APMEN Jul-Aug 2010

Lean Manufacturing:

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When lesser is better BIG Solutions for BIG problems July-August 2010

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Contents

July-August 2010

24

FIRST CUT EDM: Making The Cut

Standing in the corner of ‘unconventional machining’ is EDM, where new additions to the family are expected to pack a real punch.

By Michael E Neumann

26

TECHNOLOGY UPDATE

Lean Manufacturing: The Holistic Approach

Improvement in automotive lean manufacturing lies in a cross-functional mindset that creates lean processes from the shop floor to the top floor. By Kevin Piotrowski, director of solution management, System i, Infor; board of directors, AIAG and Wolfram Schmid, director, solution marketing, automotive, Infor

30

Productivity: Crank It Up

Using the right tool and approach dramatically improve crankshaft machining for a diesel engine supplier. By Dirk Becker, turning product manager, Iscar Germany

32

An Intelligent Solution For High Productivity

A smart and lean way of managing inventory for small parts can lead to cost savings. By Mark Mumenthaler, GM, Bossard South East Asia.

34

Limitless Optimisation Of Machine Tool Performance

Open architecture THINC system provides upgradable tools to increase productivity without costly CNC overhaul. Submitted by Julie Murphy, marketing manager, Okuma America Corp

36

SOFTWARE & MEASUREMENT

Gantry CMM Speeds Up Cycle Time And Increases Product Output Capital investments in large measuring equipment are a lot easier to justify when there are significant reductions in cycle times and improvements to accuracy. By Annette Smith, marketing, Carl Zeiss IMT

38

Smarter Ways To Measure Supersize Metal Objects Laser technology innovation redefines large-scale metrology in metalworking and assembly. By Rob Snoeijs, senior editorial writer, Nikon Metrology

2

metalworking equipment news Jul-Aug 2010

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Contents 42

Regulars

FAB & FORM

Pressing & Bending Of Sheet Metal

Augustine Quek dissects the world of sheet metal bending.

44

• 8 Business News • 75 Product Finder • 79 Exhibition Programmes • 80A Product Enquiry Card

Handling Production More Efficiently

A CO2 laser cutting system and a tandem press brake improve productivity by 40 percent and streamline operations for a material handling systems manufacturer. By Matthew Fowles, marketing manager, LVD Group

54

MATERIAL FOCUS

46

Comfort & Efficiency In Bending

In developing countries like Vietnam, the focus on efficiency and ergonomics is just as important as any other established economies. By Melvin Tham, product manager, bending technology, Trumpf Asia Pacific.

Eye On Composites

Modern technologies, particularly in the aerospace industry, require an ‘all ensemble’ cast of mechanical properties that cannot be individually met by materials like metal, ceramics or plastics.

By Michael E Neumann

58

FEATURES

Measurement arms are used to overhaul US Air Force B-52s.

By Dan Alred, product marketing manager, Faro and Richard Hansen, quality assurance manager, Mission Support.

50

INDUSTRY SPOTLIGHT

Building Towards A Sustainable Future

Christoph Conrad, senior VP, Building Life Cycle Management, Buliding Technologies, Sector Industry, Siemens tells APMEN why maximising energy efficiency in buildings is so important.

By Derek Rodriguez

Refer to Advertising Index

62

EVENTS & EXHIBITION

On The Map: Mitutoyo Open House &

Seminar 2010 Event Preview: IMTS Event Preview: MTA 2011 Event Preview: JETRO Joins

Metalex Vietnam 2010 Event Review: AMF 2010 Event Review: Metaltech 2010 Show Review: MTA Malaysia 2010 Event Review: Vietnam Manufacturing Expo

Pg 80

for Advertisers' Enquiry numbers

Mark Holloway, Nevada, USA

Re-Arming The B-52s

ENQUIRY NO 090

editor’s note

Published by:

Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

Go Go Go

managing director Kenneth Tan

With The

Flow

A river is a natural watercourse flowing towards an ocean. In many cases throughout history, rivers have brought life to areas surrounding it.

Flowing water it seems, brings s u cc e s s a n d t h i s co n c e p t i s applicable in metalworking as well.

A big part of lean manufacturing is dependent on keeping the work channel flowing. The much talked about Toyota Production System focuses on improving flow and reducing waste and ‘unevenness’.

Lean manufacturing, its concept and applicability is featured in this issue of Asia Pacific Metalworking Equipment News. Often, operators reject the concept when newly implemented; but despite all the huff and puff about how the idea brings extra work, they may begrudgingly concede that a shopfloor is a place poorer without it, after they get used to having the benefits that come along.

Changes are always difficult, but with proper training, thorough

introduction and most importantly results to back the change, most will eventually accept with no further complaints. Sometimes, flow in a workplace can be altered without a major cha nge in production philosophy. It could just be down to a tool change that brings about an increase in productivity. (Pg 30) Also in this issue, we are featuring a comprehensive review of MTA Malaysia and Metaltech 2010 held in May. (Pg 70) With some 33 percent increase in exhibition size, the show went on to post impressive sales figures.

In Fab and Form, the topic on pressing and bending is visited, highlighting the importance of using technology to improve process and workflow. (Pg 44) Taking a hint from mother natural and learning from the history books, it may not be a bad idea to bring the element of ‘flow’ to a workplace.

editor Joson Ng

josonng@epl.com.sg

business development manager Randy Teo

randyteo@epl.com.sg

advertising sales manager Yessica

yessica@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg senior art director / studio manager Lawrence Lee lawrencelee@epl.com.sg graphic designers Jef Pimentel jeffreypimentel@epl.com.sg Zhang Yue

zhangyue@epl.com.sg

circulation executive Irene Tow

irenetow@epl.com.sg

contributors Michael E Neumann, Kevin Piotrowski Wolfram Schmid, Dirk Becker Mark Mumenthaler, Julie Murphy Annette Smith, Rob Snoeijs Augustine Quek, Matthew Fowles Melvin Tham, Derek Rodriguez Dan Alred, Richard Hansen board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher.

Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.

Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 133/06/2010 PPS 840/10/2010 (028278) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

chairman Stephen Tay group executive director Kenneth Tan financial controller Robbin Lim

Joson Ng Editor

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806

6

metalworking equipment news Jul-Aug 2010

Economic miracle Economic miracle

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Singapore 65 6472 6300 Vietnam 84 4 845 31 93

Australia/ NZ 61 3 9555 55 25 China 86 21 5868 0480

Malaysia 03 7845 3930 Korea 82 31 389 9800

Indonesia 62 21 385 38 53 Philippines 632 633 8918

Thailand 66 2616 0421 Taiwan 886 2 2689 7988

Businessnews

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China & Singapore To Partner In Technological Innovations Singapore: Lee Yi Shyan, Minister Of State (MOS) for Trade and Industry and Manpower, stressed the importance of joint collaboration in technological innovations to enterprises at the closing ceremony of the Singapore-Jiangsu Innovation Cooperation Conference (SJICC) held in Nanjing.

Mr Lee said: “Science and technology is imperative for economic transformation and restructuring.

Technological innovations can help enterprises raise their value propositions and competitiveness, as well as develop new products and markets. I am happy to support this private sector initiative as our research institutes and experts work together to achieve knowledge exchange and transfer towards the advancement of both our business and social communities.”

Both Mr Lee and Jiangsu vice governor Zhang Weiguo spoke at the closing of the conference in their capacities as vice co-chairmen of the Singapore-Jiangsu Cooperation Council (SJCC), which was formed in November 2007.

Khaw Boon Wan, minister for health and Liang Baohua, Jiangsu Party secretary are the co-chairmen.

International Enterprise (IE) Singapore is the Singapore secretariat for the council.

Science and technology is one of the six key focus areas supported by the council. At the conference, Mr Lee highlighted that Singapore and Jiangsu should tap on the SJCC to develop capabilities in science

and technology together. Three potential ways of partnership include: - Encouraging institutions of higher learning and research institutes to heighten exchanges and cooperation; - Encouraging high-tech enterprises from both sides to set up R&D centres in each other’s market so as to introduce their products to new markets regionally and globally; - Encouraging high-tech start-ups from both sides to leverage each other’s existing incubators to obtain key resources and services to further develop and expand overseas.

During the closing ceremony at the SJICC, Mr Lee and vice governor Zhang witnessed 10 Memorandum Of Understanding (MOU)/ Letter Of Intent (LOI)/agreement signings between Singapore and Jiangsu companies and institutes in the R&D sector. The Singapore companies/ institutes included the National University of Singapore and Nanyang Technological University.

In addition, Mr Lee and vice governor Zhang unveiled the plaques for the establishment of the Jiangsu-Singapore Technology Transfer Promotion Centre and the Jiangsu-Singapore Joint Research Centre on Organic/Bio Electronics and Information Displays.

Siemens PLM Software Unveils Technology Framework

Shanghai, China: Siemens PLM Software has launched the High Definition PLM (HD-PLM) technology framework, which will enable decision makers throughout the product lifecycle to make better-informed decisions more efficiently and with a higher level of confidence.

Unveiled at The World Exposition Shanghai China 2010 (Expo 2010), HD-PLM will allow cross-domain 8

metalworking equipment news Jul-Aug 2010

decision-making by uniting users with the people, tools and product-related information.

The users’ experience – delivered through a variety of supported devices – will be personalised by placing them into the digital context appropriate to their role.

HD-PLM will assist users in collaborative decisionmaking, and information will be clarified and turned into knowledge through visual presentation.

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Vero & MIRDC To Promote D3 Technologies Is Now Software Solutions In Taiwan Renishaw Diagnostics

Richard Youhill, operations director, Vero and Huang Chi-Chuan, chairman of the board of directors, MIRDC

Gloucestershire, UK: Vero Software, a provider of CAD/CAM/CAE solutions for the tooling industry, has entered into an agreement with the Metal Industries Research and Development Centre (MIRDC) of Taiwan. This is to link the former’s CAD and CAM applications with the latter’s software solutions and jointly promote these solutions to the mould and die makers of Taiwan and China.

Under the agreement, the latter will link its ERP solutions to the former’s VISI die design and manufacturing applications. MIRDC will also promote and train potential and existing customers on the use and benefits of the software to further their capabilities in advanced mould and die applications.

Gloucestershire, UK: D3 Technologies, a provider of trace level detection technologies based on the exploitation of Surface Enhanced Raman Spectroscopy (SERS) and Surface Enhanced Resonance Raman Scattering (SERRS) for molecular diagnostics and research applications, has changed its name to Renishaw Diagnostics.

David A Burns, CEO, said: “The change of name to Renishaw Diagnostics reflects the direct focus of the company to become a provider of automated multiplex diagnostic and clinical research systems.

These patented technology based systems will enable our customers to carry out fast, reliable and simplified disease detection leading to improved patient care. This move demonstrates the commitment and belief of our parent company in our people, our strategy and our science, and brings the power of the Renishaw global enterprise to enable us to accelerate our development of these products.”

Renishaw’s chairman and chief executive, Sir David McMurtry, added: “We are in the process of doubling the footprint at Renishaw Diagnostics’ facilities in Glasgow and the team are recruiting a commercial organisation that will enable us to take our diagnostics products directly to market.

Development progress with our multiplex diagnostic platform has demonstrated our position in sensitivity, accuracy and speed compared to existing disease testing methods.”

Upturn In Machine Tool Orders Since The Fourth Quarter Of 2009 Brussels, Belgium: Machine tool orders turned around in the fourth quarter of 2009 in CECIMO countries, after dropping by over 50 percent in the first quarter of 2009 (in comparison with the same period one year before) as a consequence of the financial crisis. Michael Hauser, president of CECIMO, explains that: “since order backlogs are still very low, it will take a few more weeks before the turnaround is clearly observed in sales.”

Recovery in the European machine tool industry is driven by an increased consumption in the emerging markets, and notably from China. Despite the severe crisis in the sector in 2009, the global market share of machine tools exported from CECIMO countries rose from 55 percent to 61 percent. This proves the competitiveness of the European sector in global markets. The organisation expects this trend to continue in 2010.

It will take more time for European consumption to recover, since capital investment in the traditional enduser industries is still low, capacity utilisation is below 10

metalworking equipment news Jul-Aug 2010

average and credit is still difficult to get, especially for the smallest companies. The current financial instability associated with the sovereign debts of some European countries may also hinder the necessary cash flow that is required by industry to invest in modern and energy efficient production equipment.

The geographical shift of the machine tool consumption toward the emerging markets of Asia and Latin America makes it therefore necessary for the European machine tool industry to obtain fair and non-discriminatory access to those markets.

Free trade agreements, such as the EU-South Korea agreement, are expected to eliminate such nontariff barriers. The organisation is therefore a strong proponent of this agreement. Even though CECIMO understands the mitigated position of some sectors regarding the duty drawback and the safeguard clauses, the organisation requests that the European council accepts a provisional implementation of the FTA before the European Parliament gives its final agreement.

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businessnews

Emerson & KOSEP To Collaborate On Power Plant Projects

www.equipment-news.com

World’s Largest Concentrated Solar Power Plant To Be Built

New Plant For Tata Nano At Sanand Inaugurated Bombay, India: Tata Motors’ plant for the Tata Nano at Sanand, in Ahmedabad district of Gujarat, was inaugurated by the Honourable chief minister of Gujarat, Narendra Modi.

The plant’s inauguration marks the culmination of the company’s goal of making the Tata Nano freely available to hundreds of thousands of families. The capacity of the plant, to begin with, will be 250,000 cars per year to be achieved in phases, and with some balancing is expandable up to 350,000 cars per year.

Further capacity expansion has also been provided for in this location.

Deliveries from the plant, including BS4 Tata Nanos, will begin this month. The output, supplemented by the facility at Pantnagar (Uttarakhand), will in the immediate phase complete pending orders from the booking process of 2009.

Built in 14 months starting November 2008, the integrated facility comprises Tata Motors’ own plant, spread over 725 acres, and an adjacent vendor park, spread over 375 acres, to house key component manufacturers for the Tata Nano.

At the vendor park, plots have already been allocated to 41 vendors. More will be accommodated subsequently.

Vendors, accounting for about 80 percent of the value of components to be sourced from the park, have already begun construction. In the interim, they will supply the plant from their existing facilities in the country.

12

metalworking equipment news Jul-Aug 2010

Alla Leitus, Israel

Pittsburgh, USA: Emerson Process Management, a business of Emerson, and Korea South East Power Company (KOSEP) have signed a Memorandum of Understanding to collaborate on modernising existing power plants and constructing new ones in South Korea, the Middle East, Africa, Southeast Asia, and Latin America.

Projections by the US Energy Information Administration indicate that in the next 10 years, electricity generation will grow more than 25 percent globally – and more than 40 percent in the regions targeted by this agreement.

Under the agreement, KOSEP will standardise on Emerson’s automation, control, and instrumentation technologies. The two companies will also exchange technology to help power plants improve boiler and turbine efficiency.

Abu Dhabi, UAE: Masdar has appointed the bidding consortium of Total and Abengoa Solar as a partner to own, build and operate Shams 1, the world’s largest concentrated solar power plant and the first of its kind in the Middle East.

One of Masdar’s flagship projects, Shams 1 will directly contribute towards Abu Dhabi’s target of achieving seven percent renewable energy power generation capacity by the year 2020.

The joint venture between Masdar (60 percent), Total (20 percent) and Abengoa Solar (20 percent) will develop, build, operate and maintain the plant which will be located in Madinat Zayed, approximately 120 km southwest of Abu Dhabi in the United Arab Emirates (UAE).

Shams 1 will be the largest concentrated solar power plant in the world, extending over an area of 2.5 sq km, with a capacity of approximately 100 MW and a solar field consisting of 768 parabolic trough collectors to be supplied by Abengoa Solar. Construction is set to begin during Q3 2010 and is expected to take approximately two years.

Shams 1 is registered as a project under the United Nations’ Clean Development Mechanism (CDM) and is eligible for carbon credits. It is the first CSP plant registered under the CDM and the second project registered for Masdar. The plant will displace approximately 175,000 tonnes of CO2 per year, equivalent to planting 1.5 million trees or removing 15,000 cars from Abu Dhabi’s roads.

businessnews

www.equipment-news.com

Impact Of Economic Growth, Oil Prices & Future Policies On Projected Energy Trends on projected energy market trends,” said EIA administrator Richard Newell. He noted that “understanding these potential alternate energy futures can inform individuals, businesses, and policy makers as they make decisions today.”

The projected level of total US energy use depends significantly on the rate of economic growth, which is assumed to be 2.4 percent annually from 2008 to 2035 in the AEO2010 Reference case.

Annual average economic growth rates of 1.8 percent in the Low Economic Growth case and 3.0 percent in the High Economic Growth case, correspond to projections of energy use in 2035 ranging from about 104 to 127 quadrillion Btu, increases of between 0.1 percent to 0.9 percent annually. Changes in the size of the economy lead to less than proportional changes in projected US energy use because improvements in energy intensity vary with rates of economic growth.

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Washington DC, USA: The US Energy Information Administration (EIA) released the complete version of the Annual Energy Outlook 2010 (AEO2010), which includes 38 sensitivity cases that show how different assumptions regarding market and policy drivers affect the reference case projections that EIA previously released in December, 2009.

In addition to considering alternative scenarios for oil prices, economic growth, and the uptake of more energy-efficient technologies, the AEO2010 includes cases that examine the impact of changes in selected policies, such as the extension of existing policies that are currently scheduled to sunset as well as the sensitivity of natural gas shale production to variations in drilling activity and the size of the resource base.

The A EO2010 sensitivity cases show that “variations in assumptions regarding key market or policy drivers can have a significant impact

Jul-Aug 2010 metalworking equipment news

13

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MAG Endows Chair In Production Engineering At Chinese University

Stuttgart, Germany: The machine tool manufacturer MAG is to endow a chair in production engineering at Tongji University’s Chinese-German College for Postgraduate Studies (CDHK) in Shanghai. The

endowment is being made as part of the GermanChinese Year of Science and Education.

