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www.equipment-news.com M.I.C.A. (P) No. 053/06/2011

Mould & Die Industry

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Surface

Technologies:

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Hard Truth The

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Milling Milling MillingDown Down DownProduction Production ProductionCosts Costs Costswith with with Winning Winning WinningCombinations Combinations Combinationsfor for forOptimal Optimal OptimalProductivity Productivity Productivity For For For more more more information, information, information, view view view this this this interactive interactive interactive ad ad ad atatat www.iscar.com www.iscar.com www.iscar.com

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ENQUIRY NO 113 SINO SINO SINO TOOLING TOOLING TOOLING SYSTEM SYSTEM SYSTEM BlkBlk 502, Blk 502, 502, Jurong Jurong Jurong West West West Ave Ave Ave 1 #03-813 1 #03-813 1 #03-813 Singapore Singapore Singapore 640502 640502 640502 TelTelTel + +65+65 6566 65 6566 6566 7668 7668 7668 Fax Fax Fax + +65+65 6567 65 6567 6567 7336 7336 7336 sinotool@singnet.com.sg sinotool@singnet.com.sg sinotool@singnet.com.sg

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www.secotools.com

ENQUIRY NO 001

July-August 2011

M.I.C.A. (P) No. 053/06/2011

Mould & Die Industry

On The Up a MMADA exclusive

Cover credit: Seco Tools

First Cut

Surface

Technologies:

What’s underneath it all?

Hard Truth The

M.I.C.A. (P) No. 053/06/2011 • PPS 840/09/2011 (020177) • ISSN 0129 5519

30

Eye On South Korea

www.equipment-news.com

VOL. 25 NO. 5 JULY-AUGUST 2011

July-August 2011

ASIA PACIFIC METALWORKING EQUIPMENT NEWS

Contents

The Future Of MRO In Singapore

On Machining

Coming To You In Oct 2011:

New Language, New Reach MEN Goes Bahasa Indonesia!

Like Us!

APMEN is now on

Facebook

FC JulAug11-1.indd 2

6/29/11 5:36 PM

HSM Tool Paths Benefit Die & Mould Manufacturing A path previously less taken, high-speed machining tool paths in CAM are touted by some to produce better accuracy and surface finish. By Mickey Berman, SolidCAM

32 Strong Spindle Connections Key To HighPerformance Machining

High-performance machining is commonly characterised by the use of high feeds and aggressive depths of cut. As such, tool-spindle interface must withstand high loads and yet maintain its rigidity. By Keith Wiggins, Kennametal

natep182, USA

34 The Hard Truth

On Solid Carbide End Mill Systems

It is important to recognise that solid carbide milling cutters today are available as a highly evolved and comprehensive range of tools for performance machining.

By Gisbert Roth, Seco Tools

Technology Insights 38 Beneath The Surface

Laser Surface Melting (LSM), can increase the wear and corrosion resistance of Mg alloys through increasing the concentration of Al and refining the microstructure in the laser-melted zone. By Dr Zheng Hongyu, SIMTech, Prof Zhou Wei, Guan Ying Chun, NTU and Dr Li Zhongli

42 More Than Scratching The Surface

Speaking to Asia Pacific Metalworking Equipment News at the recent PE COI Annual Conference, Peter Collier, lead, surface finishing initiative, PE COI (Precision Engineering Centre of Innovation), SIMTech shed some light on the field of surface finishing. By Joson Ng

Software & Metrology 44 A New Wave Of Advanced Metrology

Non-contact metrological instruments such as laser, radio wave and white light set the trend for measuring variables and eliminating user interaction. By Natalia Tee

Fab & Form

48 Integrated Sheet Metalworking Streamlines Fabricating Operations

Integrated sheet metalworking allows programming efficiency, reduces time from concept to production and actually improves the accuracy of production parts.

By Matthew Fowles, LVD Company 2

metalworking equipment news Jul-Aug 2011

Best choice.

Local expertise now in Vietnam.

Laser | Bending | Waterjet bystronic.vn

SECC HO CHI MINH CITY 5 - 8 July 2011 BOOHT NO.

AD4 - 01

ENQUIRY NO 117

Contents

July-August 2011

50

Industry Focus

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

At the recent MTA Malaysia, Asia Pacific Metalworking Equipment News (APMEN) sat down with the president of Malaysia Mould and Die Association (MMADA) Albert Cheng, and Chew Cheong Loong, the association’s head of public relation in an exclusive interview to gain a valuable insight into its industry.

By Joson Ng

SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/ Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: irenetow@epl.com.sg

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52 Korean Manufacturers

JOINT ADVERTISING DISCOUNT WMEM, 30,000 copies circulated quarterly in China combines with M.E.N, 10,000 copies circulated bi-monthly in ASEAN in joint advertising. Ask for more details now.

APMEN takes a look at the South Korean manufacturing industry. By Michael E Neumann

Features 54 CAM To The Rescue

56 MRO On The Dot

Singapore is widely considered to be one of the MRO hubs in Asia. Asia Pacific Metalworking Equipment News finds out why and also takes a look at what lies ahead. By Joson Ng

INDUSTRY Endorsements

Tinkerbrad, Greenville, Mississippi

Using CAM systems improve productivity and forge better working relationship. By Richard Mortimer, for GibbsCAM

SPETA

Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA)

Federation of Malaysian Foundry & Engineering Industry Associations

60 Modern Rapid Prototyping: The Need For Speed

Indian Machine Tool Manufacturing Association (IMTMA)

The fast and furious nature of manufacturing today has pushed developments in prototyping to match the R&D efforts of their counterparts in machine tools. By Gilad Gans, Objet Geometries

China Machine Tool & Tool Builders' Association (CMTBA)

62 Events & Exhibition • Event Preview: Wire Southeast Asia/Tube Southeast Asia 2011 • Event Preview: Vietnam Manufacturing Expo • Event Preview: Metalex Vietnam 2011 • Event Review: MTA Malaysia 2011 • Event Review: Metaltech 2011 • Event Review: Intermach 2011 • Event Review: Manufacturing Surabaya

Regulars 8 75

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79 Exhibition Programmes 80A Product Enquiry Card

Machine Tool Club (MTC)

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For Advertiser's Enquiry Numbers

ENQUIRY NO 111

editor’s note

Published by:

A

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

Matter Of

Reg No: 199908196C

managing director Kenneth Tan editor Joson Ng

Face

Preserving ‘face’ is a sensitive and important issue especially in Asia. In a traditional sense, doing business in Asia sometimes entail giving ‘face’ to customers and a lot of times, much effort was made in order to avoid losing ‘face’. Some may say this issue is only skin deep but in metalworking, such issues have farreaching consequences that affect mechanical properties.

In surface technologies of metallic material, which sometimes can go into microscopic levels, much is dependent on ‘what lies beneath’. For example, laser surface melting can increase the wear and corrosion resistant of magnesium alloys through increasing the concentration of aluminium content and achieving microstructure refinement in the laser-melted zone.

The seemingly minute actions along the cell boundaries has big consequence as magnesium alloys have been increasingly used in the automobile, communication and aerospace industries owing to their many attractive properties, such as low density, high specific strength, and good castability.

metalworking equipment news Jul-Aug 2011

randyteo@epl.com.sg

assistant sales manager Kimberly Tian

kimberlytian@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg

Elsewhere, away from the technical domain, the business aspect of metalworking is image-conscious as well, adding to the notion of ‘putting the best face forward’. For instance, even in established industry like mould and die manufacturing, packaging is necessary and marketing is a key enabler.

The Malaysia Mould and Die Association has come up with a sleuth of initiatives to elevate the status of the industry. Some of the ideas include taking part in international exhibition as a group to attract foreign investments and certifying qualified workers who do not have academic qualifications.

In this issue of Asia Pacific Metalworking Equipment News, we also explore the topic of high-speed machining where surface treatment technology like coating plays a big role in wear resistance and the performance of solid carbide cutting tools.

Finally, we have launched our facebook page. This page will provide company and product news in and around the metalworking world. Feel free to visit us and do not forget to ‘like’ us.

Joson Ng Editor

6

josonng@epl.com.sg

business development manager Randy Teo

graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow

irenetow@epl.com.sg

contributors Mickey Berman Keith Wiggins Gisbert Roth Dr Zheng Hongyu Guan Ying Chun Prof Zhou Wei Dr Li Zhongli Natalia Tee Matthew Fowles Michael E Neumann Richard Mortimer Gilad Gans board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher.

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

Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 053/06/2011 PPS 840/09/2011 (020177) ISSN 0129/5519

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ENQUIRY NO 168

Expect more.

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Experience the new Walter.

Businessnews Thailand’s Exhibitions Industry Opens The Door To ASEAN

Singapore: The Thailand Convention & E x hibition Bureau (TCEB), in collaboration with the Singapore Business Federation (SBF), organised a business symposium entitled ‘Opp or tu nit ie s in F ive Key Business Sectors in Thailand’.

The function a ims to enhance awareness of business opportunities in Thailand and open the door to the ASEAN market through the country’s key industrial sectors.

Speaking at the symposium, Akapol Sorasuchart, president of the TCEB, said: “Last year,

the Better the Best campaign successfully brought in more than US$2,281 million in economic value into Thailand through business ne got iat ion s conclude d by participants of the events.”

“Singapore is considered a key market for Thailand’s MICE industry. Thailand has welcomed a significant number of Singaporean MICE visitors over the past five yea rs. Singaporea n v isitors represent around 10 percent of the total MICE visitors from Asia every year, and the number is expected to grow by a substantial 31 percent in 2011,” added Mr Akapol.

www.equipment-news.com

Supawan Teerarat, director of exhibitions at TCEB, told the symposium delegates that: “We are present here today to offer business opportunities through five international trade fairs of Thailand — Bangkok International Gift Fair & Bangkok International Houseware (BIG + BIH), Metalex, Propak Asia, Renewable Energy Asia, and VIV Asia — to business visitors in Singapore.”

“A l l f ive e ve nt s a re t he gateways to trade and investment in each industry. The events not only urge the economy of the country to grow in successive and sustainable ways, but TCEB also believes that the campaign will add a growth of 15 - 20 percent to Thailand’s MICE industry.

The number of foreign buyers, ex hibitors a nd v isitors into Thailand is expected to total 27,181 people, which is expected to generate revenues of more than US$74.3 million,” concluded Mr Akapol.

A cco rd i n g to t h e l a te s t statistics compiled by UFI, the exhibitions industry of Thailand continues to lead rivals in ASEAN with a total value of 10,508 million Baht (US$346 million) gained through 75 events.

Furthermore, Thailand has maintained its leadership in the exhibitions industry of ASEAN in other aspects, such as exhibition space totaling up to 466,500 sq m each year, as well as having eight exhibition venues which are recognised by UFI.

Schaeffler Group To Invest In Asia Shanghai, China: The Schaeffler Group will invest around €300 million (US$430 million) in Asia during the next few years in order to systematically further develop its existing operations here. The objective of the investment is to gear the group’s products and 8

metalworking equipment news Jul-Aug 2011

services towards the increasing demand from its Asia Pacific customers.

Inline with their objectives, the group launched its first Innovation Days in Shanghai, attracting 230 key Industrial customers from China, India, South Korea,

Japan, Southeast Asia and the Pacific. The event brought the group’s engineering experts from Germany and from the region to address technology intensive trends such as CO2 reduction, renewable energies, mechatronics and e-mobility.

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Represented by: Sutton Tools Singapore Pte Ltd No. 1, Ubi View #03-18 Focus One Singapore 408555 Tel: +65 6745-6388 • Fax: +65 6745-5080 E mail: suttontools.sg@sutton.com.au

Engineering Innovation Co.,Ltd. 3/279 Moo 9 Suvintawong Rd. Lumpakchee Nongchok Bangkok 10530, Thailand Tel: 662-9984045; 662-5435734 • Fax: 662-9984047 E mail: enginno@truemail.co.th

enginno.service@gmail.com

CBN Engineering Sdn. Bhd. No, 20 Jalan 51/205 Highway Centre, 46050, Petaling Jaya Selangor Darul Ehsan, Malaysia Tel: 60-3-77852333 • Fax: 60-3-77883318 E mail: engineering@cbn.com.my

PT. Rukun Sejahtera Teknik Komplek Ruko Glodok Jaya No. 80-81 Jl. Hayam Wuruk Jakarta 11180, Indonesia Tel: 021-628 1615 (Hunting) • Fax: 021-626 5559 E mail: marketing@abrasive-tools.com www.rsttools.com

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Bon Industrial Sales 35 Macopa St., Quezon City, Philippines Tel: 781-2740; 749-3672; 740-0458 • Fax: 712-4771 E mail: bonind@skyinet.net Manila Branch: 554 Rizal Ave., Cor. Raon St. Sta. Cruz, Manila, Philippines Tel: 734-2740; 733-1532 • Fax: 733-1534; 733-1569

ENQUIRY NO 122

businessnews

Walter In Sponsorship For ‘Winnie’ The Tigress

Tübingen, Germany: Walter Singapore has taken on sponsorship for a white tiger and raised money for their new protégée by doing a 6.2 km long charity run.

With this donation, the Singapore Zoo can finance Winnie’s keep and offer its roughly 1.6 million annual visitors an education in matters concerning tigers. The goal is to make people aware of the dramatic situation they are confronted with in the wild: The largest feline predator in the world is in acute danger of extinction both from poaching and clearing of forests.

Walter feels a special affinity with the tiger. Among other things, it has given its name to the high-performance cutting material Tiger·tec Silver, launched onto the market by the company in 2009. The company has been involved in the preservation of big cats for many years, and along with the support given to Singapore Zoo, also provides support to WWF species protection projects.

The number of tigers living in the wild in the last 12 years has drastically decreased by 70 percent. At the end of the 90s, there were around 1,200 tigers living in Southeast Asia according to estimates of the environmental organisation World Wide Fund for Nature, but today only about 350 are left.

10

metalworking equipment news Jul-Aug 2011

www.equipment-news.com

Alcoa & CDB Signed MoU For Aluminium Projects Beijing, China: Alcoa and the China Development Bank (CDB) have signed a Memorandum of Understanding ( MoU ) to collaborate on an array of aluminium and related projects both in China and abroad, focusing on Alcoa partnering with Chinese companies on global expansion projects and developing China’s domestic aluminium industry.

The agreement was signed in Beijing by Alcoa chairman and CEO Klaus Kleinfeld and CDB governor Jiang Chaoliang.

“This is an important step in expanding Alcoa’s cooperation with Chinese partners and it creates an opportunity for the company’s growth around the world,” Mr Kleinfeld said. “CDB is China’s leading development ba n k , a nd ou r pa r t nersh ip will be mutually beneficial to Alcoa and Chinese partners.

Alcoa’s extensive experience and global network combined with CDB’s financing capacity and knowledge will strengthen all parties involved.”

Mr Jia ng added: “CDB is dedicated to producing viable o p p o r t u n it i e s fo r C h i n e s e companies to expand abroad and increasing their growth capability at home. This MOU with Alcoa is an important landmark that will help further these goals.”

The MOU will support the company’s expansion around the world through knowledge sharing and potential financing support on appropriate projects. The two organisations will work together to identify potential partners and projects in and outside China.

Further, CDB will prioritise the company’s projects in China and the two organisations will engage in professional training for each other’s staff.

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ENQUIRY NO 107

businessnews

Hurco Southeast Asia Appoints Distributors In Asia

Singapore: Hurco has selected DKSH’s Technology Business Unit to be the exclusive representative of the company’s range of products in Taiwan and Vietnam. DKSH is a full-service distributor with sales, applications, and service divisions to assist customers. “ H u rco i s co m m it te d to strengthening our channels in Asia and I am confident DKSH will help us achieve our goals,” said John Donlon, executive VP of Worldwide Sales and Service for Hurco Companies.

The compa ny ha s a lso expanded its representation in Thailand. In addition to Feining Tools, the current distributor that has been representing Hurco since 1998, the company has given DKSH Thailand a non-exclusive arrangement in that country.

www.equipment-news.com

Delcam Launches Multi-Lingual CAM Learning Zone

Birmingham, UK: Delcam has launched a multi-lingual learning zone for the 2011 version of its PowerM IL L CA M system for five -a xis and high-speed machining. This includes full deta ils on the new relea se, including ‘What’s-New’ videos from application engineers and customer testimonials.

The languages included on the learning zone reflect the

range of languages in which PowerMill is available. These are English, French, German, Italian, Portuguese, Spanish, Chinese, Korea n, Japa ne se, Russia n, Polish and Czech. The site also includes links to the company’s international reseller network so that visitors can contact their local representative for further information or to request an evaluation copy.

SolidWorks Living Lab To Be Set Up At ITE College Singapore: A SolidWorks Living Lab (the Lab) will be set up at the Institute of Technical Education (ITE). The four-year partnership was signed between SolidWorks Authorised Reseller 3D ClassWorks (3DCW) and ITE Singapore. The partnership signals the creation of a one-stop resource centre that will cater to the needs of ITE students, staff and industry professionals.

The signing of the partnership marks a leap forward for Dassault Systèmes (DS) SolidWorks into Singapore’s education sector. Its Computer Aided Design (CAD) software offers the 3D CAD technologies for design, simulation, and engineering analysis which support 87 percent of the world’s top technical institutions in academic degree programs, advanced research centres and engineering outreach programs.

Ken Clayton, VP worldwide sales, DS SolidWorks commented: “SolidWorks skills prepare students to achieve their academic goals and to pursue their professional careers.”

12

metalworking equipment news Jul-Aug 2011

The reseller will provide the relevant SolidWorks training for ITE staff, for the purpose of technology transfers or updates. It will also collaborate in the development and implementation of a SolidWorks ITE CAD Certificate, which is a CAD preparatory training program targeted at secondary students who intend to pursue engineering and design courses at the ITE. Through the implementation of the Lab, ITE will become the SolidWorks Certified Training and Support Centre for Singapore. The Lab will be equipped with relevant resources provided by ITE and 3DCW, and facilitated by a certified SolidWorks professional.

Kunhimohamed Naduvanchery, CEO of 3D ClassWorks commented: “This program is designed to ensure that most of the students entering the relevant engineering and design courses in ITE would possess fundamental CAD skills that prepare them to enter the workforce and embark on successful careers.”

ENQUIRY NO 110

businessnews

www.equipment-news.com

Zhangjiagang Pohang Establishes Steel Production Line

APPOINTMENTS

Hurco Southeast Asia Names Lee Wai Yip As GM

Lee Wai Yip

Jason Cohn

South Korea: Posco’s stainless steel production subsidiary in China, the Zhangjiagang Pohang Stainless Steel (ZPSS) became the first foreign company in China to establish a one million tonnes steel production line in China.

With the operation of an annual 0.2 million tonnes scale cold-rolled plant in 1999, it was the first foreign company to introduce upstream facilities in China back in 2006 and became an annual 0.8 million tonnes stainless steelmaker.

This time, a 0.4 million tonnes low-priced dephosphorisation furnace and a 0.2 million tonnes cold-rolled facility were opened, completing a one million tonnes stainless steel production system.

By completing the integrated stainless steel production facility, the entire stainless steel production capacity including Pohang Steelworks has increased to three million tonnes, placing it in the world’s second place tier stainless steel maker aside Acerinox (3.4 million tonnes) and Taiyuan (three million tonnes).

The dephosphorisation furnace installed by ZPSS can increase the usage rate of nickel cold iron, a low cost material with high impurities, up to 60 percent, leading to an expected 40 million dollar cost reduction each year.

