Official Magazine Of Metaltech 2012 April 2012
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M.I.C.A. (P) No. 053/06/2011
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Contents April 2012
Cutting Edge 22
Sparking A Smooth Process EDM is prized for its accuracy and used by industries seeking precision. However, one issue was the surface integrity of EDM-machined components, which has now been improved on by better understanding what affects it. By Sherlyne Yong
28
Last Word‌EDM In Action
Milling and EDM machines are used to produce injection moulds and cutting tools that are deployed in an in-line progressive co-moulding system, developed to combine die cutting technology with injection moulding. By Klaus Malle, for GF AgieCharmilles
Tech Talk 30
Cryogenic Machining: A Sub Zero Performer
Starting life as a laboratory curiosity, cryogenic machining has evolved into a hot topic these days. By Augustine Quek
Software & Metrology 36
Five-Axis CMM Inspection Speeds Things Up At Engine Plant
Five-axis scanning probe systems are slashing CMM inspection and probe calibration times, and speeding up QC feedback for machining of small engine components. Contributed by Malcolm Price, Renishaw UK
Sheet Metalworking 40
48
You can have the fastest engine strapped to the leanest, lightest chassis, but replace proper tyres with wheels from a shopping trolley and you will end up going nowhere fast. The same analogy applies to the relationship between a CNC machine tool and the software that programs it. By Martin Bailey, JetCAM International
The sales manager of Salvagnini Group (Southern Asia and Pacific) shares with Asia Pacific Metalworking Equipment News his take on modular sheet metalworking system. By Joson Ng
Opinions: How To Evaluate A Sheet Metal/Composite CAM System
2
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Roberto Graziosi On Flexible Manufacturing System‌
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Contents April 2012
Industry Focus 50
Opinions: Mouldmakers, Be Courageous!
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.
Advanced software and cutting tool technologies take the fear out of pushing tools in mouldmaking. By Steve Bertrand, CNC Software
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: irenetow@epl.com.sg
52
Paperless Manufacturing In Mould Making
While paperless manufacturing environment can clearly reduce costs through the elimination of printed drawings and machine instructions, the real cost savings from a paperless approach comes from a streamlined process with fewer steps and faster time to market. By Jim Davis, Siemens PLM Software
IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS
Executive Zone 56
INDUSTRY Endorsements
DMG/Mori Seiki Pfronten Open House And Singapore GO
SPETA
Features 60
64
The heavyweights of the aviation world descended on Singapore for a round of technical exchange and at the same time explore business opportunities with local companies. By Joson Ng
On closer examination, titanium alloys and highly heat-resistant superalloys, both known to be difficult to cut, behave differently from each other under machining conditions. Contributed by Jaslin Huang, Walter AG Singapore
Aerospace Technology Leadership Forum 2012
Federation of Asian Die & Mould Associations (FADMA)
Taming The Untameable
Events & Exhibition 68
• Event Preview: Metaltech 2012 • Event Preview: CIMES 2012
Regulars
08 Business News 76 Product Finder 79 Exhibition Programmes 80A Product Enquiry Card 4
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Federation of Malaysian Foundry & Engineering Industry Associations
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Great moments in product decision-making. A shipbuilder saves a month in its launch... because an engineer saved a minute in design. Siemens PLM Software: Smarter decisions, better products.
Every great product is the product of great decisions. And sometimes, the smallest decisions can ripple through your shipbuilding lifecycle process to have the biggest impact on your product’s success. For leading shipbuilders throughout the world, Siemens PLM Software is an essential plateform for collaborative product decision-making. Our shipbuilding solutions give everyone in your product lifecycle process the information they need when they need it to make more informed decisions faster. The result: accelerated ship development, greater service efficiency and lower total cost of ownership. Find out how Siemens shipbuilding PLM solutions can help you make the decisions that make your products better. Learn more at siemens.com/plm/shipbuilding.
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editor’s
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Published by:
Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)
Reg No: 199908196C
managing director Kenneth Tan editor Joson Ng
The Economist Intelligence Unit recently identified Singapore as the third most competitive global city and the highest ranked Asian city out of a field of 120 global markets. The citystate ranked particularly well in the categories of physical capital, financial maturity, institutional effectiveness and global appeal. Attributing the country’s favourable ranking to its appeal as a global business location, Leo Yip, chairman of the Singapore Economic Development Board ( EDB), said Singapore’s competitiveness has made it attractive as a strategic location for MNCs and global mid-sized companies to manage their business, innovation and talent, in order to pursue growth in Asia. These comments came shortly after DMG/Mori Seiki established their service and application hub in Singapore, further emphasising the country’s ability to attract and compete. In a nutshell, to be attractive, one needs to be competitive. This makes a lot of sense, be it in the business world or the animal kingdom. In a ‘dog eat dog’ world, the least competitive party is most likely to be made redundant or relegated. It is therefore important to be the cheapest, fastest, and the best all at once. The desire to race ahead of everyone else can however, be detrimental at times. A sprinter may pull his hamstring, a racer may crash his car, or operators may cut corners at a workplace and injure themselves.
These analogies are all applicable to an organisation, or even a country. Balance, therefore, is the key to being competitive without having to pay a high price for it. Certain issues like staff morale, operational reliability and safety may not be quantifiable at first glance, but they can be a factor in the long run. In the pursuit of competitiveness, most decision makers may have macabre tales of cut backs and lay offs to tell. And for those left behind, one can only assume they are sympathetically classified under collateral damage. Instead of dwelling on a moral versus business dilemma, there might be a way out. A little innovation may go a long way. In this issue, we feature a story of an electromechanical components manufacturer. In addition to being a manufacturer, they act as a development partner for their client, resulting in the development of an inline progressive co-moulding system. It combines die cutting technology with injection moulding. A step up from the available manufacturing methods, this is a good example of how competitiveness is achieved with some ingenuity. At the end of the day, the message here is we got to do our best to survive and compete but there is more than one way to be competitive. Like a plane, reducing weight is not the only way to fly efficiently, enhancing fuel consumption in engines and the aerodynamics of the plane can be just as effective.
josonng@epl.com.sg
business development manager Randy Teo
randyteo@epl.com.sg
senior sales manager Derick Chia
derickchia@epl.com.sg
assistant sales manager Sally Chuen
sallychuen@epl.com.sg
editorial assistant Sharifah Zainon sharifah@epl.com.sg graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow
irenetow@epl.com.sg
contributors Sherlyne Yong Klaus Malle Augustine Quek Malcolm Price Martin Bailey Steve Bertrand Jim Davis Jaslin Huang board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR
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 MICA (P) No. 053/06/2011 PPS 840/09/2012 (022818) ISSN 0129/5519
Eastern HOLDINGS Ltd Executive Board
chairman Stephen Tay group executive director Kenneth Tan financial controller Robbin Lim
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Eastern
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Joson Ng Editor 6
metalworking equipment news April 2012
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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Businessnews Thailand On Its Way To Recovery
Chainarong Limpkittisin
S i n g a p o r e : T ha i la nd’s manufacturing sector is reported to be recovering from the floods last year that crippled many factories. Industry players have expressed confidence in the sector’s recovery, and foresee a positive outlook of the automotive industry. In his speech at the ASEAN Manufacturing Forum #1, HE Marut Jitpatima, ambassador extraordinary and plenipotentiary of the Kingdom of Thailand to Republic of Singapore said that there are government incentives
with aims to boost the growth and recovery of the manufacturing industry, by helping companies to bring in foreign experts and technicians to help rehabilitate the factories, in addition to providing duty free status for replacement machinery imports. MD of Reed Tradex, Chainarong Limpkittisin, has expressed confidence that the country will surpass the targeted production figure of two million vehicle units in 2012, especially after robust production figures seen in January and February.
T his is suppor ted by figures shared by Sakulthon Juangroongruangkit, VP of the Thai Summit Group. He has revealed that the factories in Thailand are now approaching full capacity utilisation rate, as opposed to just 13 percent in November 2011. Despite the lack of contribution from major player Honda, who contributed to 30 percent of production last year, car production in the first quarter of this year is expected to be 13 percent more than the same period last year. As a result, the healthy outlook of the Thai automotive industry has spurred the Thai Summit Group to invest a total of THB 9.6 billion (US$312.5 million) this year, of which THB 2.1 billion will be spent on procuring new machinery to increase productivity rates. Finally, Mr Juangroongruangkit said car production is also forecasted to reach 2.5 million units in 2015, with Toyota being the leader in car producers, and the compact car segment possessing the most popularity.
Stratasys Celebrates 10-Year Anniversary Of Industry’s First Low-Priced 3D Printer Minneapolis, US: Strata sys celebrated the tenth anniversary of its Dimension 3D Printer line, the first of its kind to bring 3D printing technology to a broad audience and accelerate the trend of 3D printer use in the market today. Additive ma nufacturing industry consultancy, Wohlers Associates, affirms this trend in Wohlers Report 2011, noting “Additive manufacturing’s reach was previously relegated to hightech laboratories at Fortune 100 companies, but it now extends to the smallest of organisations — and increasingly even to individuals. In the industry’s 23-year history, its compound annual growth rate has been 26.2 percent.” 8
metalworking equipment news April 2012
“Dimension laid the foundation for the 3D printing revolution we’re seeing today,” says Stratasys CEO Scott Crump.
“It opened the door to a whole new demographic of users that prev iou sly cou ldn’t acce ss additive manufacturing.”
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businessnews
Vietnam Stainless Cold-Rolled Factory Construction Completed South Korea: Posco completed the construction of an annual 150,000 tonnes scale stainless cold-rolled factory within the Nhon Trach Industrial Complex located near the city of Ho Chi Minh. The factory was completed in 13 months after starting construction in December 2010. With its completion, the annual production scale of the company’s Vietnam subsidiary will increase to an annual 235,000 tonnes. The company acquired ASC, an annual 30,000 tonnes scale Vietnam STS cold-rolled factory, in October 2009 and launched Posco VST, manufacturing 850,000 tonnes of cold-rolled products annually through facility expansion. The company decided to expand new production facilities based on projections that STS cold-rolled product demands will increase from the current 250,000 tonnes to 330,000 tonnes in 2015 in Vietnam. The company will also install an additional rolling machine by 2015 to increase annual production to 285,000 tonnes. Once completed, Posco VST will become Southeast Asia’s largest STS cold-rolled product manufacturer alongside Thailand’s Posco Thainox, which officially launched in December last year. STS cold-rolled product demand in the Southeast Asia region is forecasted to greatly increase at an average annual rate of eight percent from the 750,000 tonnes in 2012, reaching 950,000 tonnes in 2015. With this, the company secures production bases in Vietnam and Thailand, taking on 67 percent of the Southeast Asia cold-rolled product demand, securing both markets in advance while strengthening activities in the Southeast Asia market through global integrated marketing with Pohang, Zhangjiagang, and Qingdao STS factories. 10
metalworking equipment news April 2012
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NI & Asia Pacific College Open Graphical System Design Laboratory
Chandran Nair (second from left)
Austin, US: National Instruments (NI) and Asia Pacific College (APC) in the Philippines have forged a partnership and a joint Graphical System Design (GSD) Laboratory setup. Located at the APC School of Engineering, the GSD Lab aims to help engineering students move from theory to actually designing and prototyping systems using graphical tools like LabView, a visual programming environment that helps automate measurement, test and control of hardware. “Our collaboration with Asia Pacific College is a testament to our commitment to the academia. Through the Graphical System Design Laboratory and by using g raphica l tools to enha nce learning, we demonstrate what experiential engineering is all about, and enable students to take their ideas to the next level and see them come to life,” says Chandran Nair, MD for National Instruments Southeast Asia.
Graphical system design is a faster way for engineers to design systems that work in the real world. Unlike model-based design, which centres on mathematical modeling, graphical system design helps engineers focus on solving the application rather than working on computations. Complementing the GSD Lab hardware and software endowment are NI Academy courseware integration into APC’s Computer and Electronics Engineering curriculum, and a range of research and design projects, according to Stanley Glenn E Brucal, program director, School of Engineering, Asia Pacific College. “ With the acquisition of industry-relevant equipment and graphical tools, we can better train our students with skills needed by the modern electronics industry. We are also looking to optimally leverage the GSD Lab for our students and faculty members’ research projects,” Mr Brucal adds.
304 Yonggye 4-ri, Gachang-myeon, Dalseong-gun, Daegu 711-864, KOREA Tel: +82-53-760-7640 Fax: +82-53-768-8055 http://www.taegutec.com Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Egypt _ Finland France _ Germany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Malaysia _ The Netherlands _ New Zealand Norway _ Pakistan _ Philippines _ Poland _ Portugal _ Romania _ Russia _ Serbia _ Singapore _ Slovakia _ Slovenia _ South Africa Spain _ Sweden _ Taiwan _ Thailand _ Turkey _ Ukraine _ United Arab Emirates _ United Kingdom _ U.S.A _ Vietnam
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Ametek Electronic Instruments Group Expands Facilities In China
APPOINTMENTS
Autodesk Appoints New Country Manager For Singapore & Brunei
James Wong
Autodesk has appointed James Wong as the country manager for Singapore and Brunei. In this role, Mr Wong is responsible for growing the Autodesk business in Singapore and Brunei — covering all of the company’s industries and product segments, and building strategic partnerships.
ABB Pioneers Breakthrough Rail Innovation
US: The Electronic Instruments Group (EIG) of Ametek has strengthened its presence in China by adding new sales and marketing personnel, and opening new sales and service facilities across the country. The company has recently expanded the centre of excellence for electronic instruments at its China headquarters in the Waigaoqiao Free Trade Zone, Pudong, Shanghai. Its Beijing office now includes a training centre, in-house repair facility and instruments demonstration laboratory. A new Chengdu office will also open in the first quarter of 2012 with expanded facilities to serve customers in western China. “In recent years, China has proved to be a dynamic, stable and permanent driving force for growth,” notes Volker Dreisbach, Division VP, Asia Pacific, for Ametek’s Electronic Instruments Group. “Despite the global economic crisis three years ago, which was felt in the huge Chinese market, we have continued investing in our businesses. Today, we are stronger than ever in China and plan to expand even further.” OFFICIAL
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Zurich, Switzerland: ABB has developed a traction transformer that uses power electronics to reduce its size and weight while increasing the energy efficiency of the train. The Power Electronic Traction Transformer (PETT) is based on a multilevel converter topology that uses IGBT (insulated gate bipolar transistor) power semiconductors and medium frequency transformers, replacing the conventional transformer and inverter combination. The medium frequency transformer also reduces noise levels. “The use of power semiconductors in a core component such as traction transformers opens up new opportunities for rail markets around the world, and should be extendable across a range of other applications,” said Markus Heimbach, head of the Transformers business, a part of ABB’s Power Products division. “In addition to its weight and size advantages, the PETT helps improve efficiency and reduces noise levels,” he added. This technology achieves one of the rail industry’s priority objectives of reducing the weight of on-board components. The traction transformer, which is traditionally made of iron and copper, is one of the heavy pieces of equipment on a train.
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Delcam Reports Record Sales & Profits In 2011
Birmingham, UK: Delcam has achieved record sales of £41.9 million (US$66.3 million) and record profits of £3.73 million for 2011. Sales increased by 14 percent over the previous record set in 2010, with growth seen in most of the company’s international markets. The latest results continue the growth in sales seen since 2009, with the further recovery in global manufacturing prompting increases in demand for both new software licences and maintenance contracts. Sales for the second half of the year reached a new high, meaning that the company has set new sales records in each of the last four half-year periods. The company’s improved performance was evident in its traditional markets, in particular in the automotive and aerospace
industries, as well as in its newer healthcare business. The strongest overall sales continued to come from the US and Germany, while the fastest increase in sales of new software licences came from Asia, especially India, Indonesia, South Korea and the company’s direct sales in China. However, there were many global examples of significant growth, with 28 of Delcam’s resellers achieving increases in their sales of more than 20 percent. Other highlights of the year included the presentation of Delcam’s sixth Queen’s Award for Enterprise in June and the announcement by CIMdata in July that the company had retained its position as the world’s leading specialist supplier of CAM software and services.
