h a n e x p e c t e d domestic demand in Q4 2014 and January 2015, 3. More delays to government sp e ndi n g t ha n e x p e c te d, especially in public investment, and 4. Lower than expected world oil prices

I n light of t he e conomic assessment above, the MPC lowered growth projection for 2015 to 3.8 percent instead of four percent, a nd a sse ssed that risk to projection leans towa rd t he dow nside. T his comes from the possibilities of slower-than expected global economic recovery following developments in Europe and China and lower than-expected government disbursement due to limitations in implementing investment projects.

M o re ov e r, we a k p r i v a te spending, shrinking confidence of investors, slow disbursement of publ ic budget a nd slow global economic recovery are also factors contributing to the forecast cut, he said.

Besides, the central bank

also trimmed its forecast for Tha ila nd’s expor t this yea r from one percent to 0.8 percent, he s a id . Bu t he d i sm i s se d speculation that the country has entered recession.

The central bank projects that Thailand’s GDP will expand by 3.9 percent in 2016 while its export will grow at four percent.

Meanwhile, MR Pridiyathorn Devakula, deputy prime minister in charge of economic affairs, said he is still confident that the Thai economy this year will grow at four percent as targeted by the government. He also added that the government has no policy to increase the seven percent value-added tax (VAT) to 10 percent because it does not want to put more financial burden on the public.

Singapore CPI Slides Singapore: News reports have shown that Singapore's consumer prices fell in February for a fourth-consecutive month, the longest slide in more than five years, underscoring expectations that the central bank may ease monetary policy further in April.

The all-items consumer price index fell 0.3 percent in February from a year earlier, according to official government data.

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asia pacific metalworking equipment news April 2015

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BUSINESSNEWS The index has been falling on a year-on-year basis since November, pressured by sliding oil prices as well as falls in housing rents and private transport costs.

February's slide in headline CPI marked the longest decline since the second half of 2009, when headline CPI fell from a year earlier for six straight months.

Economists have stated that the most likely scenario is for the Monetary Authority of Singapore (MAS) to ease its exchange ratebased monetary policy further at its bi-annual policy review this April. This could potentially be done by re-centring the Singapore d o l l a r ’s n o m i n a l e f f e c t i v e exchange rate (NEER).

The MAS, Singapore's central bank, manages monetary policy by letting the Singapore dollar rise or fall against the currencies of its main trading partners within an undisclosed trading band based on its NEER. In January, MAS had unexpectedly reduced the slope of its policy band for the Singapore dollar in an unscheduled policy statement according to news reports.

Core inflation, which excludes car-related and accommodation costs and is the focus of monetary policy, came in at 1.3 percent year-on-year in February, higher than the market forecast of a 1.1 percent rise.

Industrial production data for February due later this week may be more crucial to the monetary policy outlook than the inflation data, said Tim Condon, head of research Asia for ING. “Because if they have to revise the growth forecast...if they deem that necessary, then I think that would be a more likely trigger of a further easing by the MAS,” Condon said.

More than 20 central banks around the world have taken advantage of cooling inflation to ease policy so far this year to boost sluggish growth.

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asia pacific metalworking equipment news April 2015

Lightweight Steel To Rival Titanium South Korea: By altering the way compounds are typically structured in an alloy of steel, researchers at the Graduate Institute of Ferrous Technology (GIFT ) at Pohang University of Science a nd Technolog y (POSTECH) in South Korea have developed new lightweight steel which has similar properties to titanium. The new steel is made from an alloy of iron, aluminium, carbon, manganese, and nickel.

P rev iou s re se a rch into lightweight steel had focused on adding aluminium to the steel alloy to reduce the steel’s density, and therefore its weight.

Unfortunately, increasing the aluminium content in steel has had a negative impact on its ductility (ability to deform under tensile stress).

To counter this problem, the research team at Pohang University led by Professor Nak Joon Kim and Han Soo Kim, uniformly dispersed nanometre-sized B2 intermetallic compounds (an amalgam of two metals with equal numbers of atoms) between and within the steel grain structure. Incorporating intermetallic compounds into steel has been tried in the past but it has typically been harmful to the structure.

However, by adding nickel and temperature-treating an alloy of iron, aluminium, manganese and carbon, the team was able to take advantage of the addition of intermetallic compounds, while at the same time increasing the ductility of the steel alloy.

The research has been carried out for the past four years with the support of the South Korean steelmaker POSCO. Pilot production runs are now scheduled to take place at the company’s Pohang Steel Mill to ensure the feasibility of the material’s full-scale production. If successful, this could potentially bring about a new era of high strength steels that will be lightweight and strong enough to produce even more fuel efficient vehicles and potentially be used in other transportation systems such as ships or aircrafts.

POSTECH professor Han Soo Kim said: “The newly developed materials can be produced using existing steel manufacturing facilities.

This means they can be applied in sectors such as shipbuilding and civil engineering where lightweight materials are an absolute necessity.”

Kennametal Recognised For Ethical Leadership Latrobe, US: Kennametal has been na med for the four th consecutive year among the World’s Most Ethical Companies by the Ethisphere Institute.

The designation recognises organisations that lead in the standards and practices of ethical

business conduct by cultivating a culture of ethics and transparency at every level, and performing to the highest standards. The cutting tool producer is one of only four companies in the machine tools and accessories category honoured this year. www.equipment-news.com

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20 - 23 May 2015 PWTC Kuala Lumpur, Malaysia Hall 4 Stand No. 4410

BUSINESSNEWS

Röhm Offers New Clamping Solutions St ut t ga r t, Ger ma ny: The significant increases in the area of renewable energy generation and the increasingly critical position against nuclear power moved the ‘Energy’ issue into the centre of all commercial and political discussions during the last few years.

This is amplified by price increases for fossil raw materials, such as crude oil and natural gas, which make it one of the most important events of the industry.

LVE Front-end Chuck Despite the new energies, the demand in these areas continues to be increasing while the production of oil and gas– among others due to the shortage of resources– is faced with ever increasing challenges.

Röhm always had a wide offering for clamping technology solutions for the crude oil and natural gas industry. The specialist for clamping technology offers all these products now in one comprehensive product program.

Application examples for the entire clamping requirements of the industry will be shown together with the new configuration of clamping products.

Different variations of the pneumatic front end chuck LVE make it possible to clamp pipes with a large diameter. As an alternative, hydraulic front end chucks HVE can be selected individually by the customer. The different centering options and the different types of drive offer a solution for each possible application.

The new series of swivel chucks is qualified for the optimum clamping of bushings. Bushings and adapters can be machined from both sides. The ring swivel chucks can produce the highest axial accuracy and at the same time they minimize the setup effort.

The clamping products for drill heads aid in all machining processes of the oil and gas industry. The special requirements in the drill head clamping area are fulfilled by special solutions.

In addition, there are also special solutions for pipe and bushing machining. For example, the stationary centre drive chucks make it possible for the conical female threads of bushings to be produced simultaneously on both sides.

Schaeffler Sees Increase In Revenue The Schaeff ler Group ha s continued along its successful course in 2014. It has generated over €12 .1 billion ( U S$13.4 billion) in revenue, representing g row th of 8. 2 percent from the prior year. Excluding the adverse impact of currency translation, the grow th rate 14

asia pacific metalworking equipment news April 2015

was 9.0 percent. The company’s Earnings Before Interest and Tax (EBIT) has increased to €1,523 million (€1,008 million), while the EBIT margin has improved to 12.6 percent (prior year: 9.0 percent). Net income amounted to €654 million.

“Our positive revenue and

Schuler Reports Strong Growth, Sets Its Sights In Asia Göppingen, Germany: The press manufacturer Schuler has recorded growth in new orders of 2.6 percent to €1.19 billion (US$1.31 billion) in its fiscal year 2014.

“We achieved significant growth in Asia, including one of the largest orders in our 175-year history.

We also received major orders in new market segments, such as equipment for the production of large pipes,” stated company’s CEO Stefan Klebert. The Asian market accounted for 34.1 percent of total new orders and was the secondlargest sales market after Europe (45.9 percent).

As part of an investment programme totalling over €90 million, the company is investing some €10 million to build a demonstration centre in Tianjin, some 150 km south-east of Beijing.

The reason behind building this centre in China is simple.

“There is growing interest in China for presses with our modern ServoDirect Technology,” stated Mr Klebert. The company says the centre will be one of eight customer centres around the world.

China plays a central role in the company’s strategy and is the source of one third of its revenues.

The company aims to serve the mid-price segment in Asia better in future “as we see huge growth potential here,” said Mr Klebert. e a r n i n gs t re nd once a ga i n demonstrates the Schaeffler Group’s great strength as an integrated global automotive and industrial supplier,” explains Klaus Rosenfeld, CEO. “By again i nc re a si n g o u r i nve s t m e nt in new technolog ie s a nd in the expansion of our global production network in 2014, we have laid the groundwork www.equipment-news.com

When microns matter Raise output, improve accuracy and lower costs Fierce competition is putting pressure on manufacturers to increase output and improve quality while reducing costs.

There are other benefits too. Machine tool probes can all but eliminate scrap and lay the foundations for higher value manufacturing.

There is a simple way to address these challenges.

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Machine tool probes automate the machine tool setting process and are up to 10 times quicker than manual methods.

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This increases the number of machines a skilled operator can oversee and frees up time for cutting metal.

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BUSINESSNEWS for future growth,” Rosenfeld continues.

W it h re ve nue g row t h o f 10 percent compared to the prior yea r (+10.7 percent at constant currency), Schaeffler’s Automotive division once again grew considerably faster than g loba l pro duc t ion volu me s of pa ssenger ca rs a nd light commercia l vehicle s. The automotive division benefited from the continuing high demand for its products, especially in the key sales markets of China and the U.S. The company’s Industrial business generated growth of 3.3 percent in 2014 (+4.2 percent at constant currency). Revenue growth was strongest in the Greater China region, where high levels of demand in the rail vehicles, renewable energy, and production machinery sectors had a particularly positive effect.

All business divisions and reg ions cont r ibute d to t he company’s growth. The Schaeffler Group experienced its highest growth rate in the Greater China region, which increa sed its revenue by 29 percent compared to the prior year, followed by the Asia/Pacific region, where revenue was up seven percent. In the Europe and America regions, revenue grew by six and five percent, respectively, compared to 2013.

The Schaeffler Group has significantly raised its capital expenditures, investing €857 m i l l i o n ( p r i o r y e a r : € 57 2 million) in new products and te c h nolo g ie s a s we l l a s i n the expansion of the group’s globa l production network .

This represents a 50 percent increase from the prior year. The company’s capex ratio (capital expenditures as a percentage of revenue) was 7.1 percent (prior year: 5.1 percent). In addition to opening its new production location in Ulyanovsk, Russia, 16

asia pacific metalworking equipment news April 2015

the group further expanded its plants in Taicang and Nanjing, both in China, as well as in Puebla, Mexico.

A s in prior years, the Schaeffler Group anticipates revenue growth of five to seven percent at constant currency in 2015. The company is forecasting

a capex ratio of six to eight percent of revenue. The group expects to once again generate a n EBI T ma rg in of 12 to 13 percent this year. The Schaeffler Group is expecting to improve its positive free cash flow for the current year compared to last year.

Airbus Celebrates Delivery Of Its 9,000th Aircraft

Hamburg, Germany: Airbus has celebrated the delivery of its 9,000th aircraft at a ceremony in Hamburg, Germany on 20th March 2015. The aircraft is the first A321 to be delivered to Vietnamese carrier VietJetAir and will join the carrier’s all-Airbus A320 Family fleet flying on its fast-growing Asia-Pacific network.

“The delivery of our 9,000th aircraft comes as we enjoy ongoing strong demand for aircraft across our product line,” said John Leahy, Airbus Chief Operating Officer, Customers.

“We are especially pleased to be delivering today’s aircraft to VietJetAir, which is a rising star in the fast-growing Asian region. With the A321, VietJetAir will be able to increase capacity on its most popular routes while benefiting from the lowest operating costs of any single aisle aircraft.”

“We are excited to be adding the A321 to our fleet today as we continue to develop our innovative value-based model in Asia-Pacific,” said Mr Luu Duc Khanh, Managing Director of VietJetAir. “Based on our proven experience, we are confident that our decision to operate an all Airbus fleet will bring us unbeatable economies of scale while offering our passengers a comfortable travel experience. It will be a great honour for us to welcome the 9,000th Airbus aircraft to its new home in sunny Vietnam.”

VietJetAir first took to the skies at the end of 2011 and now operates a fleet of 22 A320 Family aircraft on a network covering Vietnam and a growing number of destinations across Asia. The A321 delivered today is the first of seven ordered by the airline as part of a major aircraft acquisition plan for up to 100 A320 Family aircraft announced in early 2014.

The 9,000th delivery comes less than two years after Airbus reached its last milestone of 8,000 aircraft delivered in August 2013. Over the last 10 years, Airbus has doubled its deliveries to reach over 600 aircraft a year today – a figure that is set to rise further as the demand grows. www.equipment-news.com

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BUSINESSNEWS

Thai Airways To End Cargo Services And Downsize Its Aircraft Fleet

Thailand: Thai Airways is restructuring and will put an end to its freighter operations. Next week, the airline will launch its final two B747-400BCF services.

The company will also stop A340-600 services, and decommission four A330-300 aircrafts. By July, Thai Airways hopes to sell 22 of its aircrafts.

The stoppage of services and decommissioning of planes comes amidst a series of losses for the company. The Thai carrier has approximately US$5.9 billion in debts (the highest in the region) and has seen seven straight months of losses.

The company’s restructuring is being overseen by Thai Airways president Charumporn Jotikasthira. Charumporn is expected to cut capacity by 20 percent, sell non-core assets and reduce the fleet size from 101 to 77 aircraft by the end of 2015. As part of the downsizing, the company will be phasing out A340s and B747s. Plans to close routes to Moscow, Johannesburg and Madrid have also been announced.

Thai Airways has stopped and started its freight services multiple times in recent years. The carrier was the first to use a B777F in hopes of returning to freighters. Its losses are most likely partly due to the fact that air freight exports have declined. BFS (Bangkok Flight Services) stated that exports were down four percent in February year-over-year.

The decision to stop cargo services gives other competitors, like Hong Kong’s Cathay Pacific, an advantage. Cathay Pacific is investing heavily in cargo despite Thai Airways and IAG stopping their services.

Other airlines, like AF-KLM and Singapore Airlines, have decided not to re-invest.

SIA Engineering Company Pens Agreement With Airbus Singapore: Mainboard-listed SIA Engineering Company Limited (SIAEC) has announced that it has signed a Maintenance Training Services Agreement with Airbus to enter into a maintenance training collaboration leading to the appointment of SIAEC a s a n A i rbu s Ma i nte na nce Training Centre.

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asia pacific metalworking equipment news April 2015

T he co l l a b o r a t io n i s i n recognition of the company’s reputation as a leading aerospace training provider in the Asia-Pacific.

SIAEC’s Training Academy is accredited with training approvals from regulatory authorities of major jurisdictions around the world, including Singapore, Europe, Australia and China.

Under this agreement, the SIAEC Training Academy will be equipped with Airbus' latest maintenance training devices and courseware for A320, A330, A380 and A350 aircraft types. This will enable SIAEC to deliver the highest standards of engineering training to third-party airline customers and SIAEC's own technical personnel. As an Airbus Maintenance Training Centre, the Training Academy will also be able to undertake contractual training for Airbus' customers.

William Tan, Chief Executive Officer of SIAEC, said: “Driven by our commitment to service excellence, SIAEC has developed bench strength of a thousand engineers licensed to handle the latest aircraft types. As a trusted partner to our customers, it is our aim to support them with total engineering solutions, including best-in-class training services. The appointment of SIAEC’s Training Academy as an Airbus Maintenance Training Centre further strengthens our comprehensive ser v ice offerings to airlines in the region.”