The official foundation charter was signed by MAG chairman Professor Dr Jürgen Fleischer during a visit by Germany’s Federal Minister of Education and Research, Professor Dr Annette Schavan. The wbk Institute of Production Science at the Karlsruhe Institute of Technology (KIT) will be providing support for the chair in its capacity as a co-operating college.

MAG recently opened a 1,000 sq m branch in Shanghai offering facilities for engineering services, sales, service, training and live demonstrations. A plant is also scheduled for completion in Changchun in the near future. Professor Fleischer said: “The Chinese market has shown dynamic development, which is why MAG has been present here for a long time and intends to further expand its involvement on a lasting basis.”

Antonov Expands Commercial Stolthaven Singapore To Establish New Terminal Engineering Activities Warwick, UK: Antonov, the UK-based automatic transmission specialist, continues to increase its commercial engineering activities in parallel with becoming a high volume manufacturer. The company, which has recently secured a 2-speed heavy-duty alternator project, is already working on a high efficiency transmission for electric vehicles that will feature in the Jaguar Limo-Green research project and is also well advanced in bringing its TX-6 automatic gearbox into series production in China, where new manufacturing facilities are currently under construction.

Designed to improve the efficiency of electrical motors and generators generally as well as internal combustion engines, the company says its automatic transmission technology is finding ever more applications, particularly given the trend towards an increased electrification of vehicles and the quest for increased mechanical efficiency.

The company’s manufacturing capability took a step forward recently when it formalised its joint venture with Landai, one of the gearbox suppliers in China, to manufacture and market the TX-6 automatic transmission. The factory in Chongqing will have an initial capacity to build 200,000 transmissions a year.

The company is currently investigating the Chongqing plant’s potential to build its electric vehicle transmission and for low initial volumes to supply components for final assembly in Warwick.

14

metalworking equipment news Jul-Aug 2010

Singapore: Stolthaven Terminals, a division of Stolt-Nielsen, commenced ground breaking for their first phase of the greenfield storage terminal in Jurong Island, Singapore. The start of this project in Tembusu comes after a prolonged delay, which resulted from the economic downturn during the past few years.

Agreements have been made with the EPC contractor, Chiyoda and site preparation is already underway.

The first phase will comprise 61,000 m3 of capacity made up of both gas spheres and conventional liquid tanks. The intention is to build out over 300,000 m3 in successive phases to support the new chemical manufacturing plants as well as the growth for existing production.

Although it has been two years since initial announcement, Singapore is today and will remain in the future a vital link in the global supply chain for bulk-liquid chemicals.

“We are delighted that Stolthaven has decided to establish this new terminal in Singapore. This project is strategic to Singapore’s efforts in developing and capturing the emerging wave of petrochemical investments on Jurong Island, providing essential services to the new manufacturers at Tembusu.

Stolthaven’s project further strengthens and reinforces Jurong Island’s leadership position in the chemical industry,” said Manohar Khiatani, JTC’s CEO.

Tungaloy Singapore Pte. Ltd. 50 Kallang Avenue, #06-03 Singapore 339505 Tel: (65) 6391 1833 • Fax: (65) 6299 4557 www.tungaloy.co.jp/tspl/

ENQUIRY NO 103

Tungaloy Malaysia Sdn Bhd (876763-H) 50 K-2, Kelana Mall, Jalan SS6/14 Kelana Jaya 47301 Petaling Jaya, Malaysia Tel: +603-7805 3222 • Fax: + 603-7804 8563 www.tungaloy.co.jp

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AEROSPACE

Emmanuel Wuyts, Belgium

Boeing 737 Production Rate Increases To 35 Per Month

Seattle, USA: Boeing announced a second production rate increase on the next-generation 737 program, taking the rate from the previously announced 34 airplanes per month to 35 in early 2012.

In May, the company cited continued strong demand for the next-generation 737 as reason to ramp-up production from 31.5 to 34 airplanes per month and indicated plans to study further increases. This announcement acknowledges the anticipated long-term growth in this market segment and the continued pressure to raise airplane output to match expected market demand.

“Ou r cu stomers cont inue to show t heir preference for t he ne x t- generat ion 737 by exercising order options as well as by placing new orders,” said Boeing commercial airplanes president and CEO Jim Albaugh. “We’ve managed our current backlog efficiently and increasing rate is the product of our comprehensive planning and preparation. We will continue to monitor demand as we go forward.”

Airbus To Acquire 62 Faro Laser Tracker IONs Lake Mary, USA: Faro Technologies, provider of portable 3D measurement and imaging solutions, and Airbus, one of the world’s aircraft manufacturers, have signed a five-year agreement for Faro to be a supplier of laser trackers and measurement accessories for the Airbus A350 project assembly line.

This agreement includes 62 FARO Laser Tracker ION units and also covers Airbus’ key system providers for fixtures and production systems.

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metalworking equipment news Jul-Aug 2010

Sikorsky Aerospace Services Partners Timken In Australasia Connecticut, USA: Sikorsky Helitech, a Sikorsky Aerospace Services (SAS) company based in Brisbane, Queensland, Australia, has a distribution agreement with The Timken Company for bearing inspection, overhaul and reconditioning services throughout the Australasian region.

“Combining Timken’s range of bearing repair services with our OEM expertise and capabilities positions SAS to offer customised repair programs for fixed and rotary-wing customers in the AustraliaPacific basin. This teaming effort demonstrates our continued commitment to supply single-source solutions to our global customers,” said David Adler, president of SAS. Providing aftermarket support to customers in Australia and the Asia Pacific region, Sikorsky Helitech will offer an interface to the local and regional customer base. Additionally, the company will carry an inventory of bearings at its Brisbane location to facilitate and expedite regional overhauls and exchanges.

“For more than 70 years, Timken has been serving aerospace customers for a variety of platforms. Our Aerospace Aftermarket Solutions group offers reconditioning services and inventory of replacement parts. We are pleased to collaborate with SAS and Sikorsky Helitech to enable customers in Australia and adjoining regions to benefit from our bearing repair solutions,” said Scott Radcliffe, bearing repair product manager.

Rolls-Royce Celebrates First Run Of Latest Trent Engine London, UK: Rolls- Royce, the global power systems company, has celebrated the first run of the Trent XWB, the latest member of its Trent aero engine family.

The Trent XWB, the fastest-selling Trent engine program ever, with more than 1,000 ordered, ran for first time and meets program commitments set out in 2006.

The engine will power the Airbus A350 XWB family of aircraft. It is the most fuel efficient and environmentally sensitive large engine design available today, according to the company with 28 per cent better fuel efficiency than pre-Trent generation engines.

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AEROSPACE

Embraer Enhances Customer GE Aviation Receives Award Support Activities In APAC Evendale, USA: GE Aviation received an award

- A n ex tension of the storage facility to accommodate added inventory of spare parts for the company’s executive jets, which was previously held in Paris.

- Enhanced capability to manage customer support activities for Embraer’s growing number of executive aviation clients in the region.

- A four-fold increase in the prevailing office space that will house the centralised materials support team.

As of 2010, all parts and logistics support for the company’s commercial aircraft, as well as executive jets in the region will be managed from the Regional Distribution Centre (RDC) in Singapore.

ENQUIRY NO 109

These enhancements are:

from the Federal Aviation Administration (FAA) as part of the Continuous Energy, Emissions and Noise (CLEEN ) program.

CLEEN is an FAA program to accelerate the development and maturation of aircraft and engine technologies that reduce noise and emissions and improve fuel burn.

The program goal is to enable the new technologies to enter the fleet beginning in 2015. GE and the FAA will share the investment of up to $66 million for up to a five-year period.

The award will help fund three GE technologies, including TAPS II Combustor, Open Rotor and Flight Management System - Air Traffic Management (FMS-ATM).

Robert Radermacher, Germany

São José Dos Campos, Brazil: Coinciding with the company’s tenth anniversary in Singapore, Embraer announces strategic enhancements to its customer support activities in Asia Pacific.

Jul-Aug 2010 metalworking equipment news

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OIL & GAS

Honeywell To Help Maintain World’s Longest Gas Pipeline

Kevin Abbott, USA

Beijing, China: Honeywell has been selected to provide the control and safety systems for the world’s longest gas pipeline. The 8,704 km West-to-East II pipeline is the second of two massive pipelines to be constructed to transport fuel from energy-rich western China to the country’s eastern regions.

PetroChina, China’s top oil producer and operator of the pipeline, selected Honeywell’s Experion Process Knowledge System (PKS) and Safety Manager solutions to manage the pipeline operation and help guard against hazardous incidents.

The new pipeline crosses 14 Chinese provinces, autonomous regions and municipalities and will transport approximately 30-billion cubic yards of natural gas per year. It will play a critical role as the country, the second-largest energy consumer in the world behind the US, transitions from coal fuel-based energy to natural gas. Each year the gas transported by the pipeline is expected to replace 76.8 million tonnes of coal, reduce sulfur dioxide emissions by 1.44 million tonnes and carbon dioxide by 130 million tonnes.

PetroChina will use Experion as the main integration and control software platform at the pipeline’s 73 control stations. Specifically, the system will integrate alarm and event subsystems to give pipeline operators a complete view of how the pipeline is functioning. By integrating Safety Manager into the overall system, the system will help improve process-safeguarding practices such as emergency shutdowns, equipment protection, fire and gas monitoring and critical control.

DNV To Assist Vietnam On Use Of LNG Oslo, Norway: The Vietnamese Government has decided to start importing liquefied natural gas, and gasification terminals are already under development.

Vietnam’s deputy prime minister Hoang Trung Hai witnessed the signing of a Memorandum of Understanding (MoU) with DNV at its headquarters in Oslo. This sets the framework for DNV to work proactively with Petrovietnam and their subsidiary PV Gas to safely and efficiently introduce and distribute LNG within Vietnam, and to assist in creating an appropriate legislative safety regime.

The agreement enables DNV to assist Vietnam on risk management issues associated with the use of LNG, how to use the waterways to distribute LNG and how to utilise LNG as fuel for the coastal shipping and river transportation.

Vietnam has a growing demand for energy and will in future be dependent on imports. At the same time, 18

metalworking equipment news Jul-Aug 2010

it is – next to Bangladesh – the country in the world that will be most affected by the expected rise in sea level due to climate change. The nation is trying to find a balanced solution, and energy sources such as hydropower, wind energy and LNG as well as oil and coal will be part of the final solution.

By the end of this year, PetroVietnam cas Corp (PV Gas) plans to select an aggregator to buy LNG in the spot market for three years before committing to long-term supplies. The supplies will be received at a floating storage and regasification unit to be completed in 2012; this is a fast-track option in case the country needs gas earlier.

The company is finalising the location of a proposed gasification terminal in the south of the country. The 1 million tonne-per-year terminal is scheduled to be ready in 2015. Its capacity will be increased to 3 million and 6 million tpy in 2020 and 2025 respectively.

multi application sensor system The future of measuring is one solution. As production processes get more and more complex, the need for multi-functional machines grows. Carl Zeiss has recognized this and developed mass. The new multi-sensor technology unites optical and touch measuring in one machine and one software so that the best sensor for any given application is available on demand.

The all-in-one-concept makes multi-sensor technology reasonable like never before.

Active scanning

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Carl Zeiss S.E.Asia Industrial Metrology Group

ENQUIRY NO 110

imt@zeiss.com.sg www.zeiss.com.sg/imt

Malaysia Tel: (60) 3 7877 5058

Vietnam - Ho Chi Minh Tel: (84) 8 3911 8670

Singapore HQ Tel: (65) 6741 9600

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statistics

German Machine Tool Orders Rising Sharply “Following this strong performance at the start of the year it remains to be seen whether such growth levels can be sustained as the year progresses,” said Dr Wilfried Schäfer, MD of the VDW (German Machine Tool Builders’ Association) in Frankfurt, commenting on the result. “We regard the fact that the service and spare parts sectors have performed so well as highly encouraging. Our customers are starting to use their machines again. Sooner or later this is going to feed through to new investment.”

Frankfurt, Germany: Orders received by the German machine tool industry rose sharply in the first quarter of 2010. Overall, orders were up 43 percent yearon-year for the period January to March. Domestic demand rose by 25 percent, whereas foreign orders increased by 54 percent.

Looking Up But Staying Cautious There is a sense of growing optimism within the sector. In April, capacity utilisation increased to 71.6 percent, up from 67.6 percent in January. Orders on hand also increased to 6.6 months in February 2010, up from 5.6 months last October.

In no way is the sector out of the woods yet.

Compared to the peak year of 2008, order volumes remain at a low level. “For most companies, liquidity remains a major worry both their own and that of their customers,” explained Dr Schäfer. There is simply not enough money available at reasonable rates to prefinance orders, he asserted.

“A further problem is the sharp increase in fees for loan default insurance policies. In extreme cases, the lack of liquid funds can lead to further staff being laid off although they are actually needed.”

The long operating cycles involved mean that the time needed for an incoming order to yield revenue is between three months for standard engineering and two years for custom-built machinery. As such, 2010 will therefore remain a transitional year. “Even assuming that the demand for machine tools stays at the same level as at the start of the year, this will not be sufficient for an increase in production. Which is why we are expecting a further fall of 12 percent in production in the current year,” said Dr Schäfer.

Manufacturing Technology Consumption Up 50.6% Year-To-Date McLean, USA: April US manufacturing technology consumption totaled US$222.36 million, according to AMT - The Association For Manufacturing Technology and AMTDA, the American Machine Tool Distributors’ Association. This total, as reported by companies participating in the USMTC program, was down 15.6 percent from March but up 102.7 percent from the total of $109.69 million reported for April 2009. With a year-to-date total of $783.03 million, 2010 is up 50.6 percent compared with 2009.

These numbers and all data in this report are based 20

metalworking equipment news Jul-Aug 2010

on the totals of actual data reported by companies participating in the USMTC program.

“Cautious spending on manufacturing technology in January and February pushed higher levels of investment into the later part of the first quarter, propping up March results,” said Douglas K Woods, AMT president. “While April dipped slightly as compared to March, the level of activity was more than 100 percent better than a year ago. We expect this investment level to be more typical as the year progresses, reflecting manufacturers’ continued cautious optimism.”

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businessStatistics

First Quarter Industrial Lasers Down 21% Year-Over-Year

Lukasz Fus, Poland

McLean, USA: Orders of industrial laser equipment and systems in the first quarter of 2010 are reported at US$51.3 million, a decrease of 21.2 percent compared with first quarter 2009, according to AMT - The Association For Manufacturing Technology.

Although the value of orders declined, total unit sales increased by 13.6 percent. This unit growth was all in Nd:YAG, though, as CO2 lasers declined slightly. The report compiled from 19 manufacturers and distributors also shows declines from fourth quarter 2009.

Unit sales of CO2 lasers fell 23.2 percent, while Nd:YAG orders declined 18.6 percent. Of the 209 total units of all types ordered, 49.3 percent of industrial laser orders were configured as a laser system (laser source and workstation). This represented the first time in several years that less than half of orders were configured as systems, although systems continue to make up a much larger share of orders when measured by dollar value, accounting for 83.6 percent of total order values in first quarter 2010.

Ye a r- end fig ure s for 20 0 9 a re ba sed on actual data reported by companies voluntarily participating in the Laser Market Data Survey.

Growth is based on revised 2008 data reflecting any changes that survey participants made during the course of 2009.

Machine Tool Orders Starting To Rise Again: UCIMU Italy: The index of machine tool orders returns positive and in the first quarter of 2010 it marks a 15.2 percent increase, compared to the same period of the previous year, with an absolute value of the index equal to 94.8 (base 2005=100). This emerges from the data drawn up by the studies Department of UCIMUSistemi Per Produrre, the association of Italian machine tools, robots, automation and auxiliary technologies manufacturers.

After six consecutive quarters of drop, the turnaround is now gaining pace. In fact, differently than what emerged by the previous survey (related to the fourth quarter of 2009), the recovery of collected orders concerns both the internal and the foreign markets.

With reference to the foreign market the index of orders collected by Italian manufacturers highlights a 18.5 percent increase compared to the same period of the previous year.

Due to this, the absolute value of the index is 106.9.

Although a moderate recovery is noticed, the absolute index is still below the value registered in the first quarter of 2005; in other words, after the crisis, the index of orders collected on foreign markets went back

to the level registered five years ago. The comparison with the two-year period 2007-2008, on the other hand, clarifies the intensity of the orders collection drop: the absolute index of the first quarter of 2010 in fact is 40 percent less compared to the values expressed in the two-year period prior to the crisis.

Continuous Growth With reference to the domestic market, the growth trend that manufacturers already noticed at the end of 2009 is continuing. The index of orders destined to satisfy the internal demand, in the first quarter of 2010, grows with a 10 percent rate compared to the same period of the previous year. For this reason the absolute index is 70.1.

“These data – stated Giancarlo Losma, president of UCIMU-Sistemi Per Produrre – confirm that the turnaround, that we businessmen are aware of from the last November, took place. Particularly encouraging is the success achieved in foreign markets. The index related to abroad orders is finally going back to positive numbers, confirming the positive evolution of the global context.”

Jul-Aug 2010 metalworking equipment news

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cut

EDM:

Making

Cut The

Standing in the corner of ‘unconventional machining’ is EDM, where new additions to the family are expected to pack a real punch. By Michael E Neumann

W

he n it co me s to the machining of precision pa rts that demand good surface finishing, Electrical Discharge Machining (EDM) is one process worth considering.

Widely believed to be capable of producing parts of accuracies up to +/-0.0002”, EDM equipment is suitable for the cutting of small odd-shaped angles and detailed contours. The ability to achieve high accuracy and tighter tolerances translate to a wide range of applications in the aerospace, stamping and medical industries.

In EDM, a potential difference is applied between the tool and workpiece. Though a gap is present between the two, the tool and workpiece conduct electricity when immersed in a dielectric medium (usually deionised water) .

Div ided into two sub categories – Sinker EDM and 24

metalworking equipment news Jul-Aug 2010

Wire EDM, they operate by using electrical discharges to form a desired shape. The difference however, lies in the type of electrode used. As their names suggest, Wire EDM involves using a wire as an electrode and Sinker EDM literally ‘sinks’ a required shape into the workpiece.