Applied Materials & IME To Drive Advanced 3D Chip Packaging In Singapore Singapore: Applied Materials and the Institute of Microelectronics (IME) have opened the centre of excellence in advanced packaging at Singapore’s Science Park II. The centre has been built with a combined investment of over US$100 million from Applied Materials and IME. The facility features a 14,000 sq ft Class-10 cleanroom and is equipped with a fully-integrated line of 300 mm manufacturing systems to support 14
metalworking equipment news April 2012
the R&D of 3D chip packaging, a critical growth area for the semiconductor industry. The centre will be the most advanced lab of its kind dedicated to wafer level packaging and will combine the company’s equipment and process technology with IME’s research capability in 3D chip packaging. The centre is expected to help accelerate the development and adoption of 3D packaging technology globally.
Sescoi Appoints A Distributor In Malaysia
Eddie Wong
Malaysia: Sescoi is expanding its Asian network of offices and distributors by appointing WCS Solution as Malaysian distributor f o r i t s Wo r k N C C A D/ C A M software, and for WorkXPlore 3D, its high-speed view, mark-up and analysis system. L o c a te d i n Pe n a n g, t he company aims to provide a complete productivity package for the 3D engineering design and manufacturing process and has a team of skilled engineers capable of offering support. The company works across a wide range of industries within the region including automotive, mould and die, aerospace and medical, which maps exactly to the type of customers using Sescoi’s software elsewhere around the world. Mr Eddie Wong from WCS Solution says: “WorkNC is renowned for being reliable and easy to use and it has been well proven in European, US and Japanese markets where it is used to program advanced CNC machinery, right up to full five-axis, on the most complex components. Asian companies are facing challenging times. Some of it is out of their control such as natural disasters or economic downturn, so to mitigate against this they are looking for cost savings and productivity improvements through better equipment and know how.”
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Honda To Construct A Fourth Motorcycle Plant In Indonesia
Indonesia: PT Astra Honda Motor (AHJ), Honda’s joint venture company in Indonesia responsible for motorcycle production and sales, will build the fourth motorcycle plant that produces scooter model exclusively with 1,100,000 units production capacity per annum, in order to satisfy the vigorous demand of Indonesia markets.
The annual production capacity of AHJ through the construction of the plant, including the existing plants, will become 5,300,000 units in total. This plant, which will be built in Bukit Indah Industrial Park about 70 km east from central of Jakarta, has planned to start operation in the autumn of 2013. The investment amount for the new plant is approximately INR3.128 trillion (US$341 million). The motorcycle market of Indonesia is the world’s third-biggest market next to China and India, and the further expanding demand is expected on the back of the steady economic basis in recent years. The total market of motorcycles in 2011 reached 8.01 million units as the highest ever, and became 109 percent compared with last year. The sales achievement of AHJ in 2011 was updated to record the highest volume in history with around 4.27 million units, and exceeded the growth of market by 125 percent compared with last year sales. For 2012, the total market is expected to be expanding by approximately 8.7 million units, and the company is planning to sell around 4.8 million units. Honda’s motorcycle production capacity in the Asia Oceania region has currently reached 11.5 million units in total. The production bases in the Asia Oceania region are expected to expand further capacity with the vigorous motorcycle demand on the back of economic growths.
Aicon Opens Showroom In Shanghai
Braunschweig, Germany: Aicon ha s opened a showroom in Shanghai (China). Offices and conference rooms are available for presentations, seminars or training courses. A full size TubeInspect is already installed and ready for use. It measures the tube with multiple high-resolution digital cameras and calculates the tube’s geometry. 16
metalworking equipment news April 2012
Jonathan Kwon, Asia Pacific regional manager, is excited about the new options: “The show ro om w ill a llow u s to actively engage with the Chinese customers. This makes sense because this is where our keyaccounts from A sia, Europe and America have important production facilities.”
Kennametal Named Among World’s Most Ethical Companies Latrobe, US: Kennametal has been named one of the World’s Most Ethica l Compa nies by The Ethisphere Institute, an international think-tank dedicated to the creation, advancement and sharing of best practices in business ethics, corporate social responsibility, anti-corruption and sustainability. The company was selected for ex hibiting leadership in promoting ethica l busine ss standards throughout its global operations and turning ethics i nto ac t ion by i nt ro duci n g innovative ideas and better business practices.
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Material: Cast Aluminium Dimensions: 250 × 220 × 100 mm Machining time: 16 min 35 sec
Material: Aluminium Dimensions: 87 × 60 × 10 mm Machining time: 2 min 50 sec
Material: Cast Aluminium Dimensions: 120 × 150 × 80 mm Machining time: 38 sec
MILLTAP 700 Fast, stable, better
1.1 sec tool change time, highly accurate with a 700 mm X-path and the fastest control MILLTAP 700 from DMG / MORI SEIKI. This machine features a patented tool changer (1.1 sec tool change time), stable base construction for milling and the best control technology available in the SIEMENS 840D solutionline.
Highlights _ Control: Siemens 840D solutionline, optional with JobShop and SINUMERIK MDynamics _ 30 % narrower, 10 % smaller footprint – Innovative machine design and optimised table construction compared to other manufacturers _ Largest work area with travels of 700 × 420 × 380 mm _ PROGRESSline – Clear display of remaining machining time and number of pieces* _ Highest precision with the direct path measuring system* _ 30 % energy savings compared to competitors through the advanced electrical package
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Powerful tool changer _ Tool change times of 1.1 sec _ Chip-to-chip times under 1.5 sec _ 15 (25)* Tool magazine pockets _ 60 m/min rapid traverse in all axes * Optional
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All the latest news available at: www.dmgmoriseiki.com DMG / MORI SEIKI Singapore DMG Asia Pacific Pte Ltd.: No. 3 Tuas Link 1, Singapore 638584, Tel.: +65 66 60 66 88, Fax: +65 66 60 66 99, E-Mail: info@dmgasiapacific.com, info@dmgmoriseiki.com, www.dmgmoriseiki.com If your phone is equipped with QR-code recognition software, you will be directed to our homepage.
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Website For Automotive Segment
Singapore: Seco has launched a website designed to provide support to manufacturers in the automotive segment. The site also provides information of value to manufacturers producing agricultural and construction equipment, and is located at www. secotools.com/automotive.
The automotive site aggregates a variety of content in both video and written formats. Visitors are presented with a user-friendly experience that makes it easy to review information on the industry trends, process and product innovations and examples of real-world applications relevant
Thales Awarded Signalling Contract In South Korea
Singapore Is Asia’s Most Competitive City: Economist Intelligence Unit
Seoul, South Korea: Thales has been awarded a contract from Hyundai Rotem for Communications-Based Train Control (CBTC) signalling on the extension of the Sin Bundang Line. The company installed radio CBTC on the initial line from Gangnam to Jeongja, which went into service back in 2011. The extension will operate from Jeongia to Gwanggyo offering six additional stations. The Thales SelTrac CBTC solution includes moving-block technology, free-space radio for data communication between train and wayside equipment, Thales’s NetTrac MT central control system and a fully automated depot. Twelve existing trains and three new ones will operate on 18.5 km of the existing line and 12 km of the new line extension in fully driverless mode at 90 km/h. 18
to their operations. One of the highlights of the website involves 3D interactive models of vehicles that allow u s e r s to i d e n t i f y sp e c i f i c components and the current best practices used to produce them. The information provided on the site represents the wealth of data gathered by the company’s global network of experts who partner closely with automotive manufacturers worldwide. “Ma ny members of the genera l public think of the automot ive se g ment a s a mature indust r y w it h litt le change,” says Gilles Jolivet, international application expert for automotive. “In fact, it is an industry rife with innovation. From the drive to produce more eco-friendly vehicles to pursuing productivity and environmental improvements in production, automotive manufacturers face constantly evolving challenges.”
metalworking equipment news April 2012
S i n gap or e: T he Economist Intelligence Unit released its report ‘Hot Spots: Benchmarking global city competitiveness,” commissioned by Citi, which identified Singapore as the 3rd most competitive global city and the highest ranked Asian city out of a field of 120 global markets. Its number three ranking places Singapore in the company of New York (1st) and London (2nd), long acknowledged as economic and financial global hubs. Singapore ranked particularly well in the categories of physical capital (ranked joint first overall), financial maturity (joint first), institutional effectiveness (6th) and global appeal (4th). Leo Yip, chairman of the Singapore Economic Development Board, commented: “Singapore’s favourable ranking is testament to our appeal as a global business
location, plugged into the heart of a growing Asia. Our strong attributes of trust, knowledge, connectiv ity a nd liveability have underpinned our ability to attract investments, business, talent and ideas. Singapore’s competitiveness has made it attractive as a strategic location for MNCs and global mid-sized compa nies to ma nage their business, innovation and talent, in order to pursue growth in Asia. It is also becoming a strategic location for Asian enterprises to build capability to grow in international markets.” Covering a territory of only 275 sq mi, Singapore exemplifies the EIU finding that population density spurs a city’s competitiveness. The strong presence of global companies such as Proctor & Gamble and Rolls Royce in the city-
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Singapore is Asia's most competitive city
Timo Balk, Melbourne, Australia
state, alongside innovative startups and technological research, have produced a dynamic economic environment that continues to attract corporations seeking entry
into growing Asian markets. The report defined competitiveness a s “the demonstrated ability to attract capital, business, talent and visitors.”
Dieffenbacher Group Reports A Successful 2011 Eppingen, Ger ma ny: The Dieffenbacher Maschinen- und Anlagenbau is looking back on a successful business year in 2011. The company with headquarters in Eppingen increased its sales to €350 million (US$460 million) compared to the previous year. “The capital of the company could be raised and liquidity is still on a high level,” states WolfGerd Dieffenbacher, CEO of the Dieffenbacher Group placing emphasis on the financial stability of the company as a basis for further economic developments. The actual volume of orders amounting to more than €750 million ensures the full capacity utilisation in all divisions up to the business year 2013. On the basis of the existing orders, the year 2012 is expected to become the most successful business year of the Dieffenbacher Group with a record turnover to the amount of €425 million. Business Unit (Forming) The incoming orders could be 20
metalworking equipment news April 2012
nearly duplicated compared to the previous year, and the busine ss unit ha s recorded t he h i g he s t le ve l o f o rde r volumes of all time. The plants and developments within t h e b u si n e s s u n it fo r m i n g correspond to the trend in the automotive sector, ie: to develop pro ce sse s re ady for se r ia l production for the manufacture of light auto body components. Dieffenbacher has supplied to a Russian major customer two complete plants for the production of fibre-reinforced plastic components for a hybrid car. Still this year, further well-known automobile companies will produce lightweight components out of carbon fibres on Dieffenbacher production plants. Because of the consequent orientation of the company to the need for new lightweight components for emission reductions and energy saving, the company can also be optimistic about the future in this field.
The findings included 120 cities, assessed on the basis of 21 qualitative and 10 quantitative indicators. Michael Zink, head of ASEAN and Citi country officer for Singapore said: “The report comes under our Citi for Cities strategy, which aims to enhance prosperity in cities around the world. Cities are the engines of global economic growth and helping cities like Singapore to be more innovative, efficient and competitive benefits our clients, stakeholders and business overall.” “We hope the report will help enhance understanding of market competitiveness and enable Singapore to identify ways to strengthen its reputation as a worldclass financial and business hub and a great place to live.”
Alstom To Supply Trackwork For Singapore Singapore: The Land Transport Authority of Singapore has awarded Alstom a contract for the East-West metro line extension — known as the Tuas West extension — worth around €40 million (US$52.8 million). Tuas West extension works include the design, supply and installation of a 7.5 km double track on viaduct and aluminium 3rd rail, four elevated stations, plus the track in the Tuas depot, which consists of 18.5 km of single track, mainly in ballast. The construction of the trackwork is scheduled for completion in 2016. Following its completion, Joo Koon station will be connected to Tuas Link station. The Tuas West extension is set to serve 100,000 passengers a day and reduce travelling time by up to 35 minutes. “Our success in Singapore demonstrates our commitment to remain competitive while ensuring that we meet our customers’ needs for today and tomorrow,” said Dominique Pouliquen, Alstom Transport senior VP for Asia Pacific.
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Sparking A Smooth Process
EDM is prized for its accuracy and used by industries seeking precision. However, one issue was the surface integrity of EDMmachined components, which has now been improved on by better understanding what affects it. By Sherlyne Yong
E
lectrical Discharge Machining (EDM) is a machining process that is highly popular, with sinker EDM and wire EDM being the two most common techniques. As both methods do not entail direct contact with the work piece, it eliminates problems with vibration, chatter, or mechanical stresses, and creates a burrfree and smoother piece as a result. It is employed across a range of sectors, but mostly in the automotive and aerospace industries, due to its penchant for precision and the ability to form hard metals into complex shapes. Despite being highly accurate, one main concern within the EDM process is the resulting surface integrity of the work piece. Dr Yeo Swee Hock, associate professor at the Nanyang Technological University, has mentioned that surface quality “will always be an issue due to the underlying process mechanism inherent in EDM.� As a result, researchers and manufacturers alike have been looking to develop the EDM process such that good surface quality can be achieved without sacrificing too much of other factors, like material removal rate. 22
metalworking equipment news April 2012
EDM For The Aerospace Industry EDM is largely employed in the aerospace industry due to its ability to machine the hardest metals, such as Inconel and Titanium alloys, which are harder to work with traditional machining processes. It is also capable of machining small parts to exact dimensions, and produces parts with high strength and bending stiffness, low thermal expansion, and better fatigue characteristics. At the same time, surface integrity is of utmost importance to this industry, which prizes the stability of parts above all else. Currently used to manufacture
aerospace parts including engines and fuel systems, it is pertinent for all parts to be structurally sound, as even a slight defect (eg: metal flakes, micro cracks) could lead to huge disturbances in the overall system. Accordingly, the functional performance of components machined by EDM is influenced by surface quality and reliability, both in terms of topography as well as the state of the sub-surface layers. Topography would refer to superficial changes such as surface roughness and waviness, while sub-surface layer states include annealing and plastic deformation.
