APMEN April 2016 by Eastern Trade Media

BIG SOLUTIONS FOR MINIATURE PARTS p22 â&#x20AC;¢ THE TECHNOLOGY INTERPLAY p42 April 2016

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BIG IDEAS TAKE SHAPE.

When quality drives productivity.

ISCAR's Winning Edge Grooving Innovations

INN

VAL LINE

No Setup Time and Machine Downtime!

Quick Insert Indexing without the Need for Screw Removal! The Complete Array of Tools for All Your Miniature Parts Production INN

VA L L I N E

www.iscar.com ISCAR JAPAN 1-5-3 Shinsenri-Higashimachi Toyonaka-shi, Osaka 560-0082 Tel + 81 6 835 5471 Fax + 81 6 835 5472 iscar@iscar.co.jp

ISCAR TAIWAN 395, Da Duen South Rd. Taichung 408 Tel + 886 (0)4 247 31573 Fax + 886 (0)4 247 31530 iscar.taiwan@msa.hinet.net

ENQUIRY NO 039

ISCAR THAILAND 57, 59, 61, 63 Soi Samanchan-Babos Sukhumvit Rd. Phra Khanong, Khlong Toey Bangkok 10110 Tel + 66 (2) 7136633 Fax + 66 (2) 7136632 iscar@iscarthailand.com

ISCAR VIETNAM (Representative Office) Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., Ho Chi Minh City, Tel + 84 8 38123 519/20 Fax + 84 8 38123 521 iscarvn@hcm.fpt.vn

SINO TOOLING SYSTEM Blk 502, Jurong West Ave 1 #03-813 Singapore 640502 Tel + 65 6566 7668 Fax + 65 6567 7336 sinotool@singnet.com.sg

MESCO Reliance Corner Brixton St. Pasig City Metro-Manila Philippines Tel + 63 2631 1775 Fax + 63 2635 0276 mesco@mesco.com.ph

CV MULTI TEKNIK Ruko Gsa Blcok B No. 8 BN-BP, Podomoro City JL.Letjen S.parman Kav.28 Jakarta Barat 11470 Indonesia Tel + 62 21 29206242/44/45/59 Fax + 62 21 29206243 multi@centrin.net.id

PT. Tungaloy Indonesia Ruko Celebration Boulevard Grand wisata., Blok AA.10 No.3-5 Tambun selatan – Bekasi 17520, Indonesia Tel: (021)8261 5808 • Fax: (021)8261 5809 www.tungaloy.co.jp/id

Tungaloy Singapore Pte. Ltd. 62 Ubi Road 1, #06-11 Oxley BizHub 2 Singapore 408734 Tel: (65) 6391 1833 • Fax: (65) 6299 4557 www.tungaloy.co.jp/tspl/

Tungaloy Malaysia Sdn Bhd 50 K-2, Kelana Mall, Jalan SS6/14, Kelana Jaya, 47301 Petaling Jaya, Selangor Darul Ehsan, Malaysia Tel: +603-7805-3222 • Fax: +603-7804-8563 www.tungaloy.co.jp/my

ENQUIRY NO 057

ADVERTORIAL Asia Pacific Metalworking Equipment News • April 2016

THE NEW REVOLUTIONARY

ECOMILL V SERIES

Highest precision and 12,000 rpm milling spindle in standard belong to the outstanding characteristics of the latest ecoMill V series developed by ECOLINE from DMG MORI

DMG MORI has been successfully defining the standard for users of powerful entrylevel machines for many years with the ECOLINE product range. This especially applies to the new generation of ecoMill V vertical machining centres. The highlight of the latest ecoMill V series is the completely revised ECOLINE design, by means of which DMG MORI has improved working ergonomics as well as the visibility into the working area and achieved a high degree of value retention. The new 19” DMG MORI SLIMline® multitouch control with Operate on SIEMENS applies for the innovative and modern user interface so that the customer has a wide variety of 3D controls. ENQUIRY NO 066

he ecoMill V series is based on a C-frame cast iron bed for the best stiffness and vibration characteristics ensuring highest precision. Ball screws of the highest quality and a powerful 12,000 rpm spindle were combined to meet the highest standards in production. A comprehensive options kit, e.g. with linear scales for direct distance measurement or a production package with a 12-bar internal coolant supply – among many other options is at the customer’s disposal. The low connected load, ef f icient power consumption and energ y recover y ensure a good energ y utilisation. The per formance of the ecoMill V series even in the smallest size is out standing, even in the standard version. The highest precision (without direc t scales) can be realized, due to direct coupling in X / Y, no belt drive for no backlash. An optimized machine struc ture also increases stability during machining, and a high degree of manufacturing flexibility is provided in the standard version by having 30 tool pockets in the tool magazine. A fur ther highlight of the latest ecoMill V series is the completely revised ECOLINE design with per fect ergonomics thanks to an optimised visibility and accessibility. The machines combine a large working area with a table height of 850 mm making loading and unloading easier and the smallest footprint in their class. Highest reliability is guaranteed thanks to wear and scratch-resistant sur faces made of anodised aluminium and power coated me t al panel s . T he s e and other robust component s are par t of the First Quality approach with which DMG MORI substantiates the high standards of ECOLINE machines. It also includes a quality inspection with 100 hours of each machine before deliver y as well as the acceptance of new product developments by quality auditors

af ter intensive f ield trials. Altogether, First Quality results in an extended warranty by now a total of 18 months for components and ser vice without price increase. DMG MORI SLIMline® for highest efficiency and reliability The new 19-inches DMG MORI SLIMline® multi-touch control with Operate on SIEMENS and 3D control technology represents the next advanced step for a modern user inter face and is compatible with the previous version of Operate. The practical and ergonomically optimised 19” multi-touch display with its maximised resolution and 45° swivel range of fers decisive user benef its. Thanks to 3D control technolog y, you can simulate machining in advance – this is what state-of-the-ar t and user-friendly workplaces look like nowadays.

Highlights ecoMill V series • ecoMill V series for the greatest precision and highest performance with a 12,000 rpm milling spindle • Highest accuracy and precision due to direct coupling • Greater rigidity – FEM-optimised cast iron bed with a C-frame design and up to 1,000 kg load capacity – for highest stability and accuracy • Bigger workpieces due to largest Y-axis stroke of 560 mm • Perfect ergonomics with 850 mm table height and 313 mm from machine front to the table • Rigid and thermally stable design optimised by Finite Element Analysis • 30° steep covers for optimised chip evacuation

CO N T E N TS

Asia Pacific Metalworking Equipment News • April 2016

METAL CUTTING

Big Solutions For Miniature Parts

The global medical manufacturing industry is one of the world’s fastest growing industrial sectors. It has accounted for more than 10 percent of the gross volume of metalworking activities recorded in 2015. Yair Selek, product manager of face grooving systems and miniature industry, Iscar, tells us more about machining medical parts.

Getting A Clean Edge Competitive Advantages Through Cleanliness Hard material coatings improve the performance and service life of cutting and metalforming tools. However, these gains are contingent upon good coating adhesion to the substrate and this, in turn, is critically dependent on proper cleaning of the tools. By Doris Schulz.

Greater Transparency, Greater Efficiency

Closely monitoring all tools used in the manufacturing process; checking tool life and carrying out tool changes at just the right time with the touch of a button. Gan Shu Lim, marketing manager Southeast Asia, Walter shows us how.

GREAT GEAR & SYSTEM

A Clear Vision For Industrial IoT Syed Shah caught up with Scott Summerville, President, Microscan, on machine vision and the implication of the Industrial Internet of Things (IIoT) for his company and the manufacturing.

Ensuring Accuracy On The Shop Floor

With many shop-floor measurement options available in today’s marketplace, understanding the technology differences and the impact they have on performance before selecting a system. Sea Chiahui, regional product manager - stationary at Hexagon Manufacturing Asia Pacific gives an insight into the operating principles behind its 4.5.4 SF and 7.10.7 SF coordinate measuring machines.

The Technology Interplay

Where additive manufacturing is concerned the integral combination of building up material with the aid of a laser and machining is essential. DMG Mori has promised what they coin as “unlimited degrees of freedom” in construction and at the same time precision and surface qualities from this combination. Contributed by DMG Mori

IN DESIGN

Best Selection Practices With Multi Tasking

The sophistication of multitasking machining systems has made it expensive and the selection of a system for the right application an important decision becomes all the more complex.

Steel has found its master

Visit us at

25 - 28 May 2016 PWTC, Kuala Lumpur Malaysia

Hall 1, booth no. 1160

GARANT MASTERSTEEL, HIGH-END HPC END MILLS

The sword of the Samurai is a piece of art. Similar to the perfection of the Samurai sword, the new HPC mill GARANT MasterSteel also reaches new dimensions of manufacturing quality. With optimised geometry, high-quality components and the latest production methods GARANT has created a new generation of machining! Find out now at www.hoffmann-group.com Hoffmann Asia Pacific Tel: +65 6562 8163 Hoffmann Malaysia Hotline: 1800 888469

ENQUIRY NO 048

Fax: +65 6562 8161 email: asia-pacific@hoffmann-group.com

CO N T E N TS

Asia Pacific Metalworking Equipment News • April 2016

Getting Back To The Roots:

Revisiting Applications

We have come a long way since the introduction of software applications which can reap healthy rewards in machining, metrology and manufacturing. Syed Shah takes you back on a spin down memory lane.

FAST FAB

Getting Up To Speed

“Fibernomics”, describes an all-encompassing economic principle which seeks to give the competitive advantage in today’s sheet metal fabrication environment. It begins with the company’s fibre laser cutting system. Contributed by Oliver Hergt, editor corporate communications, Bystronic.

The Automotive Edge:

Less Cost, More Value

Eddy Lek, product marketing manager, Asia Pacific, Faro Technologies explores five ways that 3D measurement improves quality and productivity for the automotive industry.

THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE.

Moving & Handling Of Tomorrow

The evolution of technology pushes all those involved in the warehousing industry to start considering new means & ways not only for the today’s, but most importantly, for the tomorrow’s warehouse operation and its environment. By Petros N. Zenieris, The Business Criterion.

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Metaltech 2016:

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For its 22nd edition, the renowned metalworking exhibition will focus on building strong business connections between international suppliers and local manufacturers.

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Best choice. One fiber laser, every option Full capacity, a broad application range, and comprehensive features. Whatever the future of cutting, our fiber laser has everything you’ll need. BySprint Fiber with up to 6 kW. Laser | Bending | Waterjet bystronic.com Visit us at MTA Hanoi 2016, International Centre for Exhibition (ICE) 26th–28th April 2016, Booth #D2-01 (Saloon II)

ENQUIRY NO 062

EDITOR’S NOTE Asia Pacific Metalworking Equipment News • April 2016

Published by:

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(a fully owned subsidiary of Eastern Holdings Ltd)

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Getting A Move On Things

senior editor

Syed Shah

syedshah@epl.com.sg

business development manager

Randy Teo

randyteo@epl.com.sg

editorial assistant

Sharifah Zainon sharifah@epl.com.sg

graphic designer

Jef Pimentel

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circulation executive

Nurulhuda binte Suhaimi nurulhuda@epl.com.sg

contributors

In modern hectic life, movement is inevitable. People move from one place to another in search of a better life. The theory is the same even when it comes to cash. Cash flow is arguably the one thing that keeps a business afloat. The idea of mobility has slowly crept into our daily lives. One very good example is the mobile devices we carry. Intrusive the technology maybe for some but it is essential for many of us. In any case, one might think being mobile and connected these days is always better than being an immovable stationary object. Mobile devices have found their ways into offices, schools and perhaps more pertinently into factories as well. There is no denying the shift towards the use of mobile devices on the shop floor. It can range from simple bar code scanners to more sophisticated devices like the tablet or the smart phone. Since the very nature of manufacturing is mobile, with people always moving around the shop floor having no access to their desktop computers, there is a good business case for people to implement mobile technology on the production level. Devices like the tablet can effectively display crucial production information previously only available on the shop floor. These allow the management to have complete visibility looking at a dashboard display (visualisation tool) right from his or her phone. In metalworking, many have jumped into the mobile bandwagon. Cutting tools makers in particular, have apps available to help machinists in their work wherever they are. With these apps, users can, with their iPhone, determine cutting parameters for tools for the required operation and also place their orders online. It can compare the cost efficiency of two tool solutions and order tools and access online content from the company. The app can be used to calculate the parameters for face, shoulder and slot milling processes; hole making, including both drilling and boring; and turning (ISO turning and grooving). If time is money, the ability to save time brought forward by adopting mobility in an manufacturing environment has intrinsic value which may not be easily detected at first, but beneficial to an organisation in the long run. It is perhaps better to get a move on now than to be left behind.

Yair Selek Doris Schulz Gan Shu Lim Sea Chiahui Oliver Hergt Eddy Lek Petros N. Zenieris

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MCI (P) No. 047/06/2015 PPS 840/09/2012 (022818) ISSN 0129/5519

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MORE FORCE, MORE STAMINA, MORE BITE. Tiger·tec® Silver turning inserts for ISO P, ISO K and ISO M materials New cutting materials and new geometries – coming together to increase performance by up to 75 %. Based on the unique wear resistance and toughness, it is possible to predict what these cutting materials can endure. This is made possible by a new, patented aluminium oxide coating, which, in conjunction with the Tiger·tec® Silver procedure that is recognised worldwide, adds a whole new dimension to machining.

wintergerst & faiss

Tiger·tec® Silver – because process reliability deserves more bite.

Walter AG Singapore Pte Ltd 20 Science Park Road #01-04A/05, Teletech Park Singapore Science Park II, Singapore 117674 Tel.: +65 67736180 service.sg@walter-tools.com www.walter-tools.com

ENQUIRY NO 024

BUSINESS NEWS Asia Pacific Metalworking Equipment News • April 2016

Automotive Toolmaker Standardises On Delcam’s Products Across Devices

Germany: Over the past five years, German automotive toolmaker Konrad Schäfer Modell und Formenbau has switched all its static and portable CMMs, as well as its hand scanners, to Delcam’s PowerINSPECT inspection software. The results of standardising on a single software have included lower training expenses, greater staff flexibility and perfect CAD compatibility. “We see ourselves as one of the leading manufacturers of design and data control models, inspection and function cubing, and control gauges for the European automotive industry,” explained Jörg GroßeBeilage, head of the model making department, which has been based in Osnabrueck since 1962. Additional activities include models for vehicle interiors and prototypes for vehicle lights, as well as jigs and moulds for aerospace carbon fibre composites. Konrad Schäfer GmbH transforms customers’ ideas into reality – five to ten years before they are ready for batch production – with the help of innovative approaches to prototyping, the newest CAD, CAM and metrology technologies, and a modern machine shop. Große-Beilage also proudly pointed out that technical skill is still a crucial part of the organisation’s philosophy, something that wouldn’t be possible without motivated and well-trained staff. At nearly every workstation, there is a CMM, either a stationary manual or CNC CMM, or a portable measuring arm. The range of measuring machines are of different ages and from Mora, Zett Mess and Stiefelmayer, while the portable arms are from FARO. In addition to the extensive feature set and the support from Delcam, the user-friendly interface was a key factor for Herr Große-Beilage and his team. The CAD File Manager in PowerINSPECT is just one example; this makes it easy to manage component groups. The decision was also easy

LNG Down 38.7 Percent Year Over Year Singapore: Prices of spot liquefied natural gas (LNG) for delivery to northeast Asia averaged $4.460 per million British thermal units (/ MMBtu) for April, according to latest Platts Japan/Korea Marker data for month-ahead delivery. The figure reflects the daily JKM assessment published by Platts, the leading independent provider of information and benchmark prices for the commodities and energy markets, between February 16 and March 15, expressed as a monthly average. At $4.460/MMBtu, the April JKM was 38.7 percent below prices for the same delivery month in 2015. Platts historical data shows the JKM for

because PowerINSPECT offered by far the best price-performance ratio. Konrad Schäfer GmbH currently uses 16 licenses of PowerINSPECT, which have been purchased progressively. At the start, in 2009, the company purchased two licenses and contracted to buy four additional licenses in each subsequent year.

April delivery is also at the lowest monthlyaverage level seen since July 2009, when the monthly-average for August-delivered cargoes was $4.226/MMBtu according to Platts. Sentiment for April and further out in May continued to remain bearish due to expectations of extra supplies from both new and recently commissioned projects in the United States and Australia, as well as additional volumes from the Angola LNG project starting in the second quarter of 2016. The JKM had begun the trading month at $4.70/MMBtu, before sliding to an intramonth low of $4.25/MMBtu in the first half of the month. Expectations of oversupply from the projects coming online weighed on the market sentiment. However, the downward pres sure on prices was short-lived, as demand for April cargoes emerged at the same time from several buyers looking to quickly fill their April positions. Buy tenders from Argentina, PTT, SK, Posco, GSPC, Gail, and IOC for prompt April cargoes reversed the downward trend in prices.

Process monitoring without the bottlenecks

t: us a 2016 e e i S ano 8 A H .4.26-2 1 T M 016 -0 2 : C3 h t o Bo

Reduce bottlenecks and scrap with quick and easy process monitoring using the Renishaw Equator™ comparator Join hundreds of manufacturers worldwide who have increased flexibility and inspection capacity with the low cost Equator comparator. • Low cost increase of inspection capacity • Flexibility to inspect multiple parts • Insensitivity to workshop temperature change

Process Monitor software for the Renishaw Equator comparator allows users to view an instant status monitor bar chart of last measured features, historical results for the feature selected, and three status displays allowing management of re-mastering. The limit for re-mastering can be set on the basis of temperature drift, time since last master, or by number of parts measured.