In addition, the 0.2 million tonnes cold-rolled facility increases total production capacity to 0.6 million tonnes, increasing the cold-rolled ratio to 84 percent including Qingdao Pohang Stainless Steel, realising the highest added value in China. A 0.15 million-tonnes scale coil centre was also installed with processing abilities including coil cutting and shearing, allowing strengthened client services through various products meeting client needs on top of actual demand of the current distribution market.

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metalworking equipment news Jul-Aug 2011

Hurco Southeast Asia has appointed Lee Wai Yip as GM. Before assuming this new role, Mr Lee, a Fellow of the Chartered Certified Accountants (FCCA), was the Asia financial controller for four years at the company. He will now be in-charge of sales and marketing, and driving business development initiatives for the Hurco product range in the Asia Pacific region, excluding China and India.

Open Mind Develops Proprietary CAD Platform Wessling, Germany: Open Mind is investing in the development of a proprietary CAD platform. The CAM developer has decided to launch its own CAD solution, specifically designed for CAM machining. The software release is planned for early 2013.

“CAD and CAM are very closely related, as CAM programming is based on digital models. The better this data is prepared in CAD, the better the programs and machining results will be,” says Dr Josef Koch, head of development at Open Mind.

The company has assembled a team of CAD experts to push forward the development of a CAD platform. Their goal, set for late 2012, is to create a CAD platform that is specifically designed for the hyperMill CAM solution.

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SETTING SETTINGTHE THESTANDARD STANDARD www.bilz.de www.bilz.de www.bilz.de LMT Asia Pte Ltd 1 Clementi Loop #04-01, Clementi West Distripark 129808 Singapore Tel: (65) 6462 4214 Fax: (65) 6462 4215 Email: sales@lmta.com.sg

ENQUIRY NO 046

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Singapore Business Federation Inks MOU To Help Local Companies Develop R&D Capabilities

Singapore: The Singapore Business Federation (SBF) and Singapore I n st itute of Ma nu fac tu r i n g Technology (SIMTech), a research institute of the Agency for Science, Te c h n o l o g y a n d R e s e a rc h (A*STAR) signed a Memorandum of Understanding ( MOU ) to assist local manufacturing and services companies develop R&D capabilities and foster stronger research collaboration with SIMTech.

The MOU marks the partnership between the two orga nisations a nd ca lls for

both parties to jointly promote the transfer of knowledge and expertise, organise initiatives and programs, and identify gaps for technological enhancement to increase the competitiveness of Singapore’s manufacturing and services industries.

Leveraging on SBF’s extensive network and logistic support capabilities, SIMTech will be able to build closer links with SBF member companies who are seeking advanced and cost-effective manufacturing technologies to raise their competitiveness and

venture into emerging markets.

The MOU will pave the way for SBF members to tap on SIMTech’s manufacturing technologies, training and membership programs and obtain market insights to address the business challenges they face.

The MOU will induce more tie-ups between enterprises and SIMTech. Together with SBF, the organisation will facilitate joint seminars, workshops and training courses such as manufacturing excellence and productivity programs to keep SBF members abreast of best practices and sieve out suitable tools from t he mu lt itude of adva nce d ma nufacturing technologies av a i l a b l e . O v e r s e a s s t u d y missions in the area of technology sourcing and productivity are also some of the business exchange platforms that the organisation can organise for SBF companies to boost productivity.

Tüv Süd On Course For Growth Munich, Ger many: Tüv Süd have stepped up its pace of growth in 2010. In the past year, the international service corporation increased its revenue by 10.1 percent to over €1.55 billion (US$2.17 billion) (2009: €1.41 billion), while earnings before taxes even show a year-on-year increase of 21 percent to €123 million (2009: €102 million).

In 2010, the company spent around €133 million on expanding its business (€52.2 million) and on acquisitions (€80.5 million). In addition to building up several new legal entities in various countries in 2010, the company acquired eight large-scale companies, almost all of them located overseas; the two largest acquisitions, for example, are headquartered in the USA and South Korea.

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metalworking equipment news Jul-Aug 2011

The change in the breakdown of revenue also reflects the company’s successful international strategy: in 2010, the company generated 33 percent of its revenue abroad — a year-on-year increase of three percentage points. Dr Peter Klein, chief financial officer of Tüv Süd, explained: “Revenue growth was strongest in the Americas region at around 40 percent and in the Asia Pacific region at almost 30 percent.

However, even on our fiercely competitive domestic market here in Germany, we succeeded in achieving growth of 3.5 percent in 2010.” The company’s objective is to raise its revenue generated abroad to 40 percent in the medium term.

Strategic Expansion In Automobile With respect to the automotive

business, one of the company’s core areas, Horst Schneider, member of the board of management, announced that the company plans to expand and strengthen further automotive services in addition to its ‘classic pillars’ of roadworthiness testing and driving tests.

Here, the company is basing its strategy on the areas of fleet management, used-car strategy, vehicle reconditioning a nd registration services. In this context, Mr Schneider announced that the company’s subsidiary FleetCompany has embarked on a strategic partnership with Belgiumbased Fleet Logistics and that these two companies in combination will strive to become the European market leader in unbundled fleet management services.

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AEROSPACE

Boeing & AVIC To Open Manufacturing Innovation Centre In China Le Bourget, France: Boeing and Aviation Industry Corporation of China (AVIC), China’s largest state-owned aviation company, w i l l op e n t he AV I C - B o e i n g Ma nufacturing Innovation Centre (MIC) in Xi’an, Shaanxi Province, China. Geng Ruguang, e xe c ut i ve V P o f AV I C , a nd R ay Con ner, V P a nd G M of Boeing Commercial Airplanes S u p p l y C h a i n M a n a g e m e nt & Operations, signed the agreement on behalf of their respective companies.

The MIC will enhance Boeing’s production system by increasing AVIC’s efficiency and capacity to supply high-quality parts for Boeing airplanes. It will also support AVIC’s goals of improving its manufacturing and technological capabilities and the competitiveness of its affiliated factories to achieve global tier-one supplier status.

Boeing ha s a lso awa rded a contract to produce 737 rudders to Chengfei Commercial Aircraft Co (CCAC), an AVIC company located in Chengdu, China. That contract will serve as the initial work statement for the MIC.

Embraer: Commercial Aviation Market Outlook On The Up

São José dos Campos, Brazil: Embraer has published its 2011-2030 market outlook for commercial aircraft in the 30- to 120-seat segment.

As the industry continues its recovery from the 2008 financial crisis, a handful of world regions are leading the return to growth and will likely emerge as economic powerhouses. The downturn was harsh, but the recovery is much faster than expected. The company’s forecast reflects this strength in world air transport demand, measured by Revenue Passenger Kilometre (RPK), increasing at an average annual rate of 5.2 percent and reaching 13 trillion RPKs in 2030.

Over the next 20 years, China will be the fastest growing market, with an average annual RPK rate of 7.5 percent, followed by Latin America with 7.2 percent, the Middle East with 6.9 percent, Asia Pacific with 6.1 percent, the CIS (Commonwealth of Independent States) with 5.9 percent, and Africa with 5.4 percent. The more developed economies of North America and Europe will see lower demand due to their market maturity and slower economic recovery. These will be 3.5 percent and 4.4 percent respectively.

Embraer foresees world demand for 7,225 new jet deliveries in the 30- to 120-seat capacity segment over the next 20 years. The equivalent market value is estimated to be US$320 billion. Of this total, 3,125 jets are projected to be delivered between 2011 and 2020, and the remaining 4,100 units between 2021 and 2030.

The world fleet of 30- to 120-seat jets will increase from 4,225 aircraft in 2010 to 8,060 by 2030. During this period, 53 percent of new deliveries (3,835 jets) will be added to support market growth demand, while 47 percent (3,390) will replace ageing aircraft. By 2030, 835 jets of the current fleet (20 percent) will still be in operation.

Airbus Undertakes Large Winglet Retrofit Evaluation On A320 Family Toulouse, France: Encouraged by the popular ‘Sharklet’ program for A320 family aircraft, Airbus has decided to pursue a retrofit option of large winglets for the legacy in-service fleet. To this end, the company is evaluating the technical, operational and business aspects of a retrofit offering, to 18

metalworking equipment news Jul-Aug 2011

provide a solution for A320 Family aircraft currently in service.

Tom Willia ms, e xecutive VP, Programs, says: “We are confident that our customers will appreciate not only the benefits from improved fuel efficiency that retrofitting large winglets will bring to their in-service A320

family fleets, but also from the enhanced residual value."

H e a d d s: “ We’v e b e g u n investigating in earnest, and our technical teams are confident that we can develop a retrofit solution.

We are committed to making it happen either in-house or with external partners.”

ENQUIRY NO 067

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Automotive

Siemens PLM Software In Academic Initiative Singapore: Siemens PLM S o f t w a r e i s l o o k i n g to i t s customers (Solid Edge software and Velocity Series portfolio) to help build the next generation o f e n g i n e e r i n g t a l e nt . T he result will be a steady stream of students graduating with practical hands-on engineering experience using product design software. The academic initiative is an expansion upon the company’s GO PLM initiative, which leads the industry in the commercial value of the in-kind grants it provides.

Ford India Starts Production Of Ford Fiesta India: Ford has started production of the Fiesta at its 172,175 sq m Maraimalai Nagar plant, near Chennai. The four-door sedan will be available in showrooms later this year. Boosted by a US$72 million investment, Ford India is the sixth manufacturing facility worldwide to start production of the Fiesta.

The investment will results in the expansion of the powertrain facility at the Maraimalai Nagar plant to further support its sales and export growth plans in India.

When the expansion program i s co mp l e te d i n m i d - 2 012 , powertrain production capacity will increase from 250,000 to 330,000 units per year.

The engine plant will produce the 1.5L Ti-VCT petrol and Duratorq TDCi diesel engines for the Fiesta.

The passenger car plant utilises auto manufacturing technologies, automated systems and processes.

It also features a fully integrated stamping line, body shop, trim and final process area.

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metalworking equipment news Jul-Aug 2011

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Fraunhofer: Lasers Take The Lead

Fraunhofer ILT

Germany: Conserving energy is a top priority for auto manufacturers today. Laser technology can help. Lasers can be used to process thin light-weight components made of fibre-composite materials, as well as to manufacture more efficient engines and more powerful batteries.

Resistant to wear and universally applicable, laser light is a suitable tool in the manufacture of vehicles.

Lasers can be used to join, drill, structure, cut or shape any kind of material. Surfaces can be engineered for motors and drive trains that create less friction and use less fuel. Lasers are not only a decisive key towards faster, more efficient and economical production, but also towards energysaving vehicles.

Automotive Manufacturing To reduce weight, manufacturers are increasingly turning to the use of fibre-reinforced plastics, which are 30 to 50 percent lighter than metal. The disadvantage, however, is that these new materials are difficult to process.

“Lasers represent an alternative here,” explains Dr Arnold Gillner of the Fraunhofer Institute for Laser Technology ILT in Aachen.

“Lasers can cut fibre-reinforced plastics without wear and can join them too. With the appropriate lasers, we can cut and ablate components with minimal thermal side effects. Lasers can also be used for welding light-weight components — a viable alternative to conventional bonding technology. We can even join fibre-reinforced plastics to metals with laser welding. The laser roughens the metal surface, while the plastic, briefly heated, penetrates the pores of the metal and hardens.

Saving Energy With Low Friction Motors Laser technology is also in demand in engine optimisation. Engineers strive to keep friction as low as possible in order to improve efficiency.

“That is true not only for the electric engines currently being developed, but also for classic internal combustion engines and diesel motors, as well as transmissions and bearings,” says Dr Gillner of the ILT. Ceramic, high-performance coatings are especially desirable, because they are not only resistant to wear but also smooth, which generates less friction.

Coated metal components have until now been prohibitively expensive, being produced in plasma chambers in which the ceramic was vaporised and applied to the surface of the components. Fraunhofer scientists have now developed a less expensive and faster method in which work pieces are coated with ceramic nano-particles, then treated

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Automotive / Oil & Gas

with a laser. This finishing process has already been applied to gear wheels and bearings.

Lasers can even be used to make specific modifications to the properties of engine parts. “Friction between the cylinder wall and piston is responsible for a big part of a motor’s energy consumption.

That is why we try to minimise it. This is especially important for engines featuring modern, automatic start-stop functions that are stressed by frequent ignition,” says Dr Gillner. “To protect them, we have to ensure that the cylinder is always coated with a film of oil.

Laser technology can help reduce friction with special structuring processes that improve oil adhesion.”

Electric Cars Lasers can even increase the efficiency and life-span of electric batteries. That is good news for manufacturers and owners of electric cars, since batteries continue to be extremely expensive. The engineers and scientists at Fraunhofer are working on various solutions to make batteries more durable and less expensive. One approach is to increase the surface area of the electrodes with appropriate coating in order to increase their efficiency.

Another approach involves analysing and optimising production processes. Manufacturers produce batteries using one anode and one cathode cell, which they then connect. Fusing of copper anodes with aluminium cathodes however, creates brittle connections that break easily.

That presents a problem for application in cars that sometimes drive on cobblestone or dirt roads. With the help of lasers, researchers at the ILT have succeeded in forming durable connections between electrodes without creating the culprit brittle alloys. Researchers have developed an alternative solution in which a laser warms the surfaces and rollers press them together.

Nissan’s Iwaki Plant Produces Six Millionth Engine

Yokohama, Japan: Nissan Motor Co’s Iwaki Plant in Fukushima Prefecture has achieved six million units of cumulative engine production. With the facilities for casting, processing and assembly, the Iwaki Plant produces V6 gasoline engines named the VQ series.

A second engine facility at Iwaki started production in July 2006, featuring flexible manufacturing of multiple engines on new processing lines, based on the Nissan Integrated Manufacturing System . The addition of this second production facility increased initial production capacity from 396,000 units to 560,000 units per annum, enabling quicker response times.

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metalworking equipment news Jul-Aug 2011

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Shell & CNPC Agree On Global Cooperation

The Netherlands: Shell and C h i n a N a t i o n a l Pe t r o l e u m Company (CNPC) signed a Global Alliance Agreement emphasising their shared intent to pursue mutually beneficial cooperation opportunities internationally as well as in China.

The two parties also signed a shareholders agreement to establish a well manufacturing joint venture (50 percent CNPC and 50 percent Shell) subject to further corporate and government approvals. It is intended that the joint venture will develop an innovative, automated Well Manufacturing System (WMS) that could improve the efficiency of drilling and completing new wells onshore. The details of the parties’ respective contributions to the joint venture will be agreed during the transition phase over the coming months.

Full scale commercialisation of tight gas, shale gas and coal bed methane can require the drilling of hundreds of wells each year, over many years.

It is intended that the WMS will be designed to drill and complete wells in a standardised a n d r e p e a t a b l e m a n n e r, using adva nced automation techniques. The system aims to incorporate the best technology and procurement capabilities from both partners.

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 123

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

200,000 150,000 100,000 50,000 0

Business statistics

www.equipment-news.com

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

PM Parts

Welding

Other Uses

Metal Powder Industry Rebounds

Copyright 2011 MPIF

North American iron powder shipments (1 st = 0.9072 mt)

NORTH AMERICAN IRON POWDER SHIPMENTS 500,000

Short Tons

450,000 400,000 350,000 300,000 250,000 200,000 150,000 100,000 50,000 0

Total 353,121

PM Parts Total 315,192

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

PM Parts

Welding

Other Uses Copyright 2011 MPIF

North American iron powder shipments (1 st = 0.9072 mt)

NORTH AMERICAN SHIPMENTS OF COPPER AND COPPER BASE POWDERS 18,000 Combined Estimate

Short Tons 30,000 25,000 20,000 15,000 10,000 5,000 0

2000

2001

2002

2003

2004

PM Parts

2005

2006

2007

2008

2009

2010

Other Uses Copyright 2011 MPIF

North American copper and copper-base powder shipments (1 st = 0.9072 mt)

NORTH AMERICAN SHIPMENTS OF peak year of 2004, when iron pipeline needed refilling.

This Pr inceton, USA: The North COPPER AND COPPER BASE POWDERS

powder situation signaled a firming of American Powder Metallurgy 18,000 shipments hit almost Short Tons Combined tonnes. “Nevertheless, 474,000 demand for metal powders and (PM) industry regained its growth Estimate we are back on the growth track, PM parts. A clear indicator of momentum in 2010 after 30,000 five 25,000 regaining momentum in nearly rising production levels was the dismal years of declining demand, 20,000 every quarter,” he said. hiring spurt seen at many PM reported Michael E Lutheran, 15,000 Copper powder shipments parts fabricator plants. president of the Metal Powder 10,000 in 2010 also advanced to an Total 2010 North American Industries Federation (MPIF).

5,000 estimated 18,000 short tonnes, 2 meta l powder shipments While the rebound can be largely 0 2002 2003 about 2004 2005 2007 2008 2009 2010 a 36 percent increase from 2009. increased 35 2006 percent to an pinned on the increase in light-2000 2001 Stainless steel powder shipments estimated 451,021Other short vehicle sales, other end markets Usestonnes.

PM Parts 2011 MPIF as well to an estimated also gained, he stressed. PM’s Total iron powder shipmentsCopyrightjumped in 2010 soared by 44.23 percent 6,700 short tonnes, an increase design-engineering advantages, Americanand coppertoand copper-base st = 0.9072 mt) 353,121 short powder tonnes.shipments The of (1 almost 50 percent. contributions North to sustainability, PM parts share represented North A merican Metal proven economies are stronger 315,192 shor t ton ne s, a 5 0 Injection Moulding (MIM)-grade than ever. percent increa se over 20 09 powder shipments increased T he indu st r y ’s re a l levels. Mr Lutheran pointed out close to 29 percent in 2010 to over tu r na rou nd ac tua l ly b e ga n that 2009 was a dismal year one million pounds. during the last quarter of 2009 and the increase brought the Shipments of PM tool steel, highwhen customer inventories were industry to levels still below its alloy materials, and tungsten also at their lowest point and the 24

metalworking equipment news Jul-Aug 2011

2

Release of the VFX6 indexable end mill for machining of Titanium Alloys Mitsubishi Materials Corporation has recently released a new indexable end mill series, VFX6, that is dedicated to the machining of Titanium Alloys.

In the Aerospace Industry, the use of Titanium alloy components is widely used.

Titanium alloys has a machining characteristic in which the heat generated during machining generally concentrates around the cutting edge, leading to problems such as welding along the cutting edge that can easily lead to chipping. Additionally due to the heat generation premature cutting edge failure due to increased wear can also become a major problem.

With these problems in mind the VFX6 series was designed to ensure effective chip disposal, by removing the chips effectively away from the cutting edge welding can be reduced. This is achieved by the use of effective coolant that can be supplied right to the cutting edge where it is needed the most. This is done using coolant nozzles that can be interchanged to suit the coolant pressure of the machine in use. Additionally the insert configuration uses tangential located inserts that enable to increase the tools overall rigidity making it suitable for high load machining applications. In order to reduce the cutting edge temperatures a uniquely designed insert geometry has been employed, also a brand new PVD tool grade, MP9030, has been developed to obtain a high balance of both wear and fracture resistance.

This whole combination of insert geometry, tool grade and tool design enables the VFX6 to be able to achieve metal removal rates of up to 400cm3/ minbased on a dia. 63mm.

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registered gains in 2010.

Internationally, PM industry production rose in Europe, Asia, and South America last year. China, South Korea, Brazil, Japan, and India enjoyed substantial increases.