EDM is employed across a range of sectors, mostly in the automotive and aerospace industries, due to its penchant for precision
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EDM is employed in the aerospace industry to machine the hardest metals, such as Inconel and Titanium alloys
Phillip Capper, Wellington, New Zealand
Affected Surface Layers Surface quality is typically evaluated by the amount of recast layer and Heat Affected Zone (HAZ) that a work piece has. The recast layer is formed by molten metal particles that have been re-deposited back onto the work piece after the initial removal process. This layer is harder, and comprises of carbonised material that could potentially flake off during future operations. On the other hand, HAZ is a softer than normal layer that lies directly beneath the recast layer, and has a higher susceptibility to premature weakening and stress fractures. Both the recast layer and HAZ could contain micro cracks as well. As a result, parts that will be highly stressed were put through secondary processes such as etching and milling to remove recast layers. Some have argued that surface integrity is no longer an issue with the advancements in technology. A test conducted by aerospace manufacturer Lockheed Martin and EDM machine manufacturer Makino has revealed that today’s machines can produce components with barely any HAZ, as well as greatly reduced recast layers that can go as low as 0.0004 of an inch. However, one of the trade offs for such surface quality is the material removal rate. As Dr Yeo explains: “To have good 24
metalworking equipment news April 2012
surface quality would require lower material removal rate. Increase in material removal rate would sacrifice surface quality. This is fundamental.” Factors For Improvements • Discharge Time Improvements have been made to main components of EDM to better the process, which are the CNC-controlled axis where the electrode is attached to, the electrical generator that controls the discharge level and rates, and the dielectric container and filter. “There are a number of important factors, namely the discharge time, duty cycle, power setting and dielectric fluid,” says Dr Yeo of the parameters affecting surface quality. “To have excellent surface finish and integrity, I would say the discharge time is the most important because it would give rise to a ‘clean’ sparking.” The discharge time also refers to the pulse-on time during the EDM process, which is the duration of time
that the current is allowed to flow per cycle. While directly proportional to the amount of material removed, the discharge time is inversely related the level of precision as well. Material removal in EDM is achieved by a quick succession of discrete sparks, which makes use of the resulting thermal energy to form craters in the work piece. The size of the craters is the main distinguisher between a smooth or rough surface, with shallow craters that have large diameters contributing to smooth surfaces. This result can be obtained with a good control of the electrical discharges, by setting a small pulse-on time. • Pulse Intensity & Intervals Power settings like current and capacitance affect crater sizes as well. A higher current may save time by removing more material, but the surface quality suffers instead. Large discharges are often unstable and cause violent sparks that create deep crater erosion. This leads to inconsistency and less precision in the surface. C o n v e r s e l y, a b e t t e r surface can be created with a smaller peak current at high frequencies and the lack of capacitance. A study conducted by the National Taiwan University and Kaoyuan Institute of Technology has revealed that peak currents grew in conjunction with c a p a c i t a n c e , re s u l t i n g i n sharper waveforms that led to deeper craters and worsened surfaces. Capacitance has also affected the insulation
“The power generator is the sine qua non of an excellent EDM system.” - Dr Yeo Swee Hock
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Discharge time is the most important parameter in order to achieve excellent surface finish and integrity
Dave Bleasdale, Bushey
of the spark gap (the area between the electrode and work piece), such that energy was continuously supplied instead of reaching zero levels. It is also crucial for pulse intervals to be managed, as they affect the speed and stability of the cut by contributing to the flushing of material. There are higher chances of forming a recast layer if the intervals are too short, as the molten debris is not given time to be solidified and washed out of the gap. Wi t h t h e e f f e c t t h e s e electrical parameters have on the work piece’s surface quality, developments regarding the generator could lead to huge improvements within the EDM process. Says Dr Yeo: “The power generator is the sine qua non of an excellent EDM system. Better control of the voltage and current waveforms, supplemented with an excellent servo controller would be the best approach.” • Dielectric Fluid’s Multiple Functions All EDM processes, with the exception of dry EDM, utilises a dielectric fluid that is integral for machining. The fluid serves three main purposes of creating a dielectric barrier for the sparks, providing a flushing 26
metalworking equipment news April 2012
system, and regulating the temperature of the work piece during the process. The main types of dielectric fluid used are deionised water and hydrocarbon compounds, in which refined oil with high flash points such as kerosene are typically used. They are nonconductive, and create a plasma channel between the electrode and work piece that enables sparking. A smoother surface has also been the result of using oil as a dielectric fluid. Meanwhile, the other responsibility of the dielectric liquid is to perform a flushing function that is imperative to the construction of a quality surface. The lack of flushing would lead to the creation of recast layers and instability in the sparking process, as the molten debris contaminates the environment and affects the efficacy of sparks. Its primary function however, is to cool both the electrode and work piece. Flushing would enable fresh oil/water flow into the gap, and pulsed injection of the dielectric liquid has been shown to reduce tool wear. The presence of a cooling liquid is vital to the process as such machining processes produce a large amount of heat, which can cause plastic deformation in the work piece.
Powder-Mixed EDM For A Better Surface With a better understanding of the aspects affecting surface quality in the EDM process, new processes have been developed to create a better surface. One such development is powder-mixed EDM. Studies have shown that powdered additives have the ability to greatly reduce tool wear, increase material rates of removal, as well as produce a better surface. For instance, silicone powder can be added to the dielectric fluid to create a fine and corrosionresistant surface. It is suggested that the addition of the powder led to the erosion of a smaller crater as the impact force of the spark was smaller. Nickel powder, when added to the liquid, made the material surface abrasion resistant as well. Furthermore, a study conducted with titanium alloys as the main material showed that adding silicon carbide and aluminium powder to the kerosene enhanced the gap distance, resulting in higher debris removal rates and the depth of material removal. Better Quality Tomorrow While the surface quality of EDMprocessed components used to be a huge concern for the aerospace industr y, it is less pressing now with the advancements of technology. Researchers have a better understanding of the factors contributing to surface quality, which has led to the development of better systems, such as improving on the generator. Modern day machines can also produce parts that are structurally sound, with almost no recast layers or HAZ. However, manufacturers and engineers are continuously striving to improve EDM processes, so that surface quality and time savings can both be attained at the same time. MEN Enquiry No. 3001 Turn to page 80a or log on to www.equipment-news.com to enquire
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EDM In Action
Milling and EDM machines are used to produce injection moulds and cutting tools that are deployed in an in-line progressive co-moulding system, developed to combine die cutting technology with injection moulding. By Klaus Malle, for GF AgieCharmilles
A
part from producing electromechanical components used by the automotive industry, medical products and in the aviation and aeronautics industry, Kummer also acts as a development partner for its customers. Active in the area of tooling, die cutting, plastics and assembly technology, the parts manufacturer knows all the requirements for a stable production of metal and plastic components. This knowledge is important right from the start, ie: at the design stage. For example, in injection moulding, experts refer to the ‘reel-to-reel’ process as one in which the lead frame is provided as a strip from a reel, and it runs through the injection moulding machines before it is rolled up on a reel again. The Germany-based company has now further developed this method (reel to reel) into the progressive c o - m o u l d i n g p ro c e s s . T h i s method utilises the closing movement and closing force of 28
metalworking equipment news April 2012
the injection moulding machine for cutting and forming the stamped strip in upstream and downstream stamping tools. Cutting tool, injection mould and cutting tool form an in-line group of tools in this sequence inside a single machine. With e v e r y s t ro k e , c o m p o n e n t s are processed at three points within this tool group. In other areas of production, individual components are also handmade or inserted in injection moulds and overmoulded in complex robotic cells. The cutting tools and i n j e c t i o n m o u l d s t h a t a re featured prominently in the progressive co-moulding p ro c e s s m e n t i o n e d a b o v e a re m a n u f a c t u re d b y w i re cutting and die-sinking EDM machines. Wire & Die Sinking EDM: Key Tool Making Technologies Eleven EDM machines and one milling machine are used for erosive cutting (wire-cutting), die-sinking and milling of the g r a p h i t e e l e c t ro d e s . “ O u r
design requires a considerable amount of wire cutting and as such, we equip our machines to run unattended around the clock,” said Jens Hofmann, MD. The company mills the sinking electrodes, 90 percent of which are graphite required for this p ro c e s s , o n a h i g h - s p e e d machining centre with integrated palette magazine. Though reliable cutting and cavity sinking precision are vital prerequisites for tool making, the usage of CAD model forms the basis for a successful production. The CAD model is developed together with the client with Kummer providing the knowhow on die cutting, surface technology and overmoulding of inserted parts. Aiming for a stable process in production, designs are produced in CAD/CAM software programs. In addition, the design department produces the programs for wire cut, die sinking and milling processes. MEN Enquiry No. 3002 Turn to page 80a or log on to www.equipment-news.com to enquire
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Cryogenic Machining: A Sub Zero Performer
Starting life as a laboratory curiosity, cryogenic machining has evolved into a hot topic these days. By Augustine Quek
C
r yogenic machining involves the application of a fluid at low temperatures (cryogen) during material removal machining processes, to reduce or eliminate heating effects on tools. In certain machining processes, it could also be used as a cutting/ abrading medium. The cryogen could be applied as an external spray through a nozzle to perform both conductive and convective cooling of the cutting process, or could be applied indirectly to cool the cutting tool through conduction alone.
30
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Cryogenic cooling in machining processes offers a number of advantages and has moved from the exotic to merely out-of-the-ordinary. As tool wear decreases considerably, tool life increases, with the life of steel tools increasing to four times. In application of indirect cryogenic cooling, the surface roughness of materials machined with liquid nitrogen cooling was found to be much better than the surface roughness of materials machined without nitrogen cooling, after the same length of cutting. Liquid nitrogen
lubricated contact produced a lower friction coefficient than the dry sliding contact and the emulsion-lubricated contact. According to some researchers, cryogenic cooling did not significantly alter the cutting forces in machining of different materials. However, as energy consumption in a cutting operation is associated with friction and cutting forces, lower cutting forces can be expected for lower frictional forces. How Cool Is Cryogenic Machining? Cryogenic machining can be classified broadly into four categories based on the cooling approaches: Cr yogenic precooling of the work piece, indirect cryogenic cooling, cryogenic spraying and jet cooling. Cr yogenic pre-cooling of the workpiece or chip changes the properties of material from ductile to brittle when the chip temperature is lowered and becomes easy to dispose. This is achieved by pouring the liquid nitrogen continuously
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Liquid nitrogen is usually used in cryogenic machining
onto the work piece. However, this consumes a high amount of liquid nitrogen and workpiece dimensions may change. Indirect cryogenic cooling, also called conductive remote cooling, cools the cutting point through heat conduction. In this method, liquid nitrogen cools the tool shank instead of the tool tip, avoiding contact with the workpiece, and providing a stable cooling effect. However, the effect of this approach is highly dependent on thermal conductivity of the cutting tool material, material thickness a n d t h e d i s t a n c e f ro m t h e nitrogen source. In cryogenic spraying and jet cooling, the cutting zone, especially the toolchip interface, is cooled with liquid nitrogen using nozzles. This method can maintain a constant temperature without causing dimensional inaccuracy and geometrical distortion. Such localised c r y o g e n i c c o o l i n g re d u c e s t h e t o o l f a c e t e m p e r a t u re , enhances its hardness, and as a result, reduces its wear rate. The cold temperature 32
metalworking equipment news April 2012
maintained through this approach also embrittles the chip and allows easier chip bending with the chip breaker. It also eliminates the Built Up Edge (BUE) problem on tools because the cold temperature reduces the possibility of chips welding to the tool, and the high-pressure cr yogenic jet also helps to remove possible BUE formation. Developments In Industries In one cryogenic system, liquid nitrogen is applied to the centre of the cutting tool via the machine spindle, in order to dissipate cutting temperatures and minimise tool friction and swarf adhesion. This method of nitrogen application allows it to remain mostly in a liquid state. Because the liquid N2 is allowed to evaporate near the cutting edge of insulated tools, it promotes the dissipation of heat, which would otherwise soften tools and accelerate wear. Depending on the application, the nitrogen can be combined with minimal lubrication. In fact, the technology has been developed successfully
for the cryogenic machining of titanium. The team of Creare Incorporated, HM Dunn Company, and Mag Ias has worked with Lockheed Martin, the US Navy Small Business Innovation Research (SBIR) Program Office, and the F-35 Joint Program Office (JPO) for several years on the development of the low flow cryogenic machining of titanium. Cryogenic titanium machining supposedly improves cutting-tool life by a factor of 10 with appropriate material removal processing speed. The JPO in coordination with the F-35 Fracture Control Board (FCB) approved the process for standard roughing operations, impacting the most timeconsuming and cost-intensive machining processes associated with manufacturing titanium parts. Broadly applied, this t e c h n o l o g y c o u l d i m p ro v e affordability and efficiency in the production of the F-35, which is approximately 25 percent titanium by weight. Cutting Tools When compared with dry cutting and conventional cooling, the most pertinent characteristics of the cryogenic cooling application in machining operations could be determined as enabling substantial improvement in tool life and surface finishdimensional accuracy. It is achieved through the reduction in tool wear by controlling machining temperature desirably at the cutting zone. Goldedge Steel Solutions, a manufacturer of cryogenic cutting tools from Pennsylvania, US, has a patented cryogenic cutting tool process for drill and milling cutters. The treatment process is claimed to change the structure of the tool’s material, resulting in a significant increase in the cutting life.
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Cryogenic titanium machining has improved the efficiency in the production of the F-35
Increase Cutting Speeds & Throughput In a study conducted jointly by Air Products and Hoeganaes Corp, cryogenic cooling machining of sinter hardened materials were studied with different machining additives and four cooling options: dry, flood coolant, Liquid Nitrogen Top Cooling (LINTC) and Liquid Nitrogen Bottom Cooling (LINBC). The patented process of conductive tool cooling using cryogenic coolant was used. They found that among the cooling options, LINBC had the most positive impact on tool life for samples with and without additive, with improvements of 135 percent in tool life over dry cutting. In this method, liquid nitrogen is sprayed from the bottom of the insert through pre-machined channels in the shim, and is jetted out without contacting the work surface or the cutting area. This method has the advantage of hardening and toughening the insert by cooling it without adversely affecting the workpiece properties. 34
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This is significant because the machining of sinter hardened materials have always resulted i n i n c re a s e d a b r a s i o n a n d accelerated tool wear. The high amount of martensite in steel from the sinter-hardening process is responsible for the microhardness. Therefore, these studies prove that cryogenic machining can increase cutting speeds and throughput without tool overheating and increased
wear. This reduces machining costs and improves dimensional tolerances of parts, allowing manufacturers to remain costcompetitive. A Cold Future? Cryogenic machining technology has a high potential to cut production costs and i m p ro v e c o m p e t i t i v e n e s s . This is because continuous improvements in productivity through better cutting tools, machine tools, and processes have resulted in significant increases in cutting speeds. An unintended consequence of improving productivity gains is the significant increase in heat, generated in the cutting process. Cryogenic machining has so far proven to be the best temperature m a n a g e m e n t p ro c e s s t h a t increases machining performance and profitability, by improving throughput from the toughest materials and creating less waste. As long as the economics of part machining remains unchanged, where tooling costs greatly contribute to the total production cost, cryogenic machining will always offer a clean and a costeffective route to improve quality and performance in comparison to conventional machining. MEN Enquiry No. 3101 Turn to page 80a or log on to www.equipment-news.com to enquire
Did You Know? Cryogenic machining started as a laboratory curiosity and has found applications on the shop floor. One of the earliest known applications of cryogenic machining involved liquid carbon dioxide in machining during the early 1950s. Use of liquid nitrogen as a coolant in machining was first documented in the mid-1960s. However, issues related to economical machining with cryogenic fluids, variable material behaviour at cryogenic temperatures, and the lack of efficient delivery systems prevented industrial adoption and caused the level of research to drop off significantly in the 1970s and early 1980s. Since then, the need for more efficient machining of difficult-to-machine materials, as well as the desire to eliminate the use of oil or water-based cutting fluids has prompted renewed interest from several research groups and industries. This interest has also spawned the development of other cryogenic material removal processes.
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Metrology
Five-Axis CMM Inspection
Speeds Things Up
At Engine Plant
Five-axis scanning probe systems are slashing CMM inspection and probe calibration times, and speeding up QC feedback for machining of small engine components. Contributed by Malcolm Price, Group Marketing Services, Renishaw UK.
DIFFICULTY: Existing three-axis measuring devices require numerous probe configurations and long calibration times.