• Easy integration into automated cells • Low cost of ownership - no periodic calibration or maintenance

For more information visit www.renishaw.com/euromould Singapore Thailand Malaysia Indonesia Vietnam

T +65 6897 5466 T +66 2 746 9811 T +60 3 5631 4420 T +62 21 25504567 T +84 432 818 999

www.renishaw.com

F +65 6897 5467 F +66 2 746 9816 F +60 3 5631 5407 F +62 21 25502555 F +84 432 818 998

E singapore@renishaw.com E thailand@renishaw.com E malaysia@renishaw.com E indonesia@renishaw.com E vietnam@renishaw.com

ENQUIRY NO 054

BUSINESS NEWS Asia Pacific Metalworking Equipment News • April 2016

Kennametal’s Cheryl Bush Receives Women In Manufacturing STEP Award

Future Growth Through Synchronisation And Cooperation Singapore: ESAB, a manufacturer and supplier of welding and cutting equipment, systems and materials, successfully held the APAC (Asia Pacific) Distributor Conference 2016 in Sanya, Hainan, on 11-12, January. The conference, with the theme “Stronger Together,” provided opportunities to share and exchange experiences within the region and to foster a stable long-term cooperative relationship. During the two-day conference, ESAB’s management, technical and sales teams, together with over 70 distributors from China and Southeast Asia, envisioned how to fully leverage the development and regional advantages of APAC to maximise resource sharing and take on new challenges in 2016. “Beginning in 2015, the two challenges brought about by manufacturing upgrade and economic slow-down quickly affected the entire industrial chain, including the welding and cutting equipment supplier on the frontline. With the integration of and restructuring between ESAB and Victor, we will be a leading integrated welding and cutting solution supplier on a global scale. In the ever-changing market environment, the only way to explore market potential and opportunities, as well as achieve win-win results, is through closer cooperation with channel partners and engagement at the executive level,” said Mr. Stanley Chew, vice president & managing director, ESAB APAC. During the conference, ESAB management from China and APAC, presented a wide range of topics, including channel management, market forecast 2016, new product outlook, success stories sharing and value-selling competition. A reward ceremony for outstanding distributors was held during the conference. In the case sharing session, distributors from various industries showcased product success stories and experiences and discussed how to provide more professional and effective services to clients. One of the highlights at the conference was the value-selling competition that helped the distributors better understand ESAB’s principles of selling. Distributors were divided into groups where they role-played in different scenarios. The judges were a panel of ESAB experts on value selling. One distributor commented, “During a time of uncertain economic conditions not within our control, this conference was packed with insights and valuable information that will be helpful for our business development and planning. The team building session has built strong bonds for better collaboration and co-operation.”

Germany: Kennametal’s director of Global Strategic Pricing Cheryl Bush received honours in the 4th Women in Manufac turing STEP (Science, Technology, Engineering and Production) Awards presented by The Manufacturing Institute. The STEP Awards recognise women at all levels, from the factory floor to the C-suite, who have demonstrated leadership excellence in modern manufacturing. The awards are part of the larger STEP Ahead Initiative, launched to examine and promote the role of women in the manufac turing industr y through recognition, research and leadership for attracting, advancing and retaining strong female talent. “My career in manufacturing has linked my enthusiasm for science and math to creating tangible products and services that make a difference in people’s lives,” said Ms. Bush. “Manufacturing offers vast opportunities for innovation and value creation in all aspects of product development through delivery. Having a career in manufacturing has been quite exciting and rewarding for me.” Ms. Bush joins three other women from Kennametal, Helen Patricia, Colleen Cordova and Martina Igel, who received the honour in 2013 and 2014. “We are thrilled to have Cheryl represent Kennametal at this year’s STEP Awards,” said Colleen Cordova, Kennametal Vice President, Industrial North America and former STEP Award recipient. “Through her leadership and invaluable contributions to the company, particularly in process management, Cheryl serves as an inspiration to the next-generation of women in the industry and demonstrates the endless opportunities available to females in manufacturing.” The Manufacturing Institution will recognise Ms. Bush and 130 other honourees during a special STEP Awards reception on April 21 in Washington, D.C.

OGP SmartScope Flash CNC300 IS your parts demand high quality measurement control? OGP SmartScope has its unique Multisensor Technology capability – cooperating Vision, Laser, Touch-probe and Micro-probe in a single setup. All the sensors are calibrated to a single XYZ reference and its enhance GD&T accuracy. With powerful MeasureMind 3D MultiSensor software, the graphic and numeric analysis data are done in seconds. SmartScope Flash CNC300 features a compact 300x300x250mm XYZ axis multi-sensor capability and a high quality 12:1 AccuCentric® zoom lens:- an excellent optical performance with automatic calibration on each magnification changes.

Vici Vision Optical Measuring Machine MTL 1 DO you use traditional method to measure turned parts? MTL1, a high precision optical measuring machine for all kind of turned parts:- such as transmission-drive/cam/electric-motor shafts, hydraulic/ pneumatic/engine valves, CV joints, turbine wheels, fasteners/screws, etc. • Quick measurement:- collects hundred measurement in 10~30 seconds, compare to 30~60 minutes on traditional method • Efficient:- features with on-board step-master, this allows MTL 1 effectively used in the shop floor • Less human error:- non-contact type allows consistent and accuracy measurement (2um on diameter and 5um for length)

New from QVI: ZONE3® The World’s Most Comprehensive Metrology Software ZONE3 Metrology Software represents a totally new way of working with multisensor measurement systems. Its built-in 3D animations clearly display relationships between parts, sensors, datum alignments, and machine tooling. ZONE3 uses CAD models and other innovative features to automatically and effortlessly generate measurement routines. Truly 3D CAD enabled, ZONE3 is easy to use and can be learned with a minimum of training. Features Include: • Full 3D CAD programming.

• Interactive reporting with live data and graphs.

• ASME Y14.5 compliant GD&T functionality.

• Multisensor auto-path creation.

• Live kinematic model simulation of machine with DRF and GD&T Animation.

Welcome to our booth at: SEMICON (SEA) 26th to 28th April (Penang) & MTA HANOI 26th to 28th April (ICE)

Optical Gaging (S) Pte Ltd Multisensor Metrology

www.smartscope.com.sg

21 Tannery Road, Singapore 347733 Tel: 65 6741 8880 • Fax: 65 6741 8998 • E-mail: ogpindo@smartscope.com.sg Singapore • Malaysia • Indonesia • Hong Kong • South China Thailand • Myanmar • Philippines • Vietnam • Taiwan • Australia New Zealand • Middle East

ENQUIRY NO 052

BUSINESS NEWS Asia Pacific Metalworking Equipment News • April 2016

Desay SV Automotive Electronics Chooses Siemens

China: Huizhou Desay SV Automotive Electronics (Desay SV) has chosen Siemens as its strategic partner for product lifecycle management (PLM) software. Desay SV cited the unique ability of Siemens’ comprehensive software offerings to unify all aspects of product development as important criteria in its decision. The partnership is also a critical step in the company’s preparations for the so called fourth industrial revolution, commonly known as Industry 4.0. By adopting Siemens’ full set of PLM software solution for the automotive industry to develop its holistic automotive electronics products, Desay SV expects to increase product quality, reduce timeto-market, decrease costs and enhance its competitive edge. The two parties will also cooperate to explore the future of digital manufacturing. “Siemens is one of the pioneers of the Industry 4.0 vision and strategy,” said Tan Choon Lim, Chairman of Desay SV. “They boast extensive experience and advanced technologies in digital and intelligent manufacturing that will enable us to implement a unified solution for project management, 3D modelling, collaboration, quality and manufacturing. Their team understands our business – where we are today and where we need to be – and they can meet our product development needs. With this partnership, we plan to gradually move ahead towards our goal of transforming into a digital enterprise and fully embrace Industry 4.0 in the way we run our business model.” As a leading global provider of PLM and Manufacturing Operations Management (MOM) software, systems and services, Siemens offers a Digital Enterprise Software Suite that serves as the foundation for building a digital enterprise. This suite goes beyond Industry 4.0 requirements by creating a “digital twin” that accurately and virtually models the physical and performance characteristics of a product through the entire innovation process, from ideation to realisation to utilisation. After intensive research and careful consideration, Desay SV recognized that Siemens is the essential technology enabler of the Industrie 4.0 roadmap. The company noted that the solutions provided by Siemens will greatly improve Desay SV’s efficiency and quality of products, reduce time-to-market and realize cost savings from its manufacturing processes. Siemens’ prior experiences and expertise in the manufacturing and automotive industries also reaffirmed Desay SV’s decision to enter this partnership. Siemens continues to commit and provide solutions based on customers’ industrial needs. For automotive electronic suppliers, Siemens offers solutions and technologies to enable model-driven innovation, helping customers to overcome challenges and meet the demands of this fast-changing market. Based in Huizhou city in China, Desay SV opened R&D and branch offices in Nanjing, Shenzhen, Singapore, Europe and Japan. It is the supplier for over 60 automotive manufacturers in the global market and has been honoured as the best supplier for its strong R&D and excellent quality of service for many years. “Automotive electronics suppliers are encouraged to optimise and reorganise their processes and systems, as they face an exploding market and its rapidly-changing requirements,” said Leo Liang, Senior Vice President and Managing Director of Greater China at Siemens PLM Software. “We are honoured to partner with Desay SV to overcome the increasing challenges of business complexity together, and achieve the revolutionary goal of digital manufacturing and Industry 4.0. Through close collaboration, we will establish a benchmark of digital manufacturing in the automotive electronics industry.”

A P P O I N TM E N TS

Walter Appoints New Asia Pacific Regional President Of Sales Kim Seidelman, has been appointed the regional president of the A siaPacif ic sales region. Walter will organise its global sales in four regions, rather than t h r e e r e g i o n s i t h a s Kim Seidelman had. Alongside Asia and America, there will be two sales organisations in Europe: One for the Western and Southern European market s, and one focussing on Central and Eastern Europe. As part of the new sales structure, Walter has named Kim Seidelman the new Regional President for Asia-Pacific. Up until now, Seidelman served as Managing Director of Walter USA. “I am proud that we were able to fill this key position by an experienced manager from our internal pool at Walter,” said Mirko Merlo, President of Walter. “We are staying true to ourselves: I believe our very international management team reflects the diversity of our customers in our target markets. With the new sales structure, we shall be closer to our customers in the future and will be able to react to technological requirements in a more flexible and intensive way.” “It is my goal to make the Asia-Pacific region Walter’s fastest-growing market. We have the potential to do this with our Engineering Kompetenz and our strong customer focus,” said Kim Seidelman.

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ENQUIRY NO 046

BUSINESS NEWS Asia Pacific Metalworking Equipment News • April 2016

Vietnamese Steel Manufacturers Weary Of Formosa Ha Trinh, Vietnam: Formosa spark fears of s tif f competition in Vietnam’s domes tic steel market. Formosa, the integrated steelmaker funded by Taiwanese company Formosa Plastics Group, in conjunction with Japanese steel heavyweight JFE Steel Corporation, recently started its trial run on 24 December 2015. Flushed with an investment capital of US$10.5 billion, many initially questioned the expenditure and inexperience of its parent company, both in relation to steel and geography. But since the first batch of hot rolled coiled steel was produced in December, other Vietnamese steel producers have been eyeing Formosa with a bit more apprehension, with some analysts fearing for domestic steel companies once Formosa officially begins production in 2016. The steel plant is expected to have a capacity of 7.5 million tonnes, 12 times higher than the next largest steel producer in Northern Vietnam, Thai Nguyen Cast Iron & Steel Mill. The future of the plant seems to be headed up in a large way, with capital expected to soar to US$26 billion, and production capacity expanded to 22.5 million tonnes of steel per year. Despite their economic and manufacturing might, Formosa has maintained that they will not compete with domestic manufacturers, instead focusing on producing ingot steel and steel used in industrial produc tion, rather than the struc tural steel existing mills produce.

Metal Deactivator Market Set For Continued Growth Hyderabad, India: Metal Deactivator Additives (MDA) are expected to continue building on their strong 2015 for the coming years. The MDA market hit US$ 160 million in 2015 on the back of strong showings in the American and European market. The growing industrial segment and large number of refineries were the driving force for Americas continued dominance of the MDA market. The MDA market is expected to experience slightly slower growth in the coming years, mostly due to issues of saturation, ultimately reaching an estimated US$207 million market value by 2020. Despite the expected slowdown in growth, the Asia Pacific region is expected to contribute immensely to future market shares for MDA.

China’s Steel Exports Hits Record High 112.4 Million Tonnes In 2015 Shanghai, China: China saw their exports of steel products rise 20 percent from 2014. According to trade statistics released by China’s General Administration of Customs, the total exports reached 112.4 million tonnes, breaking through the 100 million ceiling for the very first time. The result continues six consecutive years of increase in steel product exports, and places even more distance between them and their closest competitor, Japan. The spike in exports were mainly due to the economic slowdown in China, with more local producers turning to the overseas market in order to offload their steel in response to lower domestic demand and a surplus in their production. The exponential rise in Chinese exports has caused steel prices to tumble drastically. Japan, the second largest steel producer, for one, is feeling the pinch of massive Chinese exports. They are expecting a four percent dip in crude steel productions, and have seen their total crude steel output eclipsed by China’s export volume alone.

Tata Planning Its Restructure At Home Mumbai, India: Tata Steel embarked on the integral first step to a much needed restructuring of their steel plants. While the turmoil in Europe continues, with Britain in particular feeling the brunt of China’s steel dumping. One of the main targets for the embattled British steel worker is Tata, who has been responsible for tens of thousands of lost jobs in Britain. While they have found their hands tied in regards to restructuring their European branches, Tata has begun the process of restructuring at home. The restructuring will involve all walks of the company, including human resources, transportation and production. An anonymous source revealed to economic times that Tata had a “relatively higher percentage of manpower cost because of employee philosophies” but stressed that it “does not necessarily mean job cuts. The company will look at increasing the productivity of its assets.”

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • April 2016

Steel Production Might Be In For An Unexpected Rise

China’s Steel Firms Lost More Than $11.6 Billion in 2015 China: Overproduction and slumping demand led to Chinese steel firms losing big in 2015. The economic slowdown, caused largely by China itself, weighed heavily on the Chinese steel industry. During the period January to November of 2015, China’s major steel firms saw a loss of US$11.6 billion. The chairman of China Iron and Steel Association (CISA), Zhang Guangning revealed that the total annual crude steel capacity is now 1.2 billion tonnes. These record highs in steel production are coming in the wake of drastically reduced steel prices, and Mr Zhang lamented the lack of a mechanism to allow steel enterprises to exit the market. “Some enterprises want to exit, but an exit route has not been opened up and some local governments continue to urge steel firms to produce in the interests of local economic development and safety.” said Mr Zhang. CISA, which constitutes around 100 steel mills, and accounts for nearly 80 percent of total steel output, saw more than half of their members making losses in 2015. Mr Zhang pointed to the failure of steel output reductions to keep up with the fall in steel demand as a major contributory cause of the losses. The result has been a stronger push towards exports, leading to a global market influx of cheap Chinese steel. The effect has already been evident in countries like Britain, where the steel industry, unable to compete with the Chinese steel prices, is tethering on the verge of collapse. While other countries such as India has implemented protectionist measures in a bid to protect their domestic steel producers.

Vietnam Steel Industry Conflicted Over Imports Hai Duong, Vietnam: Vietnam recently launched an investigation steel billets imports in the face of record Chinese steel flooding the market, but not everyone is happy. After a 2015 which saw steel imports rise 22.56 percent, a figure which included 1.78 million metric tonnes of steel billets, Vietnam’s four major steel producers, Hoa Phat, Southern Steel, Thai Nguyen and Vietnam-Italy Steel, called for increased regulations regarding Chinese steel. The investigation on steel billets is currently underway and could possibly result in higher punitive taxes on imports. While this might be good news for the four major producers, who in total, produce over 40 percent of steel billets in Vietnam, smaller companies are less pleased. The majority of steel producers in Vietnam are relatively small and their profit margin leans quite heavily on acquiring cheaper steel imports from China. Companies such as Pomina have already called on the government to drop their investigation. The investigation is expected to take at least six months.

US: Despite all the battering global steel has taken, the outlook for 2016 is still relatively positive compared to 2015. After suffering the first annual decline in over five years, the steel industry is expected to experience a quick rebound in 2016, despite the historical lows that China steel production is currently facing. The decrease in China’s production is expected to be mainly offset by a renewed expansion in the European and North American industry. While the production is expected to edge up a notch, the conditions for steel is expected to remain as harsh as previously expected. The supply glut from years of overproduction coupled with diminished demand has led to bottom line steel prices. The ongoing critical state of steel is expected by many to result in a number of companies declaring bankruptcy over the coming year, and various countries implementing protectionist measures as well.

India’s Steel Imports Experience 23 Percent Surge In December New Delhi, India: India bucked the worldwide steel inertia with a massive 23 percent rise in December 2015. This follows a 35 percent decline in November. Total steel imports came up to 0.94 million tonnes, an increase compared to the previous month, but a decline of 1.4 percent compared to the same month in 2014. This surge in imports defied protectionist measures, which included a hike in import and safeguard duties, put in place by the government since June 2015. The seeming failures of the measures can be traced to China’s circumvention through lowered prices in tandem with the policies. In all, imports of total finished steel during the April- December period came up to 8.389 million tonnes, a 29.2 percent increase compared to the same timeframe during 2014. The Indian government though would not be deterred as more protectionist measures are expected to be carried out in the coming months, including a provisional safeguard d u t y o f 2 0 p e r c e n t o n i m p o r t o f h o trolled flat products of non-alloy and other alloy steel.

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BUSINESS NEWS Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

Lithium Ion Battery Production Expected To Significantly Increase

Tokyo, Japan: Japanese producers are betting on an expected surge in demand for electric cars by accelerating production of Li-ion battery materials. Li-ion batteries might be the quietest big automotive trend creeping up in 2016. Demand for electric cars has steadily increased, culminating in a Li-on battery market expected to reach US$10 billion, up 50 percent from 2014. The expected increase in production has seen global heavyweights such as Nissan embarking on US$27.67 billion Li-on battery projects, Sumitomo Osaka Cement planning to double the capacity of their plant in Vietnam and Central Glass is enhancing their facilities in a bid to mass produce battery materials in China ahead of schedule. The stringent safety requirement for Lion batteries provides an elevated playing field for Japanese firms who have an inherent technological edge.

