APMEN March 2010

HEAVY INDUSTRIES:

MAKING BIG WAVES

LASER WELDING PROCESSES:

MEETING THE CHALLENGE

HSM POINTS TO

HIGHER PRODUCTIVITY March 2010

www.equipment-news.com M.I.C.A. (P) No. 233/06/2009

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P M K N S H 3 3 3 3

P M K N S H 3 3 A tough substrate with a cobalt enriched layer combined with improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Recommended for general use machining of steel in a wide range of conditions, featuring high toughness and resistance to chipping and plastic deformation.

A tough submicron substrate, improved TiAlN PVD coated grade for better chip flow. Designed for machining heat resistant alloys, austenitic stainless steel, hard alloys and carbon steel at medium to high cutting speeds, interrupted cut and unfavorable conditions.

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Recommended for milling nodular cast iron at high speeds and grey cast iron at low to medium cutting speeds under unstable conditions.

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A very hard substrate, improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Features excellent thermal stability and resistance to chipping and plastic deformation.

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A tough substrate with a new MTCVD and alpha Al2O3 coating.

Recommended for milling grey cast iron at high cutting speeds, providing excellent tool life.

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A hard substrate, improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Features excellent thermal stability and improved toughness.

Recommended mainly for grey cast iron at stable or slightly unstable conditions.

Can be used successfully also on nodular cast iron.

A hard fine grain substrate with MTCVD and alpha Al2O3 coating. Features excellent chipping and wear resistance.

Recommended for high speed drilling of cast iron and steel, to be used for the peripheral insert on DR drills.

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ISCAR THAILAND Tel + 66 (2) 7136633 iscar@iscarthailand.com

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SINO TOOLING SYSTEM Tel + 65 6566 7668 sinotool@singnet.com.sg

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Walter AG Singapore Pte. Ltd. Teletech Park, Singapore +65-67736180 service.sg@walter-tools.com www.walter-tools.com

ENQUIRY NO 035

Contents

March 2010

24

FIRST CUT

The Key To Higher Productivity

High Speed Machining is not just a technology for shortening the production time and increasing the accuracy of machined parts, but a tangible strategy for increasing productivity. By Dr Moshe Goldberg, marketing technical advisor, Iscar

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 #04-02 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

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

IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

28

Is There A Speed Limit In HSM?

To reap the benefits of significant investments in high-speed machine tools and accessories, NC programmers need to optimise and reach the safe limits of the system.

By Edwin Gasparraj, senior product manager, CAM product development, Siemens PLM.

32

TECHNOLOGY UPDATE

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.

INDUSTRY Endorsements

Metalworking Fluids: Handle With Care

Although regulations are in place to remove some harmful substances from metalworking fluids, it is still important for operators to exercise the same level of care normally reserved for operating drills and cutters. By Matthew English

34

SOFTWARE & MEASUREMENT

Using Software To Maximise Your Hardware

Given the current economic climate, working with available machineries and getting more out of them is a dream come true for many manufacturers. By Michael E Neumann

36

FAB & FORM

Robotic Laser Welding Process: The Future Is Now

Changes in production strategies and adjustments to current manufacturing climate can often give rise to a major investment. By Ryu Tan, product manager, solid state laser technology, Trumpf

SPETA

Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA) Federation of Malaysian Foundry & Engineering Industry Associations Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

Taiwan Association of Machinery Industry (TAMI)

2

metalworking equipment news March 2010

THE ALL-NEW ALL-NEW 2010 2010 THE

ST-30 ST-30 TURNING CENTER

TURNING CENTER

The all-new, 2010 ST-30 turning center is the culmination The all-new, 2010 ST-30 turning center is the culmination of 15 years of continuous development, and it offers the most of 15 years of continuous development, and it offers the most performance for the money – the best value – of any turning performance for the money – the best value – of any turning center on the market today. center on the market today.

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released for active duty: 01.01.10 released for active duty: 01.01.10

Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment.

Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment.

Haas Factory Outlet Haas Factory Outlet Singapore Singapore DKSH Technology

DKSHFront Technology Harbour Phone: +65 6471 9248 Harbour Front Phone: +65 6471 9248

Malaysia Malaysia A Division of SPC Machinery Sdn Bhd

Thailand Thailand A Division of Machine Tech Co., Ltd.

A Division of Machine Tech Co., Ltd. Bangkok: 02 726-7191-5 Bangkok: 726-7191-5 Chonburi: 6602 3811-2700 Chonburi: 66 3811-2700

Philippines

A Division of03-5569-5901 SPC Machinery Sdn Bhd A Division Philippines Kuala Lumpur: of Gaylan Technologies Kuala Lumpur: 03-5569-5901 A Division of Gaylan Penang: 604 3801581 Manila: 63 2 915 8725 Technologies Penang: 604 3801581 Manila: 63 2 915 8725

ENQUIRY NO 031

Vietnam

Vietnam Diethelm and Co. Ltd. Diethelm and Co. Ltd. Technology Technology Hanoi: +84 4 9424 725 Hanoi:+84 +84845121 9424334 725 HCMC: HCMC: +84 8 5121 334

Replacing traditional light sources with laser increases accuracy and also open doors to technologies that are light-years ahead.

By Augustine Quek

Regulars

54

M.I.C.A. (P) No. 233/06/2009 • PPS 840/10/2010(028278) • ISSN 0129 5519

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

HSM POINTS TO

HIGHER PRODUCTIVITY March 2010

www.equipment-news.com M.I.C.A. (P) No. 233/06/2009

Cost CostSaving SavingMilling Milling with withHigh HighProductivity Productivity Superior SuperiorFine FinePitch PitchEndmill Endmil

VOL. 24 NO. 2 MARCH 2010

Laser Welding: On The Spot

LASER WELDING PROCESSES:

MEETING THE CHALLENGE

g Deliver inility b a it f o r P ttss RReessuul l nntteeeess GGuuaarraa IISSCCAARR

ADVERTISEMENT

40

HEAVY INDUSTRIES:

MAKING BIG WAVES ASIA PACIFIC METALWORKING EQUIPMENT NEWS

Contents

Drilling DrillingDown Down Production Production Costs Costswith withHigh HighProductivit Productivi Indexable Indexable Carbide Carbide Heads Heads WWW.ISCAR.COM WWW.ISCAR.COM

ASIA ASIA PACIFIC PACIFIC AD AD 584x275 584x275 Delivering Delivering HSM.indd HSM.indd1 1

Accelerating Die Duplication

The process of duplicating a stamping die is generally painstaking and time-consuming. Through 3D technology and software programs, it is considerably shortened. By Sophia H Jeon, business partner manager, Rapidform

42

Multi-Axis Laser Processing In The Aerospace Industry

Laser systems continue to meet aerospace manufacturing challenges.

By Peter Thompson, technical director and Mark Barry, VP, sales and marketing, Prima North America, Laserdyne Systems

46

INDUSTRY SPOTLIGHT In The Grand Scale Of Things

From power generation to major infrastructure overhaul, the heavy industries are generating big movements that can even be felt in the metalworking community. By Joson Ng

48

Thick Section Welding With Fibre Laser

Ivan Prole, Belgrade, Serbia

52

With the availability of high power fibre lasers of more than 10 kW, new application fields in thick section welding could be developed, especially in the heavy industries. By Michael Grupp, Karsten Klinker, IPG Laser and Stefano Cattaneo, IPG Photonics.

FEATURES

Sustainability: Take it, It’s Yours!

SMC’s Dr Song Bin discusses his vision for the newly launched centre.

By Joson Ng and Derek Rodriguez

Refer to Advertising Index

Pg 80

58

Time Is Money

Economic considerations in purchasing a jet cutting machine are just as important as the machine’s capabilities. By John H Olsen, VP Operations, Omax Corp

62

Direct Digital Manufacturing: Viable Alternative

In an increasingly competitive market, major savings are still possible with new approaches to old methods. By Scott Crump, CEO, Stratasys

64

3D Technologies: Getting Into The X, Y & Z Of Things

The latest technologies in rapid prototyping reduce cost and usher in the digital age in a big way. By Augustine Quek

66

EVENTS & EXHIBITION

Event Preview: SIMTOS 2010 Event Preview: Intermach 2010 Event Preview: Medtech Manufacturing 2010 Event Review: Automechanika Shanghai Event Review: Singapore Airshow 2010

for Advertisers' Enquiry numbers

ENQUIRY NO 090 add-resize.indd add-resize.indd 1 1 add-resize.indd add-resize.indd 1 1

12/06/2009 12/06/2009 08:59:0308:59:03 12/06/2009 12/06/2009 08:59:0308:59:03

editor’s note

Published by:

The

Eastern Trade Media Pte Ltd

Metal king) (Wor

Year

(a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

managing director Kenneth Tan assistant editor Joson Ng

josonng@epl.com.sg

advertising sales manager Derick Chia

derickchia@epl.com.sg

advertising sales manager Yessica

yessica@epl.com.sg

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

The year 2010 may belong to the Tiger in the lunar calendar, it is also a year associated with natural elements such as metal according to experts practitioner of Fengshui, a traditional Chinese practice of predicting fortunes through dates and classical Chinese texts.

T hough it may me a n ot her things in Fengshui, there are several happenings in Singapore that have indicated that 2010 will be a good year for metal, or more specifically, for the metalworking industry.

The start of the year saw Singapore host the Singapore Airshow. Touted the ‘Asia’s biggest for aviation’s finest’ by the organiser, the show saw deals and announcements worth about US$10 billion over the first three days.

There was also a notable growth in the total number of countries/ regions represented, with the count moving up from 113 in 2008 to 119 this year. In terms of exhibitors, there was representation from more than 60 countries/regions.

“As the first major airshow taking place at the beginning of the year, the

Singapore Airshow is in a position to gauge the pulse of the industry,” said Jimmy Lau, MD, Singapore Airshow and Events (SAe). Judging from the response and post show results, the ‘pulse of the industry’ is showing some healthy readings on the pulse meter.

Stay ing with the Aerospace industry, this issue of Asia Pacific Metalworking Equipment News will feature the Heavy Industries in our Industry Spotlight section. We study the number of power generation and large-scale construction projects in the Asia region and how the governments in various countries like Singapore and Japan are improving infrastructures such as airports and railways.

These construction projects will or already have given the heavy industry a boost. For those who are staunch believers of astrology or constellations, they will feel that maybe it is already written in the stars that 2010 will be a good year for metalworking.

contributing graphic designer Libby Goh libbygoh@epl.com.sg circulation executive Irene Tow

irenetow@epl.com.sg

contributors Dr Moshe Goldberg, Edwin Gasparraj Michael E Neumann, Ryu Tan Augustine Quek, Peter Thompson Mark Barry, Michael Grupp Karsten Klinker, Sophia H Jeon Vandhana Venkatesan, John H Olsen Scott Crump, Matthew English Stefano Cattaneo 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. 233/06/2009 PPS 840/10/2010 (028278) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

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

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

Joson Ng Assistant Editor

6

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806 Thailand Office: Thai Trade and Industry Media Co., Ltd 16/F Italthai Tower, 2034/73 New Petchburi Road, Bangkapi, Huaykwang, Bangkok 10310, Thailand Tel: 66(0) 2716 1722 Fax: 66 (0) 2716 1723

metalworking equipment news March 2010

S 33 NEW S 33 NEW S 33 NEW STheThe SThe 33 NEW NEW reasonably priced Thereasonably reasonablypriced priced reasonably priced

The The reasonably reasonablypriced priced for unrestricted grinding length & simplest programming. for for unrestricted unrestricted grinding grinding length length & & simplest simplest programming. programming. for unrestricted grinding length & simplest programming. forforunrestricted unrestrictedgrinding grindinglength length & &simplest simplestprogramming. programming.

Worldwide unique Worldwide Worldwide unique unique Worldwide Worldwide Worldwide unique unique Even theunique most complex work pieces can now be ground in one clamping. A new wheelhead Worldwide Worldwide unique unique Even Even the most the most complex complex work work pieces pieces can now can be now ground be ground in one in one clamping.

A A wheelhead new wheelhead Even Even Even the the most the most most complex complex work work work pieces pieces cancan now can now be now be ground be ground in Internal one in one inclamping. clamping. one clamping. clamping.

A new new A new A make wheelhead new wheelhead wheelhead with two motorcomplex spindles forpieces external grinding andground an grinding unit this possible.

Even Even the most the most complex complex work work pieces pieces can now can be now ground be ground in one in clamping. one clamping.

A new A wheelhead new wheelhead with two with motor two motor spindles spindles for external for external grinding grinding and an and Internal an Internal grinding grinding unit make unit make this possible. this possible. with with two with two motor two motor motor spindles spindles spindles for for external for external external grinding grinding grinding and and an and an Internal an Internal Internal grinding grinding grinding unit unit make unit make make this this possible. this possible. possible.

Now three wheels can be used to grind a workpiece to your individual requirements and with two with motor two motor spindles spindles for external for external grinding grinding and an and Internal an Internal grinding grinding unit make unit make this possible. this possible.

Now Now three three wheels wheels can be can used be used to grind to grind a workpiece a workpiece to your to individual your individual requirements requirements and and Now Now Now three three three wheels wheels wheels can can be can be used be used used to to grind grind to grind a workpiece a workpiece a workpiece to to your your to individual your individual individual requirements requirements requirements and and and even faster than before – a complete machining in the extra class.

Now Now three three wheels wheels can be can used be used to grind to grind a workpiece a workpiece to your to individual your individual requirements requirements and and even even faster faster than before than before – a complete – a complete machining machining in the in extra the extra class. class. even even even faster faster faster than than before than before before – a–complete a–complete a complete machining machining machining in the in the inextra the extra extra class. class. class. even even fasterfaster than before than before – a complete – a complete machining machining in theinextra the extra class.class.

Munger Machine Tool Pte Ltd. Munger Munger Machine Machine Tool Pte Tool Ltd. Tel. +65 6764 63Pte 88Pte Munger Munger Munger Machine Machine Machine Tool Tool Pte Tool Ltd. Pte Ltd.Ltd. Ltd. Tel. +65 6764 +65 63 6764 88 63 88 E-mail mungermachine@pacific.net.sg Tel.Tel.Tel. Tel. +65 +65 6764 +65 6764 63 6764 88 63Pte 88 63Ltd. 88Pte Ltd. Munger Munger Machine Machine Tool Tool E-mail E-mail mungermachine@pacific.net.sg mungermachine@pacific.net.sg MMT Thailand, E-mail E-mail E-mail mungermachine@pacific.net.sg mungermachine@pacific.net.sg mungermachine@pacific.net.sg Tel. Tel. +65 6764 +65 63 6764 88Tel. 63+66 88 2 391 9953 MMT Thailand, MMT Thailand, Tel. +66 Tel. 22 391 +66 9953 2212391 Malaysia, Tel. +60 3269953 6309 MMT MMT Thailand, MMT Thailand, Thailand, Tel.Tel. +66 Tel. +66 391 +66 2 391 9953 391 9953 9953 E-mail E-mail mungermachine@pacific.net.sg mungermachine@pacific.net.sg MMT Malaysia, MMT Malaysia, Tel. +60 Tel. 12 +60 326 12 6309 326 6309 MMT Malaysia, Malaysia, Malaysia, Tel.Tel. +60 Tel. +60 +60 326 129953 12 6309 326 6309 6309 MMT Thailand, MMT Thailand, Tel. +66 Tel. 212391 +66 2326 391 9953 Integrated Machine MMT Malaysia, MMT Malaysia, Tel. +60 Tel. 12Tool +60 326Sales, 12 6309 326Inc. 6309 Integrated Integrated Machine Machine Tool Sales, Tool Sales, Inc. Inc. Bacoor, Cavite, Philippines Integrated Integrated Integrated Machine Machine Machine Tool Tool Sales, Tool Sales, Sales, Inc.Inc.Inc. Bacoor, Bacoor, Cavite, Cavite, Philippines Philippines Tel. +63 46Tool 417Sales, 1359 / 417 0134 Bacoor, Bacoor, Bacoor, Cavite, Cavite, Cavite, Philippines Philippines Philippines Integrated Integrated Machine Machine Tool Sales, Inc. Inc. Tel. +63 46 +63 417 46 1359 417 // 417 1359 0134 // 417 0134 E-mail imtsph@pldtdsl.net Tel.Tel.Tel. Tel. +63+63 46Cavite, +63 417 46 417 46 1359 417 1359 417 1359 / 417 0134 417 0134 0134 Bacoor, Bacoor, Cavite, Philippines Philippines E-mail E-mail imtsph@pldtdsl.net imtsph@pldtdsl.net E-mail E-mail E-mail imtsph@pldtdsl.net imtsph@pldtdsl.net imtsph@pldtdsl.net Tel. Tel. +63 46+63 41746 1359 417/ 417 13590134 / 417 0134 E-mail E-mail imtsph@pldtdsl.net imtsph@pldtdsl.net

Fritz Studer AG Fritz Studer Fritz Studer AG AG FritzFritz Studer Fritz Studer Studer AGAG AG CH-3602 Thun CH-3602 CH-3602 Thun FritzCH-3602 Studer FritzThun Studer AG AG 11 11 · Fax +41-33-439 1112 CH-3602 CH-3602 Thun Thun Thun Tel. +41-33-439 Tel. +41-33-439 Tel. +41-33-439 11 ··11Fax 11 +41-33-439 ·· Fax +41-33-439 1112 1112 CH-3602 CH-3602 Thun Thun Tel.Tel. +41-33-439 Tel. +41-33-439 +41-33-439 11 11 11 11 Fax 11 · Fax +41-33-439 Fax +41-33-439 +41-33-439 1112 1112 1112 www.studer.com www.studer.com www.studer.com Tel. +41-33-439 Tel. +41-33-439 11 11 ·11Fax 11+41-33-439 · Fax +41-33-439 1112 1112 www.studer.com www.studer.com www.studer.com www.studer.com www.studer.com

ENQUIRY NO 036

Businessnews

www.equipment-news.com

Metalworking Equipment News Thailand & Asia Pacific Food Industry Thailand To Cease Publication Singapore: Metalworking Equipment News Thailand (MEN Thailand) and Asia Pacific Food Industry Thailand (APFI Thailand) have ceased their publication.