The Wired (EDM) World Wire cut EDM can be further broken down into two types of machines – the submerged and flushing type. The submerged type wire cut EDM are generally thought to be more precise than flushing type making them more expensive. The ability to cut accurately in a stable fashion can be attributed to the machine structure, controls and Automatic Wire Threading (AWT).

Stability is also enhanced by the machine structure. For instance on Doosan’s W 535F and W 800F features a durable wire suction unit, engineered to

discharge wire easily. The unit has anti-wear characteristics and the main parts are made of ceramic material, which are anti-corrosion. Used to build key parts such as roller, nozzle, guide and top and down arm, ceramic assures thermal stability, electric and chemical corrosion resistance. It is also used to ensure long-standing machine accuracy and performance.

Fine Threading AW T s y s te m p e r fo r m s t he threading of the wire. It is the most i mp or ta nt automate d feature on a wire EDM machine.

Utilisation of the system will extend the unattended operation of the machine.

For e x a mple , sta nda rd on W60 0S a nd W130 0F EDM machine s, the AW T system is aided by a Z nozzle in the lower guide unit that improves automatic wire threading rate of large thickness and ensures

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high rate of wire cutting in submerged machining.

A lso, when undergoing auto m at ic w i re t h re a d , a n ex haust unit suppor ts w ire flowing through and at the same time, it is attached to a suction unit of water. It can suck in water strongly and improve automatic wire threading rate.

In Control Geometry control and accuracy play a big part in determining consistent material removal during finishing passes. The corner control function in Doosan machines automatically adjusts servo speed during the rough and skim passes in order to optimise machining in corner geometry.

This improves corner geometry accuracy by compensating for wire deflection going into and out of corners.

Furthermore, the automatic thickness control function improves machining performa nce a nd efficiency by delivering consistent spark pulses to the cut. This function monitors and adjusts machining current according to changes in workpiece material thickness, which produces a more stable machining condition – providing more consistent cutting speed, surface finish and accuracy.

In work pieces with sudden changes in thickness, this also helps reduce wire breaks at these transition points.

For W6000S/ W1300F EDM machines, the AWT can re-thread wire in machining position after its rupture without having to drain the tank and moving back to datum start position. This is a practical solution proposed for disposal of the cut-off portion of the wire prior to starting the re-threading operation of the wire after an accidental rupture of the wire.

Enquiry No. 5001

Improving Surface Quality Accuracy and reliability may be important attributes for a machine tool but in the context of today’s manufacturing industry, surface finishing is coming into prominence as well.

Makino announces the release of the UPV-3 and UPV-5 high precision WEDM designed with an oil-based dielectric fluid system for high-accuracy machining of hardened materials and mirror-like surface finishing capabilities.

“The oil-based dielectric fluid system design of the UPV series is completely different from our other EDM machinery, offering multiple benefits,” says Jeff Kiszonas, Makino’s EDM product manager. “We’ve integrated a thermal control system that maintains constant dielectric and casting temperatures, a SPG II circuit for improved finishing operations, and a PICO guide system. Together these features create a rigid, reliable, high-accuracy machining platform capable of producing surface finishes to 0.08 µm Rz.” Included in the UPV design are ceramic insulators placed between the worktable and machine casting to reduce stray electric capacitance and enable the SPG II machining circuit to stabilise micro electrical discharges.

Utilising these capabilities under standard machining conditions for a 20 mm thick work piece measuring up to 100 x 100 mm users can achieve 0.2 µm Rz surface finishes.

Enquiry No. 5002

Doosan Infracore: High-Precision Submerged Wire-Cut EDM NW 370 and NW 570, the high-precision dip-in wire-cut electric discharge m a c h i n e s by D o o s a n Infracore are suitable in the machining of precise cross sections.

The rigid mechanical structure of the submerged NW series machines enables machining with a high degree of precision.

Other features include the expa nsion of U -V a xis stroke and the adoption of table moving method concept.

In addition, a cyclone device is attached to the machine, which separates solid particles out of the liquid through the use of centrifugal force. It extends the life of the existing triple layer filter by five-fold. MEN

Enquiry No. 5003

Jul-Aug 2010 metalworking equipment news

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update

Lean Manufacturing:

Holistic Approach The

Improvement in automotive lean manufacturing lies in a crossfunctional mindset that creates lean processes from the shop floor to the top floor. By Kevin Piotrowski, director of solution management, system i, Infor; board of directors, AIAG and Wolfram Schmid, director, solution marketing, automotive, Infor

T

he automotive industry has been using lean principles extensively over the past two decades with great success. So, can the concept of lean manufacturing in the automotive industry be improved upon? The simple answer is yes, but only when a company adopts a cross-functional mindset that creates lean processes from the shop floor to the top floor.

Initially, lean principles were focused on production improvements on the factory floor to lower costs, increase customer satisfaction and enhance quality and operational metrics. All automotive manufacturers practice lean principles to optimise a specific manufacturing cell, department or facility; however, many of these lean processes and measurements are still done manually.

The entire enterprise must focus on continuous and consistent improvement to processes, product quality and customer service.

Automotive companies must embrace lean as a philosophy that goes beyond the factory floor and extend these principals to all aspects of the value chain.

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metalworking equipment news Jul-Aug 2010

When lean principles are applied holistically throughout the entire organisation, the potential pay-offs for such a company-wide practice can be dramatic.

Processes Or People?

The concept of lean is challenging because it can mean different things to different people, many of whom believe that its scope is confined to the production facility. A common question in most discussions about lean is whether it is the tools and processes or the people that make lean work. In reality, it is both.

Lean is a cultural and peopleoriented initiative, so applying lean tools, new technology and new business processes to a traditional silo-oriented culture will not work.

Instead, the key to making the transition to a lean organisation is implementing fundamental change in the corporate culture to foster cross-departmental teamwork and communication up and down the organisation.

What Does It Mean To Be Lean?

To fully understand the application of a lean philosophy across the

entire enterprise, it is important to grasp the guiding principles of lean and the elements that comprise a lean initiative.

At its core, lean is a focus on greater operational efficiency, the elimination of waste throughout the organisation and continuous improvement. Satisfying the goals of efficiency, waste reduction and continuous improvement can be a daunting task because it completely changes the way most organisations think about their business.

Lean has been defined through a variety of methodologies, tools and practices that can be considered essential. Typically, companies adopt one or more of these formal practices and then conclude that they are operating in a lean fashion.

However, adopting individual elements of lean will produce isolated improvements rather than long-term results.

Given that many lean concepts originated from the Japanese culture where balance, harmony, discipline and group organisation are central themes, it is not enough to use only the vocabulary and individual elements of the lean philosophy.

Rather, it is all the elements and

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their synchronised relationship to one another that make lean most effective. And, it is the use of lean beyond one department that makes a lean initiative most effective.

Rolling out an enterprise-wide lean initiative has three essential layers: (1) the business value stream layer, (2) the business improvement layer, (3) and the business strategies and tools layer (see Figure 1).

Business Value Stream Layer The business value stream layer is aligned with Womack and Jones’ 1996 book, Lean Thinking, which outlines the five steps to achieving lean transition for enterprises.

These five steps make up the base layer that sets the tone for how the company intends to serve its customers and differentiate itself from its competitors.

It is based on the processes that meet those customer needs and expectations. Central to this initial step is to define and optimise the way a company responds to customer demand and how it adds value to ensure customer satisfaction. Within this layer, the company defines the value stream through a cycle that includes: 1. Defining value based on the customer’s viewpoint.

2. Mapping value streams for all processes serving internal and external customers.

3. Making activities flow with efficiency.

4. Responding to customer demand.

5. Continuously improving processes based on feedback.

The business value stream activities should precede the implementation of a business software system to ensure the practices are well understood and can be matched with the capabilities of a specific solution.

Value stream mapping is the process of streamlining and optimising

Figure 1: The three essential layers to a lean initiative

specific processes or activities, such as order to cash, procure to pay, attract to perform and accounting to reporting.

Once the value streams for each department are defined, continuous improvement is critical to ensure that the procedures are enhanced based on any customer, supplier and interdepartmental issues that are uncovered.

This continuous improvement activity is also called Kaizen, a J a p a n e s e t e r m re f e rr i n g to continuous, incremental improvement of an activity that seeks to eliminate waste and inefficiency.

Often, companies will implement this philosophy as a series of event-driven activities (known as a Kaizen event), which brings all owners and participants of a process together. The purpose is to conduct a formal review of the process, solicit feedback from the group, gain buy-in from team members and ultimately work toward process enhancements that can help the organisation achieve improved results.

Business Improvement Layer The business improvement layer uncovers areas of improvement and enhancement, and supports business excellence on a daily basis throughout the company.

Most companies understand how implementing a lean initiative in the production facility creates a workplace that is more organised and efficient, resulting in a safer, more productive environment for employees and promoting good business. However, that is not the only place organisations can apply lean principals to achieve their business goals.

On the supply side, companies can use lean initiatives to minimise the procurement of material, reduce time and costs, and decrease returns and quality issues. On the demand side, businesses can deliver products faster with increased quality and at lower costs – when and where customers want them.

From a lean perspective, most companies have given less attention to customer and supplier relationship management, quality assurance, accounting, and sales and marketing automation.

However, these areas provide opportunities to improve efficiency, eliminate waste and lower operational costs.

For example, many progressive a u t o m o t i v e c o m p a n i e s a re applying a lean philosophy to replenishment, collaborating more closely with suppliers to improve quality, fulfillment and customer satisfaction.

Jul-Aug 2010 metalworking equipment news

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technologyupdate

This approach provides comprehensive visibility of the supply chain and the real-time exchange of information reduces inventory so that manufacturers and suppliers can avoid premium cost through proactive exception management.

Business Strategy Layer The business strategy layer encompasses the specific applied methodologies, including business practice and software tools. It manages and monitors the business transactions such as order placement, production, fulfillment; customer service order tracking; and material receipt and inspection.

A number of strategies and tools can be applied, some dependent upon the defined production methodology and flow.

These strategies can be based on a model of engineer to order, make to order, repetitive manufacturing or a combination of several modes.

Selected strategies are also dependent upon management’s philosophy and its willingness to embrace specific business practice strategies. In addition, each strategy involves different levels of detail for reporting and tracking.

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push-based methodologies (using tools such as material requirements planning applications) must change their thought processes and job routines. Once the whole company begins to embrace the lean-pull philosophy, each department can realise significant benefits.

Each functional area can look for improvement opportunities by developing a value stream map of the typical business process flow. Ideally, the departments begin by gathering feedback from the different internal and external customers; this can be accomplished through interviews and surveys.

Achieving The ‘Ideal State’ Adopting a holistic lean philosophy across the entire enterprise is a journey rather than a destination.

It requires continual monitoring and incremental improvement within each functional department and throughout all external relationships.

Ultimately, an organisation’s ability to adopt and extend lean across its supply chain requires not only organisational discipline and top-level commitment, but also the right technology and professional services expertise.

Enquiry No. 5101

Benefits Of Getting Lean The benefits of bringing all facets of the business under the lean umbrella can be significant, and in many cases, mean the difference between thriving and going out of business. Unfortunately, many companies view lean as a last resort instead of working proactively to make the shift. When approached as a company-wide initiative spanning all internal and external constituents, the resulting customer benefits include:

• Improved on-time delivery performance.

• Reduced lead times for faster order turnaround time.

• Improved quality and reduced defects for fewer returns.

• Potential to lower pricing due to lower operational costs.

• Increased capacity to allow for increased customer order volumes.

• Satisfied customers.

• Lean and agile suppliers.

Options include: • Theory Of Constraints (TOC) • Drum Buffer Rope (DBR) • Flow manufacturing • Just-In-Time (JIT) • Simplified Market Pull (SMP) • Lean accounting

These benefits contribute to greater customer satisfaction, long-term loyalty and repeat business. On the operational side, the organisational benefits include:

Regardless of the strategies chosen, it is critical to select a production plan that can be executed by the entire organisation from the shop floor to the top floor. Some of the newer strategies, such as simplified market pull, are embraced for their simplicity and ease with which they can be adopted by an organisation.

Companies employing traditional

employee performance.

• Elimination of waste at all levels, which can reduce overall operating costs.

• Lower inventory levels.

• Improved employee satisfaction through greater empowerment, leading to improved retention.

• Improved supplier relationships, which can lead to lower purchasing costs. MEN

metalworking equipment news Jul-Aug 2010

• Increased profitability.

• Better capacity to take on new business.

• More capital to invest in new business initiatives.

• Improved employee morale and retention, leading to better

Enquiry No. 5102

takes machining next level.

WinMax Control Software W the NEto takes machining to the next level.

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Contactyour yourlocal local distributor distributor for I

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www.hurco.com.sg www.hurco.com.sg VM Series General Purpose VM Series General Purpose

VMX Series High Performance

VTX Series 5-Axis

VMX Series

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+65-6742 +65-67426177 6177 HTX Series Horizontal HTX Series

TM Series Lathes TM Series

Performance Horizontal Address: 1High Ubi View #01-175-Axis Focus One, Singapore Lathes 408555 VMX Series VTX Series HTX Series TM Series Performance 5-Axis www.hurco.com.sg Horizontal Lathes Tel: +65 6742 6177 • Fax: +65 High 6745 7664 • Website: • email: hseas@hurco.com.sg

VM Series General Purpose

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tool-related downtime. Power consumption dropped by 10 to 15 percent. Also, one Heliturn Laydown turning tool mounted in a custom toolholder eliminated a second tool, freeing up scarce turret space.

Crank It Up Productivity:

Using the right tool and approach dramatically improve crankshaft machining for a diesel engine supplier.

By Dirk Becker, turning product manager, Iscar Germany

I

n high-volume engine manufacturing, seconds saved in a single machining operation can translate to an annual savings of a million dollars, more profitability and a competitive edge in a very price-sensitive market. It is as true for a Japanese automaker as for a Brazilian off-road equipment builder.

Face-turning the support sides, or cheeks, of diesel engine crankshafts is a good case in point.

At Deutz AG Cologne, a German diesel engine supplier, though cheek surfaces do not contact any other metal part in the assembled

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engine, their dimensional accuracy directly affects dynamic balance during engine operation. Annual volume for one model of crankshaft is 25,000 units, and the company makes 10 different models.

Cycle Time Halved With retooling assisted by Iscar, cycle time for the operation was reduced by half, from 69 s to 38 s.

That was the main goal of retooling, but the story does not end here.

E d g e l i f e i n c re a s e d a n d became more predictable, thereby improving process security and virtually eliminating unscheduled

Ops Matter The operation involves facing off both the left and right-hand cheeks as the crankshaft is spun to remove about 1.2 mm from each side. The company does it on a Niles-Simmon CNC turning machine equipped with a three-jaw chuck and lunette and tailstock. Since the crankshaft is asymmetric, the surface to be machined is essentially a ‘moving target’, presenting an interrupted cut at the start of each operation, on top of all the programming issues associated with a work surface that revolves in an eccentric path.

P re v i o u s l y t h e d i f f i c u l t process required separate right and left-hand tools. Toolholders held square CNMG inserts in the conventional flat orientation.

Because of the uneven cutting loads and interrupted cuts inherent in such an operation, sudden tool failure was a constant source of unscheduled outages. That is partly why Deutz kept machining rates on the conservative side.

Turning The Other Cheek Company engineers asked the tool manufacturer for a solution for one model of crankshaft, primarily targeting cycle time.

Its remedy: Heliturn inserts in a double toolholder, enabling a single tool to complete both sides of the cheeks as well as achieving higher machining rates.

The inserts are mounted tangentially in the toolholder,

Clean Cut • Cut cycle time by > 25 percent • Reduce power consumption by up to 15 percent

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presenting their strongest cross section to the main cutting force vector. This leads to longer, more reliable edge life. As a result, now the chief failure is due to gradual wear, rather than unpredictable rupture or edge breakdown. With the sudden edge failure threat gone, machining rates could be ramped up safely.

Smooth Cut, Close Up Tangential insert orientation aside, several other features built into Helitang facing tools account for their improved performance. High positive rake angles combine with helical cutting edges to create a free cutting action. This enables increased speeds and feeds, plus greater depths of cut, while actually improving process security. The high rakes develop a cleaving-type cutting action rather than the scraping action characteristic of low-and zero-rake tools.

Helical edges reduce the cutting forces in a different way, introducing a soft cutting action much like scissors shearing paper, a little at a time. Curving the cutting edge eliminates the kind of impact forces that typically develop when a straight-edged insert smacks into a workpiece.

The top face design features smallbump chipbreakers to create uniform rib-shaped chips, plus centre-screw clamping and a smooth top surface for unimpeded chip exit.

Good Partnership The diesel engine supplier and Iscar worked together to optimise the machining parameters to balance shorter cycle times with greater process security. In the first trial with a single Heliturn insert, cycle time was reduced considerably, the operation ran cooler, spindle load diminished and edges lasted predictably longer.

So it was time to ramp up the settings and push the tool more.

They finally settled on parameters

that not only cut cycle time by more than 25 percent, but also protected the tool enough to extend edge life and improve process security. Throughout the tests and trials, they both noticed that despite the higher machining rates, the spindle load still read much lower than before.

At this stage, the metalworking tool supplier suggested a second improvement: to leverage the lower spindle loads. This involved putting a second tool into the freed-up turret space, and to machine two pairs of cheeks simultaneously.

Without the lowered cutting forces created by the Heliturn Laydown tool, this step would have been risky. They tried it and it worked,

One Up For FMR

leading to a further reduction in cycle time.

Idea Adopted The revised operation has been running 24/7 since mid-2009, producing approximately 20,000 crankshafts of a particular model.

Cycle times have been cut in half and unscheduled outages due to catastrophic tool failure are a thing of the past.

Based on that success, the company is extending the idea enterprise-wide. The 10 Deutz crankshaft styles go into engines for equipment that ranges from farm tractors and industrial equipment to railroad machinery and icebreaking tugboats. MEN Enquiry No. 5103

Fast Metal Removal (FMR) turning combines tooling ideas with total application support, leading to more profitable machining operations for the manufacturer.