SOLUTION:
K
awasaki’s 800,000 sq ft Maryville plant (USA), produces single and twin-cylinder air-cooled or water-cooled engines, 1,000 cc or smaller, for commercial and consumer lawnmower OEMs, as well as for a sister plant that manufactures ATVs and Mule utility vehicles. Operations at Maryville include aluminium diecasting, plastic injection moulding, extensive amounts of machining, painting and assembly. “ We u s e t h e K a w a s a k i Production System (KPS),” said JC Watts, Quality Control Technical Group supervisor at the plant. The plant has 50 machining lines, typically arranged in a U-cell pattern with start and end machines across from each other. “Primarily, it’s one -piece production with machining lines running a part through multiple processes at a high rate,” Mr Watts 36
metalworking equipment news April 2012
Install a five-axis measuring system.
explained. The company utilises automation in many die cast and some machining operations, accompl i she d t h rou g h t he integration of Kawasaki robots. On one of the crankcase lines, robots load raw materials and unload finished parts that are placed into inventory for assembly to draw upon. Machined parts include aluminium, cast iron and steel. “ We ’r e r u n n i n g s i m i l a r tolera nce s that automotive powertrain uses for high-end products, and there are probably four or five critical processes for our aluminium parts and 15 for the steel parts,” he added. It is not uncommon to find tolerances “in single digits in microns” for form, and 0.05 mm true position. The QC lab is responsible for inspecting 125 different massproduced parts, as well as vendor parts and those produced for engineering development.
CONCLUSION: Inspection times cut by half or more on scanning intensive applications. Probe calibration times cut from six to seven hours to about 45 minutes.
Five-Axis Scanning “When I started here, we had a couple of three-axis CMMs with articulating heads and another CMM with a fixed probe head,” Mr Watts explained. “ We we re f r u st rate d w ith hav ing to ma ke probe configurations and being limited to what we could do even with the articulated heads. We had so many different probe configurations that calibration times of six to seven hours took a bite out of our inspection throughput too.” Kawasaki bought a new CMM in 2009 with a five-axis measuring system installed from the factory, a nd retrofitted a n identical
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capability of the system allows us to catch form errors much more quickly, without a time penalty on our inspections. It has definitely made us more proactive in catching quality problems early in the game.”
Flexibility of the five-axis measuring system has proven to be a time-saver
machine in 2010, after the first machine was up and running with all the part programs. The scanning probe head can collect up to 6,000 data points/ sec. It is engineered for highspeed precision measurement of contoured surfaces and complex geometries requiring high-volume data collection to validate fit and form with high accuracy. “Though our SP25s were scanning probes, we were doing 95 percent touch probing because scanning was too slow with a threeaxis CMM,” Mr Watts explained. “Our cylinder and crank bores are probably the best examples of where we believed touch probing was inadequate. To accurately collect enough data points to measure the geometry of a bore 80 to 100 mm in diameter and 150 mm in length, the SP25 probe took so long we limited those inspections to machine set up or special requests from our design department.” “Now on every crank case we measure, the five-axis measuring system does a spiral scan of bores and the system outputs the values to software. We also send a graph of the data points to our network that can be used by anyone in QC, engineering or production, and it really helps troubleshoot 38
metalworking equipment news April 2012
problems. You can visualise the problem. What would take three to four minutes with an SP25, we’re measuring in 10 seconds with the five-axis measuring system.” Touch Free The scanning heads have all but eliminated the need for touch probing. Now 95 percent of inspections utilise scanning, with no ‘time penalty’ as before, allowing the company to collect so much data that it challenges the speed of computers doing the analysis. “With scanning inspections, our production and engineering people have a lot more confidence that the data is valid,” he added. “With touch probing it is easy to get one speck of dirt that causes an out-of-round condition if you’re only sampling seven or eight points. It can throw the location of that circle off. We have specific documented examples of where there were flatness errors we would not have caught with touch probing, and cylinder bore geometries that would not have been caught with touch probing because of the amount of data sampled with the touch probe.” “We still caught these problems before they left the plant, but the parts were scrap. The scanning
Fewer Probe Configurations, More Flexibility With the five-axis measuring system, the Maryville operation now has two probe configurations that measure all of its mass production parts, reser ving custom probes in a changing rack for a few special applications. Special configurations for vendor parts have also been eliminated because the infinite positioning angles of the fiveaxis measuring system allow measuring of a part without special fixturing or consideration of which probe to use. With so few probes, calibration time has dropped to around 46 minutes. Now QC technicians monitor the calibration instead of calibrating every shift. “We are now able to measure all our mass production parts with just two probe configurations,” said Mr Watts. “We were able to eliminate the large ball stylus configurations because of the large approach angle the system creates between the stylus and the work piece. During scanning, t h e s y s te m m a i n t a i n s t h e approach angle which allows a large cylindrical feature such as a cylinder bore to be measured with the same stylus used for measuring a 5 mm bore, with no chance of shanking the stylus.” Flexibility of the five -axis measuring system has also proven to be a time-saver for Kawasaki. “We can measure any part on either machine with a limited amount of fixturing and no special calibrations,” said Mr Watts. “We measure all our parts on three types of fixturing. The probe orients itself to the part
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after it’s initially aligned. The utilisation of special fixtures has almost been eliminated, without concerns of measurement error due to part alignment.” Faster Inspection, Better Data Mr Watts says the transition from three -a xis to five -a xis programming is not difficult, and a programmer with limited ability can still program inspections with the new system as threeaxis. However, when it comes to optimising speed of inspection, it is critical to use head motion as much as possible. “This allows you to scan parts the quickest, without inducing measurement error,” he added. Inspection results may be relayed to the machining lines manually or they can be accessed locally by line operators over a computer network. “Some of our
inspection reports supply offsets directly back to the machining centre s coordinate system; this allows the CNC operator to read the offset adjustment right off the report, allowing no misinterpretation of what offsets the operator needs to input,” Mr Watts explained. “We take advantage of some of the ‘best fit’ algorithms and work with our production engineers, especially on parts that require more complex algorithms to get the adjustment right, and to utilise multiple process adjustments simultaneously.” Five-axis CMM scanning has been a game-changer for QC at the Maryville plant in terms of speed, data quality, and inspection capacity, according to Mr Watts. “We’ve enjoyed big gains from having two machines that are completely redundant, so if one
machine breaks or is down for calibration, it’s no problem to measure critical parts on the other machine. That’s a big advantage in the QC lab, because we were the ones who, in a pinch, had to get the large part on the small CMM, or the part requiring the odd angle probe on the machine that didn’t have it.” “We used to get requests from R&D to measure certain geometries, and it was next to impossible to achieve in the time allotted. Now we can provide the data much quicker and, being scanned data, our people have greater confidence in it. This new flexibility, the reduced fixturing, form measurement, the parametric programming — these are all collateral advantages, in addition to the raw inspection speed.” MEN Enquiry No. 3201 Turn to page 80a or log on to www.equipment-news.com to enquire
GRINDING WITH WINTERTHUR: ROBUST SOLUTIONS FOR LEAN PROCESSES 3M Thailand Limited TH-10110 Bangkok Phone: +66 2 260 8577 nkregnavakul@mmm.com Winterthur Technology Malaysia Sdn Bhd MY-47820 Damansara Perdana, Petaling Jaya, Selangor, Malaysia Phone: +603 7724 2611 michael.lee@winterthurtechnology.com.my P.T. 3M Indonesia Jakarta Selatan, 12520 Phone: +62 21 4288 8550 irwan.pramono@winterthurtechnology.co.id Winterthur Technology Korea Ltd. 441-813 Gyeonggi-Do Phone: +82 (31) 298 1777 sales@winterthurtechnology.co.kr Winterthur Technology (Taicang) Co. Ltd. 215400 Taicang / P.R. China Phone: +86 512 8161 6802 kristy.yin@winterthurtechnology.com.cn
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How To Evaluate A Sheet Metal/Composite CAM System You can have the fastest engine strapped to the leanest, lightest chassis, but replace proper tyres with wheels from a shopping trolley and you will end up going nowhere fast. The same analogy applies to the relationship between a CNC machine tool and the software that programs it. By Martin Bailey, GM, JetCAM International
C
AM systems are used to take electronic part drawings (CAD files), process and ‘nest’ them onto sheets or rolls of material, and convert the resulting nesting layouts to a series of coordinates and machining instructions, known as CNC programs so that the part can be accurately and effectively machined on a specific machine tool. The resulting code is sent electronically to the machine tool, ready for machining. These CNC programs are very specific to each particular CNC machine technology and machine controller. There are several stages to creating a CNC program, starting with the definition (drawing) of component geometry if CAD facilities in CAM system are being used, or with importing and ‘healing’ of component geometry, which was created in an external CAD or unfolding software. Nesting — The Maximising Exercise Once the correct component geometry is available within
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the CAM system, tooling and/or profiling/cutting information needs to be added. Depending on the CAM system in use, this can be done interactively, automatically or in some combination of both. This information differs from machine to machine and across machine tool technologies in use. Once all of the machining information has been applied to components, the next task is to ‘nest’ them — squeezing as many components on the sheet or a roll of given size as possible. A nest might consist of the same parts or a mixture of different parts, and can be classified as either rectangular or ‘free form’ (true shape). Re c t a n g u la r ne st i n g, a s the name suggests, nests each component as if it were a rectangle, which will result in a significant waste of material if you are cutting many irregular shapes. With rectangular nesting, parts may be nested at different angles, but are usually nested at 0 and 90 degrees. Free form nesting offers the best material yield by being able to nest parts at any angle and also taking
advantage of any scrap material within larger components, such as cut-outs. Depending on the level of automation within a particular CAM system, the placements of parts will either be a manual or automatic process (or could be a combination of the two). Manual nesting for dissimilar components is often performed by dragging and dropping parts on the nest, also known as bump nesting. Unless the operator is very skilled, this process can result in significant material waste, and in any case is invariably a very slow process. Because of this, many companies currently produce so called ‘static’ nests, which were created manually and are regularly re-used. The problem with this is that all of the parts will be produced each time a particular nest is run on the machine, regardless of whether they are all needed or not. ‘Dynamic automatic nesting’ on the other hand allows for unique nests to be created as and when required, providing a ‘Just In Time’ approach while retaining high material efficiency. This of course is especially important when processing expensive materials. A reasonable CAM system should, among others, allow you to also consider: 1. How parts will be unloaded 2. What rotations a component will be constrained to, if any 3. Heat avoidance — when cutting thicker materials, heat can build up when cutting more intricate areas. 4. Whether common line cutting should be used between parts on the nest or a sheet ‘skeleton’ between parts will be left. 5. Clustering components together, ’broken orders’ 6. Nesting flexibility — many free
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form nesting modules will run their single nesting algorithm once, producing not so spectacular results, whereas others will run through various nesting algorithms and can be set to run for a desired period of time, from few seconds to say overnight, to deliver the best possible material yield. Some systems will intelligently ‘le a r n’ your prefer red tool placement settings as you continue to apply tooling, quickly becoming self-sufficient. At this point we now have our nest with all of the cutting information applied; however, there is a nother impor ta nt consideration that ha s a significant impact on the cutting time — the sequence in which these instructions are processed. Sequencing can either be an interactive or automatic process and there can be a vast difference in the sequencing efficiency between various CAM systems. Simulation — Looking Ahead We are now in a position to generate NC code, however, programmers will often want to simulate the job prior to running it on the machine. On a capable CA M system, simulation will show exactly what will happen when the nest is run on the machine tool. A large amount of time and money can be saved by graphically simulating the machining process, and identifying any possible problems, such as a component being cut/punched/unloaded incorrectly and wrong machining sequences specified. Simulation gives the CNC programmer a great deal of confidence. Once we are satisfied with the simulation, a CNC program for the machine can be generated. This is normally done by a special module in the CAM system, which takes the ‘generic’ machining data stored in the CAM system’s database for 42
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Nesting involves ‘squeezing’ as many components on the sheet as possible
a particular nest and converts it to CNC program instructions a particular machine tool will ‘understand’. This is referred to as ‘post processing’ and the module is usually called ‘postprocessor’ (regardless whether it is an internal or external function to the CAM system). Just about every machine tool requires different instructions and to complicate the matter further, each machine tool can offer a wide range of options such as complex loading/unloading systems, tapping attachments and labelling devices. Additionally, there are so called ‘combination’ machines, which combine two or even three different machining technologies in one machine tool (ie: Punch/ Laser or Punch/Right Angle Shear combinations) and these can also have any, or all of the special options, mentioned above. When you purchase your CAM system from an independent vendor, you will choose a postprocessor to match your machine. This is actually one of the most important aspects of a CAM system, as without a well constructed postprocessor, you will not get the best out of your machine. A postprocessor could be compared to a printer driver — taking your printed document and converting it to something that your printer can understand and produce. Ask the vendor for details of
some of their existing customers that have the same machine tool so that you can find out their experiences. If the machine is new and no postprocessor exists, you will probably need to supply the machine programming manual and other information to the CAM vendor in order to allow them to develop the required postprocessor for you. Small, Medium Or Large? The price point of software that you evaluate will be determined by the functionality and automation it offers. As with everything else, you get what you pay for. It is a fact that although CAM systems have an impact on numerous areas of the business, many companies make the mistake of tasking the selection of CAM software to the CNC programming department alone. Idea lly it should have sponsorship and final expenditure sign-off at board level, members who should understand the potential impact of it on the whole operation. Which CAM system you should select depends very much on your company’s operation, machine tools in use, and the quantities and mix of parts being produced. Materials you are processing and their prices also figure strongly in this evaluation. The Process Of Evaluating A System The key to an effective evaluation
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Efficient nesting and the ability to produce complex dynamic nests quickly might allow you to standardise on fewer material sizes
pro ce ss is b eing able to demonstrate quantifiable savings in three key areas:
1. Demonstrate the process of interactively and (if applicable) automatically tooling the parts
1. S t a f f t i m e , c o v e r i n g programming, reporting and anything else related to the CAM process
2. Demonstrate the process of interactively and (if applicable) automatically nesting the parts
2. Machine cycle time (also referred to as runtime) 3. Material utilisation All of the above have quantifiable costs. Before you even consider evaluating CAM systems, you need to understand what those costs currently are. Man-hours are generally simple enough to cost, as are your machine runtimes and costs, although it is always a worthwhile exercise to follow a few jobs through all processes and note all costs associated with them. Calculating Your ROI By now you should have a clearer idea of what you need, so it is time to start investigating the market. Recommendations should carry more weight, especially if they come from users that have the same machines as you. Once you have selected your vendors you need to arrange for a benchmark comparison. Provide each vendor with a series of parts in the form of DXF or IGES files, along with tooling and nesting parameters and ask them to perform the following: 44
metalworking equipment news April 2012
3. Demonstrate how easy it is to move parts or nests between machines (useful in the event of a machine breakdown) 4. Provide the final nests and reports so that you can compare the efficiency against your own nests 5. Demonstrate how information can be extracted from the system for reporting purposes so you can compare it with current methods of creating similar reports. See if additional beneficial information that may be unavailable using your current methods can be retrieved. In addition to the savings that you can tally up, there may be other benefits which might not be so easy to spot that will help in providing a quicker return. For example, more efficient nesting and the ability to produce complex dynamic nests quickly might allow you to standardise on fewer material sizes. Not only would this make stockholding simpler, it can have a knock-on effect on your purchasing power. Once you have your set of figures, it is then a simple process
of adding them up and comparing old versus new. Various CAM Software Approaches Some CAM systems will simply take component geometries, nest them and then apply tooling or cutting at the nest level. Such practices save a CAM vendor significant development overheads and have certain advantages, but as far as the user is concerned, there is a very significant drawback using this technique. Such systems cannot retain a ny i n for mat ion re ga rd i n g the machining of individual components, which means that any machining information added or modified on a particular component only exists on that particular nest and if one needs to nest that same component sometime in the future again, that same machining information will have to be added/ modified manually again. It is impossible to use such systems for reliable automation, except for most simple machining technologies where (and if ) interactive modifications to the way a particular component is machined are never required. On the other hand, some other CAM systems will store the component’s machining information in a specia l component file together with component geometr y, but a separate component file may be required for each machine the user may want the component made on, and sometimes even for each different angular position of the component on a nest. This still complicates matters quite a bit, as any revision of component geometry or tooling may force modifications of many similar files, which is obviously time consuming and error prone. However, a s the machining information is stored together with a particular component geometry, there is no need for re-entering any
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of it when a component needs to be nested again. Paying the price of vastly higher development overheads, producers of the best and most capable CAM systems will utilise a combination of both methods to achieve the most flexible and efficient machine programming system, while storing geometry and machining information in a single component file. I n such system s, once programmed (either manually or automatically), a component file will store any important machining information for any angular position that a particular component is desired to be nested at (ie: 0, 90, 180, 270 degrees), and for any number of machines an user may be operating, ready for nesting at any time, at any angle, on any machine, without any human intervention. In this context, it is important to remember that on certain machines (ie: Punch Presses), tooling and unloading information may be very different depending on the component’s angular position on the sheet. Depending on the machine tool selected, to finalise a nest, additional machining or modifications (ie: common line cuts, trimming, tool substitution, repositions, leadin optimisation and unloading information) may be added to the nest by the system automatically. What this means to users is that if a particular machine breaks down, all unfinished component orders can immediately be redirected to another machine with new nests created in seconds, whether manually or automatically (ie: a component normally produced on a punch press can be redirected to another one, or a laser, and vice versa). It also means that components can be nested and produced ‘Justin-Time’ on any machine at any time, based on the current machine 46
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loading, ideally keeping all the machines busy all the time. Conclusion Software rarely has the same perceived value associated with hardware — you cannot touch it, for example, so it is very easy to overlook the positive and negative effects that the right or wrong product can have on your business. Whether it is your MRP system that has gone down, or your CAM system causing problems, it all boils down to the same thing — time and money. Over time, visionary companies will all opt for reliable, completely automated solutions to increase throughput and minimise overheads and waste. W hile the initia l cost of automation has a perceived price and technological barrier, a review of existing practices versus future savings can quickly identify this as false. Selecting the right CAM system to be a reliable and efficient unmanned interface between the order and the output is the key to this success. Enquiry No. 3301 Turn to page 80a or log on to www.equipment-news.com to enquire
Hang On! Ask Yourself These Questions First… 1. How many machine tools do we need to program? Will one or two seats (licenses) of a particular CAM software be sufficient to program machine(s) we have or do we need more than that? 2. Should we replace existing CAM systems programming other machines within our facility to consolidate programming of all machine tools into one system? 3. Does the vendor have postprocessors for all of our machines, and if not, are they capable of developing the ones they do not have? 4. How easy is it to get information in and out of the system (such as CAD files and reporting)? 5. If we need more than one seat (license) of the software, do we need them to all run concurrently? 6. What type of parts are we nesting? 7. How much automation do we require?