In 2003, publication for both Metalworking Equipment News Thailand (MEN Thailand) and Asia Pacific Food Industry Thailand (APFI Thailand) began with great promise, in a bid to forge greater collaboration between publisher and industry players.

Due to strategic considerations and the adverse impact of the recent global economic and financial crisis, Eastern Trade Media (ETM) has ended the joint venture in Thai Trade & Industry Media (TTIM),

publisher of both MEN Thailand and APFI Thailand.

With the conclusion of the joint venture, TTIM will have no further rights to publish both titles.

ETM would like to thank all customers and suppliers who have shown support in the Thai publications. Though the publication of MEN Thailand and APFI Thailand have ceased, efforts to serve the marketing communication objectives of customers have not.

With the industry knowledge of APMEN and APFI and the expertise in delivering marcom objectives, ETM will be striding ahead upon the strength of the relationship fostered with partners.

Yaroslav B, Moscow, Russia

Siemens To Invest More Than €250 Million In India By 2012

Berlin, Germany: As it profits from ongoing growth in the emerging nations, Siemens is seeking to expand its investment in India. Experts forecast that the Indian economy, for example, will grow seven percent in 2010 and eight percent the following year.

“India is already one of the growth drivers worldwide and will remain so in the future. We’ve been optimally positioned here for over 140 years and intend to further strengthen our position,” said Peter Löscher, president and CEO of Siemens in New Delhi, where the entire Siemens managing board met for the first time ever.

Over the next three fiscal years through 2012, the company intends to invest more than €250 million (US$341 million) in the country, thereby doubling its current annual investments. A major part of this will be invested in renewable energy and value-priced 8

metalworking equipment news March 2010

products business. The company also wants to increase its market share in India to 10 percent by the year 2012. With recently signed orders totaling over €500 million, primarily for energy technology, the company is well on its way.

The country’s power supply is of particular concern to the Indian government. Currently about 30 percent of India’s population has no access to power, which is why the Indian government is planning to add 150 gigawatts over the next seven years – an amount equal to Germany’s entire installed capacity.

One proje c t involve s a n inve st ment of approximately €70 million in the construction of a wind turbine factory in India by 2012. The first turbines are scheduled to leave the plant in a little over two years. The company also intends to invest in its value-priced products business.

Six new centres of competence for value-priced products from all Siemens sectors will be established in India by the end of 2010. Plans call for the centres to manufacture a number of various products, including new products in the area of signaling technology as well as steam turbines. These centres will also be responsible for the entire value chain, from product design, development and production to sales and marketing in India and abroad.

“India will become a major centre for value-priced products. By the year 2020, we intend to generate revenue of about €1 billion with these products – both within the borders of India and beyond,” said Armin Bruck, CEO of the Siemens regional company in India.

(6221) 8911 4611, (6221) 8911 5045 (6221) 8911 4769, (6221) 647 369

ENQUIRY NO 049

businessnews

www.equipment-news.com

Lostya Kisleyko, Russia

MHI Establishes Subsidiary To Oversee Business In China

Tokyo, Japan: Mitsubishi Heavy Industries (MHI) has established Mitsubishi Heavy Industries (China) (MHIC) in Beijing to serve as a regional headquarters overseeing all company business in China. With the establishment of MHIC, MHI aims to increase new business opportunities in the rapidly growing Chinese market by establishing a structure enabling it to leverage its company-wide capabilities.

At the same time, with this initiative the company also looks to further enhance local corporate management and administrative functions and solidify its base of business operations in China by strengthening managerial support and corporate governance to its group companies.

MHIC, capitalised at US$31 million, is a wholly owned subsidiary of MHI. Kenji Yuasa, formerly MHI’s general representative in China, has been appointed as GM. The subsidiary initially started with 14 employees, including office staff assigned to a Shanghai branch opening in February.

With MHIC’s head office located in the Chinese capital, where central government offices and the decision-making organisations of the major state-owned companies are concentrated, MHI will further strengthen its company-wide engagement in Chinese business, encompassing its entire business organisation.

Working closely with respective departments at the company’s head office in Tokyo, including the sustainability energy & environment strategic planning department, MHIC will effectively gather business information throughout China and increase its business opportunities in large-scale projects, such as urban development, energy and the environment, by offering business models incorporating its capabilities.

Plans further call for the subsidiary to set up liaison offices in China’s interior regions, where high economic growth is expected. This move aims to create a structure that will enable prompt acquisition of local information through establishment of the subsidiary’s own information network spanning from the coast to inland.

L&T Bags US$125 Million Tungaloy Set Up Office In Orders For Electrical Projects Malaysia Mumbai, India: Electrical & Gulf Projects Operating Company, a part of L&T’s Construction Division, has bagged orders worth Rs 582 crore (US$125 million) from various customers for four electrical projects in India and UAE. The projects awarded include an Rs 155 crore order from Tamil Nadu Electricity Board, Chennai, for the turnkey construction of 37 km of 400 kV environment-friendly multicircuit transmission line involving narrow base towers. The project is to be completed in 10 months and will transmit power from North Chennai Thermal Power Station Stage II to Almathy 400 kV Substation.

10

metalworking equipment news March 2010

Selangor, Malaysia: Tungaloy, the maker of cutting tools, PCB drills, wear resistant tools, civil engineering tools, and advanced material tools has set up a Malaysian office. With the setting up of Tungaloy Malaysia office early this year, the company hopes to support customers in a greater manner whereby direct technical support from Japan can be arranged on a regular basis.

In globa lly supply ing the products, the company looks to bolster the sales, manufacturing and development capabilities in order to respond more effectively to the diverse requirements of overseas customers.

JETSTREAM TOOLING

TM

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JABRO-SOLID DIRECTED COOLANT STRAIGHT TO THE EDGE. A COMPETITIVE EDGE IN ALL MATERIALS In these challenging times, everyone is looking to economise or save money. The new “easy to use” Jabro-Solid” will give you that extra edge.

Consistent good performance in all materials means you can reduce and standardise tool inventory.

The outstanding SIRON-A coating ensure optimum wear resistance in both wet & dry operations providing you with longer tool life and less machine down time.

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• Differential tooth pitch for chatter Answering a call from the aerospace industry to improve the free machining machining of difficult to machine alloys, Seco developed Jetstream Tooling – a revolutionary new solution to the age old problem offor better • Polished Siron-A allows delivering coolant precisely to the cutting zone. chip flow and superior tool life Jetstream Tooling works by delivering a concentrated high pressure jet of coolant at high velocity straight to the optimum position close to the cutting edge. This jet of coolant lifts theSingapore chip away Tel from the68412802 rake + 65 face, improving chip control and tool life enabling increased cutting Malaysia Tel + 60 3 90591833 data to be applied – not just in aerospace materials. Jetstream Tooling Thailand Tel + 66 2 7467 801 has been proven to work in nearly all material groups and with a wide Vietnam Tel + 84 8 9144393 choice of coolant pressures..

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MILLING NEWS: STEADYLINETM VIBRATION DAMPING HOLDERS

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JJ-Lapp Supplies Roller Coaster Cables Singapore: The opening of Universal Studios Singapore at Resort World Sentosa, a movie-theme park featuring 24 rides and attractions, 18 of which are unique only to Singapore, took place in early 2010.

As part of the many attractions, fun-seekers will be able to enjoy the world’s highest dueling roller coaster (42.5 m). But there is no ride without cables. To make the ride work, JJ-Lapp Cable supplied 45 km of cable, including the Olflex Classic 110 Black 0,6/1 kV, a multi-conductor, flexible control cable designed for outdoor use in all electrical equipment in dry, damp and wet conditions.

Toshiba, JSW & Toshiba JSW Celebrate Cornerstone Laying Ceremony Chennai, India: Toshiba Corp (Toshiba), JSW Group (JSW) and Toshiba JSW Turbine and Generator (Toshiba JSW) have held a cornerstone laying ceremony for the production facilities of Toshiba JSW in Chennai.

Toshiba JSW is a Joint Venture (JV) between JSW and Toshiba that will manufacture and market supercritical steam turbines and generators for thermal power plants in India.

The JV was established in September 2008, and is expected to start operation in January 2011. The site has a ground area of approximately 400,000 sq m. Over the five years from fiscal year 2009, the JV expects to invest approximately US$160 million in the plant and its manufacturing equipment and essential facilities, including waste-treatment facilities.

The JV will manufacture and market mid- to largesized steam turbines and generators ranging from 500-megawatts (MW) to 1,000 MW, for super-critical thermal power plants in India. Keihin Operations, Toshiba’s power equipment production facility in Yokohama, Japan, will support Toshiba JSW in ramping up manufacturing, and in working toward establishing an independent production scale of 3,000 MW a year by 2014.

12

metalworking equipment news March 2010

Toshiba JSW anticipates sales in the region of US$400 million by the end of fiscal year 2015. The Government of Tamil Nadu is extending support to the company and is promoting infrastructure development that includes power and water supply, and strengthening roads and bridges between the plant and the port of Ennore.

Itaru Ishibashi, MD of Toshiba JSW Turbine and Generator, said: “Toshiba JSW will manufacture products essential for future thermal power plants, and by doing so will contribute to the development of India’s power systems industry. The support we have received from the government and local community gives me every confidence for the long term success of Toshiba JSW once it starts operation in January 2011.”

Driven by strong economic growth, the Indian power generation equipment market is expected to see demand growth of more than 16,000 MW a year for the next decade, according to the Eleventh (20072012) and Twelfth (2012-2017) Five-Year National Electricity Plans published by the Indian government.

Coal-fired thermal power stations will account for over 60 percent of the capacity growth, far surpassing other energy sources.

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

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Sakhalin-1 Project Continues Drilling

Texas, USA: ExxonMobil have completed the first two extended-reach wells at the Odoptu field offshore eastern Russia, employing one of the world’s most powerful land-based rigs. ExxonMobil subsidiary Exxon Neftegas Limited (ENL) is operator on behalf of the fivecompany international Sakhalin-1 consortium.

The Yastreb rig, which is located onshore Sakhalin, drilled horizontally under the Sea of Okhotsk to a target area in the Odoptu oil reservoir over 9 km offshore. The extended-reach wells are the first two of seven, which will tap the reservoir at Odoptu. The field is anticipated to begin producing oil in the second half of 2010.

The continued application of the company’s Fast Drill technology has resulted in record performance at Odoptu, paving the way for lower development costs.

Additional ongoing activities at Odoptu include the construction of a new onshore oil and gas treatment facility and flowline to the existing Chayvo onshore processing facility.

The Sakhalin-1 Project includes the phased

development of the Chayvo, Odoptu and ArkuntunDagi fields, with an estimated total resource of 2.3 billion barrels (307 million tonnes) of oil and 17 trillion cubic feet (485 billion cubic metres) of natural gas. The Chayvo field, which was the initial phase of the Sakhalin-1 Project, began production in 2006.

Since startup, the project has produced over 240 million barrels (32 million tonnes) of oil for export to world markets. It also has been a key supplier of nearly 180 billion cubic feet (over 5 billion cubic metres) of associated natural gas to customers in Khabarovsk Krai, in far eastern Russia, to heat homes and meet growing energy needs.

The project will continue to help meet future natural gas demand in this region. Since the start of the project, the Russian State has received US$2.6 billion in royalties and its share of oil and gas, and the Sakhalin Oblast has received nearly US$650 million in production bonuses.

Foster Wheeler Awarded Contract For LNG Terminal Zug, Switzerland: Foster Wheeler’s subsidiary of its Global Engineering and Construction Group has been awarded a contract to provide project management consultancy services to Singapore LNG Corp ( SLNG ), a fully owned subsidiary of the Energy Market Authority of Singapore, in support of the development of the LNG terminal to be located on the southwestern part of Jurong Island, Singapore.

SLNG owns and oversees the LNG terminal’s 14

metalworking equipment news March 2010

development. The terminal, which will have an initial capacity of 3.5 million tonnes per annum (Mtpa), with provisions for expansion to 6 Mtpa, is targeted to be ready for start-up in 2013.

The company and Foster Wheeler will jointly manage the engineering, procurement and construction contractor through an ‘Integrated Project Management Team’ approach, which will allow SLNG to be fully involved in the management of the design and construction activities.

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SHI To Make Only Eco-Friendly Ships

Mori Seiki Wins Product Award

Resilience Shown By Automotive Industry In India

Nagoya, Japan: The NT1000 integrated mill turn centre received one of the 2009 (52nd) Best 10 New Products Awards sponsored by Nikkan Kogyo Shimbun. The company won this prize for the fourth time in a row, following the success of the Dura Series in 2006, the NZ Series in 2007 and the NT6600 DCG in 2008.

In recent years, the demand for high-precision machining of complex-shaped workpieces has been growing in the field of small precision parts manufacturing, such as medical equipment, watches and measuring instruments.

In response to such demand, the company has developed the mill turn centre. The machine features a workpiece discharge unit that is capable of transferring a workpiece, and achieves complete machining from bar or slug stock to finished parts.

India: The Indian automobile industry is thriving despite recession. A research report, ‘Indian Automobile Sector Analysis’ by RNCOS, a market research firm, has highlighted that the automobile production continued to move upward even in tough business conditions and registered close to 3 percent year-on-year growth in FY 2009 when the automobile industries of other countries were heavily battered by economic slowdown.

The passenger vehicle market constitutes nearly 80 percent of automobile sales, and holds tremendous growth potential considering the fact that passenger car stock stood at just 11 per 1,000 people in 2008.

Strong domestic demand and exports of auto components infused 16.6 percent CAGR production growth (in value terms) in the country and are well poised to sustain their phenomenal growth track in coming years.

Robert Linder, Springfield, USA

Seoul, South Korea: Samsung Heavy Industries (SHI) declared its green management policies at a ceremony that was joined by more than 120 guests. The company unveiled its plan to build only eco-friendly ships from 2015, by achieving a 30 percent reduction in greenhouse gas emissions.

The announcement makes SHI the first shipbuilder in the global shipbuilding industry to declare a green management policy that includes a detailed vision for the development of eco-friendly products and the reduction of greenhouse gas emissions.

In relation to its green management plan, the company announced three key strategies, which include the development of eco-friendly ships with up to 30 percent less greenhouse gas emissions, the development of green workplaces and green networks,

and the development of zero-energy houses.