Tan Kong Hwee, Deputy Director (Transport Engineering) of the Singapore Economic Development Board, adds, “We are pleased with SIAEC Training Academy’s app oi nt me nt a s a n A i rbu s Maintenance Training Centre. It is a strong endorsement of SIAEC’s ability to deliver high quality maintenance training for airlines in Asia-Pacific, and underscores Airbus’ strong commitment in the region to serve their customers’ training needs. This partnership further enhances Singapore’s status as the region’s leading aerospace aftermarket services hub.”

Didier Lux, Head of Airbus Customer Services said: “We are delighted to extend our business relationship with SIAEC, and we look forward to contributing our Training by Airbus know-how for enhanced commercial aviation maintenance and engineering proficiency throughout the region.” www.equipment-news.com

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flymojo Executes Letter Of Intent For Bombardier CSeries Airliners Malaysia: Bombardier Commercial Aircraft and flymojo have signed a Letter of Intent (LOI) for the sale and purchase of 20 CS100 aircraft with options for an additional 20 CS100 aircraft.

The announcement was made in parallel with the Malaysian government’s announcement at LIMA on a new airline, flymojo, which w ill be ba sed out of Johor Bahru, Johor and Kota Kinabalu, Sabah.

Upon execution of a firm purchase agreement, flymojo is expected to become the first customer and operator of the CS100 aircraft in the region.

Based on the list price of the CS100 aircraft, a firm order would be valued at approximately US$1.47 billion, and could increase to US$2.94 billion, should flymojo exercise all its options.

The ceremony was attended by a series of high profile politicians that included Prime Minister of Malaysia, Najib Tun Razak and the Malaysian Minister of Transport, Liow Tiong Lai. “The announcement of a new airline in Malaysia is an exciting way to kick off LIMA. With flymojo’s primary hub at Senai International Airport, Johor and secondary

hub in Kota Kinabalu, Sabah, the airline’s ultra-modern fleet of CS100 aircraft will play a key role in improving connectivity between the Peninsula and Sabah and Sarawak, as well as other parts of the region,” said Deputy Minister of Transport, Aziz Kaprawi.

“In addition, as the only airline utilising the Southern Corridor as its headquarters, flymojo will transform Senai into a key regional aviation and logistics hub - augmenting the government’s initiatives in developing Iskandar Ma laysia a nd the S outher n Corridor. Further strengthening Kota Kinabalu’s standing as a gateway into Malaysia, flymojo will also boost tourism into Sabah and Sarawak,” added Deputy Minister Aziz.

“With its strategic market footing and unique operations, flymojo is an ideal match for the all-new CS100 jetliner,” said Mike Arcamone, President, Bombardier Commercial Aircraft. “The CSeries family of aircraft will enable new airlines such as flymojo to cover markets efficiently thanks to its exceptional economics, op e rat iona l f le x ibi l it y a nd widebody comfort, coupled with an unmatched environmental and noise footprint.

“The CSeries family of aircraft’s ga me - cha ng ing technolog y, and its two models – the CS100 and CS300 jetliners – provide airlines the capability for natural progression in terms of market coverage and passenger capacity,” added Mr Arcamone.

DHL Express Invests US$102 Million In South Asia Hub

DHL

Singapore: DHL Express has unveiled the blueprint of DHL Express South Asia Hub, a 24-hour express hub facility located within Changi Airfreight Center at Singapore Changi Airport. The new facility, in line with 20

asia pacific metalworking equipment news April 2015

the company’s global investments to bolster network connectivity, will cost the company some US$102 million and this figure is the largest infrastructural amount invested by DHL. Occupying a land area of 26,200 sq m and a total floor area of 23,600 sq m, the hub features the first fully automated express parcel sorting and processing system in Singapore and South Asia. Upon completion, the facility will be able to handle a cargo throughput of more than 628 tonnes per day when at full capacity and process shipments at a speed of 14,000 shipments per hour. In comparison, the manual processing system in the current facility handles up to 225 tonnes per day at a speed of 2,400 shipments per hour. www.equipment-news.com

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BUSINESSNEWS

Volkswagen Delivers 920,700 Passenger Cars In February Germany: Deliveries by Volkswagen Passenger Cars remained stable in February. The brand handed over 413,700 vehicles last month, matching deliveries for the same month of the previous year in a difficult environment. A total of 920,700 (January-February 2014: 935,200; -1.6 percent) vehicles were therefore delivered to customers in the first two months of the year.

“The situation on world markets remains tense,” said Christian Klingler, board member for sales and marketing for the Volkswagen Group and the Volkswagen Passenger Cars brand.

In the Asia-Pacific region, the brand recorded a slight 0.5 percent rise in deliveries from January to February, handing over 475,200 vehicles to customers, of which 441,600 were delivered in China including Hong Kong.

MTA2015: Robotics Market Set To Grow Over Next Two Years

Singapore: The International Federation of Robotics states that demand for industrial robots w ill continue at a n average annual growth rate of 12 per cent between 2015 and 2017.

In Asia/Australia, robot sales are expected to increase by around an average of 16 percent per year. The automotive and e le c t ron ic s i ndu st r ie s w i l l cont i nue to se e i ncre a si n g investment in robots.

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Lim Say Leong, A ssistant Vice President, Marketing of ABB, thinks that in a new era of robotics, collaboration between humans and robots will become a reality. MTA2015 caught up with Mr Lim to learn more about future trends in automation technologies and robotics for the Asian manufacturing sector. ABB will be showcasing its robotics solutions at MTA2015.

Small parts assembly is leading the cha rge in huma n - robot collaboration, where humans and machines are starting to work right next to each other, with no need for cages and other protective equipment or barriers. Automation will become simpler and more user-friendly, such as modular plug-and-produce components that will enable people without extensive experience in robotics to programme and integrate a robot in the process.

“At ABB we believe very strongly in a ‘what you see is what you get’ programming interface, so it is possible – perhaps even expected – that visual apps as well as programming by teaching (rather than coding) will greatly enhance the ease of programming for the next generation,” said Mr Lim. The tools that allow robots to

interact with the world around them are also in development, such as advanced sensing and advanced gripping. In order to allow robots to do all the jobs that they are well suited for, they will need to develop more ‘human-like’ abilities to find, identify and manipulate objects.

When combined with powerful processing capability, tools like force control and advanced 2D and 3D vision systems will create a kind of robotic ‘independence’ and allow the robot to make ‘decisions’ about what to do when it encounters the inevitable hiccups that arise in everyday operation.

Already ABB has developed a new generation of Integrated Force Control and Integrated Vision to help make these advanced technologies available to more and more end-users.

Singapore has always set the lead for countries in Asian markets; in the recent budget announcement it was disclosed that while our wages have caught up with developed countries, our productivity had been lagging in the last three years. This exposes a stark impediment in productivity growth especially when businesses have to compete internationally.

Industries must act now to prepare themselves in integrated automation for when the economy recovers; where further automation will lead to a less labour intensive and more productive future, with less resources and time used to produce more goods at a high and consistent quality.

For manufacturers, robots not only bring productivity, but also huge reductions in energy consumption and carbon dioxide emissions. Automation lines equipped with vision systems can also operate without the need for ambient factory lighting or air-conditioning (subject to the requirements of the manufactured product itself), allowing for the possibility of 24/7 operation with substantial energy savings. www.equipment-news.com

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BUSINESSNEWS Comp a n ie s w it h a we l l established manufacturing base can also leverage on systems that can collaborate and determine solutions that minimise the cost to the business.

In Asia, companies manufacture items ranging from one-off design to large volume production of the same design. These pose great challenges for robots to be innovative, and yet robots can be productive to meet the desired return on investment.

The growing middle class in Southeast Asia and higher levels of education are producing new generations of youth who receive less job satisfaction with dirty, dangerous and dull tasks that are characteristic of some manufacturing processes.

This creates a demand for more engaging and meaningful jobs in the market, which could pose a challenge to manufacturers in the region who will need to revamp their organisation of human resources. In fact, some small medium enterprises have started employing robotic automation as a means to retain talent and even attract their next generation to inherit the business.

Faced w ith a n uncer ta in economic outlook, lower oil prices and increased market volatility, businesses have to rethink ways to add value to their products and services. Cheaper Asian countries have the competitive advantage of high volume and low cost in their production chain; players that will stand out are those who provide

customisation and cater to the individual needs of customers.

For example, product cycles in the electronics industry are getting shorter, with new models and functions being introduced at a blistering pace.

Fa st deploy me nt a nd incredible flexibility are key to meeting the demands of low volume but high mix products. In this regard, manufacturers can be flexible in switching between different products and processes with robots, rather than needing large scale production with high product volume.

By offering higher quality products coupled with fresh varieties, companies can bring a difference to the table and disrupt the market.

February 2015 Crude Steel Production

World crude steel production for the 65 countries rep or t i n g to t he World S te e l A s so c iat ion ( Worldsteel) was 128 million tonnes (Mt) in February 2015, a 0.6 percent increase compared to February 2014.

China’s crude steel production for February 2015 was estimated at 65.0 Mt and the total production for January and February 2015 in China has been confirmed at 130.5 Mt. Elsewhere in Asia, Japan produced 8.4 Mt of crude steel in February 2015, down by 0.2 percent compared to February 2014, while in South Korea it was 5.1 Mt, down by 4.4 percent compared to the previous year.

In the EU, decreases were seen in crude steel production for February 2015, when compared to February 2014. Germany produced 3.5 Mt (1.6 percent decrease), Italy produced 2.0 Mt of crude steel (9.7 24

asia pacific metalworking equipment news April 2015

Source: Worldsteel

World steel capacity utilisation ratio

Source: Worldsteel

Crude steel production

percent decrease), France produced 1.3 Mt (1.6 percent derease) and Spain produced 1.1 Mt of crude steel (4.4 percent decrease).

Turkey’s crude steel production was 2.4 Mt, down by 12.2 percent from February 2014, while Ukraine’s 1.6 Mt, down by 33.2 percent for the same month in 2014. Russia however, produced 5.7 Mt of crude steel, up by 5.6 percent from February 2014.

The US produced 6.3 Mt of crude steel in February 2015, a decrease of 7.9 percent compared to February 2014.

Brazil’s crude steel production was 2.7 Mt, up by 2.3 percent from February 2014.

The crude steel capacity utilisation ratio for the 65 countries in February 2015 was 73.4 percent, 1.7 percentage points lower than February 2014. Compared to January 2015, it is 3.8 percentage points higher. www.equipment-news.com

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METAL CUTTING Case Study:

Quicker Returns With Smart Systems Good toolholding systems and planning can improve ROI on new machines. Contributed by Erica Lee, marketing communications & Andrew Sim, engineering (machine investment), Sandvik Coromant

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asia pacific metalworking equipment news April 2015

Time taken as early as possible in the planning stage can pay dividends in terms of reducing the total cost of acquisition in terms of a smooth installation, shorter run-off period, minimum business disruption, reduced costper-component and the earliest possible payback.

If you fail to plan, you plan to fail. Good planning can reap dividends in the production stage.

Capturing The Benefits Of Smart Tooling As mentioned, smart tooling solutions can play a part in improving ROI. For instance, the Coromant Capto toolholding system is designed to rationalise the tool management process through the use of a single system for both turning and rotating tools. The toolholding system is said to provide repeatability and rigidity, facilitating the highest possible metal removal rates.

According to the manufacturer, no modifications are needed — standard tools can be used straight away. Tool changeover times are typically reduced from 10 minutes to 60 seconds, which can mean a saving of around €50,000 (US$56,590) a year on a typical CNC lathe.

Without a doubt, tooling has a big influence on ROI. For instance, while milling is demonstrably better for roughing and semifinishing operations than rival processes, even when the need for straightforward turning is required, turn-milling with an endmill or facemill may be a better solution with regard to metal removal rate.

Planning

LATE PARTNER INVOLVEMENT EARLY PARTNER INVOLVEMENT Effect

D

espite the significant investment that a new machine repre sents, the fact that a round 70 percent of machines are purchased un-tooled means that many manufacturers are still missing opportunities to reduce payback times and improve the Return-On-Investment (ROI) from their capital outlay.

Achieving the best possible ROI requires recognition that a machine purchase is only one element of a successful installation. Carefully planned machine investment strategies should encompass both capital machine purcha se a nd a detailed assessment of the best methods and tools for the chosen production task.

Indeed, in some cases e a rl y id e nt i f ic a t io n o f t he b e st appro ac h a nd to ol i n g solutions may even present the opportunity to further improve ROI through the purchase of less expensive machines than originally planned.

Run-off

Production

• HIGHER COSTS • PRICE-BASED DECISIONS

• TROUBLE-SHOOTING • UNEXPECTED COST

• THOROUGH PROCESS AND ENGINEERING ANALYSIS

• QUICKER RUN-OFF

• TECHNOLOGY COMPARISON

• HIGH COMPONENT QUALITY

• SLOWER PRODUCTION • CONSTANT “FIRE FIGHTING”

• LESS FRUSTRATION

Time

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METALCUTTING quality, unmanned operating possibilities, predictable tool life and toolholding/changing.

Proactive planning is the key to success.

Similarly, drilling is usually most efficient using an indexable insert short-hole drill. However, when there is a variation in hole sizes along with limitations to tool magazine stations or spindle power for large diameters, the flexibility of an endmill producing holes by helical interpolation may well be the best way forward.

Close Liaison Away from tooling matters, cutting tool producer Sandvik Coromant has a support service that helps manufacturers to get their investment strategy ‘right from the start’. The service, called ‘Machine Investment’ (MI), considers how OEMs, machine tool agents and tool manufacturers can all work together to deliver the best possible outcome for a given environment.

Ca lling it a step - by- step approach designed to save time, trouble and money, the service defines, both in technical and commercial terms, the end user’s needs and the new opportunities that investment can bring.

A team from the cutting tool producer is created to work closely with the customer and the machine manufacturer to ensure that these requirements www.equipment-news.com

are realistic and achieved. All key specialist players are involved at the earliest possible stage, including software, clamping and coolant suppliers.

The focus is on priorities such as production costs and output, with discussions typically involving capacity objectives, process definition, choice of machining method, component machining cost s, c ycle t ime s, to oling requirements, programming, workholding, process flexibility,

Up-Front Planning From experience, the cutting tool producer knows that if planning is not done correctly, the result will be extra costs for new tools and the loss of key people to other commitments. Also, the machine often becomes very busy very quickly and it gets hard to find the time to address issues, which in turn leads to reactive ‘fire fighting’ rather than proactive planning.

By spending a little more time and effort in the beginning, those adopting MI practices will experience less surprises and frustrations, and come out ahead in the long run.

This is about more than just equipping the machine — MI support relies on a combination of tools, tooling solutions, service a nd industr y experience to help attain higher productivity, faster throughput, more rational tool management and reduced downtime.

Got a Question? Make An Enquiry.

ENQUIRY No.

3001

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Can ‘MI’ Help You? Through MI suppor t, machine shops quickly see a new world of opportunities based on providing the power to run a new machine to its full potential. After all, custom-matched cutting for specific operations can increase cutting data by 20 percent, which can mean a 15 percent reduction in total component cost.

Of course, lower component costs are just one of many modern pressures facing the manufacturing fraternity. Others include global competition, reduced lead-times, high raw material prices and ever more complex designs and exotic materials. As a result — and regardless of the size of the company — those paying for a new machine should make sure it pays them back.

Got a Question? Make An Enquiry.

ENQUIRY No.

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April 2015 asia pacific metalworking equipment news

27

METALCUTTING up to 800 mm are quite common.

Mr Schober invested in shrink fit chucks and shrink fit machines that are easy to use and offer a very important advantage for his company, ie: the possibility of internal cooling of the tools — even if extensions are used.

“Due to the high feed rates, we require internal coolant to remove the chips from the bores. Before the introduction of shrink fit technology, this was impossible,” he explains.

Case Study:

Tool Balancing A balanced tool can contribute to a healthy manufacturing process. By Peter and Wolfgang Klingauf, k+k-PR, for Haimer.

T

hrough shrinking and balancing technolog y, Fendt, a manufacturer of agricultural machines like tractors, has increased its productivity in metal cutting production processes at its plant.