There is a trend towards asking for solutions rather than ordering tools from a catalog or website.

Iscar favours this trend because it leads to better answers for the customer; sooner. In the latest move to support this trend, the tool supplier launched Iscar Tool Advisor (ITA), a parametric search engine that aids computer-aided tool and process selection.

This resource is available for free at the company’s website. The right tool for the job is selected, based on a huge knowledge base of best practices worldwide.

Enquiry No. 5104

Iscar: Improved Groove-Turn Inserts Iscar has improved its line of Cut-Grip and Heli-Grip groove-turn tools with a CVD coated substrate that doubles tool life while raising productivity by 15 percent. It performs well on steel, but handles other materials effectively as well.

The inserts are made of grade IC8250, which has proven superior to the familiar grades IC9015, IC9054 and IC9025. The Sumo Tec surface treatment improves tool performance by an average of 30 percent as it seals surface microcracks in the insert. This treatment reduces friction and built-up edge, improves cutting edge chipping resistance.

Enquiry No. 5105

Jul-Aug 2010 metalworking equipment news

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An

Intelligent

Solution For

High

Productivity

A smart and lean way of managing inventory for small parts can lead to cost savings. By Mark Mumenthaler, GM, Bossard South East Asia.

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a steners may not be everything, but almost nothing works without fa steners: electric razors, lawn mowers, tractors, trains, computers and printers – all of these products which we take for granted in our everyday lives contain fasteners. They work as well as their fasteners allow them to.

One might almost say that they are natural resources like electric power or water. If they flow erratically, production slows down, if they do not flow at all, production breaks down. The most expensive fastener or c-part is the one that is missing.

C-Parts Generally valued less than US$10 a piece, a c-part is a direct assembly item (not tool room, or maintenance part, etc) that is physically no bulkier than a box of shoes.

Widely available from a number of suppliers, it does not by itself add any particular strategic value, although the customer's finished product cannot be completed without 100 percent of all the c-parts. The complete range may 32

metalworking equipment news Jul-Aug 2010

account for up to 50 percent of all items in the bill of material.

C-Parts generally only accounts for five percent of the finished product's value, the assembly and logistic costs are far greater than the hardware itself.

The Big Picture On average a fastener itself only accounts for 15 percent of the customer’s total fastening costs.

The remaining 85 percent of the costs come from development, procurement, testing, inventories, and assembly logistics. This shows that cost efficiency is not primarily a question of the fastener; the much larger cost factor is the smart and lean way of managing the logistics.

To explain the rationale behind a customer’s decision to go towards a new way of inventory management for c-parts, it is worth looking back at the old way doing things.

Having sourced a supplier for fasteners, the purchaser would request for quotation. A customer would then decide on the quantity, and at what levels deliveries should begin. Upon receiving those individual small order quantities the parts would be checked upon

receiving before passing them on to the incoming quality control. Part would then be stored in a general warehouse before picking them again for the final assembly.

A customer uses between 50 - 300 items to assemble a certain product, and would handle in average about 120 invoices annually dealing with 5 - 15 different suppliers and make countless phone calls to follow and chase parts.

The entire process incurs huge amount of cost (people, electricity, general activities) and not to forget the inefficiency of people involved in managing such parts, which in general cost less than US$100 per lot and purchase order.

Productivity Increase & Cost Savings The automatic inventory management allows savings of up to 50 percent of the process costs and reduce the administrative part substantially.

With the system, customers do not have to issue orders or follow up on orders anymore. With the open PO concept, parts are delivered whenever a signal is triggered.

Together with the payment terms, a customer basically do not carry inventory anymore. Administration work is optimised by not entering and following up on orders anymore and by reducing invoices to be paid every month.

The overall goal is achieved by reducing the activity for the ‘small’ C-items and by putting all efforts on A- and B-items which, is a big contributor to the overall cost saving.

The system will help to reduce unnecessary trips for delivery, documents and packaging material as parts are delivered in multiusable containers. In order for this to happen, mindset needs to change followed by procedures, processes and overall administration. Mindset is the main challenge. MEN Enquiry No. 5106

ENQUIRY NO 106

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Limitless Optimisation

Of Machine Tool Performance

Open architecture THINC system provides upgradable tools to increase productivity without costly CNC overhaul. Submitted by Julie Murphy, marketing manager, Okuma America Corp

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apital investments on machine tools often come with some heavy baggage. While shortterm gains are measurable and impactful, the use of a proprietary control system may close the door for future system improvements.

The challenges of today’s aerospace industry create a need for smarter, more flexible solutions.

Open architecture control systems provide a platform for customisation and ongoing upgrades that provide users with the kind of controls they need to maximise lean performance. This keeps the door open for continuous process improvement, increasing the lifetime return on investment.

Any machine tool can cut metal, but one of the keys to improving the process is to capture and analyse the data associated with the processing and cutting. The machine control plays a critical role in being able to capture that data. A Windows-based, open architecture system provides connectivity, traceability and adaptability. This enables end users to continuously improve processes, impart management control, reduce costs and improve quality.

All machine controls allow you to operate the machine – turning, cutting, drilling or milling – whatever the machine capabilities might be. However, machine

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functionality provides only one part of the production picture.

To truly improve machine tool performance, it is essential to have the ability to control and upgrade the various inputs in order to impact the overall manufacturing or cutting capabilities of the machine.

Taking Control THINC (THe Intelligent Numerical C o n t ro l ) i s t h e a e ro s p a c e industr y’s limitless control platform that grows with emerging technology even after a machine is on the factory floor. Its PC compatible motherboard runs all aspects of the machine, including real-time motion as well as all Windows applications. Because of its single processor design, it can be swapped to remain technically current over time.

Memory can be upgraded independently by the end user, eliminating expensive memory options and providing the ability to use any preferred off-the-shelf technology. The standard PCcompatible Ethernet and multiple USB ports at the motherboard allow integration between the factor y floor and corporate communications channels, paving the way for a paperless environment and data acquisition, plus easy integration of computer and industrial peripherals.

Comparing Other Controls Conventional CNC capability is frozen in time the day the customer takes delivery. The THINC open architecture platform will grow with technology, allowing it to adapt to changing customer requirements.

Anything that runs on a Windows system can run on the platform.

Traditional CNC design is a static reflection of the customer’s needs, as perceived by a corporate development organisation. This limits growth over time. Now, an open and fluid platform can allow the end user to take advantage of new capabilities as they become available from various sources, without a costly CNC control overhaul.

Expansion of capabilities over time can be made using off-theshelf, or even custom, solutions.

The result is a control platform that provides optimisation efficiencies resulting in a competitive advantage.

True Manufacturing Solutions Require Connectivity By connecting various programs, equipment and information, layers of intelligence can be added, allowing for collection and analysis of data. This provides the tools needed to make informed decisions about process improvements.

Open architecture controls provide a link between the machine, the human and the information

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components of manufacturing.

The control enhances the ability of the machine to cut parts by interfacing, via Ethernet cable or USB connection, with peripheral equipment, accessories and information sources.

The ease of connectivity and the ability to read and process information reduces the need for redundant inputs, minimises human intervention and provides security controls.

The Need For Smarter Controls Traceability of product and processes is important in many industries for a variety of reasons: compliance with regulator y directives, product recall risk aversion, quality intelligence, or to build customer trust. Especially with government regulations in the aerospace industry (whether it be commercial aircraft or military), there is a high demand for traceability.

With the control, it is possible to trace things such as the origin of raw materials, what tool was used, which operator was running the machine, at what time the parts were made, on which machine the parts were made, etc.

Adaptability Allows Monitoring & Measurement Storing and processing data on the control (using API) provides the capability to adapt to various manufacturing environments, formats, and philosophies. Each part program may require a different level or routine of measurement, and the control can adapt to these requirements. Even if you have an FMS with multiple pallets and multiple part programs, each can be custom handled. From statistical process control to 100 percent inspection, the control will adapt.

Touch-sensitive probing is used to gauge, measure and verify key features on a part. If a part is found to be out of spec, a variety of

actions can occur: - A flag or alarm can be triggered - In pre-process situations, geometry can be identified and adjustments made to avoid damage to the tool, workholding or machine - Part rejection - Reworking of the part - Other human intervention to determine cause and resolution Adaptive Control Software monitors software and sensors within the machine to make automated, real-time decisions regarding feed rate and depth of cut. Applying predetermined parameters, the control makes adjustments such as decreasing the depth of cut when an increase in horsepower is detected, or increasing the feed rate with a decrease in horsepower. Monitoring and measurement through the control provide end users with robust, adaptable tools to reduce waste and downtime.

The Open Architecture Approach Given the challenges and demands faced by today’s aerospace industry, incremental process modifications are inadequate to produce the scale of efficiencies needed to remain viable. A seed change that shatters the traditional silo model of doing business is not only needed, it is inevitable.

Open architecture is based on a philosophy of removing the barriers, limitations and planned obsolescence imposed by proprietary control systems. It places focus on continuous improvement of control systems by allowing ongoing incorporation of best-in-class upgrades. This involves opening the door to connectivity, which has traditionally been viewed as risky.

The truth is, it allows all parties to focus resources on expanding performance continuously.

Enquiry No. 5107

Real-World Applications: 66 Percent Reduction In Cycle Time

Accurate Grinding & Manufacturing Corp in California, USA supplies shafts, carrier assemblies and housings to the aerospace industry. Okuma, along with distributor partner Gosiger, helped them analyse their processes and develop a fully automated production line that reduced cycle time by nearly 66 percent, eliminated waiting time between operations and reduced loading and unloading time.

The THINC control allowed them to connect an Okuma Captain L370MW lathe with live tooling, a Fanuc robot and a conveyor. This transformed a process that formerly involved five steps to a continuous process that can run unattended. MEN

Enquiry No. 5108

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measurement

Gantry CMM Speeds Up Cycle Time And Increases Product Output

Capital investments in large measuring equipment are a lot easier to justify when there are significant reductions in cycle times and improvements to accuracy.

By Annette Smith, marketing, Carl Zeiss IMT

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eing able to offer customers maximum product quality and fast turnaround times are some of the key competencies that are required of most manufacturers today. They are particularly important when it comes to retaining current and attracting new accounts.

This is what Dennis Ethen, key accounts manager at Tru-Stone Technologies, realised when one of his main customers approached him with higher accuracy requirements. Mr Ethen knew that the existing measuring equipment was not capable of meeting these specifications. He decided to upgrade existing technology.

Benefits Of Scanning Technology Prior to purchasing the MMZ-B gantry Coordinate Measuring

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Machine (CMM) from Carl Zeiss, the company used a cantilever CMM that provided an accuracy of 0.0005 - 0.0004 inches to measure its granite pieces. “Our customers, the semiconductor industry in particular, are demanding higher accuracies. Today, 0.0002-inch positional accuracy is not uncommon,” says Mr Ethen.

The company installed an MMZ B with Vast scanning technology and Calypso CADbased software. In addition to tighter accuracies, the machine also features a measuring volume of 2 x 4 x 1.5 m that is large enough to accommodate the oversized granite blocks. The ability to withstand environmental factors such as temperature variance and humidity allows the company to achieve reproducibility even in their challenging environment.

“This machine has two major

benefits. The sensor gives us faster scanning speeds and the software lets us create measuring plans in a short time. That’s exactly what we need to handle our current workload,” reports Mr Ethen.

“With the gantr y CMM, a measuring process now takes 45 minutes, compared to six hours before. This right here is an 80 percent reduction in measuring time. In addition, the accuracy has increased by 90 percent.”

DIFFICULTY: Existing measuring equipment are not capable of meeting rising expectations

SOLUTION: Upgrading existing measuring equipment

CONCLUSION: Some 80 percent reduction in measuring time and 90 percent increment in accuracy

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“We are using micrometers and other small measuring tools are used for all in-process measurements. The CMM is used for final inspection,” he explains.

With the gantry CMM, time taken for the measuring process has reduced from six hours to 45 minutes

Tru-Stone uses granite, porous and dense ceramics, carbon fibre and metals for their plates. Before the plates are ready for the final inspection process, the granite blocks must undergo several processes. Each incoming block is

sawed, trimmed, ground, polished, and finished. Flatness and repeat readings are critical factors. When inaccuracies are detected during final inspection, the part is sent back to the respective step where the inaccuracy occurred.

Ahead Of The Game After the gantry CMM was installed, it took about a week for two of their operators to become familiar with the software and take advantage of all its features. “The reporting capabilities in Calypso have reduced our cycle time and that means more product for the customer,“ says Mr Ethen. The company now produces around 640 jobs per month.

“The key driver for this investment was our customer,” he continues. “We knew it was time to update our equipment.

And the CMM provided us with the desired results.” MEN Enquiry No. 5201

ENQUIRY NO 060

After the gantry CMM was installed, it took about a week for two of their operators to become familiar with the software and take advantage of all its features

Jul-Aug 2010 metalworking equipment news

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Smarter Ways

To Measure Supersize Metal Objects

Laser technology innovation redefines large-scale metrology in metalworking and assembly.

By Rob Snoeijs, senior editorial writer, Nikon Metrology

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ome metal parts are simply too large in size to fit on a bridge CMM granite. Even as technology evolves away from traditional contact CMMs, largescale precision systems continue to include some element of contact.

Not so with innovative contactless laser technologies that bridge longer distances and yield better economics. iGPS is a technology that transforms an entire ship yard or aircraft assembly hall into an immense imaginary CMM, allowing parts to be measured and tracked concurrently. Another enabling solution is Laser Radar, a laser tracker lookalike offering contactless 3D measurement without requiring SMR or other handheld probes. This is why it is deployed to automate the inspection of large specimens, 38

metalworking equipment news Jul-Aug 2010

such as wings, fuselage sections, satellite parts, ship propellers and solar panels.

Supersize CMM Offering Multi-Sensor Capability 3D inspection of supersize objects like an aircraft section or cargo ship is quite challenging. Typically, manufacturers encounter issues with transportation, manpower, data capture and accuracy, not to mention operator safety or data sharing. To be able to play a role in large-scale metrology, the dimensions of CMMs are stretched to the limit.

Recently, a leading Asian aerospace manufacturer took delivery of one of the widest bridge style CMM ever manufactured in the world. The system is a gantry type CMM with a measurement volume of 6 x 6 x 3 m, deployed to run geometry verification on

large aerospace components and assemblies.

The length of the measuring volume was well within the capability of many CMM manufacturers and Nikon Metrology was able to meet the requirement for the superwide width in combination with the customer’s tight accuracy specifications.

The geometric accuracy of the supersize gantry style CMM is eight microns, which could only be achieved by using ceramic guide ways for the beam and spindle components.

Ceramic material offers stiffness combined with low weight and good thermal properties. Used in combination with double air bearings that

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Next-generation digital scanners bring laser scanning in the accuracy range of tactile measurement

prevent torsion, this ceramic CMM provides high and longlasting measurement accuracy.

The CMM’s granite rails will be positioned on a purpose built ‘U’ shaped concrete foundation in order to provide the 3 m vertical measurement range.

Laser Scanners Support Fast & Detailed Inspection Multi-sensor capability was another key decision driver for the aerospace manufacturer. Next to touch trigger and continuous contact scanning, the gantry CMM supports noncontact laser scanning with plugand-play operation of 3D digital laser scanners.

For decades, the use of traditional touch probes on CMMs has been the gold standard for component inspection and verification. Metrology system operators are charged with increasingly complex freeform part surfaces that take an exceptionally longer time to thoroughly inspect.

Quickly and accurately digitising metal freeform surfaces was the first niche application for laser scanning probes, a technology that uses a single laser. Laser scanners are fast, accurate, and can collect thousands or measurement points per second, promoting 3D laser scanners as the

preferred tool for digitising freeform shapes. They play an important role in tackling dimensional problems related to cast metal shrinkage and spring back issues of sheet metal, for example.

In metalworking and manufacturing, fast and flawless part assembly is realised through accurate placement of features that allows for a perfect fit of the product’s constituent parts.

With a multi-laser instead of a single-laser scanner, system users are able to accurately measure deep into critical features. Incorporating three lasers into a cross-pattern configuration, a so-called cross scanner simultaneously captures geometric features from all around.

The dense point cloud that is acquired represents a fully digital duplicate of the scanned part that allows the location, size and roundness of features to be extracted much more accurately.

It makes much more sense to fit features through hundreds of points, rather that relying on a handful of tactile inspection points.

Software appends feature related information to graphic part-to-CAD comparison charts, which are structured according to Geometric Dimensioning and Tolerancing (GD&T) standards.

Real-Time Tracking & Concurrent Measurement The successful use of 3D technology in working with large objects in a manufacturing environment often has less to do with measuring and more to do with the location and alignment of parts and fixtures.

As iGPS technology has been developed specifically for largescale inspection applications, it overcomes a number of the typical limitations of other metrology solutions.

Mention the term GPS to the average person and most will associate it with small earth orbiters that can provide surveillance or driving directions. However, iGPS metrology product is being used by world-class manufacturers to perform large-scale measuring and alignment tasks. The metrology product does not use satellites; instead, it works by installing infrared laser-pulse transmitters around the object to be measured.

These objects are generally large manufactured items such as parts and assemblies for aircraft, cars or ships. The sensors pick up the signals from the transmitters, and calculate angle and position based on the timing of the arriving light pulses. An amplifier converts the analog signals into digital pulses, and a receiver converts the pulses into angle data. Because the number of transmitters that can be used is practically unlimited, the size and shape of the work area can even be extended factory wide.

A Non-Contact Alternative To Laser Trackers Another powerful laser-based metrology system for large-scale inspection applications is Laser Radar. In contradiction with laser trackers, it is a system that is truly non-contact. In a nutshell, the Frequency-Modulated Coherent Laser Radar (FMCLR) instrument speeds up manufacturing, improves quality and lowers manufacturing costs.

Jul-Aug 2010 metalworking equipment news

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The Laser Radar system can be used to accurately align large reflective metal parts during assembly, or certify tooling and then monitor repeatability during production. It is equally suitable for scanning objects that were previously impossible to scan due to their size, inaccessibility or very complex geometry. The metrology system operates at the object’s location without a conditioned environment and without the need for expensive tooling.