As the first step of its journey, the company aims by 2015 to design the optimal shape of ships that will maximise fuel efficiency, and to develop diverse technologies to improve energy efficiency, including heat recovery devices and low-temperature combustion devices, in order to reduce the greenhouse emissions of its ships.

The greenhouse gas reduction achieved by building a single ship in this manner is the equivalent to the gases absorbed by 12 million pine trees in a year. In other words, building a single eco-friendly ship is like planting 12 million pine trees in the sea.

Experts predict that companies that enter the green technology shipbuilding market early will lead the shipbuilding and marine transportation industries in the future, as ships account for 3.3 percent of CO2 emissions worldwide, and IMO is introducing standards for the reduction of the greenhouse gas emissions of ships.

The company also announced that it has organised a green management committee, chaired by its CEO. It aims to develop eco-friendly ships and introduce green management policies to its shipyards and partner firms.

In detail, the company aims to make the Geojeo Shipyard a green workplace by developing eco-friendly shipbuilding facilities, using eco-friendly paints and saving energy, while building a green network by providing technical support to its partners to reduce greenhouse gas emissions, and by introducing a certification system.

16

metalworking equipment news March 2010

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Greenkote Coating Process Chosen By Daimler

Tata Steel & Nippon Steel In Joint Venture

Ohio, USA: Greenkote, a coating technology company, will provide corrosion protection for selected Daimler automotive parts beginning the first half of 2010. Initial orders include components for passenger safety related applications. Additionally, the automotive industry giant is finalising technical approval of the company as one of its suppliers of zinc diffusion coatings, using the company’s thermodiffusion coating process.

The decision by Daimler to use Greenkote zinc thermal diffusion coating protection comes after nearly two years of testing zinc diffusion systems and topcoat on its products, especially those most sensitive to corrosion.

The extensive testing involved mostly small screws, with more than 10 potential products identified to undergo the duplex coating process.

Other small parts include fasteners, fixtures, screws, nuts and some critical wiper parts on several of Daimler’s automotive platforms including Limousine E-Class and S-Class vehicles.

Mumbai, India: Tata Steel Board approved a framework for a Joint Venture (JV) between Tata Steel Limited (TSL) and Nippon Steel Corp (NSC) for the production and sales of automotive coldrolled flat products at Jamshedpur, India. This is to address the localisation needs of Indian automotive customers for high-grade cold-rolled steel sheet and contribute to further expansion of the Indian automobile industry.

TSL will hold 51 percent and NSC will hold 49 percent of equity capital of the JV company. The JV aims to capture the growing demand for high-grade automotive cold-rolled flat products in India by setting up a continuous annealing and processing line with a capacity of 600,000 tonnes. NSC will transfer its technology for producing high-grade cold-rolled steel sheet for automotive application, including skin panels and high tensile steels.

In addition to this, both companies will continuously discuss further collaboration in other fields such as automotive CGL or up-stream processes.

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Endress+Hauser Expands Production In India

Reinach, Switzerland: Endress+Hauser inaugurated production facilities for flow measurement, level and pressure measurement engineering equipment in India. The company has invested a total of €19 million (US$25 million) in land, buildings and machinery at the Aurangabad site.

The €6 million premises are divided into three buildings, with a total of 5,000 sq m of floor space for the production of level and pressure measurement instruments as well as logistics and administration.

“Our new production facilities enable us to serve our customers in India and throughout the whole of East Asia even faster, better and more flexibly,” declared Matthias Altendorf, MD of Endress+Hauser in Maulburg, Germany. “In this way we can safeguard our future growth, learn faster from the markets we supply and at the same time strengthen the position of our Maulburg plant.”

Immediately next door, Endress+Hauser Flowtec has invested €13 million euros in the extension of their production facilities for flow measurement engineering.

The production facilities, built in 1999, have been expanded by 11,400 sq m and now cover a total of 14,500 sq m. “In the past few years the Indian market has grown at a rapid pace,” said Dr Gerhard Jost, MD of Endress+Hauser Flowtec in Reinach, Switzerland.

“With the expanded capacity, we are now equipped to meet future developments. In addition, our plant houses the precise flowmeter calibration facility in India – calibrations are a central feature of our customer services.”

In addition to the Indian market, Aurangabad also directly supplies the markets of Australia, South Africa, Singapore, Malaysia, Thailand and Japan. Expansion into other countries in the Southeast Asian region and the Middle East is planned for the future.

Husky Energy Announces Third Discovery In South China Sea Calgary, Canada: Husky Oil China, a wholly owned subsidiary of Husky Energy, has made its third gas discovery on Block 29/26 in the South China Sea. The Liuhua 29-1 exploration well was drilled 43 km northeast of the Liwan 3-1 gas field and 20 km northeast of the LH 34-2 gas field in a water depth of 723 m. The well encountered a gross gas column of 145 m, with a significant thickness of high quality gas charged reservoir, and an oil zone was encountered in a deeper reservoir. The well tested natural gas at an equipment restricted rate of 57 million cubic feet (mmcf) per day, with indications that the future deliverability of the well could exceed 90 mmcf per day.

18

metalworking equipment news March 2010

The front end engineering design for the Liwan 3-1 deepwater project has been completed. Husky expects the plan of development for the project to be submitted to the regulatory authorities in early 2010.

The company anticipates the Liwan 3-1 field and the Liuhua 34-2 field are to be developed in parallel with first gas production from both fields targeted to be in the 2013 timeframe. The new Liuhua 29-1 field, which will be appraised later this year, will utilise the Liwan field infrastructure.

The West Hercules deepwater drilling rig is currently preparing to spud the first delineation well on the Liuhua 34-2 discovery.

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AEROSPACE

SP’s Students Take Flight With Pratt & Whitney Singapore: Singapore Polytechnic (SP) and Pratt & Whitney have signed a three-year Memorandum of Understanding (MOU). Under the MOU, SP’s students will have the opportunity to embark on their overseas industrial training programme at Pratt & Whitney’s customer training centre in Beijing, China.

Over a six-week period, the students will gain relevant exposure and training in aviation at Pratt & Whitney. They will receive the same training, both

instructional and practical, as aircraft maintenance engineers under this program.

The company’s customer training centre in Beijing is a joint venture company partnered with China Aviation Supply Holding Company. Opened in 2002 and serving more than 400 students annually, this training centre offers a wide range of aerospace courses and hands-on training opportunities for aviation professionals in the Asia-Pacific region.

Derek Rodriguez, Singapore

Bombardier Aerospace Delivers 302 Aircraft In FY 2009/10

20

Montréal, Canada: Bombardier Aerospace delivered 302 aircraft for the fiscal year ending January 31, 2010, compared to 349 aircraft deliveries in the previous fiscal year 2008/09 (year ending January 31, 2009).

It received 11 aircraft orders, net of cancellations, compared to 367 orders, net of cancellations, for the previous fiscal year. With the aviation industry continuing to struggle in the current difficult economic environment, the company’s performance was solid.

“The global economic crisis which began in 2008 continued to impact the civil aviation industry throughout 2009 as conditions remained challenging,” said Guy C Hachey, president and chief operating officer, Bombardier Aerospace.

“While indicators of market stabilisation have started to emerge, we remain cautious as economic uncertainty still prevails. We have taken steps to strengthen our operations and continue to invest in future programs. We believe that by creating a loyal customer base for our products and services, we will emerge from this crisis a stronger and more efficient company,” he added.

business jets, compared to 235 for the same period last fiscal year, in line with the 25 percent decrease in business aircraft delivery guidance provided in 2009.

Business aircraft deliveries for the current fiscal year 2010/11 are expected to be approximately 15 percent less than fiscal year 2009/10.

Business Aircraft In fiscal year 2009/10, the company delivered 176

Note: All fiscal year 2009/10 delivery and order numbers are unaudited.

metalworking equipment news March 2010

Commercial Aircraft In fiscal year 2009/10, the company delivered 121 commercial aircraft, compared to 110 for the previous fiscal year. This is in line with the 10 percent increase in commercial aircraft delivery guidance provided last year.

The company expects that most of the deliveries of its commercial aircraft will take place in the last three quarters of the current fiscal year 2010/11 as a result of the production rate reductions announced in 2009 and the delay in the certification and entry into service of the CRJ1000 aircraft to the second half of fiscal year 2011. Compared to the previous fiscal year, the corporation expects to deliver approximately 20 percent fewer commercial aircraft in fiscal year 2010/11.

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AEROSPACE

Derek Rodriguez, Singapore

Asia-Pacific Airlines To Buy 8,000 Aircraft Over Next 20 Years

Toulouse, France: Airlines in Asia and the Pacific will acquire some 8,000 new passenger and cargo aircraft over the next 20 years, according to European aircraft manufacturer Airbus. Valued at US$1.2 trillion, the requirement represents one third of predicted global deliveries between now and 2028, with the region driving demand for larger aircraft types.

In the passenger market the manufacturer predicts that traffic in the region will grow at an average annual rate of 5.9 percent, while cargo traffic will increase by 6.3 percent per year. This compares with a global average of 4.7 percent for passenger traffic and 5.2 percent for air freight. As a result of this growth and continuous fleet replacement, the region is expected to take delivery of some 880 very large aircraft, 2,570 twin aisle widebodies and 4,560 single aisle aircraft.

The high proportion of larger aircraft types reflects the concentration of populations around main urban centres in the region, generating high density traffic on key intra-regional routes, as well as to capacity constrained international destinations in Europe and North America. Meanwhile, demand for single aisle aircraft in the region is expected to accelerate in the coming years, driven by the growth of low cost carriers and opening of new routes between secondary destinations, especially in China, India and South East Asia.

In the cargo sector, the region will continue to dominate the global air freight market, with the dedicated freighter fleet operated by Asia-Pacific airlines 22

metalworking equipment news March 2010

growing five times to 1,500 aircrafts. While many of these will be converted from passenger models, Airbus predicts that around 340 new production freighters will be delivered to the region over the 20-year period.

These will be predominantly widebody aircraft and will represent 40 percent of expected global demand for new production freighters.

Presenting the details, John Leahy, Airbus chief operating officer, Customers said that within 20 years the region would overtake the US and Europe as the world’s largest air transport market, with Asia-Pacific airlines carrying over 30 percent of global passenger traffic and around 40 percent of all air freight.

“To meet this demand larger aircraft will be needed to ease congestion and do more with less,” he said.

“This will see airlines from the region account for over 40 percent of twin aisle deliveries and more than 50 percent of the demand for very large aircraft, such as the A380.”

Service Centre For Triumph Actuation Systems Singapore: ST Aerospace’s subsidiary, ST Aerospace Systems, has been appointed by Triumph Actuation Systems as an authorised service centre for the repair and overhaul of power transfer units installed on A320 aircraft. This agreement is for three years, with an option for renewal for an additional three years.

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statistics

World Crude Steel Output Decreases By -8.0 Percent In 2009 Brussels, Belgium: World crude steel production reached 1,220 million metric tonnes for the year of 2009.

This is a decrease of -8.0 percent compared to 2008.

Steel production declined in nearly all the major steel producing countries and regions including the EU, North America, South America and the CIS in 2009.

However, Asia, in particular China and India, and the Middle East showed positive growth in 2009.

In December 2009, world crude steel output for the 66 countries reporting the World Steel Association (worldsteel) was 106.4 mmt, an increase of 30.2 percent compared to December 2008. Most majorsteel producing countries showed two-digit growth in December 2009.

The world crude steel capacity utilisation ratio of the 66 countries in December 2009 was 71.5 percent, a decrease from 74.7 percent in November 2009.

Compared to 2008, the utilisation ratio in December 2009 increased by 13.4 percentage points.

China’s crude steel production in 2009 reached 567.8 mmt, an increase of 13.5 percent on 2008. This is a record annual crude steel production figure for a single country. China’s share of world steel production

continued to grow in 2009 producing 47 percent of world total crude steel, an increase of nine percentage points compared to 2008.

Asia produced 795.4 mmt of crude steel in 2009, an increase of 3.5 percent compared to 2008. Its share of world steel production increased to 65 percent in 2009 from 58 percent in 2008. Japan produced 87.5 mmt in 2008, a decrease of -26.3 percent on 2008. India’s crude steel production was 56.6 mmt in 2009, 2.8 percent growth on 2008. South Korea showed a decrease of -9.4 percent, producing 48.6 mmt in 2009.

The EU-27 where all major steel producing countries including Germany, Italy and France showed substantial decline recorded a decrease of -29.7 percent compared to 2008, producing 139.1 mmt of crude steel in 2009.

In 2009, crude steel production in North America was 82.3 mmt, a decrease of -33.9 percent on 2008.

The US produced 58.1 mmt of crude steel, 36.4 percent lower than 2008.

The CIS showed a decrease of -14.7 percent in 2009.

Russia produced 59.9 mmt of crude steel, a -12.5 percent reduction on 2008 while Ukraine recorded a decrease of -20.2 percent with year-end figures of 29.8 mmt.

World Production World Crude crude Steel steel production 22 January 2010

Summary Table million metric tons

2003

2004

2005

2006

2007

2008

2009/2008 2009%2009/2008

Europe of which: EU (27) EU (15) CIS

320.3

339.8

333.8

355.1

364.5

344.1

265.8

-22.8

192.5 161.0 106.5

202.5 169.1 113.4

195.6 165.1 113.2

207.0 173.2 119.9

209.7 175.2 124.2

198.0 167.7 114.3

139.1 117.7 97.5

-29.7 -29.8 -14.7

North America of which: United States

126.2

134.0

127.6

131.8

132.6

124.5

82.3

-33.9

93.7

99.7

94.9

98.6

98.1

91.4

58.1

-36.4

South America

43.0

45.9

45.3

45.3

48.2

47.4

37.8

-20.1

Africa

16.3

16.7

18.0

18.8

18.8

17.1

15.2

-11.0

Middle East

13.4

14.3

15.3

15.4

16.5

16.6

17.2

3.3

442.3

512.5

595.5

672.3

756.5

768.3

795.4

3.5

222.3 110.5

282.9 112.7

353.2 112.5

419.1 116.2

489.3 120.2

500.3 118.7

567.8 87.5

13.5 -26.3

8.4

8.3

8.6

8.7

8.8

8.4

6.0

-28.6

969.9 1 071.5 1 144.1 1 247.3 1 345.8 1 326.5 1 219.7

-8.0

Asia of which: China Japan Australia/New Zealand World

March 2010 metalworking equipment news

23

FIRST

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cut

T

he essence of High Speed Machining (HSM) is to apply higher spindle speeds a nd feeds to achieve machining results. Very thin walls, very smooth surfaces and high metal removal rates are only a few examples of the performance that can be achieved with applying HSM. This strategy can be applied not only to nonferrous materials and more precisely, aluminium, but even to ha rdened steel and exotic materials; making it applicable for industries such as the aerospace, die/mould, miniature and medical.

Even though high-speed cutting has been known for a long time (the first attempts were made in the early 1920’s), there is still large ambiguity concerning its definition. It was Carl Salomon in 1931 who proposed the first definition of HSM, defining it as a certain cutting speed which is 5 to 10 times higher than that used in conventional machining.

The

KeyTo Higher Productivity

High Speed Machining is not just a technology for shortening the production time and increasing the accuracy of machined parts, but a tangible strategy for increasing productivity.

By Dr Moshe Goldberg, marketing technical advisor, Iscar

24

metalworking equipment news March 2010

High Speed Zone Process that requires fast metal removal, (in many cases automotive components, small computer parts or medical devices made from aluminium) calls for HSM. For the wings or aircraft fuselage, the aerospace industry also requires machining long aluminium parts which often have thin walls, relying heavily on HSM, applying cutting speeds as high as 15,000 - 50,000 rpm coupled with high feeds.

The die and mould industry is another area for HSM milling, demanding tight tolerances, high accuracy and strict surface finish conditions on hard and soft materials, as well as electrodes made from graphite and copper for the Electrical Discharge Machine (EDM) industry.

High speed cutting also makes it practical to use small tools and light depths of cuts in the machining of dies and moulds, so slots and intricate details can be

firstcut

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produced with milling instead of EDM. Moreover, the inherently smooth finish achieved from this technique makes it possible to eliminate manual polishing.