With increasing efficiency and quality an ongoing task at the plant, Werner Schober, department head in the production of housings, started converting his tool holders to shrink fit technology in 2003.

Back then, the increase of

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asia pacific metalworking equipment news April 2015

efficiency by improved runout accuracy was central. In the ma nu fac tu r i n g of t rac tors, the construction of housings is not only about some small components but about almost all elements, of which the bearing structure of the tractors are assembled, plus the transmission and rear axle housing. The often comple x ge omet r ie s of t he approximately 50,000 tons of cast parts per year often require long and slim designed tools. Lengths

Higher Feed Rates & Better Surface Quality The next leap in efficiency and quality took place in 2012. Shrink fit chucks increase the run out accuracy per se. However, the combination of tool and tool holder results in unbalance — even if every single component itself has a good balancing quality.

This has been a problem for Mr Schober, as he could hardly ever reach the suggested feed rates for his work piece material. In order to reach the required surface quality, he had to reduce spindle speeds and feed rates.

When he knew the potential of balancing, it immediately aroused his interest. “This is because we were constantly concerned with the question of how to get faster and better,” he says. Later the application of these tools made him realised that they could produce faster and achieve a higher quality with the balanced tools.

In addition to higher machining speeds, the company achieved further improvements. With new tools, better surface qualities can be achieved — despite higher feed rates up to 40 percent. As in many cases, when this high quality is not required, the tools can be used for a longer time, until the quality decreases to a value that is not acceptable. As a result, the tool life at Fendt were raised by 20 to 30 percent. Advantages www.equipment-news.com

METALCUTTING also arise regarding the costs of machines. This is because even a very small unbalance does not only damage the tool, but also puts a strain on the valuable spindles in the CNC machine. The direct drive high performance spindles in particular are more heavily loaded and have to be replaced earlier.

Problems With Unbalanced Tools Unbalance produces centrifugal forces which increase exponentially with spindle speed.

Assuming the same unbalance on a tool, a spindle running at 10,000 rpms produces a centrifugal force which is 25 times higher compared to the force at a speed of 2,000 rpms.

The resulting vibrations put a strain on the spindle bearing which can reduce the spindle life time by approximately 50 percent.

But the vibrations are not only detrimental for the spindle and the tool. They impair the entire process reliability and that is transferred to the machining results. They create chatter marks that have to be removed by additional finishing.

Due to this it is mandatory to reduce the vibrations. The machine operator can reduce spindle speeds,

Balanced tools are responsible for better processing time and quality at Fendt’s Marktoberdorf plant that produces up to 20,000 tractors

feed rates and cutting depths — but at the expense of productivity. The better alternatives are balanced tools and tool holders, as well as the deployment of balancing machines.

The Balancing Process Balancing machines may be foreign to a lot of people. From the operation standpoint, it is therefore not surprising that users tend to wonder about the amount of effort required for a balancing process. These questions can be answered by trial runs and the company did exactly that. After two months of

testing, the company acquired the Tool Dynamic 2009 Comfort Plus balancing machine.

I n addit ion to te c h n ic a l characteristics like balancing in two planes, the handling was an important argument. The operator places the tool adapter into the balancing machine and chooses the suitable specifications from the menu.

Subsequently, the program ta kes the user through the ba la ncing proce ss. A la ser marking on the tool which needs to be balanced shows where the corrections of weight through removal or addition are necessary.

The required input can take place using a touchscreen or keyboard.

As a result, balancing can be done quickly, even if employees have not worked on the machine for several days.

Normally, new tools or current tools in use that create vibrations, which indicate unbalance, are tested and balanced. Special tools are also tested and balanced.

This is testament to the focus the company has on balancing because a balanced manufacturing process is a healthy and productive one.

Got a Question? Make An Enquiry.

ENQUIRY No.

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April 2015 asia pacific metalworking equipment news

29

GREAT GEAR & SYSTEM

PlatformBased Design For Modern CNC Applications Machine builders are starting to face limitations with the traditional CNC control, opening the door for platformbased approach to CNC as they allow higher performance, flexibility and cost management. By David Chia, MD of Beckhoff Automation

C

NC control has been w ide l y u s e d i n t he manufacturing industry to cont rol va r iou s applications of machines such as welding machines, coordinate measuring machines and electronic assembly. Just like all other industries, there has been a lot of improvement in the development of CNC, making it more accurate and safer to operate. However, in the past years, the adoption of the new CNC technologies is very slow. Now, there is a changing trend in the adoption of CNC due to the availability of open-source technologies, resulting in the proliferation of CNC machines at home or small industries.

As a result, machine makers need to continuously look for ways to keep costs down and to increase productivity at the same time. And with the dawn of technology such as the smartphones that place an importance in user-friendly interaction, machine builders also

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increasingly demand that the machines to be easy to learn and easy to operate. With advances in technology of machining tools, CNC machine makers are also demanded to keep up in order to accommodate more complex applications.

Platform-Based Approach To CNC Let’s start by drawing a parallel between this to what we saw in the commercial smartphone world.

In the past, we have Symbian OS running on exclusively Nokia mobile phones and this was a stable and well-liked product. However this creates inconvenience if and when one user wishes to move to another brand.

Today, we have Android OS (open-source) and iOS (closesource) dominating the smartphone world. Individually they are two separate platforms where Apps can be designed, developed and deployed. This platform-based

approach in the commercial world leads to the unlimited possibilities of realisable functions on a smartphone vs a phone of yesteryears where phone calls are about the only capability.

For the industrial world, this same platform-based approach can be taken though I am not suggesting we can be taking a smartphone and running a CNC application on it. By platform-based, we are looking at standard Windows OS running on an Intel-based PC, or the famous Wintel combination since the 1980s. In the broad sense, this can mean any variants of Windows OS running on either x86/x64 or even ARM-based architecture.

O n t h is com mon W i ntel combination, we can select the type of Windows OS and the type of CPU processors, and we also benefit whenever Intel introduces better, faster and often cheaper processors. This effectively enables us to choose and decide a costeffective hardware/OS setup depending on the complexity of the machine. On top of this Wintel architecture, we will add an industrial software layer to achieve the real-time control and fieldbus communication capability. This completes our platform, and the rest is just about the Apps.

From a design perspective, such platform-based approach to CNC or in a broader sense machine building allows higher performance, flexibility and cost management. From an operations and maintenance standpoint, Apps does not go obsolete unlike proprieta r y ha rdwa re. This protects the long-term capital investment and reduces the operational expenses.

Improving Efficiency, Allowing Retrofitting It is said that through the use of EtherCAT and Beckhoff TwinCAT on a software-based CNC control solution, one Chinese turret pu nc h pre s s ma nu fac t u re r www.equipment-news.com

GREATGEAR&SYSTEM CNC control for execution, is implemented and running on a single Intel Celeron-based C6920 Industrial PC. New Industry 4.0 Concepts For CNC Industry 4.0 is an Industry Initiative in Germany, and along with other buzzwords like Internet-of-Things (IoT), Big Data, Cloud, etc, we are at the beginning of a very exciting phase for the industry. Just as I mention earlier regarding the limitation of conventional CNC control and increased cost pressure by alternatives and open-source substitutes, a new approach is definitely needed.

Interestingly, Industry 4.0 is anticipating the revolutionary changes that will propel our general industries forward for decades to come, so what can we actually do?

On the machine itself, have

you considered to use a dynamic dashboard instead of the fixed rotary knobs and dials? How about having a multi-touch display changing according to the exact functions that the operator is using? Such technology is already adopted in the higher-end automotive models.

IoT talks about the intelligence down to the level of machines but it goes beyond Machine-toMachine communication. If the machine has a Tweeter account and is able to tweet its status, then it makes it easy for a maintenance engineer or even another machine to follows its status by simply subscribing to its tweets. There are a lot of possibilities, and now is the time to relook convention CNC control. I am quite sure by the end of this decade, CNC control will look vastly different.

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managed to achieve a 20 percent performance improvement over their previous solution.

In this particular example, a ll automation functions in the combined punching and laser cutting line as well as in the equipment for loading and unloading material can be run on one computer. As a result, both the hardware and space requirements as well as system costs are reduced.

One US-headquartered waterjet cutting machine manufacturer equipped a PC-based controller that can cut complex, 3D components precisely and repeatedly onto its five-axis waterjet system. The openness of the PC-based control platform allows the company to retain their existing motors and drive components running on SERCOS II. The complete machine control, including HMI and PLC functions as well as the complex

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GREATGEAR&SYSTEM

CNC System Case Study:

A New Lease Of Life

While it is possible to extend the life cycle of production lines at an engine manufacturer with just a CNC upgrade, it requires a fair amount of thought in order to do so without interrupting production in a big way. By Steven Schilling, GM, Num Corporation

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art of the Fiat Chrysler group, Fiat Powertrain operates manufacturing pla nt s at st rateg ic locations around the world, including four in South America.

Its Campo Largo plant on the outskirts of the Brazilian city of Curitiba currently produces about 230,000 engines a year.

The plant makes extensive use of multi-axis CNC transfer machines, machining centres and specialist machine tools throughout its manufacturing operations. In total, the plant’s crankshaft and cylinder block production lines are equipped

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with 20 key CNC machines, involving more than 120 feed axes.

Minimising Disruptions As the CNC systems aged, Fiat Powertrain became increasingly concerned with the likelihood of increased downtime.

Troubleshooting and sourcing spare parts, as well as performing general machine maintenance, was threatening to take too long and impact production throughput.

Since mecha nica lly the machines were perfectly serviceable, the company took the strategic decision to extend the

life cycle of the production lines by upgrading all 20 machines with modern CNC controllers, drives and motors.

A f te r re v ie w i n g v a r io u s CNC manufacturers’ products a nd ser v ice s, t he compa ny conclude d t hat Nu m ha s a suitable upgrade solution for the plant because it is the CNC OEM for the current machines and was able to provide a fasterto-implement solution with the best benefit/cost ratio.

A s Ta rc i si o C r u z F i l h o, technical support manager at the plant, explains: “The fact that we are upgrading machines used for everyday production imposes some very demanding conditions.

The systems themselves had to provide exactly the same level of functionality as our existing CNC equipment.”

A key requirement of the replacement CNC systems was that they needed to be engineered in such a manner that the upgrade cou ld b e acco mpl i she d a s quickly as possible to minimise manufacturing disruption. In the end, the team established that Num’s Axium CNC platform prov ided the lea st inva sive www.equipment-news.com

One grease. All business.

There are two ways you can look at greases: as something that keeps your machines running — or your business going.

With Mobilith SHCTM superb-performance multipurpose greases, it would have to be the second. Designed to stay on the job longer than conventional greases in severe conditions and perform in a wide temperature range of applications — in a broad variety of machinery and components — Mobilith SHC helps extend machine life and provide protection of your capital investment. And, as the only grease you’ll need, it can help reduce maintenance and inventory costs.

All of which adds up to one thing: productivity that sticks.

Mobil SHC products are endorsed for use in over 5,800 applications by more than 1,100 major equipment builders around the world. They’re backed by state-of-the-art services and technical support. And they’re reason enough to rethink the role lubricants play in your operation. Don’t just make it run. Make it fly. For more on Mobilith SHC and other Mobil-branded greases, go to mobilindustrial.com.

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A key requirement of the replacement CNC systems was that they needed to be engineered in such a manner that the upgrade could be accomplished as quickly as possible.

Prior to upgrade, each machine controller was based on Num’s earlier-generation 1050 series CNC.

upg rading solut ion for t he machines, by using the same a rchite ctu re a s t he e a rlier generation 1050 series CNC to keep wiring and software modifications to a minimum.

Speed Is Key As part of the CNC upgrade process, the servo drives on each machine are being replaced by models from the company’s NumDrive C range, which is said to simplify installation by removing the need for complex rack cooling arrangements.

The upgrade program also calls for the motors on all the feed axes of the machines to be replaced.

Originally, these were fitted with Num BMH series brushless

servomotors, which are medium inertia designs that were popular with machine tool designers for diverse positioning applications.

However, they have now been superseded by the company’s BPH series motors, which provide enha nced performa nce a nd environmental protection.

The motors have physically ide nt ic a l sha f t e nd s, pi lot diameters and flange squares a s t he i r e a rl ie r- ge ne rat ion counterparts and the orientation of t heir p ower a nd se n sor connectors can be altered during installation to suit the machine configuration. The CNC system developer also provides short adapter cables so that the existing motor wiring does not need to be

Carrying out upgrading work in a fully operational plant requires a little bit more consideration to ensure disruptions are kept to the minimum.

changed, which saves a significant amount of time.

Mr Filho points out that speed of upgrade is vital to Fiat Powertrain’s production schedules. “We allowed for a maximum of four days out-ofservice time for each CNC machine on our crankshaft and cylinder block production lines. Most of the machines on these lines have now been upgraded and in each case — even on complex machines with seven controlled axes plus spindles — it has taken less time than we allocated, which says much for the CNC design and planning.

“The machines’ diagnostics are now better, allowing us to perform more efficient preventative maintenance, and our technicians are now familiar with the CNC systems, all of which will help reduce production downtime in the future.”

While the quality of t he replace me nt sy ste m is obviously important, carrying out upgrading work in a fully operational plant requires a little bit more consideration to ensure disruptions are kept to the minimum. By picking a system that is similar to the previous one, the plant operators have done themselves a massive favour.

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INDESIGN 3D Measurement:

A Multifaceted Endeavour

Developments in multisensor 3D metrology systems promise much for businesses who are looking to maximise the potential of their equipment. By Khoo Chin Hock, product line manager at Hexagon Metrology Asia Pacific

S

electing any kind of equipment for a metalworking factory environment is a balancing act, and metrology systems are no different. There is no shortage of technology out there — in fact there is an almost bewildering choice. When researching options to measure a particular part, buyers may be faced with several different inspection methods, all with their own merits and drawbacks, and that is before they have even begun to think about which supplier to go with.

Usually, a quality inspection system will be chosen based fundamentally on what needs

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to be measured, accounting for the workpiece size, the type of application, the tolerances or accuracy levels required and the throughput speed. But there is always a degree of compromise.

For example, the most accurate way to measure is perhaps not likely to be the quickest, so you might give up a little on tolerance to gain something in speed. Of course, the ideal scenario would be to have the best of everything, and while this is unlikely to happen overnight, metrology manufacturers are now offering increasingly flexible multisensor measurement equipment that has the potential to help ease the decision-making process.

New Sensors The concept of using more than one probe type on a single Coordinate Measuring Machine (CMM) is not new. In fact, systems combining tactile and non-contact probes have been around since the 1980s. Early versions were not particularly successful as the software and controllers struggled to match the potential of the hardware, diminishing some of the advantages gained by the presence of both probes.

However, progression in these technologies mean that many CMMs today can be fitted with a number of different types of sensor — and it is not unusual for companies to utilise this option by using an automatic probe changer.

Progress does not stop there of course. In recent years, there has been an explosion of new types of sensors for CMMs, and this is where true multisensor systems — CMMs with more than one inspection method physically integrated within the system — come into their own.

Specialised software and machine controllers enable seamless switches between the sensors so that all the available methods can be reconciled within a single inspection program leveraging the relative advantages of each type of sensor collaboratively on a complicated part.

Typically, the multisensor CMM has been heavily associated with 2D vision sensors, but in fact you can now equip this sort of machine with a whole metrology arsenal to give a complete 2D and 3D measurement setup: • Touch trigger sensor: Perhaps the most commonly used type of probe, a touch-trigger sensor returns a single measurement point on contact with the part • Analogue scanning sensor: Offers a tactile scanning option, returning multiple measurement www.equipment-news.com

INDESIGN points from the surface of a part by moving the probe tip over the surface • Vision sensor: Image-processing non-contact probe which uses the pixels in a camera image to measure multiple points simultaneously at high speed • Chromatic white light sensor: A non-contact sensor that uses focused white light to return a highly-precise measurement point even on reflective or lightabsorbing surfaces • Laser point sensor: Laser-based sensor that returns single data points without physical contact with the part • Laser line sensor: Returns multiple data points using a laser line sweep across the surface of the part Measurement For The Future So what advantage is to be gained by combining sensors to measure a single part? At the most basic level, two or more sensors can be used within one program to inspect different areas of the workpiece.