The 2011 Outlook Based on the first quarter of 2011, PM industry executives remain optimistic about the business outlook, Mr Lutheran reported. Iron powder shipments increased 9.1 percent in the first quarter, with the PM parts/friction materials sector up 10.1 percent. Stainless steel powder shipments remain robust and copper powder shipments are positive as well.

According to discussions with leading PM parts makers, business in the first half of 2011 looks very favourable. First-quarter sales reports show increases ranging from 10 to 35 percent with strong back orders. While many companies have rehired previously furloughed

North American Metal Powder Shipments 2009

2010

Iron & Steel

244,839

353,121

Stainless Steel

4,500 (E)

6,700 (E)

13,239

18,000 (E)

Copper & Copper Base Aluminum

55,000 (E)

55,000 (E)

Molybdenum

2,000 (E)

2,000 (E)

Tungsten

4,000 (E)

4,500 (E)

Tungsten Carbide

5,900 (E)

6,000 (E)

Nickel

4,500 (E)

5,000 (E)

543

700 (E)

334,521 short tons

451,021 short tons

Tin (E) estimate

production workers, they are still running with leaner workforces than before.

Automotive Scene Through April, demand remained firm in PM’s largest market. PM parts found in new engines and six-speed transmissions use substantial amounts of metal

powder. For example, GM and Ford six-speed models contain from 28 to 34 pounds of PM parts. Overall, the average USmade vehicle in 2010 contained an estimated 41.6 pounds of PM parts, with a slight gain to almost 42 pounds forecast for 2011. In Europe, the average per vehicle in 2010 is estimated at 18.5 pounds.

Machine Tool Orders In Q1 Saw Increase Of 19.1 Percent: UCIMU Italy: There has been a double figure increase in the index of machine tool orders, that, in the first quarter of 2011, has grown by 19.1 percent, compared to the same period of the previous year.

Data drawn up by the studies department of UCIMU-Sistemi Per Produrre — counting five consecutive quarters of growth, confirms the recovery of investment in capital goods. Notwithstanding this increase, the gap between internal market performance, which is still stagnant, and the foreign market, which has recovered most of the ground lost in 2009, remains quite profound.

The index of orders from the national market, suffered a 1.3 percent drop, with respect to the same period of 2010. This demonstrates once again the weakness of internal demand that continues to be faint in its restart, as evidenced by the absolute index that stops at a quota of 69.2.

On the contrary, the feedback received by Italian manufacturers in foreign markets is satisfying, as shown by the index of orders collected abroad, that after a growth of 32.7 percent compared to the same period of 2010, has reached an absolute value of 141.9, nearing again the record levels of 2007.

From the export data analysis developed by the Centro Studi & Cultura di Impresa, starting f ro m t he I STAT dat a , it i s clear the heterogeneity of the outlet markets of the Italian supply sector.

In 2010, China reached the top position of the destination areas of the made-in-Italy sector, gaining 14.2 percent of total exports by the Italian industry, followed by Germany (10.5 percent), United States (5.8 percent), India (5.6 percent), France (5.6 percent), Russia (4.8 percent) and Brazil (4.7 percent). BRIC countries occupy all the first seven positions.

Coming in October 2011:

26

metalworking equipment news Jul-Aug 2011

Indonesia

ecoGrinder

The simplified for complex demands.

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DKSH (Thailand) Limited 1696 New Petchburi Road, Bangkapi, Huaykhwang 10310 Bangkok thanit.s@dksh.com

DKSH Technology Sdn Bhd No. 14, Jalan Bersatu 13 / 4 46200 Petaling Jaya Malaysia terence.hong@dksh.com

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Providing for

Tomorrow’s Designers Siemens PLM Software’s latest offering, Solid Edge ST3, advances the future of 3D Design CAD offerings in the mid-range market, this flexibility is coupled with a major advancement in dealing with imported foreign models that allow 2D drawing dimensions to become editable 3D driving dimensions. Furthermore, end users making their initial moves into 3D benefit from new accomodating design approaches.

Years in the Making

Siemens PLM Software has always had a vision for the future of CAD modeling and with the release of their latest mid-range design application, Solid Edge, it would seem that they have achieved it, thanks to their groundbreaking implementation of synchronous technology. When they first introduced synchronous technology back in 2008, Siemens promised that it would advance geometric design above parametric, historybased modeling, yet co-exist in synergy with it. A tall order, no doubt, but one that the aptly named Solid Edge ST3 has met.

In the initial release of synchronous technology, Siemens was careful to provide both their current users and new clients with a smooth path to the adoption of the technology.

Essentially, existing users did not have to disrupt their current design processes and could maintain the more traditional approach of ordered features with history.

In the new version, users can now make the choice to model using the traditional approach, while identifying a subset of the model geometry based on synchronous technology OR they can design broadly with synchronous technology and identify a desired subset of geometry with ordered, historybased features.

Setting Solid Edge apart from other

60

metalworking equipment news March 2011

Solid Edge ST3 is the culmination of years of intense focus and when it comes to accelerating model creation, the product certainly delivers.

With synchronous technology managing geometric dependencies, design pre-planning is eliminated and engineering change orders (ECOs) to the product model can be easily and rapidly executed. This is not limited to native models, either, as imported data can be modified just as effectively, extending designers abilities to reuse customer or supplier data.

With this latest release, Solid Edge ST3 now handles the full range of applications at the assembly level with synchronous technology, and in order to achieve that, Siemens had to implement advances across the full application.

These advances now mean that users can blend both synchronous and ordered modeling in the same part model as best fits their need.

A Natural Progression One of the key benefits for current users of Solid Edge is that they can make the shift to Solid Edge ST3 seamlessly. In the design methodology and its implementation in the new version, an important aspect is that an existing modeling approach and workflow using ordered features is preserved and can be continued. As such, existing users of Solid Edge, comfortable with their design process using ordered features, need not change.

In Solid Edge ST3, both synchronous and

ordered features can coexist in the same part and users have the flexibility to choose what type of feature to use and where, depending on their need and design intent.

Moving into 3D Every year, more and more users of 2D design technology make the move upward into 3D. This transition does not happen all at once and very often, a developer must deal with a collection of both 2D and 3D models, usually in different native formats, and must merge them into a unified 3D product design.

Unfortunately, most tools can only import foreign data as an unintelligent block of geometry, making the user’s job of interacting with subsets of that data almost impossible. At worst, it forces the user to re-author the data.

With Solid Edge ST3, users can now map 2D drawing dimensions direc tly into the 3D model as driving dimensions, speeding up the integration process and bypassing manual interactions that can introduce errors. With this new capability, designers can better reuse imported 3D and design intent defined in 2D can be brought forward.

With more realistic design scenarios that help reduce the need to construct and test physical prototypes, easier transitions from 2D to 3D, greater flexibility and easier transition for current Solid Edge users to the new version, Solid Edge ST3 marks a major milestone in advancing the technology while still catering to customer’s specific needs. Regardless of whether you are a new or existing user, Solid Edge ST3s wealth of enhancements and productivity improvements, many of which are in response to users’ comments and requests, make it a must have design tool for the market.

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Three weeks of design… all done in a day?

It’s simple with SOLID EDGE. Slashing design time is just one of the benefits users of Solid Edge with synchronous technology are already realizing. This ground-breaking solution accelerates design time AND speeds engineering change orders. All while helping your designers better reuse more imported 2D and 3D models. The result? Dramatic leaps in productivity and reductions in time-to-market.

Take a closer look at the future of 3D design and see what’s new in Solid Edge ST3 by visiting www.siemens.com/plm/st3 today.

Answers for Industry. © 2010 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. All other logos, trademarks or service marks used herein are the property of their respective owners.

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HSM Tool Paths Benefit Die & Mould Manufacturing A path previously less taken, high-speed machining tool paths in CAM are touted by some to produce better accuracy and surface finish. By Mickey Berman, iMachining chief scientist, SolidCAM

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anufacturing a die or mould has traditionally been a long, difficult and expensive process, demanding deep technological know-how and skills. With today’s advances in CAM software, die and mould making is fast becoming a rational, predictable process, saving the manufacturer time, money and requiring a lot less technological expertise.

CAM systems are used to produce CNC programs for a required shape.

Ideally the CAM system will accept a geometric model produced on any CAD system, but in cases where the CAM is integrated into the popular and prevalent CAD system, it will work with the CAD models as its native models, without any need of model translation.

In such an integrated CAM system, savings are realised whenever a modification is required to the mould shape (geometry). By making the necessary changes directly to the CAD model, all associated mould geometry is automatically changed and the CNC tool path is automatically synchronised.

High-Speed Machining – The Extra Edge In CAM There is a new High-Speed Machining (HSM) technology that 30

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can reduce the time and cost of machining a mould by at least 50 percent and produce a more accurate mould with an increased lifetime. This technology is capable of producing tool paths that will enable ordinary, mid-range milling machines to machine cavities directly into pre-hardened mould steel of 62 HRC hardness and higher.

This is an advantage over the traditional CAM systems. The HSM tool paths produce better accuracy and surface finish. Only a minimum of manual polishing is required before the mould can be used.

No more heat affected zones to remove, no more warping and inner stresses and no more micro cracks that reduce mould lifetime.

The mould is machined to the final dimensions with a high finish, and only a micron or less needs to be removed by manual polishing.

HSM tool paths achieve these results by taking small cuts (chip thickness typically less than 20 percent of tool diameter, and mostly less than two to four percent in very hard materials) at high feeds and cutting speeds. They must also keep the mechanical and thermal load on the tool as constant as possible. To achieve this, these systems should strive to keep the tool cutting constantly, ideally in a

continuous spiral path.

Since real parts and moulds have irregular shapes and islands, it is generally not possible to remove all the material that needs to be cut in one continuous spiral. Most HSM CAM systems employ a trochoidal (or D-Type) tool path, to remove all the remaining material in the cavity, once the spiral has come up against a wall or an island.

Ideally, the HSM CAM system would have the intelligence to analyse the shape of the section of the cavity that is to be removed and be able to divide it into a number of detached areas, by using a special D-Type tool path to cut separating channels, and machine each of these areas with a non-symmetric (morphing) spiral tool path. These channels usually occupy a small percentage of the total area to be removed, which results in most of the area being removed by spiral tool paths. They are twice as efficient as D-Type tool paths.

Algorithmic Machining A technology wizard incorporates a mathematical model of the behaviour of all the machining variables and their interdependence.

When presented with a machining task (which includes target and stock geometries, tools, material and machine data), the wizard finds the optimum cutting conditions for sustainable HSM. It should be noted that the wizard is not a set of pre-calculated look up tables. It carries out complex iterative optimising calculations aimed at producing values for the cutting parameters that will produce fast, chatter free, constant load machining, taking into account the limitations of the machine, the target geometry, the material and the tool.

In addition, since it is generally impossible to keep a constant feed throughout the milling process, (acceleration/deceleration limitation of machine vs small arcs), it provides the tool path

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generator algorithm with matching formulae, to enable it to produce an exact match of the speeds and tool engagement for each point along the tool path.

1. Using the cutting conditions produced by the wizard, the automatic tool path generator calculates all the tool paths necessary to efficiently produce the target geometry from the given stock geometry with the required surface finish.

2. The first sets of tool paths produced are the rough cut and rest-rough. Both are cut with the biggest diameter flat end-mill.

The rough cut algorithm uses two basic types of tool paths: • Morphing Spiral Tool Path • Modified D-Type Tool Path Ideally, one would want the whole area that needs to be cut (at a certain Z), to be milled with one continuous spiral tool path.

Generally this is not possible.

The rough cut algorithm does the next best thing. It subdivides the area into the optimal number of sub-areas, each of which can be cut with a morphing spiral path, such that the total machining time for the whole area is minimal. It uses modified D-type tool paths to cut slots to subdivide the area.

Another advantage of the rough cut algorithm is the fact that on each point along the tool paths created, the values of the chip thickness, the feed and the spindle speed are always matched up according to the optimal rules laid down by the wizard. This exact matching of the cutting conditions, coupled with the optimal subdivision of the area, produce first cut parts safely, with total machining time savings ranging from 40 to 70 percent, on regular, mid-range machining centres.

Morphing Spiral Tool paths: 1 ; 8 ; 10 Modified D-Type Tool paths: 2 ; 9

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Sausage widening of moats & slots: 3 ; 4 ; 5

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Moats with trapped concave areas: 6 ; 7

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3. The morphing spiral tool path is as such because unlike the spiral tool paths in most other CAM systems, it gradually adopts to the shape of the area it has to clear, rather than symmetrically expanding in a circular fashion.

This ability reduces machining time considerably.

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large steps on sloping surfaces), it starts going up, cutting away only where it needs to cut, in order to reduce the step size to be within the requested limits. It avoids going around the pocket to other sloping walls, even if it needs to cut them too, if they are far. After it has finished going up, reducing the step size on one set of slopes, it will go down again and cut the steps on other sloping walls going up, keeping repositioning time to a minimum.

4. The rest-rough algorithm also uses the roughing tool. After the roughing tool has cut down most of the material to be cleared in a pocket or around an island (boss), using relatively large step down values (and creating

Enquiry No. 5001 Turn to page 80a or log on to www.equipment-news.com to enquire

Accelerating Growth In HSM The plastic mould industry is and will be the number one growth market for 3D HSM. Here are the reasons why.

Engineering Factor: Cutting a mould cavity directly in a block of hardened tool steel, including a high quality finish cut, has six main advantages for the mould maker: 1. Shorter manufacturing time.

2. Unattended machining.

3. No thermal deformation.

4. Less manual finishing and polishing.

5. Better final dimensional accuracy.

6. No micro cracks — better quality moulds.

Market Factor: There is a market trend in the global market for electronic products, gadgets, appliances and even toys. This results in greater demand for more variety of models.

Material Factor: The rate at which new thermoplastic polymers with ever more characteristics coming out of the labs is growing exponentially. As a result, the rate at which parts that were once made of metal or wood are re-engineered to be made of plastic is also growing exponentially. MEN

Enquiry No. 5002 Turn to page 80a or log on to www.equipment-news.com to enquire

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Strong Spindle

Connections Key To High-Performance Machining

High-performance machining is commonly characterised by the use of high feeds and aggressive depths of cut. As such, tool-spindle interface must withstand high loads and yet maintain its rigidity. By Keith Wiggins, leader, Tooling Systems Team, Global Product Management, Kennametal

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o build today’s modern aircraft, many engineers are switching to highstrength lighter alloys like titanium for component materials to increase fuel efficiencies.

Machinists are challenged to maximise metal-removal rates to achieve production efficiencies, yet face low cutting speeds and considerably higher cutting forces. Machine tool builders m u s t a l s o p ro v i d e g re a t e r stiffness and damping in their spindles to minimise undesirable vibrations that deteriorate t o o l l i f e a n d p a r t q u a l i t y.

When machining tough materials like titanium, cutting speeds are relatively low due to thermal effects on cutting tools.

In response, machine tool builders have improved stiffness and damping on spindles and machine structures over the years. Spindles have been designed with abundant torque at low rotational speeds.

Although all these advances add to greater productivity, the spindle connection often remains the weak link in the system.

Existing Spindle Connections The tool-spindle interface must withstand high loads and yet maintain its rigidity. In most 32

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cases it will determine how much material can be removed on a given operation until the tool deflection is too high or the onset of chatter is reached.

High-performance machining is commonly characterised by the use of high feeds and aggressive depths of cut. With ongoing advances in cutting tools, there is a need for a spindle connection that makes the best utilisation of available power possible.

Several different types of spindle connection have been developed or optimised over the last few decades. Due to a good cost/benefit position, the 7/24 ISO taper became one of the most popular systems in the market. Used successfully in many applications, limitations in its accuracy and speed prevent it from growing further. Generally, the taper starts to open up around 20,000 rpm, and if a system does not have any interference fits, this is the point that the taper starts to lose contact on taper face contact tools and standard V-flange tooling moving within the spindle.

The advent of face contact represented a major step forward over the standard 7/24 taper. The combination of face contact with 7/24 solid taper provides higher accuracy in the Z-axis, but also

presents some disadvantages, namely the loss in stiffness at higher speeds or high side loads.

Most of these tools in the market are solid, and the spindles have relatively low clamping force.

Connection stiffness is limited, as radial interference needs to be kept to a minimum. Required tolerances to achieve consistent face contact are therefore very tight, leading to high manufacturing costs.

In the early 80’s, Kennametal introduced the KV system, which was a shortened version of CV tooling with a three-ball mechanism acting on a conical surface of a bore.

Later versions were designed and sold with face contact.

In 1985, the company and Krupp Widia initiated a joint program to develop a universal quick-change system, now known as KM and recently standardised as ISO 26622. The polygonal taperface connection known as PSC, now also standardised as ISO 26623, and the early 90’s HSK system started being employed on machines in Europe and later became DIN 69893, then ISO 121.

Why Bending Capacity Is Important As mentioned earlier, when machining tough materials like

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titanium, cutting speeds are relatively low due to thermal effects on cutting tools. In response, machine tool builders have improved stiffness and damping on spindles and machine structures over the years. Spindles have been designed with abundant torque at low rotational speeds.

The spindle connection m u s t p ro v i d e t o rq u e a n d bending capacity compatible with machine-tool specifications and the requirements for higher productivity. It becomes obvious in end-milling applications, where projection lengths are typically greater, the limiting factor is spindle interface’s bending capacity. As an example, an indexable helical cutter with 250 mm projection from spindle face, 80 mm in diameter generates 4,620 Nm of bending moment and less than 900 Nm of torque.

The most critical parameters of a taper-face spindle connection are the clamping force and radial interference. Maximising clamping force and selecting appropriate values of interference can further improve connection rigidity.

Looking Ahead The next generation system will address the problems faced by some systems, which may be able to transmit considerable amount of torque, but cutting forces also generate bending moments that will exceed the interface’s limits before torque limits are exceeded.

The combination of the system’s clamping force and interference level lead to a robust connection, high stiffness and bending capacity for improved performance in titanium machining. It overcomes the limitation on bending capacity present in other connections, allowing maximum available spindle power and torque to be utilised in critical operations like milling of high-strength materials.

Manufacturers have several spindle interface choices when making a machine tool investment.

With more materials that are tougher to machine and require considerably higher cutting forces, choosing wisely to achieve and maximise cutting-edge performance is a must.

Enquiry No. 5003 Turn to page 80a or log on to www.equipment-news.com to enquire

T h e M i l l 1-14 h e l i c a l c u t t e r and its Load-Optimised Insert Spacing (LOIS) concept have been developed by Kennametal.

It represents a full range of helical cutters that provides manufacturers needed flexibility and versatility.

The cut ter s can have inser ts stacked two, three and four high, and custom tools are available with up to 13 rows of inserts.

Micro-geometry features contribute to enhanced performance, various rake angles, negative T-land, and small hone.

Results include reduced cycle times and lower cutting forces. Adding to the insert stability on the cutters are axial support pins. The pins help align all the insert bases for improved surface finishes and tool life. MEN

Enquiry No. 5004 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 126

Kennametal: Improving Machining Productivity

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The Hard Truth On Solid Carbide End Mill Systems

It is important to recognise that solid carbide milling cutters today are available as a highly evolved and comprehensive range of tools for performance machining. By Gisbert Roth, manager marketing operations (Asia-Pacific), Seco Tools

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basic question often asked if one has both an insert based cutter and a solid carbide cutter; which one is best and in what areas do they excel? This is not so much a question of one being superior to the other but rather a question about the features of a specific type of cutter and how that particular tool should be applied to deliver good results.