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US Companies Join Growing Calls For AntiDumping Measures US: Four major producers of stainless steel sheet and strip filed antidumping and countervailing duty petitions in response to the ongoing influx of Chinese steel. Continuing the wave of steel companies scrambling to protect their domestic market against the onslaught of cheap steel from China, the four principal US producers of stainless steel sheet and strip, filed petitions alleging that the current level of China steel imports are causing material injury to the domestic industry. AK Steel Corporation, ATI Flat Rolled Products, North American Stainless, and Outokumpu Stainless USA, Limited Liability Company filed its petition for relief in the face of stainless steel imports from China increasing by 133 percent since 2013. The Commerce Department will determine whether to initiate the anti-dumping and countervailing duty investigations within 20 days and the United States International Trade Commission (USITC) will reach a preliminary determination of material injury or threat of material injury within 45 days, with the entire investigative process expected to take around a year.

The Unsolved Kinks In Autonomous Vehicles California, US: A clear new trend in automotive technology has presented itself in the past few years. Autonomous cars. There has been a lot of attention on these autonomous vehicles recently, Tesla introduced a Summon system, the Google Car is constantly popping up on the news and the recently concluded Detroit Auto Show served as a showcase for any concept cars that promised a semblance of automation. The future is near, but by no definite measure, here. A report by the Californian Department of Motor Vehicles shows just how many kinks there still are to be untangled before angry autonomous car horns start beeping in automated traffic. The report, which compiled data from September 2014 to November 2015, laid bare the oft ignored reality of advancing technology, the failures. Six companies were involved in study, all of them volunteering information on any disengagement that occurred in their cars while driving. The aforementioned companies included in the report are Tesla, Google, Volkswagen, Nissan, Mercedes, Delphi Automotive systems and Bosch. Tesla had the most encouraging results, attaining a perfect score of no interventions, though their disclosure was the least detailed of the companies. Google had 341 interventions, but drove the furthest distance of any of the companies, with over 400,000 miles. Nissan had 106 interventions, Mercedes had 1,051 interventions, Delphi had 405 interventions, Volkswagen encountered 260 interventions and Bosch faced 625 interventions.

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ENQUIRY NO 047

METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

BIG SOLUTIONS For Miniature Parts The global medical manufacturing industry is one of the world’s fastest growing industrial sectors. It has accounted for more than 10 percent of the gross volume of metalworking activities recorded in 2015. Yair Selek, product manager of face grooving systems and miniature industry, Iscar, tells us more about machining medical parts.

he demand for the production of smaller, more intricate and accurate Medical Industry parts that are often manufactured from difficult-to-machine materials continue to increase. When referring to medical industry machining, the term encompasses all machining related surgical implants, orthopaedic devices and medical instruments. The expression also includes small scale machining and micromachining, as today’s implanted devices often consist of, or include minute components. Amongst other difficult to machine advanced materials, titanium is often used in medical devices. This is due to its non-reactivity characteristics associated with the human body. Small metalworking shops wishing to compete in the challenge of producing medical parts must develop a range of advanced capabilities to meet the specialized demands of the medical industry, especially when involved in small batches and prototype work. Mindful of the specific requirements of this challenging sector, the creative work and exhaustive field trials undertaken by Iscar’s advanced R&D department has resulted in the significant expansion of the company’s range of cutting tools associated with the medical industry. In addition to innovative new products, Iscar’s R&D staff has applied a series of ingenious modifications to existing popular tools to

Opthalmic 9% Lab Apparatus 7%

enable the efficient and economical machining of smaller parts. Is c ar ’s e x panded r ange of op t imum machining solutions for highly ef f icient , small scale cutting tools has been made possible by technical progress in several important areas •

The use of the most suitable base materials

•

The application of advanced metallurgical coatings

•

The development of unique tool geometries

•

The upgrading of ultra-secure clamping systems,

New Grooving & Turning Tool Iscar’s new GEHSR/L-SL tool family, designed for Swiss-type and screw machines, are an improved version of the previous, popular GEHSR/L screw-clamped tools. The newly developed, user-friendly insert clamping system enables the secure fastening of inserts by the use of a key from either side of the tool. Following the rapid clamping procedure the torx screw can be used from either side of the tool, while a specially designed plastic screw blocks the opposite side of the tool preventing chip entr y. If

Electromedical 8%

Surgical and Medical Instruments 25%

IVDs 4%

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Surgical Appliances and Supplies 28%

Irrodiation 3% Dental 16%

METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

indexing is required from the opposite side, the screw can be switched to the opposite side of the tool. The GEHSR/L-SL tools are now available in 10, 12 and 16 mm shank sizes, which house GEPI and GEMI inser t s bearing dif ferent chipformer geometries. The inser ts range between 2.2 to 3.2 mm widths. When turning small parts, light cutting parameters are applied. Rather than making use of large inserts, small sized economical inserts are much more appropriate for this kind of machining. The shorter head design of GEHSR\L tools provides higher rigidity and improved machining stability, which enables the application of higher cutting conditions and by doing so, assures enhanced surface finish results. When using Iscar’s older generation toolholders, or other currently available toolholder types, the tool needs to be removed from the tool gang for inser t indexing on small Swiss-type machines. A major advantage is that Iscar’s inventive new tools enable insert indexing without removing the tool from the turret. In addition to the above, and available in the same size range, Iscar also provides the GHSR\L-JHP-SL variant with high-pressure coolant capabilities. The new tools feature 3 independent coolant inlet ports providing suitable machining solutions for different machine configurations. (see fig. 1) Swisscut INNOVAL Iscar has upgraded its Swisscut line. The new inser t s feature an advanced oval-shaped hole that enables the inclusion of two major improvements. Within the existing Iscar range and in all major competitors’ equivalents, different tools and inserts are used for back and front clamping orientations. Whereas in the new improved Swisscut INNOVAL line, the same tool and insert can be used in both clamping orientations. The imaginative new Swisscut INNOVAL clamping design uses a special screw that can be accessed and operated from both sides of the tool, enabling inserts to be indexed without the need to fully remove the screw. When comparing Iscar’s Swisscut, there are similar systems available in the market, in which the clamping screw has to be fully removed for insert indexing. When using these products, the screw can easily fall and be lost. The advanced new range of Swisscut Innoval tools reduce the amount of items needed by half and slashes users’ inventory costs. (see fig. 2)

Fig. 1

Fig. 2

Accuracy, Rigidity & Flexibility The growing demand for high accuracy and increased flexibility in clamping orientation has inspired Iscar to develop an advanced new range of PICCO holders. The innovative PICCOACE series features a unique patented clamping system that sets new standards in three highly important areas - accuracy, rigidity and flexibility of clamping orientation. PICCOACE’s fast action and very secure clamping system increases machining efficiency by saving time when replacing an insert, it ensures rapid indexing and guarantees extremely high clamping repeatability of 0.005 mm.

METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

The system’s solid carbide bars have two holes that enable precise coolant delivery to the cutting edge and the frontal flank. When high-pressure coolant (of up to 100 bar) is introduced through the coolant holes, the resulting chips are small and easily pushed out of the groove. Other advantages provided by PICCOCUT’s efficient cooling configuration are a substantial increase in tool life and improved surface finish characteristics. The new PICCO bar s are available in Isc ar ’s IC1008 P VD coated g r ade, which is suit able for machining acros s a wide range of cutting speeds and on a variety of workpiece materials.

Fig. 3

Fig. 4

The currently available wide variety of Swiss-type machines has increased the demand for multi-orientated clamping. Most of the existing available tools provide a single clamping orientation. In contrast Iscar’s PICCOACE offers a high-quality, universal solution that is suitable for all Swiss-type machines, enabling operators to install and remove an insert from any desired direction. (see fig. 3) Aiding Efficiency The new PICCOCUT face grooving range is intended mainly for external / internal and grooving along a shaft. PICCOCUT has a reinforced geometry that aids efficient deep face grooving and is available in 3, 4 and 5 mm widths, for depths of up to 40 mm and a minimal grooving diameter of 16 mm.

Iscar’s Expanded MINCUT Line Following the global success of Iscar’s MINCUT face grooving family, Iscar has further expanded its application range with the introduction of inserts for internal grooving, undercutting and threading and solid carbide boring bars. MIGR 8 internal shallow grooving inserts are available in 0.5 to 2 mm grooving widths, in straight and full radius configurations. MIUR 8 internal, 45° full radius undercutting inserts are available in 1 to 2 mm grooving widths. MITR 8-MT internal, partial profile, ISO metric threading inserts are available for 0.75 to 2 mm pitch sizes, for 10mm minimum thread diameter. All of the new inserts are made from Iscar’s IC908 PVD coated grade which can be used on a very wide variety of materials and across a range of machining conditions. The MR8 inserts are screw-clamped into a long pocket of the MIFHR bars, with very rigid clamping (patent pending). Chip flow on the insert rake is uninterrupted and the tools feature internal coolant holes that are directed to the cutting edge. MIFHR 8SC-8-8-SRK is a new solid carbide boring bar with 8 mm shank size that offers high rigidity and can also be used on the MG PCO-6-8 bar holders used for PICCO inserts. (see fig. 4) ‘Turning’ - Efficiency Into Profitability To accommodate small boring diameters, Iscar has expanded its internal turning application range by introducing new ranges of positive and negative boring tools with steel and solid carbide shank options and new small sized inserts. Each of the new tools feature coolant channels directed precisely to the insert’s cutting edges. The tools carry new positive (single-sided) ground EPGT and CCGT inserts. EPGT has a 75° geometry for a minimum bore diameter of 4.5 mm and CCGT features an 80° geometry for

METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

Fig. 5.0

Fig. 6

New negative, double-sided ground inserts for Dmin=12 mm, WNGP 0403 and DNGP 0703, include F2P and F2M chipformers for steel and stainless steel respectively, were designed for medium range boring diameters. (see fig. 5.0 & 5.1)

Fig. 5.1

minimum bore diameter of 5.0 mm. Shank sizes are available in a diameter range of 4 to 7 mm. Tools for negative (double-sided) inserts Dmin=12 mm carry ground WNGP and DNGP inser ts. WNGP has an 80° geometr y for a minimum bore diameter of 12 mm and DNGP features a 55° geometry for minimum bore diameter of 13 mm. Shank sizes are available in a diameter range of 10 to 20 mm for forward and back turning operations. The new positive, single-sided ground inserts can accommodate a 4.5 mm minimum bore diameter EPGT 03X1, and a 5 mm minimum bore diameter for bars that carry the CCGT 04T1 inserts. Both insert geometries are available with a new F1P chipformer specially designed for super finishing applications.

Drilling For Profit Iscar has further expanded its popular SUMOCHAM drilling head options by introducing two major new innovations. The first revolutionary drilling head geometry features concave cutting edges that substantially enhance the self-centring ability of the drill. The new HPC-IQ drilling heads using up to 12xD long drills, negate the need for a pilot-hole operation and are available in 8–25.7 mm diameters, in 0.5 mm increments. The advanced, new drilling heads provide a substantial cost reduction by cutting machining cycle times and reducing the number of tools required for drilling operations. The second SUMOCHAM innovation is the extension of the line’s application range by adding flat face drilling heads. The new flat face drilling heads are designated FCP and are designed for drilling steel components (ISO P material group). Drilling with the FCP inserts provides a nearly flat bottom in the drilled hole, a feature required across a variety of applications. Made from IC908 TiAIN PVD coated grade, the FCP drill heads can be mounted on any SUMOCHAM drill that features the appropriate pocket size and the recommended cutting conditions. The FCP drilling heads have the same features and are the same as those recommended for ICP drilling heads. (see fig. 6)

The advanced, new drilling heads provide a substantial cost reduction by cutting machining cycle times and reducing the number of tools required for drilling operations.

METAL CUTTING Asia Pacific Metalworking Equipment News • March 2016

Photo Credits: Dürr Ecoclean

GETTING A

CLEAN EDGE

Competitive Advantages Through Cleanliness Hard material coatings improve the performance and service life of cutting and metalforming tools. However, these gains are contingent upon good coating adhesion to the substrate and this, in turn, is critically dependent on proper cleaning of the tools. By Doris Schulz.

R 3002

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educed tool costs, increased productivity, improved precision and extended maintenance inter vals – these are objectives which top the priorit y list of manufac turing companies today. The service life and production reliability of metalforming and cutting tools such as indexable inserts, drill bits and milling

cutters are key parameters for performance optimisation and hence, safeguarding the user’s competitive edge. In order to minimise wear, tool s are often surface-coated with a hard material such as titanium, aluminium, zirconium, or diamond-like carbon (DLC). The coatings are deposited in the micron gauge range

METAL CUTTING Asia Pacific Metalworking Equipment News • March 2016

To minimise wear, the surfaces of metalforming and cutting tools such as indexable inserts and drills are often coated with a hard material. Proper coating needs an extremely clean surface.

by means of a PVD, PACVD or CVD process. On a cutting tool, a hard material coating ensures a longer service life while reducing the formation of built-up edges. In the case of punching and metalforming dies it can reduce unwanted effects such as abrasive wear and cold welding. A Ready-To-Coat Surface Standard Is Essential For the hard layer to deliver its beneficial effects, it is critical that the coating material is perfectly matched to the application and that the tool itself has a proper surface finish. Any particulate or film-forming residue is bound to degrade the coating-tosubstrate adhesion. “In order to attain an adequate level of cleanliness in a cost-efficient and processreliable manner, one mus t consider the en t ir e t o o l mak in g p r o ce s s . O t h er w i s e , contaminants will be carried over through the manufacturing chain and can then be removed only through an intense effort at the final cleaning stage, or not at all,” comments Volker Lehmann, managing director of UCM AG. When Is Cleaning To Be Performed? Tools such as indexable inserts, which are often made of hard metals, are ground upon leaving the sintering furnace. Grinding commonly involves the use of machining fluids, the residue of which must then be removed. “This is typically done with the aid of hydrocarbons, i.e., solvents which effectively remove nonpolar contaminants such as oils while exhibiting a good material compatibility,” Volker Lehmann explains.

Dürr Ecoclean’s product portfolio comprises solvent-based cleaning systems for this purpose which can be adapted to individual cleanliness, throughput and part geometry needs by selecting a suitable machine size, process technology, fluid treatment and drying system. One important factor is the system’s ability to handle the incoming oil loads, which may be substantial at times. The equipment must therefore have fluid treatment systems which ensure high degreasing performance of the solvent in multi-shift operation. If the indexable inserts are polished as well, this operation must be followed by another cleaning step. This should be performed directly after the polishing cycle to prevent polishing paste residue from drying into a difficult to remove film on the part surface. The preferred solution here is a multi-chamber

Final cleaning before deposition of the coating is commonly performed in multi-chamber systems with the aid of ultrasound.

METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ March 2016

Sufficient tool cleanliness requires a coherent design of the overall cleaning process, not just an individual machine.

In tool cleaning, solventbased systems are typically used downstream of grinding operations involving machining fluids.

system in which intermediate cleaning is performed with an aqueous medium. This has the advantage that parts can be run through the cleaning system immediately in a single layer so that the polishing paste will be fully removed without residue. A common subsequent step before coating is alumina blasting, i.e., surface finishing of the product using a fine-grained aluminium oxide. Complete Development Of The Cleaning Process Next, the parts move on to the final cleaning stage which takes place in multi-chamber systems with the aid of ultrasound. The objective of this cleaning step, on the one hand, is to remove all residue from the part and to dry each product to a stain-free finish. On the other

hand, an aqueous cleaning process must always be designed to minimise the so-called cobalt leaching effect, i.e., the dissolution of cobalt from the hard metal. â&#x20AC;&#x153;Especially for the final cleaning operation, it will normally be necessary to develop an overall process in which aqueous media as well as parameters such as temperature, utilisation of ultrasound and treatment cycle times are perfectly matched to the parts being cleanedâ&#x20AC;?, Volker Lehmann notes. The associated cleaning trials are performed by UCM at its own Technology Center under production conditions. The frequent problem of part carrier marks being inflicted on indexable inserts during cleaning is also resolved at this stage. At the equipment engineering level, a consistently high level of part cleanliness is ensured by the four-sided overflow developed by UCM. The cleaning or rinsing fluid enters each tank from below, then rises up and flows out over the rim on all sides. As a result, a permanent flow is generated in the tanks which ensure an intense treatment of each part. At the same time, removed residue and particles are discharged from the tanks and filtered immediately so that no re-contamination will take place when the parts are lifted out or transferred. In order to obtain a stain-free surface, moisture is blown off the part before the actual drying cycle commences. Thus, proper cleaning after each processing step is a key contributor to an optimised coating quality and can provide a competitive advantage to toolmakers and coating contractors.

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METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

Walter AG

The Tool ID data is assigned via an identifier, for example a laser-engraved data matrix code, on the tool.

Greater Transparency,

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p until recently, the above notion have been just wishful thinking, it is now becoming a reality with Tool·ID from Walter. This solution means that the manufacturer of precision tools is well on the way to becoming a smart factory

– a production environment in which manufacturing machinery and logistics systems are largely organising themselves, without any human intervention. For a manufacturing company to be able to work in a profitable manner, processing

METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

All Data At The Touch Of A Button In the smar t factor y, production sites and operating sites are linked in such a way that all processes can be coordinated centrally and controlled automatically. Walter is currently developing a system in addition to Tool ID which sees it taking yet another step towards the smart factory and Industry 4.0. This solut ion allow s all t he accessible data within the pro-

Live Tools for machining centers

times and machine down-times have to be kept to a minimum. In short: A transparent manufac turing process is required. With Tool·ID, the precision tool specialist Walter has developed an appropriate solution that ensures comprehensive transparenc y of production processes. This innovative solution allows the user to transfer tool data from the pre-setting device to the machine and to evaluate the parameters that are run on the machine. The data is assigned to the tool via an identifier, for example a laser-engraved data matrix code on the tool. Information about the manufac turer or user can then be added to this. The data is called up using a scanner and automatically transferred to the machine control unit – meaning that time-consuming and er ror-prone manual en t r y becomes superfluous. “Thanks to Tool ID, the user can save time. T hey al s o bene f i t f rom improved process reliability and gain an insight into the real application of tools in production,” explains Holger Langhans, director of Walter Multiply. The system is currently being tested by a customer in the automotive sector. It is an essential component for communication between the tool and the machine. The tool also provides production information in a form that can be read by the machine. Using this information, for example tool life or pre-setting data, the individual produc tion steps can be controlled. Thanks to this comprehensive overview, it is possible to detect potential problems early on and remedy them in good time. With this new system, Walter sees itself as being one step closer to Industry 4.0.

duc t ion env ironment to be v iewed and processed according to the user group. The open, independent system takes the current situation at each customer as its basis. “The aim of this new development is to digitalise all relevant information relating to the production process and make it available for analysis and for the purpose of optimisation,” explains Mr Langhans. This universal, fully integrated “System of Systems” digitally links all production units involved in the process via a shared

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heimatec GmbH (Asia/Pacific) 19 A Hillview Ave. Hillview Park 01-06 Postal Code 669554

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METAL CUTTING Asia Pacific Metalworking Equipment News • April 2016

Walter AG

The Tool ID solution from Walter AG saves the user time and improves process reliability.