Low density data can be taken by a touch-trigger probe in areas where simple geometry is sufficient, while higher-density data like that offered by laser scanning can be employed where more detailed knowledge of form is necessary. But in contrast, sometimes the solution to a problem can be more complex.

For example, if a manufacturer wants to take high-density scan data of the contours of a surface with very high accuracy, very quickly and maintain 100 percent inspection, simply combining two inspection methods within the program would not achieve the desired outcome.

Analogue scanning would offer the accuracy but not the speed, while laser scanning would offer the speed but not the accuracy. In www.equipment-news.com

The predicted growth of electronics manufacturing and the subsequent diversification of other supplier industries look set to accelerate the growth of multifaceted measurement technique.

this case it might be necessary to operate the sensors in sequence.

The laser probe could be used to scan the volume of parts required at the speed required against some specified limits. If the data gathered indicated that there may be a problem, the system could be programmed to automatically switch to the analogue probe for more detailed analysis.

As the sensors, controllers and software have moved on, so has the CMM hardware itself. In the past, the flexibility offered by these sensors has been at the expense of some level of part accessibility — the cluster of sensors making part programming more difficult for the operator and increasing the risk of collision. But now, manufacturers are catching up and really working on technologies to better integrate the multisensor capabilities.

For example, Hexagon Metrology has introduced the Dual-Z concept to its Optiv Performance and Optiv Reference line machines, so that the different sensors can be mounted on completely independent Z-axes. The idea is to minimise the impingement of any sensor that is not in use on the measurement volume of the machine, ensuring optimum part accessibility and allowing the full potential of the different sensors to be realised.

Also introduced recently is the through-the-lens laser sensor, which combines a vision sensor with a laser on the same optical path to enable easy shifting between the

measurement methods while also saving space on the machine.

Globally, mature multisensor systems have found a niche in the medical equipment sector, where the non-contact measurement options are particularly attractive to the manufacturers of small, fragile and sterile workpieces.

However, t he i ncre a si n g sensor options have seen their app e a l w ide n a nd de ma nd from the booming consumer electronics industry has also helped to drive adoption. Part of the reason for this demand is the fact that vision sensors are ideally suited to measuring microelectronic components like printed circuit boards.

However, supporting industries will also face new metrology challenges as supply chains extend — for example the metalworking industry might face demand to produce the micromachined LED moulds that enable the tiny electronic diodes to be cast.

So while adoption rates for multisensor systems in the APAC region have yet to catch up with those of Europe or the US, the predicted growth of electronics manufacturing in over the next few years and the subsequent diversification of other supplier industries look set to accelerate the growth of this multifaceted measurement technique in this part of the world.

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INDESIGN

Take A

Quick Scan

Mobile and accurate 3D measurements play an important role in the manufacturing of complex castings. By Annick Giesen, regional marketing manager EMEA, Creaform Deutschland

B

enninger Guss develops protot y pe s and manufactures replacement parts with the digital production of castings.

The company has been using a portable 3D scanner with a posttreatment software to carry out quality control and to reverse engineer castings and sand cores since March 2013.

In addition, the company has been producing sand moulds with a 3D printer for the casting work of prototypes, replacement pa r ts a nd seria l pa r ts w ith specific geometrical shapes.

The 3D printer and the 3D portable scanner are important elements in t he compa ny’s manufacturing chain. While the attributes of 3D printing is widely known, it is important to quantify the usage of portable 3D scanning technology in the company.

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Accuracy, maximum flexibility in handling, the ability to scan in the production environment while moving, the fast starting up of the system as well as the possibility to measure different component sizes were all crucial reasons for the investment in the portable scanner.

Finding The Right Mix When manufacturing components that require casting, being able to carry out a casting simulation in real time is mandatory. The production of such a replacement part must be successful on the first attempt otherwise the part would not be tenable due to costs and time delays.

Martin Jans, team leader of Technical Model Assembly and DGP (Digital Production of Castings) at Benninger Guss, explains: “For the application

mentioned above there is, in our view, no suitable alternative available on the market that meets our requirements. It is the purchase of a 3D scanner together with a 3D printer for sand casting that has made it possible for us to generate more turnovers in the replacement parts business.”

After all, when dealing with some complex components, it is almost impossible to obtain exact results from conventional measuring tools. Inspection is only possible with modern scanning technology, which can be used to validate potential geometric and dimensional deviation between the manufactured component and the original documentation.

Moreover, when the original documentation of parts that need to be reproduced using casting is not available, scanning technology can also be used to recreate 3D CAD models based on the existing parts.

With these attributes, Mr Jans says: “The advantage is quite obvious. Now we can handle tasks which we would not have been able to carry out before faster.

As we inevitably have to work very closely with the customer when making replacement parts, an outsourcing solution was not advantageous.”

3D Technology: Mobile & Accurate 3D Measurements I nspe ct ions in ca st ing a nd forging require the acquisition of dimensions on parts of various shapes and complexity that are potentially performed in any kind of environment. Due to its portability and versatility, the portable 3D scanner can perform the acquisition of any part not only directly at the foundry, but also at the customer’s premises, on the production floor or at the supplier’s location.

Qua lit y inspectors or o p e r a to r s u su a l l y n e e d to perform quality control of the www.equipment-news.com

INDESIGN

Compared to traditional measurement methods, the scanning solution helps save a considerable amount of time.

scanner delivers complete and accurate mesh file (.stl format) regardless of environmental conditions (eg: instabilities, vibrations, heat differences or suboptimal user skill).

Compa re d to t radit iona l me a surement methods, the scanning solution helps save a

considerable amount of time. The scanned data is documented in real time and is reproduced easily, more so than data resulting from visual inspection and manual testing devices.

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physical part themselves using its corresponding digital model.

Because of that, acquisition data must be accurate a nd the 3D model must include all the information needed for a complete inspection.

In casting and forging, raw parts are usually machined in particularly critical areas to obtain the final part. To make sure that the raw casting holds enough material to be machined, it is possible to carry out dimensional inspections. A 3D scan allows operators to align the raw part on the machine and orient it so as to guarantee enough material for the operation. Moreover, time and money are saved because unqualified casting and forged parts will not be machined.

With the integrated TRUaccuracy technology, the portable and self-positioning 3D

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INDESIGN

Production Snippet:

Intelligent 3D Digitisation Fringe projection systems are limited when different areas of the surface to be digitised exhibit stark differences in reflexive properties. A sensor takes a new approach in this regard by automatically adapting the amount of light projected based on the local reflexive properties of the measured object. By Christian Thamm & Sebastian Oberndorfner, Development 3D Digitization, Steinbichler Optotechnik

C

ompared with conventional coordinate measurement methods, fringe projection systems have certain advantages. Instead of tactile scanning of a few selected points, these systems allow contact-free, full-surface measurement of complex object surfaces with high point densities.

Once the measurement data have been acquired and saved, features previously not taken into account can be evaluated sub se que nt ly, a l low i n g for retrospective evaluation of the production process. Moreover, due to their compact size and

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light weight, the sensors can be transported and used in a variety of applications. Typical applications include quality control, reverse engineering and the design process, for instance.

Limitations Of Fringe Projection Systems Successful measurement with all fringe projection systems has previously hinged on an adequately diffuse reflexion of the projected light onto the surface to be digitised. This is due to the fact, amongst others, that directional reflexions result in excessive outshining or undercut effects of

the fringe pattern in the camera image, which in turn prevents measured data being generated in the appropriate places.

As a result, when digitising shiny objects, users are frequently obliged to prepare the object surface in advance with chalk spray in order to ensure a diffuse reflexion of the fringe pattern. But because this type of pretreatment of the object always entails extra work and in many cases is undesired by the user, the only remaining option is the addition of further measurements with modified exposure times. This increases the total measurement time, making it more difficult to use fringe projection systems particularly in industrial applications.

An Intelligent Response An Intelligent Light Control (ILC) technology found in a sensor, which adapts the intensity of the projected light to the reflexive properties at specific points, irrespective of the camera exposure, is said to be able to meet this challenge.

This is possible because the projection display allows pixellated modulation of the light intensity. Since the amount of detected light depends in particular on the orientation www.equipment-news.com

INDESIGN Fringe pattern on a sheet metal panel. Outshining camera pixels are coloured red.

Fringe pattern on a sheet metal panel with activated Intelligent Light Control. The camera pixels are homogeneously balanced.

of the camera with respect to the measured object and the projector unit, such a method can only be used with a singlecamera system.

Each time a measurement begins, a brief series of different brightness is first projected onto the object area to be digitised in order to determine the ideal projection intensity individually for each camera pixel.

A correspondence search also determines which part of the projection display is illuminating t he por tion of object surface observed by the respective camera pixel. This enables measurements with locally adapted light intensity a nd e n su re s homo ge ne ou s lighting of the measured object, ensuring optimal utilisation of the camera’s dynamic range.

For automated applications with a repeated accuracy of sensor positioning, through the use of an industrial robot for example, the defined correspondences and intensities can also be saved once and retrieved each time t he me a su re me nt pro g ra m commences, helping further decrease measurement times.

Shiny measured objects such a s unmachined sheet meta l panels, whose surface primarily reflects incidental light in a directed manner, previously placed high demands on fringe projecting systems. With the ILC found in the sensor of the Comet 6 fringe projection system, the system is capable of digitising such shiny measure objects more efficiently.

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FAST FAB

Waterjet:

A Clear Cut

Solution Asia Pacific Metalworking Equipment News spoke with Georg Scheiba, product manager (waterjet) at Bystronic to get his view on waterjet cutting technology.

APMEN: In your opinion, what are the main advantages of waterjet cutting?

Georg Scheiba (GS): A waterjet cutting machine can cut virtually any material from ceramics, high-strength special alloys and armoured glass. In addition, foam, rubber, and composite materials can be cut with high process reliability.

Waterjet cutting is a suitable manufacturing technology in many sectors. For example, it is suitable in the aerospace and automobile industries, plant engineering, food industry, glass manufacturing and medical technology.

The most important benefits of the technology are: • E fficienc y — because t he user can choose from a wide spectrum of quality levels (from separation cuts right through to quality cuts) • T he cut t i n g je t t ra n sfers virtually no heat to the material • No structural changes within the material, ie: no strain hardening and micro-cracks 42

asia pacific metalworking equipment news April 2015

• High degree of processing precision and surface quality on the cutting edge • Best material utilisation due to small cutting clearance • G o o d e n v i r o n m e n t a l compatibility and a high degree of work safety (the cutting process does not release toxic pollutants) APMEN: Bystronic launched the ByJet Flex last year and the main feature is the ability to cater for 2D and 3D cutting.

Is this modularity the future for waterjet cutting machines?

What other technical trends do you expect to see in the future?

G S: In the field of water jet cutting, we a re obser v ing a trend amongst our customers worldw ide towa rds f le x ible machine systems. T he se systems can be upgraded at any time using variable modules and various additional features in order to meet indiv idua l requirements.

W it h t he B yJ e t F le x , we have de ve lop e d a mo du la r

machine platform that enables us to realise this trend in an uncompromising manner.

For example, the basic version of the machine can be equipped with up to two exchangeable 2D cutting heads. And if someday the user requires 3D cutting capabilities, the machine can simply be expanded with 3D cutting heads. This is a clear added value for the customer, because he has a machine that offers two technologies.

An additional trend is towards large machines between 6 and 10 m in length. These machine sizes allow entire shifts to be operated unmanned, because sufficient work can be prepared for a complete shift.

The ByJet Flex also allows our customers to implement this trend, because the machine is based on a modular water ba sin system. T his enable s the machine’s cutting range to be extended according to requirements from 2 by 3 m up to a maximum of 10 by 3 m.

APMEN: Do you feel the pressure pumps used www.equipment-news.com

FASTFAB

A modern waterjet cutting machine will be able to be extended according to prevailing requirements

over the next few years, we will continue to optimise the reliability of the high-pressure technology. We do not believe that ma ximum operating pressures will increase further.

APMEN: Some common limitations of waterjet cutting are cost and material

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in waterjet cutting is a significant area that R&D will look at and why?

GS: The high-pressure pump is the heart of the machine, but it is also the component that is exposed to the greatest stress.

Our pump systems deliver a good level of quality, a fact that our customers confirm. However,

thickness (ability to hold good accuracy when cutting thicker materials). Do you agree?

GS: A counter-question: What other cutting technology allows a 200 mm thick titanium block to be cut with the precision of a waterjet cutting machine? The manufacturing costs of waterjet cutting are very much dependent on the cutting precision.

Compared with laser cutting, a waterjet cutting machine can represent a genuine alternative already with production cuts (coarser than quality cuts) in 8 mm aluminium. With other materials, such as high-strength steels, waterjet cutting frequently offers cost benefits, because it eliminates the need for costly reworking of the cut edge.

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FASTFAB satisfied with the edge quality and easy assembly of its finished parts. With the waterjet we’re able to move from raw material to finished parts in as little time as possible while improving our products’ quality and precision.”

Case Study:

New Opportunities

With New Solutions

One company swapped their plasma table for a waterjet system to improve quality and increase productivity.

By Nancy Lauseng, marketing manager, Jet Edge

A

t one point, AndersonCra ne Compa ny wa s so busy it had to turn down work. The material handling equipment manufacturer and a job shop operator had to find a way to increase productivity, and it had to find it fast. They eventually decided to swap out its labourintensive plasma cutting table for a precision waterjet, which promised cleaner parts and the ability to cut virtually any material and thickness.

The system has made an impact on Anderson- Crane’s productiv ity, sa id compa ny spokesman Rob Crane, who noted that parts are finished 20 percent faster with the waterjet machine versus the plasma because the waterjet leaves a burr-free edge and no heat-affected zone or slag,

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eliminating the need for timeconsuming finishing operations prior to welding. This has freed the company’s skilled employees from hours of grinding parts so they can concentrate on more important and challenging tasks, primarily welding. “ We b o u g h t a w a t e r j e t specifically for its clean cut,” Mr Crane said. “We have a very high demand for quality and we were spending a lot of time cleaning parts that came off our plasma.

Our goal was to reduce rework and part cleaning time. We wanted a system that cuts parts with little or no edge cleanup required.

“A laser proved too costly and a waterjet allowed us to cut metal (our main working material), but also softer material such as gaskets. We had been outsourcing waterjet cutting and were always

New Opportunities With its system, the company has not only improved part quality and productivity; it also has been able to take on new projects cutting UHM W and rubber gaskets, Plexiglas and thicker metals, including mild and stainless steel and aluminium.

In addition, the company has been able to add a new revenue stream by expanding its contract manufacturing business.

“The ability to cut UHMW and rubber gasket is important in our field,” he said. “We have found new opportunities with these materials, something that was not available before we got the waterjet. Also, before we installed the waterjet, our cutting capabilities were limited to about 3/4” thickness. Now we’ve found a lot of our existing customers coming to us more because we have no thickness constraints.

We would have never taken on a project in house that involved 2” thick plate. Now it’s no problem.”

The new waterjet cutting capabilities are helping the company maintain its competitive edge, Mr Crane noted.

“Manufacturers in the material handling industry do not focus on the same level of quality as we do,” he said. “Adding a waterjet to our fabrication process set the quality bar even higher. Our goal is to minimise the time it takes to go from raw material to assembly. As we implement this, we’re striving to consistently deliver a product with outstanding quality.”

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ENQUIRY NO 083

FOCUS

Aerospace Focus:

Measure Up

To The Standard

To remain competitive, aerospace manufacturers and suppliers must effectively manage compliance to the standards that drive their business. By Andy Reese, manager, IHS uality standards are vital to managing the global nature of today’s aerospace indu st r y, whether for Original Equipment Manufacturers (OEMs) or suppliers. At the same time, the trend toward globalisation means the number of standards, reg ulations a nd sta nda rds related organisations any one aerospace company has to deal with continues to grow.