Offset calculations are not required because measurements are taken directly from the part surface. The system – whether used indoor or outside – can operate in any lighting and on any surface with a reflectivity of one percent or more.

The system operates using a sensor to direct a focused invisible infrared laser beam to a point and coherently processes the reflected light. As the laser light travels to and from the target, it also travels through a reference path of calibrated optical fibre in an environmentally controlled module.

The two paths are combined to determine the absolute range to the point. Huge laser-modulation bandwidth (100 GHz) makes precise measurement possible in a millisecond. The distance measurement is then combined with the positions of the two precision encoders to determine a point on a surface in space.

Major manufacturers of aircraft, large automotive parts and heavy machines are integrating Laser Radar technology into their manufacturing processes because they do not want to wait until parts fail dimensional inspection to take corrective action. By embedding the technology into critical processes, they are able to eliminate scrap and increase production speed in a broad range of manufacturing areas.

Enquiry No. 5202 40

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Case Study 1: A Quick Return On Investment In LNG Tanker Assembly For about five years, iGPS is being used at a SouthKorean ship manufacturer.

For shipbuilding markets worldwide, the growing demand of energy drastically increased the demand of highvalue-added vessels, such as container vessels, crude and chemical oil carriers as well as Liquefied Natural Gas (LNG) carriers. A key characteristic of LNG tankers is that their cargos are stored around 160 deg C. Compared to container ships, for example, the demand for accurate alignment and fitting of the structure is much higher.

The first of many inspection tasks has been to assist in the layout process of a 40 m3 inner membrane tank. The inner metal lining plates are tracked in real time and can be quickly positioned according to the original CAD design data shown on the display of smart phone alike handheld device. This in itself has eliminated one shift in every six and has brought down the operational accuracy from 6 mm to around 1 mm. A significant amount of rework reduction has been achieved and scrap has also been eliminated considerably, altogether demonstrating a quick return on investment.

Where traditional metrology practices failed, iGPS is able to run 3D data acquisition and analysis under rough shipyard conditions, typically involving paint and metal particles, fumes, gases, heat and welding light. As a single system setup supports an unlimited number of sensors, shipbuilding manufacturers can easily add operators for larger or more difficult measuring and assembly jobs.

Enquiry No. 5203

Case Study 2: 20% Reduction In Fabrication Variation Within A Year A manufacturer of private jets replaced laser trackers with Laser Radar to lower the production variation across its aircraft assembly process. The production starts with parallel manufacture of aircraft cabin and empennage (tail body and surfaces). The fuselage is created by mating these two subassemblies. Later on, wings and other subassemblies are added to the fuselage. Measurements taken on metal aircraft parts and analysis of core manufacturing processes are essential in providing higher production stability.

Laser Radar is used for both inspection and diagnostics purposes. Thanks to the capabilities of the technology, the aircraft manufacturer has been able to realise 20 percent reduction in fabrication variation within a year. MEN

Enquiry No. 5204

Time for your productivity to really fly.

A successful precision machine shop is one that runs like clockwork. That’s why we don’t just sell you lubricants. Our team of engineers and sales representatives can work with you on an ongoing basis to provide the tiered support you need to help keep the machines you depend on running to their fullest potential. We don’t just make industry run, we make it fly. Visit www.mobilindustrial.com for more.

©2008 Exxon Mobil Corporation. The Mobil logotype and the Pegasus design are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.

ENQUIRY NO 108

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Form

Pressing &Bending Of Sheet Metal

Augustine Quek dissects the world of sheet metal bending.

B

ending is a process by which force is applied to metal to plastically deform the material a nd cha n ge it s shap e . T he material is stressed beyond the yield strength but below the ultimate tensile strength.

By doing so, the sheet can be bent or stretched into a variety of complex shapes, although the surface area of the material does not change much.

Occuring about one a xis, bending results in both tension and compression in the sheet metal. The outside portion of the sheet undergoes tension and stretches, while the inside portion experiences compression and shortens. The neutral axis is the boundary line inside the sheet metal, along which no tension or compression forces are present.

As a result, the length of this axis remains constant.

When bending occurs, residual 42

metalworking equipment news Jul-Aug 2010

stresses build up in the material and causes the sheet to springback.

As a result, there is a need to overbend the sheet in order to meet the requirement in terms of bend radius and bend angle.

The Machinery A press brake is typically used to perform bending. Press brakes are available in a range of sizes commonly up to 200 tonnes depending on applications.

Containing a punch and die, the press brake forces the sheet metal, which is placed between the two, to bend. The distance the punch lowers into the die is also known as the depth, which is controlled to achieve the required bend.

Standard die sets are used to produce a wide variety of shapes for many different forming jobs.

V-type dies are the most common and extensive family of punches and dies for bending. The lower

dies, with different die openings, for air bending have included angles of up to 85 degrees, while dies for bottom bending normally have a 90-degree angle.

V-type tooling can come in various material capacities and with acute-angle dies that permit forming angles as small as 30 degrees. Rotary bending dies are cylindrical in shape with an 88-degree V-notch cut along its axis. It is seated in the ‘saddle’ of the punch to act as an anvil over which the rocker bends the sheet. Other types include U-bend, box-forming, curling, corrugating, multiple-bend and rocker-type.

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The plethora of metal components in the market is testimony to the availability of sheet metal processing techniques

Roll Forming – Meeting High Tolerances In addition to direct bending, other sheet metal forming processes include roll forming, deep drawing and stretch forming. Roll forming involves a continuous process whereby the sheet metal passes through several roll stations.

The metal forming process is progressive in this case. Roll forming line consists of roller dies positioned on both side of the roll station that plastically deforms the sheet as it is forced through each roll station.

According to custompartnet, an online resource for manufacturing cost estimation, roll forming is used to create very long sheet metal parts with typical widths of 1 - 20 inches and thicknesses of 0.004 - 0.125 inche s. However w ider a nd thicker sheets can be formed, some up to 5 ft wide and 0.25 inches thick. The roll forming process is capable of producing parts with tolerances as tight as Âą0.005 inches.

Stretched To Shape Deep drawing is a form of metal pressing which stretches sheet

metal into shape. A tool pushes downward on the sheet metal, forcing it into a die cavity in the shape of the desired part. The deep drawing process requires a holder, punch, and die. Sheet metal to be formed into the part is clamped down by the holder over the die. The punch

moves downward into the blank, stretching the material into the die cavity. Tensile forces are the main driving force that plastically deform the sheet into a cup-shaped part.

Deep draw n pa r ts a re characterised by a depth equal to more than half of the diameter of the part. These parts can have cross sections with straight, tapered, circular or even curved walls. Deep drawing can also occur in steps. In each step, a punch forces the part into a different die, stretching the part to a greater depth each time.

After a part is completely drawn, the punch and blank holder can be raised and the part removed from the die.

The plethora of metal components in the market is testimony to the availability of sheet metal processing techniques.

Since demand for metal parts a nd products is unlikely to decline in the forseeable future, metal bending and pressing will continue improving.

Enquiry No. 5301

Press Brakes A closer look at what the machine can do.

An interesting press brake concept was developed by Dutch company Wila. In the Universal Press Brake Concept, the machine builder supplies the press brake with upper and lower beams that are flat, equipped solely with screw holes with which the clamping system can be attached to the beam.

Instead of a product-specific adaptation (New Standard, European Style, American Style or customised) integrated into the upper beam, the press brake builder machines a flat upper and lower beam, equipped only with (threaded) holes to which the preferred clamping system can be attached, the so called Universal Press Brake Concept. By means of keyslot fixing holes, the clamping systems can be attached to the upper and lower beams.

Using adjustment screws all along the upper beam, the clamping can be aligned in relation to the x-axis or the back gauge over the entire length of the machine.

Stringent requirements are therefore no longer needed for the straightness of the upper beam. This allows correction not only for machine deflection, but also for local deviations to the y-axis all along the machine length. Inaccuracies occurring in the course of time due to machine wear can also be corrected. MEN

Enquiry No. 5302

Jul-Aug 2010 metalworking equipment news

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A

s a manufacturer of automate d mater ia l handling and factory automation systems, Matromatic Handling Systems recognises the value of providing complete solutions. Since its inception in 1995, the company has evolved from producing conventional unit material handling systems to providing turnkey material handling solutions.

Critical to this transformation was its investment in sheet metal fabrication machinery, which has expanded its manufacturing capabilities, reduced production costs, improved productivity and streamlined operations.

Opening The Chequebook To produce the wide range of high precision components that make up a turnkey material handling system, the company uses LVD precision equipment. Initially, the company installed an Orion 3015 laser cutting system with 4 kW laser source. Twelve months later, it invested in a custom tandem press brake comprised of two Easy-Form 220 -tonnes press brakes each with 3.5 m bending capacity. The company also purchased the CADMan offline programming software.

The addition of the equipment has improved the accuracy of the component parts Matromatic fabricates and improved its lean processes.

“Our goal is to operate as lean as we can, with small batches, justin-time and minimum inventory, which presents the challenge of more changeovers and the possibility of more waste at each setup,” said MD, BK Ong. “With the LVD equipment, we have tackled these problems head on and witnessed improvements on the production floor.”

Bent On Performance The company uses the laser system to cut mild steel up to 20 44

metalworking equipment news Jul-Aug 2010

Handling Production

Efficiently

More

A CO2 laser cutting system and a tandem press brake improve productivity by 40 percent and streamline operations for a material handling systems manufacturer. By Matthew Fowles, marketing manager, LVD Group mm thick and stainless steel in thicknesses from 0.8 to 15 mm.

The laser replaced conventional gas and plasma cutting equipment that required seconda r y machining processes to achieve an acceptable finished edge. This limitation was particularly an issue when cutting parts with small holes, which required substantial processing time.

The system’s total power control feature automatically adjusts the laser power in relation to the cutting speed, ensuring an optimal cut at every contour width and minimising the heataffected zone.

As a result of the high accuracy and good edge quality achieved using the laser system, Matromatic has eliminated the need for timeconsuming secondary operations.

This in turn has helped the company reduce lead times and improve pricing on its systems.

The ta ndem pre ss bra ke configuration has also yielded improvements on the production floor. Using the Easy-Form Laser angle measurement system to produce accurate bends from the first piece, the system has eliminated the trial bending process and, in doing so, has improved productivity by 40

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Mr Ong (R) says the company’s goal is to operate as lean as possible

The company produces automated material handling systems from an 88,000 sq m facility located in Malaysia

percent. This is especially critical for the company, as much of its work is custom in nature.

“To minimise material waste, we save cut-off pieces to use in other operations,” explained manufacturing division manager, Chua Khe Yang. “Our previous press brake had a lot of trouble handling the different grain direction, hardness and thickness of these cut-off materials, so we could not achieve a correct bend angle without a second bend.”

In Control The tandem press brakes feature CADMan CNC controls which create and store interactive databases for bend allowance, angle corrections and spring-back.

These user-generated databases created by actual bending results are searched and applied each time a part program is generated.

This automatic optimisation of the part program eliminates trial bending for Matromatic, and reduces the time required to produce a quality part.

The tandem press brake allows the company to form mild steel in thicknesses up to 6 mm and

in part lengths up to 6 m. These parts are often formed using cut-off materials without the need for any corrections or adjustments.

The tandem design has proven a key advantage in producing the company’s telescopic belt conveyor, a part the company could not previously manufacture inhouse. They relied on subcontractors to form the 7,000 mm length components for the

conveyor and was often faced with inconsistent quality, long delivery times, and material waste because of trial and error bending.

This resulted in additional time and cost to rework parts, and further delays in delivery.

The company now has complete control of the bending process and is producing these oversized components faster and with greater accuracy than ever before.

The programming software has also helped reduce the time from part design to completed component. It is used to provide a bending simulation of a part design, proving the feasibility of the design before its gets to the production floor, saving the company a significant amount of processing time.

“Thanks to the software our operators have become familiar with the machines in the shortest time possible, which has helped us easily implement the new machinery,” said Mr Ong. With the use of advanced sheet metal working technology, Matromatic needs fewer operators to complete laser processing and bending operations.

Enquiry No. 5303

LVD: Mid-Range Press Brakes A line of press brakes by LVD designed as a mid-range bending solution, offers a balanced mix of performance and value for less challenging forming applications.

The PPEC press brakes, including PPEC-6 and PPEC-7 models, provide capacities from 80 tonnes, 2 m up to 220 tonnes, 4.2 m with four to seven CNC controlled axes, depending upon machine model.

Microprocessor technology is linked to servo-controlled hydraulics and electronics to ensure good control of the bending process and optimum precision. MEN

Enquiry No. 5304

Jul-Aug 2010 metalworking equipment news

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&

Comfort Efficiency In

Bending In developing countries like Vietnam, the focus on efficiency and ergonomics is just as important as any other established economies.

By Melvin Tham, product manager, bending technology, Trumpf Asia Pacific

A

t local jobshops in Hanoi, Vietnam, a popular topic of discussion related to bending processes usually involves this question: “What is your cost per bend?”

Most of the replies are: “It depends on the price of the machine.” It is not surprising to hear such a statement in many developing economies nowadays.

It is well-k nown that the prices between press brake manufacturers can vary by 50 percent or more based on identical machine specifications (same tonnage and bending length).

Jobshop owners in Vietnam have a need for more efficient machines but they believe they cannot afford to invest in expensive machinery as they think it is out of their budget.

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metalworking equipment news Jul-Aug 2010

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Most of the jobshops in Vietnam use conventional machinery and the manufacturing process takes longer to complete a product.

Wages for operators are low and therefore, it is not an issue to hire more manpower to increase output. However, it will be an issue when the production needs more machinery to fulfill the required orders. For a typical production manager from a local sheet metal jobshop, this is a familiar problem.

Reduce Your Part Cost Example: Frame • Sheet Size: 215 x 145 mm • Sheet Thickness: 1 mm • 7 bends on 2 stations Assumptions/Conditions • Lot size: 100 pieces • Programming duration: 5 minutes • Set-up time: 5 minutes • Machine cost/h: €3.13 (US$3.74) • Wage cost/h: €1.00

Get Up To Speed For example, the manager starts off with two units of second hand press brakes for his initial production setup. However, when he receives a larger order, he would have to take a step back to consider how many press brakes he needs to invest in. In most cases like this, he is only able to take on a small portion of the job due to the low productivity of his machines and in some case’s, he would lose his profit margin if he were to engage subcontractors for the job.

Sec. / Part 50

0,6

40

0,5

-39%

0,3 20

0,2

10

0,1

0

0 Part Time

Scenario A: Using Conventional Machinery If he is using low productive press brakes, his maximum capacity per hour is about 200 bends* and in 24 hours, it is 4,800 bends. If he needs to produce 2,000 boxes with four bends each per day, he requires 8,000 bends. Based on this calculation, he will need to invest in

Costs

TruBend 7xxx

Competition

€

85,000

40,000

Using duration

Years

8

8

Using hours per year (2 shifts)

H

3,400

3,400

Machine cost per h

€

3.13

1.47

Gross wage per h

€

1

1

Energy cost per h

€

0.5

1.30

Total cost per h

€

4.63

3.77

Sec

4

6

Possible no. of bends per h (at 75 percent of bending time of 1 hour)

675

450

Ergonomics factor

0.9

0.7

Real no. of bends/h

Bends

608

315

Cost/bend

€

0.008

0.012

Saving/Bend %

%

36%

New

two more press brakes in order to meet his production target.

Scenario B: Using Modern Machinery With the creation of the high speed press brake from Trumpf with a working speed of up to 25 mm/sec and an approach/return speed of 220 mm/sec, this press brake is able to achieve more than 600 bends* per hour. In a 24-hour operation, it can achieve almost 15,000 bends*.

The production need not suffer due to lack of capacity, as there are 10 surplus hours from his 24 hours operation. A 14-hour shift is possible in this case. * Calculation based on 75 percent efficiency of the time, operating on the machine.

-50%

Value

Part Cost Old

Investment

-36%

0,4

30

Calculation Of Profitability

Seconds per bend

EUR / Part 0,7

Ergonomics: The Bridge Between Man & Machine In the past, when using conventional pre ss bra ke machine s, t he operators would need to learn the bending method and get used to the bending process of that particular part. This would lead to time lost in the bending cycle. But, after a period of time, the operator would eventually reach the maximum productivity level before he again slows down due to fatigue.

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Ergonomic seating and working positions are made possible by flexible adjustable footrests and height-adjustable arm rests

Usual machines

TruBend Series 7000

Time advantage

Time per part Learning phase P1:

Working phase P 2 :

Fatigue phase P 3 :

Time per part decreases continuously, until operator gets the part individual know-how

The operator has achieved his max productivity level, L

The operator gets tired, time per part will differ

L

L* Ergonomic seating and working positions are made possible by flexible adjustable footrests and height-adjustable arm rests. In addition, non-heat LED lighting and intuitive control features are within arm’s reach to enhance the ergonomics of the machine.

Using a faster machine with enhanced ergonomics, the operator has a shorter learning curve and reduces the fatigue level. This results in an overall increase in productivity and the consistency of the parts manufactured.

Quantifying Energy Efficiency Having a high torque driven motor, it can generate up to 360 kN of force. Surprisingly, it does not consume a great deal of energy and therefore, there is a substantial saving in utilities. For a normal hydraulic press brake, the power consumption could be three times higher compared to the new high torque motor driven type.

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metalworking equipment news Jul-Aug 2010

Shorter learning time P1 because of ergonomics

Longer working period P 2 because of short learning time and less tiring

Shorter fatigue phase P 3 and fewer differing part time and quality by better ergonomics

Run of one job of n parts

Therefore, we can compute that there could be up to 60 percent savings on the usage of the machine, if the cost of utilities is the same in the operating environment. In the long run, the savings could be quite an attractive amount.

With ergonomics consideration in the design of the TruBend 7000 series machine, operators are able to work with less stress and achieve the output targets with high level of consistency.