It is an essential component for communication between the tool and the machine.

ser ver. This means that the user can, for example, see all changes made in the machining programs. “In future, the user will be able to view, combine and evaluate data at the touch of a button – also using apps on a smar tphone or tablet ,” explains Mr Langhans. This gives them a complete view of the processes in real time. Downtimes and processing times are reduced, and damage to

components and equipment is minimised, which all has a positive impact on productivity. The solution is aimed at users who employ ten or more CNC machines. The direction the system should pursue is currently being specified in consultation with potential users. Mr Langhans hopes to see the initial concrete results during the test phase. The first pilot customers are due to implement the solution in the near future.

Together we move the world

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The Schaeffler Group is a leading global integrated automotive and industrial supplier. The company stands for the highest quality, outstanding technology and strong innovative ability. The Schaeffler Group makes a decisive contribution to â&#x20AC;&#x153;mobility for tomorrowâ&#x20AC;? with high-precision components and systems in engine, transmission and chassis applications as well as rolling and plain bearing solutions for a large number of industrial applications. It has a worldwide network of manufacturing locations, research and development facilities and sales companies at approximately 170 locations in 50 countries.

apore) Pte Ltd . 151 Lorong Chuan, #06-01, New Tech Park, Lobby A, Singapore 556741 . Tel: +65 6540 8600 . Fax: +65 6540 8668 . marketing_sg@schaeffler.com Regional HQ: Schaeffler (Singapore) Pte Ltd . 151 Lorong Chuan, #06-01, New Tech Park, Lobby A, Singapore 556741 . Tel: +65 6540 8600 . Fax: +65 6540 8668 . marketing_sg@schaeffler.com

Vietnam Malaysia Philippines Thailand Vietnam IndonesiaBearings (Malaysia) Sdn. Bhd. Malaysia Philippines Thailand(Vietnam) Co., Ltd. Schaeffler Schaeffler Philippines Inc. Schaeffler (Thailand) Co., Ltd. Schaeffler Schaeffler (Thailand) Schaeffler (Vietnam) Co., Ltd. PT.Wisma Schaeffer Bearings Indonesia Schaeffler (Malaysia) 6th Floor, TMS Building.Co., Ltd. 5-2 Fiamma 5th Bearings Floor Optima Bldg. Sdn. Bhd. 388Schaeffler ExchangePhilippines Tower, 34thInc. Floor Regional HQ: Schaeffler (Singapore) Pte 5-2 LtdWisma . 151 Lorong Chuan,Village #06-01, New TechUnit Park, LobbyOptima A, Singapore +65 6540 8600 . Fax: +65 6540 8668 marketing_sg@schaeffler.com 6th. Floor, TMS Building. Lippo Kuningan Fiamma 5th Floor Bldg. 556741 . Tel: 388 Exchange Tower, 34th Floor No 20 Jalan 7A/62A Salcedo St. Legaspi 3403-3404 172 Hai Ba Trung Street, District 1. SalcedoRoad, St. Legaspi Village 172 Hai Ba Trung Street, District 1. 19th Floor Unit A & F No 20 Jalan 7A/62A HoUnit Chi3403-3404 Minh City Bandar Menjalara Makati City 1229 Sukhumvit Klongtoey Sukhumvit Road, Klongtoey Ho Chi Minh City Jl. HR Rasuna Said Kav B - 12 BandarTel: Menjalara Makati10110 City 1229 Vietnam. 52200 Kuala Lumpur +63 2 7593583 Bangkok, Tel: +63 2 7593583 Bangkok, 10110 Vietnam. Jakarta 12920 52200 Fax: Kuala Lumpur Thailand Tel: +84 8 222 02 777 Malaysia +63 2 7798703 Vietnam Indonesia Malaysia Philippines Thailand +63 2 7798703 Thailand Tel: +84 8 222 02 777 Tel:+603 +62 21 29110280 Malaysia Fax: +84 8 222 02 776 Tel: 6275 06 20 marketing_ph@schaeffler.com Tel:Fax: +662 697 0000 PT. Schaeffer Bearings Indonesia Schaeffler Bearings (Malaysia) Sdn. Bhd. Schaeffler Philippines Inc. Schaeffler (Thailand) Co., Ltd. Schaeffler (Vietnam) Co., Ltd. Tel: +603 6275 06 20 Tel: +662 697 0000 Fax: +84 8 222 02 776 Fax:+603 +62 21 29110281 Fax:marketing_ph@schaeffler.com +662 697 0001 marketing_vn@schaeffler.com Fax: 6275 64 21 5th Floor Optima Bldg. 388 Exchange Tower, 34th Floor 6th Floor, TMS Building. Lippo Kuningan 5-2 Wisma Fiamma Fax: +603 6275 64 21 Fax: +662 697 0001 marketing_vn@schaeffler.com marketing_id@schaeffer.com marketing_th@schaeffler.com marketing_my@schaeffler.com 172 Hai Ba Trung Street, District 1. 19th Floor Unit A & F No 20 Jalan 7A/62A Salcedo St. Legaspi Village Unit 3403-3404 marketing_my@schaeffler.com marketing_th@schaeffler.com Jl. HR Rasuna Said Kav B - 12 Bandar Menjalara Makati City 1229 Sukhumvit Road, Klongtoey Ho Chi Minh City Jakarta 12920 52200 Kuala Lumpur Tel: +63 2 7593583 Bangkok, 10110 Vietnam. Malaysia Fax: +63 2 7798703 Thailand Tel: +84 8 222 02 777 Tel: +62 21 29110280 marketing_ph@schaeffler.com Tel: +662 697 0000 Fax: +84 8 222 02 776 Fax: +62 21 29110281 Tel: +603 6275 06 20

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

A CLEAR VISION

For Industrial IoT

Syed Shah caught up with Scott Summerville, President, Microscan, on machine vision and the implication of the Industrial Internet of Things (IIoT) for his company and the manufacturing.

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What are your thoughts on the increasing relevance of machine vision in manufacturing? There is a lot more capability to create demand and solve customer issues when you are talking about intelligent sensing devices like machine vision smart cameras with fully-featured software. These tools are what I would categorize as advanced manufacturing, and I would consider PLC-driven process machinery as a more baselevel automation. There are a lot of companies that install automation systems to achieve acceptable product quality levels, or simply because human interaction is no longer sufficient to do things like building cars and making steel. That being said, machine vision technology is still highly discretionary. It is not necessarily a requirement, because you could potentially accomplish your quality goals through manual inspection (although it is not as tireless or accurate).The same goes for barcode reading for traceability – it is highly efficient, but it is not necessarily mandatory. It is incumbent upon us as the manufacturing supplier to help the cus-

tomer justify ROI and demonstrate the benefits of our automation technology. Could you explain a little more about the difference between ‘mandatory’ and ‘discretionary’? There are some regulatory requirements, particularly in the life sciences, that are beginning to require unique device identification for items like medical devices and pharmaceuticals. These requirements are mandatory and will soon be applied as a global standard. The use of machine vision and barcode reading for traceability is largely discretionary. There is enough impetus to put in traceability systems to ensure that the products manufactured reach their intended destination and they can be tracked and traced directly to the consumer in the event that there is a recall. This is not necessarily mandated, but many manufacturers (if they have had any experience with recalls) they know that it is important to have traceability systems in place. This is especially true for consumer-driven products like cars where there could be accidents involved, or

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

food products or pharmaceuticals where there could be health concerns. While it might not be mandated by the government, automation systems may also be installed for reputational or image issues. Machine vision is all about quality control and precision inspection to make sure products are assembled and aligned properly, and that company brand and product aesthetic are maintained. Besides reputation, automation systems can also aid customer satisfaction, (for instance, by reducing scrap rates), so really it is again incumbent upon us as the supplier to help the end user justify our technology. And with the advent of technology becoming more powerful, more miniaturized, and more competitively priced, more businesses are now adopting it. How is Microscan positioning itself to leverage IIoT to its own advantage? What does the IIoT mean to Microscan when it comes to product development today? To explain Microscan’s position and philosophy on the Internet of Things, we are highly invested as producers of, well, the “thing”. We see the camera or the barcode reader as the “thing” that has intelligence, that is able to be connected, and thus it is imperative that we look at the IIoT with the concept of connectivity in mind. We manufacture our products in such a way that they can connect readily and easily across all modes of communication. This is to ensure that our products can transmit data to another system, like a PLC for instance, without compatibility obstacles. This facilitates the pervasiveness of data for widespread and variable use. Aside from this, we pack as much intelligence into our devices as possible, because it is the persistence of the “thing” that is really at the crux of our role in IIoT – the irreplaceable device. What you see in factory automation today is the flattening of control architectures with a lot more intelligence being embedded in the lowest sensors in the factory floor so they can connect peer to peer without peripheral equipment. With this architecture, you don’t have to go through a labyrinth of devices or communication media to make decisions. Ultimately, this simplification of the factory network is what is going to drive IIoT. The ability to transmit data efficiently and quickly to other devices that needed to consume it to optimize any function of manufacturing processes – that’s where we see our technologies playing a role. We aim to make our devices as intelligent as possible because these devices will persist. No matter what manufacturing scenario, businesses will always need sensors, like cameras and barcode readers, to acquire data from the factory floor to enable any process in the IIoT.

During manufacturing operations, codes can get dirty or damaged, so having a robust set of decoding algorithms to read codes regardless of unpredictable results of environmental conditions was essential. How far has track and tracing come along and how has IIoT impacted its development? When I first started my journey with Microscan, someone told me that it would not be long before you will be able to track and trace a product from manufacture to the end user with the use of a smart phone. I have not seen this yet, but with the rate at which connectivity technology is evolving, I believe that this scenario will be entirely possible sooner than later. Privacy issues are the main obstacle in the road to achieving this because of all the data collected from various parties along the way. However, I think that the ability to track a product directly to a household and advise the consumer about the quality of the product, should there be any concerns about it, is going to happen eventually. This would be the ultimate display of the capabilities of the IIoT – a scenario where I can use a smart phone to access information acquired from barcode readers at the various stages in the manufacturing supply chain. So it is only a matter of time before the technology that is able to tie all these data together, and present them at the touch of a finger, is available. Could you tell us more about the MicroHAWK platform then, and how in line is it with IIoT? The MicroHAWK series is what I would call a complete product platform. We had four design principles that we were focused on. The first principle was to produce the smallest and most capable product on the market today. This is because customers are downsizing the footprints of their machines on manufacturing floors, so they need the most bang for the size of the product on the manufacturing line. Next is the ease of use, or “the out-of-box” experience. Our latest web interface for the MicroHAWK platform, WebLink, offers an unprecedented user experience and gives us patent-pending technology that also plays into IIoT. With regards to performance, we have upgraded our decoding algorithms to X-Mode 4.0, which is the most robust set of decoding algorithms in the industry today. During manufacturing operations, codes can get dirty or damaged, so having a robust set of decoding algorithms to read codes regardless of unpredictable results of environmental conditions was essential. The fourth design principle

Privacy issues are the main obstacle in the road to achieving this because of all the data collected from various parties along the way.

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

Verification uses machine vision technology, rather than barcode reading technology, because you are not just reading a code but rather analysing its physical appearance as well as acquiring data for further code string format analysis.

in the product design was modularity and scalability. We wanted to come up with products that leveraged a common software and hardware platform, providing customers with a range of products that could achieve different requirements with one highly-configurable toolset. MicroHAWK is built on a common imaging engine at the core of the ID-20, -30 and -40 barcode readers, with two gigabytes of memory and interchangeable lenses across the board. The three readers differ in terms of connectivity. For instance, in the ID-40, there is an Ethernet port, whereas there is a Micro USB port in the ID-20. Other differences include the reader size, industrial rating, and illumination options. The choice of reader for a given application is dependent on the environment that they are going to function in. For instance, the ID-20 is better suited for a closed environment, for instance, a lab. The ID-40 would be best suited for more robust manufacturing spaces and applications where exposure to harsh manufacturing conditions is more likely. On each reader, there is an embedded browser-based interface called WebLink. The actual Graphical User Interface (GUI) for WebLink (that is, the software) is embedded on the reader itself. Typically, with many barcode and vision products in the market, the software would be provided separately in a dongle which you would have to load onto a PC and interface it with the product. But in the case of the Microscan’s MicroHAWK series, by embedding the browser in the camera, you can bring up the interface on a PC or any device with a web browser without worrying about the stability of the software, its compatibility, or version, in the same way you would if it were loaded onto a PC separately. So as long as you have any sort of updated web browser at your disposal, all you need to do is enter the URL of the device and you can access the reader immediately.

Which verticals will the product be targeted at and what kind of offerings can it provide? The ID-20 is targeted at instrument manufacturers, where we have had a lot of success in clinical and laboratory applications. We are working directly with those manufacturers to educate them further about the benefits of the ID-20; for example, the flexibility of its read range. Some of our competitors’ products, for instance, have had to use mirrors or other peripherals to achieve the same read performance that our readers can achieve at various mounting angles or orientations within equipment. The ID-40 would be targeted more towards sectors like the FMCG and electronics because of its high-speed Ethernet communication capability. The ID-30 would be somewhere in the middle of what the ID-20 and -30 can offer, and can cater to customers that are in both closed and open manufacturing environments. The ID-30 has serial communication, five volt input, and has an IP54 rating at a cost-efficient price point, so it has a competitive value standpoint. LVS was recently acquired by Microscan. How does the LVS brand strengthen Microscan’s position in the machine vision market? Traceability is critical when it comes to the health and pharmaceutical sector. Making sure that the barcodes are of good quality so that they can be tracked throughout the supply chain is critical. Recently, we acquired a company called Label Vision Systems, which verifies barcodes to barcode quality standards like ISO, GS1, and others, to meet the traceability requirements of certain industries. This is getting back to government mandates and regulatory requirements – they are hitting the medical device and pharmaceutical industry more directly to ensure that there are unique barcodes or identifiers on every product, and that those codes have sufficient quality so they can be read downstream. Ensuring readability of codes means that they need to be graded. So with Label Vision Systems, we now have a full range of technology intended specifically for grading barcodes and other identifiers to meet these customers’ needs. Verification is a critical element in traceability. Verification uses machine vision technology, rather than barcode reading technology, because you are not just reading a code but rather analyzing its physical appearance as well as acquiring data for further code string format analysis. The synergy of LVS verification technology within the Microscan portfolio is compelling because Microscan was already providing verification, but this was primarily for direct part

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

marks. By adding LVS products to our offerings, we expand our expertise from DPM verification to the verification of any barcode, printed or marked. LVS also allows us to expand our role in the manufacturing process into more areas of the supply chain. Take a medical device company as an example – LVS may be working with their packaging operations to make sure that the label on the outside of a box can be tracked. Meanwhile, we at Microscan are working with the same company ensuring traceability through the manufacturing operations of the product itself after it is packaged. With the acquisition, we can now offer all of these capabilities as a single solution, including the capability to do offline and inline verification through LVS products. Not only is our unified product line extremely synergistic, but LVS also addresses the same customers as us, so there is a lot of synergy from a market and customer standpoint as well. How does Microscan differentiate itself from in the market? Looking back at the four design principles that the MicroHAWK is based on, we are going to be smaller in terms of footprint, bigger on functionality as compared to other readers out there,

and offer a much better “out-of-box” experience through superior ease of use, especially with WebLink. Compared to the competitors in the market today, we have better decoding performance and offer more modularity and scalability using a common imaging engine, and we are able to drive cost down as a result. We also try to differentiate ourselves in how we work with our customers. Here at Microscan, we strongly believe in the element of trust playing a critical role in how we do business with our partner or our customer. We want them to trust us in providing them with accurate information through thick and thin to get their application right. Strategically, we strive to bring to our customers the highest level of quality in the market in terms of products and service. For example, as part of our service, we can provide custom interfaces for specific applications, such as installations that enable real-time verification of barcode quality on products as they are passing down the production line. Wherever we see the customer or the market has a real need, we will take our core technology, maybe customize some software, and provide the right solution that will fit that application.

Here at Microscan, we strongly believe in the element of trust playing a critical role in how we do business with our partner or our customer.

ENQUIRY NO 050

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

ENSURING ACCURACY

On The Shop Floor With many shop-floor measurement options available in todayâ&#x20AC;&#x2122;s marketplace, understanding the technology differences and the impact they have on performance before selecting a system. Sea Chiahui, regional product manager - stationary at Hexagon Manufacturing Asia Pacific gives an insight into the operating principles behind its 4.5.4 SF and 7.10.7 SF coordinate measuring machines.