Maintaining standards compliance across different Quality Management Systems (QMS) as specified by various bodies has become far more dema nding tha n ever. From research required for standards se le c t ion , to ve r i f y i n g t he reliability of information used, to reporting and documentation, the added time and costs associated with ma inta ining sta nda rds compliance have created new business challenges for companies 46

asia pacific metalworking equipment news April 2015

in the aerospace industry.

Fortunately, these increased compliance expectations for aerospace manufacturers and suppliers can be effectively de a lt w it h t hrough ca ref u l and methodical research of the particular standards that apply in each case, and through the adoption of an effective compa ny - w ide st rate g y for managing standards, codes and specifications.

Challenges & Issues Of Today’s Standards Climate Despite the universal proliferation of standards over the last four decades, there is no single QMS or standards-related organisation t hat prov ide s t r u ly g lob a l standards. Furthermore, despite the ever increasing number of standards-related bodies, there is no single organisation to regulate complia nce to the multiple standards continually being

created. Rather, the responsibility for compliance management falls on the shoulders of the aerospace manufacturers and suppliers themselves.

Given the requirement to employ standards, on the surface it can seem obvious that companies need to take a ‘best practice’ approach for managing their standards acquisition and usage. Frequently, however, senior management objects to the cost of individual standards based on the price of obtaining and legally using standards.

This narrow focus on the cost of an individual standard ignores all the underlying costs of not properly managing standards, such as blind referencing of standards, duplicate purchasing of standards across the organisation, lack of version control and the risk of using outdated standards, and the potential for copyright abuse — let alone the quality and liability risks associated with improper application of standards.

Version control, for example, is one serious possible consequence of poor standards management. This is potentially a major issue in the aerospace i ndu st r y, whe re st a nda rd s may change periodically and, unfortunately, not on any kind of regular schedule.

A STM International alone has averaged nearly 300 new www.equipment-news.com

FOCUS national and international laws.

They could face lawsuits brought by the copyright owners and spend significant amount of time and money on fighting legal sanctions and, ultimately, in penalties and damages.

standards in fact have that access where and when they need it. If people do not have what they need, they will find some other way to cope, whether or not they are in compliance with the organisation’s policies.

Six Steps To Effective Standards Management For many companies, understanding the larger orga nisationa l implications and risks of poor standards management outlined above is the first step towards getting their standards management approach up to speed. As an organisation looks to improve its standards management, the following six steps can provide a roadmap for progress:

2. Keep standards use consistent.

Dating back to the days of Eli Whitney and Henry Ford, manufacturers have recognised that consistent, repeatable proce sse s a re t he key to efficiency and productivity on the plant floor.

Similarly, you should ensure that employees have consistent, repeatable processes to access the standards content they need. This kind of consistency breeds productivity, quality, and speed that businesses need in order to react to a changing environment.

1. Ensure access. This means that those who need access to

ENQUIRY NO 082

documents, rev isions, re a pprov a l s, or w it hd raw a l s every month — and that is just one sta ndards development organisation. Without a system in place to ensure that only the most up-to-date standards are employed, companies run the risk of additional development cycles, rework or, most importantly, product failures.

Copyright abuse is another potential consequence of improper standards management, and it is a problem that, not surprisingly, has only grown more challenging with the rise of the Internet.

The web makes it easy to find, copy and illegally distribute documents. Organisations that do not establish and enforce st r ic t p olicie s de sig ne d to eliminate copyright abuse may find themselves at risk of violating

www.equipment-news.com

April 2015 asia pacific metalworking equipment news

47

FOCUS 3. P u rcha se sta nda rds from a reliable source. Make sure that you have the licensing in place that you need, that you are covered legally and from a copyright standpoint, and that you are able to get the updates that you need in a timely manner.

Your standards provider must be a good partner to your business and support your goals.

4. Avoid copyright abuse. Violating the copyright on a standard can present legal challenges to your company, and those problems are only made more serious when a lack of proper controls leads to systematic, unchecked abuses. Again, ensuring access is crucial to avoid hav ing employees ‘do it their way’ and thereby expose the company to the risk of copyright abuse.

5. Understand usage. Business intelligence is increasingly important to all companies.

With regard to standards, ‘doing business intelligently’ means being able to answer questions like: How is the content being used, who needs which content, and how frequently do they need it? Do they immediately need updates, or do they need historical content through the lifecycle?

What are the patterns that are going to govern your needs as a business and therefore drive your standards requirements?

6. Stay current. This last priority is particularly important for any discussion of standards in the aerospace industry, based on the regulatory requirements and the increased risks that this industry faces. In part, this means having a reliable source, but your standards management partner also must know when things change and be able to react quickly by providing the right information at the right time to the right members of your team.

active in your industry.

You also must look for tools that provide fast search and study capabilities, providing access to the ‘right’ content at the right time.

Users should not have to spend too much time searching for the standards they need, so having an effective discovery process is an important building block for your standards management.

Search should be intuitive, offering robust filtering options, with full-text search and ‘redline’ (o r ‘ v e r s i o n c o m p a r i s o n’ ) capabilities. In addition, the ability to mark ‘favourites’ within the system and to set up automated email alerts when changes are made to a standard will allow for ongoing monitoring of frequently used standards.

Finally, to enable a consistent process, your standards management tools should provide for uniform shared access to standards in way that ensures that even globally dispersed teams are able to ‘work off the same sheet of paper’. Team members ought to have the same process for how they obtain and apply standards, and that process should be built into the tools that the team uses.

Companies looking to adopt standards management tools inevitably must ask themselves whether it is better to build or buy a standards management solution.

It is possible to ‘do it yourself’, and a company can go out and

Choosing The Right Standards Management Capabilities With those six steps in mind, what do effective enabling technology c a p a b i l it ie s fo r s t a n da rd s management look like?

Starting with the need for reliable access, effective standards management tools should provide anytime, anywhere access to all the necessary content. ‘Necessary,’ in this case, includes standards that you need today, but also content that you might need tomorrow to keep up with changes in an everevolving industry.

This is particularly important in an industry where companies are under pressure to maintain strict adherence to the latest regulatory requirements, and where the standards required may vary year to year. The breadth of standards covered should include comprehensive, up-to-date standards from multiple SDOs

The frequently changing standards landscape makes it imperative for aerospace suppliers to track new revisions of industry standards.

#Revisions by month in 2014

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asia pacific metalworking equipment news April 2015

3,202

3,462

4,378

3,601

3,724

4,004

3,246

3,690

4,811

3,205

3,637

Source: IHS date

5,220

46

thousand+ revisions to standards, codes and specifications from 200+ publishers in 2014

Jan

Feb

Mar

Apr

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

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FOCUS Effective Standards Management

Local or global product or project teams

Automatic Monitoring of frequently used standards

What does it look like?

Fast Search & Study of a single standard • Easy & intuitive • Filtering options • Full-text • Redlining

• Mark ‘favourites’ • Set automated ‘alerts’

Shared Access to common standards

• Team ‘watch lists’ • List sharing • Uniform standards use across enterprise • Teams receive alerts for revisions

Anytime, Anywhere Access to millions of standards documents Comprehensive, up-to-date standards from multiple SDOs AIAA AIA-NAS ANSI API

ARINC ASD-STAN ASME ASTM

AWS BSI DIN DoD

IEC IEEE IPC ISO

JAA NASA NEMA NFPA

SAE More…

From design through compliance

Characteristics of an effective standards management solution.

individually acquire the standards it needs.

However, this ‘go it alone’ approach carries the risk of having staff spend the bulk of their time on requirements collection, data acquisition, and document management rather than on actually analysing and employing the information they require — again creating delays and impairing the company’s ability to respond rapidly to the changing environment.

Leveraging a prov ider of standards management solutions, on the other hand, shifts the responsibility for data collection to the information provider and can significantly compress the time that your staff must spend on collection and aggregation.

That can free up your resources to devote more time to applying the standards in practice, as well as making decisions more quickly, cutting time to market and improving your ability to react to changes in the landscape.

Carpe Diem — Where To Get Started?

For companies throughout the aerospace supply chain, standards management can represent a www.equipment-news.com

significant opportunity to seize ‘low hanging fruit’ to lower costs, reduce risk, and improve market performance simply through the better use of tools and techniques to manage the standards they already use.

If you wish to embrace standards management within your company, you can follow three simple steps to seize this opportunity: 1. First, establish a formal priority around standards management.

That means enlisting executive sponsorship that can drive this initiative within the organisation, sell the importance of standards management to other functions or business units, and endorse funding of the project at an adequate level.

2. N ext, engage with internal sp e c i a l i s t s a n d e x te r n a l experts to look at current use, inventorying the current library of standards, and understanding how staff members access standards, as well as the current and future needs for standards within the company.

3. F inally, the road to better standards management will

involve eliminating paper from the process, digitising and automating access at the desktop level from a single reliable source (or a s few sources as practical), and investing in a corporate-wide standards management tool suited to the requirements of your company and its industry.

The aerospace industry is highly advanced, highly competitive and highly regulated, with literally hu nd re d s of st a nda rd s for all a spects of development, manufacturing, use, and disposal — not to mention the myriad of regulations.

As this article has discussed, improving standards management offers aerospace companies benefits in terms of mitigating the risks attendant to standards but also in terms of the ability to meet customer requirements fa ster. Put in this way, improved standards management is clearly shown to be a competitive weapon that should be in the arsenal of every aerospace company today.

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49

FOCUS

Supply Chain

Opportunities In Aerospace Manufacturing

With rising demands in the aerospace industry come greater opportunities for aircraft part suppliers.

By Scott Walker, president, Mitsui Seiki USA

A

irlines will need more than 35,000 new airplanes valued at $4.8 trillion between 2014 and 2032. The major aerospace OEMs are currently outsourcing about 40 percent of the machining to their suppliers, a nd that percentage will increase.

Airplane factories want to build aircraft like automotive plants build cars. This means they require consistent, predictable output from their assembly bays.

The demand on the supply chain is to provide exceptional quality parts and sub-assemblies exactly when the OEMs need them.

While this paradigm is developing, suppliers must be smart and agile to manage the peaks and valleys in their businesses.

The aerospace industry has calculated the number of ‘spindles’ required in its supply chain to make a number of different structural and engine parts. This term refers to the machine tool spindle ready to make parts 98.9 percent of the time.

In some cases, there are enough spindles in the supply base for the volume; however those machines may need to be replaced featuring the latest design attributes, control systems, spindles, and tooling technologies to meet the

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management mandates for quality and reliability to support peak production rates.

A ‘Lengthy’ Process There are basically four size cla ssifications of structural components a nd machine capacities to match the need: less than a half meter in length, less than a meter in length, less than 2.5 meters in length, and over 2.5 meters in length.

Currently, there are enough machines in the global supply ba se to produce str uctura l components under a half a meter — titanium parts such as end support brackets that go on the composite floor beams in a 787, wing tip leading edges, and trunnion straps.

If a shop is not able to machine titanium cost-effectively, and wants to remain in or go after

this highly competitive market sector, it should start researching the machine tool characteristics required to cut titanium in the vertical or horizontal trunnion styles with 500 mm pallets.

In the medium size range, about 1 m, the estimated number of new spi ndle s ne e de d to support the rate increases is 1,200 units. That is a growth area that will require horizontal trunnion style machines with 630 to 1,000 mm pallet sizes to machine such components as wing flap hinges, wheel well squash plates, and a variety of engine mounts for the various new engines.

Another category for structural component growth is the 1 to 2.5 m parts such as helicopter rotor components, squash plates, hinges and cuffs. About 600 additional 2.5 m horizontal trunnion machines

200 new five-axis simultaneous control machines are required to accommodate the manufacturing of blisks, impellers, and fan blades. www.equipment-news.com

FOCUS will be required to cut these difficult alloy materials.

In the category for components greater than 2 m, such as side body cores and bulkheads that require typically large gantry mills to make them, there are currently enough of these in the chain to accommodate the volume. If a supplier is serving this market already, the company may want to consider rebuilding the heads and retrofitting those massive tools with advanced controls to ensure continued customer satisfaction with quality and delivery.

The Engine Room O n t h e e n g i n e si d e , t h e r e a r e b a s i c a l l y t wo g e n e r a l categories of parts — engine ca se s a nd gea rboxe s a nd a variety of blades. There are enough machines competitively producing cases and gearboxes

to meet the anticipated rates.

To keep this business, machines need to be very accurate (not just machining accuracy but the machine itself). This means stra ightness, pa ra llelism, flatness, a nd squa reness to within two arc seconds accurate.

To ach ieve t h is level of construction precision, which also provides the necessary high volumetric machining accuracy, require s the experienced craftsmanship of hand scraping and fitting, a temperature- and humidity-controlled factory, a special foundation imparting ne g l ig ible v ibrat ion i n t he assembly bay, meticulous laser inspection as routine, and more.

The variety of blades needed presents a significant growth oppor tunity. Approx imately 200 new five-axis simultaneous control machines are required

to accommodate rises in blisks, impellers, and fan blades. About 1,600 new units will be necessary to handle single blade production and 600 to support the surge in IBR production.

Conclusion Aerospace component manufacturing is engaging and challenging. Working with tough stainless blends, nickel alloys, and titanium grades can be difficult. Then there are the OEM mandates, which are strict.

However, if a supplier is ready now or working towards attracting aero customers, the opportunity is here, along with the knowledge, guidance, and manufacturing technology to be successful and rewarded.

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endless flexibility High-Performance Swiss ST 26 by Tornos      

9 CNC axes control Diameter up to 23 mm (25.4 mm with bar-end preparation) Designed to work with or without guide bush. Switch =< 30 min 2 independent opposed gang-tool posts to increase productivity Modular tooling systems including up to 36 tools Powerful main and back spindles (9.5 kW ; 10’000 rpm) Large work zone allowing easy access to the tools from both sides of the machine

TORNOS SA, TORNOS TECHNOLOGIES ASIA LTD. MALAYSIA REPRESENTATIVE OFFICE Tel: +6(04) 642 6562/642 6563, www.tornos.com TORNOS SA, THAILAND REPRESENTATIVE OFFICE Tel: +66 2746 8840-1, www.tornos.com

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ENQUIRY NO 069

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April 2015 asia pacific metalworking equipment news

51

FOCUS

Christof Merten, aerospace product manager at Schuler Pressen looks at the aerospace industry from a forming viewpoint.

T

ita nium is growing in importance in the aircraft manufacturing industry.

If the high-strength metal is used at a rate of six percent in conventional aluminium aircraft manufacturing, this figure would increase to 15 - 20 percent in modern composite designs.

For better or worse, processing titanium is often associated with lower quantities. This calls for special ma nufacturing processes, forming technology and part handling. In order to increase quantities and decrease u n it cost s eve n i n a i rc ra f t manufacturing, titanium forming must be performed to maximum efficiency and reliability.

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asia pacific metalworking equipment news April 2015

Hard Work Use of tita nium is justified ba sed on its qua litie s. The use of titanium components, however, is made less attractive by the fact that titanium alloys can only be worked with great difficulty at room temperature.

Efficient forming technology p ro ce du r e s , su c h a s d e e p drawing or hydroforming can only be applied with a great deal of limitations and are restricted to working with pure titanium alloys with a low tensile strength.

Even thin-walled complex co m p o n e n t s a r e g e n e r a l l y ma nufactured using cutting procedures, instead of being joined from sheet form parts. If you wish to manufacture complex

Schuler

Forming An Opinion On The Aerospace Industry

components through forming technolog y procedures, this can only be done at increased temperatures. Depending on the forming procedure, for the majority of alloys, the machining temperature is between 700 to 1,0 0 0 deg C. T his pose s cha l le nge s for t he for m ing processes a nd the required systems and tools.

Forming Titanium A s prev iously mentioned, titanium parts are used in the widest range of applications.

The component geometries are also rather diverse and so are the forming procedures used.