Such applications require not only speed but also a stable process that can accommodate it. That process involves tooling, control and programming considerations that are completely different from the demands of conventional cutting.

In some cases the process requires the understanding of the machine’s behaviour at different speeds.

Think Before You Speed Concerning the machine specifications, achieving high speed machining performance in a variety of applications requires a machine design that harmonises all of the machine’s components into a well - propor t ioned system. This requires taking

into consideration important mechanical design elements, such as: Cutting Tool Materials The grades and parameters of cutting tools play a significant role in the process. Iscar developed the IC903 grade, a carbide grain with 12 percent cobalt, TiAlN PVD coated with wear resistance and toughness for HSM of hardened steel (up to 62 HRc), titanium, nickelbased alloys and stainless steel.

These tools exhibit toughness properties for sustaining impact at high frequency, as well as defeating heat and thermal expansion.

Toolholder – The Unbalancing Problem To o l s u b - s y s t e m s t h a t determine efficiency of HSM are:

Process that requires fast metal removal calls for HSM

spindles, axes, motor drivers, toolholders and cutting tools.

The spindle is probably the most critical element, so in order to maintain maximum productivity and accuracy it is important to ensure runout as small as possible. The smaller the runout, the shorter the time between the necessity to replacement of endmill cutters or index inserts.

Especially in HSM applications the size of runout is crucial for accuracy.

The Total Indicator Readout (TIR) should be maximum 10 microns at the cutting edge. Every 10 microns in added runout gives a 50 percent reduction of tool life. Even if the tool, toolholder and spindle are precisely balanced, there still can be several sources of instability.

One of the sources of instability is the fit between toolholder and spindle interface, where there is often a measurable amount of clearance. Moreover, this gap can also be attributed to clogged chip or residue of dirt inside the taper.

In practice, an endmill running at 20,000 rpm may not need to be balanced to any better than 20 g x mm.

Other parameters, which need to be considered for ensuring precision of HSM are spindle construction, thermal stability, movement guides, hardware, centrifugal expansion, thermal expansion and vibration.

Regarding vibration, it can result from interaction between the tool and workpiece, resulting in ‘chatter’; or from the centrifugal force that acts on an unbalanced mass in the tool and toolholder assembly.

C o nt rol l i n g v ibra t io n i s essential not only for the accuracy and productivity of the process, but also for the length of service of the spindle and the tool. Vibration also gives rise to poor surface finish, cutting edge damage, and irritating noise.

March 2010 metalworking equipment news

25

firstcut

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Improving Productivity The shape and accuracy of a produced part is essentially determined by the kinematic machine tool behavior and the static, dynamic and thermal stiffness of the machine tool system. Moreover, the surface quality that needs to be achieved depends on the geometry of the cutting edge, machining parameters and the dynamic behavior of the system. This implies that a mechanically sound unit will provide the best return over time in HSM. Productivity can be improved by using linear motors for axis motion in place of rotary motors and ball screws. A linear motor does away with much of the axis reversal error, or backlash, inherent in systems that make use of rotary motors or ball screws.

Ma k ing t he most of t he evolving technology of HSM is a manageable affair. It also involves harmonising other key aspects of shop floor operations in order to fully capitalise on the increase in machining productivity.

Conclusion & Benefits Stiff competition in the market calls for rapid development of machining technology and the design of new solutions. HSM is a prime example how high metal removal rates can boost productivity and at the same time cut down on production costs.

In spite of high requirements of machining tools, this technique gives numerous benefits. It allows the shortening of production time and eliminates some treatment (such as manual finishing), while simultaneously retaining accuracy.

Even though this technique has been known for a long time, the research is still being developed for further improvement of quality and minimisation of costs.

Enquiry No. 2001 26

metalworking equipment news March 2010

HSM is a prime example how high metal removal rates can boost productivity and at the same time cut down on production costs

HSM: Concepts & Definitions Theoretical and experimental analyses have shown that increased local stability occurs when the tooth passing frequency of the cutter is equal to the natural frequency of the most flexible system. Selection of the maximum available spindle speed that corresponds to these stable tooth passing frequencies is also referred to as HSM. This concept relies on regeneration of waviness as a primary cause of instability (selfexcited vibrations) in machining.

This waviness regeneration occurs

when a cutter tooth encounters an undulating surface left by the previous tooth.

The prediction of system stability depends on the phase relationship between the displacement of the current cutter tooth and the waviness it encounters. For certain phase relationships, the succeeding tool vibrations diminish, while for others they increase until either failure or a system non-linearity limits the motion. MEN Enquiry No. 2002

ENQUIRY NO 089

firstcut

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Two cuts showing stable and chatter machining conditions

O

Is There A

Speed Limit In

HSM?

To reap the benefits of significant investments in high-speed machine tools and accessories, NC programmers need to optimise and reach the safe limits of the system.

By Edwin Gasparraj, senior product manager, CAM product development, Siemens PLM

28

metalworking equipment news March 2010

ne of the major challenges an NC programmer faces everyday is identifying critica l machining parameters, such as depth of cut, step over, spindle speed and feed rate. Traditionally, the starting point for this data has been either a machining data handbook or the experience of senior machinists on the floor.

In a majority of cases, this data is very conservative and/or outdated.

When problems arise, the usual recourse is to reduce one or more critical machining parameters.

T he se reme die s inva r iably reduce the Metal Removal Rate (MRR). While this may have been acceptable in the past, today’s highly competitive die/mould machining market is forcing users to push the limits of productivity.

The widespread application of high-speed machines in the past several years necessitates a fresh look at how things are done on the shop floor. Simply increasing the spindle speed and feed and decreasing the chip-load significantly do not constitute high speed machining.

Making The Cut Unstable machining results in poor and wavy surface finishes that many people associate with the pinging noise of chatter. A new methodology leverages these simple characteristics to identify optimum spindle speeds and cutter loads for any given tool, holder, machine and workpiece material combination. In

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Figure 1: Z level cuts on a test piece – each pass is performed at increasing spindle speed and feed, maintaining the same chip load for all passes Figure 2: Stable and unstable machining conditions – notice that the third and eighth steps indicate clean cuts at 7,000 rpm and 9,500 rpm

essence, this method cuts a number of Z level passes at varying spindle speeds to identify stable machining conditions.

A series of identical passes are made on an inclined face of a test block, as in Figure 1. Each pass is performed at increasing spindle speed and feed, maintaining the same chip load for all passes.

Listening to cuts and inspecting the surface finish of each pass can identify stable-cutting conditions.

Trials & Tribulations A newly proposed alternative was put into practice on a Makino V33.

In this instance, a 10 mm diameter Jabro Tornado ball end mill was analysed. The length of the tool was set at 30 mm on an HSK holder. A P20 workpiece measuring 82 mm in length, 65 mm in width and 48 mm in height was used as a test piece. A 30deg taper was cut on one side of the block to accommodate the holder and to view each cut distinctly.

For this example, assume a depth of cut equal to approximately 30 percent of the tool diameter.

If there are other considerations limiting the load on the tool, follow the lesser one. Make sure the tool creates clear cusps to distinguish one depth from another.

The height of the block should accommodate at least 12 depths of cut. Slope on the cutting side should clear the tool holder. Length of the block should be sufficient to hang off the vise to allow at least 10 side passes. The width should be sufficient to be able to see the cuts.

The tool manufacturer provides two very important pieces of information – the maximum cutting speed and the chip load. The maximum cutting speed depends on the type of coating on the tool and the maximum temperature it can safely withstand. Chip load (feed/tooth) is based on the material and the geometry of the tool tip.

Take for example, a maximum cutting speed of 280 mm/min and the chip load of 0.072 mm/teeth.

This example assumed side rough milling conditions for the trial. In order not to violate the maximum cutting speed, you need to stay below 9,000 rpm.

Maximum RPM = (Max Cutting Speed in mm/min) ( ∏ x Tool Diameter) Maximum RPM = (280 x 103)

( ∏ x 10) = 8,912 ≈ 9,000 For these trials, the spindle speed was varied from 6,000 to 11,500 at intervals of 500 rpm. The maximum rpm was increased to keep the results applicable to finishing conditions as well. The depth of cut for each Z level cut was 4 mm. The program was manually edited to reflect the changing spindle speed at each cut level.

The feed was correspondingly

adjusted to maintain constant feed/ teeth throughout the trial.

Feed mm/min = Feed per Teeth x Number of Teeth x RPM Crunching Number Cutting Metal An initial cut with a 0.5 mm side stepover was cut on the slope. The side stepover was adjusted on the X offset register of the machine.

This eliminates the need for a new program for each cycle.

The initial cut with 0.5mm stepover was repeated once again to allow similar starting conditions for each cycle. This cut produced stable cutting conditions throughout the slope.

(Some of the cuts were dull at the bottom of the cusp due to decreased cutting speed.)

The stepover was increased to 1 mm and the cycle was repeated.

Even though the stability lobe diagram predicts stable-machining conditions at all spindle speeds, very low chatter signals were noticed at both extremes of the spindle speed.

This process was repeated with increasing stepover values until severe chatter signals were noticed at 2 mm. This cycle clearly showed stable cutting at 7,000 rpm and 9,500 rpm.

The stepover was progressively increased all the way to 3 mm.

The cuts at 7,000 and 9,500 rpm remained stable.

March 2010 metalworking equipment news

29

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Dispelling The Myths Fact or fallacy, true or false, let the numbers to the talking.

WRONG

Reducing speed is the most efficient remedy for chatter Spindle Feed Speed Rate (rpm) (mm/min) 6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500

840 910 980 1050 1120 1190 1260 1330 1400 1470 1540 1610

Chip Load (mm/teeth)

Depth Of Cut (mm)

0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072

4 4 4 4 4 4 4 4 4 4 4 4

Side Step Over (mm) 0.5

1.0

1.5

2.0

2.5

3.0

3.5

A

Option 2: Increase spindle speed to 9,000 rpm. Chatter is eliminated, but machining efficiency is improved

Diagram A

Machining at higher speeds is the most efficient

6000 6500 7000 7500 8000 8500 9000 9500 10000 10500 11000 11500

840 910 980 1050 1120 1190 1260 1330 1400 1470 1540 1610

Chip Load (mm/teeth)

Depth Of Cut (mm)

0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072 0.072

4 4 4 4 4 4 4 4 4 4 4 4

WRONG

Side Step Over (mm) 0.5

1.0

1.5

2.0

metalworking equipment news March 2010

3.0

3.5

B A

Often times, when using highspeed machines, the inclination is to run the machine at its top permissible speed. While chatter free conditions can be achieved at extreme speeds, the machining efficiency as measured by the MRR can be quite low.

Material Removal Rate = Feed rate mm/min x Depth of Cut mm x Side Step Over mm In diagram B, stable cutting is achieved at 11,500 rpm with

30

2.5

Chatter-free machining at 9,500 rpm with 3.5mm side step over MRR = 18,620mm^3/min

Diagram B

Legend: Stable Slight Chatter Severe Chatter

An increase in spindle speed results in stable cutting condition and improved machining efficiency

with 2.0 mm side step over).

Outside of re-programming the part with a smaller step over, there are two easy options to remedy the chatter, either decrease or increase the spindle speed. Because the lobe diagram clearly illustrates that a stable cutting condition can be achieved by increasing the spindle speed, this is best option because it is more efficient.

In many cases, when chatter is encountered, machinists tend to reduce spindle speed to eliminate chatter. While this technique will result in a stable cutting condition, it may not be the most efficient.

Instead, it is often possible to increase the spindle speed, which will eliminate chatter, while also improving cutting efficiency.

In diagram A, slight chatter is encountered at Point A (8,000 rpm

Spindle Feed Speed Rate (rpm) (mm/min)

Option 1: Reduce spindle speed to 7,500 rpm. Chatter is eliminated, but machining efficiency is decreased

Chatter-free machining at 11,500 rpm with 0.5mm side step over MRR = 3,220mm^3/min

Results & Analysis The part in Figure 2 shows stable and unstable machining conditions.

This indicates a 4 mm depth of cut and 3 mm side step. Notice that the third and eighth steps indicate clean cuts at 7,000 rpm and 9,500 rpm.

The stability lobe diagram is a useful tool for identifying stable cutting conditions at varying spindle speeds and MRRs. The diagram can be used to find the maximum allowable MRR, a key performance indicator for machining efficiency, for a given spindle speed.

It is important to note that stable machining can be achieved at any RPM, but at the cost of MRR. A global view of the stability lobe diagram, either computed with chatter prediction hardware tools or by the method prescribed in this article, helps users achieve high MRRs at certain stable RPMs. MEN Enquiry No. 2004

Useful Tips In Machining Stable machining at a slower rpm with a greater depth of cut is much more efficient than machining at a much higher rpm with a lighter depth of cut

0.5mm side step over (Point A).

Because the spindle is running at a high rpm, it is quite common to assume that the system is performing efficiently. However, as illustrated in the lobe diagram, this is not the case.

Point B, a much slower rpm but with a greater depth of cut results in nearly six times greater machining efficiency.

Enquiry No. 2003

• Follow prac tical, repe atable conditions (for example, tighten the collet-holder with the same torque every time). This needs to be repeated for every tool/holder/ machine combination. While this sounds like a lot, it can easily pay off.

• The sweet spots are transferable to other workpiece materials directly.

The corresponding maximum depth of cut and stepover values will vary.

• You could replace the tool with a similar replacement tool from the same manufacturer. The results are still valid. It is true for holders as well.

• Reset the tool length as close as possible to the testing conditions.

• You could increase the depth of cut while decreasing the stepover correspondingly and vice-versa.

• Do not use this data on thin walled parts since the natural frequency of the part being machined changes during the machining process.

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301 Chestnut Street, East Longmeadow, MA Zip: 01028-0504 Customer Service: 800-628-8810 Technical Service: 800-642-0010 Website: www.lenoxtools.com

Asia Headquarters China

3/F Building D, Red Town, 570 Huaihai Road West Shanghai, China Zip: 200052 Phone: +86(21)2208-5112 Fax: +86(21)2208-3517 E-mail: asia@lenoxtools.com

LENOX® GTO: Guaranteed Trial Order. Our blade will outperform the blade you are using now or your money back.

Malaysia Office

Lot 5. Jalan Pemaju U1/15, Hicom-Glenmarie Industrial Park, 40150 Shah Alam, Selangor Zip: 40150 Phone: +603 5569 2519 Fax: +603-5569-3500

ENQUIRY NO 042

technology

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update

Metalworking Fluids:

Handle With

Care

Although regulations are in place to remove some harmful substances from metalworking fluids, it is still important for operators to exercise the same level of care normally reserved for operating drills and cutters. By Matthew English

Protection From The Mist MWF is widely used in metalworking processes such as turning, grinding and drilling. The purpose for using these fluids are mainly for cooling and lubricating although using different MWF may result in different 32

metalworking equipment news March 2010

Meral Akbulut, Istanbul, Turkey

S

afety is number one priority in any machine shops. While many are doing a very good job in protecting the operators by deploying warning signs and demarcating plant walk-through paths, some subtle danger still remains, largely hidden to the naked eye.

Metalworking fluids (MWFs), the usage and disposal are important both from the operators’ health and environmental point of view.

From the minute the MWF leaves the drum, while it is in use and finally to the time it is disposed of, proper handling procedures must be in place to protect operators from the fluid.

While the transportation and eventual disposal of the fluid arguably poses less risk or is deemed more controllable, it is the mist created during usage (machining process) that requires more attention, care and ultimately more protection.

performance and part quality. MWF is a mixture of petroleum products, animal and vegetable fats and some additives. Their usage is usually for properties enhancement.

During machining in particular, fine droplets or ‘mist’ of MWFs are developed. They are potential occupational health problems.

Operators are usually the ones at risk as they are exposed to MWF either by inhalation or through skin contact, which can cause a variety of health problems like dermatitis and respiratory problems. Long-term exposure can even lead to cancer.

With health and safety in mind,

it is imperative to take steps to protect operators from harmful exposure. A way to mitigate risk posed by MWF mist or vapour is by installing appropriate filter and ventilation system.