An insert milling cutter is different from a solid carbide milling cutter in many ways. Different types of coatings and different types of substrates are used with solid carbide cutters as compared to insert based systems and that makes for a number of significant feature differences between these two main groups. If some of the features in one of these two groups become more important in a certain application, then that tool is perhaps more suitable for the application and a better approach.

Generally it can be said that the tolerances on a solid carbide milling cutter are much tighter compared to a traditional insert based system.

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However, this fact applies only to the tool being observed in cut.

Tolerances on both tools can be equally narrow, but since solid carbide as a material is much stiffer compared to a steel shank tool with a mounted insert, it is prone to less bending and so has a higher level of precision under the influence of cutting forces during machining.

Another important fact to remember is the arc of tool contact.

The arc of tool contact or the length of the circumference of a particular tool that is in contact with a machined part is directly linked to the amount of heat that is generated and absorbed into either the tool, the component or the chips. Solid carbide and steel based tools have completely different characteristics in temperature handling and this should be reflected in the cutting strategy selection.

Considering these facts and putting things further in perspective one has to look at tool dimensions too. In the smaller diameter range below 10 mm there are very few insert based alternatives to solid carbide cutters and the choice is

clearly going toward solid end mills.

The opposite applies for tools with large diameters where solid carbide tools are not a viable choice for economical reasons. This leaves us with the intermediate range of sizes between 10 to approximately 25 mm where many system overlaps exist (see figure 1). The complexity of the shape to be machined, its accessibility and tolerances to be held are the guides for initial tool selection here.

Solid Carbide Milling Cutters A large part of the capability defining features of solid carbide milling cutters depend on the type of carbide substrate used, the core material of the cutter below the coating on which the tool is based on. The substrate material is of high importance since it has to support the cutting edges of the tool and it has to resist cutting forces and prevent against breakage of any kind.

In order to ensure adequate toughness and provide good dynamic resistance, micro grain substrates are most often used as base substrate materials in solid carbide end mills (figure 2). Micro-grains allow for higher h a rd n e s s a n d b e t t e r e d g e sharpness while still retaining a good toughness; however their thermal conductivity, the ability to transport heat away from the cutting zone, is lower compared to normal grain sized substrates.

This means that the heat generated while the tool is in cut tends to stay on the surface of the cutter. The cutting edge has to be able to withstand this heat and the control of the arc of contact is again an important condition with solid carbide cutters and always needs to be considered.

Solid Carbide Cutter Coatings & Edge Preparations Coatings are applied to solid carbide cutting tools to increase wear resistance and isolate the

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area where the heat is generated from the substrate of the tool, in which it could potentially accumulate and affect the tool life span negatively. Additionally, solid carbide tools have relatively sharp cutting edges, as such, it is very important to have correct coating adhesion between the substrate material and the coating layers (figure 3). In particular with smaller diameter solid cutters, cutting edge sharpness is a crucial element contributing to tool performance.

An ideal cutting edge would consist of a sharp cutting edge with the highest possible hardness without the risk for breakage. This can be in part achieved with an appropriate edge preparation.

Most often, the style, shape and sharpness of the (cutting) edge preparation sets different solid carbide milling cutters apart both in terms of generated work quality and tool life levels reached. A relatively sharp cutting edge is achieved through grinding both the top rake face as well as the clearance face on the tool. The line where the two faces meet each other is referred to as the cutting edge. Cutting edges will need reinforcements or a so- called edge treatment/honing in order for the coating to better adhere to it and to prevent edge breakouts. In other words some of the edge sharpness is traded for stability and coating functionality, which in turn leads to longer tool life (figures 4 and 5).

A large part of the capability defining features of solid carbide milling cutters depend on the type of carbide substrate used.

It can even be discussed that the edge preparation has the highest importance of all followed by both substrate type and coating technology. Logically this has implications on tool regrinding. A reconditioned tool will not reach its full potential without the correct re-application of its original edge honing. Considering the initial cost of the solid carbide milling cutter, it is therefore important to have the re-grinding process done at source with the original cutter manufacturer and its qualified service centres.

Important Facts Of Solid Carbide Cutters Dimensions and geometrical design features on solid carbide cutters subdivide them into few generic and many specialised sub-groups with different application areas.

Flute geometries, top angles, rake and clearance angles as well as helix angles all play important roles in the application areas of different cutters and set them apart clearly.

This leads us to the selection process and the application strategy itself. So which strategy is best then? Well, that depends on the overall machining objective. Is the main goal to maximise productivity

Figure 1: Application area mapping: solid carbide cutters vs insert based systems

and component output or minimise tool cost and simplify inventories?

It also depends on the component and all facts related to it. Is the tool intended for slotting or side milling or perhaps both?

Last but not least one also has to consider constraints. What are the possibilities of the machine tool, how rigid is the component clamping? These elements might act as limiting factors and can prevent the application of some m o re a d v a n c e d m a c h i n i n g strategies and also the application of some of the more specialised solid carbide cutters.

Machining Strategy The correct solid carbide cutter selection as a result depends on many factors, the most important being the correct machining strategy. In reality, constraining factors cannot be changed in most cases, ie: machine tool, CAM system and component size, material, tolerances and shape are a given.

However, within this existing framework a correct strategy approach can still be set and there are many ways where one can influence the machining result and fine-tune the cutting conditions (figure 6) by changing feeds, speeds

Figure 2: Carbide grain size influence and functionality

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and depths of cut related to the overall machining objective.

Related to the main direction and the technological strategy chosen, the selection of the tool can be accomplished. In this respect two possible avenues are evident: a) Performance driven selections with highly specialised individual solid cutters for best performance in for example side milling, slot milling or 3D milling, each one of them covered with its own tool or b) Application driven selections with few cutters but with a wide range of applications and more broad-based appeal.

The choice of either path will direct the user to a more narrow part of the wide range of available solid carbide cutter available.

Specialists Vs Versatile Tools With approximately five distinct solid carbide milling cutter types in existence today for common applications in metallic materials (figure 7), one generic tool type stands out as being somewhat outdated. It is a solid carbide cutter that dates back to the days when small end mills were made of HSS (High-Speed Steel).

Historically referred as the first generation of solid carbide end mills, it has the typical geometrical features that were used in HSS tools at the end of the 1970’s except that its base material has been switched to solid carbide, which was found to be suitable for the task at that time.

These types of cutters today define the lower end of the market both in 36

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Figure 3: Coating effect on edge sharpness

“Edge preparation”

Figure 4: Edge preparation illustration on a solid carbide end mill Figure 5: Edge preparation and coating effect demonstration

terms of cost and performance.

The second group of cutters, which in contrast is highly contemporary, is the High-Speed Milling (HSM) type of cutters defined for high cutting speeds.

These tools typically feature a rather short usable cutting edge length and their design is optimised for maximum stability.

With the application of high cutting speeds, high temperatures are generated and this heat typically accumulates in the tool corner. This is the reason why HSM end mills most often have larger corner radii for extra protection against plastic deformation in this area. The third group is High Performance Milling (HPM) that holds tools specifically designed for high depths of cut and larger arc of engagement. With the depth of cut being the optimising factor here, the tool design reflects this with long cutting edge length and chip dividers to make large chip volumes more manageable. Helix

angles and chip cavity capacity are other visible elements of importance. Increased cutter core diameters are also found with these tools. Their aim is to increase tool stability and again reduce deflection.

HFM cutters, the fourth group, are specialist tools designed for high feed applications where very low depths of cut is combined with high table feeds. The shape of these HFM cutters clearly reflects their purpose. It sees very small cutting edge angles combined with the cutting edge being relocated to the front of the tool. In short groups 2 - 4, HSM, HPM and HFM, are tools that are specialised toward a specific task and while substrate and coatings may vary, the geometry of these tools is the main differentiating factor.

The last but not least of the five main groups is new generation of solid carbide cutters designed for versatility and performance.

These tools have a large application

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Figure 6: Machining strategy selection and optimisation

Figure 8: Examples of modern, versatile solid carbide milling cutters

Figure 7: Specialist cutters vs versatile tools

area and provide much higher general performance than the first generation HSS technology based solid end mills. Group five tools do not reach the peak performance levels of HSM, HPM and HFM in their respective fields, but as a compromise they combine many of the specialist features into one tool and are a good basic choice for mixed production and varying applications. It is a modern version of the generic, versatile solid carbide end mill (figure 8).

Modular Solid Tools With Replaceable Front Ends Besides classic solid end mills and insert based, small end mills; there is additional, interesting group of carbide milling cutters placed into the same field of applications.

These systems essentially provide the same type of performance as classic solid carbide end mills yet they combine it with extra flexibility and modularity. It is the

Figure 9: Modular end milling systems

replaceable solid carbide head end milling systems.

Pioneered in the late 1980s, the latest generation of these tools incorporates the best features of classic solid end mills such as precision, strength and advanced cutting edge designs and coatings with the possibility to add extra stability through steel shanks in various lengths (figure 9).

Tools of this kind can be configured in a near unlimited fashion from ultra stable short clamping to the very long, tapered setups designed to reach deep cavities or constrained component areas where a standard solid carbide cutters will not be able to reach into. These systems allow for cutting head exchanges in the machine tool, eliminating the time needed for tool re-measuring and re-setting. Modular head systems overlap many of the solid carbide

solutions outlined in this article in the diameter range of 8 mm to approximately 16 mm in diameter and they provide a viable and flexible hybrid complement to traditional solid carbide end mills.

Making The Right Choice With all the solid carbide cutter and hybrid modular solutions available today, it is important to choose the correct strategic approach to both selection and application of the tools.

In line with the overall machining goal, be it performance, maximised component output or lowest possible tool cost per component, correct tool selection and application is the key to profitable machining with quality solid carbide end milling systems. MEN Enquiry No. 5005 Turn to page 80a or log on to www.equipment-news.com to enquire

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natep182, USA

Insights

Surface The

Laser Surface Melting (LSM), can increase the wear and corrosion resistance of Mg alloys through increasing the concentration of Al and refining the microstructure in the laser-melted zone. By Dr Zheng Hongyu – group manager, Machining Technology, SIMTech, Prof Zhou Wei – associate professor, Guan Ying Chun – PhD student, (MAE)/NTU and Dr Li Zhongli

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SM is known to enhance the wear and corrosion resistance of Mg alloys, but its effect on microstructural evolution of Mg alloys is not well understood. An effort has been made to study the effect of rapid solidification following LSM on the microstructural evolution of AZ91D Mg alloy.

The effect of LSM on magnesium alloys has attracted considerable a t t e n t i o n i n re c e n t y e a r s .

Studies found that the improved corrosion resistance of AZ31, AZ61 and WE43 Mg alloys following LSM was associated with the increased concentration of Al and microstructure refinement in the laser-melted zone due to surface melting and rapid solidification during the laser process.

Cooling Rates Affect Microstructure The microstructural evolution of an as-cast AZ91D magnesium alloy following LSM was studied in three different regions of the laser-melted zone. Cooling rates of these regions were calculated from a numerical simulation based on the heat flow model. The aim was to study the kinetics of phase transformation and the effect of cooling rates on the solidification microstructure under rapid solidification condition 38

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induced by laser processing.

Microstructure of the asreceived AZ91D Mg alloy contained bulk and lamellar β-Mg17Al12 phase distributed non-homogeneously in a matrix of α-Mg grains. After laser irradiation, XRD analyses indicated that the laser-melted layer also consisted of β-Mg17Al12 and α-Mg phases, as shown in Figure 1.

Solidification microstructure in the LSM AZ91D alloy presented a continuous network of β-Mg17Al12phase precipitated at dendrite/cellular boundaries as bright areas and the primary α-Mg solid phase as dark areas in the melted zone, as shown in Figure 2.

Figure 2(a) indicates the whole morphology of the solidification microstructure within the lasermelted zone, and the melted depth is nearly 150 μm. It can be found that the refined microstructure is not uniform in the melted zone and coarse network of β-Mg17Al12 along the overlapped regions might be formed due to the inadequate energy distribution near the tail of Gaussian distribution in the laser beam together with the re-melted process during laser irradiation.

Al-Mn intermetallics were also found in both laser-melted zone (they did not melt during LSM due to high melting point) and substrate microstructure. Moreover,

the Heat Affected Zone (HAZ) in the experiment was very small due to the rapid laser heating and subsequent rapid cooling. The depth of HAZ is typically less than 50 μm.

At the bottom of the melted zone, coarse dendrite structure was found derived from the partially melted bulk β-Mg17Al12 phase due to insufficient heat and relatively low cooling rate. Moreover, the resolidified microstructure had grown epitaxially from the substrate due to the high temperature gradient, as shown in Figure 2(b).

In the middle and the upper regions of the laser-melted zone, the refined microstructure did not change the morphology due to the ratio of Temperature Gradient (G) and Solidification Rate (V).

Therefore, the microstructure was dependent on the cooling rates varying with the irradiation depth, as shown in Figures 2(c) and 2(d). In Figure 2(c), the eutectic mixture was observed due to the precipitation of β-Mg17Al12 phase at the dendrite/cellular boundaries and the amount of eutectic mixture was increased as the solidification moved further to the melt zone.

Increase Concentration Of Al Based on the kinetic undercooling theory in rapid solidification process, although the formation of β-Mg 17 Al 12 dendrites was thermodynamically favoured in the melt zone, the α-Mg cells propagated into the liquid from the original interface into the melt zone, while β-Mg17Al12 dendrites must nucleate first.

As a result of the much lower entropy of fusion for pure Mg, the α-Mg cells had a higher growth rate than the β-Mg17Al12 dendrites.

In a situation governed by kinetics rather than thermodynamics, t h e f a s t e r g ro w i n g p h a s e predominated the microstructure.

Therefore, Al in the melted zone was rejected by the α-Mg cells and β-Mg17Al12 precipitates formed the eutectic structure at the cell

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boundaries together with the α-Mg cells.

Moreover, the dendrites formed close to the top surface of the melted zone were directed at the surface, as shown in Figure 2(c), and it could be related to the manner of changing cooling rates in the laser melting process, which reached its maximum at the surface. At the top layer of the laser-melted zone (Figure 2 (d)), the coupled eutectic combined with equiaxed dendrite structure and fine cellular structure were formed due to the cooperative growth of α-Mg and β-Mg17Al12 that happened under very high cooling rate.

The distribution of main elementary compositions based on EDS analysis is shown in Figure 3. It can be seen that average Al content increased in the melted zone, which is likely due to relatively more Mg evaporation during the laser process and the fine β-Mg17Al12 precipitation during the laserinduced solidification.

Quantitative analyses of the micrographs confirmed that the Al content in the α-Mg matrix (79.2 - 82.4 wt percent Mg) was in the range of 10.7 - 12.1 wt percent and was enriched at the dendrite/ cellular boundaries (61.3 - 65.8 wt percent Mg) in the range of 30.8 33.3 wt percent, which were higher than the value of 9.0 wt percent in the untreated substrate (89.9 wt percent Mg).

Furthermore, a bright-field micrograph of TEM, presented in Figure 4, is a typical image that depicts the β-Mg17Al12 phase precipitated at dendrite/cellular boundaries in the top layer of the melted zone and the size of the dendrite cell was less than 1 μm.

Moreover, the diffraction pattern of the corresponding area suggests the crystal structure is body centered cubic in the β-Mg17Al12 phase.

This indicated that Al microsegregation in the dendrite /cellular structure took place when the solute was ejected at the liquid/

Figure 1: X-ray diffraction patterns of the as-received AZ91D ingot and the sample sectioned from the laser-treated surface

Top surface layer

Middle region

Boundary

Figure 2a: Three dimensional image of the laser-melted zone Figure 2b: Magnified view of the boundary between laser-melted region and substrate Figure 2c: Magnified view of the middle region Figure 2d: Magnified view of the top surface

2a 2b

2c

2d

Figure 3: Distribution of Al and Mg in the laser-melted zone and substrate of AZ91D alloy

solid interface, and a boundary layer enriched Al developed in the liquid immediately ahead of the solidification front, resulting in the formation of β-Mg 17Al 12 precipitated in the inter-dendritic spaces. The considerable amount of α-Mg supersaturated with Al is maybe one of the reasons for the appearance of primarily α-Mg dendrites, even though the alloy has a nominally eutectic composition.

Cooling Rate & Cell Size To obtain the thermal aspects of the solidification process that in turn has a bearing on the resulting microstructure, the cooling

rates in the melted zone were calculated from a one dimensional heat flow model by the product of Temperature Gradient (G) within the solid at the solid/liquid interface and the Solidification Rate (V) of the solid/liquid interface.

The governing equation is as follows: Equation 1

where α is the thermal diffusivity of the material and is equal to k/ ρCp; k is the thermal conductivity of the materials; ρ is the density of the material and Cp is the specific heat. The initial condition of T = T0 Jul-Aug 2011 metalworking equipment news

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size in μm, γ is the cooling rate in K/s, B is a proportionality constant and n is an exponent ranging from 0.3 to 0.4. This relationship cannot be explained physically, but it can be useful in practice. In this case the relationship between the dendrite cell size and the cooling rate can be given by dendrite cell size = 85 γ-0.33, where the constant B is 85 and n = 0.33.

Figure 4: TEM micrograph showing β-Mg17 Al12 phase precipitated at dendrite/cellular boundaries in the top surface layer, and SAD pattern identifying the β-Mg17 Al12 phase (the zone axis is indicated).

Table 1: Calculated cooling rates and average values of measured dendrite cell sizes in three different regions of the melted zone.

Location Top surface layer Middle region Boundary

Figure 5a: Top surface layer

Cooling rate (K/s) 1.68 x 106 4.77 x 105 8.05 x 104

Figure 5b: Middle region in the melted zone

= 298.15 K was applied at time t = 0.

For AZ91D alloy, k = 55 W/m K, ρ = 1.81 g/cm3, Cp = 1,050 J/kg K. To correlate the microstructure with the laser parameters employed, an attempt has been made to predict the thermal profile and related thermal history (heating/cooling rate and thermal gradient) resulting from the present laser treatment through numerical solution of the concerned transient heat balance equation (Equation 1) considering heat flow within the solid only through conduction.

The dendrite cell size or dendrite arm spacing in the laser-melted zone was measured to evaluate the rapid solidification microstructure induced by laser irradiation. In this study, the measurements of dendrite cell size values were the results of the average of 300 calculations carried out in 15 different fields in the specimen.

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metalworking equipment news Jul-Aug 2011

Dendrite cell (μm) 0.7 ± 0.1 1.3 ± 0.1 2.1 ± 0.1

Figure 5c: The boundary between the melted zone and the substrate

The effect of cooling rates on the dendrite cell morphology of the laser-melted zone can be understood from Figure 5, and Table 1 summarises the calculated values for the cooling rates and the experimental values for dendrite cell size measurement.

Furthermore, the dendrite cell size of the top layer is in agreement with the result of TEM in Figure 4.

It can be seen that as the cooling rate decreases with the melted depth from 106 K/s in the top surface to 104 K/s in the boundary of the laser-melted zone, the dendrite cell size increases from 0.7 ± 0.1 μm to 2.1 ± 0.1 μm.

This agrees with the solidification theory that relates dendrite cell size and the cooling rate according to the literature, described by the function λ = B γ-n, where λ is average dendrite cell

Al, Cell Size & Cooling Rate Are Key Factors An attempt has been made to study the solidification microstructure and the thermal aspects of the solidification process of as-cast AZ91D magnesium alloy after laser surface melting.