In general, these procedures are forging procedures (hammer www.equipment-news.com

forging, die forging, isothermal forging, etc.) and isothermal sheet forming. In addition, there are also bonding techniques such as diffusion bonding for ma nufacturing intermediate layers for subsequent m a c h i n i n g /c ut t i n g or for sandwich structures.

Sheets a re formed either using hot gas while utilising the super plastic properties of the materia l used (SPF = S u p e r Pl a s t i c Fo r m i n g ) or mechanically by hotforming without clamped edges. It can also be done by stretch drawing with a permanently clamped edges and by hot deep drawing with a blank holder and lagging edges.

The adva ntages of hot forming are predominantly in near-net-shape manufacturing of components with uninterrupted fibre course, high degree of tensile strength and low residual stresses, without the extremely time- consuming and difficult machining of an already expensive basic material.

Types Of Processes Just as diverse as the available forming procedures are the various types of presses used.

An optimum design inevitably calls for a high degree of process knowledge. Apart from spindle presses and hammers in forging, system solutions with hydraulic presses are predominantly offered

Schuler

FOCUS

SPF system with automated part handling

for the large group of isothermal forming procedures.

Taking a close look at the similarities used to describe this procedure group, it quickly becomes clear. As their name implies, isothermal processes are characterised by the fact that they are processed at a constant temperature.

The tool and part are generally located in a heating chamber, w h ic h i s a ble to ke e p t he necessary process temperature (approximately 50 percent of the melting temperature in Kelvin) constant throughout the entire process duration. The forming rate Ď&#x2020; is very low. The process duration can be one minute

Schuler

Compressor blade

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during hot forming, but more than two hours in the case of complex SPF components.

T he se sp e cia l b ou nda r y co n d it i o n s ke e p t h e y i e l d stresses low. The material can be distributed well in the die while also conserving the tool. As such, complicated components can be manufactured with good dimensional accuracy in one step.

In doing so, very high deformation ratios of several hundred percent can be achieved.

Hydraulic presses can be used to precisely implement exactly these conditions â&#x20AC;&#x201D; very slow slide movements with variable speed or long holding times with variable force. In connection w ith a n integ rated, exactly controlled heating chamber, high temperature resistant tool fittings and an adequate production data acquisition and management system, the requirements of the aerospace industry as well as other industrial sectors can be precisely met.

Adjusting temperature and forming rate, the above-mentioned procedures can also be used for a varied range of other materials such as Al, Mg, Ni-based alloys and stainless steel.

April 2015 asia pacific metalworking equipment news

53

FOCUS B a s i c a l l y, t wo d i f f e r e n t press ty pes a re common in isothermal forming.

On the one hand, the isothermal forging press typically has the following equipment features: • High force density • Very stiff, slide guided without clearance • Slow slide axis (0.05 - 2 mm/s and lower) • Integrated heating chambers with precise temperature control • Load transmission via high temperature-resistant die fittings On the other hand, isothermal sheet metal forming presses possess: • Integrated heating chambers with direct load transmission • Slide with optimised cylinder arrangement, depending on requirement with parallelism control • Two-channel gas control system for inert gas (for SPF gas forming and diffusion bonding) • Regulated load holding for gas formation and diffusion bonding

• Slow slide axis for mechanical forming processes

• Which furnace technolog y is used?

• Hydraulic bed cushion for hot deep drawing

Looking Ahead In future systems, the field of production data acquisition and management will play an increasingly important role, pa r t icula rly w it h rega rd to tracking individual parts.

Also of particular importance are die changes, especially in terms of flexibility and in decreasing nonproductive times. If a system needs to be cooled and then re - he ate d to t he pro ce ss temperature (700 - 1,000 deg C) every time the die is changed, the primary processing time will be considerably reduced a nd t he se r v ice l i fe of hot components decreased.

With this in mind, intelligent and efficient systems for heated die replacements are growing in importance, in order to minimise unproductive replacement times. Consequently, the need for automated clamp and tool handling systems is on the rise.

Let us summarise by stating that in today’s industry and i nc re a si n g ly i n t he f ut u re , there are various interesting applications for titanium. The direction this development takes depends on the availability of system solutions for forming the required components, which meet the particular boundary conditions that titanium places on the forming process.

System solut ions w it h hydraulic presses offer good options here. High-performance, flexible systems with maximum efficiency and reliable pro ce s s e s c a n b e a da pte d to a wide range of customer requirements regardless if it is an individual machine or a fully automated system.

In order to ensure an optimum system solution, simply looking at the central forming process is not enough. The entire process chain needs to be examined.

All upstream and downstream processes must be included in the system planning: • Preforming, bending, upsetting • Coating • Cutting • Calibration / thermal stabilisation • Washing / blast cleaning / chemical ablation The high process temperatures, low quantities and frequent component replacements call for additional boundary conditions to be considered: • Does automatic component handling make sense, if yes, where and how?

• Where and how do components get heated or cooled in the process?

FormTech

Hot deep drawing part (750 deg C, formed with blank holder)

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asia pacific metalworking equipment news April 2015

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ENQUIRY No.

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FEATURES

German Machine Tool Industry Expects Higher Production Output In 2015: VDW Production figures are looking up after a weak 2014.

T

he German machine tool industry is anticipating a three percent rise in production output during 2015. “The low oil price and the fall in the euro’s exchange rate are invigorating capital investment and thus also increasing the dema nd for machine tools,” says Martin Kapp, chairman of the VDW (German Machine Tool Builders’ Association).

Ox ford Economics, the VDW’s forecasting partner, is predicting an improvement in the global business cycle during 2015. This will benefit the major user sectors for machine tools.

In Germany, the automotive industry and the mechanical engineering sector (who together buy about 70 percent of machine tool production output) are each expecting growth in their own production volumes.

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asia pacific metalworking equipment news April 2015

I n addit ion, pu ndit s a re forecasting a moderate global recover y in dema nd on a relatively broad base for 2015, driven primarily by America.

Due to the ongoing process of re-industrialisation in the US, the market is set to expand beyond its traditional drivers: the automotive and aircra ft construction industries.

C a p it a l i n v e s t m e nt by t he automotive industry, moreover, is underlining the particular importance of the NAFTA region.

The result is high double-figure growth rates for machine tool orders in Germany.

Europe & Asia European demand was hit last year by developments in Russia.

Nonetheless, orders from some E a s te r n E u r o p e a n n a t i o n s are already showing positive

si g n s i n a me d iu m - double figure order of magnitude. In Ita ly, government subsidie s for capital investment in the shape of reduced-rate loans have been proven beneficial.

Elsewhere, good business with Switzerland is owed to close entrepreneurial interweaving between German manufacturers and their Swiss subsidiaries. In 2015, a moderate recovery in European demand is expected.

In Asia, due to China and South Korea, machine tool consumption stabilised last year. Recently, there has been a rise again in orders placed with Germa n manufacturers.

“We are cautiously optimistic about the ongoing year, since the German machine tool industry is in good shape, as a vendor of production equipment for the entire world,” says Mr Kapp. He www.equipment-news.com

ENQUIRY NO 042

FEATURES

Martin Kapp

adds that the sector is fully aware that the numerous crises around the globe continue to entail manifold risks, and that it is still waiting for clearer growth signals in many important markets.

Falling Output Experienced In 2014 Last year, the German machine tool industry saw its production output fall for the first time in three years. With a minus of one percent, production output came to €14.4 billion (US$16.1 billion), the second - highest pro du c t io n f i g u re t hat t he sector has ever achieved.

Exports fell by three percent to €8.9 billion. Deliveries to Europe came out best, with growth of one percent. Both Asia and America performed less impressively. The export ratio, however, remained high overall, at around 67 percent.

Imports suffered less severely, rising by four percent. Almost 70 percent of imports come from Europe; Switzerland remains the most important supplier.

The order backlog, averaging 7.3 months over the whole of 2014, wa s slightly dow n on the preceding year’s figure.

Capacity utilisation remained high, averaging 90.1 percent over the year.

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asia pacific metalworking equipment news April 2015

The year 2015 is expected to be a good one for German machine tools.

Germany Remains The Top Exporter In the context of international competition, the sector has put up a good performance. In its rivalry with the Japanese, it has retained its top ranking in exports, despite a decrease of five percent (excluding parts and accessories), with a share of 21.2 percent in global exports.

The Japanese are benefiting from the weak yen, and have increased their exports by seven percent when ca lculated in euros. German manufacturers, with a share of 17.7 percent, also rank among the top three of the world’s biggest producers, behind China and Japan.

While Germany is flying high in the export segment, there are some worries about the Russian market. “ T he big ge st discer nible risk for our sector currently is our business with Russia,” says Mr Kapp. Russia is (or rather was) the third-largest market with a volume of €500 m i l l i o n . H o w e v e r, s e v e r e setback s occu r re d in 2 013, due to a marked weakness in growth, declining interest from investors, rising interest rates, and the free-fall of the rouble. In the same time period, Russia’s

industrial production output shra nk . Orders for G er ma n machine tools fell to less than half the figure for 2013.

“It remains for us to hope that the ongoing negotiations for a politica l solution w ill soon meet with success,” says Mr Kapp. Even then, he adds, it will take a long time before b u si n e s s e s c a n n o r m a l i s e , since the confidence a nd fina ncing crise s w ill ta ke a long time to heal.

On the other hand, machine tool manufacturers see major opp or tu n it ie s for bu si ne ss with the US, due to the prompt conclusion of the Transatlantic Tr a d e a n d I n v e s t m e n t Partnership (TTIP). The focus here is on unrestricted market access at the same conditions as for domestic manufacturers.

The harmonisation of technica l sta nda rds, in pa r ticula r, enable s Ger ma n firms, without any additional outlay, to offer their products a good 20 percent cheaper on average. With a share of around 10 percent, the US is the secondbiggest market for the German machine tool industry.

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The 11th International Manufacturing Machinery, Equipment, Materials and Services Exhibitions

10 - 13 JUNE 2015

Grand City Convention and Exhibition Centre Surabaya, East Java, Indonesia Supported by:

Ministry of Industry, Republic of Indonesia

Organised by:

Indonesia Precision Tooling Industry Association

Indonesia Woven Polyolefin Manufacture Association

Indonesian Machine Tool Industries Association

Indonesian Mould & Die Industry Association

Indonesia Packaging Federation

Indonesian Automotive Parts & Components Industries Association

For Further Information Please Contact Your Nearest Office: Maysia Stephanie PT Pamerindo Indonesia Jakarta T: +62 21 2525 320 F: +62 21 2525 482 E: maysia@pamerindo.com www.pamerindo.com

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FEATURES

Auto Suppliers Facing

A Tight Squeeze Auto suppliers must improve their networkoptimisation efforts to balance the competing demands of cost reduction and the desire to carry out manufacturing close to the customer. By The Boston Consulting Group

A

utomotive suppliers a re under mounting pressure to satisfy two conflicting customer demands: to cut costs and to open more factories in fast-growing emerging markets so that they can be closer to their customers’ production plants.

Striking the right balance between cost and proximity in global manufacturing networks will be one of the industry’s greatest challenges, according to a report by The Boston Consulting Group ( BCG), conducted in partnership with the Fraunhofer Institute for Ma nufacturing Engineering and Automation IPA. Under Pressure A recent BCG survey of auto suppliers found that an over whelming majority of respondents — 86 percent — are under increased cost pressure from their automotive customers.

Suppliers will bear the brunt of deeper-than-usual cost reductions sought by large automakers, some

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of which are apparently planning to cut annual spending by four to six percent.

At the same time, suppliers are also under intense pressure from their customers to localise production. Suppliers surveyed expect to increase their number of global manufacturing sites by an average of nine percent over the next five years.

“We call the dilemma over how to balance these conflicting d e m a n d s — fo r b o t h co s t reduction and manufacturing close to the customer — the proximity paradox,” says Daniel Spindelndreier, a BCG senior partner and a coauthor of the report. “It is among the most serious management challenges that the global automotive-supply industry will face over the next few years.”

T h e p a r a d ox i s h e r e to stay. “Pressure to cut prices is unlikely to relent, and avoiding emerging ma rkets is not a n option because they are critical to growth,” says Manfred Beck,

a BCG associate director and a coauthor of the report.

Indeed, China surpassed the US in 2009 as the world’s biggest automotive market and is emerging as the engine of global growth for the industry. Nearly 60 percent of surveyed auto suppliers’ total production capacity — including ma ny core ma nufacturing operations for certain products — is expected to be located in emerging markets some five years from now, compared with only 45 percent five years ago.

“Germany’s automotive-supply industry alone is projected to lose 35,000 jobs, including highly skilled blue- and white-collar workers,” adds Mr Beck.

The Need To Get Organised Auto suppliers recognise these challenges while acknowledging that their efforts to address them are insufficient. Although 79 percent of respondents stated that they are satisfied overall with the performance of their localised production facilities in emerging markets, 68 percent reported that the cost savings were lower than expected.

“Ever y supplier sur veyed agreed that it is important that it adjusts its manufacturing network,” says Frank Lesmeister, a BCG associate director and a coauthor of the report. “But our research found that most suppliers lack the organisational capabilities, business processes, and tools to achieve an optimal manufacturing footprint.”

These insights emerged from a survey of 42 automotive suppliers from around the world. This sample comprised one-quarter of the world’s 100 biggest players and a selection of midsize companies.

Confronting The Paradox “The essential paradox faced by auto suppliers is that production decisions that are intended to cut costs and those made to be close www.equipment-news.com

FEATURES

Some of the processes in the manufacturing of a car.

to the customer often lead to very different practical solutions in allocating products to sites,” says Mr Spindelndreier.

If cost is the prima r y consideration, most production decisions rest mainly on the basis of total landed cost, which takes into account such factors as labour, logistics, and energy.

Economies of scale and the expertise and process capabilities needed to build a plant are also important considerations.

The logic behind a localisation demand can be different: the primary factor is the customer’s requirement that pa rts a nd co m p o n e n t s a r r i v e a t t h e automotive assembly line at the precise time and in the precise sequence needed.

In a typical year, suppliers are asked to shave two to three percent off their prices. But after several years of relative price stability, the coming round of cost reductions is likely to cut much deeper.

Some of the largest automakers have adopted programs to cut $2 billion to $6 billion in annual costs, constituting about four to six percent of total spending.

Suppliers will bear some 55 to 65 percent of these cutbacks.

Meeting these cost targets w i l l b e e sp e c ia l ly d i f f icu lt because they come at a time when auto suppliers’ production networks have been growing to www.equipment-news.com

be more globally dispersed and more complex.

The number of companies in the study with lead plants (the sites of core manufacturing operations) in China is expected to double to 16 in 5 to 10 years, and the overall number of lead plants located there is projected to jump by 150 percent over that period.

The number of lead plants is expected to rise by 29 percent in Mexico, by 50 percent in Eastern Europe, and by 50 percent in the rest of developing Asia, a region that includes India and the Southeast Asian nations. Emerging markets will not be the only ones to gain. The survey respondents also expect to increase their number of lead plants in the US and Canada by 25 percent over the next 5 to 10 years.

Developing An Optimal Production Network To a d d r e s s t h e p rox i m it y paradox, the authors recommend that suppliers adopt a more comprehensive approach to adjusting their manufacturing networks, one that balances the necessity to have certain production close to customers with a cost analysis that goes beyond direct factors such as labour rates, materials, and shipping.

A manufacturing-networkoptimisation program should encompa ss improvements

Auto suppliers must improve their network-optimisation efforts

to the globa l supply cha in, orga nisation structure, a nd manufacturing processes.

“To be really successful, these programs must be ongoing so that suppliers have the flexibility to adjust their manufacturing footprints in response to shifts in global cost, market demand, and technology trends,” says Mr Lesmeister. “For many suppliers, this will require at least some transformation of their organisations.”

Suppliers should start the approach by ga ining a f u ll understanding of the strengths and weaknesses of their current manufacturing network and their ability to make adjustments.

The authors recommend that suppliers conduct a thorough ‘health check’ of their optimisation progra ms that assesses the past performance of the network and whether current capacity in a region can meet projected demand.