With higher productivity, cost savings on operating this machine will reduce unnecessary investment on hydraulically driven machines. Moreover, it also reduces the electrical consumption and therefore contributes to a cheaper part cost.

Ma nufacturers who a re constantly seeking a faster part delivery schedule (time to market) and higher margins from their parts produced should seriously study these effects before their nex t machine investment.

Saving initial investment costs with lower technology capability might not be the best solution in the long run. Instead, it might hinder the ability to achieve lower part costs. The next machine that manufacturers invest in must be able to produce more parts, save costs on operations and reduce the fatigue level of the operators working on the machine. MEN Enquiry No. 5305

look closer

Do you think all measuring systems are identical? That is not true.

Look closer at SmartScope® dimensional measuring systems from Optical Gaging Products (OGP®), and you will see the difference. OGP® is the world leader in video and multisensory metrology, and our machines can measure a variety of parts with optical, laser, touch probe, and micro-sensor technology. With tens of thousands of OGP systems installed in more than 65 countries, manufacturers everywhere rely in OGP systems and trust us for expert advice and service, for innovation, for productivity, and for reliability. See for yourself how OGP® can help you solve your measurement challenges.

Optical Gaging (S) Pte Ltd www.smartscope.com.sg

21 Tannery Road, Singapore 347733 Tel: (65) 6741 8880 Fax: (65) 6741 8998

Email: sales_epl@smartscope.com.sg

Singapore • Malaysia • Thailand • Indonesia • Philippines • Vietnam • Hong Kong • Taiwan • South China • India • Australia • New Zealand

ENQUIRY NO 100

industry spotlight

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Building Towards A

Sustainable

Future

Christoph Conrad, senior VP, Building Life Cycle Management, Building Technologies, Sector Industry, Siemens tells APMEN why maximising energy efficiency in buildings is so important. By Derek Rodriguez APMEN: What are the major factors that contribute to energy wastage in buildings?

Christoph Conrad: The problem starts during the design and build phase. In most cases, life-cycle costs are not a consideration during the procurement process.

Investing in an efficient heating and lighting system right from the beginning might be more expensive. But here, we are talking about a 3-5 year ROI phase, and a reduced energy consumption of up to 40 percent, compared to using ‘normal’ heating and lighting.

The amount of energ y consumed by any equipment or system is very much dependent on its operation, and the interaction between different components within the building.

In order to make the right decisions on how to counteract the energy wastage in a building, it is 50

metalworking equipment news Jul-Aug 2010

essential to first have a full transparency of the energy flow within the building. This is the basefloor to optimise the energy efficiency in a building.

APMEN: What are some of the ways to maximise energy efficiency in buildings? Is energy efficiency more dependent on the types of instruments/lights/ products used or is it more than that?

CC: To maximise energy efficiency in buildings, it is absolutely necessary to have a building life-cycle cost consideration at the start of the building project, instead of trying to minimise the initial investment.

In addition, to reach maximum energy efficiency, it is a must to create an ongoing transparency of monitoring the building. Based on that we can decide if energy efficient equipment (eg: new lighting systems requires up to 80 percent less energy) ought to be installed, or if a total building energy management process is required.

industryspotlight

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To have a green and sustainable building concept, we need more than just green products. We can liken this to an orchestra – where the key element is not just the performance of a single musician. It is the integration and collaboration of all the musicians, guided by an excellent conductor. This is how we perceive building automation to be and why we invest a lot in the implementation of ‘total building solutions’ to optimise the building behaviour.

APMEN: How much savings, in terms of energy and money, can customers expect in employing energy efficient techniques?

CC: This depends of course on status quo, age, technical equipment of the building, and the possible investment and efficiency approach. Additional considerations are the operator qualification, user motivation and the intended energy concept.

In some cases, we have seen savings of up to 40 percent. The average value is in the range of 25 percent.

In some cases we have been able to optimise the energy consumption in a three year old building by 30 percent, just by adjusting the installed equipment.

In total we have completed more than 1,500 energy efficiency projects worldwide over the past 10 years and helped our customers achieve close to €2 billion (US$2.9 billion) in energy savings. Worldwide, we have significantly reduced energy consumption and CO2 for hospitals, schools, public facilities, multi-unit housing complexes, etc.

APMEN: Considering the cost of your services and other costs, what is the estimated time frame that customers can recoup their investment in?

CC: From an economic standpoint, it usually depends on the cost of energy from the original source such as the main power grid, coal, oil, etc. If the original cost is very high, then the economics of green technologies may be more appealing.

On the other hand, from a climate protection standpoint, using green technologies is sometimes dependent on the desire of the private sector to model a sound environmental policy versus public sector organisations that need to adhere to certain legislation or mandate to reduce the carbon footprint of their facilities.

www.wire-southeastasia.com www.tube-southeastasia.com 3rd International Wire, Cable, Tube & Pipe Trade Fairs for Southeast Asia

13 - 15 Sept 2011 Incorporating :

Industry partner :

BITEC • Bangkok Bangkok International Trade & Exhibition Centre

wire & Tube Southeast ASIA 2011 Officially supported by :

IWMA - International Wire & Machinery Association

IWCEA - International Wire & Cable Exhibitors Association • Austrian Wire and Cable Machinery Manufacturers Association (VÖDKM-AWCMA) • International Wire and Cable Exhibitors Association - France (IWCEA-France) • German Wire and Cable Machine Manufacturers Association (VDKM)

Italian Wire Machinery Manufacturers Association (ACIMAF) Industry Partner Associations :

Organized by : Supported by Messe Düsseldorf / Organizer of

ENQUIRY NO 105

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Jul-Aug 2010 metalworking equipment news

51

industryspotlight

APMEN: Is it difficult to convince someone of the need to be energy efficient, especially in Asia where customers might not be receptive to the idea?

CC: Our clients all have concerns and focus on ecological issues regardless of country of origin.

It is of course always a question of investment and payback. That is why we offer from the beginning a total life-cycle-cost consideration and see ourselves as a partner to the customer in this process.

Some countries have more strict mandates or legislation regarding CO2 emissions and energy efficiency while others provide the framework for their corporate citizens within which to operate.

APMEN: What other barriers are there in employing energy efficiency?

CC: Regardless of the economic conditions, we believe customers and the general public continue to be concerned about the environment and climate change. And in general, many businesses will weigh the economics of doing a green or energy efficiency project with the return on their investment.

But there are also many corporations committed to doing whatever is necessary to minimise their carbon footprint, reduce energy consumption, and lessen the impact to the environment. And we are convinced that today’s technical solutions available can solve the climate challenges to a large extent.

APMEN: How can large technology companies such as Siemens promote awareness for the need to save energy, not just because it makes sense economically, but also to be more environmentally conscious?

CC: Innovation is the strongest lever to increase energy efficiency and reduce greenhouse gas emissions. Many of the technologies needed are already available today.

And the best way of promotion is always to show proof that they work.

Siemens launched a ‘Green Building Initiative’ which ensures that all new Siemens buildings will consume 25 percent less energy than local standards, and reduce energy-consumption by 20 percent reduction by 2011.

The long term goal is to develop a zero-energy standard for our buildings in the future.

APMEN: Which countries will the CoC in Singapore cater to?

CC: The CoC in Singapore is an expertise hub and offers professional consulting and implementation 52

metalworking equipment news Jul-Aug 2010

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Christoph Conrad says: “To have a green and sustainable building concept, we need more than just green products.”

support for energy efficiency in buildings and gives guidance and support to local Siemens representatives dealing with energy efficiency. It is closely interlinked with all CoCs worldwide to ensure top quality for our global customers.

From the Singapore hub we will support South Korea, China, Taiwan, Australia, Hong Kong and India.

The CoC does not replace the need of a local presence in the country. The CoC will provide trainings and special know-how to guarantee and to expand this know-how in the countries it serves.

APMEN: Does opening the CoC signal an intent to get more of a foothold in the region?

CC: It is the responsibility of an innovative company like Siemens to be even more attractive to its customers in Asia Pacific due to significantly enhanced position in the field of outstanding customer support.

The CoC is a commitment of our long term investment in the field of energy expertise for buildings in Asia Pacific. It will continue to evolve and expand, in close alignment with our customer needs.

APMEN: What, in your opinion, is the energy technology that is the most promising at the moment?

CC: The future in building automation belongs to smart buildings. It will be a challenge to consider the building as an active energy component within the total concept of smart production, smart grid and smart consumer.

Growing customer demands for open, interoperable subsystems, along with widely available, high-speed information-technology networks, have fueled the transformation of the buildingautomation sector.

And in the face of the mega trends of demographic change and urbanisation, an intelligent energy management system in a building will play a very central role in the management of new and existing cities. MEN Enquiry No. 5401

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Material

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Focus

C

omposites – a multiphase material that displays properties of individual constituents materials resulting in improved application range. Artificially made, the constituent phases are chemically different and separated by an interface. As such, composites display improved combination of mechanical characteristics like toughness and strength. Most composites consist two phases – dispersed and matrix phase.

The dispersed phase is aligned differently, resulting in differences in property.

Composites are often classified into three main divisions. They are the particle reinforced, fibre reinforced and structural.

Sub-divided into large particle and dispersion strengthened composites, the dispersal phase for particle reinforced composites e x h ib i t s s i m i l a r p a r t i c l e s dimensions in all directions.

In most large particle composites, the particulate phase is harder and stiffer than the matrix. The matrix transfers some of the applied stress to the particles, which bear the fraction of the load. Improvements in mechanical properties of this type of composites depend on the strong bonding at the matrixparticle interface.

In dispersion strengthened composites, particles are much smaller and strengthening occurs on an atomic level. The small dispersed particles act as a 54

metalworking equipment news Jul-Aug 2010

EyeOn

Composites Modern technologies, particularly in the aerospace industry require an ‘all ensemble’ cast of mechanical properties that cannot be individually met by materials like metal, ceramics or plastics. By Michael E Neumann hindrance for any potential motion of dislocations on the matrix, which bears most of the applied load, leading to restriction to plastic deformation. This increases hardness and tensile strength.

material. This critical length (lc) is dependent on the fibre diameter (d) and its ultimate strength (σ*f), and on the fibre-matrix bond strength (τc) according to lc= (σ*fd)/2τc.

Fibre Reinforced Composite A s the na me sugge sts, the composite material in this case is strengthened by the presence of fibres. Fibre length in this case plays a very important role in determining the strength and stiffness of the composite material.

The mechanical property of a fibre reinforced composite is dependent on the length of the fibre, and also the degree the load is transferred to the matrix phase. It is also noteworthy to know the interfacial bond between the fibre and matrix phases dicates the extent of the load permmisible to the material.

Some critical fibre length is necessary for effective strengthing and stiffening of the composite

Glass Fibre Reinforced Polymer (GFRP) Composite Fibreglass is simply a composite material consisting of glass f ibre e it he r cont i nuou s or discontinuous within a polymer matrix. Glass is popular as a fibre as it is easily drawn into high strength fibres from molten state; readily available; relatively strong; and when coupled with various plastics, it possesses a chemical inertness that renders the composite material useful in a variety of corrosive environments.

Many fiberglass applications can be found in the automotive and marine industries where weight reduction leading to fuel efficiency is one of the main draws.

Materialfocus

Metal Matrix Composite The matrix in this case is a ductile metal. The superalloys, as well as the alloys of aluminium, magnesium, titanium, and copper are employed as matrix materials.

The reinforcement may be in the form of particulates both continuous and discontinuous fibres a nd whiskers. Fibres materials include carbon, silicon carbide and boron.

Finding applications in the automotive industry, this composite material is used in some cases to build engine components and driveshafts.

The aerospace industry also uses metal matrix composites.

Machining Composites Though composites offer good strength to weight ratio and have found applications in the aerospace industry, they are also difficult to machine. As such, tool designs are crucial and factors like point angles are important especially for drilling holes.

Delamination is also another phenomenon to look out for when drilling composite materials like Carbon Fibre Reinforced Polymers (CFRP). Fibre position in this case, is one of the points to look out for. When dealing with such specialised material, more care is required in order to pick out the correct tool for the job.

Fo r i n s t a n ce , P r e co r p’s Composite Metal Drill (CMD) is designed for hand drilling of composite metallic stacks.

The CMD has been successfully utilised in stacks containing aerospace CFR P and metals including aluminium, titanium and stainless steel.

T he dr ill come s in bot h piloted and unpiloted designs for predrilled and nonpredrilled applications. The point design allows the drill to centre itself quickly and not wander on the surface of the part. Once the drill engages in the cut, minimal force MTA 2011(S)_APMEN_Jun/July10.indd 1

In dispersion strengthened composites, strengthening occurs on an atomic level

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Materialfocus

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is required by the operator to finish the hole. When used with a handheld guide, bushing the CMD produces holes with minimal size difference between the materials in stack.

Though not exactly the easiest of material to machine, composite materials look set to stay. Judging from the rising number of tools designed to machine composite materials, the onus is very much on the machining technologies to keep up.

Enquiry No. 5501

Composite & Titanium The ‘new age’ materials have found plenty of applications in the aerospace industry.

Composites

Titanium

The physical proper ties are dependent on the direction of the applied force or load.

Titanium is often used in a form of an alloy.

Compared to metals, composites have relatively poor bearing strength.

High corrosion and fatigue resistance.

High potential to develop materials with an extremely favourable ratio between strength and weight.

High tensile strength to density ratio.

In the aerospace market, commercial aerospace market will drive the growth of composites

Composite Materials In Aerospace Market To Top $35.8 Billion By 2018 Despite the global economic downturn, significant opportunities continue to exist for composites in the global aerospace market.

According to a market study c o n d u c te d by L u c i n te l, a global management consulting and market research firm, aircraft production is expected to decline in 2009. However, composites demand is expected to grow during next 10 years due to the need for high fuel efficient, durable, and low maintenance aircraft.

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metalworking equipment news Jul-Aug 2010

In the research report entitled ‘Opportunities for Composites in the Global Aerospace Market, 20092028’, the repor t claims that the total demand for composites in commercial aerospace, regional jets, defence, general aviation, helicopter and other s e g m e nt s of a e ro s p a c e market is expected to be worth $35.8 billion during 2009 - 2018.

In the aerospace market, commercial aerospace market will drive the growth

of composites demand due to new programs such as B o e in g 787, A ir b u s 3 8 0 and Airbus 350, which has significant usage of composites. In the defence and general aviation market as well, there is increase in penetration of composite materials but still the demand for composites is less in these markets as compared to commercial aerospace market.

This study also reveals that while composite materials currently represent a relatively

Cylonka Bsg, Poland

small segment of the aerospace industry, enormous potential exists for composite materials to become a more integral component within the industry in the future. Although aluminium is currently the predominant material used in the overall aerospace industry, aerospace companies are showing increased interest i n c o m p o s i te m a te r i a l s because of a desire for more fuel-efficient and corrosiveresistant aircraft. MEN

Enquiry No. 5502

ENQUIRY NO 101

features

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Re-Arming

B-52s

Mark Holloway, Nevada, USA

The

Measurement arms are used to overhaul US Air Force B-52s.

By Dan Alred, product marketing manager, Faro and Richard Hansen, quality assurance manager, Mission Support.

M

ission Support Incorporated ha s been involved in t he co mb i n a t io n of sheet metal fabrication and modern CAD/CAM dimensioning te chnolog y for improve d pro duc t ion capabilit ie s. I n addition, they have a lso implemented real-time CA D/ CAM digital manufacturing and inspection of US Air Force legacy aircraft components.

As a depot-level overhaul service provider for both the Department of Defense (DOD) and some of the major commercial aerospace companies, Mission Support ( MSI ) has been engaged in the repair/overhaul and manufacture of aircraft subassemblies since 1990.

T he co mp a ny ove rhau l s a nd ma nufacture s a ir fra me structural components, flight controls and the associated

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metalworking equipment news Jul-Aug 2010

a c t u a t i o n s y s te m s , a e r i a l refueling, la nding gea r, a nd other flight critical components for the DOD. The Utah (USA) based company was contracted by the US Air Force to overhaul the engine bypass ducts on B-52 Stratofortress bombers.

The most difficult issue confronting the company in the performance of this contract was the lack of adequate technical data, which resulted in fit and conformance problems with the overhauled bypass ducts.

The company’s solution to this dilemma demonstrate s an intertwining of many years of sheet metal expertise with modern CAD/CAM technology.

The following article describes how the company solved several different production issues with these bypass engine ducts using FaroArms and Verisurf Digital 3D CAD software.

Difficulty:

Lack of adequate technical data

Solution:

Incorporating measurement arms and digital 3D CAD software in production

Conclusion:

Reduced production hours

Problems In The Remanufacturing Process MSI essentially remanufactures the bypass ducts of the B-52, often performing a complete disassembly/reassembly during overhaul. Most of these engine ducts have been in operation on the aircraft for over 30 years and many are misshapen, corroded, or distorted and using the original hard tooling to re-build them proved to be a non-viable option.

Even though they often have the original hard tooling and fixtures

features

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Rebuilding engine ducts have proved to be a difficult task, paving the way for the usage of CAD measuring arms

from the OEM, these tools are cumbersome and less accurate than required and the associated mylar data was incomplete. This makes it difficult to reconstruct the needed parts because the older tools lack the accuracy needed to locate the critical attach points to be within the OEM drawing tolerances.

Also, a lot of the upstream and downstream tooling originally used by the manufacturer to create these parts simply does not exist anymore. Even so, without a better alternative, this old tooling was used for years to overhaul these structures.

As the dimensioning technology utilised for inspection improved, the company found it increasingly difficult to produce conforming products using the original hard tooling – even after calibration of these tools. Increasing reports of fit problems from the field showed the need for a better solution.

As the Air Force made the determination that the B-52 was to be kept in service for three more decades, they were also requiring overhauled components to be rebuilt to much tighter tolerances. It was apparent that a better solution needed to be implemented.

Solutions: Using CAD & Measuring Arm The first step to solving these problems was to convert the existing technical data into a CAD format utilising reverse engineering. The company conducted dimensionally accurate scans of the available mylars. Utilising the FaroArm with Verisurf CAD software in ‘reverse engineering mode’, the company generated point cloud profiles of the old master moulds.