When To Buy A New CAM System? • The ones developed by machine manufacturers usually support only their own machine tools, so keep in mind that if you acquire such CAM system and you decide to buy another machine tool from another manufacturer in the future, your CAM system will not be compatible with it and you will need another one to program the new machine. • When you are buying another machine tool and you have an existing CAM system, which cannot support it. • When there is a decision to consolidate all the programming into one single CAM system. • If you want to improve production yield and minimise material wastage. • If you desire to fully automate component ordering, nesting, CNC program generation, and improve machine efficiency and loading
Enquiry No. 3302 Turn to page 80a or log on to www.equipment-news.com to enquire
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Roberto Graziosi On Flexible Manufacturing System… The sales manager of Salvagnini Group (Southern Asia and Pacific) shares with Asia Pacific Metalworking Equipment News his take on modular sheet metalworking system. By Joson Ng APMEN: Please give us a brief introduction to a typical modular sheet metalworking system. Rober to Gr a zio s i ( RG ): A S a lva g nini F M S ( F l e x i b l e M a n u f a c t u r i n g S y s t e m) i s o n e example. It is a combination of two different systems, S4 punching-shearing centre and P4 automatic panel bender. The two systems can be connected in several different ways depending on the customers’ needs and according to their manufacturing proce ss. The single systems may have the flexibility to work independently or in line, and the user can switch the operating mode in accordance with the products and the volume they produce from time to time. A PM E N : M o d u l a r s y s t e m s a r e k n ow n to carry out punching, shearing and bending processes automatically. How important or relevant are these ‘3-in-1’ machines in today’s sheet metalworking industry? How closely are they related to productivity? RG: Having the three operations of punchingshearing-bending combined together in a single FMS enhances the lean manufacturing process. End users simply load the materia l or cut to size sheets on one side of the FMS and they get
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finished panels on the other side without any WIP. This is the ultimate goal for any manufacturer in t he she et meta l indu st r y, a nd on ly t he additiona l operations of welding, grinding, powder coating and assembly are left to be carried out. The efficiency of the whole system is related to the kind of parts the customer is manufacturing, but almost the whole production of sheet metal parts is covered. With more customisation you can also produce smaller and smaller parts such as door frames. APMEN: What are the advantages modular systems have over a traditional setup? RG: The advantage of Salvagnini FMS is its ability to produce a large variety of parts with no set ups in a flexible way. The end user has the freedom to produce by batches or by kit (producing by kits means making batches of one single part). Kit production is only feasible in an efficient way by using an FMS; you can nest the different parts, punch, shear and bend in one single step, and completely unmanned. APMEN: Modular Sheet Metal Solutions — Are there limitations to such systems? RG: There is no limitation for such systems in the panel industry, but only a full feasibility study
will clarify if there are some components that cannot be bent using a panel bender and help to find alternative solutions. APMEN: Would you say such systems are more relevant for large factories/corporations with high production volume compared to small and medium enterprises? RG: An FMS can be used in most of the industries because it has the flexibility to process efficiently, big and small batches of parts. The FMS is even more relevant when the end user is producing very small batches of parts. Regardless of the batch size, the overhead running cost is identical because there is no set up and downtime involved when switching from one product to another. APMEN: Do you think these systems aid the implementation of lean manufacturing? Why? RG: There is no doubt about the aid that the FMS can give to achieve lean manufacturing, because the whole process of punching, shearing and
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bending is carried out by one single system, unmanned and without set-up. APMEN: What is the take up rate of such systems in Asia? Are they more common in certain industries compared to others? (eg: more in automotive vs aerospace?) RG: In Asia, the situation differs from country to countr y but we have a ver y w ide ra nge of applications, from elevators to furniture, electrical cabinets, kitchen components, lighting fixtures and refrigerators. APMEN: In your opinion, what is the future development of such systems? (eg: more automation?) RG: The FMS is full of automation, it is the concept of FMS that has automation embedded. We go from the raw material to the finished bent part without touching it. MEN Enquiry No. 3303 Turn to page 80a or log on to www.equipment-news.com to enquire
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o put it simply, CAD/CAM software developers create code that controls tool motion. The operating parameters we live by are that toolpaths be efficient, safe, and respectful. In other words, the software creates tool motion that is economical and smart, yet would not cause harm to the tools, machine, or operator. While that is a commendable approach, akin to the Hippocratic Oath — ‘first do no harm’ — there are new software and cutting tool developments that allow programmers to crank up the speeds, feeds, depths of cuts, and the resulting productivity gains. How Does A Tool Want To Cut? The features and intelligence that software developers and cutting tool manufacturers have in the box right now are all well and good, but here is the catch: they must be used! I understand it is uncomfortable, maybe even scary to reach beyond the safe zone of programming for ‘any tool condition’. That is, programming using the old 50 percent radial stepover formula. For example, a 1-inch tool should go down into the material by ½ inch. It is the classic, safe approach. The machining motion of choice is normally climb milling, but this can be inefficient in terms of moving the tool out of, and into, the next cut (retracts and entry motion). A zigzag machining approach can minimise wasted tool motion, but is inefficient for the cutting tool, since the cutting motion switches between climb and conventional milling. When the job is done, tooling buyers might wonder why their new, expensive cutters that promised getting in and out of the mould faster, did not work out as they had hoped. Doing something the same old way provides the same old results, no matter how many years of R&D that went into that tool’s development. Pushing cutting tools to get the
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Opinions:
Mouldmakers,
Be Courageous!
Advanced software and cutting tool technologies take the fear out of pushing tools in mouldmaking. By Steve Bertrand, director, International Sales/Strategic Partnerships, CNC Software. benefits they promise has a lot to do with understanding how the tools should be applied. For one thing, most cutting tools do not agree with zigzag machining due to changes that take place when switching from climb to conventional milling. The more aggressive you want to be, the more important it is to maintain a consistent approach. Also, these cutting tools can thrive, maintaining aggressive metal removal rates when used with a smaller radial sidestep, but it typically requires advanced programming knowledge, toolpaths, calculations, and experimentation for this approach to benefit over older techniques. This is an area that has been addressed by building the aforementioned toolpaths and cutting tool knowledge into the CAM software. In Mastercam, for instance, when a programmer selects a certain High Efficiency Machining (HEM) tool, the interface changes and would not allow the programmer to choose a sidestep greater than 10 percent. In fact he or she can only choose 10, 7, or 5 percent. Now, b e c au se a sma l le r sidestep is selected, the interface guides the programmer to make up for it by increasing the depth
of cut. We recommend a depth of cut up to a maximum of three times the diameter of the tool. So instead of ½ inch deep, this ½ inch tool would be optimised by going 1 or 1½ inches deep. Further, because the radial sidesteps are so small, the software suggests increasing the feed rate and spindle rpm, too, so that the chip thickness is correct and the tool is shearing the material, which is the way it is designed. Heat, the enemy of carbide is managed appropriately in this scenario with most of the heat being transferred into the chip. Other benefits: higher Material Removal Rate (MRR) on machine tools equipped with high speed spindles, less spindle horsepower required, and longer tool life — all of which lower production costs. Mouldmaker Reaps The Benefits Mouldmaking is an industry with large volumes of 2D and 3D milling work. Together with Iscar, we have conducted trials on HEM machining using the CF (Chatter Free) tools and the dynamic milling toolpaths. As a case in point, Classic City Mold in Indiana (US) was cutting A and B plates from standard mould
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bases purchased from a catalog. They had to cut three parts for the A side and three parts for the B side. The job used to take them 65 minutes. With an approach using an Iscar feedmill, they reduced the cycle time to 45 minutes. With an HEM approach using a CF tool and dynamic milling toolpaths, the job now takes them 15 minutes. This is the type of work this shop does day in and day out. It would typically take the better part of a day to manufacture all six plates prior to implementing the new procedure and tooling. No Pain, No Gain Most who run these tools, even at the lowest HEM setting, will be venturing into a zone of aggressiveness they have never experienced before in machining applications, particularly roughing operations.
When we first attempted these new parameters in our in-house machine shop, I could sense our team’s nervousness at the machine. However, we were assured to go ahead and take the plunge. After hundreds of documented trials in the Mastercam shop and at customer beta sites, we ultimately broke out of our comfort zone and became believers ourselves. Before long, zigzags, simple offsets, or flowtype toolpaths became old school. It takes courage, but let the new software intelligence be your guide. If tools are used appropriately, the way they are designed to be applied, the result will be real productivity gains for your shop. The Machine Tool Has To Be Cool In light of all this being said about throwing caution to the wind, you know the capability of your
particular machines better than anyone else. If you choose a certain HEM and 12,000 rpm, and the program says that the machine needs to run at 500 inches a minute to create the right chip load, you have to ask yourself if that is possible with that particular machine and workpiece. If it can only run at 180 inches a minute, then very thin chips will result and burn up the tool. The sensible thing to do is lower the HEM factor. Intelligent tools do not relieve the responsibility of the user to be a smart machinist. The good news is that even at the lowest settings, this dynamic software approach and advanced tooling will result in safe and significantly improved roughing throughputs. MEN Enquiry No. 3401 Turn to page 80a or log on to www.equipment-news.com to enquire
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Paperless Manufacturing In
Mould Making
While a paperless manufacturing environment can clearly reduce costs through the elimination of printed drawings and machine instructions, the real cost savings from a paperless approach comes from a streamlined process with fewer steps and a faster time to market. By Jim Davis, pre-sales solutions consultant, Siemens PLM Software
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aperless manufacturing cou ld b e v iewe d a s a methodolog y of inter weav ing new te ch nolog ie s to me et you r automat ion in it iat ive s. For example, tool design software does not just replace the manual methods of design on paper; it provides all sorts of automation to make the designing task faster, easier and more repeatable. While the use of almost any computerised system, from CAD/CAM to ERP solutions, will reduce the need for paper based methods, there are some less obvious ways in which the use of a paperless approach can offer real business value. Early Customer Collaboration Today many toolmakers will find themselves working with large companies that utilise a Product Data Management (PDM) system to manage the flow of data internally and externally for both current and new product projects. They may have a mechanism in place to allow suppliers to log-in to a specially controlled area of the system. By aligning or forming a partnership with these customers and being granted this type of entry 52
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into their systems, a toolmaker may be in a position to do more by downloading job requirements as electronic data files rather than to receive traditional drawings or hard copy specifications. By collaborating electronically and early on the overall project, the toolmaker may be able to help influence the design of their customer’s product, especially in the field of manufacturability. This can save time and money when it comes to the tool design and manufacturing process. By becoming a preferred supplier to a customer, you may find yourself having a head start over your competitor for business. Unified Engineering & Manufacturing Platform Once the tooling business is won and customer data is obtained, we can look at another opportunity to derive additional value from the full use of a paperless system. Most toolmakers will have software applications for CAD and CAM and maybe CAE (analysis and simulation), but all too often these are standalone products that are deployed separately in design engineering and manufacturing. The big problem with most
combinations of these solutions, even though it could be considered ‘paperless’, is that the resulting overall design to the manufacturing workflow is typically non-associative. A s a n exa mple of a non associative workflow, a company could have one generic CAD tool that is used to import customers’ data and prepare it for mould design (edit draft conditions, material wall section and blends), then a second CAD system to design the mould, and a third (CAM) system to generate NC programs to drive machine tools. If a generic data format such as IGES or STEP is used to translate data between each of these systems, the time taken to do this is not only dead time (ie: has no added value to the production process), the cost of that time can add up — fast, without engineering or manufacturing taking place. Inject an engineering change into this process and the costs continue to mount. By investing more up front in a fully integrated CAD/CAM solution that can perform all the design and manufacturing tasks without the need for data translation, tooling companies can reduce costs, and gain extra time
Industryfocus
to take on significantly more jobs to boost their revenue and reputation. Automating The Process Another advantage of using closely connected, paperless systems is that today’s technology can allow more than just the geometry to be passed from stage to stage. To day we ca n add most of this data to the 3D model definition such as PMI (product manufacturing information). This can be defined according to national standards for formatting associated with dimensions, tolerances or surface finish. Alternately, a more informal, company specific method could be employed, such as the use of surface colours in models where design and manufacturing have agreed upon, for example, that certain face colours represent the need for different levels of surface
finish or tolerance. In either case, the latest CAM and CMM programming software can be set up to read this non geometric data, and use it to drive NC programming or the creation of quality inspection programs automatically. In the CAM area, this is often coupled with the use of feature based machining technology. The result is not just the further reduction of the use of paper as the need to read this data from prints is diminished, but also the dramatic increase of CAM or CMM programming productivity. Another important benefit of this kind of paperless automation is a reduction in errors. Automated programming driven by PMI type data is not only faster compared to normal interactive programming methods, it is also virtually error free once the system is configured.