The health check should also evaluate capabilities and managerial responsibilities across the network, examine the tools and methods used to identify and quantify improvement opportunities, and determine whether the capabilities and processes are in place to implement the strategy and adjust the network.

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EVENTS& EXHIBITIONS

Moving Ahead Through Technology

Since 2012, the Taiwan machine tool industry has been recovering steadily and picking up steam. This year, it readies itself for the next lap in technology. By Syed Shah

T

he Taiwanese machine tool industry has certainly picked up steam ever since the slowdown in 2012. Uncertainties are still going on in markets around the world especially Europe, but the scene has generally improved in tandem with the United States economy and floundering crude oil prices. This is evident according to the Taiwanese growth in the machine tool industry which reached US$3.7 billion in 2014 – a 5.8 percent growth compared to the same period in 2013.

Just in January this year, manufacturing in Taiwan rose to a five-month high according to HSBC’s latest Purchasing Managers Index (PMI), while export orders data has shown a pickup in

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growth. The monthly survey had demonstrated a 51.7 reading, up from 50 in December. A PMI score of above 50 indicates expansion.

China, which had recently lowered interest rates, is also the favourite destination for Taiwan’s exports.

Economists and analysts have noted that economic and export numbers have taken a turn for the better to be in the black. Inflows to Taiwan’s stock market may remain strong in the near term; though gains in the local currency will be capped by depreciation in China’s yuan and South Korea’s won.

T he show a l so s aw t he discussion of technologica l advances like the incorporation of Industry 4.0 and Big Data analytics in the products offered now and in

the future. Mr Alan Lu, Chairman of Machine Tool Committee, TAMI, said, “The underlying automation of Industry 4.0 is actually not difficult to achieve, and the industry can collaborate with R&D corporations.

It is estimated that Taiwan will take five to ten years to establish Big Data. Before it happens, the machine tool industry should introduce TPS.” Mr Lu also echoed his thoughts back in the previous TIMTOS event where he mentioned of the importance to develop high end products like multi tasking machines and multi axis tasking machines. For the Taiwanese tool making market to thrive, they need to present products that are distinctly different in terms of superiority and at the same time satisfy the needs of customisation.

“If Taiwanese machines do not possess specialised functions or cannot provide solutions to the customers, they can only be sold as general-purpose machines. There will be no chance to get orders in these sectors.”

The sentiment was shared by Mr King Wang who urged Taiwanese machine tool manufacturers to invest in developing products that “fulfils Industry 4.0”. “We improve ourselves by working with countries that possess advance technology and then we can share these learnings with Taiwanese partners,” said Mr Wang.

Overall, the demand of the machine tool market has slowed in China and the buyers are revisiting their strategy in Southeast Asia and looking into markets that have been passed by in the past like that of Indonesia, Malaysia and Myanmar. Along with these new initiatives for growth and expa nsion, there a re other considerations like environmental issues, the management of the flow of information and the intricacies of the market.

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EVENTS&EXHIBITIONS

Productivity Coupled With

Affordability

T

Richard Su

a i w a n Ta k i s a w a Technology came into the show with their usual array of machines but the marquee piece was the brand new FX-800 model in the FX series.

APMEN interviewed Richard Su, Section Manager of Takisawa who gave us more insight on the offerings of this model. One of the main features he mentioned

was the ability to have the same workload of two machines. “The FX series has twin spindles and, twin turrets. The main spindle has a 65 mm bar capacity, and the south spindle has a 52 mm bar capacity. You can machine one part from this side, and then it will be caught by the subspindle to this side to make the machining in another side so it saves time.”

Differentiation

a curve on a flatbed and you’re machining it, the chips on the table can affect the quality of the mould.

Whereas if you use a boring metal, you can have the mould stand up and it could do the mould and the chips are falling down.”

Femco says that currently that they rely heavily on our dealers, partners and distributors but they intend on moving forward over the next 10 years because they want to start taking that service to the next level. “Our dealers may do a good job, but there are always deficiencies because they’re not the manufacturer. There are many times when, in countries like Indonesia for example, if there’s a problem and the dealer can fix it, then it’s good but there are also times when he can’t fix it, and he needs to call us so we know exactly what’s going on.”

Mr Chuang says that they’re going to start going to different places to source for viable areas to set up tech centres so that customers

The Key

A

PMEN met up with David Chuang, president of Femco whom we asked to give his thoughts on the technology of boring and milling in today’s machine tool market.

“We’re probably one of the oldest companies in Taiwan to make more on mills. And until 5 or 6 years ago, we were actually the only ones.” He mentioned that there significantly more companies in Taiwan that are making it too, so they need to start differentiating ourselves. “The machine that we are displaying is, for example, what large moulding industries require for creating moulds with angles. Traditionally a double column vertical machining centre is used, but that presents other problems. When you’re doing

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One of the standout features of the machines is its ability to support high speeds and also rigidity together with its stability, reliability and accuracy. This machine supports the use of big screens which can synchronise with computers, making it easy for engineers to create programmes.

Moreover one other thing that Takisawa prides itself on is the affordability of its machines while maintaining high standards in productivity and machine life.

“We have already received orders from European customers because labour cost in Europe is very high, they need these machines to save money. If they buy one, they can save on buying another and then save on labour costs. They just have to set the programme to create the machining, which will be completed in a very short cycle time.”

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David Chuang

in those areas can get better service from them. However, they will still be working with the dealers despite setting up these centres.

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EVENTS&EXHIBITIONS

TIMTOS 2015

Highlights

There is no way one can pass through a show without giving some spotlight on the standouts during the event. So here they are in no particular order.

Getting The Axes Right The UA Series by Wele is a robust design for five axes simultaneous application jobs for aerospace parts machining.

It has high rigid design of AB tilting head with max torques of 4950nm/3650ft-lb on A axis and 7960nm/5870ft-lb on B axis. The series features a dual driven feed system on Y axis that provides heavy movement performance.

Saving Space The Key The AWEA MB series possesses compact exterior design. Floor space is less than 30 square metres which saves valuable space.

The compound four guide ways design gives support on bed and reportedly eliminates table overhang problem and ensures support rigidity. It has 40T/60T arm type ATC with a maximum tool load of 24 kg and maximum magazine load is up to 600 kg.

Multi-Tasking To The Next Level YCM’s multi axis turning centre NT-2000SY2 was featured here for its multi-tasking machining efficiency.

The Y-axis capability provides true milling capabilities that cannot be achieved through traditional turning centre. The NT-2000SY allows ±50mm travel that is sufficient for most mill/turn applications.

Turning The Tech Takisawa’s FX-800 twin turret twin spindle turning centre has a standard turning diameter of 210mm and maximum turning length of 657mm. In total it has two turrets with milling speeds of up to 4000 rpm.

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55,000 international visitors 1,800 brands of technologies from 30 countries 6 National Pavilions International conferences, e.g. Automotive Summit, Surface & Coatings Forum, and more

JUNE

24-27 (WED. - SAT.)

BITEC > BANGKOK THAILAND

THE COMPLETE VALUE CHAIN There is only one event that can provide the manufacturing and supporting industries with the most comprehensive value chain of the latest machinery and technologies, new knowledge, and global networks that the industrialists need to thrive in the ever-challenging business environment. Whether you are in the auto- or industrial-parts manufacturing sector, “Manufacturing Expo” will be the all-in-one sourcing platform that you will want to mark your calendar for. From mold making, plastic injection, to automation, all you will ever need is here.

Thailand’s Most Comprehensive Event for Auto-parts Manufacturing Technologies, Consisting of 3 International Exhibitions

Exhibit space is open for reservation. +66 2686 7299 manufacturing-expo@reedtradex.co.th www.manufacturing-expo.com ENQUIRY NO 084 www.facebook.com/manufacturingexpopage

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EVENTS&EXHIBITIONS

Event Preview:

Metaltech 2015

T

he 21st edition of Metaltech is returning from May 20 to 23, 2015 following last yearâ&#x20AC;&#x2122;s success. In fact, the organiser refers the 2014 edition as its most successful

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event to date. All in all, the 2014 edition hosted more than 1,800 exhibitors from 37 countries and featured some five national pavilions.

For the 2015 version, the

organiser says that they have t a r g e te d m o r e t h a n 1, 8 0 0 exhibitors and the international pavilions will include South Korea, Taiwan, Singapore and Germa ny. The event will be spread over an area of 35,000 sq m and the opening ceremony will held on May 21, 2015.

Visitors to the show can expect to mingle with trade buyers in related industries such as aerospace, automotive, marine/ offshore, metalworking, energy, electrical and electronics, and even medica l, from va rious leading machinery countries such as Thailand, China, Malaysia, Singapore and South Korea. In fact, the organiser says that the 2014 edition attracted more than 27,000 buyers.

Metaltech is also a show where automation technologies can be found. The Automation Technology Exhibition (AutoMex) showcases automation technologies focused on specific industr y a nd commercia l applications for all automation professionals.

L a st ye a r, t he orga niser enhanced the show to cover all components ranging from complete systems to integrated automation solutions, as well as motion control technology and associated technologies; making it the very first international event in Malaysia that brings together all branches of the robotics and automation industry in a single event.

Finally, the organiser says they are looking to expand further by bringing in more companies related to the aerospace industry a s well a s the medica l a nd pharmaceutical industries.

Putra World Trade Centre Kuala Lumpur, Malaysia May 20-23, 2015 Got a Question? Make An Enquiry.

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EVENTS&EXHIBITIONS

EMO Milano Press 2015 Conference Asia Pacific Metalworking Equipment News was at a press event to bring the latest update from EMO’s organiser.

By Joson Ng

M

ila n ‘came’ to Singapore on March 6, 2015, as the organiser of EMO Milano 2015 hosted a press conference at the Marina Mandarin Hotel. Alfredo Mariotti, exhibition director of the show told the attendees that with about seven months left before the opening of the show, it is reasonable to assume that the exhibition will occupy 120,000 sq m, an increase compared to 95,000 sq m achieved in 2009, the last time the show was held in Milan.

So far, some 1,200 companies have registered for the show. Italian companies unsurprisingly lead the way in terms of participation followed by the Germans and the Taiwanese. China and Swiss companies are ranked fourth and fifth respectively. In fact, he said there has been a “huge increase compared to past edition” as far as the number of Asian exhibitors are concerned.

He told APMEN that up till now, the number of Taiwanese

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c o m p a n i e s s t a n d s a t 12 0 , occupying some 9,418 sq m.

The Chinese contingent is 69 companies strong, taking up some 2,567 sq m. Other notable Asian countries are South Korea and Japan, with 39 companies and 59 companies respectively.

A l l i n a l l, some 1,6 0 0 exhibitors and 150,000 visitors from about 100 countries are expected at the event. The show

will also be held concurrently with Expo 2015. As a result, the city of Milan has strengthened its public transport service to cater to these events.

The tradeshow will take place from October 5 to 10, 2015 in the fairground centre of fieramilano.

The halls of the fairground will host the biggest ‘factory’ in the world, where machine to o l s, rob o t s, au to m a t io n , additive manufacturing, auxiliary mechatronic and technological solutions will be ex hibited.

Together, they represent an industry that accounts for €64 billion (US$70.5 billion).

Numbers Looking Up Unlike 2009, the 2015 edition will be held following a good year for the Italian machine tool, robot and automation industries.

According to the preliminary figures processed by the studies department of UCIMU-Sistemi Per Produrre, in 2014, the production of machine tool, robot a nd automation increased by 4.6 percent compared to the value registered in the previous year, achieving €4.695 billion.

Claudia Ma st rog iuseppe, coordinator, external relations direction and press office of UCIMU Sistemi Per Produrre said: “2014 was a remarkable

Additive Manufacturing Debuts At EMO This year’s exhibition will mark the debut of additive technologies, a fast developing sector yet to be fully explored. A special area will be devoted to additive manufacturing.

There, exhibitors will display machines along with other products designed for the mechanical engineering industry.

A whole series of meetings, workshops and conferences will take place during the exhibition, including an event organised by UCIMU in cooperation with AITA and CECIMO, aiming to highlight the competitive edge arising from the use of additive technologies for specific manufacturing processes and processing techniques.

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Italian consumption of machine tool recorded double digit increase of 18.2 percent to €2.4 billion in 2014

2015 is expected to reach a value of €4.89 billion, reporting a 4.2 percent increase versus 2014.

In addition, a positive trend is envisaged for exports, which is expected to rise by 4.2 percent, to €3.5 billion. There are good news on the domestic (in Italy) front as well. Manufacturers’ deliveries are expected to grow by 4.1 percent to €1.39 billion.

Domestic consumption will have a 4.5 percent upturn, attaining €2.53 billion.

Fairground Centre of Fieramilano Milan, Italy October 5 - 10, 2015 Got a Question? Make An Enquiry.

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ENQUIRY NO 068

year. Italian consumption of machine tool recorded double digit increase of 18.2 percent to €2.4 billion.”

In addition, export figures were stable too at €3.36 billion.

She said Italy exports some 75 percent of their machines to countries like China, the US and Germany. Over at Singapore, things are looking rather rosy as well. “Made-in-Italy sales in Singapore have been growing constantly for many years,” she said, pointing out that in 2013, import to Singapore increased by 74 percent.

According to Mr Mariotti, Italy mainly exports cutting machine centres to Singapore.

He also noted that there has been a “huge increase” in the forming machine sector.

Looking ahead, the Italian machine tools production in

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EVENTS&EXHIBITIONS

Event Preview:

Intermach & Subcon

Thailand 2015

I

nter mach a nd Subcon Thailand 2015 will feature some 1,200 companies from 40 countries and will display around 4,000 pieces of machinery and equipment. Out of which, more than 150 technologies will be introduced for the first time in ASEAN and Thailand.

According to the organiser, s o m e 3 0 0 i n d u s t r i a l p a r tmakers from 15 countries in the automotive, electrical & electronics, mould & die and machinery industries will take part. In addition, there will be a business matchmaking event orga n ise d by t he T ha ila nd Board of Investment (BOI) to link Thai, ASEAN and Japanese subcontractors with buyers.

Incidentally, these buyers will be able to see technologies from all over the world as the event will include 10 International Pavilions including representatives from Japan, Taiwan, South Korea, China, ASEAN Subcontracting

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Association, MedTec, Mould & Die Industr y Susta inable Development Project (MDS), the Thai Subcontracting Promotion Association and BOI Pavilions from Chiangmai and Korat.

F i n a l l y, t h e o r g a n i s e r said over 10 0 semina rs a nd conferences will be held to further enhance the Thai and ASEAN manufacturing industry.

Helping Businesses To Grow For more than 30 years, the show has been presenting high-tech machinery and technology from around the world, all at one event. It helps manufacturers and subcontractors deal with growth and increased competitiveness in the region.

The organiser said that the show is the only exhibition in Thailand that focuses exclusively on industrial machinery. Each year, the event continues to attract more than 40,000 trade visitors from over 40 countries.

The 2015 edition will be held from Wednesday to Saturday, May 13 - 16, 2015, at BITEC, Bangkok.

The organiser said that the show can help companies stay globally competitive and SMEs improve their business strategies by investing in new capabilities and business opportunities.

Thailand has become known for its reliable labour force with efficient production and assembly, all of which will help SME’s even further.

The AEC will also bring increased competition, encouraging partmakers to raise their standards. As a result, products will provide better value, especially items that require precision accuracy and top quality.

Sanchai Noombunnam, group director at UBM Asia (Thailand), the show organiser, said: “Thailand has the ability to manufacture more sophisticated items but needs to employ more advanced technology and machinery. By visiting the show to inspect or view new machinery and technology, Thai subcontractors and part makers will gain a competitive advantage by cutting costs and increasing efficiency.”