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GREAT GEAR & SYSTEM

he promise of ef f icienc y savings are making shop-f loor measuring systems an increasingly attractive p r op o s i t ion f or manu f ac t ur er s . But, like any quality control or manufacturing technology, there is a great diversity of product offering, and the different operating principles can be confusing for businesses looking to acquire new equipment . Even within the Hexagon range, there are multiple approaches to the challenges of shop-floor metrology, and knowing which is best for a par ticular installation is key for ensuring return on investment. Coordinate measuring machine (CMM) accuracy is dependent upon the ambient thermal environment in which it operates. Changes in temperature cause the scales, machine structure and artefacts being measured to expand, contract, and, in some cases, distort in a non-linear manner. T houg h o f ten comp en s a te d for in a variety of ways, these thermally-induced changes can lead to significant measurement uncertainty, particularly in the context of measurement on the shop floor, where temperature can be difficult to control. With the ever-continuing trend of moving dimensional inspection from thermally controlled metrology labs to the shop floor, understanding how temperature affects CMM accuracy is more important than ever before. Traditionally, the thermal dependence of a CMM’s accurac y has been specif ied using broad temperature bands centred at about 20°C (68°F). For instance, a manufacturer might specif y a hypothetical CMM’s maximum permissible error of indication for size measurement, E0, MPE , according to ISO 10360-2 over a temperature band of 18-22°C (64-72°F) as: E0, MPE = 3.0 + 3.0 * L / 1000 where E0, MPE is in microns, and L is the measurement length in millimetres. While this is a logical way (for both the CMM manufac turer and the customer) to specify the temperature dependence of CMM accuracy for a machine in a lab environment, the logic falls apart for machines installed and used in an environment where the temperature is not well controlled over both long and short timescales. While a single temperature band specif ication (whether it is wide or narrow) is convenient for the CMM manufacturer, the customer is left with only the manufacturer’s

Asia Pacific Metalworking Equipment News • April 2016

conservative, but not terribly detailed estimate of how machine accuracy changes with temperature. After all, a primary reason that customers purchase a shop-floor machine is to position it in a location where the ambient temperature will, in all likelihood, affect the CMM’s measurement accuracy.

Coordinate measuring machine (CMM) accuracy is dependent upon the ambient thermal environment in which it operates.

Stair-Step Specifications Typically, CMM manufacturers have attempted to deal with this problem by specifying accuracy by way of multiple temperature bands. Again, consider a hypothetical CMM with accuracy specified as: E0, MPE = 3.0 + 3.0 * L / 1000 (18-22°C) E0, MPE = 3.3 + 4.2 * L / 1000 (16-26°C) E0, MPE = 3.5 + 5.0 * L / 1000 (15-30°C) With a measuring length L of 500 mm, this is portrayed graphically as a step function of ambient temperature.

7.5 7 6.5 MPEE (um) With L = 500mm

6 5.5 5 4.5 4 15

AMBIENT TEMPERATURE (ºC)

Coordinate measuring machine (CMM) accuracy is dependent upon the ambient thermal environment in which it operates.

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

Metrology structures do not normally exhibit changes in accuracy as a step function of temperature, with instantaneous degradations in accuracy occurring when the temperature crosses some threshold value.

7.5 7 6.5 MPEE (um) With L = 500mm

6 5.5 5 4.5 4 15

AMBIENT TEMPERATURE (ºC)

In addition to providing the user with a more precise picture of the CMM’s accuracy at varying temperatures, a continuous specification is a compact and elegant way of defining machine accuracy specifications and is particularly well suited to being incorporated into automated reporting of measurement results.

Clearly, a more detailed description of CMM accuracy under varying ambient temperature conditions is needed in environments that lack sufficient thermal controls.

Continuous Thermal Specifications Considering the physics involved when metrology frames expand, contract and distort with changes in temperature, we intuitively know that this type of step function is inaccurate. Metrology structures do not normally exhibit changes in accuracy as a step function of temperature, with instantaneous degradations in accuracy occurring when the temperature crosses some threshold value. Or, if they did exist, we probably would not want to make measurements with them. Clearly, a more detailed description of CMM accuracy under varying ambient temperature conditions is needed in environments that lack sufficient thermal controls. A more physically realistic alternative is the specification of accuracy as a continuous function of ambient temperature. And from the pragmatic viewpoint of the metrologist or quality engineer, it is eminently more useful. To illustrate the point, let’s take a look at an actual CMM. Consider the accuracy statement of the 4.5.4 SF shop-floor CMM: E0, MPE = 3.1 + 0.05 * ?T + (3.0 + 0.2 * ?T) * L / 1000 (15-40°C) where ?T is the departure of ambient temperature from 20°C. Again, let’s consider a measuring length of 500 mm and plot E0, MPE as a function of ambient temperature. This time we find a more physically intuitive result and one that is much more useful to the metrology practitioner. The usefulness is further demonstrated when we display on the same graph the previous hypothetical example where performance was specified over a series of broad thermal ranges.

Temperature Variation Over Time Another factor to take into consideration when one is equipped with an extended temperature range specification, continuous or not, is the permissible temperature changes that the manufacturer specifies over time. Normally this is expressed as the change within a one hour and a 24 hour period. This specification tells the user how much temperature variation is allowed over a given time interval in order to maintain the specified accuracy performance. A larger permitted change in a given period means the machine is better able to cope with changing workshop thermal conditions. Shop-Floor Deployment Of A CMM When choosing to deploy a CMM on the shop floor, it is important to evaluate the measurement tasks to be performed and calculate an uncertainty budget. Then, calculate the accuracy of the machine using a continuous thermal specification at all of the different temperatures that your shop may encounter, making sure that you do not exceed the total thermal variation per hour or per day. This gives you the expected accuracy of the machine at any time of the day. If the machine accuracy is acceptable to your uncertainty budget at all times, great – you can use your machine all day long. If not, then you must consider alternatives, such as only using the machine at certain times of the day, or running parts with looser tolerances during times when the shop is warmest. The use of a CMM with a continuous thermal specification on the shop floor equips the operator with a more complete picture of a machine’s expected performance in an uncontrolled environment. This enables better decision making and more confidence in measurement results.

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GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

Got a Question? Make An Enquiry.

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The Technology

INTERPLAY

n times when components are becoming increasingly more complex and more individual additive manufacturing processes, with their high degree of geometric freedom with regard to component design, rank as a proven way out of the complexity trap. However, the technology is seen as slow, inaccurate and expensive; an attitude that has hitherto made its entry into the market difficult, especially in the metal machining sector. In the light of the above, the combination of laser deposi-tion welding using a powder nozzle combined with machining opens up completely new perspectives. In the field of additive manufacturing the powder is melted onto the base material by the laser beam. Unlike other laser-based processes in additive manufacture that work according to the layer principle, whereby a component is built-up layer by layer from powder material. “ We al so build up layer by layer, but we only use the powder where it is actually needed”, says Friedemann Lell, sales manager at Sauer GmbH, pointing out the significantly lower quantity of powder used. Other advantages include the around ten times faster build-up of the material and

simple integration into existing machine tools. “This allows the integral combination of additive and machining manufacturing in a single setup, so we can offer our customers the best of both worlds.” By the best of both worlds it means that additive manufacturing on its own still has its limits with regard to speed, accuracy and surface quality. But proven 5-axis machining can compensate these limits. The combination of additive manufacturing and machining brings us the geometric freedom, while machining guarantees the precision and quality of the component. The time-saving benef it derives from the fact that no sequential production necessitating a machine changeover is necessary. In practice this combination of the two technologies allows completely new complexities. Friedemann sees examples of this in the free formed geometric elements in turbine and engine construction and in the internal cooling channels of injection moulds: “In the case of sequential manufacturing it would not be possible to reach many of the contour areas with turning, milling or grinding tools after additive manufacture.” In the final analysis, every component can first be built up to a specific height and then certain

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

Technology integration made by DMG Mori: Laser deposition welding and 5-axis milling combined intelligently for best surfaces and prefect component precision.

areas machined. â&#x20AC;&#x153;Large components in particular can be manufactured cost-effectively in this way.â&#x20AC;? So the unique interplay of the technologies results quite literally in free formed workpieces that feature high precision and excellent surfaces. Getting Ahead In Additive Manufacturing DMG Mori offers hybrid machining in the form of the Lasertec 65 3D whose basic design is similar to that of a classic 5-axis machine for high-precision milling operations with up to 5-axis simultaneous machining. For additive manufacturing the machine has been equipped with a 2.5 kW diode laser. So the machine is suited for the complete hybrid produc tion of component s as well as for repair work and applying partial or full coatings, for tool and mould making, for example. A s of 2016 the company is expanding its additive manufacturing programme to include the Laser tec 4300 3D. This second hybrid machine will add the possibility of turning operations to laser deposition welding and 5-axis milling, so that rotation-symmetric components can now also be produced with

Lasertec 65 3D whose basic design is similar to that of a classic 5-axis machine for high-precision milling operations with up to 5-axis simultaneous machining.

the hybrid process. Equipped with a mirrored C-axis workpieces can also be machined on the rear side with the counter-spindle thus enabling in total 6-sided complete machining of the f inished par t. Not even longer workpieces present a problem, because in this case the lower tool turret supports the component during machining. In both machines the laser, including the powder application head, is installed in the HSK tool holder of the milling spindle and if required can be changed over automati-

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • April 2016

Hybrid CAD / CAM - module for the laser and milling process: integral solution for additive build-up and subtractive machining for construction, programming and machining.

The expectations of the both the machine tool manufacturer and the customers have been confirmed now that DMG Mori has already installed a number of Lasertec 65 3D machines on the market.

cally. An additional special feature of the machine is that there are up to five powder deposition heads available for dif ferent operations – for inner or outer coating of cylindrical components, for example. This creates extra degrees of freedom with regard to the manufacturing strategy. The expectations of the both the machine tool manufacturer and the customers have been confirmed now that DMG Mori has already installed a number of Lasertec 65 3D machines on the market. However, Friedemann does not as yet see additive manufacturing as a standard process. He says, “That would awaken false expectations. Additive manufacturing, especially in metal machining, is a complex process, which depends like nowhere else on the perfect interplay between machine, material and process.” This means, for example, that the process must be newly developed in all its param-

eters for every material. “We suppor t our customers intensively in this respect and cooperate very closely with research institutes in the field of material and process development.” Driven by the fascinating possibilities of this process and based on ever more impressive examples of success, especially in the f ield of aircraf t cons truc tion and medical technology at the moment, additive manufacturing ranks as one of the future technologies in metal machining. This applies in par t icular in view of digitalised processes in the era of Industry 4.0 and the trend towards individualised products. Friedemann says, “Anyone wishing to produce finished products directly from C AD data needs additive manufac turing. And if high-precision and excellent surface qualities are also required, then our hybrid machines are what is needed.”

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IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

Best Selection Practices With

MULTI TASKING The sophistication of multitasking machining systems has made it expensive and the selection of a system for the right application an important decision becomes all the more complex.

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cross all indus trial market s and sectors the production challenges facing manufac turers revolve ar o un d c u t t in g le a d t im e s , in creasing throughput and getting products t o mar ke t quicker. O t her is sue s f acing ma s s produc tion shops include shor ter runs , higher produc t mix , tighter tolerances, more complex geometries in tougher material s, and complete machining in a single handling. The introduc tion of new technologies and innovations has made a new generation of machine tools known as Multitasking Machining (MTM) systems more responsive t o t h e s e c hal len g e s . MT M s y s t em s ar e Computer Numerical Control (CNC) systems capable of per forming a variety of operations with multiple tools and/or spindles in single setup.

The t ang ible benef it s of MTMs have drawn the at tention of a large sec tor of the manufacturing industry including automobile, mould and die manufacturers, and aerospace companies as a means to gain substantial productivity, quality improvement and prof it. Framework Of The Selection There is a framework of factors involved in the decision-making process for a selection of a MTM system. Determination of production goals and available budget represent the starting point for MTM-selection process. Next, a decision is made to consider a basic two-five-axis machine or a more complex one with a higher number of axes, spindles and/or tool systems. At this stage a detailed analysis of needs and constraints determine the number of axes, spindle and type of tool

IN DESIGN Asia Pacific Metalworking Equipment News • April 2016

There is a framework of factors involved in the decision-making process for a selection of a MTM system.

systems that match the production goals. In final stage, general machine characteristics are determined to compliment the MTM-selection process. These factors are discussed in the following sections along with application recommendations. Production Goals Before adopting a multitasking system a decision maker must have a clear understanding of the production goals for using such complex technology and major capital investment: 1. Production flexibility – A key feature in MTM systems is flexibility, which takes various forms from machines that can do more because of multi-axis, multi-tool, and multi-spindle capabilities to those that can adapt to changes in product and market demand. 2. Cycle time reduction – Most MTM systems are capable of processing multiple parts simultaneously using multiple spindles and/or axes of motion. Because of these attributes, once material is loaded on t he mac hine , a comple t el y f ini s he d workpiece is output, allowing substantial reductions of in-process time. 3. Lean manufacturing – Multitasking can contribute to a leaner operation by re-

ducing non-value added times such as setup time as well as process simplification and streamlining. 4. Quality control – MTM systems have the potential to improve par t accuracy by not having to handle par t s bet ween operations, which eliminates the risk of stacked tolerances, reduces scrap rates and eliminates re-fixturing. General Attributes The determination of general attributes of MTM systems includes the machine’s body, way system and spindle drive system, among others. is not much different from conventional machine tools. A brief recommendation is provided for each feature: • Machine’s body – For the most part, machine tools utilise castings in their body because they exhibit good overall strength and vibration damping characteristics at a low cost. It is necessary for castings to have uniformly thick walls as variation in wall thickness can cause cooling and distortion problems. •

Way system – The way system of a machine tool is one of the most important factors af fec ting charac teristics such as par t surface finish and overall accuracy. The

For the most part, machine tools utilise castings in their body because they exhibit good overall strength and vibration damping characteristics at a low cost.

IN DESIGN Asia Pacific Metalworking Equipment News • April 2016

way system has two main functions. The first function is to support the spindle and table, and the second is to guide the movement of the machine components. There are two primary types of way systems: box ways and linear guides. Of the two primary types linear guides provide faster positioning. This speed comes at a price as linear guides offer less vibration damping, less ability to withstand side thrust, and less ability to resist damage from crashes. • Controls – The control of any machine is the brain, which translates all the written code into precise movements and actions. The control interprets programmed code, sends commands to the machine to move its various components, monitors machine response, processes part programs and offers the ability to edit and fine tune existing programs.

Ergonomics may seem like a low priority and is easy to ignore but the operator must have ready access to various areas of the machine to work effectively.

Once material is loaded on the machine, a completely finished workpiece is output, allowing substantial reductions of in-process time.

time accounts for a significant portion of overall machining time. Second, the faster dissipation of cutting heat through faster chip removal, which results in less thermal expansion and high-dimensional tolerances. •

Materials of workpiece – One of the basic requirements evaluated when determining performance needs is the type of materials to be machined. This will determine the levels of critical features such as spindle RPM, torque, and high-speed horsepower.

•

Spindle drive system – The spindle is considered the heart of a MTM system. For consistent parts quality the spindle must maintain proper stiffness, rolling torque, spindle run-out, low-heat generation, and thermal stability. Machining different materials will affect these areas differently so there are many types of spindles, each for specific applications.

•

Ergonomics – Ergonomics may seem like a low priority and is easy to ignore but the operator must have ready access to various areas of the machine to work effectively. For instance, the machine table should be within the reach of the control and located at an accessible height.

Multitasking Attributes Most MTM systems contain five or more axes of motion, capable of utilising any combination of x, y, z, a, b, and/or c-axes. This group of machines is commonly equipped with two or more tool systems and spindles and can operate in synchronous or asynchronous machining modes. With the non-stop development of new machining methods and options, users must determine what type and configuration of MTM will best match their needs. While most MTMs can be identified as milling or turning type machines a hybrid MTM may comprised of a wide range of functions such as turning, milling, contouring with the c-axis, off-centre machining with the y-axis, milling of angled surfaces with the b-axis, heat treatment by laser, and grinding. MTMs can be also subdivided into machines with vertical and horizontal spindle orientations. This structural feature which is inherited from conventional milling machines affects other machine features such as rigidity, chip excavation, machine size and fixturing capability.

• High-speed machining – The decision for adopting a high-speed MTM system is influenced by two major factors. First, the reduction of cycle time when cutting

Multi-Axis Impact The number of axes of motion influences the performance of a MTM system in a number of ways. For instance, a five-axis machine can

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IN DESIGN Asia Pacific Metalworking Equipment News • April 2016

With the non-stop development of new machining methods and options, users must determine what type and configuration of MTM will best match their needs.

often equal the output of two three-axis machines and generate additional savings in inventory, floor space, and energy consumption. •

Closely related issues are the tooling and fixturing aspects of MTM systems, which were not included in this study.

Part geometry – One of the major factors that influence the number of axes is the complexity of par t geometr y. Typically a multisided par t or multisurface par t requiring multiple setups is a good candidate for MTM.

• Accurac y – For some applications the selection of a MTM system depends on how much movement or re-fixturing of the part can be eliminated rather than just looking at complex geometry. This is because every time a part is moved, there is a potential for error. • High-speed advantage – Conventional three-a xis high-speed machining has limitations when milling deeper cores or cavities. The leng th of the cut ters that have to be used with a three-axis system can result in chatter and poor surface quality. Five-axis machining enables shorter cutters to be used since the head can be lowered toward the job and the cutter-oriented toward the surface. As a result, higher cutting speeds can be achieved with no loss in accuracy. •

Many-axis advantage – When the number of axes in a MTM system goes beyond a common f ive-axis machine the ability to streamline the process by combin-

ing several operations can be enhanced significantly. Turning, milling, contouring with the c-axis, and off-centre machining with the y-a xis, are among many capabilities of fered by such advanced hybrid MTM systems. One of the recent developments in design of multitasking systems is the addition of y-axis spindle and its associated rotary b-axis. Further Research MTM s ys tems provide the capabilit y for manufac turing a wide range of produc t s at a cost, which will be insignif icant over the life of the system. While these systems are capable of meeting several production goals such as cycle time reduction, minimising non-value added times and concurrent processing of multiple parts, they possess inherent programming and reliability challenges due to their complex configuration and simultaneous machining functions. Closely related issues are the tooling and fixturing aspects of MTM systems, which were not included in this study. Although, it typically represents a very small percentage of total system cost, tooling can have a disproportionate impact on throughput and total parts cost. In recent years, machine tool builders and cutting tool suppliers have paid more attention to new tool designs that can take better advantage of the MTM unique capabilities. Article adapted from Manocher Djassemi, Industrial Technology Area of Orfalea College of Business, California Polytechnic State University, San Luis Obispo, California, USA.