The solidification microstructure of AZ91D Mg alloy within the lasermelted zone mainly consisted of a continuous network of β-Mg17Al12 phase precipitated at the dendrite/ cellular boundaries and the primary α-Mg solid phase. The dendrite cell size was observed to increase with the decrease in cooling rates from the top surface to the bottom in the melted zone. Moreover, the Al micro-segregation was found in the inter-dendritic spaces because Al was rejected by the α-Mg cells at the liquid/solid interface, and β-Mg17Al12 precipitation was formed the eutectic structure at the cell boundaries together with the α-Mg cells.

Furthermore, coarse network of β-Mg17Al12 were found along the overlapped regions due to non-uniformity energy distribution of the laser beam and re-melted process during the laser irradiation. The relationship between the rapid solidification microstructure in terms of dendrite cell size and cooling rates of the laser-melted zone was derived from the heat flow model of laser processing and solidification theory. MEN Enquiry No. 5101 Turn to page 80a or log on to www.equipment-news.com to enquire

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More Than Scratching The Surface Speaking to Asia Pacific Metalworking Equipment News at the recent PE COI Annual Conference, Peter Collier, lead, surface finishing initiative, PE COI (Precision Engineering Centre of Innovation), SIMTech shed some light on the field of surface finishing. By Joson Ng

S

omething that is only a few microns thick but has a big role to play on a part’s performance and operational life — welcome to the world of surface technology.

Its application in metalworking is traditionally to improve hardness and wear but in recent years, its sphere of influence has spread even further.

In order to cater to the special characteristics of up and coming industries like the Aerospace and Medtech industries in Singapore, there are government-backed initiatives to help push the surface engineering sector to greater heights.

At SIMTech, the surface finishing initiative according to Mr Collier focuses on four areas of capability building. They are vapour deposition coating, electrochemical coat, wet chemical coating and thermal spray coating.

“First of all, we survey local industries, do market analysis and identify trends and gaps in industrial capabilities,” said Mr Collier. The results of the studies and analyses have led to some projects, which are in various stages of development within the organisation.

Some of the pertinent projects according to Mr Collier include chromium and chromate re p l a c e m e n t s . H e x a v a l e n t chromium, which has the ability to self-passivate was previously used in the industry for corrosion 42

metalworking equipment news Jul-Aug 2011

resistance applications. But with European regulations like the RoHS, EOL-V and REACH coming into play, trivalent chromium coatings are now being used.

Widely used in the automotive and other industries with the exception of the aerospace industry, which was exempted, it is worthwhile to note these coatings may actually provide lower corrosion protection in some applications. It is therefore a priority to improve the coatings by introducing additives to inhibit surface reactions, with the end goal of achieving some self-healing capability in the event of damage to the coatings.

Improving Performance In the area of cutting tools, temperature and wear protections are traditionally provided by TiAlN PVD coatings. Over at the research institute, Mr Collier said they have developed nano composites based on TiAlSiN and CrAlSiN. They give higher wear resistance, higher hardness and toughness for tooling applications. The nano composites can be likened to fibres in a matrix that give the extra performance.

Also in the pipeline for the aerospace industry are thicker PVD coatings. “They can potentially increase erosion-corrosion resistance at high temperatures.

Greater thickness is achieved by high-density plasma deposition.

With high deposition rate, thicker PVD coatings may be production viable,” he said.

Challenges & Trends In Surface Technologies “Surface engineering is an enabler for complex manufacturing in precision engineering. In Singapore, the surface finishing industry focused on the electronics sector, dealing with data storage devices that had the high volume low mix manufacturing model,” said Mr Collier.

“Recent developments in the Aerospace and Medtech industries in Singapore are shifting the profile to low volume high mix, high valueadded manufacturing,” he added.

This movement has posed challenges in surface technologies as the regulations in these industries are arguably more stringent.

Companies in Mr Collier’s mind have since responded. He said: “Companies are taking the steps to take on new quality standards such as ISO 13485 and NADCAP, in line with international best manufacturing practices.”

In Singapore, other than regulations, cost is also a challenge.

Lower cost chemical coatings as alternatives to anodising are also a topic for investigation and development.

In addition, Mr Collier said SIMTech has an operational innovation initiative called the SME Manufacturing Excellence Programme. It looks into the areas of operation analysis and lean manufacturing. It is planned to design a modified program particularly for the needs of surface finishing companies with a view to increase productivity and embracing automation. In conclusion, he said: “We can help in training, providing mentorship, on-site consultancy and advise on automating existing processes.” MEN Enquiry No. 5102 Turn to page 80a or log on to www.equipment-news.com to enquire

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Metrology

Measurement Without Contact While measuring instruments use probes to measure variables including length, non-contact measuring instruments aim for precise measurements through the elimination of user interaction.

Laser scanning is a developing technology suited to today’s quality control and reverse engineering challenges. It has found applications in CMM, providing its users with greater versatility, shortened development cycles and increased productivity. In addition, software programs are being developed to enable better accuracy and to allow traceable measurements. This 44

metalworking equipment news Jul-Aug 2011

A New Wave Of

Advanced Metrology

Non-contact metrological instruments such as laser, radio wave and white light set the trend for measuring variables and eliminate user interaction.

By Natalia Tee

push for better accuracy has led to collaborations between companies.

Deva Electronic Controls has teamed up with Nikon Metrology to integrate the CMM Controller, digital laser scanning probes and Focus Scan software. The company’s scanning probes take the technology a step further by tripling traditional scan rates and eliminating user interaction when scanning components with varying colour or high reflectivity.

The software program offers a 2D preview window, which facilitates laser set up and operation. With the joystick PC View feature, personal computer information can be viewed remotely on the screen enhancing ease of use and leading to more effective operation.

Ilker, Izmir,Turkey

M

etalworking industries have always relied on advanced measuring equipment to facilitate quality control for their manufactured products. The demand for accurate3D surface metrology systems continues to increase as industries implement higher precision.

While non-contact measurement equipment such as laser and white light technology seem to be setting the trend for the future, contact measurement equipment continues to serve the industry.

Por table a rm Coordinate Measuring Machines (PCMMs) are used for dimensional verification, alignment for assembly, CAD compa r ison inspection, 3D scanning, reverse engineering, product development, rapid prototyping, tube geometr y inspection, and many other quality control, inspection and verification applications across many industries.

The Absolute Arm from Romer features a semi-automatic laser power control that works with different surface types without special adjustment. With the integrated laser scanner and the absolute encoders, operators can switch on the measuring arm, launch the software and start measuring.

Another laser scanner example is the HN - 6060 multi-sensor system. Incorporating advanced laser scanners and five -a xis synchronised hardware control, it fits into Nikon Metrology portfolio of 2D and 3D solutions.

In scanning, high-density 3D point clouds from part surfaces can be captured. The laser-scanning sensor extracts surface form and waviness data in one scan, whereas previous tactile gear inspection tools needed to rely on 2D sections of data. Different inspection possibilities are therefore captured.

Optical and hardware control technolog y are combined to develop a laser scanner system that acquires point clouds at a rate of 120,000 points per second

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with an accuracy of five micron.

In specific gear measurement benchmarks, the repeatability has reached less than one micron with non-contact measurement.

The laser scanner and shape from focus sensor use active texture projection to perform highprecision measurement of shapes even with glossy surfaces or with no surface texture. Users can use this system to perform diverse shape measurements of parts such as complex automotive and machined components, moulded parts and medical devices.

Radiowave probe is another example where users do not need to make any direct interaction with the materials. Hexagon Metrology’s radio-wave probe and tool measuring system measure parts and tools directly on the machine tool. The single receiver communicates with up to three

different measuring machines.

Measuring versatility is therefore retained while investment costs are kept low.

Although some measuring tasks cannot be achieved with ordinary probes, for example with large machines, the radio-wave probe has a removable threaded arrangement that allows extensions to be screwed on to arrive at the required length. Using this feature, the probe can accurately measure deeper points.

See The Light Besides laser scanning and radiowave probe systems, a white light sensor may be used as a portable and automated 3D measurement system. Users can choose between a portable configuration and an automated system that can be operated with all common industrial robots.

In the Cognitens system, the white light measurement uses digital stereovision technology to generate accurate 3D data.

This technology is applicable in the automotive industry and accelerates quality control.

Users will be able to observe t he me t rolo g y se n sor t hat enables them to complete a huge variety of shop floor inspection t a s k s . L i n k i n g s e n s o r s to positioning dev ices enables them to automate production line inspection processes.

These advanced measuring equipment are a step forward in measuring length and surface roughness of materials. Accurate measurements give confidence in terms of quality control and assurance of products.

Enquiry No. 5201 Turn to page 80a or log on to www.equipment-news.com to enquire

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Laser

Jul-Aug 2011 metalworking equipment news

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Using Electrons To Measure Material Surface?

Instead of using electromagnetic waves to scan a material surface, a Scanning Electron Microscope (SEM) scans the material with a high-energy beam of electrons in a raster scan pattern. The electrons interact with atoms to make up the sample producing signals that contain information about the sample’s surface topography, composition and other properties such as electrical conductivity.

Back scattered electron imaging, quantitative X-ray analysis, and X-ray mapping of geological specimens and metals require that the surfaces be ground and polished to an ultra smooth surface.

Metals are not generally coated prior to imaging in the SEM because they are conductive and provide their own pathway to ground. In essence, this microscope generates high-resolution images of shapes of objects. It also shows spatial variations in chemical compositions: first, acquiring elemental maps or spot chemical analyses; second, discrimination of phases based on mean atomic number; and third, compositional maps based on differences in trace element activators. Precise measurement of very small features and objects down to 50 nm in size can also be accomplished using the SEM. MEN

Enquiry No. 5202

Vasiliy Cheptsov, Moscow, Russia

Turn to page 80a or log on to www.equipment-news.com to enquire

Product Highlights Carl Zeiss: Comprehensive Inspection Of Round Parts

Faro: Measurement Arm

The O-Inspect is a multi-sensor measuring machine from Carl Zeiss that allows for the inspection of small and complex parts. It is developed for the use in the electronics and plastics industries, for medical and automotive technology, and precision engineering.

The rotary table developed for machine can be mounted and removed by the measuring machine operator. It can be positioned both horizontally and vertically for added benefit. In particular, it enhances the effectiveness of the measurement of round parts, which no longer have to be re-clamped for the optical measurement.

The Faro Edge is a portable measurement a r m t h a t a l l ow s manufacturers to verif y their product qualit y by per forming inspections, tool certifications, CAD-to-part analysis, and reverse engineering.

Designed with the customers’ inputs, the measurement arm features an integrated personal measurement assistant. With its built-in touchscreen and on-board operating system, it provides stand-alone basic measurement capability. As such, a laptop is no longer needed to perform quick and simple dimensional checks, or to optimise system performance with its on-board diagnostic routines.

Additional features include enhanced connectivity with Bluetooth, WiFi among others; sensors that warn against excessive external loads and detect possible setup problems; and a multi-function handle port for quick-change handle.

Enquiry No. 5203 Turn to page 80a or log on to www.equipment-news.com to enquire

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metalworking equipment news Jul-Aug 2011

Enquiry No. 5204 Turn to page 80a or log on to www.equipment-news.com to enquire

Hexagon Metrology: Radio-Wave Probe & Tool Measuring System

The RWP38.41 radio-wave probe and the RWT35.50 tool-measuring system from Hexagon Metrology can be used together — a single receiver can communicate with up to three different measuring machines.

Measuring versatility is therefore retained while investment costs are kept low.

Tools are now held more tightly in the spindle, an improvement to keep up with the growing requirements of accuracy and process safety. The tool measuring system can be used on various places on the machine or even on the parts themselves — this is desirable in particular for very large parts or with shuttle machining.

On the other hand, measuring in the machine using RWP38.41 probes does away with the need for expensive special measuring fixtures and jigs.

Enquiry No. 5205 Turn to page 80a or log on to www.equipment-news.com to enquire

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Form

Integrated

Sheet Metalworking Streamlines Fabricating Operations

Integrated sheet metalworking allows programming efficiency, reduces time from concept to production and actually improves the accuracy of production parts. By Matthew Fowles, group marketing manager, LVD Company

T

he design and fabrication of sheet meta l pa r ts require both 3D design for finished parts and 2D design for flat pattern layouts, as well as punching, laser cutting and press brake programming.

Traditionally, these processes required separate, standalone software tools or un-integrated modules forcing programmers to manually transfer design and program data between systems and machines.

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metalworking equipment news Jul-Aug 2011

The sharing of sheet metal design and programming data from production requirements a n d d e si g n p a r a m e te r s to machine operations and inventory strea mline s the fabrication process and is possible through the use of one programming system to design, unfold, punch, laser cut and bend sheet metal parts. Such a programming system is capable of providing a single, integrated package that allows the user to program all fabricating

operations with optional links to MRP and production planning systems to improve the efficiency and productivity of sheet metal fabrication.

By using a single, integrated software package to program a l l fa br ic at i n g op e rat io n s, product design is streamlined and part programming is made more efficient and accurate. Less programmer training is required and common expertise can be shared among different functions.

Seamless Integration A complete and fully integrated CA D/CA M prog ra mming system not only generates and automatically downloads CNC code to the appropriate fabricating machine but is also able to fully pre -production engineer the piece part in a ‘virtual machine’ e nv i ron me nt , c he c k i n g for manufacturability prior to the punching, laser cutting or bending of any material.

Such integ rated systems can also automatically provide the user with detailed, tool set up graphics and lists, 3D part simulation screen shots (for bending), graphical job reports, including cost and run time analysis. Such a system typically operates on a Windows platform in standalone or networked installations.

Programming starts with a 3D part, directly importing solid models or wireframe designs.

The CAM programming software automatically unfolds the part to generate an exact flat pattern blank design. To laser cut the blank, the software automatically exports the flat part as a DXF file and nests the part, automatically determining the optimal cutting parameters to suit the geometry / material / thickness of the part.

To punch the part, the software again automatically assigns tools and automatically nests the part to achieve optimal material

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utilisation and sheet cycle time.

To bend the part, the program automatically determines bending sequence and press brake setup; checking for part collision with the tooling and the machine.

Throughout this automatic process, the programmer is able to manually or semi-automatically select and assign punches, laser cutting parameters, nesting layout , se qu e nce s, st at io n assignments and machines. Once programmed, the CNC code is automatically delivered to the machine control for production of the required parts.

More flexible programming systems are able to accept 2D design files from a CAD system in IGES, DXF and DWG format.

These 2D flat pattern designs can be refolded (or reconstructed) within the programming software to recreate a 3D design of a part or can be processed directly into laser cutting or punching nests.

More sophisticated systems also include sheet metal oriented 2D CAD tools for the design of complex flat parts for punching and laser cutting. All fabricating functions are programmed with one system, which networks press brake, turret punch press and laser cutting machines. CNC programs and setup information are automatically delivered to the machines.

The software’s punching, laser cutting and nesting data are managed on an SQL server where fabricated parts are itemised in a requirements list. The software evaluates the job requirements and automatically develops optimum nests for the requirements, providing maximum material utilisation and remnant usage, without the need for programmer intervention. Inventory control data is automatically updated for sheets and remnants.

To d a y ’s i n t e g r a t e d programming software supports a wide ra nge of fabricating

machinery and can also support water jet, plasma and flame cutting equipment.

Optimised Operations For bending applications, an integrated software package can simplify the programming of formed parts by automatically determining the correct unfolding / development of the part, as well as the bend sequence, gauging positions and tool selection.

These functions can be optimised for minimum tools stations and part turns.

Laser cutting is optimised using an integrated software package as automatic functions such as nesting, optimisation of cutting and machine parameters elim inate t he ne e d for t he machine operator to calculate parameters. The software is able to provide flexible lead-in / lead-outs for contours, bridges, loops and micro-joints, defined and classified by the cutting requirements, material type, and sheet thickness.

Punch press programming time can also be shortened

through the use of automatic to o l s e l e c t i o n a n d t u r r e t configuration, and identification of optimum tool stations. Support of advanced punching functions such as auto-index, multi-tools, standard and special punches, further enhances the flexibility of punching operations.

T h e g o a l o f i n te g r a te d fabrication is that the process of fabrication — from the design and programming of a part to its manufacture — is more quickly and easily rendered using the best possible unfolding, nesting, punching, laser cutting and bending programming solutions.

Integrated sheet metalworking improves programming efficiency, reduces time from concept to production and actually improves the accuracy of production parts.

The technology is made more flexible by recent developments aimed toward a more intuitive man-machine interface. Today’s icon-driven user interfaces aid the integrated process. MEN Enquiry No. 5301 Turn to page 80a or log on to www.equipment-news.com to enquire

LVD: Software To Analyse Equipment Effectiveness LVD has developed an Overall Equipment Effectiveness (OEE) module to its CADMan family of offline software. It provides an added integration module to measure equipment effectiveness for a variety of sheet metalworking machinery.

The software program examines and reports on equipment productivity and performance. It provides analysis in simple, easy-to-understand graphical charts and uses an intuitive presentation of the ‘real’ shop floor information to systematically improve the production process by increasing uptime and throughput through closely monitoring machine availability, performance (theoretical cycle time vs real cycle) and quality.

Enquiry No. 5302 Turn to page 80a or log on to www.equipment-news.com to enquire

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Focus

Mould & Die Making:

Albert Cheng (L) and Chew Cheong Loong (R)

Marketing & Skilled Labours

Required At the recent MTA Malaysia, Asia Pacific Metalworking Equipment News (APMEN) sat down with the president of Malaysia Mould and Die Association (MMADA) Albert Cheng, and Chew Cheong Loong, the association’s head of public relation in an exclusive interview to gain a valuable insight into its industry. By Joson Ng

F

re sh from a genera l meeting with the rest of his Asian counterparts in the mould and die industry, Mr Cheng had good news — growth all round. “With the cost getting higher in China, a lot of orders are finding themselves back in Southeast Asia, benefiting Malaysia, Thailand and Singapore. For us, the market in Malaysia has been good in the first quarter of the year. Whether our members can take advantage of this growth depends very much on their ability to be export friendly,” he said.

Touted by some to be a ‘hidden treasure’, the mould and die makers in Malaysia have versatility.

They serve a broad spectrum of industries like the automotive, oil and gas, aerospace and precision mechanics, according to Mr Chew.

In addition, Mr Chew said the quality of Malaysia’s mould and die ranks top in the region. As such, more companies will be venturing into mould making for medical applications, which require a high level of precision.

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metalworking equipment news Jul-Aug 2011

Automation To The Rescue The rising cost in China may have benefited the region but it cannot be said that Southeast Asian countries are protected against this phenomenon. However, it can be mitigated. Said Mr Cheng: “Based on current developments, I think when it comes to cost, we are on par with our Thai counterparts. But with rising cost a factor, it is down to our members to think about how to improve their efficiency.”

One way to achieve a high level of efficiency according to Mr Chew is to embrace automation. He said: “Automation improves productivity.

For instance, a job can be preset and left to run smoothly with minimum operator input leaving them to concentrate on in-process control, contributing to the quality of the final product.”

Challenges For Malaysia’s Mould & Die Industry One common challenge in the mould and die manufacturing sector is the shortage of skilledlabour. To illustrate a problem

that transcends national borders, Mr Cheng said: “The shortage of skilled-labour is a problem but we are not the only ones facing it. We just came back from Indonesia at the end of last year. They have a lot of general workers but they are not skilled. So in a way, we are still in a better position.”

A change in mindset is required to tackle this problem. Mr Cheng felt automation is “one of the important criteria” to fulfill in order to overcome this challenge.

Coupling it with the usage of software programs, this helps to alleviate the existing problem of labour shortage.

Mov ing away from the labour conundrum, Mr Cheng revealed the country does not have a full range of mould and die steel available, which limits the choice of raw materials. In addition, there are not many heat treatment companies that can provide quality treatment, making outsourcing the only solution for now as in house capability is only adequate for small parts.