Shop Floor Delivery Making the 2D and 3D mould design information available through computers on the shop floor can virtually remove the need for paper prints in the stage of the process where they are still most commonly seen. The mould desig ner will continue to create assembly and component drawings electronically, but not printing the drawings for the shop can reduce the cost of paper, ink and copying supplies. But once again, the real value comes from other aspects. First, the data access and view on a display screen can be controlled based on the user’s role or log in. Depending on the system controlling the data, shop floor users can be given access only to the latest working data, reducing the risk of working from the wrong revision or an old print. Just one
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CAD/CAM solution can perform design and manufacturing tasks without the need for data translation
mistake in the ‘used the wrong drawing’ category can cost the profit on a tool. The sa me applies to the delivery of CNC files to a machine tool. Although paper tapes for transporting NC programs went out years ago, and are replaced with electronic data files today, there are still tool lists, set up sheets and drawings to be delivered as part of the work package. While the use of electronic systems for DNC (Direct Numerical Control) to connect to machine tools is a standard capability, it is less common to make the rest of the work package available in electronic formats at the point of use, such as the work cell, the tool presetter and so on. The availability of low cost, large, flat display screens as big as 24 inches or even more, makes the viewing of complex data and drawings much more viable than it used to be on older equipment. All of this can be considered a part of the paperless environment and the viewing technology is relatively simple. The critical step that can add significant value is managing the source of the data that is being accessed in this paperless world. Data & Process Management A paperless environment implies the widespread, perhaps complete, 54
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switch to electronic data. This brings with it the opportunity to be just average or to be world class. Average could mean just using basic PC-based file managers, explorers, folders and home-designed file management. The alternative utilises the latest in engineering data management to manage all of the information created or needed at each stage of the process. These systems are designed to manage all types of engineering information, to understand what each data file represents, manage its revision and release status as well as control who can see and who can edit every item. For example, when the ‘save’ button is selected in the CAM software, the full set of data that is being worked on, including NC
output files, set-up sheets, tool lists and more, can be stored automatically under the correct program and job reference. The data set is attached to a manufacturing process reference under full revision control. All this means that anyone can go back and find that exact set of data for that job, for that revision and so on. This greatly reduces the risk of data errors, reduces the time spent looking for the right data, and makes it easier to go back and pick up the good examples as a start for the next similar job. This approach of managing data really starts to pay off when we use it as the basis for providing a work package for access on the shop floor. We can set the approved data set for job XX into a shop floor accessible section of the system, with full release status on it. Using web style browsing technology, we can provide access for shop floor users to any part of that released work package, even allowing them to connect directly to a machine tool. We can do this without sending the data over to a separate, standalone shop floor PC where it can become less controlled or duplicated. This can be really useful for shops where being able to demonstrate data control and security is a key requirement imposed by customers. Enquiry No. 3402 Turn to page 80a or log on to www.equipment-news.com to enquire
Paperless Is Gold In Mould Making If each CAD file translation and review takes five minutes and this happens 12 times per day then one hour per eight-hour day has been spent compensating for multiple CAD systems. At typical shop rates this alone could cost US$20,000 each year just to move data between two CAD systems. For the data movement into a separate CAM system the costs can go even higher. Say there are 120 components in the mould design that need NC programming and each requires a data export / import / data review process, then at typical rates you could easily incur costs of 10 hours — or US$1,000 — per tool in non-value added data movement.
Enquiry No. 3403
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ENQUIRY NO 088
Executive
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DMG / Mori Seiki
Open House
At Deckel Maho Pfronten
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tarting the year 2012 with a traditional open house, DMG / Mori Seiki welcomed 5,113 visitors to the open house at Deckel Ma ho P f ronte n. T he eve nt, from February 7 – 11, 2012, was the setting for presenting the company’s machine program, including six world premieres. The orga niser capped the
event with a seminar program fe atu r ing f utu re - or iente d topics from the fields of fivea x is machining, aerospace, horizontal machining centre (automotive), medical, energy solutions, and XXL machines. The topic of energy efficiency is a common theme at the open house. More fuel - efficient machine technologies, energy-
saving manufacturing processes, or automatic shutdown routines a re just a s popula r a s new sof t wa re to ols a nd ser v ice pro duc t s for a su sta i nable increase of energy efficiency in developing, manufacturing and using machine tools. Enquiry No. 3501 Turn to page 80a or log on to www.equipment-news.com to enquire
Six World Premieres The highlight in the field of horizontal centres is the DMC 60 H linear, which is characterised by its precision and option to perform five-axis machining with a swivel rotary table. In the field of horizontal centres, the exhibition also features the NHX 4000 of cooperation partner Mori Seiki. The horizontal machining centre can, in future, be optionally equipped with the Siemens 840D solutionline or the MAPPS IV control. An example for the milling-turning competence is the DMU 85 FD monoBlock. Along with the universal machining centre, DMC 65 monoBlock with pallet changer, these are examples of the ‘up to five-axis’ simultaneous machining in production. The fifth development is the DMU 80 eVo with pallet changer. More features are added, such as the fast changeover cycles for short idle times and compact construction for minimal space requirements. The sixth world premiere is the CTX beta 800 4A. Notable features are the usage of two turrets in combination with the integrated cross stroke of the counter spindle tailstock. Details like the ‘Trifix’ precision interface for minimum tool setup times, or the direct drive (to be integrated optionally) round off the overall picture.
Enquiry No. 3502 Turn to page 80a or log on to www.equipment-news.com to enquire
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r Ruediger K apitza, chairman of the board of Gildemeister, kicked off the press conference by giving an update on the share of cooperation markets measured by the worldwide machine tool consumption in 2012. With 55 percent, or â‚Ź29.8 billion (US$39.1 billion), the share of cooperation markets has shown growth over the last three years. In addition, he also reported an increase in market share in the US market. Staying in the US, he mentioned a new Mori Seiki factory would be ready for production at the end of July. The plan is to produce 80 machines per month (Horizontal Machining Centres by Mori Seiki). Finally, he also touched on the plan to build a factory in Russia catering to rising demand for the Ecoline products. It is a green field project and is expected to be completed between 2013 - 2014. Dr Masahiko Mori, president of Mori Seiki, talked extensively about the joint development and procurement projects between the two companies, including the Milltap 700. According to Dr Mori, the machine is popular with electric car parts and motorbike
Press Conference At Pfronten The higher management from DMG / Mori Seiki took time out to give an update on the cooperation and answer some questions from international trade journalists.
production. Production of the machine has begun in both Germany and Japan. Moving away from development, he reported that joint sales and service efforts in Asia and Europe are almost complete with more cooperations in other parts of the world currently in discussion. As such, the current 62 sales and service locations in the world will increase. To illustrate the success
of the cooperation, he revealed that Mori Seiki has sold close to 600 DMG products. During the questions and answers session, Dr Kapitza and Dr Mori answered various queries from the media and they revealed the company spent about â‚Ź57 million in R&D regardless of the prevailing economic climate. Enquiry No. 3503 Turn to page 80a or log on to www.equipment-news.com to enquire
Opening Of Service & Application Hub In Singapore The cooperation of machine tool manufacturers DMG and Mori Seiki introduced its redesigned service and application hub for Southeast Asia with a grand opening in Singapore on February 21, 2012.
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naugurated by Dr Masahiko Mori and Dr Ruediger Kapitza, t he Singapore premise s provide a new home to a successful collaboration. B o a s t i n g a s e r v ice a n d applications centre, a warehouse, seminar rooms, a technology centre with 568 sq m of space for new machines, and an additional 246 sq m for used machines, the service hub serves the region with a range of facilities and services. April 2012 metalworking equipment news
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The training centre features a spare parts store as well, strengthening the companies’ customer support for South East Asia. The collaboration of DMG and Mori Seiki also resulted in the first joint machine development, the Milltap 700, which celebrated its South East Asia premiere at the grand opening. The machining centre combines work capacity and chipping performance, making it a suitable solution for the tapping centre market.
The showroom in Singapore was thronged by visitors on the opening day
Enquiry No. 3504 Turn to page 80a or log on to www.equipment-news.com to enquire
Roundtable Discussions Dr Masahiko Mori and Dr Ruediger Kapitza sat down with members of the trade media for a round of extended discussion.
Q: The Milltap 700 represents the first joint development between the two companies. Tell us more about it and also if we can expect more joint developments in the future? Masahiko Mori (MM): The cost of R&D was shared evenly. It is exciting to bring many things from the two companies together as we have different software systems, suppliers and technical knowledge. Ruediger Kapitza (RK): More joint developments will come in the future, but will be introduced step by step. These projects also entail the developments of components like drives and software programs. Q: What synergies in your partnership with DMG would help Mori Seiki grow into a stronger position in today’s economy? MM: The world is getting ‘smaller and smaller’, but it is still big e nou g h. B a se d on my ow n calculations, there are about three million machine tools 58
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working today in the world. Lifespan of machine tools are about 20 years, therefore about 150,000 to 200,000 machines are replaced each year. That means our annual production rate of 10,000 to 12,000 is too small to cover the global market. The partnership allows us to cover more ground as customers have become more global as well. Q: Do you see ASEAN as one single market? RK: No, for example, we cannot manage other ASEAN markets remotely from Singapore. We have to be ambitious regarding other markets and support every market, which is different in their own way. Just like Europe, there are different languages, cultures, and the level of technical competency is different in certain countries as well. Within this cooperation, we want to be big enough and strong enough to move into all the markets we wish to. Q: Would you entertain the thought of setting up an R&D facility in Singapore to serve the markets in ASEAN?
RK: We would carry out R&D activities in our factories because R&D must be centralised along with the machines. In addition, Mori Seiki has a strong technology centre in Thailand. At the end of the day, these decisions must be made based on the turnover and market share numbers. Q: Do you view expor t regulations as a stumbling block, particularly in your partnership in R&D and also regarding future expansion plans? MM: For Germany and Japan, we can exchange information based on fair trade rules. For export rules, there are some differences in Germany and Japan but we strictly follow those rules. Q: Do you foresee issues in Russia and China? RK: The same international laws apply although certain local laws differ depending on the machine type and whether the customer is in the civil or defence business. In Russia, after two years of discussions, we are allowed to produce five types of Ecoline machines there. They are for sale to everyone in Russia but not for export. MEN Enquiry No. 3505 Turn to page 80a or log on to www.equipment-news.com to enquire
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Aerospace Technology Leadership Forum 2012 Although he said countries like China and India are to be the main growth markets and with Indonesia and Vietnam also looking at fast growth, Singapore would continue to play a leading role in the support of regional aerospace activities. As part of enhancing R&D capabilities, he said the Singapore government has injected S$16.1 billion (US$12.8 billion) into a five year Research, Innovation and Enterprise plan (RIE 2015).
The heavyweights of the aviation world descended on Singapore for a round of technical exchange and at the same time, explored business opportunities with local companies. By Joson Ng
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*STA R held it s leadership forum on aerospace technology on February 13, 2012 at Marina Mandarin Singapore. Guest of honour Lim Chuan Poh said in his opening address that 60
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the aerospace industry would continue to be a “high-growth” market despite uncertainties in the global economy and he forecasted revenue growth in commercial aerospace to be 20 percent with deliveries of over 1,100 aircraft.
New Members The organiser also announced the inception of new members to A*STAR’s aerospace program consortium. The group attracted E m b r a e r, S T A e r o s p a c e , Honeywell, GE, Safran and DSTA as its membership grew to 18. The consortium underpins Singapore’s vision to enhance the value add to the aerospace business through innovation and talent. Since 1990, the country’s aerospace industry has grown at an annual rate of more than 10 percent CAGR. In 2010, the industry achieved S$7 billion (US$5.6 billion) in revenue. Partnership With MNCs Boeing has agreed to transfer 10 A*STAR-developed technologies from research areas such as nondestructive testing, materials, and coatings that will contribute towards enhancing airline value and improving factory operations. In 2009, SIMTech and RollsRoyce set up a joint surface finishing lab to enha nce productivity in manufacturing
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production. Together, they have over 75 collaborative projects including those on manufacturing process development for the aerospace and marine sectors. Technical Presentations The forum also included a series of talks tackling aircraft and propulsion-related issues. One of them was given by Prof Ric Parker, director, research and
technology, Rolls-Royce Group. He spoke about aviation’s climate impact and the ongoing e f for t s by h i s comp a ny to mitigate it. Some of the ways include technolog ie s to improve the engine’s propulsive efficiency, thermal efficiency and combustion process. Enquiry No. 3601 Turn to page 80a or log on to www.equipment-news.com to enquire
Aerospace Technology At The Singapore Airshow
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Over at the Singapore Airshow, A*STAR showcased 15 solutions for the aerospace industry pertaining to safety and productivity. For the airframe, a fast curing sealant and adhesive has been developed to reduce the time taken in the curing process. It now takes one to two hours instead of seven days without compromising the integrity of the sealant according to the manufacturer. For those with an interest in the MRO business, they can look forward to a metal forming technology. The flexible forming technology is being developed to bend and form high-performance materials and thin-walled components of light-weight materials without secondary processes, saving time and material cost by 14 and 40 percent respectively. In addition, the agency has developed a laser-aided additive manufacturing technique to repair engine components. Laser Aided Additive Manufacturing (LAAM) can be used to repair damaged parts and directly manufacture nickel-based and titanium-based superalloy 3D components. According to the developers, LAAM’s advantage over traditional repair processes such as Tungsten Inert Gas (TIG) welding and thermal spraying is its speed, low heat input and high automation level. For example, TIG cladding requires about 54 percent material removal whereas LAAM requires 20 percent.
Enquiry No. 3602 Turn to page 80a or log on to www.equipment-news.com to enquire
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Metalworking In Aerospace you look at the knock-on effects of the high levels of composite material used on the Boeing 787, we went from single-digit use of titanium in the airframe to double-digit use of titanium. That brought about whole new challenges. APMEN: The quest to achieve better ‘buy to fly’ ratio, does this open the door to additive manufacturing? MG: Absolutely. Additive manufacturing is another way to achieve good ‘buy to fly’ ratio. We carry out research in additive manufacturing, using both metals and non-metals. APMEN: The aerospace industry is blossoming in China, India, Indonesia and Vietnam. What are your future expansion plans in this region?