Oil mist collectors are available in the market to aid the efficient removal of oil mist. Some collectors use centrifugal impaction method to collect the mist, removing them from the source. As a result, clean air is returned to the work place as clean oil is returned to the machine. These collectors are compact and can be mounted to the machine.

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Alternative Protection Another way to get around the potential hazards of certain MWF is the usage of fluids that is claimed by the makers to be non-toxic, non- carcinogenic, readily biodegradable, safe to use, store and dispose. Those fluids do not contain petroleum fractions, sulphur, chlorine and heavy metals according to the manufacturers.

L a st ly prote c t ing t he hardware, ie: the machines, should also rank high on the list of priority. Though the importance of protecting operators cannot be ignored, protecting machines from MWF can also bring about practical savings in cost. One good example is rust. Prevention of rust should be one of the main concern as metal corrosion can cause products to be sold at a lower grade or rejected.

Using suitable MWF and coupling that by protecting operators and machines from potential harm from MWF can go a long way in ensuring not just a safe work place, but also savings in terms of cost.

Enquiry No. 2101

Play It Safe To protect yourself from potential hazards associated with metalworking fluids, knowing more about it and taking relevant precautions will keep you safer.

• Adopt the safety training given by employer • Follow all safety instructions • Use splash guards • Allow time delay before opening the door to machine • Report all damages to protective equipment • Reduce contact with wet surfaces • Wear suitable PPE • Avoid eating, drinking or smoking in areas where metalworking fluids are used.

The usage and disposal of metalworking fluids are important both from the operator health and environmental point of view

H Berends, Netherlands

World Demand For Lubricants To Exceed 40.5 Million Metric Tonnes In 2012 World lubricant demand will increase 1.6 percent per year to 40.5 million metric tonnes in 2012. Although growth will be modest in volume terms, value gains will be more substantial as more expensive high performance lubricants are substituted for lower value ones. Advances will be the strongest in the developing Asian countries due to ongoing rapid industrialisation as well as rising car ownership rates, particularly in China.

These trends will also favour growth in the Africa/Mideast region and Latin America. In contrast, greater availability of high performance lubricants, increased global competition and increasingly stringent environmental regulations will restrain advances or contribute to negative growth in lubricant demand in the more developed countries of Western Europe, the United States and Canada, as well as in the European Union member countries of Eastern Europe and in Japan. These and other trends are presented in World Lubricants, a study from the Freedonia Group, a Cleveland-based industry research firm.

The more developed countries of North America and Western Europe, as well as the European Union member countries in Eastern Europe and Japan, will experience reduced or negative growth in lubricant demand due to greater availability of high performance lubricants, increased global competition and increasingly stringent environmental regulations.

Despite the downturn in the global motor vehicle market in late 2008 and early 2009, motor vehicle lubricant demand will continue to expand throughout the forecast period once an economic recovery begins to take hold. Increases in lubricant demand will be led by strong gains in the Asia/Pacific region due to rapid expansion of the motor vehicle park in developing countries such as China and India.

While the fastest growth will be in manufacturing and other markets, it will still represent a slowdown from the 2002 to 2007 time period as the global economic slowdown of 2008 and 2009 restrains upward advances in lubricant demand through 2012. The Asia/Pacific region, led by China, will continue to be the primary driver of growth in these markets due to companies worldwide pursuing the region’s key advantages of relatively low labour costs and political stability. MEN

Enquiry No. 2102

March 2010 metalworking equipment news

33

software&

www.equipment-news.com

measurement

Using

Software Maximise To

Your

Hardware Ilker, Izmir, Turkey

Given the current economic climate, working with available machineries and getting more out of them is a dream come true for many manufacturers.

By Michael E Neumann

34

metalworking equipment news March 2010

Though software programs bring about improved performance in machine tools, there are times when they themselves are in need of an upgrade

increasing demands brought by technological advancement, have placed the onus firmly on quality, or rather, how to achieve them repeatedly. In addition, it should be achieved with no strain on the operator.

Enter The Software Upgrading existing machinery can just simply be buying the latest machines that are available in the market. While many may balked at the idea of splashing the cash at uncertain economic times, making use of CNC software programs and controls may be the answer. Incorporating software into machine tools is by no means

a breakthrough technology but the real question here is the type of CNC software programs available today. Pick the correct one which fits your operation and the benefits of CNC software can be seen.

The Siemens Sinumerik 802D solution line, an operating panel control, is said to make available all CNC components (NC, PLC, HMI) in one single unit. The maker claims that this control is suitable for turning and milling machines in the lower and medium performance range.

Solutions provided include ‘standard’ solution milling and ‘standard’ solution turning. In ‘standard’ milling, time-saving

Dima V, Israel

M

achine automation is part and parcel of modern manufacturing.

Under this big umbrella, there are various subsets like CNC programming, software, CNC controllers, ser vomotor and motion controllers.

CNC machines utilise digital electronic computers and circuitry to direct machine movements.

They provides adaptable control over machine tools. This is highly desired a s most machining operations demand that a cutting tool to be fed to a workpiece at considerable speed.

Another salient point is the mechanism used in these machines allows the automatic correction of a mechanism, by means of error-sensing feedback. This work is carried out by the servomotor systems in which the feedback and error-correction signals control mechanical position or velocity.

The face of the manufacturing industry was dramatically changed with the introduction of CNC machines. Human intervention has been reduced and complex machining operations were made easier. Though this technology has made manufacturing easier, the issue of consistency, especially with

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is possible through the DIN/ ISO programming with graphic assistance through technological machining cycles according to Siemens. In addition, 2-D simulation with zoom and calculation of machining time makes the operation easier for users.

Keeping With The Times Though software programs bring about improved performance in machine tools, there are times when they themselves are in need of an upgrade. Manufacturing solutions provider Cimatron has developed the CimatronE 9.0, which provides a machine simu lator t hat ver ifie s t he machining process. The simulator displays material removal within the machine environment for both 3-axis and 5-axis machines.

The program provides NC programmers with increased

machining efficiency, better surface quality and improved performance. Version 9.0 also includes a Product Manufacturing Information (PMI) display.

Programming functions allow a higher surface quality to be achieved. Finishing functions include features that improve accuracy and smoothness. Area left by the previous cutter can be machined using a ‘cleanupall along’ function as it enables long uninterrupted tool passes.

T he ve r sio n a l so i nc lu de s e n ha nce me nt s to ma i nta i n the sharpness of external and embedded edges.

Other enhancements include further adaption of the interface to work with STL free form files and improvements in high speed machining and micro milling capabilities. Enhancements for 5-axis tilting include new machining

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

Would modern equipment fit in here?

What would be the fastest solution?

Would that be expensive?

Can we handle that without specialists?

strateg ie s to speed up the calculation process.

Calculation times have been reduced in this version in most areas and performance of the software in general has improved, with full support of dual core and quad core processors.

The software allows manufacturers to store PMI; annotations and notes are passed on through the different stages of the project from design to the shop floor. PMI is also transferable to and from other standard CAD systems.

CNC software programs have provided platforms for better operation and at the end of the day, improved quality. Incorporating software with existing machines may yet be the way to squeeze the extra performance out of machines in the shop floor. MEN Enquiry No. 2201

The Ipsen for do-it-yourself metal heat treatments. If only every decision were this easy.

For more information, call +49 2821 804-293, e-mail us at ENQUIRY NO NO 043 043 ENQUIRY

rgi@ipsen.de or www.ipsen.de

Hard work wins

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05.02.10 15:16 March 2010 metalworking equipment news

35

Fab&

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Form

Robotic Laser Welding Process:

The

FutureIsNow

Changes in production strategies and adjustments to current manufacturing climate can often give rise to a major investment.

By Ryu Tan, product manager, solid state laser technology, Trumpf

S

eeing itself as a ‘digital s h e e t f a c t o r y ’, t h e Thailand based sheet metal fabrication company Jinbao has six factories in its premises. They deal with sheet metal, stamping, hard tooling, CNC machining, painting and welding factory.

The economic crisis hit most companies over the world hard.

As a result, most businesses are considering cutting budgets on capital investment during this time or putting everything on hold. The company is an exception although they were not spared from the downturn.

36

metalworking equipment news March 2010

fab&form

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Thailand based sheet metal fabrication company Jinbao has six factories in its premises

The Highs & Lows Of Manufacturing Generally, in the manufacturing sector, there a re two ma in production strategies – the highmix, low-volume and the highvolume, low mix production.

High volume, low mix manufacturers win businesses based on primarily the cost and quality of these products. In contrast, high-mix, low volume manufacturers earn businesses based mainly on how quickly they can deliver exactly what their clients expect.

Says Victor Chung, MD, Jinbao: “After eight years of business involvement with our clients in these industries, we have found that production volumes have decreased, while the production variety has increased. Our clients increasingly want products tailored to their particular mass-customised markets. Therefore quite some time ago, we have shifted our production strategy to the highmix, low-volume approach, which fits well to the current changing demands in the marketplace.”

Robotic Laser Welding Laser welding technology and robot technology have both become established fixtures in industrial production technolog y. The combination unites the precision of high-performance laser technology on the one hand and the flexibility of the robot on the other. Modern

Victor Chung: “We have shifted our production strategy to the high-mix, low-volume approach, which fits well to the current changing demands in the marketplace.”

lasers are reliable, and are being utilised in material processing for all kinds of different applications.

With these advantages too attractive to ignore, the company invested in a Trumpf TruLaser Robot 5020. As Mr Chung explains, the company is very much looking into the future.

“The installation of the robot in our welding factory was an important step in this strategy ( high-mix, low-volume). Our approach gives us the opportunity to react better to changes and it is one of the reasons why we haven’t been too badly hit in this economic turmoil. This decision is an investment in our future.

When I’m talking about the future I’m thinking of the next five years, not only the next few months,” he says.

Another aspect that led the company to using a more high-end machine is the issue of workforce.

In fast developing countries like Thailand, costs are rising and that demand new strategic decisions.

Robots solve complex movement and positioning tasks in all degrees of freedom, and are flexible in their motion sequences.

Both the laser and robot enable simultaneous exploitation of the flexibility of the robot and easy integration of high power solidstate laser, while at the same time

offering low cost, easy access to laser material processing.

Light-Years Ahead The laser units used in the system can be pulsed, disk or continuously emitting either solid-state or disk lasers, with outputs from 40 W to over 16,000 W. A constant focal diameter across the entire performance ra nge g ua ra nte e s con sta nt quality processing. One major benefit here is the fact that the laser beam is guided along a flexible laser light cable, enabling it to be applied with precision.

In laser welding, narrow yet deep weld geometries assure that distortion and the need for subsequent straightening is reduced to a minimum or even entirely eliminated. With the welding depth easy to verify, visible backwelds on the underside are prevented.

The use of high-power lasers in industrial production has been steadily increasing for a number of years, especially in subcontractor, sheet metal, aerospace a nd automotive industries, where more than 10,000 cars are welded per day.

YAG laser welding technology allows designers to expa nd the types of joints, materials and plating options for their products. Applying laser welding March 2010 metalworking equipment news

37

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m a ke s i mp o s sib l e we l d i n g possible. Reliability, minimal heat distortion, high processing speeds, a noncontact process and the flexibility of CNC programming are just a few advantages that have resulted from the increased

use of laser welding.

There are several considerations to change designs with laser welding to avoid the disadvantages of conventional welding. This will open the door to new clients in different industries.

With the well-trained employees and the new machines from

Trumpf in the welding factory, Jinbao has set a benchmark on sheet metal forming in the Thai market by fully adopting European standards in their factories, particularly, in the welding operation.

Enquiry No. 2301

Other Laser Applications In Sheet Metal Processing

Using universal sheet metal processing systems in automotive assembly process can result in cost reduction. finally, welding them using the laser systems.

“Overall, the automotive manufacturer can reduce component costs using this concept compared to conventional methods,” says Mr Löffler.

A u t o m o t i v e manufacturers are currently facing a multitude of challenges.

On the one hand, they have to comply with the legal requirements for the CO2 emissions of the cars they produce. On the other hand, customers are demanding more and more from their cars.

In order to face these challenges, automotive manufacturers have to adapt their production accordingly and become more flexible. “Traditional production methods that

38

metalworking equipment news March 2010

use press brakes to produce deep-drawn par ts are becoming less and less suitable for this purpose,” says Klaus Löffler, specialist in automotive production technology, Trumpf.

O n e way to m a ke production work flows more flexible and meet customer and legal requirements is to use u n i ve r s a l p r o d u c t i o n equipment such as sheet metal processing machines. Components are produced by first cutting the blanks in the laser cutting machine, then forming them in the bending machine and,

Saving Time & Cost With Laser Just-in-time production used where the components are needed eliminates logistics costs because transport and storage are no longer needed. Since the automotive manufacturer wo r k s w i t h u n i ve r s a l sheet metal processing tools, it can upgrade the entire production system to the new series faster when replacing models; sometimes only changes in the machine software are needed.

The use of laser s, which are key to this production method, considerably lowers the costs per component.

“Even using the laser to cut blanks allows the mate r ia l to b e b et te r utilised. The scrap from

a window cu tou t, for example, can be used for other components,” adds Mr Löffler. “This means that the usual material utilisation quota of 50 percent can be increased to more than 80 percent,” he says.

By using combined punch-laser systems, automotive manufacturers can integrate additional features such as threadtapping, angles, louvers or brackets directly onto the component – without additional joining steps.

This reduces the number of components, saving material and lowering weight and costs.

The production system has already passed the test phase among several automotive manufacturers and will be used to produce structural components such as panels, longitudinal supports, seat frames and other similar components.

Even in motor spor ts, sheet metal processing systems have already proven their value. MEN Enquiry No. 2302

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Quality + Productivity + Availability

Dörries Scharmann Technologie GmbH (DST) is one of the few European owned companies playing a leading roll in the worlds premier league of heavyduty machine tool constructors. Precision, costeffectiveness and reliability are the qualities in which the company, headquartered in Mönchengladbach, is claiming to lead this challenging business. Having gained decades of experience in the construction of heavy-duty machine tools in the Dörries, Droop + Rein, Scharmann, and Berthiez divisions, and with the Italian brand name of Mecof DST offers different unique technologies for a wide variety of applications At Liebherr Aerospace Lindenberg GmbH a Droop+Rein FOGS D40 Over-Head Gantry High Speed Machining Center is used to machine forged steel Landing Gears for the Embraer series EJR190/195 passenger aircraft. Currently the clamping area of the machining center (2,500 x 6,000 mm) is divided in to a section for machining and a section for set-up. This was done to accommodate future orders requiring a greater work piece size, where the total area of the clamping area would be available for the work piece. The FOGS D40 has full 5-axis machining capabilities and roughs and finishes the parts in three set-ups. The final “high speed” finishing operations completes a uniquely wide range of operation for this type of machine tool.

This performance is facilitated by the machines innovative design concept. The “Over Head” gantry principle provides the high stiffness required for rough machining combined with the high dynamic performance needed for the finishing. The extremely

well proportioned cross rail on which the cross rail head (Y-axis) is mounted also contributes to the outstanding all round performance of the FOGS D40. Mounted in the cross rail head is the ram (Z-axis) to which is attached the Fork Type Head, which provides the 5-Axis capability through the rotary “B” and “C” axes.

The choice of the relevant appropriate machining head forms the basis of optimum results on the various work steps and requirements such as roughing, semi-finishing and finishing. Changeable milling heads and spindles are available to do this.

For application within the general engineering sector, the product range Scharmann offers two different machine lines.

The ECOFORCE line are horizontal machining centers in central design. The modular designed products are capable of providing efficient, flexible machining solutions. Configured with traversable spindle, facing head or tilting spindle the ECOFORCE with up to 63 kW power is the right solution for optimized horizontal heavy duty machining with high performance.

The HEAVYSPEED line of ram type boring mills was designed for machining large and heavy workpieces. With a combination of machining tables in various sizes and versions, floor plates and special solutions such as facing heads, or universal milling heads the HEAVYSPEED line can be adapted to meet the exact requirements of the application.

Permanently high machining capacity and high damping are obtained by means of hydrostatic guides for the linear axes and the powerful main drive with up to 100 kW and 20,000 Nm. Jan-Feb 2010 metalworking equipment news

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Applications Of Laser Welding Among the conventional welding techniques, applications for laser welding have increased steadily in recent years because it offers a number of advantages. These include improved optical appearance, small HAZ, miniaturisation, less thermal, mechanical or electrical load upon the product, less flash or no flash at all, feasibility of 3D weld geometries and even the possibility of welding thermoplastics and elastomers.