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Initiatives: Attract Foreign Investment In order to address the root cause of labour shortage and promote the industry further, Mr Cheng felt marketing is key. It has dual benefits that not only elevates the awareness of the industry so as to attract more people to join, but also brings in foreign investments.

MMADA has been in talks with government bodies to help bring members to the global arena and make the industry an attractive destination for school leavers.

Marketing is an enabler but unfortunately, Mr Cheng had identified it as a weakness among the Malaysian mould and die fraternity. “Despite producing parts of high quality, these companies lack marketing know-how. They need to tell others how good they are. That is why MMADA is trying to encourage our members to join

Intrade,” said Mr Cheng.

“Intrade is an annual show organised by the Malaysia External Trade Development Corporation (MATRADE). This year is a little specia l. We have requested the organisers to arrange for a promotion that showcases the manufacturing engineering supporting industry. We have now a pavilion of 40 booths. Those companies eligible under the SME category are entitled to the market development grant, which can be as much as 50 percent of the expenditure at the exhibition.

On top of that, they are also allowed to apply for double tax deduction,” he said.

Initiatives: Increasing The Standard Zeroing on the labour issue, Mr Chew said: “The Malaysian government is putting a lot of

Couldn’t I harden my high-cost components myself right here?

Couldn’t I harden my high-cost components myself right here?

Would modern Would that be Couldn’t I harden my high-cost equipment fit in components here? expensive? myself right here?

Would modern Would that be equipment fit in here? expensive?

Would Would be What would be modern Canthat we handle that equipment fit in here? expensive? the fastest solution? without specialists?

What would be Can we handle that the fastest solution? without specialists?

What would be Can we handle that the fastest solution? without specialists?

effort and budget into training skilled-labours. There are training institutes under the ministry of labour and also polytechnics training the younger generation.

Within MMADA, we are helping our members to conduct training in practical areas rather than just pure theoretical studies.”

One other initiative by the association is to help older skilledlabours achieve certification that befits their level of proficiency in mould and die manufacturing because more often than not, they do not possess academic certificates.

This, the association hopes, will help give the industry the glamour it deserves. Also, perhaps more pertinently, it helps bring up the income of the workers. MEN Enquiry No. 5401 Turn to page 80a or log on to www.equipment-news.com to enquire

The Ipsen The Ipsen for do-it-yourself do-it-yourself for The Ipsen metal heat treatmetal treatdo-it-yourself for ments.heat If only every ments.heat If were only every metal treatdecision this decision this ments. only every easy. If were easy. decision were this easy.

You contact us by phone at Forcan more information, +604-646 7793 or by email at sales@ipsenmalaysia.com

Hard work wins Hard work wins

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05.02.10 15:16 05.02.10 15:16

NO NO 125043 ENQUIRY ENQUIRY ENQUIRY NO 043 NO 043

call +49 2821 804-293, e-mail us at For more information,

Regional address: rgi@ipsen.de or www.ipsen.de call Industrial +49 2821 804-293, Ipsen Furnaces Sdn. Bhd.e-mail us at For more information, Plot 48b, Jalan Hilir or Sungai Kluang 5, rgi@ipsen.de www.ipsen.de call +49 804-293, e-mail us at Bayan Lepas2821 Non Free Industrial Zone, Phase IV, 11900 Bayan Lepas, Penang, Malaysia Hard work or wins rgi@ipsen.de www.ipsen.de www.ipsenmalaysia.com

Jul-Aug 2011 metalworking equipment news 05.02.10 15:16

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Tinkerbrad, Greenville, Mississippi

Korean Manufacturers

APMEN takes a look at the South Korean manufacturing industry. By Michael E Neumann

T

he South Korean manufacturing sector today serves a myriad of industries worldwide.

With household na mes like Samsung and Hyundai, each of them a trendsetter in their own rights; they have pushed South Korea up the league of international manufacturing powerhouses.

In metalworking, there has been a drive in the positive direction, with companies like Doosan Infracore, Hyundai Wia, Hwacheon, Korloy among others playing significant roles. The industry is looking to add to the general optimistic mood when the Korea Institute for Industrial Economics and Trade forecasted that in 2011, strong demand is expected in the automobile industry due to the need to replace cars older than 10 years.

Over at shipbuilding, some 1.1

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metalworking equipment news Jul-Aug 2011

percent increase is expected in 2011 due to sales of high-priced vessels. As one of the leaders in this field, the key to staying ahead lies in differentiation, in which South Korea should focus on its strength and maintain its lead through R&D. Dome stic compa nie s a re expected to continue investing in genera l machiner y, w ith additional pressure to replace ageing facilities keeping demand high. This as a result will keep the production of steel on a stable increase. The global steel industry recovery is accelerating in emerging markets, with South Korean steel experts on the rise.

Machine Tool Industry: Order/Production Figures According to the Korea Customs Service, machine tool orders in March 2011 rose 34.3 percent compared to the previous month

to 525.5 billion won (US$490 million), an increase of 75.3 percent compared to the same month in 2010. Machine tool orders in the first quarter of 2011 rose 77.5 percent over the same period of the previous year to reach 1.3 trillion won, which is the best quarterly showing.

Machine tool production in the first quarter of 2011 rose 31.5 percent over the same period of the previous year to 781.7 billion won. Machine tool shipping has also increased 45.7 percent to 798.2 billion won in the period.

R&D Lead Spendings From design all the way to manufacturing, these processes can all be supported by South Koreanmade equipment or products.

For example, CAD/CAM software programs, machine tools and cutting tools have South Korean

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The sharp rise in investment is mainly attributable to enterprises’ investments designed to enhance globa l competitiveness a nd secure new growth engines.

By industry, investment by manufacturing is expected to grow by 4.4 percent to 71.4 trillion won and that by non-manufacturing is likely to rise by 19.6 percent to 43.1 trillion won. In 2010, the top 600 firms investment totalled 104.5 trillion won, up 22.6 percent from the previous year.

Own your laser weld with FREE €2,500 training!

Enquiry No. 5501 Turn to page 80a or log on to www.equipment-news.com to enquire

KOAMI Sees Malaysia As Gateway To Southeast Asia

By Joson Ng

The Korean machinery industry has high hopes for Southeast Asia and its first stop is Malaysia.

Kim Jin Oh, marketing team manager of Korea Association Of Machinery Industry (KOAMI), recently led the South Korean contingent at MTA Malaysia as the machine makers from the country aim to generate more support in this region for machines made in South Korea.

This drive southwards, according to Mr Kim, is supported by the South Korean government and the focus is on innovation. He explained: “To cope with a changing world, South Korean machine makers are very R&D driven. In addition, there is plenty of assistance from the government in terms of grants and subsidies because they fully understand the importance of markets in Southeast Asia.”

The role of KOAMI is to initiate governmental policies in the machinery industry on a civil level. According to Mr Kim, it also addresses the holistic revenue generation in respect to the machinery industry.

In order to maintain and improve on the current level of revenue especially in Southeast Asia, the South Korean machinery producers have to rely on their competitive edge. Said Mr Kim: “We focus on the convergence between IT and R&D with machinery. As such, we have already achieved a certain level in the global standard and it is still progressing.”

He is in a right place to exercise his judgment as the organisation certifies the quality of the machines supplied to the end users. Through this, he felt it “guarantees the increase in consumption of the machines and contributes to national growth.” MEN Enquiry No. 5502 The South Korean machinery industry has high hopes for Southeast Asia

Turn to page 80a or log on to www.equipment-news.com to enquire

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manufacturers in the respective fields. In order to cater to such a wide range of products and applications, there is a strong focus on R&D, which can be seen in various companies’ expenditures.

In a survey by the Federation of Korean Industries (FKI) on top 600 firms’ investment results and plans, the forecast reads that their investment volume in 2011 is expected to rise by 9.7 percent over the previous year to mark 114.6 trillion won, the biggest ever.

In particular, R&D investment is likely to increase by 17.1 percent.

Jul-Aug 2011 metalworking equipment news

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CAM To The

Rescue T he GibbsCAM system at Double M Engineering in High Wycombe has enabled the company to produce CNC programs in 10 minutes instead of an hour or more, according to MD Mark Phillips.

The company manufactures precision parts for F1 racing teams, marine, oil and gas, and aerospace industries. Typical components include valve bodies, brake and fuel hose connectors, and critical parts for Martin-Baker ejection seats.

Good Parts Make Good Relationship As some of the materials are supplied by its customers, manufacture has to be right first time. The CAM system plays a key role in achieving this, and has enabled the company to build close relationships with its clients.

“We looked at a lot of systems, but GibbsCAM was the easiest to use. It is predictive, making useful assumptions about what we want to do next. We are also able to quickly move and edit operations in response to what is happening on the shop floor, enabling us to optimise our machining 54

metalworking equipment news Jul-Aug 2011

Using CAM systems improve productivity and forge better working relationship.

By Richard Mortimer, for GibbsCAM

processes,” says Mr Phillips.

The company receives both paper drawings and CAD models, so the Parasolid modelling capability in the CAM software helps the company to create and manipulate its customers’ designs ready for production. Models created in CATIA V5, NX 5, Pro/ Engineer and SolidWorks can all be imported directly into the software ensuring its compatibility with all Double M Engineering’s clients.

Mr Phillips adds: “We can produce a CNC program in 10 to 15 minutes, which enables us to meet the delivery demands of our F1 customers, which can be as short as four hours.”

Keep It Simple Programming the different axes is simple in GibbsCAM. The software generates a plane to match the axis requirements of each part of the job, automatically extracting the profile that needs to be machined.

Mr Phillips says: “For C-axis and sub-spindle work, it makes it easy to visualise the cutting process and avoid collisions. The software also takes account of the reversed Z-axis

when working on the sub-spindle, eliminating the possibility of error.

For the valve bodies we machine, we can quickly get the compound angles we need to cut different faces of the part. The visualisation allows us to examine the methods we have chosen so that, for example, we can see if we are drilling across an existing hole, which can cause inaccuracies in the finished part, and take corrective action.”

Fast and reliable programming has enabled the company to machine much more complex parts than was previously possible.

Mr Phillips says: “We can evaluate the job more effectively and allow ourselves plenty of time to order special tools and develop the most effective cutting methods. The downtime on the machines through programming is much reduced, and productivity has improved by around 30 percent. The complex components and tough materials which we can now cut with ease are more profitable, enabling us to build improved partnerships with our customers.” MEN Enquiry No. 5601 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 115

MRO On The

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Features

Singapore is widely considered to be one of the MRO hubs in Asia. Asia Pacific Metalworking Equipment News finds out why and also takes a look at what lies ahead. By Joson Ng

S

ingapore celebrates its centenary in aviation this year. Aviation in the country has come a long way since Singapore witnessed her first flight 100 years ago.

Home to international names like Singapore Airlines and the Changi Airport, Singapore has established herself as an air transport hub. The island state has many open-skies agreements with countries all over the globe, opening doors for its aerospace industry.

The Maintenance, Repair and Overhaul (MRO) cluster in Singapore has capitalised on this policy and has established itself as a major force in the region.

A sleuth of programs by the Civil Aviation Authority of Singapore (CAAS) continues to help boost this sector.

One of its programs, called the Process Innovation Challenge (PIC), has been launched to promote a culture of continuous process improvement in the aviation sector to enhance productivity. Some S$500,000 (US$400,700) has been set aside for this program, which seeks to encourage companies to carry out manageable ‘quickwin’ projects, targeting either job redesign or process improvement in order to raise worker productivity in the sector.

The program will also facilitate intra-industry learning and accelerate the adoption of good ideas across the aviation sector.

The Changing MRO Landscape In Asia Asia is a fast-changing neighbourhood in the world and its MRO clusters are no exception. With globalisation, the MRO market worldwide is expected to grow. The 56

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factors for growth include the increase in aircraft order, airline expansion, as well as the increase in air traffic. With airlines looking to be more cost-effective, outsourcing is expected in areas like maintenance. As such, this will benefit the MRO cluster.

In order to reap those benefits, MRO services providers must be prepared to invest in themselves to be more innovative in providing solutions with various options.

Future Technologies From turboprop engines to jet engines like the turbojet and turbofan, a modern aircraft has gone through several rounds of developments. The ethos of the engine builders now rests on producing more fuelefficient engines that emit less noise.

The trend taken by major aircraft engine builders revolves around CO2 and NOx reduction, as well as weight reduction, therefore achieving the ultimate aim of lower fuel consumption. With an eye on achieving the environmental target set by Advisory Council for Aeronautics Research in Europe (ACARE), some builders are looking at open rotor advanced turbofan to help them meet the standards.

The industry can expect lighter engines and even a wider usage of SMAs (Shape Memory Alloys) in the construction of future engines. Other developments may address issues like maintenance cost, safety and usage of biofuels.

Enquiry No. 5602 Turn to page 80a or log on to www.equipment-news.com to enquire

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Gearing Up For Changes Using materials other than metal in an aircraft was unimaginable in the past but this belief is fast changing with the rise of direct digital manufacturing processes like FDM and others.

Pradeep Nair (L) and Darin Everett (R)

FDM technology can improve flexibility, efficiency, time and costs The future in the aerospace industry seems to be pointing towards lighter, more fuelefficient aircraft operating at lower noise levels. This push has opened the door for lighter material and the more flexible process of Direct Digital Manufacturing (DDM). One such process is Fused Deposition Modeling (FDM) by Stratasys.

“With DDM, engineers have the capabilit y to design a par t without constraints imposed by the manufacturing process. Strategies can be incorporated to lower weight, reduce cost or increase performance. For instance, with FDM, if desired, part weight can be reduced with internal honeycomb structures,” said Darin Everett, business development manager, Stratasys.

Aero Strategies Exhibiting at ASX, Pradeep Nair, regional director (ASEAN and India) of Stratasys shared with APMEN the company’s view on the aerospace industry in the region.

APMEN: What is Stratasys’ strategy in this region?

PN: There is a good market for direct digital manufacturing in this region. We are in talks with Nanyang Polytechnic in Singapore, trying to establish a good partnership with them. At Nanyang Polytechnic, the Fortus 900mc machine is used to support its diploma curriculum and in-house development projects. The polytechnic is also actively engaging the industry to support their rapid

The process of DDM evolved from the rapid prototyping industry, and has come a long way, according to Mr Everett.

Speaking to APMEN in an exclusive interview, he said: “Until 10 years ago, we only had lower strength plastics, which was a barrier into manufacturing applications. This is a materials-driven industry. Each time we introduce another thermoplastic and provide appropriate test data, barriers are lowered. These ba r r ie r s a re fur the r lowe re d whe n customers carry out their own testing.”

However, there are unique entr y barriers to the aerospace industry, which according to Mr Everett takes effort to overcome. While it may take work, he says it is “happening today and well within

the capability of FDM.” Though there are multiple applications for FDM in the industry, he does not feel it will replace traditional processes. It does however play a complimentary role to traditional manufacturing processes.

He revealed when used on a plantwide basis, for prototyping and DDM applications, FDM te chnology can improve flexibility, efficiency, time and costs. For instance, it can be used to create tooling in composite, sheet metal, and plastic shops. Response time is faster, bringing along cost reduction and performance enhancements as well.

prototyping, tooling and manufacturing needs and to enhance productivity at the workplace and competitiveness. Besides rapid manufacturing, the polytechnic is also actively involved in developing competence in direct rapid fixturing, direct rapid manufacturing of aerospace components and composite tooling for aerospace applications. Because they are addressing the MRO market, we hope they can help prove the effectiveness of this alternative technique. As such, we are providing them technologies over the next few months.

We believe the Singapore market is going to be big.

A P M E N : H ow m u c h o f yo u r business in ASEAN is devoted to the aerospace industry?

Enquiry No. 5603 Turn to page 80a or log on to www.equipment-news.com to enquire

PN: I am confident in 24 to 26 months, it will take up some 15 to 20 percent of my business.

APMEN: Tell us about the machine at the show.

PN: The uPrint is a personal 3D printer. It is the first commercial quality 3D printer under the price tag of US$15,000. Stratasys also makes a range of professional and production 3D printers priced as high as US$450,000.

Enquiry No. 5604 Turn to page 80a or log on to www.equipment-news.com to enquire

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Metrology Going Skywards An established force in the automotive industry, one metrology company is looking to stake its claim in the aerospace industry.

Going for quality rather than quantity is Shaun Lim Singapore is one of the aerospace hubs in Asia with its Seletar aerospace park being the kingpin of the country’s aerospace master plan. The push by the Singapore government coincides with Carl Zeiss’ foray into this industry globally. Shaun Lim, regional sales manager of the company’s Southeast Asia region told Asia Pacific Metalworking Equipment News (APMEN) that the development plan was formulated a year and a half ago.

“Some of our colleagues were given extra responsibilities to cover the aerospace industry as key accounts manager worldwide (eg: America, Europe and Asia). As such, we are now trying to learn and gather information about this industry. Although our core

competency is in the automotive industry, we feel we have the right machines and software programs for the aerospace industry. An example is Blade Pro. It is a specialised software developed to measure turbine blade,” he said.

In its effort to be known to the aerospace industry, the company recently took part in the Aerospace Supplier Exchange show in Singapore. At the show, the company showcased its Accura 2 CMM. Said Mr Lim: “This range of CMM is what we call the performance range, a mid-level type of machine in terms of accuracy and performance. Since its launch in Germany last year, we are trying to achieve a more visible launch in Singapore. So far we have

sold two units in Singapore, one of them to a company in the aerospace industry. We are also in talks with another aerospace company in Malaysia to provide them with a turnkey solution. We will be setting up their QA department for them.”

Quantifying quality is obviously the company’s business. This focus on quality can also be seen in Mr Lim’s expectations in par ticipating in an exhibition that caters for a niche industry such as the aerospace industry.

“When we first decided to come for the show after visiting it two years ago, we knew this is a small show exclusively for the niche market. As such, our expectations were already adjusted compared to MTA Singapore. Though we did not expect a big turnout, we knew that the quality of visitors would be quite good,” said Mr Lim. He was proven right when he disclosed in two days at the exhibition, he made quite a number of good contacts, including potential customers previously unknown to them.

Enquiry No. 5605 Turn to page 80a or log on to www.equipment-news.com to enquire

Event Review: ASX 2011 Riding on its successful inauguration in 2009, the Aerospace Supplier eXchange (ASX) 2011 returned for its second edition this year from April 27-29, 2011 at the Sands Expo and Convention Centre, Marina Bay Sands, Singapore.

The event is a regional conference and exhibition that showcases the latest technologies, solutions and support capabilities of aerospace suppliers. This biennial event is a business platform that meets the vital sourcing needs of both

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Original Equipment Manufacturers (OEMs) and Maintenance Repair and Overhaul (MRO) companies.

A component of this year’s event was the ASX 2011 Conference, organised by the AAIS in partnership with aerospace

consultancy firm, AeroStrategy. It was held concurrently with the exhibition. The first two days of the conference focused on suppliers, while day three targeted Asian MRO perspectives. Industry professionals and practitioners also had the opportunity to hear from influential industry leaders.

The ASX Business-to-Business (B2B) Meetings, titled Global-Asia Trade Exchange (GATE) Aerospace 11 was also an important component of the event. An International Enterprise (IE) Singapore’s initiative, GATE Aerospace 11 was a business matching platform for one-to-one meetings between global aerospace OEMs and top tier suppliers, and Singaporebased companies.