Matthew W Ganz (L) and Peter L Hoffman
Asia Pacific Metalworking Equipment News (APMEN) spoke with Matthew W Ganz, VP & GM and Peter L Hoffman, director, Global R&D Strategy, Boeing Research & Technology in an exclusive interview at the A*STAR Aerospace Technology Leadership Forum 2012. APMEN: How has the rise of composite materials affected the usage of metals in the aerospace industry? How have new materials affected metalworking processes like machining? Matthew Ganz (MG): I think even though a lot of attention is paid to composite materials, metals will continue to be important to airplanes. For instance, I think there are new alloys, both titanium-based and aluminium-based alloys, which are important for electromagnetic shielding. New alloys give rise to new machining techniques. We currently do a lot of machining that is not very efficient because we take large ingots of metal and machine away almost the whole ingot, so it’s very wasteful from the manufacturing and efficiency point of view. What we like to do is to maximise the ‘buy to fly’ ratio so the ingot weighs similar to the finished part. As such, we do very little machining. Peter Hoffman (PH): Anytime we have a change (in materials), there is a distinct change in the way we design our airframe. If
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MG: I think we will continue to be present and active in Asia, but we will balance the desire to be everywhere with the desire for focus. So if we do not go somewhere, it is not because we do not want to. In many of our metals programs we focus on the geographic area where a particular metal is prevalent. So we look to China for magnesium and Russia for titanium work, for example. APMEN: How do innovations such as advanced propulsion engines and airframe structure affect CAD/CAM design and metrology? MG: Certainly when you have a new material you need to have integrated material property as an integral part of the CAD/CAM models. You have to understand the engineering of the parts as we design the part. What we want to do is eliminate steps between aeronautical designs and engineering design and between design for manufacturing and design for maintainability. Putting material properties in the CAD tool is of critical importance for us. I think many of the metrology systems that we need would be evolutionary from what we have from the existing metrology. There are more optical techniques, eg: laser beam that allows you to potentially do some form of metrology at very high rates. The big change in metrology is probably towards faster data collection rate. However, there will always be a trade off between the precision of measurement and measurement speed. PH: The idea of in line metrology is a positive development — verifying parts before they are taken off the tooling or fixtures in the machine. As a result, you do not have that secondary process. I have seen a lot of development in that area. MEN
Enquiry No. 3603 Turn to page 80a or log on to www.equipment-news.com to enquire
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Taming
fdecomite
The Untameable
On closer examination, titanium alloys and highly heatresistant superalloys, both known to be difficult to cut, behave differently from each other under machining conditions. Contributed by Jaslin Huang, Walter AG Singapore
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n practice, titanium and superalloys are often machined by one and the same type of insert. Here, the use of cutting tool materials and geometries proven in the machining of ISO-M materials — stainless and acid-proof steels — is not at all uncommon. “While it is possible to machine difficult-to-cut materials using a combination of solutions in this way,” explains Stefan Lenischenko, tool developer at Walter, “these
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are merely compromise solutions that fall well short compared with other options available to us today. For maximum performance and a long tool life, the best insert solutions are the ones that have been optimised either for titanium alloys or for superalloys.” For steel and cast iron, universal indexable inserts may be costeffective to use, but, in the area of ISO-S-materials, special solutions pay dividends.
Meeting The Requirements These two material subgroups do have a few things in common. They tend to gum up and promote a built up edge. They are poor thermal conductors, which results in most of the heat from cutting flowing into the cutting edge. The specific properties of these materials mean that titanium alloys and superalloys produce completely different chip shapes on the tool cutting edge and are susceptible to different types of wear. Titanium alloys are prone to crater wear caused by diffusion. Carbide particles migrate into the chip and the indexable insert is eroded and weakened in the machining zone. Very hard forged skins and high strengths increase the risk of spalling and plastic deformation on the cutting edge. In addition, the materia l has a low modulus of elasticity, which increases the tendency to oscillate. With build-up on the cutting edge, the cutting edge erupts even more quickly. All these phenomena are exacerbated in line with the percentage of betastabilising elements in the alloy microstructure. If the widely used material Ti6Al4V, which contains both alpha and beta elements, was already difficult enough to machine, the new material Ti-5553, a commercially pure beta alloy, is even more unyielding. Cutting speeds generally have to be reduced by half. Yet, properties that give the machinist cause to worry are welcomed by the structural engineer: the extremely high strength of the material makes it ideal for aircraft landing gear parts and load-bearing structural components. The Superalloy Challenge From lightweight to heavy-duty components, the machining of superalloys is not only hindered by the for mation of forged skins, but also by the material’s
ENQUIRY NO 030
Features
susceptibilit y to cold work hardening. In addition, the high cutting forces intensify the problem of an overloaded cutting edge. With forged components, as typically used for engine parts in the aviation industry, the depth of cut varies. In such cases, it is difficult to select the appropriate cutting data. In a similar way to steels, superalloys also undergo heat treatments. Around 80 percent of components arrive at the lathe in a hardened state. Machinists are then faced with hardness levels of 40-45 HRC or strengths of 1,200-1,600 N/mm². Along with plastic deformation, chip impact and notching, these are typical conditions on the cutting edge and can bring a rapid end to the life of the tool. During chip formation, the chip usually impacts on the flank face of the indexable insert. With superalloys, this impact is particularly powerful and the cutting edge runs the risk of breaking up sooner or later. Another phenomenon, caused by cold work hardening, is the formation of notches. Counteracting each of these effects requires a stable cutting edge on one hand, and a positive, cutter-friendly geometry on the other. As a result, developers are presented with the challenge of reconciling two contrary requirements. Solutions For Titanium & Superalloys Developers have introduced two groups of indexable insert for ISO-S materials, each with optimised geometries: for both titanium alloys and superalloys. The objective of development was, above all, to maximise tool life and to optimise chip breakage, as tools with these properties are usually in short supply in the machining of ISO-S materials. Both ISO-S subgroups are used in 66
metalworking equipment news April 2012
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Stefan Lenischenko (left)
gas turbines. The cold side of these assemblies is made mainly of alloys such as Ti6AlV4. The hot side is made mainly of highly heat-resistant materials such as Inconel 718. All indexable inserts for the ISO-S material group feature a very slightly rounded cutting edge radius, which is essential to keeping built up edge and heat generation low. The specific details and differences are mainly in the macrogeometry, which determines the respective area of application. T he inser ts for tita nium have narrow chip breakers. To achieve good chip breakage during turning operations, it is
necessary to reshape the forming chip considerably, even under an advanced state of wear. The characteristic property of (titanium and superalloys) indexable inserts for superalloys is their sharp macrogeometry. Stability at the cutting edge is provided by a positive primary chamfer. The positive geometry of the cutting edge is combined with a PVD aluminium oxide coating. The indexable inserts for superalloys are generally given a coating, which helps to realise an improvement in tool life. MEN Enquiry No. 3604 Turn to page 80a or log on to www.equipment-news.com to enquire
ISO-S Materials Titanium alloys represent 80 percent of the materials used in the aerospace industry. Other important applications for these materials include the medical, chemical and petrochemical industries. Based on their microstructure, a distinction is made between alpha alloys (Ti13V11Cr3Al), alpha-beta alloys (Ti6Al4V) and beta alloys (Ti-5553). Superalloys are subdivided into nickel-based alloys (eg: Inconel, Waspaloy), cobalt-based alloys (eg: Corodur, Jetalloy 209) and the less common marginal group of iron-based alloys (eg: Incoloy 800, Jethete M-152), which in some ways resemble steel materials. In addition to the aerospace industry, which needs superalloys for its engines, other major sectors that generate great demand for highly heat-resistant materials include the chemical and petrochemical industries, the energy sector and, to a certain degree, the automotive industry, which uses these materials for turbochargers or valves.
Enquiry No. 3605
Turn to page 80a or log on to www.equipment-news.com to enquire
21>24 June 2012
Supports ASEAN status as Global Manufacturing Hub
BITEC, Bangkok, Thailand
Co-located with 3 Specialized Trade Exhibitions for Parts Makers A part of Thailand’s Largest Manufacturing and Supporting Industries Trade Exhibition - “Manufacturing Expo 2012”
Thailand’s Largest Show for Mold & Die Manufacturing
Mold & Die Materials & Components Processing Machinery Tools & Tooling
Measuring & Testing
Auxiliary Equipment
InterMold Thailand
intermoldexpo
Scan this code to visit the show’s website for more information and pre-registration. Or email your enquiry to delegation@reedtradex.co.th
ENQUIRY NO 090
Supported by :
w w w . i n t e r m o l d t h a i l a n d . c o m
Organized by :
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exhibitions
Event Preview:
Metaltech 2012
T
he 18th international manufacturing solutions event Metaltech would once again be held at the Putra World Trade Centre, Kuala Lumpur, Malaysia. This year’s event would take place on May 15 – 19, 2012. Incorporating the Welding Technology Exhibition 2012 (WeldTek) and Automation Te c h n o l o g y E x h i b i t i o n & Conference (Automex), the event is expected to attract 25,000 trade visitors. They hail from many industries such as aerospace maintenance, parts manufacturing, automotive manufacturing and electronics production. The total number of exhibiting companies is expected to hit 1,500 with seven national pavilions contributing to the numbers. The seven countries are Austria, China, Germany, South Korea, Singapore, Taiwan and United Kingdom. Together with the local exhibitors, they will take up a total exhibition area of 30,000 sq m (gross). High Growth The machinery and tools industry is a high performance industry sector, with companies ensuring their technological advancement through expertise and continued innovation. Malaysia has a diverse and growing manufacturing sector that plays a huge role in the economy, plus initiatives to promote manufacturing related activities granted by the Malaysian government makes the country a suitable place for proper business development and investments.
Other Highlights
PWTC Kuala Lumpur, Malaysia May 15 – 19, 2012
• Automex is the Malaysia International Exhibition and Conference on process automation, factory automation, industrial automation, instrumentation and control, bus and wireless technology, hydraulics and pneumatics and robotics
Enquiry No. 3701 Turn to page 80a or log on to www.equipment-news.com to enquire
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metalworking equipment news April 2012
To emphasise on the diverse nature of the manufacturing sector, the two sub-events at Metaltech are expected to provide a comprehensive coverage for visitors who might have interests other than metalworking. • WeldTek is the 12th Malaysian International Exhibition on welding equipment and technology, welding services and welding competition
Enquiry No. 3702
Turn to page 80a or log on to www.equipment-news.com to enquire
EVENTs&exhibitions
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Exhibitors Profile Sheetmetal Technology • Bending • Drawing • Forging • Laser Cutting • Notching • Punching • Wire and Tube Forming • Riveting • Roll Forming • Shearing, Stamping, WaterJet Cutting • Sheetmetal Processing / Metal Forming
Tools & Toolings • Power Tools • Hand Tools • Cutting Tools • Workholding Devices • Hydraulic & Pneumatic Tools • Air Tools
Enquiry No. 3703 Machine Tools • Boring • Broaching • CNC Wire Cut • Cutting Tools / Inserts • Deburring • Drilling • EDM/ECM • Filling • FMC/FMS • Gear Cutting • Grinding • Honing • Lathes • Metal Cutting Machine Tools • Milling • Planing • Threading • Sawing • Screw Cutting • Shaping • Slotting • Special Purpose Machine and Unit Heads • Tapping • Turning Software and Prototyping Systems • CAD/CAM/CAE and Prototyping Machine • Computer Hardware • Fused Deposition • Software • Laminated Object Manufacturing • Selective Laser Sintering • Stereo Lithography Measurement Technology • Metrology Equipment • Sensors • Testing Machines • Precision Measuring Machines and Instruments • Optical Measuring Instruments for Machine Tool Industry Mould and Die • Die Sets • Die Cast Moulds • Graphite • Mould Bases • Mould Repairs • Moulds and Dies • Pins • Special Steels / Tool Steels
Turn to page 80a or log on to www.equipment-news.com to enquire
Products At Metaltech Alfa Laval: Separator System For Cleaning Of Oil Using high-speed centrifugal separation makes it possible to increase the reliability of the oil system and extend the service life of oil. Alfa Laval’s disc-stack separators provide fast, efficient, simultaneous three-phase separation of water and particles. Emmie.2 removes more than 99 percent of all solid particles between 2 and 5 μm from the oil, and virtually all of the water but none of the additives. It effectively separates airborne dust and undesirable particles from wear on paint, metal, plastic or rubber components from the oil. It also removes water that causes additives to oxidise and decompose too.
Enquiry No. 3704 Turn to page 80a or log on to www.equipment-news.com to enquire
Surface and Heat Treatment • Accessories for Casting • Forging and Casting Equipments • Chemicals • Chroming and Other Surface Finishing Technology • Furnace • Foundry Engineering • Lapping • Super Finishing • Polishing • Spray Painting Systems • Surface Treatment and Finishing • Vibrator Deburring Machines and Consumables Shot / Sand Blasting Equipment Material Handling and Storage • Material Handling • Factory • Storage and Warehousing • Industrial Robots Welding Technology • AC/DC Power Sources • Fume Extraction System • Software • ARC-Welding MIG / TIG / SA Equipment • Plasma Cutting Equipment • Manual ARC-Welding Equipment • Spot / Stud Welding Equipment • Welding and Fastening Equipment • Training • Welding Flux and Other Consumables
Autodesk: Simulation Software Au to d e s k Inve n to r s of t wa re t a ke s engineers beyond 3D to digital prototyping by giving them a set of tools for 3D mechanical design, simulation, tooling, visualisation and documentation that enables them to design, visualise, and simulate products before they are ever built. The software produces an accurate digital model, which is a virtual representation of the final product that can be used to validate the form, fit, and function of the product prior to production.
Enquiry No. 3705 Turn to page 80a or log on to www.equipment-news.com to enquire
April 2012 metalworking equipment news
69
EVENTs&exhibitions
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Bechem: Corrosion Protection
TaeguTec: Economical Double Sided Inserts
The Avantin 402 by Bechem is a mineral oil free and water soluble coolant concentrate with corrosion protection properties. Treated with special additives, it is successfully used for cutting operations with cast material and steel as well as for thread rolling. Since it will not emulsify tramp oils, there will be no formation of smoke and will also result in minimum drag out losses.
TaeguTec has developed the Chase2mold, a concept product line suited for machining applications in the mould and die, power generation, aerospace and general engineering industries. This product line offers double sided positive geometry round inserts for profiling applications, therefore offering economy compared to the prevalent single sided inserts widely used in the aforementioned industries.
Enquiry No. 3706 Turn to page 80a or log on to www.equipment-news.com to enquire
Enquiry No. 3709 Turn to page 80a or log on to www.equipment-news.com to enquire
Idemitsu: Long Life Lubricant
Techni Waterjet: Waterjet Cutting
Daphne Super Screw Series by Idemitsu is a long life lubricant developed specially fo r o i l c o o l e d a i r compressor. Prepared with a refined mineral-based oil and various additives, it features high temperature oxidation stability and resistance to sludge formation. In addition, it extends the maintenance interval for the compressor. The grades available are 32, 46 and 68.
Techni Waterjet has developed a profile abrasive Waterjet cutting that is economical. The Quantum Electric servo pump is a waterjet pump, with up to 60 percent more efficient and up to 75 percent less cooling water than standard hydraulic intensifiers, according to the manufacturer. The PAC 60 cutting head is capable of producing parts with a true angle up to +/- 60 deg with continuous rotation.
Enquiry No. 3707 Turn to page 80a or log on to www.equipment-news.com to enquire
LDS: Aluminium Alloy Worm Gear Reducer
Tesa: Precision In Motion
LDS right angle worm gear reducer is designed with high thermal capacity diecast aluminium housings for good heat dissipation. The manufacturer uses high efficiency gear design to create maximum torque output in a compact package. The housings come with a rust-free powder coat paint finishing. The gear reducer is also compatible with compact gear motor and major motor brands with IEC flange from Europe and USA. It is available in high precision design (low backlash < 8 arcmin) and can achieve high-speed operation with maximum design torque.
The two Tesa-Hite 400 and 700 height gauges are fitted with the opto-electronic measuring system with incremental glass scale. Due to their construction, they are suited for dimensional inspection on the shop floor. Full autonomy is ensured through battery power. Each model allows height or step dimensions, diameters, centre-to-centre distances, groove width and the likes to be accurately measured. They feature a wide application range with two sizes available, with measuring spans of 415 mm or 715 mm respectively. In addition, their electronics are totally protected against oil and water splashing and dust particles (IP65).