Laser welding is versatile and is applicable for joining miniature electronic components or welding steel structures in excess of 1 inch (25 mm) thick, at greater productivity and lower cost.

Using Light Differently Since the laser light relies upon the material’s heat conductivity to produce the weld, a relatively large HAZ can develop in certain 40

metalworking equipment news March 2010

On The

Spot

Laser Welding:

Replacing traditional light sources with laser increases accuracy and also open doors to technologies that are light-years ahead.

By Augustine Quek

Ilker, Izmir, Turkey

A

ll types of lasing sources such as carbon dioxide, he l iu m a nd N d:YAG (neody mium -y ttrium aluminum garnet) are based on the excitation of atoms. The focussing lenses concentrate the beam energy into a focal spot as small as 0.005 inch (0.127 mm) in diameter or less.

Welding starts when this directed laser beam is targeted on the work piece surface to be welded. At the surface the large concentration of light energy is converted into thermal energy, which is transmitted through the material by surface conductance.

This thermal energy produces melting and coalescence before a Heat Affected Zone (HAZ) is developed, as the surface of the work piece starts melting. For welding, the energy is maintained below the vaporisation temperature of the material to reduce material loss. Because the penetration of the work piece depends on conducted heat, the thickness of the materials to be welded must be considered.

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types of metals with high thermal conductivity such as aluminium, resulting in limited downward penetration of less than 2 mm.

To get around this problem, a technique known as ‘keyholing’ is used. It involves higher power lasers (>106 W/cm²) that can make deeper penetrations. A vaporised hole is formed in the metal by heating the spot of laser focus above the boiling point. The hole traps about 95 percent of the laser energy into a cylindrical volume, known as a keyhole.

Temperatures within this keyhole can reach as high as 25,000 deg C, making the keyholing technique very efficient. As the laser beam moves along the work piece,

the molten metal fills in behind the keyhole and solidifies to form the weld. This technique permits welding speeds of hundreds of centimeters per minute or greater, depending on laser size.

Another technology combines laser welding with conventional Gas Metal Arc Welding (GMAW). It brings together the advantages of the two techniques, ie: deep weld penetration with low heat input and small HAZ and improved tolerance of joint root openings, surface conditions, impurities, root opening filling and contouring.

Originally used as a costeffective method for producing beams from high-strength plate for use on US Navy ships, it can now

fab&form

Kalyana Sundaram, Chennai, India

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Another major improvement in laser welding has been its use in medical devices

be used to join sandwich panels, structural beams and pipelines.

According to US-based ESAB Welding & Cutting Products, it can even be used in shipyards for ship fabrication and assembly, as well as superstructures in bridge building.

The company also provides hybrid laser arc welding in a 2D gantry, 3D robotic, or custom mechanised solution, together with its real-time closed-loop process control and automated quality assurance system. These systems are claimed to have welded beams from ordinary and high-strength plate at rates that are five to ten times that of conventional welding processes.

Laser Automation L a ser automat ion i nvolve s combining laser welding devices with robotics. One example is the Servo Robot Digi-Las laser welding head from Canadian company Servo-Robot. The laser welding head combines seven different functions into one tool.

T he se f u nct ions include integrated joint finding, integrated joint tracking, adaptive weld parameter control, robot error compensation, process and system monitoring and integrated weld bead inspection.

The system is compatible with any Nd:YAG or fibre laser interfaced with either a CNC welding machine

or welding robot. According to the company, 3D complex joint welding can be achieved when the laser head is interfaced to a robot.

Putting Medical Devices Together Another major improvement in laser welding has been its use in medical devices. Requiring exceptional precision in their welding processes, medical device manufacturers are looking to laser technology to provide solutions that enable a high degree of accuracy.

Advances in laser resonance design and fibre optic based beam delivery have made possible laser spot welds up to 30 micrometers.

Take the example of a guidewire, a 250 - 500 micrometer diameter wire that can be up to 3 m long.

T he se de v ice s a re u se d along with other technologies, such as catheters, to establish a pathway through a portion of the human circulatory system for drug delivery or deployment of angioplasty devices.

A t y pic a l la se r we ld i n g application in the production of guidewires is welding the spring to the core wire. A consistently successful guidewire laser welding process requires innovative design of parts fixtures to ensure intimate contact between the core and the spring, and a modern laser with realtime instantaneous power feedback

to guarantee that every laser weld pulse in within specifications.

Other devices such as heart rhythm management devices require seam-welding two halves of the device together to achieve a reliable hermatic seal. This requires motion control systems, which usually includes a rotary stage holding the implantable device while applying pressure to clamp the two halves together. An XYZaxis robot aims the laser beam at the edge seam, maintaining orthogonality to the seam.

A conventional approach has been to slow down the whole operation so the force impulse of the changes in direction of the work piece is low enough to not affect the performance of the weld, but at a much reduced production rate and higher cost.

An improved solution is to set up the motion system to minimise the magnitude of the sharp changes in acceleration by slowing down as needed at these inflection points and then speeding up along other segments of the contour. Using special software, it is possible to fire the laser in response to the work piece’s actual position rather than at a constant repitition rate.

La ser welding process continues to expand into modern industries and new applications because of its many advantages like deep weld penetration and minimised heat inputs. Since the invention of the laser in the 1960s, laser welding use has grown from one for exotic applications to today’s high-speed, automated welding processes.

Laser welding is now a fullfledged part of the metalworking industry, routinely used for many products, from common items such as cigarette lighters and watch springs to specialised uses such as pacemaker cans and hybrid circuit packages. MEN Enquiry No. 2303 March 2010 metalworking equipment news

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ulti-axis laser processing system t e c h n o l o g y continues to provide advantages to manufacturers i nvol ve d i n t he a e ro sp ace industry particularly for suppliers of turbine engine components.

Driving this movement is the global aerospace competition in military, commercial, and private aviation sectors. Another factor is rising aviation fuel costs and the need for greater fuel efficiency that is being addressed by innovative engine design and manufacturing techniques. Also there is the desire for consistent manufacturing processes that can be better controlled.

A further factor is the use of improved or new aerospace materials in combination that pose manufacturing challenges. Last, but certainly not least, is the growing concern for environmental issues including the need for lowering engine emissions and noise. All of these factors are opening the door

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Multi-Axis Laser Processing In The

Aerospace Industry Laser systems continue to meet aerospace manufacturing challenges. By Peter Thompson, technical director and Mark Barry, VP, sales and marketing, Prima North America, Laserdyne Systems

wider for the use of multi-axis laser system technology.

Multi-Axis Laser Technology The advantage that these systems bring to the user is obvious. As an example: In India, a company has begun to produce a legacy aero-engine component using multi-axis laser technology. When compared to the original parts manufacturing process using older laser technology, the quality of the processing using the new system

is more consistent (less rework and scrap), the manufacturing cycle time is lower, and the skill set required of the system operator is reduced. The net result is a superior part with total manufacturing costs that are lower.

Another example involves a North American company that produces land based turbine components. This company was able to reduce part cycle time by 75 percent using the technology versus their previous process.

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An array of aerospace turbine engine transition components shows complex holes produced in many shapes at difficult angles

Growing Market For Hole Making Today’s turbine engines operate at above the melting point of the materials from which they are made. For proper cooling and to prevent damage to engine components, complex cooling schemes relying on elaborate hole patterns are required.

Consider the engine cooling requirements of the Joint Strike Fighter aircraft. It has over 2,000,000 holes in each of its two engines.

These holes are ‘drilled’ or created using a pulsed Nd:YAG laser as part of a multi axis processing system.

W it h t ho u s a n d s o f ne w commercial aircraft being built annually requiring similar complex engine cooling systems, it is easy to see that the market for hole making is growing.

This growth is compounded by in-service engines that require periodic maintenance also using the same laser systems to refurbish cooling holes. Size, shape and positioning as well as metallurgy are key considerations in the creation of cooling holes for this market.

In earliest turbine engine designs, holes were round and positioned in an easy to describe fixed pattern. Today’s engine designers call for many different hole sizes, in increasingly complex

Complex aerospace transition components processed with laser gives aerospace engine manufacturers improved processing and quality

shapes and irregular patterns.

Performance analysis has proven that non-round holes and less formal hole patterns provide more efficient cooling and therefore less polluting engine emissions.

Today’s designers are not seeking to simply make a hole to a particular shape or diameter but rather the goal is to produce a rate of flow through a given component. The most efficient flow rate is determined by complex modelling and trials to determine the best hole size, shape and location.

This means that the manufacturing process must be capable of adapting to changes in design. The latest multi-axis hole drilling technology now allows for drilling to a flow rate that can often be held to ± 2 to 3 percent of specification at high throughput.

This recent achievement further clarifies laser-processing position as the standard process system for creating turbine engine components.

The Challenges Of New Materials As cooling requirements for turbine engines have required increasingly more sophisticated designs, so has the use of exotic materials for these designs. Many of these materials are new or combinations of materials that have high strength features and high heat resistance but by their nature have limited options for processing.

The materials of choice by turbine engine designers now include Inconel 617, Titanium, Hastelloy X and single crystal materials.

To achieve increased heat resistance, designers are specifying a growing array of Thermal Barrier Coatings (TBC) to be applied to the surface of the metal material prior to processing. These TBCs add to the processing difficulty. For all practical purposes, most of these new coated and uncoated materials can only be efficiently processed with quality results using a multiaxis laser system.

March 2010 metalworking equipment news

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The type of material and the constraints employing that material in a design most often is overcome with the Convergent Lasers CL50k Laser, which has features that are the result of the focus on high speed hole drilling.

This laser produces both the high-energy pulses required for drilling meter sections (cylindrical portion of the hole) and the shorter, higher frequency, loweraverage-power pulses required for machining diffusers (shaped portion of the hole).

Refurbishing Turbine Engine Components High value engine components, such as combustors, nozzle guide vanes, blades and other transition parts, for both land and aerospace engines, are regularly refurbished and put back into service. This is a growing and technically demanding business.

One leading turbine engine manufacturer for aircraft alone re p o r t s 2 5 ,0 0 0 e n g i ne s i n active service, all of which are continuously monitored for periodic maintenance. To keep maintenance costs as low as possible and to extend time between overhaul, engine manufacturers are requiring suppliers to improve t heir processes. Once again, multi-axis laser system technology stands up to the challenge.

Refurbishing airflow holes requires ‘recreating’ in the same position a nd with identica l precision size characteristics as the original part when new. Recreating precision holes can be more difficult than generating precision holes in a new part because there is little margin for error.

Holes are positioned closely together and have diameters as small as 0.020 inches (0.508 mm) and require tolerance accuracies as tight as ±0.002 inches. To position and laser process each of these holes accurately – without damaging the part – requires the 44

metalworking equipment news March 2010

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Overcoming the problems encountered with conventional processing options such as EDM, multi-axis laser drills holes in thermal barrier coated parts with precision

best multi-axis laser machining technology and often a high level of operator skill.

Pe rc u s sio n d r i l l i n g a n d trepanning processes recreate the cooling holes. Percussion drilling is frequently used and generates a hole with the laser’s focused beam diameter. With the part held stationary, the laser beam is moved with simultaneous multiple action motion. The beam is focussed at the point where the hole is.

A single pulse or a series of pulses removes the material in the beam path, with an assist of coaxial flowing gas until the hole is recreated. Repair material, whether weld or braze, and foreign material that has built up in the holes during engine operation including slag and exhaust refuse is removed cleanly and accurately by operating the laser system in this way.

Laser System Projects Airflow Rate A real time hole measurement technique that is currently in development using multi-axis laser processing is called Dynamic Automated Visual Inspection System (DAVIS). DAVIS is designed to capture images of laser-drilled holes and shapes in real time and analyse the data on-the-fly

for conformance to specification including proper hole size and projected airflow.

The DAVIS system is being developed to interact w ith Laserdyne’s 795 laser drilling system and its S94P laser process control.

The system is designed to provide information for dynamic holes size control and compensation for deviations in real time. While still in the developmental stages, the nearterm outlook for its use in engine hole making appears promising.

Standardisation Of Laser Processing Techniques An international movement is underway for the standardisation of laser processing techniques within the aerospace industry. Real time data logs such as the information projected to be captured using the DAVIS process. It can be used for creating National Aerospace and Defense Contractors Accreditation Program (NADCAP) reports.

Increased mandatory reporting to a NADCAP standard to satisfy OEM’s is now influencing Asian and other global turbine engine component manufacturing centres to increase the scope and number of reports. MEN Enquiry No. 2304

28. – 31. March 2007 · Hall 6/Booth 6H1-01

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Different parts used in the communication industry require an extremely high level of accuracy arising from complex bending and coining stages. The BSTA series offer not only accuracy but also unsurpassed repeatability and high performance for increased output and reduced manufacturing costs.

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In The

Grand Scale Of Things From power generation to major infrastructure overhaul, the heavy industries are generating big movements that can even be felt in the metalworking community. By Joson Ng

T

he rapid development in Asia has ushered in a period of construction boom.

Singapore’s construction demand (exclude reclamation projects) for 2010 is projected to reach between S$21 billion and S$27 billion (US$14.9 and 19.2 billion) according to a media release by the Building and Construction Authority of Singapore. This is a continuation of a sustained workload from last year’s S$21 billion worth of contracts awarded.

The bulk of this year’s demand will come from the public sector, which is projected to form 65 percent of total demand. It is expected to range between S$14.0 billion and S$17.9 billion and will largely be fuelled by higher growths in most categories of building construction demand and strong civil engineering projects led by Land Transport Authority’s MRT (Mass Rapid Transit) projects for Downtown Line Stage 3 and major road projects.

Elsewhere throughout Asia, the heavy machineries are all out in force with bridges, dams, railways

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metalworking equipment news March 2010

Ivan Prole, Belgrade, Serbia

industryspotlight

www.equipment-news.com

Madmick99, UK

Jarik, Kyiv, Ukraine

The trend towards larger turbines is driven by economics

Following industrialisation in many parts of the world, the demand for electricity is higher than ever

and airports propping up the heavy industry. Such as the scale of this industry, it not only touches on construction of infrastructures, it also covers power generation and even space exploration.

Construction of major infrastructure requires plenty of raw materials like steel bars, which ultimately benefits the metalworking industry where various fabrication works are necessary to ensure the quality of the product supplied.

Apart from constructions of buildings or other large-scale projects, metalworking technology is very much in demand in power generation where large turbines are produced.

Power Generation Electricity is essential in modern life. Following industrialisation in major parts of the world, the demand for electricity is higher than ever. There are many ways to generate electricity. Coal burning power stations are still available even with cleaner alternatives like wind power and hydroelectricity.

Although the main source of propulsion (ie: wind, water, natural gas or coal) is different, the way to generate electricity is still somewhat the same. Take a nuclear power station for example, the steam is generated in boilers heated by nuclear reactors. The steam subsequently is captured by turbines to convert mechanical

energy to electricity.

Players in heav y industry have long been involved in power generation. Mitsubishi Heavy Industries (MHI) has completed the construction of a manufacturing facility at its Takasago Machinery Works in Hyogo Prefecture, Japan, that is dedicated to production of forged turbine blades for Nuclear Power Plants (NPP), a core component of nuclear power generation systems.

The facility can integrally perform all processing required for blade production and enhances the company’s capability to supply forged blades, including one of the world’s largest 70-inch class turbine blades, for NPPs in Japan and other countries, according to the company.

The facility achieves expanded unmanned machining in blade shaping and surface processing, enabling both quality enhancement and cost reduction.

N PP t u rb i ne s a re a ke y component of nuclear power generation systems that efficiently convert thermal energy produced b y s te a m g e n e r a to r s i n to rotational energy. The turbine, a rotating body, is composed mainly of forged blades and a rotor that functions as the turbine shaft or axis into which the blades are set.