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The event is a regional conference and exhibition that showcases the latest technologies, solutions and support capabilities of aerospace suppliers

It allowed key procurement decision makers to better understand Singapore companies’ capabilities, especially in the areas of precision machining, heat and surface treatment, avionics, casting and sheet metal fabrication. The GATE Aerospace meetings were jointly managed by the AAIS and IE Singapore.

Aerospace Manpower Study Last year, the AAIS Aerospace Human Capital Steering Committee (AHCSC) initiated the Aerospace Manpower Study to better understand the human capital needs of the industry. The study, commissioned by the AAIS under the auspice of the AAIS AHCSC, and conducted by Mercer, is one of the first manpower landscape studies done in any industry locally.

Following the release of phase one in 2010, which outlined the current state of manpower affairs in the industry and diagnosed the future state of manpower in the aerospace industry, phase two revealed more detailed findings and strategies to address manpower gaps and development of the next generation of aerospace professionals.

The study incorporated a broad range of perspectives — including students and other prospective employees, existing employees, aerospace industry employers and HR professionals, institutes of higher learning, and relevant industry and government bodies — to provide a comprehensive view of the attraction issues and retention challenges, so as to develop effective manpower strategies for the industry.

“The Aerospace Manpower Landscape Study launched in September last year resulted from the need to understand individuals and HR practices within the industry. Phase two was commissioned thereafter, and I am pleased to report that the findings highlighted a number of critical touch points that the industry should tend to in their efforts to attract, recruit and retain manpower,” said Gary Nutter, second VP, AAIS, and Projects Sub-Committee, AHCSC.

Attracting Qualified School-Leavers Phase one of the study revealed that in order to cater to the industry’s growth aspirations, a key priority for the industry was to step up recruitment for technician jobs to meet the necessary demand. A major source for such jobs has been students studying aerospacerelated courses in polytechnics and ITE. At first glance, the number of graduating students seems sufficient to meet future industry demand.

The study found that the perception of the industry among both groups of students is positive. However, more than 60 percent of polytechnic student respondents indicated that they would pursue further studies, and more than 30 percent indicated that they are considering doing so. This suggests that while there is an ample supply of polytechnic graduates, many of them are unlikely to join the industry as technicians needed to fuel industry growth. Among ITE students, an estimated 70 percent of graduates from aerospace courses actually join the industry, with a smaller percentage pursuing further studies.

Re-Skilling & Attracting Employees From Other Industries While school-leavers are a key source of manpower for technician roles for the aerospace industry, there is potential to seek manpower from other industries, particularly those experiencing cut-backs. In fact, there are examples of mid-career recruits from other industries who have successfully made the switch to the aerospace industry. The stability of the aerospace industry in different economic cycles is one factor that makes the industry attractive. However, the study indicated that employees in other industries are often not aware of the opportunities available in the industry. They appeared to have a less positive view of industry stability than warranted.

The study recommended that the industry expand its recruitment drive to attract recruits from other industries and non-traditional sources (eg: women), through targeted outreach programs and to provide the necessary support and re-skilling for mid-career recruits to settle into the industry.

To that end, increasing awareness of the aerospace WSQ framework will highlight an alternate pathway for locals seeking to enter the aerospace industry.

Reducing Attrition Of Current Industry Workforce Wh il e wo r k fo r c e c h u r n w i th i n th e aerospace industry is greater than attrition to other industries or other countries, it is not a desirable state for companies as it results in loss of experience, skills, and productivity, as well as increased recruitment and ramp-up costs.

The study showed that different staff groups value different components of a company’s value proposition to its employees.

For example, the topmost consideration for Gen Y employees in choosing a job is career potential and development, so initiatives to assist them in continuing their studies (such as scholarships or permanent day-shifts for those attending evening classes) are effective retention mechanisms.

Enquiry No. 5606 Turn to page 80a or log on to www.equipment-news.com to enquire

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Features

T

he challenge of our industry and even the economy today is one of competitiveness. In order to compete in an ever-tighter globalised marketplace, companies need to identify real pains, work hard to build better products to answer those pains, and provide them to market at the right time and the right price.

Businesses who want to survive and grow must deliver fast turnaround from initial design to final production of goods. The cost/quality of the goods must continually aspire upwards.

Getting it right of course is part science and part art/intuition.

Industry Recognises Speed Companies now recognise in the emergence of 3D printing as an essential tool for delivering a fast design to production turnaround and improving the cost to quality ratio of the end products that go to market.

Once upon a time no one would have believed it possible to design a product on a computer screen and then be able to hold and test the actual part less than an hour later. 3D printing technology does just that.

And the advantages are two-fold: speed and realism.

Prototyping The Modern Way Unlikemachinetools,thedevelopment of prototyping has remained stuck in the pre-industrial era. Architects pay students to painstakingly build and glue cardboard models of their buildings. Car manufacturers hire teams to build heavy clay models of their next generation of vehicles; dental labs use inconvenient and messy bite impressions to design veneers, crowns and orthodontic appliances. All of this takes up manpower hours, is difficult and expensive to repeat, and does not accurately represent the end product they are seeking to test.

And because machine tools, presses, injection machines and moulds remain expensive to

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The

Modern Rapid Prototyping:

NeedForSpeed The fast and furious nature of manufacturing today has pushed developments in prototyping to match the R&D efforts of their counterparts in machine tools. By Gilad Gans, executive VP, Objet Geometries produce, rather than replace the capital equipment, it is often easier to simply live with a mediocre design. As such, the end quality of the products we make has been allowed to suffer as an inevitable ‘cost’ or sideeffect of modern production.

Even with the advent of CAD/ CAM, projects with massive budget items that can stretch on for years — particularly in the larger strategic manufacturing sectors such as defence.

Advantage Of 3D Printing Technology However, with 3D printing technology, the prototyping process has now finally caught up. Three-dimensional printing technology puts an immediate end to the manual prototyping bottleneck by providing a rapid and automatic means of fashioning parts that can be accurately tested in real-world scenarios, well before the design is placed into production.

Along with speed, 3D printing provides the advantage of producing realistic representations that can be properly tested and checked for design faults early

on in the design cycle. Once a design fault is identified in the model, designers and engineers can simply tweak the design on the CAD program and print and test again, as many times as they like, until the design is perfected.

While conceptually inkjet based 3D printing is similar to 2D printing, in reality it jets a polymer instead of ink and the printer surface moves down as the model ‘grows’ on the build tray. One of the most outstanding aspects of this type of additive technique is its ability to jet different materials with different properties within homogenously grown parts. So, for example, a toy car can be printed with rubber-like properties at the wheels and a hard chassis. The wheels will actually revolve — with no need for assembly at all.

Using additive 3D printing techniques, designers and engineers can create whole 3D prototypes and functional parts from nothing, layer by layer, directly from their standard CAD design software. The result is a faster, simpler prototyping process, which results in a better end product. MEN Enquiry No. 5607 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 119

EVENTs&

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exhibitions

Event Preview:

Wire Southeast Asia/Tube Southeast Asia 2011

E

xhibitors from more than 20 countries have already confirmed their presence at the event and the organisers expect the final numbers to reach more than 300 exhibitors from 30 countries. National pavilions from Austria, China, Germany, Italy, the USA, United Kingdom, and Taiwan have also been confirmed, lending the event a global flavour.

Backing up the global nature of this regional event, the show also enjoys strong support from industry organisations, one of them being the International Tube Association (ITA). Says ITA president Dr Gunther Voswinckel: “The ITA is delighted to be the main international sponsor of Tube Southeast Asia, having been a strong supporter of its predecessor Tube Singapore since the very first edition.”

While Dr Voswinckel feels that the previous Tube Southeast Asia event in 2009 undoubtedly suffered from the tail end of the global recession. Now, with very positive economic forecasts coming from Malaysia, Vietnam, Indonesia and Thailand itself, averaging at growth rates of five to seven percent fuelled by major infrastructure projects, the 2011 exhibition should prove to be scheduled at a very opportune time for the industry.

Growing Demand As noted by key supporting organisations, Thailand and Vietnam are major users of wire and tube solutions. Thailand has a well62

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developed industrial infrastructure with large automotive, electrical/ electronic, petroleum and petrochemical industries boosting demand. As income levels rise in the country, high levels of infrastructure spending will also be essential.

The need to develop infrastructure in Vietnam, is becoming increasingly pressing as the country emerges as a production base integrated with the global economy. Vietnam’s Ministry of Planning and Investment estimates that between now and 2020, Vietnam will require some US$150 - 160 billion for infrastructure development.

Indonesia & Malaysia Spur Demand Indonesia has enjoyed an extended period of political stability and the outlook remains positive for continued investment in infrastructure, petroleum and petrochemicals, and mining. GDP growth is also forecast to remain strong in coming years, exceeding six percent per annum.

The Indonesian automobile

industry has recovered strongly and double-digit growth is forecast for the next four years, with industry estimates pointing to a doubling of production between 2010 and 2015. The country is transforming into a global manufacturing base for MPVs. In addition, the country will require an estimated US$150 billion of infrastructure investment over the next five years.

Malaysia and other ASEAN economies are benefiting from a renewed emphasis on FDI in the Southeast Asian region, partly to counter higher labour costs and reduced incentives in China. To consolidate its position as an investment destination, Malaysia is promoting several logistics infrastructure projects that will accelerate demand for wire and tube solutions.

BITEC Bangkok, Thailand September 13 – 15, 2011 Enquiry No. 5701 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 120

EVENTs&exhibitions

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Event Preview:

Vietnam Manufacturing Expo

Industrialists will discover more business opportunities as three trade exhibitions are joining forces

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or the first time in Vietnam’s manufacturing and supporting industries, industrialists will discover business opportunities as three trade exhibitions are joining forces for parts makers to meet buyers from Japan and other countries.

They will enhance their productivity with machinery and technologies in ‘Industrial Components & Subcontracting Vietnam 2011’, ‘SI Exhibition: The fourth Vietnam – Japan Exhibition on Supporting Industries in Hanoi’ and ‘Vietnam Manufacturing Expo 2011’.

Hanoi Industry and Trade Department, Trade Promotion Centre (HTPC), Japan External Trade Organisation (JETRO) in Hanoi together with Vietnam

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metalworking equipment news Jul-Aug 2011

Trade Promotion Agency, and Reed Tradex Company will cooperate in the organisation of the shows during September 15 - 17, 2011, at ICE Hanoi, Vietnam.

Rapid Growth The fast growing number of foreign investors leads to an expansion of Vietnam industrial manufacturing, especially the local production.

According to the Minister of Industry and Trade, Vu Huy Hoang, Vietnam achieved 14 percent industrial production growth in 2010, nearly double the previous year’s growth rate. The country will accelerate its industry trial production from this year to become an industrialised nation at the end of this decade.

Realising the requirement to shift

Vietnam’s industrial production structure, the government of Vietnam seeks to achieve their goals by providing a greater trade opportunity for domestic part makers through exposure to technology, while at the same time strengthening Vietnamese suppliers’ capability to reduce the need for import.

Nguyen Huy Tuong, vice chairman of Hanoi People’s Committee presides over the signing ceremony and press conference at Hanoi City Hall, whereby Luu Tien Long, director of Industrial and Trade Department, Hanoi People’s Committee said: “Vietnam expects a bright growth scenario in 2011.

Accordingly, the value of industry and construction is expected to

EVENTs&exhibitions

climb to 8.2 percent. State budget revenue is estimated to increase 16.7 percent, which is equal to 26.7 percent of the country’s gross domestic product. Foreign Direct Investment (FDI) is expected to increase 15.5 percent to VND 198.6 trillion (US$20 billion), accounting for 21.4 percent of the total social investment capital.”

This means that the manufacturing sector, especially the supporting industries will need to be prepared for the growth.

The coming together of the three important shows will both offer local parts makers a chance to meet buyers while keeping abreast of manufacturing innovations and for overseas investors to meet the right suppliers while reducing the needs to import parts.

Three-In-One The first show is the Industrial

Components & Subcontracting Vietnam 2011, which promises to match local parts makers with overseas buyers in a profitable networking platform. Vietnamese delegates will learn new know-how in concurrent seminars and earn the confidence of overseas investors.

The second show is Vietnam Manufacturing Expo. Chainarong Limpkittisin, MD of Reed Tradex said: “This is a special year for Vietnam Manufacturing Expo. The two events alongside the show will bring benefits to the supporting industries. Both shows will be the meeting places for local industrial parts makers who want to meet buyers from Japan and many other countries. Visitors at the event will discover ideas to upgrade their productivity, reduce costs, and increase profits from 200 exhibitors from 20 countries.”

The third show is ‘SI Exhibition:

The 4th Vietnam – Japan Exhibition on Supporting Industries in Hanoi’

by JETRO in Hanoi. This event will be a meeting place for industrialists in the supporting industries as sellers of industrial parts will meet buyers from Japan.

The chief representative of JETRO, Hirokazu Yamaoka said: “Japan External Trade Organisation or JETRO in Hanoi has been working towards trade and investment development between Japan and Vietnam for almost two decades. Our major targets are to Support Japan’s direct investment in Vietnam, promote Vietnam and Japan trade relations and support development of market economy in Vietnam.”

ICE Hanoi Hanoi, Vietnam September 15 – 17, 2011 Enquiry No. 5702 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 010

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Event Preview:

Metalex Vietnam 2011

M

etalex Vietnam 2 0 1 1 , Vi e t n a m ’s machine tools and metalworking technology exhibition, is happening for the fifth time this year. The event is the national business platform where all attending Vietnamese manufacturers will experience firsthand, a number of technologies in Vietnam without having to travel aboard.

Visitors to the show can expect to be connected with more than 10,000 professionals from the electronics manufacturing i n d u s t r y, s u b - c o n t r a c t o r s , and more. With buyers from the aerospace, automotive, electrical, electronics, building and construction, oil and gas and petrochemical sectors, the show is a platform to market products, technologies and equipment for over 500 international brands from 25 countries worldwide.

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The fast growing number of foreign investors leads to an expansion of Vietnam industrial manufacturing, especially local production. According to the vice-chairman of the municipal People’s Committee of Ho Chi Minh City, Nguyen Thanh Tai, the Vietnamese southern economic hub will invest nearly US$615.38 million in projects to build and upgrade 18 transport works this year. In the next five years, it estimates to acquire US$67.34 billion for infrastructure and urban development projects.

Following the success of last year, the organiser of the show is aiming towards an even bigger and more exciting show this year. The prospect is also bright — as it will be co-located with NEPCON Vietnam, which would expand the range of products and services available in the show. Moreover, five international

pavilions: Singapore, China, Japan, Taiwan and South Korea will be participating.

Apart from the new innovations expected to be seen at the show, plenty of activities will also be available. There will be a high-tech zone called ‘Robot Demonstration’ as well as panels of selected conferences and technology presentations, all of which will be tailored to respond to the fast moving technology and trends in the manufacturing world nowadays.

SECC Ho Chi Minh City, Vietnam October 6 – 8, 2011 Enquiry No. 5703 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 091

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Event Review:

MTA Malaysia 2011

I

ncorporating Metrology Malaysia 2011 and Subcon Malaysia 2011, MTA Malaysia was a platform for both foreign and local exhibitors to showcase their technologies and products. For instance, angle-

measuring devices, coordinated measuring equipment, measurement and inspection system and test monitoring equipment among others were shown at the metrology show.

The visitors who visited the

show were from the aerospace and automotive manufacturing, electronics manufacturing, machinery manufacturing and the product manufacturing sectors.

Enquiry No. 5704 Turn to page 80a or log on to www.equipment-news.com to enquire

LAG: Eye On Asia

The Italian company recently took part in MTA Malaysia, bringing their bending machines with them. Frank Vanin, export sales manager of LAG felt the Southeast Asia market is a significant one for them. He said: “Based on our previous experiences, we feel this region is important to us. We achieved our first breakthrough in this region with our bending machine with CNC function in Malaysia,” he said.

Backing up this claim with actual figures, Mr Vanin told Asia Pacific Metalworking Equipment News, since the start of the year, the company had sold four machines in Malaysia.

He expects the second half of the year to be “interesting” and hopes to sell four to five units during that time. If achieved, this result according to him would be good for a company of its size. Using Malaysia as a springboard to the rest of Asia, the company aims to extend their influence into countries like China, Thailand, Indonesia and Vietnam.

Machines At MTA Exhibiting two out of three of their range of products, Mr Vanin brought the Mini GP 815 and the GBS press brakes to Malaysia.

“The Mini is produced only in the range of 15 tonnes. The up-stroking machine at the show is a manual version but it can

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also be equipped with CNC. The entry-level machine is useful for bending small parts in the electronic field where there are a lot of small components to be bent,” he said. “The bending concept in the GBS is similar to other machines in the market but the structure of the machine is different because it allows the possibility to bend roll forms (round shapes) at a fast approaching speed of 250 mm/s.”

What’s Next In Bending?

With high level of R&D across all sheet metal fabricating machine makers, Mr Vanin felt that technology in this field had reached a “saturated point”. Though that may be the case, he believes that important considerations like quality and reliability have to be kept close to the heart. The next step in developments could be a significant one, one that could see more robots joining the fray.

He concluded: “The next stage of bending would see the influx of automation. Some processes would be robotised. In Europe, we are already seeing a lot of press brakes with robots attached. We would try to introduce those to Asia.”

Enquiry No. 5705 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 118

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Event Review:

Metaltech 2011

T

he 17th edition of Metaltech 2011 exhibition ended with most exhibitors reporting better than expected sales and business transactions. The sales generated at the show are estimated to be well over RM800 million (US$264 million). Both the organisers and exhibitors are taken by surprised with the increased market demands for machinery and tools, the boost in sales has given the organiser an insight that the Malaysia economy is picking up from the downturn in year 2009.

The show was held from May 4 – 8, 2011 at Putra World Trade Centre, Kuala Lumpur. It was visited by more than 20,000 visitors from all around the region. Albert Lai, MD of Trade-Link Exhibition

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Services, and organiser of the show said: “Metaltech has just won the MACEOS Excellence Industry Award. This prestigious award is presented by the Malaysia Association of Convention and Exhibition Organisers and Suppliers for exhibition which has achieved at least 10 editions of excellent standard, which means the effort put in by the exhibitors and supporting organisations has made an impressive impact.”

Welding Competition The fourth welding competition was held during the show and it saw 40 participants. The participants consist of students from various institutions as well as welders from the private sector.

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Desmond Yeap, executive director of Welding Institute (Malaysia) said: “Metaltech is a platform to promote the interests of the industry. We are grateful to work with Trade-Link in organising the welding competition annually at the exhibition. It is also a platform for us to promote the courses that are available for welders to gain international employment opportunities.”

M r Ye a p a d d e d : “ T h e competition has been a success.

We h o p e m o r e i n d u s t r y participants will compete for this nationally recognised award as it will provide better employment opportunities. For employers, this competition would also help their welders up their skills level, which would lead to more quality and productive output.”

Enquiry No. 5706 Turn to page 80a or log on to www.equipment-news.com to enquire

Show Numbers Exhibition Space Take-Up: 35,000 sq m Number Of Participating Companies: 1,500 Number Of Exhibiting Countries: 31 Including Australia, Austria, Belgium, Canada, China, Denmark, Finland, France, Germany, Hong Kong, India, Indonesia, Iran, Ireland, Italy, Japan, South Korea, Malaysia, Netherlands, New Zealand, Norway, Singapore, Spain, Sweden, Switzerland, Taiwan, Thailand, Turkey, United Kingdom, USA, Vietnam.