Enquiry No. 3708 Turn to page 80a or log on to www.equipment-news.com to enquire
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Enquiry No. 3710 Turn to page 80a or log on to www.equipment-news.com to enquire
metalworking equipment news April 2012
Enquiry No. 3711 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 005
EVENTs&exhibitions
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Event Preview:
CIMES 2012
A
s China’s largest machine tool event in 2012 with 120,000 sq m gross area, CIMES is a global machine tool sourcing and trading platform. It provides an array of products, technologies and solutions showcased by players from overseas as well as machine tools made in China. The show opens its gates in Beijing from June 12 - 16, 2012. One thousand three hundred exhibiting companies with industry experts from 28 countries/regions will display some 3,000 pieces or sets of machineries and tools in the show, including metal cutting, metal forming, special purpose technology, tools, accessories and components, automation and NC systems and a variety of other exhibits onsite. Show Enhancement Generating US$284 million 72
metalworking equipment news April 2012
business transactions during the show in 2010, the show demonstrated its efficiency i n c re a t i n g re a l b u s i n e s s opportunities for purchasers from automobile, aerospace, production machinery, energy and other fast emerging industries. CIMES 2012 will enable its 55,000 visitors from more than 70 countries to actively preview, test and efficiently source the technology that fits into their production line to improve their manufacturing efficiency. The organisers — Reed Exhibitions, China National Machine Tool Corp and China National Machinery Industry Corp are seeking to improve various aspects of their show. In 2012, they are keen to enhance the show’s role as a machine tool industry forum
by offering not only a variety of exhibited technologies and brands, but also providing insights into the latest industry and technology trends with s e m i n a r s a n d c o n f e re n c e s held by the organisers, official scientific institutes and key media partners. Technical Seminars The conference program includes seminars on the developments in the areas of NC systems, machining centres, and high-speed, high-precision processing. F u r t h e r m o re , t h e re w i l l be an ‘Industry Leaders’ award ceremony that directly addresses delegations of the most important application industries with specific manufacturing topics such as
ENQUIRY NO 076
EVENTs&exhibitions
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trade buyers to enhance the visitor quality and exhibitors’ ROI. To assure the mutual benefits of both buyers and exhibitors, the organisers will actively arrange prescheduled appointments. The show will launch a diamond club consisting of 1,500 senior business executives, a hosted buyer program with 500 identified top buyers from across China, a delegation program inviting 70 visiting delegations from major application industries of both China and abroad, and an international buyer program for 3,000 international professionals from key machine tool importing countries.
the seminar about high-speed processing and applications for difficult-to-machine materials in the aerospace industry, and another one on the advanced manufacturing technology of the automobile Industry. International Exhibitors In this year’s edition, there is a high number of new German exhibitors like Matec, Zeiss or Schwaebische We r k z e u g m a s c h i n e n , w h o followed the call into the world’s largest machine tool consumption country, China. The biggest new local exhibitor from mainland China attending the show is the Chinese producer for special purpose machines, high-speed machining centres and components, Dalian Machine Tool Group (DMTG). Among the 30 international 74
metalworking equipment news April 2012
supporting associations and international government bodies from the world’s leading industry countries are, the German Industry and Commerce Greater China — Beijing (GIC), the German Bavaria International and the Federation of Thai Industries (FTI), while South Korea provides three exhibitor pavilions from KOMMA, SBC Gyeonggi and SBC Gyeongnam. For the 2012 edition, the organiser is proud to welcome international country pavilions with exhibiting companies and associations from Taiwan — TMBA and TMTF, Spain — AFM and AMT, the UK — EIA, Turkey, Germany — Bavaria International and Italy. High-End Buyer Programs The show will target a number of
China Buyer Survey Indicates Promising Onsite Purchase One reason for the show to achieve high booking status at an early stage lies in the visitor quality. The recently released pre-show China Buyer Survey Report indicates that 74 percent of surveyed buyers will definitely, or probably make purchases at the event. The survey results also indicate ‘exhibition’ as the top channel for China buyers to source and purchase machine tools. With regard to the primary objectives for visiting the show, 87 percent of the surveyed buyers intend to gather latest trends or products technologies information, 45 percent will place an order for new products and technologies, and 43 percent plan to identify new products or providers. Some 84 percent of surveyed buyers prefer viewing the cost efficient quality products at CIMES 2012, whereas 64 percent look forward to viewing highend products. NCIEC Beijing, China June 12 - 16, 2012 Enquiry No. 3712 Turn to page 80a or log on to www.equipment-news.com to enquire
Product Finder
ENQUIRY NO 058
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Pure power
www.suhner.com
SUHNER Abrasive Expert AG P.O. Box CHâ&#x20AC;&#x201C;5201 Brugg Phone +41 (0)56 464 28 80 info.sae@suhner.com
Shanghai Tong Lee Hardware Pte Ltd. 200 Jalan Sultan #01-01 Textile Centre Singapore 199018 Phone (65) 6291 7288 (5 lines) sales@shanghaitonglee.com.sg
ENQUIRY NO 081
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High-performance drives with flexible shafts from SUHNER - for high torque applications. Flexible and easy to use.
April 2012 metalworking equipment news
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Delcam: CAM System For 2012
Schunk: Polygonal Clamping Technology
Delcam has developed the 2012 R2 release of its FeatureCAM feature-based CAM system, which includes strategies for roughing and turn-mill operations, alongside a range of more general enhancements to allow faster toolpath generation. The strategies for 2.5D roughing include a continuous spiral option to minimise wear on the cutter and machine tool, high-speed roughing options, including trochoidal machining, the company’s Race Line Machining, and ‘tear-drop’ moves to clear corners more smoothly. Stepovers for 2.5D mill roughing can now be set as large as the tool diameter itself.
T h e Tr i b o s polygonal clamping technolog y from Schunk is a program for pre cision tool clamping. From micro to volume cutting, the clamping system scores with true -running accuracy, vibration damping, and the possibility to pre-adjust the length. The fully automatic Tribos SVP-4 clamping device is more compact and lighter than its predecessor. Moreover, a type of pump ensures that the device works more quietly. On request, it can be actuated with a 220 V alternating current from the grid, or for mobile use by battery.
Enquiry No. 3801 Turn to page 80a or log on to www.equipment-news.com to enquire
Dormer: Extended Tap Range
Sodick: Eco-Friendly EDM
Dormer has expanded its high performance, multiappl ic at io n t h re ad i n g program with the introduction of Titanium Nitride coated taps. Available to DIN or ISO standard in both spiral point and spiral flute geometries, the taps will be of interest to anyone performing threading operations in steel, alloy steel, stainless, copper or aluminium. The surface treatment provides high hardness combined with low friction properties. This ensures longer tool life and better cutting performance over uncoated taps. All spiral flute geometry taps feature a three radii flute profile with a constant rake angle that facilitates the creation of narrow, regular chips.
Sodick, a manufacturer of EDM technology, ha s developed the eco-friendly AG10 0 L Sin ker EDM. The EDM features a simplified control mechanism, which provides a direct link between the drive and the control. This ensures the fastest possible servo response time and optimal spark gaps at all times. The automatic three sided vertically sliding drop tank enables large work pieces to be easily loaded and unloaded. The machine has linear motor drives on the X, Y and Z axes, a 10-year positioning guarantee and glass scale feedback. The machine also comes standard with a zero electrode wear circuit and a fine finishing circuit.
Enquiry No. 3802 Turn to page 80a or log on to www.equipment-news.com to enquire
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Enquiry No. 3803 Turn to page 80a or log on to www.equipment-news.com to enquire
metalworking equipment news April 2012
Enquiry No. 3804 Turn to page 80a or log on to www.equipment-news.com to enquire
productfinder
ENQUIRY NO 086
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with highest precision! heimatec速 ASIA /PACIFIC Phone +65 8112 6550 Mail: kmoessmer@heimatec.com Web: www.heimatec.com
heimatec速 GmbH GERMANY Phone +49 7843 94660 Mail: info@heimatec.de Web: www.heimatec.de
ENQUIRY NO 033
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We manufacture tools
April 2012 metalworking equipment news
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SolidAce: Structural Steel Design In SolidWorks
Tungaloy: Heavy Turning Cutting Tool
SolidAce has released the 3.0 version of BuiltWorks, a structural steel design and engineering add-in application for SolidWorks CAD environment. The software supports the corresponding version of 3D CAD platform — SolidWorks 2012. Some of the pertinent features and enhancements are the automated dimensioning option in drawings generator; databases of steel section profiles for Australia and New Zealand; support of end plates and free plates in import of CIS/2 interoperability format and improved connection handling performance.
For heav y t u r n i n g applications, the Tungaloy Corp has now extended its high feed TurnTec range of cutting tools. The insert and toolholder design has been extended to include LNMX12 and LNMX24 insert dimensions to improve performance, tool life and chip evacuation when conducting facing, external and internal turning processes. Suitable for heavy industry and general machining sectors, the extended range that has a thicker and more robust insert design is the turning tool of choice for machining steel and stainless steel. The inserts incorporate a positive rake angle that reduces cutting forces while the four edged insert geometry offers the economical advantage of reduced tooling costs and increased productivity.
Enquiry No. 3805 Turn to page 80a or log on to www.equipment-news.com to enquire
Suhner: Flexible-Shaft Machines Suhner has developed the Rotomax, a flexible-shaft machinery. Separating the drive unit and the tool g ive s t he u ser a powerful dr ive w it hout having to hold a heavy tool. The lightweight tool holde r s m a ke for delicate and fatigue-free work wherever high power levels are needed — even in locations with restricted accessibility. Two power outputs featuring on-off control and infinite speed regulation deliver exactly the right speeds for a wide variety of tasks. A range of tool holders, attachments and abrasives round out the machine to create a complete processing system. Available at the main power output, with a DIN 15 connection, are speeds from 500 to 10,000 rpm while the secondary, high-speed drive with its DIN 10 connector delivers from 500 to 25,000 rpm. Enquiry No. 3806 Turn to page 80a or log on to www.equipment-news.com to enquire
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Enquiry No. 3807 Turn to page 80a or log on to www.equipment-news.com to enquire
Walter: Indexable Insert Range For ISO P Materials
With the Tiger·tec Silver indexable insert range for ISO P materials, machinists are turning at the cutting edge of what is technically feasible. For deeper cuts, the choice falls to the MP5 geometries for medium machining operations and to RP5 for the roughing of steel materials. In addition to the insert designs for finishing with the FP5 geometry and for long-chipping materials with the MP3 geometry, Walter is offering two further types for greater depths of cut. The MP5 geometry has been designed for general medium machining operations, while the RP5 geometry has been designed for roughing operations. Enquiry No. 3808 Turn to page 80a or log on to www.equipment-news.com to enquire
Exhibition Programmes
April
17 – 22 SIMTOS 2012 KINTEX Seoul, South Korea KOMMA intl@simtos.org www.simtos.org
18 – 21 InterMold
Intex Osaka, Japan Japan Die & Mold Industry Association iminfo@itp.gr.jp www.itp.gr.jp
May
3–6 MT Duo 2012
Taipei Nangang Exhibition Hall Taipei, Taiwan TAITRA & TAMI mt@taitra.org.tw www.mtduo.com.tw
9 – 12 INAMarine 2012
JIExpo Jakarta, Indonesia PT GEM Indonesia info@gem-indonesia.net www.inamarine-exhibition.net
15 – 19 Metaltech 2012 PWTC Kuala Lumpur, Malaysia Trade Link info@tradelink.com.my www.tradelink.com.my
17 – 20 Intermach 2012
BITEC Bangkok, Thailand UBM Asia intermach@intermachshow.com www.intermachshow.com
24 – 26 Indo Automotive
Jakarta International Expo Kemayoran Jakarta, Indonesia Wakeni www.indoautomotive.com
2012
June
6–9 Manufacturing Surabaya 2012
Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo www.pamerindo.com
23 – 27 EuroBlech 2012 Exhibition Grounds Hanover, Germany Mackbrooks Exhibition info@mackbrooks.co.uk www.euroblech.com
November
12 – 16 CIMES 2012
1–6 JIMTOF 2012
21 – 24 Intermold Thailand 2012
7–9 Indonesia Oil & Gas Expo 2012
Tokyo Big Sight Tokyo, Japan JMTBA www.jimtof.org
NCIEC Beijing, China Reed Exhibitions (Shanghai) cimes@reedhuayin.com.cn en.cimes.net.cn
BITEC Bangkok, Thailand Reed Tradex intermold@reedtradex.co.th www.intermoldthailand.com
July
Balikpapan Int'l Sport Arena Balikpapan, Indonesia Fireworks info@asiafireworks.com www.indonesiaoilgas.com
7 – 10 Indo Aerospace 2012
3–6 MTA Vietnam
JIExpo Jakarta, Indonesia www.indoaerospace.com
SECC Ho Chi Minh City SES mta@sesallworld.com www.mtavietnam.com
December
October
4–6 Metalex Vietnam SECC Ho Chi Minh City, Vietnam Reed Tradex rtdx@reedtradex.co.th www.metalexvietnam.com
5–8 Manufacturing Indonesia 2012
Jakarta Int'l Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com
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
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DEES HYDRAULIC INDUSTRIAL CO LTD
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DELCAM PLC (INTERNATIONAL DIVISION)
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16A/16B
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DMG ASIA PACIFIC PTE LTD EOS SINGAPORE PTE LTD
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FACTORY AUTOMATION TECHNOLOGY CO LTD
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HEIMATEC GMBH
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HPMT INDUSTRIES SDN BHD
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KENNAMETAL INC
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ISCAR LTD
80
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MITSUBISHI ELECTRIC ASIA PTE LTD
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082
NEWELL RUBBERMAID (M) SDN BHD
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OKUMA TECHNO (THAILAND) LTD (SINGAPORE BRANCH)
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PT PAmerindo indonesia
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057
REED EXHIBITIONS (SHANGHAI) CO LTD, BEIJING BRANCH (CIMES 2012)
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030
REED TRADEX COMPANY (INTERMOLD THAILAND 2012)
67
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RENISHAW (HONG KONG) LTD
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SECO TOOLS (S.E.A) PTE LTD
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Siemens Industry Software Pte Ltd
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091
SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2012)
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sodick singapore pte ltd
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suhner abrasive expert ag
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062
sumitomo electric hardmetal asia pacific pte ltd
31
066
TAEGUTEC CO
11
073
TAIWAN machine TOOL AND ACCESSORY BUILDERS’ ASSOCIATION (TMBA)
73
076
TAIWAN TAKISAWA TECHNOLOGY CO LTD
75
058
TUNGALOY SINGAPORE (PTE) lTD
23
068
WALTER AG SINGAPORE PTE LTD
07
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WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG
25
069
WINTERTHUR SCHELEIFTECHNIK AG
39
060
YIH CHUAN MACHINERY INDUSTRY CO LTD
51
080
ZWCAD SOFTWARE CO LTD
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033
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ASIA PACIFIC METALWORKING
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Fritz Studer AG CH-3602 Thun Telephone +41-33-439 11 11 · Telefax +41-33-439 11 12 www.studer.com ENQUIRY NO 071
The new definition of heavy duty. That’s KM4X. That’s Different Thinking. TM
Kennametal redefines heavy duty with KM4XTM — the next generation of spindle interface. In addition to its three-surface contact for improved stability and accuracy, KM4XTM provides optimized clamping force distribution and interference fit for higher stiffness. The result? A machine connection that delivers unmatched performance in heavy-duty conditions on even the most difficult-to-machine materials. Now that’s Different Thinking. That’s Kennametal. To learn more about KM4XTM and the latest machining technologies, contact your authorized Kennametal distributor, call 800.446.7738, or visit www.kennametal.com.
Extreme resistance to bending in heavy-duty applications. Extraordinary strength for high-torque milling. Designed to excel when machining large components in titanium and other high-strength alloys. Higher speeds or heavier loads — KM4XTM outperforms your expectations in any application, in any environment. Easy to retrofit existing machines for increased through put without investing in new equipment.
KM4X three-surface contact means stability and accuracy: • Heavy-duty rigid configuration with evenly distributed clamping force. • Balanced by design for high-speed spindle capability. • Capable of performing in a wide range of operations. TM
ENQUIRY NO 009 ©2011 Kennametal Inc. l All rights reserved. l A-11-02685