See Where The Wind Blows Staying in the common area where heavy industry, wind energy

and metalworking converge, manufacturing of energy harnessing turbines is looking to move up like the wind. According to the American Wind Energy Association, in 2010, over 1,000 wind turbines larger than 2 megawatts (MW) are already in commercial operation in the US, and the year-end order for 338 GE 2.5 MW wind turbines for the Shepherd’s Flat wind project in Oregon, signals a big shift in orders toward such larger turbines.

This foreca st a ssumes that inventory will have been exhausted and that there will be a growing market for wind turbine orders in 2010 and beyond. The trend towards larger turbines is driven by economics – taller turbines with larger swept areas produce more power at a lower cost per kilowatt-hour.

As wind penetrations grow higher in the US and Europe in 2010, utilities and grid operators should become more comfortable with this new source of power. Several major wind integration studies slated for release in 2010 are expected to add further evidence that wind can be reliably integrated with the grid at low cost.

The colossal infrastructure construction and energy generation projects are only two areas where heavy industry are making its presence felt in Asia and beyond.

Be it turbine manufacturing, railway or building constructions, there are no lack of opportunities for the metalworking community to make a big splash into the pool of heavy industry. MEN Enquiry No. 2401 March 2010 metalworking equipment news

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W

Thick Section Welding

Fibre Laser With

With the availability of high power fibre lasers of more than 10 kW, new application fields in thick section welding could be developed, especially in the heavy industries.

By Michael Grupp and Karsten Klinker, IPG Laser and Stefano Cattaneo, IPG Photonics

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metalworking equipment news March 2010

he n i n 2 0 01 t he first fibre lasers of severa l hu ndre d watts were i nt ro du ce d to t he m a rke t , t he in it ia l intere st of R & D depa r tments for this new technolog y was followed by interest from industr y. The economical and technological advantages compared to other lasers sources were obvious and the potential for future applications could be shown in research results for fibre la ser mater ia ls proce ssing.

These advantages drove rapid acceptance of these lasers in the market and enabled new applications or replaced other laser technologies by fibre lasers.

The range of applications starts from micro-processing with pulsed and continuous fibre lasers of highest beam quality – single mode or Gaussian beam – to high power applications in cutting and welding of thick metals. Laser cutting as the largest market of laser technology today has come to a change due to the availability of fibre laser cutting systems of numerous machine builders, who realised the technological advantages in cutting.

T h e w av e l e n g t h o f 1. 07 micrometer has a significant higher absorption on all metals compared to CO2 lasers, which leads to higher processing speeds and lower required laser power.

Within a very short time the modular fibre laser concept allowed the development of ultra high power fibre lasers (Figure 1).

Today lasers of 50 kW are already introduced and higher power is only a question of market demand.

Fibre Laser Technology Fibre lasers are diode pumped solid state lasers with an active fibre doped by rare earths such as Ytterbium, Erbium or Thulium.

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The main advantages are very good beam quality together with wallplug efficiency of about 30 percent. The use of passively cooled single emitter diodes for pumping the active optical fibre results in very high power stability and maintenance-free long-term operation.

Multi mode fibre lasers for high power materials processing applications have a modular de sig n. T his a llows a lmost unlimited power generation by the combination of multiple single mode modules to a multimode system.

Applications In Shipbuilding T he first 10 kW fibre la ser, introduced in 2004, generated a great interest in the shipbuilding industry. The main advantage of thick section welding, in addition to significantly higher welding speed is the reduction of weld distortion from reduced heat input.

In the combined ‘hybrid’ process of laser and Gas-MetalA rc (GM A), welding speeds of more then 1 m/min can be obtained for sheet thicknesses o f m o re t h a n 10 m m . T he combination of processes results in a stabilisation of the electrical arc at high speeds together with a gap tolerance that can be wider

The first 10kW fibre laser, introduced in 2004, generated a great interest in the shipbuilding industry. than the laser beam diameter.

The advantage of fibre lasers compared to CO2 lasers was seen in the simple beam delivery by optical fibres, this reduces costs and avoids the technological limits of a solid beam delivery by mirrors as used by CO2 lasers.

Due to long process fibres (>50 m) there is no need to move the laser along the axis of travel and no adjustment of beam guiding systems in these large area welding systems is necessary.

Concerns about laser safety for the wavelength of 1,07 μm were overcome by intensive research and development of local shielding of the radiation at the processing head. Meanwhile two panel lines with 6 and 10 kW laser power are installed in European shipyards.

The other main technological advantage of fibre lasers is the high beam quality, which is defined by a very small process fibre diameter and allows the focussing of the beam to very

small spot sizes. Fibre lasers up to 10 kW can be equipped with fibres of only 100 μm core diameter, corresponding to a beam parameter product (BPP) <4.5 mm*mrad.

This small spot size together w ith high welding speed results in very narrow needle shaped welds with low heat input. Welding depth and weld seam shape are comparable to electron beam welds.

For this reason fibre lasers can replace EB -welding in a wide range of applications such as welding of gear box parts (differentials, shafts, gears) and other components with no need of a vacuum chamber. Especially for high volume production and large parts this results in shorter processing times and cost reduction.

Ultra High Power Fibre Lasers Since ultra high power fibre lasers of more than 10 kW are available, welding of more than 20

Development Of Low Order Mode Fibre Laser

Figure 1: Time scale of fibre laser development for multimode high power fibre laser

March 2010 metalworking equipment news

49

industryspotlight

mm thickness became possible.

This is of high interest in tube fabrication/pipeline construction, heavy industries and power plant construction.

Figure 2 shows the performance of the 30 kW fibre laser YLR30000 equipped with a fibre of df= 200 μm. All welding tests were done in bead- onplate arrangement with the same optical configuration. A welding head with f= 320 mm focal length and an optical magnification of M= 2.1x was used. This results in a spot diameter of 420 μm on the workpiece.

Figure 2 shows that penetration depths of more than 25.4 mm could be achieved with 20 kW at a speed of 1 m/min.

Increasing the power to 30 kW enabled a speed of 2 m/min at the same thickness. The cross sections of the welds show that at a speed of below 1 m/min the typical V-or Y-shape of the weld geometry occurs, while at higher speed the weld is very narrow with almost parallel flanks.

Outlook & Summary Re ga rd i n g t he i nc re a se o f welding depth with increased laser power, it is obvious that up to the actual experimental limit of 30 kW, an almost linear increase of penetration depth could be achieved (Figure 3).

This leads to the expectation that with further increase of the power, welding depths of more than 50 mm could be achieved in single-pass welding. Welding applications in this thickness range are known in power plant and reactor construction, as well as in heavy industry.

One example is the construction of the international thermo nuclear reactor ITER where wall thicknesses of more than 60 mm have to be welded on large sections of the reactor.

Within a very short time fibre lasers have become an efficient 50

metalworking equipment news March 2010

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Welding Speed m/min Figure 2: Welding performance of 30 kW fibre laser YLR30000. Bead-on-plate weld on stainless steel 1.4301 and X70 alloy steel

Laser Power kW

Figure 3: Penetration depth vs. laser power. Experimental limit and potential increase in welding depth with higher power

tool in welding of thick section materials. The power and flexibility allows the integration of fibre lasers in large production lines for the shipbuilding and offshore industry, tube and pipeline production and other areas of heavy industry.

Today material thicknesses of more than 30 mm can be welded by the fibre laser with weld seam geometries which are

very similar to electron beam welds, but with the advantage of no use of vacuum chambers and no limit to workpiece size.

Today’s experimental results show the potential of fibre laser welding for future applications for thicknesses of more than 50 mm. MEN Enquiry No. 2402

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Sustainability:

Take It, It’s

Yours!

SMC’s Dr Song Bin discusses his vision for the newly launched centre. By Joson Ng and Derek Rodriguez

U

n v e i l e d to the public late la st yea r, SIMTech’s (Singapore Institute of Manufacturing Technology) S u st a i nable M a nu fac t u r i n g Centre (SMC) is already actively col lab orat i n g w it h se ve ra l government agencies a nd companies.

SMC director Dr Song Bin reveals that the setting up of the centre has been a long time coming. For many years, SIMTech has been developing sustainable technologies, but on an ad hoc basis and did not use terms like ‘sustainability’ or ‘environmental’.

According to Dr Song, the centre was set up “with the belief that the manufacturing industry is undergoing a paradigm shift towards green manufacturing to minimise the emissions, waste and the toxicity in the manufacturing process”. To achieve such an objective, he believes that the key will be “technology innovation and 52

metalworking equipment news March 2010

the implementation in the industry”.

“Since 2007,” says Dr Song, “we have started to put in a more systematic effort to research into technologies for sustainability in manufacturing. Included are tools that can help companies to quantify sustainable performance like carbon footprint, depletion of resources and the impact on human health from a manufacturing process; and technologies that reduce toxicity, increase energy/ resource efficiency, recovery and recycling waste, and processing and application of eco-friendly materials.”

Open To All Industries There are many industries in which sustainability can play a huge role, suggests Dr Song. In the aerospace and automotive industries, weight reduction is crucial; in the food industry, manufacturers want to reduce energy consumption and improve packaging in terms

of environmental impact. Other industries, he says, include machinery, moulding, stamping, electronics and mechanical.

Companies that are interested in sustainability but are unable to pursue it due to lack of resource can still consider sustainability as a viable avenue.

Says Dr Song: “We don’t provide funding but there are orga nisat ions in Singapore that will support companies to innovate technologies that help to reduce waste and improve energy efficiency. For example, SPRING have this capability development fund, companies that have the need or idea to come up with new capabilities can apply for this funding, which can be around 50 percent or higher, to offset the cost.

NEA have this 3R fund; companies that want to implement some sort of technology or process to reduce waste can apply for funding from NEA. And IE Singapore can help companies that wish to carry out some sort of technology upgrading that can help them to export their goods overseas.”

Enquiry No. 2501

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Dr Song On SMC’s Three Areas Of Focus: Quantifying Carbon Footprint “To help companies quantify their carbon footprint, we are developing our own methodology and software toolkit embedding relevant international standards like PAS 2050, ISO 14064, and the coming 14067.

More and more companies are very keen to do this with us.

Companies are very keen to improve their carbon emissions and reduce wastage. They are looking for ways to reduce the consumption of resource in manufacturing process. That will help the companies to be more competitive, and open a lot of opportunity for research.”

Remanufacturing “We have all these precision engineering companies, they’re quite strong in their core competence, but the electronic industry which they have been supporting, is declining in Singapore. However, their capabilities are very suitable and provide the base requirement for remanufacturing.

In the meantime the EDB is attracting large remanufacturers in Singapore and these manufacturers need support. We also have a strong trading industry distributing products and components worldwide. Through taking-back schemes and partnering with precision engineering companies, used products/components can be remanufactured and marketed. All these open up opportunities for business growth with environmental benefits.”

Packaging “Packaging is often the first area for a company to improve their environmental performance while gaining cost benefits. We are looking into the use of sustainable materials for packaging, eco-design of packaging, and technologies to reduce costs. Most of the materials used in packaging are not renewable and some are not even recyclable, so we can improve through the use of new materials.

To maximise the results, we need to rethink about packaging design from the viewpoint of energy and material optimisation. Once you use the new material you have to develop a new and efficient manufacturing process. This includes preparing the industry to apply the materials and looking for potential applications.” MEN Enquiry No. 2502

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Features

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Accelerating

Die Duplication The process of duplicating a stamping die is generally painstaking and time-consuming.

Through 3D technology and software programs, it is considerably shortened.

By Sophia H Jeon, business partner manager, Rapidform Difficulty:

Replacing or duplicating stamping dies – time consuming

Solution:

Adopting reverse engineering process, utilising 3D scanner and software programs.

Conclusion:

Shorten die duplication tryout processing time by 30 percent

G

M Daewoo of South Korea, which is now part of General Motors’ family, replacing or duplicating a stamping die leads to unnecessary costs, inefficiencies and delays. Even though the original die has been put through an exhaustive quality check, making duplicates involve more than another round of machining and assembly operations.

Inste ad, sta mping die engineers must repeat the entire die tryout process to produce quality stampings.

W hen Genera l Motors announced a second Chevy Aveo production facility in Poland, the stamping die engineers at the GM Daewoo facility sought an alternative that would condense, or eliminate, the multi-week tryout process. With more than 25 large die sets for the Aveo, which is called Kalos in South Korean markets, the gains in efficiency, cost reduction 54

metalworking equipment news March 2010

and lead time would be enormous.

Culminating a three year search, the team found and implemented a 3D scanning procedure that uses Rapidform XO scan-to-CAD software. By documenting the asbuilt condition of operational dies, the company slashed die tryout times by five weeks. It also ensured that the Polish-built Aveos would have the same fit and finish as the South Korean-made Kalos.

Die Tryouts Fol low i n g CA D de sig n a nd simulation, stamping dies go t h rou g h a r i gorou s t r yout process. Samples are stamped, measured and scrutinised to uncover tolerance deviations and surface defects.

When flaws are discovered, the die is hand worked to fine-tune it so that stampings match print specifications. For parts like the

Aveo’s tailgate, the tryout process is a 16-week endeavour.

The challenge in duplicating an operational die is that the handmade adjustments created an as-built condition that no longer matches the original CAD data.

Therefore, the 16-week tryout process is repeated for each replacement or duplicate die set.

The alternative can eliminate t his cost ly re du nda nc y by measuring the die and documenting the modifications in the CAD data.

The carmaker’s stamping die engineers had considered both CMM and 3D scanners for the task but found each to be impractical.

CMMs required too much time and labour to capture all necessary measurements. 3D scanning resolved this issue, but the scanning software could not produce surfaces sufficient for tool path creation. This lead to

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The original dies of Kalos were duplicated using 3D technologies and software programs Redesign Assistant aids interpreting the design intent of features of the hand worked, and slightly worn, dies

a cumbersome and convoluted effort that divided the point cloud processing and solid modelling efforts between two separate software programs. In the end, there was little benefit because the time saved in die tryouts was offset by the time and effort to generate the as-built CAD data.

Parametric Modelling The Chevy Aveo’s tailgate was the first sheet metal part to be stamped from a die that was duplicated using a 3D scanning methodology.

GM Daewoo converted 3D scanner point cloud information into a full-function CAD model using Rapidform XOR/Redesign.

According to the stamping die engineers, correcting the CAD data to as-built conditions in XOR yielded an 85 to 90 percent time savings, when compared to prev ious 3D sca nning attempts. This time sav ings gave them a viable solution for

die duplication with minimal die tryout delays. The company’s engineers noted that the key to making this possible was the program’s combination of point cloud processing tools with parametric, solid modelling.

In prev ious 3D sca nning attempts, surface data wa s exported from the 3D scanning software and imported to UGS NX, where it was used as reference data for the manual recreation of the CAD model.

In contrast, the program performed the CAD modelling functions. It created parametric solids, with the full history tree, that drove the automated update of GM Daewoo’s UGS NX models.

In XOR, the die engineers used a variety of CAD correct tools for refitting and redesigning the original UGS NX files. These functions were supported by the Redesign Assistant that aids in

interpreting the design intent of features of the hand worked, and slightly worn, dies.

3D Scanning For As-Built CAD T he c a r ma ker sele c te d a CogniTens Optigo scanner for the Chevy Aveo project. The scanner captured dense point clouds that documented measurements for both the untouched and hand worked features of the tailgate die set. For the fouroperation stamping process, there were eight die components for draw ing, pu nching a nd bending. Following scanning, the point cloud data and original UG S N X solid models were imported into Rapidform XOR. The point clouds were then cleaned, merged and aligned to the CAD model.

The first step in the CAD refitting process was identifying ‘regions of interest’, which are the areas where the scan data does not match the CAD model. To do so, the carmaker’s die engineers used Accuracy Analyzer, which is a visual tool that highlights March 2010 metalworking equipment news

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The diagram shows a summary of the duplication process

GM Daewoo engineer scans original die with 3D scanner

discrepa ncie s bet we en t he two die descriptions. As the redesign progressed, the tool also monitored the changes, in real time, to confirm that the modifications were within userdefined tolerances.

Another tool the die engineers used was Redesign Assistant.

This XOR function automatically extracts the design intent of individual features. For example, it determines the radius and centre point of fillets even if there are slight changes in curvature resulting from imprecise, hand grinding or tool wear. Having 56

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extracted the design intent, the die engineers remodelled features with CAD-like solid modelling functions such as sweep, extrude and revolve.