They then hand entered as

much data as was available from existing tooling drawings.

This effort produced 3D CAD solid models for all sixduct configurations. MSI then calibrated the original assembly f i x t u re s a nd sub se qu e nt l y revamped manufacturing of the ducts themselves, eventually incor p orat ing CA D/CA M technology at every level of their production process. These implementations effectively solved the fit problems for all of the critical attach points and contours that were being encountered by the Air Force in the field.

These ducts are fairly large aluminium sheet metal assemblies (typically 3’ to 5’ in size) that have a lot of inherent distortion and damage from being on the aircraft for several decades. The CAD data was initially used solely to evaluate the condition of damaged engine ducts sent from the field for overhaul, as well as to inspect the finished bypass ducts with a measuring arm.

Production continued using the hard tooling to reconstruct the ducts. However, very few of

the bypass ducts produced in this manner would pass inspection since using the hard tooling could only get them to within approximately 0.060”, while the required tolerance is +/- 0.010”.

In an effort to improve the dimensional accuracy of the placement of the piece parts reattached to the ducts, the company production personnel tried locating everything using the measuring arm. Eventually they developed a number of production techniques using the measurement arm as a ‘virtual tool’ in the production process to rebuild these engine ducts instead of the hard tooling.

Results & Advantages The results were positive once the FaroArm was used to locate all of the features, in lieu of the hard tooling. The manufacturing and inspection process of parts became more accurate. The company now uses the measurement arm for both their production and QA inspection needs. The portable CMM that can be used directly on the shop floor and provides accuracy comparable to a traditional CMM. Jul-Aug 2010 metalworking equipment news

59

Features

Since implementing this system, the dimensional conformity of the engine ducts is more consistent and they have not had one quality defect on the fit. It has been such a successful program that Mission Support was granted a sole-source supplier contract for these ducts to the Air Force.

That is not to say that the transition was completely smooth.

There was a lot of painful trial and error during the implementation process. The production department was initially reluctant to use the technology, but, once they had been trained, MSI technicians discovered that using the measuring arm to reassemble the ducts reduced the number of inspection failures and improved product quality.

Using this system, which the company developed, to rebuild the ducts makes it much easier, less time consuming, and much more accurate. This allows production to do their job in overhauling the ducts with new sheet metal components.

This process, one where the company’s veteran sheet metal technicians use the old art of sheet metal fabrication – building and shaping parts by hand – and then using Faro and Verisurf to show them in real time where all of the profiles, trim lines, and attach points are supposed to be.

It is a marriage of archaic hand fabricated sheet metal aluminium fabrication techniques and CAD/ CAM technology.

After production rebuilds the ducts, the company’s quality assurance team then inspects the ducts using the measuring arm with software. Each serialised engine duct receives a generated report for all of the critical attach points and profiles and this report is used to demonstrate their acceptance to the government QAR representative, as a final validation of its dimensional conformance.

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metalworking equipment news Jul-Aug 2010

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A successful system for the company, there had been zero quality deficiencies on these ducts since implementation. It has made the fit of each engine duct consistent and accurate within the required tolerances.

The company is so confident in this production technique using the hardware and software combi nat ion t hat t hey se e a market for using this same technique on other older legacy aircraft.

Faro was used at all stages of inspection and production – including the initial dimensional e v a luat ion , te a r dow n a nd inspection of the B-52 ducts, the reconstr uction of the components and profiling of features, to the production, and the final QA inspection. It is also used to reverse engineer many of the old legacy components where technical data may be lacking, and use the CAD data to re-manufacture new components via CNC, and to inspect the finished components prior to their use.

The proof, as they say, is in the pudding. The first article engine ducts built using this system of producing and inspecting the ducts with the measuring arm were tested on the wings of several B-52s at Barksdale Air Force Base.

It was immediately apparent that the attach points and profiles fit correctly to the aircraft. In the words of one Air Force technician at Barksdale after installing one of the first components, the new ducts ‘fit like a glove’.

Return On Investment For Mission Support, the FaroArm has improved the consistency of their product and its overall quality.

What used to take production weeks to locate and profile components on these ducts now takes days.

It is difficult to calculate precisely, but with the reduced production hours to overhaul these ducts, MSI estimates the savings could possibly be as high as US$100,000 over the life of their B-52 overhaul contract.

Enquiry No. 5601

Faro: Scan Processing Software The Scene 4.7 features efficient point cloud handling and visualisation due to the 64 bit architecture which ex tends the usable memory. The version also incorporates ‘one-click’ web-share functionality. Scanned images can now be put on the Internet, enabling companies from the architecture, engineering and law enforcement industries to share scan information with customers.

The web-share functionality is built into the software and requires no additional software to publish the scan data on the web. It will be delivered with every Faro laser scanner and current users of a 4.X version of the software will be provided with an upgrade at no cost. MEN Enquiry No. 5602

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exhibitions

Application engineers were on hand to give product demonstrations

On The Map:

Mitutoyo

Open House & Seminar 2010

O

n June 3 – 4, 2010, Mitutoyo Asia Pacific (MAP) hosted its annual MAP Open House and Seminar 2010, at Mitutoyo Building, M 3 Solution Centre.

This two-day event saw some 150 visitors. The next open house and seminar will be held in 2011.

Product Demonstrations The company’s application engineers and product sales specialists were available to demonstrate the metrology measuring machines and small tools instruments, as well as answer technical questions and help visitors solve specific product applications. Some of the products on display in the showroom were: CMMs, vision measuring machines, form measuring machines, optical instruments, hardness tester, bore gauge, u-wave and micrometers.

During the event, participants were allowed to purchase the company’s metrology equipments, which came with discount offers.

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metalworking equipment news Jul-Aug 2010

Speakers from as far as Japan were invited to give participants valuable insights to topics on metrology

Furthermore, the company’s customers were even able to purchase showroom units at discount prices.

Technical Seminars This year, MAP organised a series of seminars especially for registered participants. On the first day, two seminars, ‘CMM rapid scanning to inspection’ and ‘reverse engineering’ were organised. They were followed by ‘form measurement: geometric dimensioning and tolerancing’ and

‘basic rules of using metrology instruments’ on the second day.

The seminar speakers were specially invited from Mitutoyo Japan and Geomagic, each with their own forte and expertise.

The seminars gave the participants an opportunity to learn about some of the technology advancements in the measuring industry, as well as in-depth product demonstrations for machines in the showroom.

Enquiry No. 5701

ENQUIRY NO 053

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Event Preview:

IMTS

A

ccording to John Krisko, director – exhibitions, for IMTS, the 2010 show is on track to be the 8th largest IMTS since the show’s inception in 1927.

“We are on track to fill well over 1,000,000 net sq ft of exhibit space and host more than 1,000 exhibitors,” says Mr Krisko. “It is encouraging that the show is holding steady in these uncertain times and that there appears to be confidence in the future and importance of global manufacturing. We’re moving ahead with our planning for an event that will inspire the industry for a bright future.”

The largest IMTS ever was in the year 2000 with slightly over 1.4 million net sq ft of exhibit space used. IMTS 1986 was the first show to exceed 1,000,000 net sq ft of exhibit space.

Manufacturing professionals attend this event to see more than 15,000 new machine tools, controls, computers, software, components, systems and processes that can improve their efficiency.

“They come to the show to learn, to network and to find new resources and innovative manufacturing technology resources,” explains Mr Krisko.

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metalworking equipment news Jul-Aug 2010

Keynote Speakers For Industry Inspiration Day Renowned experts from the aerospace, medical, automotive and energy industries will present the keynote program on manufacturing innovation for the first-ever Industry Inspiration Day at IMTS on September 13, 2010.

Representing the aerospace industry will be Allan McArtor, chairman of Airbus Americas who oversees the activities and strategy for Airbus in the United States, Canada and Latin America in key areas including governmental affairs and Airbus industrial strategy in the US. Leading the discussion for the automotive sector will be Jim Tetreault, VP of North American Manufacturing for Ford Motor Company. Nationally recognised energy policy expert and CEO of the American Wind Energy Association Denise Bode will complete the panel.

The conference program, September 14 - 17, will focus on

five topic tracks featuring a wide range of industry specific sessions including: Materials Engineering (Physical Properties, What’s New, Future [R&D]) Machining Technology and Trends (General Cutting [turning, milling, etc.], Grinding, Tooling / Workholding) Alternative Manufacturing Processes (Waterjet, Laser, EDM, Welding, Fastening/ Joining) Metrology (Measuring, Testing, Inspection, 3-D Inspection, Standards) Plant Operations (Lean Manufacturing, CAD/CAM, Training/ Work Force, Government, Energy Efficiency, MTConnect)

McCormick Place Chicago, USA September 13 – 18, 2010 Enquiry No. 5702

ENQUIRY NO 099

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Event Preview:

MTA 2011

B

oosted by the steadily recovering manufacturing sector in Singapore and the region, MTA2011, the trade exhibition and business forum for the precision engineering and metalworking industries in Southeast Asia, will return from March 23 – 26, 2011, at the Singapore Expo.

Industry professionals and business visitors from Southeast Asia, India and China are expected to form the majority of the attendees.

On The Mend Confidence has returned to the manufacturing sector following strong rebounds in industry and economic performances in 2010.

Singapore’s manufacturing activity soared by 43 percent year on year

in March, the fourth consecutive month of double-digit gain.

With the China-ASEAN Free Trade Agreement (CAFTA) in place on January 1, 2010, zero-tariff madein-China products and components will enter previously sheltered markets in Southeast Asia.

Other Events Happening Concurrently The Precision Engineering Business Forum will also return to facilitate the exchange of knowledge and sharing of collaboration strategies

and partnership opportunities for the industry.

The programme is designed to gather senior executives from international manufacturing OEMs and various tiered suppliers to meet and discuss how precision engineering will drive manufacturing investments and technologies.

Singapore Expo Singapore March 23 – 26, 2011 Enquiry No. 5703

Event Preview:

JETRO Joins Metalex Vietnam 2010 companies. Amid the crisis period, Vietnam’s GDP has grown by 6.5 percent in 2010.

O

n June 10, 2010, Yoshida Sakae, MD of JETRO, Ho Chi Minh Office, Nguyen Anh Ngoc, deputy director of the Investment and Trade Promotion Centre of Ho Chi Minh City and Nichapa Yoswee, MD of Reed Tradex, attended a contract signing ceremony for JETRO to officially confirm its co-location at Metalex Vietnam 2010, to network with Japanese industrialists for machinery import reduction and urge Vietnamese SMEs to develop

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metalworking equipment news Jul-Aug 2010

higher competitiveness for Japan’s investment expansion.

“This is JETRO’s first participation in Metalex Vietnam. We are confident that Reed Tradex’s professionalism and expertise, which is wellaccepted in Vietnam, will make this trade fair a real industrial platform between buyers and sellers to meet and create wider business networks, particularly for Japanese investors to expand their businesses in Vietnam,” said Mr Sakae.

He added that Vietnam is one of the promising countries for Japanese

Foreign Participation In the event this year, several countries have confirmed their continuous participation in international pavilions.

By 2020, Vietnam will become an industrialised country with sufficient supplies of raw materials and basic fuels. Currently, Japanese are the biggest foreign investors in the country in terms of investment size, due to the advantages in low labour cost and a larger market.

Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam October 7 – 9, 2010 Enquiry No. 5704

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Event Review:

AMF 2010

T

he 5th Annual Manufacturing Forum is a manufacturing conference targeted at invited industry leaders to discuss technology issues and trends facing the manufacturing industry.

Organised by SIMTech, the forum includes an exhibition to showcase various aspects of sustainability in manufacturing from the industry and the research community.

At the event, the Workforce Skill Qualifications Graduate Diploma in Process Technology (Sustainable Manufacturing) was launched

by SIMTech and the Singapore Workforce Development Agency to provide fundamental training on sustainable manufacturing for industry.

In addition, the Singapore Environment Council (SEC) and the Singapore Institute of Manufacturing Technology (SIMTech), a research institute of the Agency for Science, Technology and Research (A*STAR) inked an agreement to launch Singapore’s and South East Asia’s first carbon label.

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metalworking equipment news Jul-Aug 2010

This is a Singapore initiative to support the country’s transition to a recognised low carbon economy by measuring and communicating the carbon content of the products and services consumed and produced.

The carbon label in quantifying and declaring the carbon content is an advancement of the Singapore Green Label.

Aim Of Carbon Label The principal aims of the Singapore Carbon Label are to differentiate Singapore products and services and provide a new, compelling source of competitive advantage to industry and the economy. A ‘Singapore solution’, the label builds on international standards and best practices, including the UK’s PAS 2050 and the draft standard ISO 14067.

The scheme partners will make available a stringent methodology and standards alongside readymade tools that will deliver both immediate impacts and longer term emissions reductions for businesses.

This will help local enterprises to boost the competitiveness of Singapore’s exports globally.

Working Together In the collaboration, SEC and its advisors are responsible for project managing the Singapore Carbon Label through concept development, launch and ongoing operations. SIMTech is responsible for the technical development of the carbon label including the development of the data analysis, methodologies and tools required for quality footprint measurements and the provision of robust emissions reduction recommendations and guidelines to industry clients.

SEC’s executive director, Howard Shaw said: “We’re delighted to be working with SIMTech to launch Singapore’s and South East Asia’s first carbon label. The label will encourage businesses to take steps to reduce the carbon content of their products and services.

It will create real opportunities for businesses to innovate, grow revenues and reduce costs.”

Dr Lim Ser Yong, executive director of SIMTech, commented: “Since 2007, SIMTech has developed core competence and tools on the methodology, related standards, and techniques for carbon footprint quantification. We have quantified carbon footprint for an increasing number of manufacturers in different sectors, signalling an increasing demand for a carbon label. The Singapore Carbon Label will enable manufacturers and users to know for the first time how much and why the products and services we produce, contribute directly to climate change, and we are able to take action to reduce carbon emission and waste in meaningful ways.”

SIMTech Auditorium Singapore May 18, 2010 Enquiry No. 5705

ENQUIRY NO 086

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Event Review:

Metaltech 2010

T

he 16th Metaltech ended on an encouraging note for the manufacturing industr y with 21,923 global visitor and buyers. With most exhibitors reporting better than expected sales and business transactions, the sales generated at the event are estimated to be well over RM700 million (US$213 million).

Both the organisers and exhibitors were pleasantly surprised with the upswing demand for machineries and tools, after a cautious business outlook in the midst of the economy recovery. The event was held from 5 - 9 May, 2010 at Putra World Trade Centre, Kuala Lumpur.

Better Than Expected Result Dato’ Jacob Dungau Sagan, deputy minister of international trade and industry commented that: “The better than expected global and domestic recovery is reflected in the response to MTA and Metaltech. These exhibitions have attracted stronger participation from industry players and resulted in a 33 percent growth in exhibition size to 30,000 sq m. The fact that 70

metalworking equipment news Jul-Aug 2010

foreign participation accounts for 55 percent of the 1,200 participating companies from 22 countries is heartening and points towards an upside economy potential.”

Albert Lai, MD of Trade-Link Exhibition Services added: “This year, exhibitors have been happy with the sales achieved at the show. We are proud to announce that the show not only raked in a substantial amount of sales but have also attracted stronger crowd of visitors comprising of owners and decision makers from the manufacturing industry.”

Exhibitors’ Voice Commenting on this year’s event, Yap Sun Heng, sales manager of Tungaloy Malaysia said: “This exhibition is a prestigious one in our field and through the event, our company was given the opportunity to be exposed to the relevant market plus getting genuine business leads. This won’t be the first and last time for Tungaloy to exhibit here, we are looking forward to coming back in 2011.”

Stella Shim, assistant sales manager of Torq-On Technologies (M) said: “Our company deals with the assembly industries and

through this exhibition we were able to promote our brand to the proper target audience and at the same time getting brand recognition. We are happy with the crowd turnout at the event.”

David Wee, assistant manager of Winsaw Engineering Supplies said: “We are pleased to be back at Metaltech 2010. It has been the platform for us to meet new customers and we have been exhibiting for at least 11 years

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Some 21,923 visitors thronged the PWTC in the five-day event

now, and through this event our company managed to expand our business.”

Held alongside MTA, Metaltech 2010 is endorsed by Malaysia External Trade Development Corporation (MATRADE) and the Global Association of the Exhibition Industry (UFI) amongst others.

The exhibition is also supported

by SME Corporation Malaysia, Malaysia’s Hardware, Machinery and Building Materials Dealers’ Association (MHMBA), Singapore Manufacturers’ Federation (SMa), Singapore Industrial Automation Association (SIAA), Small and Medium Enterprises Association (SAMENTA) and Taiwan Machine Tool Builders’ Association (TMBA), just to name a few.

The next exhibition will be held from 4 - 8 May, 2011 at PWTC. It is the event for manufacturers and metal industry players from around the world to showcase and source for metal work, machine tools, CAD / CAM, metrology, mould and die, surface and heat treatment, subcontracting, foundry, industrial automation, robotics, precision engineering and welding technology and products.

Putra World Trade Centre Kuala Lumpur, Malaysia May 5 – 9, 2010 Enquiry No. 5706 Jul-Aug 2010 metalworking equipment news

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Event Review:

MTA Malaysia 2010

H

eld from May 5 – 9, 2010 at the Putra World Trade Centre, Malaysia, MTA Malaysia was opened by Dato’ Jacob Dungau Sagan, the deputy minister of international trade and industry. Along with Metaltech 2010, some 33 percent increase in exhibition size was recorded.

MTA Malaysia 2010 and Metaltech have attracted 1,200 participating companies showcasing the latest machinery as well as equipment and tools for the manufacturing industry.

The exhibits are valued over RM350 million (US$107 million). Impressed with the show, Dato’ Jacob Dungau Sagan commended the efforts made by exhibitiors and organisers after taking an informative tour around five exhibition halls.