National Pavilions: 4 Austria, South Korea, Singapore, Taiwan Total Number Of Trade Visitors: 21,506 Total Number Of Visiting Countries: 55 Total Estimated Sales: RM 800 million (on-the-spot and follow-up)

Past.Present.Future Albert Lai, MD of Trade-Link Exhibition Services spoke to APMEN on his thoughts on Metaltech 2011 and its future developments. By Joson Ng The busy scenes during exhibitions are generally good signs to behold. Equally busy are the people running the show behind the scenes, their tireless efforts allowing the show to go on without any hitch. Taking a break from his busy schedule, Mr Lai assessed the performance of the show and also alerted us to some changes to the show next year.

“So far, comparing this show (Metaltech) to its previous edition last year, there is a 20 percent increase in floor space. This is almost unavoidable as the exhibits get bigger and the technology improves,” he said.

When asked if the sterling result this year would add pressure to his marketing team, Mr Lai revealed with Metaltech taking over MTA Malaysia’s exhibition space next year, his team will have more space to sell, no doubt placing more pressure on them.

With just one show next year, Mr Lai ruled out the possibility of any major makeover. Status quo will remain and he expects the familiar faces to return next year.

He said: “We will continue to sell (the space). All the exhibitors in MTA this year will still require a marketplace. I think for them, to exhibit in Metaltech or MTA Malaysia will be the same because the profiles of the visitors are the same.”

Going Solo Trade-Link Exhibition Services and Malaysian Exhibition Services (MES) have been working together for a number of years on Metaltech and MTA Malaysia. With TradeLink going alone next year, Mr Lai took time out to look back on his working relationship with his counterparts from MES. “With them, we shared a lot of strategies and cost. Our working relationship with them is very cordial. When we first started working together, there were some frictions, for example which company should get publicity in the show daily but these are minor issues that we ironed out within one or two years into the cooperation,” he said.

Working together according to Mr Lai is all about compromising and understanding. But one thing his team would not compromise is quality, an attitude he is adopting on the event next year.

On a separate note, in order to deliver a better show with more new machines and technologies, he will be leading a team to South Korea to source for good machines to bring to this region.

Metalworking Industry In Malaysia With the show happening in May, it was an opportune time to ask Mr Lai his thoughts on the metalworking industry in Malaysia for the first half of 2011. He said: “Through the feedback I get from the exhibitors, the fourth quarter of 2010 was very good. It slowed down a little in the first quarter of 2011 but it is picking up again. You can tell by looking at the machines at the show, and the ‘sold’ signs on them.”

As for the rest of the year, he expects there to be “enough work for everyone” in the manufacturing industry. With new projects initiated by the government, the future looks promising. MEN

Enquiry No. 5707 Turn to page 80a or log on to www.equipment-news.com to enquire

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Event Review:

Intermach 2011

I

ntermach, Subcon Thailand and Sheet Metal Asia 2011, organised by UBM Asia (Thailand) turned out to be a success. The events are now considered a driving force behind dozens of new business partnerships, which are making a contribution to the booming Thai economy.

Originally conceived as an exhibition where manufacturers 72

metalworking equipment news Jul-Aug 2011

would just display equipment, the show has evolved into an event that buyers and manufacturers now use as a central meeting point.

Subcon Thailand offers both challenge and opportunity. It attracts expert contractors who are seeking quality manufacturing sources and tier one par t manufacturers who are looking for reliable contractors. This is a mutually beneficial situation.

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The total number of trade visitors for all three shows covering the four-day event was 33,016. Arrivals were from 35 countries — a 20 percent increase from the previous year. There was also a 25 percent increase in overseas visitors. The number of business transactions from the event is believed to be valued at around 7.4 billion baht (US$244 million), with more expected in follow-up deals. At Subcon Thailand, there were 3,109 pairings — signalling an increase in business matchmaking that took place at the show with buyers from 14 countries.

Thoughts On The Show Sanchai Noombunnam, the show director said: “Intermach and Sheet Metal Asia are the first machinery exhibitions of the year and are timed with the manufacturing industry’s buying cycle. Many exhibitors took the opportunity to present their latest technology and launch products for the first time in Asia.”

“This year there were also many seminars throughout the four-day event. These events attracted over 2,500 people, many of whom were decision makers, VIPs and important people in the manufacturing industry. Seminars related to the automotive industry proved to be very popular,” he added.

Chanin Khaochan, director of the BOI Unit for Industrial Linkage Development (BUILD), Thailand Board of Investment (BOI) and co-organiser of Subcon Thailand 2011, said: “Trade visitors and buyers increased 30 percent over the previous year. There were many oversea buyers from foreign countries, especially Japan. Contributing to the show’s success were overseas offices that helped invite buyers to the exhibition.”

Business matching saw meetings take place at Subcon

Thailand. Surveys conducted after each meeting revealed that 76 percent of participants believed the program to be positive. During the three-day event, partnerships believed to be worth around 5.4 billion baht were transacted. Intermach and Sheet Metal Asia will be returning to BITEC on May 17 – 20, 2012.

BITEC Bangkok, Thailand May 19 – 22, 2011 Enquiry No. 5708 Turn to page 80a or log on to www.equipment-news.com to enquire

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M

anufacturing Surabaya will return June 6 - 9, 2012 following the conclusion of this year’s event, which attracted a record 7,419 trade visitors from throughout East Indonesia. In addition to the manufacturing sector, this year’s exhibition featured displays catering to East Java’s electric, power, marine, shipbuilding and oil and gas industries.

Held for the third time at the purpose-built Grand City Convention and Exhibition Centre, the exhibition proved a success in meeting the demand from the regions industry professionals to upgrade their equipment and technology.

A total of 281 companies from 25 countries like Australia, Austria, Canada, China and Denmark among others participated in the exhibition that included national and regional pavilions from Singapore and Taiwan. The show took up some 3,931 sq m of exhibition space.

The exhibition was officially opened by Ir Budi Setiawan, head of department of trade and industry, province of East Java on behalf of the East Java governor.

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Event Review:

Manufacturing Surabaya

The show was supported by the Ministry of Industry, The Republic of Indonesia, Association of Electrical Industries of Indonesia (APPI), Association of Plastic Converting Industry, Indonesian Precision Tooling Industry Association (AIPPINDO), Indonesian Electric Cable Manufacturers Association (APKABEL), Indonesian Electrical Lighting Industry Association, The (APERLINDO), Indonesian M a c h i n e To o l I n d u s t r i e s

Association (ASIMPI), Indonesia Woven Polyolefin Manufacturers Association (GIATPI), Indonesian Electrical Power Society, The (MKI) and Indonesian Packaging Federation (IPF).

Grand City Convention & Exhibition Centre Surabaya-Indonesia June 8 – 11, 2011 Enquiry No. 5709 Turn to page 80a or log on to www.equipment-news.com to enquire

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ProductFinder

Blum: Compact Tool Setting Probe

Diebold Goldring: Endmill Cutting Tool

Blum-Novotest has developed their probe Z-Nano. This compact tool mea suring system is used in CNC machining centres for automatic tool length measurement and breakage detection as well as for temperature compensation in one machine axis.

The probe is the further development of an approved system known under the identical name.

Instead of the previously used sliding guide, the probe is working with a ball guideway by which the measuring force could be reduced once more. The advantage is that now even smaller tools starting from diameter 0.1 mm — depending on tool geometry and material — can be measured.

Mounted onto a shrink fit tool holder with an integrated coolant su p p l y, D i e b o l d Goldring’s JetSleeve is usable with any CNC machine capable of through coolant supply.

For usage of air-oil mist lubrication, a booster for the media supply and a MMS capable rotary unit are required.

Its chucks are ShrinkFit chucks with a coolant sleeve attached to the nose part of the holder. Coolant or air-oil-mist can be supplied through the holder body and accelerated through nozzles in the tip portion of the tool. Tiny nozzles at the tip of the tool create a Venturi effect whereby the high velocity of coolant flushes the chips efficiently away from the cutter.

Enquiry No. 5801 Turn to page 80a or log on to www.equipment-news.com to enquire

Enquiry No. 5802 Turn to page 80a or log on to www.equipment-news.com to enquire

WORLD INNOVATION «ROUND FINE CENTERING SYSTEM» Smart Hybrid Finishing

New OptiRough Toolpath

New Dynamic Milling Techniques

Easier Multiaxis Machining

New Plunge Turn Toolpath

STANDARD GUIDING ELEMENTS FOR THE MOLD CONSTRUCTION.

Mastercam Machine Simulation

WWW.AGATHON.COM

Design Enhancements See Mastercam X5 in action at www.mastercam.com.sg

Techtown Pte Ltd

www.techtown.com.sg • info@techtown.com.sg Tel : +65 6636 8215 • Fax : +65 6636 8221

AGATHON AG | CH-4512 Bellach phone +41 32 617 45 01 | fax +41 32 617 47 01 normalien@agathon.ch | www.agathon.com RENOWNED FOR EFFICIENCY AND PRICE!

ENQUIRY NO 108

ENQUIRY NO 112

High-precision standard and special design guiding elements.

Jul-Aug 2011 metalworking equipment news

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productfinder

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Elcometer: Coating Thickness Measurements

Fa st, reliable and accurate, the E lcometer 45 6 is available in a range of models for measuring dry film thickness on ferrous and non-ferrous metal substrates.

Key features include a 2.4” colour display, clear menu structure and large buttons making the equipment easy to use. The impact resistant gauge is also sealed against dust and water. With measurement capability to ± 1 percent on smooth, rough, thin and curved surfaces, the equipment produces repeatable and reproducible results and is backed by a two-year gauge warranty.

Enquiry No. 5803 Turn to page 80a or log on to www.equipment-news.com to enquire

Komet Group has developed the MicroKom BluFlex fine adjustment head, equipped with Bluetooth technology developed for wireless networking devices over short distances.

This technology in the tool system means that the display has been disconnected from the fine boring head, thereby making it easier and more convenient to read off the data, which is available in both inch and mm with a display adjustment of 0.002 mm.

With integral part balancing, the system can reach a rotational speed of up to 16,000 rpm. The modular ABS interface makes adjustment easier on both the spindle side and tool side. This fine boring system is available from diameter 0.5 – 215 mm, with universal ABS interface.

Enquiry No. 5805 Turn to page 80a or log on to www.equipment-news.com to enquire

Heimatec: Quick-Change System

Mori Seiki: Vertical Machining Centre

Heimatec ha s developed its own quickchange system that can be set up in the least amount of time by adjusting the clamping screw of the U - tec system. A set of live and static tools can remain in the turret by only changing the adaptors. As such, it is no longer necessary to reset the tools.

The system has high precision connection between the drive spindle and the quickchange adaptor. This consists of a cylindrical centre with tight tolerance and an accurate flat face, which brings high precision and rigidity into the system.

Users can use the adapter with standard collet nuts. Repeatability accuracy reaches a maximum of 0.005 mm.

The NVX5000 Series of vertical machining centres is Mori Seiki’s second series launched as the X-class.

The machine is packed with features including measures against thermal displacement, MAPPS IV + Esprit and compliance with safety standards. It also achieves a transverse rate of 30 m per min in all axes.

Thermal displacement is minimised by dispersing heat evenly. In addition, the coolant circulation inside castings allows the machine to achieve active control over thermal displacement caused by cutting heat and changes in the ambient temperature.

Enquiry No. 5804 Turn to page 80a or log on to www.equipment-news.com to enquire

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Komet Group: Fine Boring System With Bluetooth Technology

metalworking equipment news Jul-Aug 2011

Enquiry No. 5806 Turn to page 80a or log on to www.equipment-news.com to enquire

productfinder

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Mitsui Seiki: HMC For Machining Hard Metals

Mitsui Seiki’s 2,500 mm HU100A-5XLL HMC is designed for machining large, complex, and heavy (up to 6,600 lbs) hard metal parts. The HMC offers an X, Y, Z working envelope of 2,500 mm x 1,750 mm x 1,400 mm.

The A and B tilting and rotating trunnion table axes represent the fourth and fifth axes of motion. Its standard spindle offering is a 50 taper, although many manufacturers taking extra heavy roughing cuts in titanium and tough steels could opt for the HSK 100 or HSK 125 spindle with high torque of 3,332 Nm.

Prima Power Laserdyne: Laser Processing System

Prima Power Laserdyne’s 795XS BeamDirector is a sixaxis laser processing system with a 1 m x 1 m x 1 m work envelope including a 320 mm diameter high accuracy rotary table and the company’s controller, the S94P. The S94P control, which is a personal computerbased CNC designed for multi-axis laser processing systems, is the basis for numerous hardware and software features that lead to productivity, process control, and quality of laser-processed parts.

Being referred to as the third generation BeamDirector, the system provides access to parts for cutting, drilling and welding.

Enquiry No. 5807

Enquiry No. 5808

Turn to page 80a or log on to www.equipment-news.com to enquire

Turn to page 80a or log on to www.equipment-news.com to enquire

10 to 6,000 Ton Capacity DEES' Taiwan and China Factories are all ISO-9000 Certified

DEES HYDRAULIC INDUSTRIAL CO., LTD. TAIWAN HEADQUARTERS / FACTORY: Tel.: +886-2-2601-8661

Fax: +886-2-2601-8936

E-mail: sales@spc.com.tw

www.deesgroup.com.tw

ENQUIRY NO 057

ENQUIRY NO 040

1600 tons Front Runner with 2 x 1000 tons and 2 x 800 tons

Jul-Aug 2011 metalworking equipment news

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productfinder

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Sandvik Coromant: Drills For Composite Materials

Vero Software: CAD Software For Tooling Industry

Sandvik Coromat has developed CoroDrill 452, which is a range of drills used for rivet and bolt holes in carbon reinforced plastics and metallic stack materials.

Each ca rbon fibre material has its own demands that increase the risk for delamination or splintering. The series geometries are designed to reduce t his r isk a nd ensure the stringent hole tolerances are met with finish and quality, particularly with respect to the prevention of exit-hole damage.

Benefits of use include the elimination of secondary processing steps such as de-burring. In addition, the series includes reamer geometries and a countersink tool with microstop for chamfering.

Vero Software ha s relea sed its software product for tool design and ma nufacture.

VISI 19 includes a 64-bit engine and a core 3D CAM development.

CAM routines include ‘HM Rib Cutting’ for the machining of very thin walls, ‘Deep Cavity Machining’ for the automated splitting of roughing and finishing toolpaths into separate Z ranges based on collision checking between the piece and tool or holder.

‘HM constant z’ tool path complements the existing steep and shallow tool path. This combined finishing routine replaces the 3D pocketing calculations with 2D projection calculations for shallow areas and can reduce calculation times.

Enquiry No. 5809 Turn to page 80a or log on to www.equipment-news.com to enquire

Seco Tools: Solid Carbide End Mills

Walter: High-Tech Drill

Two solid carbide end mills for high performa nce in titanium and super alloys have been added to Seco Tools’ machining product family.

JHP770 and JH780 offer a high metal removal rate with secured and chatter free machining. The JHP770 has been designed for machining titanium while the JHP780 is suitable for heat resistant super alloys and aerospace components in particular.

B o t h e n d m i l l s h av e differential flute spacing to avoid vibrations and polished coatings to increase tool life. The JHP770 also has radial relief and an internal central coolant channel while the JHP780 offers a double core providing extra stability.

Walter Titex UFL drill has shown that the development of tools made of HSS has still not come to an end. In comparison with conventional drills made of this cutting tool material, the drill gives more performance, especially when drilling deep holes.

The particular identifying feature of the drill is its flat flute profile. The core diameter is larger than that of a standard type N twist drill, which results in higher rigidity. This design was made possible through the use of a helix angle of 40 deg — the standard helix angle is 30 degrees. Additional features include a U form tip geometry for low feed forces as well as a TFP tip coating for maximum tool life.

Enquiry No. 5810 Turn to page 80a or log on to www.equipment-news.com to enquire

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Enquiry No. 5811 Turn to page 80a or log on to www.equipment-news.com to enquire

metalworking equipment news Jul-Aug 2011

Enquiry No. 5812 Turn to page 80a or log on to www.equipment-news.com to enquire

Exhibition Programmes September 13 – 15 Wire Southeast Asia 2011

BITEC Bangkok, Thailand Messe Duesseldorf Asia wire@mda.com.sg www.tube-southeastasia.com

13 – 15 Tube Southeast Asia 2011

BITEC Bangkok, Thailand Messe Duesseldorf Asia wire@mda.com.sg www.wire-southeastasia.com

15 - 17 Vietnam Manufacturing Expo 2011 ICE Hanoi Hanoi, Vietnam Reed Tradex Sirirat.Sung@reedtradex.co.th www.vietnammanufacturingexpo.com

19 – 24 EMO Hannover Exhibition Grounds Hannover, Germany VDW www.vdw.de www.emo-hannover.de

2011-2012

21 – 23 Asiamold

Poly World Trade Centre Expo Guangzhou, China Messe Frankfurt asiamold@demat.com www.asiamold.de

Sep 28 – Oct 1 KOMAF 2011

KINTEX Seoul, South Korea KOAMI exhibit@koami.or.kr 2011.komaf.org

16 – 19 Metalex

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

Nov 29 – Dec 2 Euromold Frankfurt, Germany DEMAT Info@demat.com www.euromold.com

6–8 Metalex Vietnam

Nov 30 – Dec 3 Manufacturing Indonesia 2011

November

February 2012

Shanghai New International Expo Centre Shanghai, China Hannover Milano Fairs mwcs@hmf-china.com www.metalworkingchina.com

KL Convention Centre Kuala Lumpur, Malaysia SAMPE SAMPEAsia@sampe.org www.sampe.org

October SECC Ho Chi Minh City, Vietnam Reed Tradex contactcenter@reedtradex.co.th www.metalexvietnam.com

1–5 MWCS

Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

21 – 22 SAMPE Asia 2012

APMEN goes on the road...

Visit our booth at: • Metalex Vietnam • Wire & Tube • Vietnam Manufacturing Expo • Metalex

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067

PARAMETRIC TECHNOLOGY (SHANGHAI) SOFTWARE CO LTD

43

124

PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA 2011)

69

118

REED TRADEX COMPANY (METALEX THAILAND 2011)

67

091

REED TRADEX COMPANY (METALEX VIETNAM 2011)

63

120

REED TRADEX COMPANY (VIETNAM MANUFACTURING EXPO 2011)

61

119

SECO TOOLS (S.E.A) PTE LTD

01

001

SIEMENS PLM SOFTWARE (SG) PTE LTD

28

109

TECHTOWN PTE LTD

75

112

TUNGALOY SINGAPORE (PTE) lTD

23

123

WALTER AG SINGAPORE PTE LTD

07

168

WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG

21

098

YAMAZAKI MAZAK SINGAPORE PTE LTD

IBC

127

ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing,Automation & Quality Control

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❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

NEW MAZAK STYLE Design

Functionality

Ergonomics

The new Mazak machines are designed to have a modern and timeless appearance - a trend for this new century. They have a unique presence and it is clearly obvious from any direction that they are Mazak machine tools. With the backlit Mazak logo and the orange identity stripe on the edge of doors, these new machines strongly project the Mazak brand.

You will be proud to have them at work on your shop oor.

Integrex e-670H II

Large CNC Display Up To 19 “

Stainless Steel Borders

Ease Of Operation

Large Window

Ergonomics Design

YAMAZAKI Mazak Singapore Pte Ltd 21 Joo Koon Circle, Jurong Singapore 629053 Tel : +65 6862 1131 (12 Lines) Fax : +65 6861 9284

www.mazak.com

ENQUIRY NO 127

Our complete portfolio.

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ENQUIRY NO 135

From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction.

Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call (65) 6265.9222 or visit www.widia.com.

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