ENQUIRY NO 058

IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

Getting Back To The Roots:

REVISITING APPLICATIONS

We have come a long way since the introduction of software applications which can reap healthy rewards in machining, metrology and manufacturing. Syed Shah takes you back on a spin down memory lane.

Editorial

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hese days there are many types of software products and the perhaps the one of mos t interes t to t he metalworking world are application software solutions which come in the form of CAD applications in a variety of applications on the machine f loor. These applications allow users to complete one or more tasks. From industrial automation all the way to computer games, application software prod-

ucts are everywhere, impacting our lives for better or worse. Back in the world of metalworking, the introduction of application software products has resulted in higher productivity and the ability to produce complex parts with tight tolerances. Hands Off Process In modern machining, computers have taken

IN DESIGN Asia Pacific Metalworking Equipment News • April 2016

over in a big way. With the advent of CNC machining, the playing f ield has changed drastically. Computer aided machining however has evolved massively from the 1960s to present day. Today’s CNC machines are arguably more reliant on software compared to their predecessors. Though there are pros and cons about the ‘new age’ machines, even the staunchest supporters of manual machines cannot deny that they have pushed the envelope well into the micron level. The success of modern machines can par tly be attributed to the proficiency of CAD/CAM and their integration to the manufacturing process. Computer aided design allows simulation that is crucial for engineers in selecting the right processes and anticipate any potential hiccups along the way. Changes can also be made easily following discussions between designers and engineers, making it an important tool prior to the prototype phase. Computer aided manufacturing on the other hand is a tool used by engineers and machinists in manufacturing or prototyping product components. It uses designs from

CAD programmes and turns them into CNC code to drive the machine tools to manufacture the actual physical parts. Human Judgement Out Application sof t ware solutions in addition to making a big splash in the f ield of machining have also made considerable inroads into the realms of metrolog y. When par t s become more accurate, measuring devices have to be one notch higher in terms of accuracy. In order to stay ahead of their machining counterparts, software solutions are used to ensure metrolog y keeps pace with machining. A s such, to accommodate the rapidly changing scene, application software products are programmed to define the different types of features they measure. For ins t ance in CMM, the cons t ant emerging technologies in probing are always changing the way customers measure their parts. Software solutions are adapted to process tens of thousands of points to give a better representation of the actual par t compared to probing a few points in

Software solutions are adapted to process tens of thousands of points to give a better representation of the actual part compared to probing a few points in the past. ENQUIRY NO 045

IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

CNC machines are arguably more reliant on software compared to their predecessors.

Software solutions are adapted to process tens of thousands of points to give a better representation of the actual part compared to probing a few points in the past.

Usage of software products opens the door to manual CMMs in some of the most demanding applications.

the past. It is used to calibrate the probing system, control its motion and handle large amounts of data. The PC-DMIS CAD++ from Wilcox Associate is a typical software that aids measurement. Makers of sheet metal parts, in particular automotive manufac turers, face a set of measurement requirements and difficulties. Their parts are hard to measure and they have to deal with rare types of features and dimensions. In this case, software applications are used to aid measurements. Usage of sof tware products opens the door to manual CMMs in some of the most demanding applic at ions . Manual C MMs , par ticularly ar ticulated arms, though mechanically simpler and oftentimes portable, face a criticism of being limited in terms of capabilities. With application sof tware solutions, they are enhanced, increasing their operating range. Leave It To The Computers A ppl ic a t ion s o f t w ar e s o lu t ion s c an b e deployed to plan and maintain the whole produc tion c ycle. This holis tic approach manifests itself as Product Lifecycle Management (PLM). From planning, design, realisation and service, software products are used extensively. Defining the needs of the customer is always a good starting point. From this, major understanding in terms of process parameters can be formulated. This stage is necessary to give designers and engineers alike a brief idea about the product.

ENQUIRY NO 040

IN DESIGN Asia Pacific Metalworking Equipment News • April 2016

Process plans are formulated and toolings are designed using integrated or separate CAM software.

When that is done, actual designing, tolerancing and prototyping of the product starts. The main tool used for design and development is CAD programmes where simulation, validation and optimisation tasks are carried out. Various tasks like geometric tolerancing analysis and stress simulation are done using computer programmes.

Once the design of t he produc t ’s compo nent s is completed, the nex t s tep will see t he me t ho d o f manufacturing def ined. Process plans are formul a t e d and t o ol ing s are designed using integrated or separate CAM software. T he f inal pha s e o f t he l i fe c yc le involve s managing of in ser vice information. It includes providing repair and maintenance suppor t . A lt houg h PL M r un s in phases, they are closely related and cannot be viewed in isolat ion. A major part of PLM is the co-ordination of and management of product definition data. Application sof t ware produc t s ha s s t re tche d i t s con sider able mus c le and imposed it self of many a spec t of the me t alwor k ing indus t r y. From t he look s of it, the industry has a soft spot for this particular approach.

Optimisation For Savings Business process management (BPM)

At a London event , at tendees

from any other management ef for t .

investments can provide a cost savings

were a sked about the impac t the

Technolo g y is only a small par t of

of as much as 20 percent within the

economy was having on their business.

the problem. Changing the behaviour

f irst year of implementation.

G ar t ner e s t ima t e s t ha t 70 p er cen t

of process par ticipants is the bigger

Enterprises can achieve the

of at tendees were from companies

challenge. Projec t s can get bog ged

payback from their BPM implementation

that are in ‘survival’ mode, and their

down in organisational politics and can

within a year according to Gar tner, an

organisations view the programme as

lose the way amid a swamp of change

information technolog y research and

a lifeline keeping them above water in

management and communication

advisor y company headquar tered in

the economic crisis.

techniques.

the USA.

Approximately 20 percent of

“ S ome or g anis a t ion s ge t mire d

“Economic woes are driving

attendees said they were ‘thriving with

in debates about who should drive

increased usage of the sys tem as a

BPM’. These were typically organisations

the ef for t , who should own the

cost-cutting mechanism for sur vival.

that had successfully implemented BPM

end-to-end proces s , how to def ine

We are seeing one-third of companies

projects in the past. Some were moving

processes, and how to prioritise

increasing their inves tment s in this

resulting cost savings into other similar

which process improvement ef for t s

s of t w are s olu t ion ,” s aid Michele

projects for ongoing business process

t o t a c k l e f i r s t ,” s a i d M s C a n t a r a .

Cantara, research VP at Gar tner. “It

improvement , rather than sur vival .

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makes busines s proces ses visible

Approximately 10 percent of attendees

that unders tand the sys tem and

to bot h busine s s manager s and IT,

were from organisations that viewed the

can sus tain continuous process

allowing them to work together

software as a weapon for capitalising

improvemen t . T he s e or g anis a t ion s

and change processes more quickly

on t r an s for ma t ional opp or t uni t ie s

are able to cope with the thorny

and ef fec tively. In today ’s troubled

unavailable to beleaguered competitors

problems of getting star ted with BPM,

economy, companies need to

in this recessionary environment.

affecting organisational change, using

continually reduce cost s and rapidly react to market changes.”

Gartner analysts said that in some ways, the programme is no dif ferent

appropriate technologies, as well as staf f ing and maturing BPM ef for ts.”

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Exhibit space is open for reservation. +66 2686 7299 manufacturing-expo@reedtradex.co.th www.facebook.com/manufacturingexpopage

FAST FAB Asia Pacific Metalworking Equipment News • April 2016

GETTING

up to

SPEED

“Fibernomics” (as coined by Bystronic), describes an all-encompassing economic principle which seeks to give the competitive advantage in today’s sheet metal fabrication environment. It begins with the company’s fibre laser cutting system. Contributed by Oliver Hergt, editor corporate communications, Bystronic.

Editorial

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n business, success is often the product of a company’s vision – the aspirations for the future and the plans for creating oppor tunities and managing grow th. Differentiation from the competition is an important factor in uncovering and realising those opportunities. This typically means doing things better, more efficiently, and more economically than anyone else. Continually challenging the way things have been done in the past and viewing them from a new perspective ultimately lead to innovation and a strong competitive edge. Fabricators are constantly searching for ways to manufac ture things faster, more economically, and with even higher quality.

Properly integrating a new technology requires a disciplined analysis to assess its effect on the existing process and the business as a whole. Fab shops are busy, and it’s easier to maintain the status quo than find time to engage in such an assessment. But this is the first step toward differentiation. Developing and executing a strategy for implementing new technologies propel a metal fabricator forward and separate it from the competition. What such a strategy would look like and the hidden benefits and opportunities it might provide are best illustrated with an example. In this instance, we have Carl, an owner of a midsized job shop called “The Fab House”.

FAST FAB Asia Pacific Metalworking Equipment News • April 2016

High-speed fibre lasers have had a significant impact on the fabrication industry, and the introduction of one in his shop would create immediate differentiation.

The Fab House recently was awarded a long-term contract to fabricate a high volume of complex parts in sheet metal thicknesses from 0.040 in. to 0.375 in. He is contemplating upgrading his shop’s cutting capabilities with the addition of a fibre laser. Hig h- sp e ed f ibre l a s er s have had a significant impact on the fabrication industry, and the introduction of one in his shop would create immediate dif ferentiation. C arl’s decision to purchase a fibre laser was based on pretty obvious features that the cutting technology demonstrates:

Fabricators are constantly searching for ways to manufacture things faster, more economically, and with even higher quality.

1. Fibre lasers in the 6-kW power range are up to 400 percent faster in cutting thin sheet and also faster across a large majority of metal thicknesses when compared to the industry-standard 4-kW class of CO2 lasers. 2. Fibre laser technology requires 1.5 times less electrical energy to produce the same wattage and overall consumes about 50 percent less in hourly operating costs. Because the fibre laser uses highly efficient laser diodes to initiate the lasing process instead of high voltage or radio frequency, the elec trical input requirement s and consumptions are far less compared to CO2 technology. In addition, the fibre does not require the use of gas turbines because there are no lasing gases, unlike the CO2, which utilises lasing gases and turbines. 3. Maintenance tasks that would normally consume several hours per month, such

as beam alignments on a CO2 laser, are not required in the routine maintenance of a fibre laser. 4. C o n s umab le co s t s s u c h a s mir r o r s , lasing gases, and beam delivery bellows disappear because fibre lasers don’t have these elements. 5. The combination of faster cutting speeds and reduced maintenance time increases machine availabilit y and capacit y when compared to a similarly powered CO2 machine.

Additionally, the back gauge could be automatically programmed as each bend is set. In addition, the programmer may choose to change any bend sequence that the software has calculated automatically and simulate the final program as it will be used at the brake.

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

This web-based arrangement allows complex calculations to be performed quickly on multiple computers and then captured onto a central processor for final optimisation.

The major portion of part cost ties directly to the cost of the material itself, followed by the labour and process time consumed in fabricating the part.

When looking at a reduction in overall operating expenses and the prospect of up to three times faster feed rates, he recognised that he could reduce his cost per part while producing more par t s per hour. The big question remained: What kind of an impact would the f ibre laser have on his overall production process?

High-speed fibre lasers have had a significant impact on the fabrication industry, and the introduction of one in his shop would create immediate differentiation.

The Front-End Pull Carl runs an efficient, modern job shop in which business sof tware systems process orders into bills of materials and job routings and programming software automatically sets up machine tools for production jobs. All of these systems, however, need to keep up with the increased throughput and capacity made possible by the new laser cutting technology. How quickly can an order be translated into a job ready to process? This is an important question for him because a bottleneck results if the fibre laser produces parts faster than nes t s can be queued in the produc tion pipeline. Once jobs have been released to production, the nesting software needs to create programs that are ready to process on the fibre laser. In addition to creating timely nes t s , programming systems also need to make the most of sheet material utilisation because this

is a key element in the overall cost per part. Like most fabricators, he knew that the major portion of part cost ties directly to the cost of the material itself, followed by the labour and process time consumed in fabricating the part. The time it takes to process the nest is also important. (This is a function of the laser processing speeds and cut path optimisation.) Reducing material utilis ation cos t s and processing times are key elements in reducing the overall cost per part. Optimising material utilisation. With the faster cutting rates made possible by his new fibre laser, he wondered if something could be done to carry nest optimisation to a higher level. He discovered that by subscribing to a â&#x20AC;&#x153;sof tware as a ser viceâ&#x20AC;? (SaaS) provider, more complex optimisation algorithms could be run using high-end computer hardware and s of t w are s y s tems . T his web -ba s ed arrangement allows complex calculations to be performed quickly on multiple computers and then captured onto a central processor for final optimisation. This enhanced process produces a better material yield and a much faster optimisation than can be achieved using a conventional, stand-alone PC. Carl found that it also reduces the required cutting time because of optimised cutting paths. A database with more than 300 parameters provides him with comprehensive information about the material behaviour and ideal cutting paths. The result of this advanced optimisation is not only a safe cutting process, but one that leaves very little in the way of material waste per sheet and reduces total cut ting times. On average, an additional 10 percent material savings and 15 percent savings in processing time can be realised over conventional PC-based algorithms. Push Demand With Press Brakes With parts being cut faster than ever before, it was important that Carl adapt his downstream processes to meet push demand created by the fibre laser. Press brake setup time, in particular, is an easily identifiable target for improvement, given the different tooling setups and the variety of programs that must be processed each day. When the machine is not bending parts, it is both a non-productive and a non-revenue-generating asset. he began looking for ways to increase the utilisation of his press brakes. Cutting down on non-productive time The mos t impor t ant a spec t of reducing non-produc tive time on press brakes is the incorporation of of fline programming

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

c apabilit ie s , par t icul ar ly in today â&#x20AC;&#x2122;s predominantly high-mix , low-volume environment. Although he was aware of the benefits of offline programming, he had not taken the step of introducing it to his press brake operations. When an operator uses a press brake control for programming, he takes away valuable processing time, produces fewer parts per day, and reduces the capacity for processing other jobs. He decided to make the move and soon learned that good offline programming would do more than just select the correct tools and generate bend deductions. It was also possible to set up tool mapping and automatically set up additional tool stations along the table to accommodate all of the required bends. Additionally, the back gauge could be automatically programmed as each bend is set . In addition, the programmer may choose to change any bend sequence that the software has calculated automatically and simulate the final program as it will be used at the brake. During this simulation, the software will check for possible collisions of the part against the tooling, the table, or

the ram, allowing for corrections to be made before the program is sent to the press brake for final production. This also reduces the nonproductive bending time.

It was also possible to set up tool mapping and automatically set up additional tool stations along the table to accommodate all of the required bends.

ENQUIRY NO 043

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

A variety of technological advancements in press brake design address a troubling issue for many other fabricators: the critical shortage of trained and skilled operators.

Removing variability from each and every aspect of the process ensures that process times become more predictable and accurate.

Increasing press brake productivity In addition to reducing downtime through sequencing and offline programming, Carl discovered the availability of productivity packages for press brakes that can drastically improve setup times. He saw quick-change tooling, for example, as a must-have feature. A safety mechanism is part of the top tool, enabling the ver tical changeover of tool segments by simply clicking them in and out of the holder.

Combined with hydraulic clamping s y s t em s , t hi s make s f a s t t o ol chang e s pos sible â&#x20AC;&#x201C; 80 percent f a s ter t han wi t h conventional tool holders, in most cases. Moreover, upper and lower hydraulic tool clamping systems can seat, align, and clamp the complete upper and lower set of tools with the push of a button. Another safety feature that was appealing wa s an advanced camera-ba sed s ys tem capable of reading the tip of the tool prior to starting the job, ensuring that the operator has set the proper tool in the machine. If not, it simply wonâ&#x20AC;&#x2122;t start the job and sends an error message to the operator. A variety of technological advancements in press brake design address a troubling issue for many other fabricators: the critical shortage of trained and skilled operators. Among these advances are dynamic hydraulic crowning systems, thickness measuring, and angle measuring. These can automatically account for all of the variability that once required operator adjustments when transitioning from one job to the next. All of this information is now stored in the press brake control, which means that the operators can quickly produce quality parts. Automating For Part Consistency The changes to his front-end, cutting, and back-end operations have positioned Carl to consider the f inal step for increasing produc t i v i t y, economy, and quali t y : automation. Af ter all, addressing the pull demand on the front end does not end with a finished cutting program. The raw material must be ready without delays in presenting it to the laser for processing. Once the laser begins processing the jobs, the consistency of the cut material unloading and raw material loading cycle times becomes critical. Completing the unload/load cycles while the machine is still processing the current sheet is critical to maintaining the advantages gained from highspeed fibre laser processing. Automation is the key to creating consistency in the manufacturing process. Removing variability from each and every aspect of the process ensures that process times become more predictable and accurate. In s h or t , f a s t er c u t t in g m e an s t ha t all processes need to keep pace. Having the right technolog y in place to maintain consis tenc y with new large-machine investments provides fabricators with the ability to reduce their cost per part, increase their profit potential, and stay ahead of the competitive curve.

ENQUIRY NO 016

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

Eddy Lek, product marketing manager, Asia Pacific, Faro Technologies explores five ways that 3D measurement improves quality and productivity for the automotive industry. Editorial

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The Automotive Edge:

LESS COST, MORE VALUE I n the manufacturing world, the notions of efficiency, quality, and cost are most often surfaced as top concerns when it comes to product development and execution. Companies are constantly on the lookout for solutions to improve workflow, either by doing more with less, eliminating activities that do not add value, or by increasing production volume through innovation. For an automotive manufac turer, this would mean a hastening of its time-to-market or an improvement in production speed, all without compromising product quality. While 3D measurement systems are not new to the industry, here are five ways in which they have been simplifying workflow and lowering overall costs for automotive industry users.