He added that Subcon Thailand 2015 has enjoyed success by linking regional and international corporations, industrial part buyers and entrepreneurs from dome stic a nd inter nationa l companies from over 15 countries including the ASEAN region and Japan. The show will help further advance Thailand and ASEAN as a major manufacturing hub. www.equipment-news.com

4-7 rket Where Manverge Leaders Co test

a to Unveil L ies g lo Techno s e Solution id v o r P o t ves & Alternati ery to Meet Ev Need ring Manufactu

Join market leaders and major stakeholders at MTT Indonesia to meet key industry players and expand your database of Quality Buyers from the fastest growing economy and most promising marketplace in the region.

he strong support and proactive participation of renowned T machine tool manufacturers and market leaders clearly reflect a high confidence and expectation towards Indonesia’s industrial development and in particular, on the manufacturing sectors of automotives, electronics, mould and dies, precision parts, machineries, oil and gas engineering, as well as the marine and shipbuilding engineering sectors.

Indonesia’s economic growth secured track record as the world’s third best after China and India. Great opportunities are abounding for exhibiting companies to contribute significantly to the country’s need for capital goods and technology through their supply and services, ces, as the nation mount up to the next level of growth and development.

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EVENTS&EXHIBITIONS

International Industrial Subcontracting Event According to the orga niser, Subcon Thailand is now the largest industrial subcontracting exhibition for industrial parts and Business Matchmaking in the ASEAN region. It is the only event organised jointly by Thailand Board of Investment, the Thai Subcontracting Association and UBM Asia (Thailand).

“Thailand features an excellent supporting industry. Today it is known as a regional manufacturing hub and is home to a highly skilled labour force. Foreign investors, especially Japanese SMEs are seeking business partnerships here. The event has become the destination of choice for industrial part buyers, and business matchma k i n g pro g ra m s b e t we e n buyers and part-makers,” said Sonklin Ploymee, director — the BOI Unit for Industrial Linkage development, Thailand Board of Investment (BOI) The ninth edition will feature activities and special pavilions from key Japanese prefectures and organisations. They are OsakaKansai, Kanagawa, Yokohama, Yamanashi and SMR J. There will also be special showcases on fastener, ASEAN Supporting Pavilions including industrial parts capability from Singapore, Malaysia, Philippines, Myanmar and Vietnam.

These are some other events visitors can look forward to at the show.

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Sonklin Ploymee

• A Bu ye r’s V i l la ge , whe re participating buyers feature their parts requirements and procurement policies with local manufacturers.

• Bu ye r P re se nt at ion s — a plat for m for procurement officer from manufacturers where they w ill prov ide their requirements a nd procurement policies.

• Semina rs on productiv it y en ha ncement te chnique s, i n v e s t m e nt m a n a g e m e nt , procurement policies of local and international buyers, and efficient procurement ma nagement related to the automotive and emerging industries.

Sheet Metal Section Finally, the organiser said that

a showca se w ill be held in conjunction with Sheet Metal Asia, ASEAN’s International Sheet Metal Fabrication Technology and Machinery Exhibition.

Laser machines, press brakes, punching machines, bending machines, folding machines, water jet equipment and more will be shown for the first time in Thailand and ASEAN. Hundreds of major international brands from Japan, Germany, Belgium, Italy, Switzerland, Turkey, China, Taiwan, the US and Thailand will exhibit the latest industry technology.

BITEC Bangkok, Thailand May 13-16, 2015 Got a Question? Make An Enquiry.

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More Information Look no further â&#x20AC;&#x201D; event location, supply contact details,etc can all be found in the new website

M.E.N Mall Our new exciting product offering for 2015. You can advertise in the M.E.N Mall for as low as US$150 per month.

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PRODUCT FINDER Aicon: Automated Scanning In Production T he stere o S ca n white light scanner can capture minimal deviations and delicate structures with high accuracy (<0.1 mm). In contrast to a c o o r d i n a te measuring machine which touches single points, the scanner captures the entire surface of the component.

This results in a higher density of information. The user gets an exact 3D image of the measuring object with a colour map showing the deviations from CAD-data.

Manufacturer Aicon says that the 3D scanner comes with two 16-megapixel-cameras and is characterised by an detail resolution and an accuracy previously only known from coordinate measuring machines.

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Comau has developed the Racer 999, a sixaxis articulated robot.

With a reach of under a meter in length (999 m m), t he rob ot i s suited for applications in a lim ite d space including assembly, ha ndling, machine tooling, pack a g ing and more.

De sig ned for a payload of 7 kg, the robot can carry up to 10 kg. In addition, the robot features an E-motion software to optimise movements and increase their fluidity in order to reduce cycle times by up to 25 percent compared to the previous-generation robot.

Finally, the reduced dimensions of the robot and the controller also provide lower energy consumption due to the installed energy reduction system.

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Comau: Compact Robot

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75

PRODUCTFINDER Dormer Pramet: Carbide Rotary Burrs

Dormer Pramet has added a range of carbide rotary burrs to enhance its support tools program for general machining processes. The burrs will be available with an assortment of designs and shapes to choose from, including ball nosed cylinder, pointed tree, oval, flame, 60 deg and 90 deg countersinks, cones and inverted cones varieties.

Its combination of carbide head and steel shank (above 6 mm) provides a mix of rigidity and strength.

This feature reduces vibrations, resulting in a consistent and secure performance, as well as an improved tool life.

Got a Question? Make An Enquiry.

ENQUIRY No.

3703

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GOM has developed the V8 version of its measurement and evaluation software, GOM Inspect Professional.

One of the functions enables the tracking of movements and deviations in real time. The live module allows Atos 3D scanners to trace single points as well as complete component geometries in space.

In addition, the software simplifies the analysis of recurring structures, which often occur on mould cavities, gears or connectors. Using the cluster analysis, a complete set of evaluations can be marked and shifted to the next position within a structure. At the push of a button, the software recalculates the individual inspection elements. In this way, the entire inspection process for recurring structures can be repeated quickly.

Got a Question? Make An Enquiry.

3704

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76

asia pacific metalworking equipment news April 2015

Iscar has developed the SpinJet, a coolant driven high-speed spindle.

The range has been specifically designed for use with small diameter tools on low rpm machine tools and is suitable for semi-finish and finish machining applications such as milling, drilling and grinding.

The system utilises the machine tool’s existing coolant supply, driven by a high pressure pump (minimum 20 bars) as an effective energy source to rotate an integral turbine at speeds up to 40,000 rpm.

The manufacturer says that the device is not intended to replace a machine’s spindle, but rather to upgrade the existing machine. The system is said to increase productivity by up to 65 percent when compared to machining with a machine’s existing low rpm spindle.

Got a Question? Make An Enquiry.

ENQUIRY No.

3705

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Sandvik Coromant: Vibration Damper For Deep Hole Machining

GOM: Quick Measurement

ENQUIRY No.

Iscar: Low Cost High Speed Machining

A vibration damper from Sandvik Coromant is said to help maintain stable production during Deep Hole Machining (DHM) operations. Using the machine control adjustment unit, the device allows operators to step away from the machine and manage process modification without hand tools or the risk of personal injury.

According to the manufacturer, the vibration damper offers bi-directional functionality, ensuring it can be deployed for both push and pull applications.

In addition, there is a self-locking unit in the event of a power loss.

Got a Question? Make An Enquiry.

ENQUIRY No.

3706

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PRODUCTFINDER

Studer has developed the S131 and S151 grinding machines, following the success they had with the S141. The S131 is smaller than the S141 — with a swing diameter over the table of Ø250 mm and a maximum grinding length of 175 mm for internal and 125 mm for external grinding. It is available for workpieces with a maximum length of 300 mm.

The S151 is larger than the S141 — it has a swing diameter over the table of Ø550 mm and a maximum grinding length of 400 mm for internal and 150 mm for external grinding. It is available for workpieces with a maximum length of 700 mm.

Got a Question? Make An Enquiry.

ENQUIRY No.

3707

ENQUIRY NO 085

Studer: Internal Grinding

ENQUIRY NO 081

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April 2015 asia pacific metalworking equipment news

77

PRODUCTFINDER Sutton Tools: High Productivity Tap

Walter: Carbide Drilling Tools

Sutton Tools ha s ex tended its Black Magic Family of Tap range that enables component manufacturers to achieve productivity while minimising tap inventory.

The tool features a three percent vanadium grade powdered metallurgy high speed steel (PM-HSSE) as a base material. According to the manufacturer, the base material incorporates a finer grain and homogenous structure compared to conventional HSS. This design offers greater toughness while maintaining high hardness.

Wa lter ha s develop e d the DC170 and is offering the first two models in dimensions 16x Dc a nd 20xDc. The company says the drill offers more process reliability, stability, running smoothness and efficiency than carbide drills with traditional geometries.

The drills are internally cooled. As a result, the coolant flows unimpeded, while hazardous chip jams are at the same time avoided. The manufacturer also says that the solid carbide mass directly behind the cutting edge makes the drill sturdy.

Finally, drills straight from the factory are supplied with eight visible channels that can be used as a scale for regrinding. The drills can be reconditioned up to three times, until only two cooling channels are left remaining.

Got a Question? Make An Enquiry.

ENQUIRY No.

3708

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3710

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Tsugami: Versatile Machine

Widia: Universal High-Precision Collet Chuck

T h e Ts u g a m i S206II with IMG 400LS laser cutting system combines six- a x is Swiss machining w ith laser cutting on one machine, allowing manufacturers to perform both operations with a single setup.

While originally designed for the production of small cylindrical parts for the medical industry, the machine has potential applications for other industries that manufacture similar sized parts.

According to the manufacturer, the machine allows users to machine complex parts while using the main and back spindle simultaneously. All laser cutting operations are programmed and driven from the machineâ&#x20AC;&#x2122;s Fanuc 32iB NC machine control.

Widia has developed a universal, high-precision collet chuck offering use in multiple applications (milling, drilling, reaming, and tapping), while maintaining runout accuracies of 0.003 mm at 3xD. Some of the features include added versatility, thicker chuck walls and longer spindle and tool life.

In addition, the collet is available with Safe-Lock pull-out protection from Haimer. Helical grooves are ground into the shank of the milling tool that, together with the respective pin drivers in the chuck, prevent the tool from spinning or being pulled out of the holder altogether under extreme machining conditions.

Got a Question? Make An Enquiry.

ENQUIRY No.

3709

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78

Got a Question? Make An Enquiry.

ENQUIRY No.

asia pacific metalworking equipment news April 2015

Got a Question? Make An Enquiry.

ENQUIRY No.

3711

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EXHIBITION PROGRAMMES APRIL

13 – 17 Hannover Messe

20 – 23 Metaltech

Hannover, Germany Deutsche Messe www.hannovermesse.de/en/contact/ www.hannovermesse.de/home

PWTC Kuala Lumpur, Malaysia Tradelink info@tradelink.com.my www.tradelink.com.my/metaltech/

14 – 17 MTA 2015

27 – 29 BuildTech Yangon 2015

Singapore Expo Singapore SES mta@sesallworld.com www.mta-asia.com

Myanmar Convention Centre Yangon, Myanmar Sphere Exhibits sphere@sph.com.sg www.btyangon.com

12 - 14 Inapa Surabaya

Grand City Convention & Exhibition Centre Surabaya, Indonesia info@gem-indonesia.net www.inapa-exhibition.net

SEPTEMBER 7–9 Aluminium India Bombay Exhibition Centre Mumbai, India Reed SI Exhibitions aluminium@reedsi.com www.aluminium-india.com

MAY

JUNE

BITEC Bangkok, Thailand UBM Asia Sukanya.A@ubm.com www.intermachshow.com

Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo Indonesia maysia@pamerindo.com manufacturingsurabaya.com

13 – 16 Subcon Thailand

24 – 27 Manufacturing Expo 2015

8 – 10 Metalex Vietnam

JULY

28 – 31 Korea Metal Week

13 – 16 Intermach

BITEC Bangkok, Thailand UBM Asia Sukanya.A@ubm.com www.subconthailand.com

10 – 13 Manufacturing Surabaya

BITEC Bangkok, Thailand Reed Tradex manufacturing-expo@reedtradex.co.th www.manufacturing-expo.com

7 – 10 MTA Vietnam

SECC Ho Chi Minh, Vietnam SES event@sesallworld.com mtavietnam.com

AUGUST 4–7 MTT Expo

JIExpo Kemayoran Jakarta, Indonesia ECMI exh@mtt-indonesia.com mtt-indonesia.com

26-29 PDMEX 2015

World Trade Center Metro Manila, Philippines MAI (Market Access & Innovation) Management Philippines mai_mgt@compass.com.ph www.equipment-news.com

2015

18 – 23 EMO

Hannover Fairground Hannover, Germany www.emo-hannover.de

OCTOBER

SECC Ho Chi Minh, Vietnam contactcenter@reedtradex.co.th www.metalexvietnam.com

KINTEX Seoul, South Korea Korea Trade Fairs master1@ktfairs.com www.korea-metal.com/en/asp/main.asp

NOVEMBER 18 – 21 Metalex

BITEC Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th

To be considered for inclusion in the calendar of events, send details of event to:

The Editor (APMEN) Eastern Trade Media

1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Email: josonng@epl.com.sg Tel: +65 63792888 April 2015 asia pacific metalworking equipment news

79

ADVERTISING INDEX Page No.

Enquiry No.

AGMACHINE TECHNO CO LTD

77

081

BENIGN ENTERPRISE CO LTD

35

066

BYSTRONIC PTE LTD

FC/01

061/062

CARL ZEISS S.E. ASIA

17

072

DEES HYDRAULIC INDUSTRIAL CO LTD

69

068

DELCAM PLC

07

075

02/03

078

ECMI SERVICES PTE LTD (MTT EXPO 2015)

71

058

EVERISING MACHINE CO

45

083

EXXON MOBIL

33

077

HAAS AUTOMATION INC

11

055

HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD

13

064

HWACHEON ASIA PACIFIC PTE LTD

21

057

ISCAR LTD

IFC

063

KENNAMETAL INC

BC

102

LICO MACINERY CO LTD

47

082

LIEH CHIEH MACHINERY CO LTD

39

067

MAI (MARKET ACCESS & INNOVATION) MANAGEMENT PHILIPPINES (PDMEX 2015)

73

079

OKUMA CORPORATION

IBC

056

OPTICAL GAGING (S) PTE LTD

05

010

PT PAMERINDO INDONESIA (MANUFACTURING SURABAYA 2015)

59

080

RE-ATLANTIS ENTERPRISE CO LTD

75

070

REED TRADEX CO LTD (MANUFACTURING EXPO 2015)

65

084

RENISHAW (HONG KONG) LTD

15

053

ROHM ASIA PACIFIC PTE LTD

19

076

SCHUNK INTEC PTE LTD

25

074

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2015)

67

012

TAEGUTEC CO

23

065

TAIWAN TAKISAWA CO LTD

31

073

TORNOS TECHNOLOGIES ASIA LTD

51

069

TRADE LINK ITE SDN BHD (METALTECH 2015)

57

042

TSUGAMI UNIVERSAL PTE LTD

41

011

UBM ASIA (THAILAND) CO LTD (INTERMACH 2015)

55

059

WALTER AG SINGAPORE PTE LTD

09

060

YIH CHUAN MACHINERY INDUSTRY CO LTD

43

071

Advertiser

DMG ASIA PACIFIC PTE LTD

80

asia pacific metalworking equipment news April 2015

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ASIA PACIFIC METALWORKING

No. 3 2015

The Engineering Journal For Manufacturing,Automation & Quality Control

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Motor Vehicles Parts

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ENQUIRY NO 056

is Better Thinking. ™

INTRODUCING

The Stellram Platform

®

7792VX High feed milling cutter designed to yield the highest levels of productivity by increasing metal removal rates — as much as 90% — in titanium and other mission-critical metallics. ™

X-Grade Carbide inserts with up to 3 times the normal tool life for high-temperature heat resistant alloys. Designed for use on nickel-, cobalt-, and titanium-based alloys. ™

Different Thinking is the leadership to transcend what customers need — and deliver solutions they can’t live without. Kennametal’s unique perspective, forged from more than 75 years of experience, allows us to see beyond the expected and engineer perfect solutions.

Different Thinking is Better Thinking — and this powers our continued commitment to delivering productivity in the most demanding environments.

www.kennametal.com ©2014 Kennametal Inc. l All rights reserved. l A-14-03805

ENQUIRY NO 102