Putra World Trade Centre Kuala Lumpur, Malaysia May 5 – 9, 2010 Enquiry No. 5707

Exhibitors’ Voice Lenox: On A Charge Aggression according to Vincent Chai is the name of the game

Vietnam. For them, their strategy is simple – act fast. “To be number one, they must make opportunity and seize them. As for their current establishment in Singapore and Malaysia, they share our beliefs in investing in people. We have seen an increase in their manpower by 50 percent (welders, field engineers and delivery personnel),” he says.

One Stop Approach

Aggression according to Vincent Chai is the name of the game. Fronting Lenox at the recently concluded MTA Malaysia, the technical engineer, who is in charge of the Malaysia and Singapore markets speaks to

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Asia Pacific Metalworking Equipment News candidly on the company’s marketing plans and strategies for this region.

One of the countries that their distributor, Metalis, is looking at is

Although occupying a modest 18 sq ft of booth area, the booth was packed full of products, an indication of the ‘one-stop concept’. Mr Chai explains: “There are many competitors around but only a handful are specialised in cutting technology which make us a prominent

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figure in this industry. It is important for our customer to experience hassle free supports from us. It’s just like a 3-S centre, we do sales, we service, and we provide spare parts.”

In line with the concept, the company also provides optimisation services to their customers. Says Mr Chai: We are available to perform a thorough, 13-point tune-up to make sure every blade cut smoother, straighter and faster to give customer an optimised blade, good machine performance and lower costs.

Furthering The Brand One of the ways to put the brand on the market is participating in major exhibitions. Mr Chai discloses that their distributor is participating in the next MTA in Singapore and Malaysia with a 150 percent increase in their booth space. By all accounts, the concept booth will be in a prominent position.

In addition, the company’s distributor plans to streamline their logistical operations (store, delivery and stock management) in order to be more

aggressive in their push to gain a bigger piece of the market share in Malaysia.

In line with this is also an advertising campaign, which is ongoing. Finally, Mr Chai has been going to end-users, listening to their problems, anticipating customers’ needs and inventing solutions.

It is important to create awareness among users early so in the future, the Lenox brand ‘rings a bell’ at the back of every potential customer’s mind.

Enquiry No. 5708

Sumitomo Electric Hardmetal: Catching The Wave With a flexible and dynamic approach to business, Chia Yee Cheong, sales manager of Sumitomo Electric Hardmetal brings to MTA Malaysia an array of products for the metalworking community. According to Mr Chia, the event this year is “better than last year” and they have received good enquiries. Summing it up, he says: “Even on the first day, when I stepped into the hall, I could feel a buzz in the hall, which was a welcomed change.”

The much talked about ‘buzz’ can be partly attributed to the general economic situation in the region as Mr Chia explains: “Most of the industries are picking up, especially the automotive industry.

Countries like Thailand and Indonesia are also looking good.”

With the positive economic outlook in Asia Pacific, Mr Chia feels people should be prepared to “catch the wave”. Citing an example, he says: “Robust recovery is expected in ASEAN. It is also expected in Australia where the manufacturing industry was quite stagnant last year. Our Australian customers have reviewed and changed their usual business practices to adapt to the current manufacturing demands, even to the point that they are willing to take in projects that were not in their previous portfolio.”

Products At The Show Amongst the products featured at the booth this year is the Super MultiDrill GS/ HGS type. Spotting a combination super multi-layered coating consisting of two alternatively stacked layers of super multilayered coatings, Mr Chia says: “With this

According to Mr Chia, the company regularly sends their engineers to look into customer’s process and try to improve the overall performance and efficiency

combination of super multi layer coating, we could increase overall hardness.

Basically, the pertinent point here is to increase tool life. With improved hardness supplied by the new coating (DEX coating), operators can run the process at higher speeds and feeds. That in a way increases the range of the drill.”

The drill also features a ‘J’ flute design, which helps better chip control and stability. Says Mr Chia: “The wide flute pocket ensures smooth evacuation of chips created at the centre position of the drill.”

Customer Services In addition to producing tools for improving tool life and efficiency, the company also conducts technical seminars and process improvement activities for their customers.

According to Mr Chia, the company regularly sends their engineers to look into customer’s process and try to improve the overall performance and efficiency. They also conduct training sessions in their technical centre in Thailand.

“Apart from conducting seminars in our technical centre, we also have sessions at our customer’s locality. In rural parts of Australia for example, we will usually invite around 30 customers for a two-hour seminar where we will go through some general technical knowledge and also update them on the latest cutting tool technology. We usually ensure that the participants for a particular session have somewhat similar technical levels so that the pace and depth of the seminar is better appreciated,” he says.

“In general, the seminars we conduct are usually either requested by the customers or organised in partnership with our distributor as part of their main customer care program where they will have their open house or some special occasion where we will take the opportunity to provide those present with some product updates,” he adds.

Enquiry No. 5709

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Event Review:

Vietnam Manufacturing Expo

F

rom May 20 - 22, 2010, some 7,863 visitors attended Vietnam Manufacturing Expo and Nepcon Vietnam 2010 to get themselves up to date with the latest technology and industry best practices.

Deputy minister, Ministry of Industry and Trade, Nguyen Thanh Bien, chairman of the o p e n i n g c e re m o n y w a rm l y welcomed the active response and participation from domestic and overseas exhibitors to represent the latest products and technology achievements for industrial and electronics parts manufacturing industries.

Vietnam Manufacturing The buzz in Vietnamese manufacturing circle is getting stronger as the visitors caught a glimpse of the next generation of manufacturing technologies.

At the show, a comprehensive host of innovative manufacturing technologies were showcased and demonstrated by more than 400 brands from over 25 countries.

Manufacturing industrialists from across Vietnam and 20 other countries including Australia, China, Japan, South Korea, and the US, attended the events. They expressed satisfaction that they had found the new technologies and knowledge they were looking for, in the exhibitions and their special feature such as ‘Hi-Tech and Robot Zone’ as well as their seminars and technology presentations, and had established the business network their business growth needed.

Manufacturing industrialists from across Vietnam joined the forum and together discovered valuable business visions on Vietnam’s industries, especially the automotive, electronics and 74

metalworking equipment news Jul-Aug 2010

manufacturing sectors.

Also, they had the chance to upgrade their knowledge with new business strategies and to forge successful partnership with industry fellows. On the topic of ‘Bridging Partnerships. Empowering Vietnam Manufacturing Industry’, useful knowledge and visions were shared by industry gurus.

Thoughts On The Show Chanin Khaochan, director of BOI Unit for Industrial Linkage Development (BUILD), The Board of Investment of Thailand said that in the age of globalisation where challenges spring from many sources and competition allows no margin for errors. There is an

urgent need for the Vietnamese entrepreneurs to keep themselves up to date on the current market demand as well as the technologies that can help them to respond to those demands with efficiency.

As a result, high satisfactions of all participants were witnessed, which led to immediate exhibit space reservation for the future edition. This clearly reflected Vietnam’s industrial movements and active economic developments.

ICE Hanoi Hanoi, Vietnam May 20 – 22, 2010 Enquiry No. 5710

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ProductFinder

3DQuickPress: Die Design Software

Delcam: FeatureCAM Certified For Autodesk Inventor 2011

3DQuickPress is a SolidWorks add-on for progressive die design. With a 3D solid model of the part, a 3D strip can be created and also be communicated throughout the work group using the SolidWorks eDrawings viewer before further detailing of the die without time wasted.

Powerful Unfold, a feature recognition technology, can handle native SolidWorks sheet metal parts for imported data, and provide a knowledge base for spring back and bend allowance. Form features can save valuable time from die designs and give them more design productivity tasks.

Delcam’s range of feature-based CAM software products has been certified by the Autodesk Inventor Certified Application Program for Autodesk Inventor 2011 mechanical design and engineering software.

This program certifies that the software applications have been tested by Autodesk engineers to ensure that they meet the highest standards set for robustness, quality and interoperability with the latest version of Inventor, the industry’s digital prototyping software that enables engineers to design, visualise and simulate products before they are built.

Enquiry No. 5801

Enquiry No. 5803

Bossard: Inventory Management System

Haas: High-Speed Turning Centre

Bossard has developed a f u lly automate d system for managing and controlling fastener inventor y on the manufacturing floor.

SmartBin increases the effectiveness of stock management as compared with the long-term provincial methods that exist today. The products will literally order themselves and initiate the necessary processes, so replenishment shipments will automatically be delivered.

The supply cycle is improved and leveraged with an easier, faster, and of course, more economical and reliable logistics solution.

Haas Automation’s ST-20ss turning centre is equipped with a 24 -station hybrid BOT/VDI turret that indexes tools in 0.5 second. The machine provides a maximum cutting capacity of 10” x 20.5”, with maximum swings of 31.75” over the front apron and 20.75” over the cross slide.

Standard equipment on the machine includes rigid tapping, a 15” color LCD monitor and a USB port. Other available equipment includes a belt-type chip conveyor, hydraulic tailstock, automatic tool probe, live tooling with C axis, an automatic parts catcher and highpressure coolant systems.

Enquiry No. 5802

Enquiry No. 5804 Jul-Aug 2010 metalworking equipment news

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Hankook: CNC Vertical Lathe

Lap: Laser-Based Thickness Gauges

Hankook has developed the VTC-40/50E. This CNC vertical lathe consists of a 4 m table diameter, 5 m maximum turning diameter, 3 m turning height and allows a 50 tonnes maximum table load.

The vertical lathe is optimised to cut windmill parts, ship-building parts, industrial valves and plant parts.

This model was made by the company’s very own inhouse technology.

Lap has developed a generation of laser-based thickness gauges, representing a cost-efficient alternative to radiometric systems. Comprehensive tests have shown that the Calix sensors reach a measuring accuracy of +/- 4 µm and a repetition accuracy of +/- 0.4 µm (2 σ) over the complete measurement range of 0.02 - 30 mm.

Measurements with the systems are independent of the strip properties. Therefore it is not necessary to input any chemistry and density data for the strip or store such information in a database, as required by radiometric methods. This feature prevents any hidden, material-inherent error propagation due to material inhomogeneities in the strip material.

Enquiry No. 5805

Enquiry No. 5807

Kennametal: Economical Coolant Control

Leica: Portable Inspection System

Kennametal’s Beyond Blast allows a meeting of coolant through the insert, at the interface of the milling cutter and insert.

Traditional flood coolant jets are aimed at the cut and often hit behind the cutting zone, and custom highpressure solutions (1,000 psi or higher), can cost tens of thousands of dollars to install and maintain. With Beyond Blast, coolant hits as close to where the tool meets the workpiece as possible, ensuring efficient coolant delivery, heat transfer, and lubricity.

The Leica TDRA6000 Laser Station is a portable insp e ct ion system designed for precision measurements on large structures. It has an operational volume of 600 m measuring 3D coordinates both with standard reflectors, and non-contact (reflectorless).

The direct drive technology has been designed from the ground up for this sensor. Based on piezo technology, these direct drives enable high speed motorisation and acceleration, at up to 4x the previous generation, but still allow sub micron level fine positioning. This piezo technology has low power consumption and because there are no gears, the drives require almost no maintenance, and are near silent.

Enquiry No. 5806

Enquiry No. 5808

metalworking equipment news Jul-Aug 2010

productfinder

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Mitsui Seiki: 5-Axis Horizontal Machining Centre

Renishaw: Five-Axis Head For Touch-Trigger Inspection

To satisfy new aircraft and power generation production needs, Mitsui Seiki has released several 4- and 5-axis machining centres.

Features and specifications for their 5-axis horizontal machining centres include up to 2,500 mm work diameter capacity, 3 tonnes work / fixture weight capacity, variety of increased axis stroke options, larger pallet sizes (1,200 mm square, 1,200 x 1,500, 1,900mm diameter) and high torque spindles (2,700 Nm – 1,990 lb-ft continuous). In addition, it includes tuned structure for heavy cutting in hard metals and a large capacity FMS systems.

Utilising technology developed for the Revo measurement system, the Renishaw PH20 probe head offers ‘head touches’ for rapid touch-trigger measurement, and fast infinite 5-axis positioning to allow feature access. Its compact design makes it suitable for new CMM purchases and as a retrofit to the vast majority of existing CMM touch-trigger installations.

The probe head also benefits CMM users with adaptive positioning to accommodate part misalignment, fast calibration routines, and TP20 probe mount that optimises the working volume of the CMM, bringing 5-axis capability to smaller machines for the first time.

Enquiry No. 5809

Enquiry No. 5811

Mitutoyo: Portable Surface Roughness Tester

Sunnen: Servo Honing System

Small, lightweight, and easy to use – Mitutoyo’s portable surface roughness tester, Surftest SJ-210, allows view surface roughness waveforms on the 2.4-inch LCD colour display. It even comes with backlight support for improved visibility in dark environments.

Other features include: internal and/or external data storage capabilities, extensive display features, stylus alarm function, multilingual display interface supporting up to 16 languages and passwordprotected function.

The tester is also capable of performing measurements in any orientation, including vertical and upside-down.

Custom bore profiles for diesel cylinder liners are among the capabilitie s introduced on the SV-500 series vertical CNC honing system.

The series by Sunnen produces accuracy and surface finish specs, using technology that allows creation of whole-bore, constant crosshatch, as well as custom profiled or tapered bores.

The machine is suitable for profile machining of diesel cylinder-liner bores to manufacturer’s specs, while eliminating the ‘flattening’ of the crosshatch angle at stroke-reversal points, sometimes required for MilSpec parts.

Enquiry No. 5810

Enquiry No. 5812 Jul-Aug 2010 metalworking equipment news

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Tornos: Multi Spindle Automatic Lathe

Walter: High Performance Mill

With MultiSigma 8x24, Tornos offers a solution to produce complex parts in one set up. Eight independent spindles provide flexibility whilst an integrated robot allows the unloading of parts into a pallet.

The TB-Deco programming software offers comfort in programming. Combined with an array of options such as up to eight independent frontal units, y-axis, multiple tool holder, PC control and remote diagnostics, the automatic lathe is the machine of choice for highly demanding parts.

It comes in various configurations such as working from bar or from a blank, single cycle or double cycle, one or two pick-up units, with or without robot or palletising.

The features of F4030

by Wa lter a re its Trigon indexable inserts made of the highperformance cutting material Tigertec Silver, grade designation WKP35S. The negative, double-sided indexable inserts are stable. A rake angle of 20 degrees, however, ensures a positive overall geometry and, at the same time, the features typical of the Xtratec range such as a soft cutting action and a reduction in machine power.

Due to the solid design of the tool body, the tendency towards vibration is reduced to a minimum. This improves the tool’s process reliability, even where long projection lengths are involved.

Enquiry No. 5813

Enquiry No. 5815

Trumpf: Industrial Grade Diode Lasers

Widia: High-Performance Taps

Trumpf has expanded its TruDiode Series. These diode lasers are now available with output power of 800, 1,000, 2,000 and 3,000 watts for welding, brazing, hardening and heat treatment. These industrial grade diode lasers possess a beam quality comparable to that of lamp-pumped lasers – even at high output power – all at significantly lower operating costs.

In a three-shift operation, the variable costs can be up to 95 percent lower. The reason for this is the high wall plug efficiency of the diode laser, which can reach up to 40 percent.

Widia GTD HSS-E powder-metal taps represent the combination of grade, geometries, and coatings for accomplishing precision tapping applications in steel and stainless steel materials. The powder-metal substrate contains higher than standard levels of cobalt content for a combination of greater heat resistance and improved tool life.

Choices include 15-degree left-hand helix for pushing chips ahead in tapping through holes or 45-degree righthand helix for retracting chips from blind holes.

Enquiry No. 5814

Enquiry No. 5816

metalworking equipment news Jul-Aug 2010

Exhibition 2010/2011 Programmes July

6–9 MTA Vietnam 2010

21 – 24 Wire & Tube China

9 – 13 CIIF

15 – 18 Eastpo 2010

22 – 25 Linkage Metalworking 2010

24 – 27 Metalex Thailand 2010

October

December

Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam events@sesallworld.com www.mtavietnam.com

Shanghai New International Expo Centre Shanghai, China Eastpo International Expo eastpo.net@gmail.com en.eastpo.net

August

4-7 Taipei International Mold & Die Industry Fair Nangang Exhibition Hall Taipei, Taiwan Chan Chao International ken@chanchao.com.tw www.odm-dmi.com

September 13 – 17 IMT 2010

Exhibition Centre Brno Brno, Czech Republic Veletrhy Brno imt@bvv.cz www.bvv.cz

13 – 18 IMTS

McCormick Place Chicago, USA AMT AMT@AMTonline.org www.imts.com

15 - 17 Asiamold

Poly World Trade Centre Expo Guangzhou, China Messe Frankfurt tracey.robertson@hongkong.messefrankfurt.com www.asiamold.de

Shanghai New International Expo Center Shanghai, China Messe Dusseldorf China shanghai@mdc.com.cn www.tubechina.net

SECC Ho Chi Minh City, Vietnam Chan Chao machine@chanchao.com.tw www.linkage-vn.com

7–9 Metalex Vietnam

Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam Reed Tradex metalexvietnam@reedtradex.co.th www.metalexvietnam.com

26 – 30 EuroBlech 2010 Hanover, Germany Mack Brooks Exhibitions info@euroblech.com www.euroblech.com

28 – Nov 2 JIMTOF 2010

Tokyo Big Sight Tokyo, Japan JMTBA jimtof@tokyo-bigsight.co.jp www.jimtof.org

Shanghai New International Expo Centre Shanghai, China National Development and Reform Commission ciif@shanghaiexpogroup.com www.ciif-expo.com

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

1-4 Machine Tool Indonesia 2010 Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo info@pamerindo.com www.manufacturingindonesia.com

2011 March 23 – 26 MTA 2011

Singapore Expo Singapore Singapore Exhibition Services mta@sesallworld.com www.mta-asia.com

November 3–7 TMTS 2010

ShuiNan Economic & Trade Park Taichung, Taiwan Taiwan Machine Tool & Accessory Builders' Association ricky@tmba.org.tw www.tmts.tw

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Manufacturers and advertisers that are featured in this issue will send you free information about their products and services. Fill up the Product Enquiry Form on-line at www.equipment-news.com.

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ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing,Automation & Quality Control

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