Rapid Prototyping of Virtual Models & Reverse Engineering Clay modelling is a technique that car makers of today still rely on despite the advent and ubiquity of 3D computer modelling systems. Clay models range from scale- to full-sized vehicles, and include mock-ups of interiors and a variety of other parts (e.g. wheels, trim components, and steering wheels). As a design process may start off with a clay model, manufacturers have found it useful to be able to perform a quick scan on these models in order to convert them into digital data that computer-aided design (CAD) programs can further evaluate or manipulate. In fact, manufacturers now have access to devices that possess both contact and non-

FAST FAB Asia Pacific Metalworking Equipment News • April 2016

contact measuring capabilities, which essentially integrates the 3D modelling processes into a single step. Using a portable laser line probe, users can quickly and easily digitise the clay model. Once generated, the virtual model can then be distributed to various departments for further evaluation and design review. Examples of such tests include computational fluid dynamics (CFD), finite element analysis (FEA), wind tunnel airflow simulation, crash simulation, and others. Furthermore, potential problems can also be identified before the parts are brought together for assembly. In fact, a virtual assembly of parts can be performed even before parts are shipped to the plant. The ability to ‘assemble’ components this way is a requirement for companies that subscribe to the digital factory vision, and it can amount to significant costsavings for a car manufacturer. Engineers often also rely on 3D imagers to extract CAD data from an existing part, so as to use the data for reproduction or for design modifications. 3D imagers can be integrated into the production environment as required, whether in conjunction with a rotary table, robot, or industrial inspection cell. And technological advancement has enabled metrology suppliers to come up with 3D imagers that provide high resolution scans, process data on-board, and allow adaptable multiple imager arrays, all of which push the envelope to shorten inspection cycle time. With the advent of such technology, automotive manufacturers in search of an effective way to conduct in-process or near-process inspections have more options than ever before. Body Panel & Stamp Die Inspection A passenger car typically consists of hundreds of stamped, shaped metal parts, including structural components, interior panels, and

visible panels (e.g. hood, fender, door, roof, etc.) that form the “look” of the car. The quality of the visible surface of these parts is crucial to the overall aesthetic appearance of the finished vehicle, and is affected by the quality of the stamp die on which it is formed. A stamp die commonly goes through several modifications before it produces a good panel part. This means that the surface of the die might look considerably different from its initial CAD model by the time it is ready for mass production. Auto manufacturers usually capture a scan of the modified press die, so as to update the CAD model to reflect these changes. In case the stamp die is damaged or altered in any way during transportation, or if an additional one is required, a second one can then be reproduced easily. Portable coordinate measuring machines (CMMs) such as laser trackers and articulated arms have proven to be exceptionally useful to engineers for these types of inspection jobs. As test panels and stamp dies are typically bulky and heavy, the ability to perform inline inspections is highly valued. Instead of transpor ting an object of interest to a climate-controlled room for measurements, the engineers can simply bring the portable CMM to the production line. This helps the company to save on time and manpower, and also improves workplace safety.

Engineers often also rely on 3D imagers to extract CAD data from an existing part, so as to use the data for reproduction or for design modifications.

Production Fixture Inspection Production fixtures are used to securely locate or control the position of a work piece, such that it remains in a specific orientation. By impeding all degrees of freedom, the tool allows an operator to perform the same action to each work piece consistently. A poorly developed f ix ture can cause problems down the production line, as minor errors on components will be compounded during assembly. For example, a slight variance

Process of digitising a clay model into a CAD model through the laser scanning technique.

FAST FAB Asia Pacific Metalworking Equipment News • April 2016

Color map of a car seat, indicating the amount of deviation on a test piece when compared to the original CAD model.

An articulated arm with a laser line scanner attachment.

inspec t ions , manuf ac turer s have found por table 3D measurement devices to be an effective solution, mainly because they provide versatility and high accuracy at the same time. As mentioned earlier, engineers can move a CMM to the production fixture when performing an inspection, eliminating the need to transport the fixture to an inspection station in another part of the facility. This reduces production turnaround time, and ultimately increases produc tivity for the manufacturer.

from design specifications at the component level may translate to a misalignment during the welding process. These types of issues can lead to an eventual product recall or time wastage (e.g. rework, root cause analysis), and inflict a dent on the company’s reputation. For these reasons, automotive manufac turer s t ypically inspec t their production fixtures with a reliable measuring tool to ensure accurate positioning of all critical components. In doing so, they eliminate any potential issues early in the production process, and save on costs, time, and their reputation. For the purpose of production f ixture

Gap & Flush Measurements One of the most common in-line inspection processes conducted on finished products in an automotive assembly line is the gap and flush measurement. The purpose of this test is to check for horizontal and vertical distances between two closely located parts (e.g. the exterior surface area between the car door and car body), to ensure that they are within design tolerance. T hi s t e s t i s an imp or t an t one a s i t determines the visual ‘fitness’ of a car, Also, this allows the engineers to eliminate any rattling that may occur when the car engine is running. Automotive OEMs are increasingly strict about controlling the gap and flush tolerance, some to within a window of ±0.3mm. At this level of precision, manufacturers call on improved measuring tools and methods such as portable CMMs with laser scanning capabilities to perform the task. One such device is the Faro Edge ScanArm HD, which features a laser line probe that provides non-contact scanning capabilities. Laser scanning is an ideal way to create a dense point cloud for inspection or reverse engineering purposes, and is a quick way to obtain a full surface model of a part. The device projects a laser line on the par t to be inspec ted, which is ref lec ted

FAST FAB Asia Pacific Metalworking Equipment News • April 2016

back towards the scanner and captured by a camera. Through standard triangulation methods, 3D locations are determined and recorded accordingly. By moving the laser line across the entire surface, the probe captures the 3D profile for further processing. Car Seat Ergonomics In the development of car seats, the ‘hip point’ – which is the theoretical, relative location of an occupant’s hip – is of particular interest to manufacturers, for both design and regulatory requirements. Importantly, manufacturers must ensure that the hip point is within safety tolerance. A portable 3D measurement system such as an articulated arm allows safety engineers to complete their checks swiftly and easily. Encoders in the articulated arm determine and record the location of the ball probe in 3D space and report the results through software. Using the coordinates of the hip point obtained by the CMM, the engineers can then determine the critical safety of a passenger during a crash, and also accurately implement necessary safety features.

Apart from the ‘hip point’, the other aspect of car seats that manufacturers are interested in is the foam component. Using non-contact measurement methods, engineers can obtain scans of foam component s to conduc t a sur face deviation analysis. The sof tware compares a test file against the reference file (original CAD model) and shows the variance comparisons clearly on a color map, allowing engineers to quickly zoom in on problem areas that exceed the tolerance levels. As is evident, the automotive industry is heavily reliant on advanced measurement tools and methods across the various vehicle produc t ion s t age s . While mea surement technolog ie s improve a manuf ac turer ’s productivity and product quality, they most certainly benefit consumers as well. And as the automotive industry continues to evolve with market demands, the workflow and methods that suppor t it need to develop and grow accordingly. Metrolog y suppliers that are quick to identif y these changes can then offer automotive players nimble, ef fective solutions that best suit their requirements.

Apart from the ‘hip point’, the other aspect of car seats that manufacturers are interested in is the foam component.

ENQUIRY NO 049

FEATURES Asia Pacific Metalworking Equipment News • April 2016

Erik Söderström

MOVING & HANDLING Of Tomorrow

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n the past 30years the role of the warehouse operation has drastically changed and it has already moved away from its ver y basic core functions such as the receiving, storing, tracking and supplying of f inished stock keeping unit s (SKUs) to various cus tomers, or the supply of raw and packing materials to factories for their eventual manufac ture/conversion to f inished goods.

In our today’s warehousing environment more emphasis is being placed on matters related to speedy but accurate receipt and delivery of SKUs, the optimum warehouse space utilisation, the correct use and proper application of all material handling equipment (MHE), the application of lean process and the 5S Technique all the way to ensuring their customers’ satisfaction and retention, but most importantly to safeguard their loyalty.

FEATURES Asia Pacific Metalworking Equipment News • April 2016

In our today’s warehousing environment more emphasis is being placed on matters related to speedy but accurate receipt and delivery of SKUs.

Owing to the complexity and sophistication of the today’s warehouse operation, its role provides a twofold benef it, aiming to achieve an optimum position between minimising t he tot al cos t of oper at ion, whilst providing the expected ser vice level for the business. In view of this fast changing environment, the employees involved in the warehouse business must be well equipped with all relevant knowledge as their role has substantially been upgraded to a higher level. In the light of this, I have selected four advanced warehouse technologies (could I say my favourite ones?) and I would be more than happy to share these with you all.

to the s ys tem. This wearable computer, or voice terminal, communicates with the warehouse management sof tware via a radio frequency (RF) local area network (LAN). Each warehouse worker/picker needs a belt-worn, wireless terminal, which consists of a headset with a microphone and receives instructions by voice and verbally confirms actions back to the system. For instance: In a voice technology operating warehouse environment an order picking application for 10 cases of X SKU is transmitted to an operator. •

The operator receives his instruction via his headset and collects the 10 cases of X SKU.

These are: 1. Voice Technology 2. Pick-To-Light 3. Automated Storage & Retrieval Systems (AS & RS) 4. Pick N Go Order Selection

•

To complete this task he reports through his portable microphone a pre-arranged phrase such as “Yes” or “Done”.

Voice Tecxhnology A new way for warehouse workers, which enable s t hem to communic ate ver bally with the system via radio frequency. It is similar to RFID technolog y, but this is more advanced. Voice technolog y uses speech recognition and speech synthesis to allow warehouse workers to communicate with the w arehous e management s y s tem (WMS). Warehouse workers use a wireless, wearable computer with a headset and a microphone to receive ins t ruc t ions by voice and to verbally conf irm their actions/results back

• The computer in the warehouse of f ice captures the phrase and records the text “Yes” to the programme. • The database reduces the quantity of X SKU by 10 cartons from the stock. Benefits Of Voice Order picking productivity usually improves by 10 to 20 percent because pickers’ hands and eyes’ free operation speeds up the picking of SKUs. It also reduces all unnecessary movements/walks back to the assignment desk. The warehouse productivity is also improved by paperless picking because the work of printing and distributing picking lists or labels is mostly eliminated.

Order picking productivity usually improves by 10 to 20 percent because pickers’ hands and eyes’ free operation speeds up the picking of SKUs.

TIP -

Difference between speech recognition & voice recognition: Speech recognition is the method of capturing the voice to identify and to return what someone has spoken. Voice recognit ion is a met hod o f c ap t ur in g t h e voice to iden t i f y the person that is speaking.

FEATURES Asia Pacific Metalworking Equipment News • April 2016

On the other hand, such technology is more relevant to small size SKUs placed in bins, or on shelves and not so applicable for big size SKUs placed on pallets (pallet load) or bulk stacking.

Voice technology uses speech recognition and speech synthesis to allow warehouse workers to communicate with the warehouse management system (WMS).

Pick-To-Light This system could be used for picking (collecting) or putting (placing) products as an alternative to manually picking or packing various SKUs within the warehouse area. Its aim is mainly to electronically assist warehouse personnel to locate the pick or pack location of the specific SKU(s) by the flashing indicator light hence, enabling pickers/packers to work in a more efficient and effective way in their respective areas. The devise is located at the bottom or on top of the bin, shelf or rack warehouse area to attract the attention of the picker or packer. The Methodology: • The order is scanned and the quantity required is shown on the “display module”. •

A light illuminates to prompt the operator to collect the specific SKU(s) from the respective location.

•

The operator collects the exact quantity and then presses the “send” button at the bottom of the location to conf irm transaction.

•

Stock is updated “real-time”.

Benefits From Pick-To-Light Technology It provides additional speed and accuracy in the order processing. Pick-to-Light technology reduces the time required searching for the location or the correct SKU hence, it increases the picking or packing rate. On the other hand, such technolog y is more relevant to small size SKUs placed in bins, or on shelves and not so applicable for big size SKUs placed on pallets (pallet load) or bulk stacking. Automated Storage & Retrieval Systems (AS & RS) It is a computer-controlled robot type system for sorting, storing and retrieving various SKUs (usually pallet loads) vertically or horizontally as it moves along f ixed isles within the warehouse area. It represent s a much fa s ter, reliable and most impor tantly accurate operation as the system doesn’t require human operator to function (unlike wise other MHE forklif ts etc). Although such an application requires a large size - wide warehouse areas for the business to get the full benefit of such technology, it is worth to mention the increasing demand for such automated systems in our today’s warehousing environment.

FEATURES Asia Pacific Metalworking Equipment News • April 2016

AS & RS can signif icantly improve the warehouse productivity in many industries and not only in the Fast Moving Consumer Goods (FMCG). (A few examples will include auto manufacturing, various paints and chemicals) Benefits From AS & RS Technology It can help increase productivity levels as the system can pick, replenish and sort SKUs without human operator’s intervention. Being constructed in modules it could be easy to adjust them in order to meet warehouse expansion plans. It also reduces labour costs and increases inventory accuracy levels. Pick-N-Go Order Selection It is similar to pick-to-light selection as it enables the order picker to easier handle the fulfilment of the order and respond with speed and accuracy. It is based on an automated fork lift process which can be provided from a variety of fork lif t suppliers. This system allows the warehouse picker and the automated fork lift to work together so, whenever a picker pick s a ca se/unit there is always a fork lif t readily available and waiting for him/her. In this way the picker’s productivity will increase substantially. It works as such: - The WMS sends the customer order to t he picker along wit h an au tomated fork lif t. -

The picker receives the customer’s order via a pick by voice headset.

- At the same time the automated forklif t loaded with a pallet is dispatched at the right place (following the picker) with its forks at the right height. - The picker can now pick the assigned quantity of each SKU and places them on the top of the pallet. - As the picker receives a new customer order the forklif t automatically escor ts the picker to the next location hence, enabling the picker to pick instead of driving the forklif t. - When t he pallet on t he forklif t get s loaded, the system dispatches a new p alle t to t he picker and t he lo aded pallet is automatically driven to the dispatch area.

Benefits From Pick-N-Go Order Selection Technology It is hands’ free process, which increases the picker’s flexibility in the warehouse. It also minimises the picker’s time spent in searching for the correct SKU or moving front and back to the warehouse office to collect/ deliver orders. The picker continues working in his designated warehouse area never leaving his picking area. The Pick-N-Go system is compatible with mos t forklif t brands . It removes unproductive steps in the Warehouse business environment. It increases substantially the productivity rate. In this fast moving and ever demanding environment, for one to be ahead of the game, one has to be not only familiar with the current warehouse developments, but to be able to constantly and continually upgrade his knowledge with current and advanced trends in order to provide the expected service level and be able to contribute to the optimisation of his company’s performance.

Pick-To-Light technology provides additional speed and accuracy in the order processing.

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

Intermach & Subcon Thailand 2016

GETTING DOWN

TO BUSINESS T Editorial

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3501

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he Thai government has declared 2016 as the year of investment. Part of it s polic y is to at trac t foreign investors to invest in Thailand by offering a range of special investment privileges including exemptions on corporate income tax and import duties on machinery. Late last year the automotive industry saw total exports increase by almost 10 percent well on the way to achieving the target of 1.2 million units. Thailand has also planned some 20 infrastructure projects worth nearly 1.8 trillion baht which will cover everything from railways, roads, air transport and maritime ports throughout the country. All will be underway before 2018. Thailand is depending on the manufacturing industry to help raise the countryâ&#x20AC;&#x2122;s economic development . The recent announcement of the new digital economic policy will also help to drive and develop the country in multiple sectors. As Thai industry upgrades and moves away from labour

intensive industry to production via semiautomatic or fully automatic procedures the benefit to entrepreneurs who require precision products will be considerable. Sp e cial de sig n s t ha t are adjus t able according to customer requirement s will add value. All stakeholders need to work together to help raise industry and become multinational corporations. Thailand has the potential to manufacture its own products. Entrepreneurs need to look ahead to find a par tner countr y that can be used as a production base. This will ensure that Thai industry goes far beyond the home country and takes full advantage of labour availability and cost savings. UBM Asia (Thailand) the organiser of both events, will provide its expertise in order to make the 2016 event another success and benefit the Thai and ASEAN manufacturing industr y and businesses involved to the fullest extent. Intermach 2016 will present the latest high-tech machiner y & cutting

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • April 2016

edge technolog y from around the world. This of course will help entrepreneurs to stay competitive and prepare for business oppor tunities and economic development on the horizon. Intermach is the only exhibition in Thailand that focuses exclusively on industrial machinery. Each year the event continues to attract more than 40,000 quality trade visitors from over 40 countries. Mr. S anchai Noombunnam, group direc tor at UBM A sia (Thailand) the show org aniser, s aid; “Entrepreneur s need to be prepared for future growth and should study government suppor t measures that are most suited to their business. The most impor tant factor to help entrepreneurs especially those in the industrial sector - is the introduction of appropriate technology. B y in v e s t in g in n e w m a c hin e r y an d technolog y entrepreneurs will gain a competitive edge by substantially reduce production costs and increasing ef f iciency to an international level. The exhibition also hos t s impor tant international Seminars, Workshops and Activities related to automotive, electrical and electronics and other manufacturing industry. And you will find all at Intermach 2016 - an event you just can’t af ford to miss.” Also at the same venue, ASEAN’s largest industrial subcontracting and business matching event is again being co-organised by Thailand Board of Investment, the Thai Subcontracting Promotion Association and UBM Asia (Thailand). The event is a unique showcase of industrial par ts and business linkage opportunities between parts manufacturers and buyers from 18 countries. Major manufacturers from f irst to third tiers, leading industrial par t-buyers and entrepreneurs from both home and abroad will meet with over 300 indus trial par tmakers who will come from the automotive par t s, elec tric, elec tronic industr y along with mould and machiner y sec tors with more than 3,500 quality industrial parts will be on display. Ms. Sonklin Ploymee, director of the BOI Unit for indus trial linkage development , Thailand Board of Investment said, “Over the past nine years, the business- matching activities at Subcon Thailand generated more than 60 billion Baht in transactions by matching over 21,000 business par tnerships and creating business oppor tunities for more than 3,500 SMEs in suppor ting industries. Subcon Thailand 2016 – is truly an event that creates serious business oppor tunities.”

Both exhibitions will feature: • Over 1,200 exhibiting companies from 38 countries around the world. More than 100 machinery and equipment will be seen for the first time in ASEAN and Thailand. •

350 leading industrial part manufacturers from 15 countries including 12 International Pavilions at SUBCON Thailand

• Over 30,000 business-matching pairs established over the past 9 years that generated over 60 billion Baht in business transactions. • Buyer’s Village – where Industrial part buyers display their needs for specific par ts and provide details on their requirements and procurement policies. • O ver 10 0 in ter nat ional con ference s , workshops, and seminar highlighted key industries such as automotive, medical device and aerospace. •

Both events are held in conjunction with Sheet Metal Asia, ASEAN’s International Sheet Metal Fabrication Technology and Machinery Exhibition.

Intermach Thailand 2016 & Subcon Thailand 2016 Bangkok International Trade & Exhibition Centre (BITEC) May 11 – 14, 2016

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • April 2016

Metaltech 2016:

For its 22nd edition, the renowned metalworking exhibition will focus on building strong business connections between international suppliers and local manufacturers.

Editorial

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3502

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BUILDING CONNECTIONS C ontinuing strongly in spite of the economic downturn and a weakened ringgit, Metaltech, Malaysia’s premier exhibition for the metalworking and machine tool industries, has announced an exciting new approach for its 22nd edition this year. The exhibition, which will be held from the 25th to the 28th of May at Putra World Trade Centre (PWTC), will feature over 1,800 exhibitors from a total of 38 countries worldwide within a grand 35,000 sq m space, with over 27,000 local and international visitors expected throughout the 4 day event. To provide value to those in attendance, organiser Trade Link ITE Sdn. Bhd. has announced the debut of a new business matching programme that will premiere during the exhibition. The service will profile attending companies and pre-arrange meetings with exhibitors who supply technology in fields relevant to their immediate and medium term needs. Said Dato’ Albert Lai, Chairman of Trade Link ITE: “Malaysian manufacturers are more discerning than ever. They have greater access to suppliers from across the globe and when they come to an exhibition they want to make sure that they can meet companies who can help them on their path to growth.”

“Helping to build these connections is our core purpose as the provider of the Metaltech platform and our new business matching programme is just the newest way that we are achieving this objective”. Aside from the new service, Metaltech 2016 will continue to operate a calendar of networking events bringing together suppliers, buyers and influential government officials, and will also be the site for various new product launches, on which specific information will be disclosed at a later date. With a particularly strong presence expected from ASEAN countries, trade buyers at Metaltech can expect to see technology catering to a multitude of industries including aerospace, automotives, marine/offshore, metalworking, energy, electrical and electronics, and medical. Also featuring during Metaltech will be the 9th Automation Technology Exhibition (AUTOMEX), which covers all aspects of automotive technology from complete systems to integrated automation solutions. The Welding Technology Exhibition 2016 (WELDTEK) and the Malaysia International Robotics and Automation Technology Exhibition (IATECH) will also be displaying specialist wares during the four-day period.

PRODUCT FINDER Asia Pacific Metalworking Equipment News â&#x20AC;˘ April 2016

ENQUIRY NO 044

ECH METALSTIA 2016

MALAY

Hall 2 061 Booth 2

BendingStudio 3.0

Aicon 3D Systems BendingStudio 3.0 offers many new features, which facilitate daily work in bending production. The software platform connects all data and processes around production of bended parts: from production and process planning to manufacturing and quality control. It is the only tool to meet and combine these requirements with emphasis on metrological processes. With the revised control concept, Aicon reacts to customer requirements. The software is even clearer structured and easier to handle. The new CAD-Wizard enables the user to create bending elements for a bending machine from a componentâ&#x20AC;&#x2122;s CAD data in IGES or STEP. Editorial

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Behringer: HBM500SC

Behringer GmbH with its Speed Cutting Technology (SC Technology) improves bandsawing cutting in terms of cutting output, saw blade life and material savings. The HBM500SC is the culmination of a successful symbiosis of innovative machine technology and newly developed tools, and is setting whole new standards in terms of speed. It uses extremely thin standard saw blades just 1.1 mm in thickness and 67 mm in height. The minimal thickness of the saw band reduces the cutting forces required per tooth, and the significantly narrower kerf channel saves material. This material saving has a major impact particularly in comparison to conventional large-scale circular sawing plants. Editorial

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3602

PRODUCT FINDER Asia Pacific Metalworking Equipment News • April 2016

Kasto: Kastowin F 10.6 Sawing Machine

Faro Scene WebShare Cloud 2.0

Faro has announced the achievement of another milestone in cloud-based as-built data management with the release of version 2.0 of its well-known web hosting service, Scene WebShare Cloud. Scene WebShare Cloud 2.0 is the first cloudbased software unleashing the power of fluid 3D viewing of 3D laser scan data within a simple and easy-to-use website. For applications within the fields of BIM, architecture, and construction information management (CIM), user-friendly access to reliable as-is information of buildings, plants and construction sites is essential. Users also need immediate access to this data at the office, on the job-site or in transit. Editorial

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3603

Kasto has introduced the newest addition to the Kastowin series of sawing machines, the Kastowin F 10.6. Equipped with a 1,000 x 1,060 millimetres cutting range and moveable material support table, the automatic band sawing machine is suitable for steel manufacturers, steel traders and large scale toolmakers due to its ability to feed ingots, permanent moulds and materials with pre-forged geometry in a way that meets process requirements The support length of the table is 2,600 millimetres, with a travel distance of 3,700 millimetres, a bearing capacity of up to 18 tonnes and travels at a speed of up to three metres a minute. Editorial

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3605

Interroll: ZoneControl

The ZoneControl controls the RollerDrive EC310 in every single zone and is used for zero pressure accumulation conveyors that require no advanced control. Additional functions and communication to upstream and downstream conveyors are provided via digital inputs and outputs (I/Os). For communication between ZoneControls, a standard CAT-5 cable is used. The configuration of the ZoneControl can simply be handled by DIP switches. Two versions of conveyor logic are available: individual or train release. The features include the adjustment of 15 speeds internally and seven speeds externally via I/OChoice of direction of rotation, start signal input (visually decoupled), rotational direction signal input (visually decoupled), fault signal output (visually decoupled), LED status display and sealed cable openings for IP54. Editorial

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3604

Laserdyne: CylPerf

Laserdyne has updated its S94P laser process control feature to include fiber lasering improvements and throughput in “on-the-fly” percussion drilling of small shallow angle holes in aerospace engine combustors. “On-the-fly” drilling has historically been associated with the shortest cycle time for drilling sheet metal components but compromised hole consistency. The updated fiber laser control ensures higher quality holes, in terms of metallurgy and geometry, with reduced cycle time. It took 0.3 seconds per hole compared to the previous 1.2 seconds needed to drill through a thermal barrier coated component, with 1.5mm thick, 0.4mm diameter holes at 30 degrees from the surface. Editorial

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3606

PRODUCT FINDER Asia Pacific Metalworking Equipment News • April 2016

ENQUIRY NO 061

Efficient, versatile and easy to use Featuring a bar capacitiy of 25.4 mm diameter, the Tornos Swiss GT 26 is a Swiss-type lathe equipped with six linear axes and two C axes. Versatility, high performance in value-added operations, and ability to work with or without a guide bush make the Swiss GT 26 a comprehensive bar turning solution. Discover more : www.tornos.com

Your advanced machining solution

CH H EC TE ALLT TA ME ET M 016 2 6 1 IA 0 S 2 Y A L A

HHall 22 1 h 2200661 BBooootth

Swiss GT 26

We keep you turning

ENQUIRY NO 051

ARNO® - Turning System

Mitsui Seiki: CNC Jig Mills

Mitsui Seiki has produced CNC Jig Mills suitable for mould base production, mould plates, precision hot runners, progressive and transfer dies, and other jig boring and milling applications. The fixed crossrail, massive ram design of the new Jig Mill J1620 and J1620X machines, provides a straightness accuracy in X and Y axes better than 10 microns according to the company. Further, table squareness to the Z-axis is also better than 10 microns. Working size range is for the J1620 is X – 2100mm x Y – 1600mm x Z – 500mm. Table size is 2400mm x 1600mm with a load capacity of 4000kg. With the J1620X version, all the specifications are the same except X-axis is 2500mm and the table is 2200mm x 1500mm. Editorial

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3607

Tool Holders With Through Tool Coolant ARNO® Werkzeuge is expanding its product range with through tool coolant holders with precise coolant straight to the cutting edge. The holders are available in shank sizes 12x12 and 16x16. The coolant inlet is individually placed, it can be inserted from the rear of the holder or the side. We offer various threaded connectors. Every holder is manufactured to your specification and delivered in a week. Auto Lathes With Through Tool Coolant Most modern sliding head auto lathes have a high pressure pump installed, and therefore the ARNO® through tool coolant auto lathe holders would offer maximum performance. The precise coolant flow directly to the cutting zone (between the insert and the swarf) effectively reduces the heat and thereby making chip breaking easier.

ARNO Werkzeuge S.E.A. PTE. LTD. 25 International Business Park #04-70A German Centre, Singapore 609916 Tel.: +65 65130779 Fax: +65 68970042 E-mail: info@arno.com.sg

www.arno.com.sg

PRODUCT FINDER Asia Pacific Metalworking Equipment News • April 2016

Sandvik Coromant: Corobore 826

Oxford Instruments: X-MET8000 Hero Window

Oxford Instruments has launched the Hero for reliable X-ray fluorescence (XRF) analysis of hot samples, for use with their range of X-MET8000 series handheld XRF analysers. The Hero heat resistant protective window allows hot samples of up to 400ºC to be directly analysed for alloying elements including light elements such as silicon. When testing hot samples using the X-MET8000, the operator simply swaps the analyser’s normal Prolene window for the Hero heat resistant window. Unlike other solutions available, there is no need for special spacers, shields or tilting techniques, which may have a detrimental effect on the accuracy of the results, especially for light elements. The use of the new window allows the operator to carry out in-service testing, therefore minimising downtime. Editorial

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3608

TaeguTec introduced the SBMT 09 insert line, the latest in a line of SBMT inserts and relevant holders. The insert comes with a high positive helix cutting edge and is suited for smooth machining applications. It is a single-sided, four cutting-edge insert specifically suited to generate a lower cutting load during machining. The line includes end mills in diameters 25-40 millimetre, modular types in 25-42 mm and face mill types in diameters 32-80 mm. The inserts can reach a feed rate of 1.5 mm/tooth at a maximum depth of cut 1.2 mm. Got a Question? Make An Enquiry. Turn to page 80a to enquire or log on to: www.equipment-news.com

Editorial

Got a Question? Make An Enquiry. Turn to page 80a to enquire or log on to: www.equipment-news.com

ENQUIRY NUMBER

3610

Sunnen: SH-5000 Horizontal Honing Machine

TaeguTec: SBMT Inserts

Editorial

Sandvik Coromant has taken another step in the development of fine boring technolog y by introducing CoroBore 826, a groundbreaking h i g h - p r e c i s i o n (H P) coolant tool for troublef r e e m a c hinin g an d close hole tolerances. Machine stops caused by chip tangling around the tool or spindle are a common problem in fine boring. With the highprecision nozzle, CoroBore 826 HP directs the high-precision coolant jet to the cutting edge in order to efficiently control and break the chip. Chips are then easily evacuated from the hole. Combined with the user-friendly stepwise scale setting of the tool diameter provides the perfect tool for accurate fine boring. CoroBore 826 HP is the ideal first choice fine boring tool for requirements in the range of 36–1260 mm (1.417–49.606 inch). It is optimised for process repeatability, hence ensuring excellent surface finish and close hole tolerances.

ENQUIRY NUMBER

3609

Sunnen introduced a new low cost, automation ready horizontal honing machine for high-volume processing of gears, turbocharger bushings and other small parts. It comes with a 4.1-kW (5hp) spindle drive and 1.1-kW (1.5hp) stroker drive, with carriage travel up to 392mm and an adjustable spindle speed of 200 to 3,000 rpm and stroke rates of 10 to 550 SPM. The product is also equipped with cycle-time control that prevents glazing of the abrasives. Its 225-mm (9 inch) touch screen includes infinite part program storage and intuitive setup and run screens to allow inexperienced operators to run the machine more efficiently. Editorial

Got a Question? Make An Enquiry. Turn to page 80a to enquire or log on to: www.equipment-news.com

ENQUIRY NUMBER

3611

CALENDAR 2016 Asia Pacific Metalworking Equipment News • April 2016

APRIL 26 – 28

MTA Hanoi 2016

I.C.E. Hanoi (Cung Van Hoa) Cultural Palace

91 Tran Hung Dao Str., Hanoi, Vietnam Singapore Exhibitions Services Pte Ltd

MAY 11 – 14

Intermach Thailand 2016, Sheetmetal 2016, Subcon 2016

Bangkok International Trade & Exhibition Centre (BITEC) 88 Bangna-Trad Road (Km.1), Bangna Bangkok 10260, Thailand UBM (Thailand) Co Ltd

25 – 28

Metaltech 2016

Putra World Trade Centre Kuala Lumpur, Malaysia 41, Jalan Tun Ismail, 50480 Kuala Lumpur, Malaysia Trade Link ITE Sdn Bhd

JUNE 22 – 25

Manufacturing Expo 2016, Intermold Thailand 2016, Nepcon Thailand 2016 Bangkok International Trade & Exhibition Centre (BITEC) 88 Bangna-Trad Road (Km.1), Bangna Bangkok 10260, Thailand Reed Tradex Company

JULY 5–8

AUGUST 3–6

Manufacturing Surabaya 2016

Grand City Convention & Exhibition Centre

JL. Walikota Mustajab, Kusuma Banja, Surabaya 60272, Indonesia PT Pamerindo Indonesia

SEPTEMBER 22 – 24 Manufacturing Myanmar 2016

Myanmar Event Park

Shin Saw Pu Rd, Yangon, Myanmar Singapore Exhibition Services

OCTOBER 6–8

Metalex Vietnam 2016 Saigon Exhibition & Convention Center (SECC)

NOVEMBER 23 – 26

Metalex Thailand 2016

Bangkok International Trade & Exhibition Centre (BITEC) 88 Bangna-Trad Road (Km.1), Bangna, Bangkok 10260, Thailand Reed Tradex

23 - 27

Taiwan International Machine Tool Show (TMTS) Greater Taichung International Expo Center

No. 161, Gaotie 5th Rd., Wuri Dist., Taichung City 41456, Taiwan Taiwan Machine Tool & Accessory Builders’ Association (TMBA)

NOVEMBER 30 – DECEMBER 3

799 Nguyen Van Linh Parkway, District 7, Ho Chi Minh City, Vietnam Reed Tradex

Manufacturing Indonesia 2016

25 – 27

Gedung Pusat Niaga Lt. 1 Arena PRJ Kemayoran Jakarta 10620 Indonesia PT Pamerindo Indonesia

Indometal 2016

Jakarta International Expo (JIExpo)

Gedung Pusat Niaga Lt. 1 Arena PRJ Kemayoran Jakarta 10620 Indonesia Messe Dusseldorf Asia

25 – 29

Euro Blech 2016

Deutsche Messe Hannover Messegelände D-30521 Hannover Germany Mack-Brooks Exhibitions Ltd

MTA Vietnam 2016

Saigon Exhibition & Convention Center (SECC)

799 Nguyen Van Linh, District 7, Ho Chi Minh City, Vietnam Singapore Exhibition Services Pte Ltd

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ADVERTISING INDEX Asia Pacific Metalworking Equipment News â&#x20AC;¢ April 2016

Page Number

Enquiry Number

AGMACHINE TECHNO CO LTD

044

ARNO WERKZEUGE S.E.A. PTE LTD

051

BENIGN ENTERPRISE CO LTD

055

BYSTRONIC PTE LTD

062

COMPRO PRECISION MACHINERY CO LTD

049

DEES HYDRAULIC INDUSTRIAL CO LTD

045

02/03

066

EVERISING MACHINE CO

056

HAIMER ASIA PACIFIC LTD

IBC

042

HEIMATEC GMBH

027

HEXAGON METROLOGY C/O LEICA GEOSYSTEMS

063

HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD

048

HWACHEON ASIA PACIFIC PTE LTD

046

INGERSOLL-RAND SOUTH EAST ASIA (PTE) LTD

047

INTERROLL (ASIA) PTE LTD

059

ISCAR LTD

IFC

053

KENNAMETAL INC

031

LIEN CHIEH MACHINERY CO LTD

043

OPTICAL GAGING (S) PTE LTD

052

REED TRADEX COMPANY (MANUFACTURING EXPO 2016)

065

RENISHAW (HONG KONG) LTD

054

SCHAEFFLER (SINGAPORE) PTE LTD

009

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2016)

016

TAEGUTEC CO

060

TAIWAN TAKISAWA CO LTD

050

TORNOS TECHNOLOGIES ASIA LTD

061

TRADE LINK ITE SDN BHD (METALTECH 2016)

040

TUNGALOY SINGAPORE (PTE) LTD

057

UBM ASIA (THAILAND) CO LTD (INTERMACH 2016)

058

WALTER AG SINGAPORE PTE LTD

024

WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG

064

Advertiser

DMG ASIA PACIFIC PTE LTD

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ASIA PACIFIC METALWORKING

No. 3 2016

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HAIMER Basic Mill Reduced to the essentials â&#x20AC;&#x201C; but still unique.

25. - 28. May 2016 visit us in Kuala Lumpur Hall 4 | Booth 4016 ENQUIRY NO 042

Tooling Technology Shrinking Technology

Balancing Technology

Measuring Instruments

GROOVING CUT-OFF, AND MULTI-DIRECTIONAL TURNING MADE...

Face Grooving

Grooving

Deep Grooving

Beyond Evolution is the new single-sided grooving and cut-off tool that also performs multi-directional turning.

Cut-Off

Side Turning

Beyond Evolution EASY kits are currently

50%* OFF CALL when you order using the promotion code:

B 0 1KG L1C 116 - P 3

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kennametal.com/BeyondEvolution

* Savings compared to sum of kit component list prices. Offer cannot be combined with other discounts/offers. Offer ends June 30, 2016. Only available through participating distributors.

www.kennametal.com

ENQUIRY NO 031

Chamfering

Profiling

Facing