W hile the sta nda rd CA D modelling functions were used throughout the project, the bulk of the time savings came from automated tools that have been developed specifically for 3D scanning.

Manufacturing Duplicate Stamping Dies After completing the modification of the CAD data to reflect the as-

built stamping die, the parametric model, with its history tree, was transferred to UGS NX. Although time reduction for the CAD refitting process was important, the true test of this new approach to die duplication was the quality of the surfaces for machining of the production die.

Machined from the XORgenerated solid model, the Aveo tailgate stamping die is now in operation in Warsaw, Poland. It is an exact duplicate of the Kalos die that has been stamping parts in South Korea.

Replicating all of the original hand worked modifications, this duplicate die is producing stampings that match the quality of the Kalos tailgate, and it is doing so without duplicating the lengthy tryout process.

Using 3D sca nning a nd software programs, GM Daewoo cut five weeks from the tryout and approval process. For the tailgate, this 30 percent reduction resulted in an estimated savings of US$200,000. Extended over all large die sets for the Aveo, the company estimated total saving of US$5 million. MEN Enquiry No. 2503

ENQUIRY NO 164

Features

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Time Is Money Economic considerations in purchasing a jet cutting machine are just as important as the machineâ&#x20AC;&#x2122;s capabilities. By John H Olsen, VP Operations, Omax Corp

I

n a n e v e r- co m p e t i t i v e manufacturing environment, it is important and crucial to make prudent investments.

For a typical job shop or a manufacturer, making investments in machineries is arguably one of the most significant decision. It requires serious considerations and even analyses.

The purpose for buying any machine is to make money with it.

If you buy nothing, it costs nothing, but makes no money. If you buy a premium machine it costs more than a low grade machine but it is more productive. Finally, the machine must match the work it is intended to do. A buyer must strike the balance between price, productivity and machine capability.

Matching Machine To The Work A job shop and a manufacturer have slightly different considerations

when choosing a machine. The manufacturer knows exactly what type of parts he will be making and the production volumes. Some factors for the manufacturer to consider are: 1. A small machine with low accuracy may perfectly match the work to be done.

2. A large machine can achieve material savings via nesting and lower unit cost of material in large sheets.

3. An accurate machine can often eliminate secondary operations.

The job shop owner is concerned with these factors as well, but he also worries that his machine will be too small for the work his customers may request. He tends to buy a machine for the largest imaginable part.

Machine accuracy is sometimes overlooked, but customers prefer

precise parts that require little or no secondary processing. The revenue of the shop depends on the ability to produce parts the customer wants.

Costs Of Jet Cutting Costs are of two kinds: the costs of capital that are fixed no matter how much the machine is operated and those that depend on the operating time of the machine. We will consider two shops to see the effect of these two kinds of costs.

The first will be a shop that only operates the machine part time about 24 hours per week. The second operates two shifts and runs the machine 70 hours per week. These hours will be used to calculate the hourly cost of capital for comparison with the other hourly operating costs. â&#x20AC;˘ Capital Costs Consider a machine that costs US$100,000 and is financed with a five-year loan at 8.5 percent. The monthly payment is US$2,052.

At 24 and 70 hours per week operation, the hourly costs of capital are US$19.73 and US$6.76 respectively.

Costs of a jet cutting machine running 24 hours per week 58

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Costs of a jet cutting machine running 70 hours per week

â&#x20AC;˘ Labour Costs An operator might be paid as

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Figure 1: During cutting, the jet exit lags the entry by an amount dependent on speed

Figure 2: Colours ranging from white (fast) to blue (slow) show the speeds in an optimum tool path

much as US$20 per hour with a fringe rate for vacation and health insurance of 40 percent. That would result in an hourly cost of US$28.

But, the jet cutting machine runs more or less by itself after the initial set up is done and one operator can either run multiple machines or perform some other useful task while the machine is completing its work. For this example, we allocate half of these costs (US$14/hr) to the part making costs.

• Maintenance Abrasive jet machinery has a higher maintenance cost than most other machine tools. The flowing abrasive wears out all parts that it touches and in particular the mixing tube where the abrasive is accelerated to high speed by the water wears out in about 100 hours. Between US$1 and US$2 per hour should be allocated for replacing parts worn by the abrasive.

The high-pressure pumps and plumbing systems that provide the high-pressure water to the nozzle are also maintenance items. The higher the pressure, the higher the maintenance costs.

Normal maintenance items are seals and check valve seats.

Occasional failures of other high-pressure parts from metal fatigue occur. A good budget for pump maintenance is about US$5 per hour giving an overall maintenance cost of up to US$7 per hour.

• Abrasives Abrasives represent the largest consumable cost in abrasive jet cutting. Prices for garnet abrasive are very transportation dependent and range from a low of about US$0.10 per lb to as high as US$0.72 per lb.

Costs are also somewhat dependent on the grade of garnet and can vary by a factor of three based on quality.

It is generally not a good idea to run with low grade garnet full of dust and dirt particles because these impurities cause frequent nozzle plugging and lost production. A moderate price for garnet is about US$0.30 per lb.

Garnet flow rates range from about 0.5 lb per minute to about 1.5 lb per minute in the larger nozzles in use today. At an average flow of 1 lb per minute with US$0.30 per lb garnet, the hourly cost is US$18 per hour.

24 Cost Category Capital Abrasive Maintenance Power Water Labour Total

Hrs/Wk Hourly Cost US$19.73 US$18.00 US$7.00 US$2.48 US$0.60 US$14.00 US$61.81

• Electricity Many shops would regard electric power as an overhead cost like building rent, but it is a real cost of operating an abrasive jet cutting system. The cost is dependent upon the type of pump being used. At US$0.10 per kwh, a 0.014” orifice operating at 55,000 psi with a crank drive pump costs about US$2.48 per hour whereas the less efficient intensifier pump costs about US$3.26 per hour in electricity.

• Water & Sewer Many utilities charge a fixed rate for water usage that also includes the sewer charge. A price of about US$0.01 per gallon is typical. The 0.014” orifice operating at 55.000 psi mentioned above draws just under 1 gallon per minute for a cost of US$0.60 per hour. An intensifier pump is often cooled with an additional 2 gpm of giving a total cost of US$1.80 per hour.

Productivity & Cost These costs are much greater than the costs for most other machining processes. So, why is this process the fastest growing segment of the machine tool industry? The answer is productivity!

Job shops charge US$100 per hour and up for nozzle time that costs no more than US$65 per hour. Yet, the customer feels that the part price is low because the part time is low.

The major factor affecting

70 Cost Category Capital Abrasive Maintenance Power Water Labor Total

Hrs/Wk Hourly Cost US$6.76 US$18.00 US$7.00 US$2.48 US$0.60 US$14.00 US$48.85

Total costs for operating an abrasive jet 24 and 70 hours per week March 2010 metalworking equipment news

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Features

part time is the software driving the machine. The jet is not a rigid tool and an optimum tool path is one that varies the speed according to the shape being cut.

The jet exit point lags the entry point by an amount depending on the cutting speed. (Figure 1) A large lag is fine on straight lines, but causes major accuracy errors on arcs and corners.

Modern control softwa re automatically adjusts for this effect and does a much better job than a human can. (Figure 2) The part time difference between a control that runs at a constant compromise speed for corners and arcs and one that properly varies the speed everywhere along the path can be more than a factor of two.

Software also handles the taper in the kerf to make a square edge.

As the jet slows down, the kerf goes from widest at the top through parallel to widest at the bottom.

There is a speed at which the taper is minimum. However, cutting the entire part at this speed will take a very long time. Through software, a two dimensional flat part is input, but the machine automatically moves in five axes to compensate for and remove the edge taper. Again, the precise part is made much more quickly with the taper removing software.

Why is part time so important?

Consider a part that takes 10 minutes to make on a premium machine and only 30 percent longer or 13 minutes on a lesser machine.

Suppose that both machines operate at a US$60 per hour or US$1 per minute cost. The part cost in the first case is then US$10 and it is US$13 from the other machine.

Now suppose that the entire 24 hours per week of the two machines are spent making these parts or parts like them. The premium machine will make 7,488 parts in a year. The other machine will make only 5,760 in a year with the same cost. To make the same 60

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quantity as the premium machine, the other machine would have to run an additional 374.4 hours (7.2 hours per week) at an additional cost of US$22,464. A manufacturer would consider that he saved this amount by purchasing the premium machine.

An ever-greater difference is apparent if the gross margin generation is considered. Suppose that the customer is willing to pay US$20 for this part. The premium machine makes 7,488 of these parts at a margin of US$10 each giving a total margin of US$74,880.

The lesser machine makes 5,760 at a margin of US$7 each for a total of US$40,320. The difference is US$34,560. The premium machine owner could pay US$30,000 more for his machine and get all his money back in less than one year.

All these numbers get even better if the machine is used more than 24 hours per week.

Sadly, many buyers never take the time to do time studies on the machines they are considering.

Some even get a part made on a premium machine and then buy on price alone without making a part on the lower cost machine.

They learn what they have missed only when they are forced to compete with a premium machine.

Conclusion: Importance Of Time Study Jet cutting machines are more expensive to operate than many conventional machines, but they are productive.

The productivity is highly dependent on the software that manages the jet. Buyers are urged to compare actual part times and make an economic analysis before purchasing a machine.

Enquiry No. 2504

Omax: Large-Scale Abrasive

Waterjet Machining

The 120X JetMachining Centre is designed for manufacturers with large-scale abrasive waterjet requirements. Four specific models are available from Omax, with lengths of 13 feet (3.96 m), 20 feet, 26 feet and 32 feet.

Each of the models is 10 feet in width and features work envelopes capable of handling standard international sheet material sizes.

Applicable for large-scale precision machining from manufacturers serving a variety of industries, including aerospace, petroleum, food processing and equipment fabricators. It features a pending drive system with closed loop, high pole vector drives, to achieve accurate and precise movement. MEN Enquiry No. 2505

ENQUIRY NO 170

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Direct Digital Manufacturing:

Viable Alternative In an increasingly competitive market, major savings are still possible with new approaches to old methods.

By Scott Crump, CEO, Stratasys

O

ver the past 20 years additive fabrication technology has m i g r a te d f r o m u s e in rapid prototyping to a fullfledged manufacturing solution, which is referred to as Direct Digital Manufacturing or DDM. Increasingly, companies are applying it to manufacturing applications, and with each success, they prove that it is a viable alternative.

While the general concept of additive fabrication is the same as when it was introduced 20 years ago, the change is in its intended use, ie: production, not just prototyping. So while the concept has been around for a while, in the minds of many, it is a new thing and difficult to understand.

Additive fabrication is the generic name given to processes that create a part by building it up in layers â&#x20AC;&#x201C; as opposed to milling or machining, which are subtractive processes. Additive fabrication was developed as a way to automate the creation of prototypes, and it was therefore originally known as rapid prototyping. It also goes by various other names, including 3D printing.

Direct Digital Manufacturing There has been some confusion about DDM in part because of the many terms that have been used synonymously with it. To most people it is synonymous 62

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with rapid manufacturing, additive manufacturing, or layer manufacturing, although others make subtle distinctions among these terms.

DDM is the process of using CAD or other data to drive an additive fabrication machine that makes usable parts. Examples are the components that go into sellable products, pieces of production machinery, replacement parts, or manufacturing tools, such as jigs and fixtures.

Besides CAD data, which is the majority of data used, other types of data may be used to drive additive fabrication machines. Among others it includes 3D scan data (for reverse engineering) and DICOM data (for making a physical representation of 3D medical imagery).

T h e p ro ce s s e l i m i n a te s moulding, machining, casting and forming. Instead of material removal or shaping, a companyâ&#x20AC;&#x2122;s finished goods are produced by adding material one layer at a time.

Other than a few minutes of preprocessing to prepare a production run and some light post-processing to clean up a part, DDM progresses directly from CAD data to final part. Eliminating the upfront and back-end operations common to traditional methods mean that there is no extraneous time, cost,

or labour.

Due to the elimination of tooling, the process can save tens or hundreds of thousands of dollars on a single project. Using our FDM additive fabrication process for DDM, Stratasys eliminated about US$200,000 in tooling costs for one of our newer machines.

We did t h is by dire c t ly manufacturing 32 components rather than having them produced via traditional means. From our customers, we hear similar stories with varying degrees of savings regularly. The savings on one project can outweigh the cost of the machine purchase.

One Process, Many Technologies DDM is a process, not a technology.

It can be performed with various additive fabrication technologies with diverse capabilities. The additive fabrication technologies that perform the process share the fundamental technique of producing parts directly from a CAD data file.

They do so by adding material layer-by-layer. However, the many

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processes vary greatly, so in order to determine if the process is suitable for a project, it must be evaluated with respect to a specific technology.

The most often cited advantages of DDM are: • Eliminate investment in tooling • Eliminate lag time between design

and production

• Eliminate design constraints • Eliminate penalty for redesign • Eliminate lot size minimums

Collectively, these benefits translate to efficiency, flexibility, responsiveness and affordability.

DDM is a manufacturing process that introduces alternatives in product design, manufacturing methodology and business operations.

As an added benefit, many additive fabrication technologies are fairly ‘green’ processes. They have very little waste material as compared with milling processes because only the needed material is used.

No unnecessary inventory is produced because there is no benefit to building more than you need at any time. Most additive processes require no harmful chemicals and vent no harmful fumes into the environment. Among a list of other green benefits, is the relatively small amount of electricity that is required to produce parts via additive fabrication.

Application Diversity In the manufacturing environment,

DDM is a process of using CAD or other data to drive an additive fabrication machine that makes usable parts

Because the tools are used by the company, not the customer, and the time and cost to produce them is small, an unsuccessful attempt has little consequence. But when successful, DDM has a major impact on productivity, quality and the cost of producing parts. it often performs one of two roles.

Companies will use the process to manufacture the products it sells or to make the devices that aid in the manufacturing of the products.

When first introduced to the process, the application most people envision is the production of finished goods. The word manufacturing conjures images of high-volume production of consumer products. People often jump to the definition ‘the making of goods on a large scale’, even though manufacturing also means ‘the making or producing of anything’.

This process is suited for lowvolume manufacturing – not mass production, but before you think ‘We can’t use it because we do massproduction’, keep in mind every manufacture has low-volume needs in the production of manufacturing tools, such as jigs, fixtures, gauges and hand tools.

Producing manufacturing tools presents the opportunity to try DDM. These tools are deployed to

make manufacturing and assembly fast, efficient, repeatable and cost effective.

In this manufacturing context, the process becomes a lowrisk, high-return alternative to standard practices. Because the tools are used by the company, not the customer, and the time and cost to produce them is small, an unsuccessful attempt has little consequence. But when successful, it has a major impact on productivity, quality and the cost of producing parts.

Performing DDM of manufacturing tools is currently greater than DDM for end-use parts.

That is partly because it is such a low-risk opportunity, and partly because every manufacturer has a need for such tools.

Manufacturing can also be a bit of a misnomer when the entire spectrum of industries using the process is considered. Some of the greatest successes are not in the manufacturing industry. Because of the inherent need for custom fitting devices, the medical and dental professions have been early adopters of the process.

Orthotics, prosthetics, hearing aids and dental bridges have all benefitted from DDM. Companies have discovered that this process is a powerful alternative, rather than a direct replacement, to the conventional manufacturing processes. MEN Enquiry No. 2506 March 2010 metalworking equipment news

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Harry Fodor, Germany

3D Technologies:

Getting

T

Into The

XYZ , & Things

he latest developments in 3D technologies for metalworking include 3D scanning, modelling, rapid prototyping and rapid manufacturing.

Todayâ&#x20AC;&#x2122;s digital 3D scanners, modellers and rapid manufacturing technologies has reduced not only manufacturing costs and time, but also accelerated advances in innovation. A whole product approach can now be taken for any metal work, from 3D scanning to digitising to rapid prototyping or manufacturing.

3D Scanning A 3D scanner is a device that interacts with a physical object through various means to collect data of the objectâ&#x20AC;&#x2122;s physical parameters, such as its size, shape and possibly its appearance (ie: colour). The collected data can then be used to construct digital 3D models, useful for reverse engineering and prototyping, quality control and inspection.

Many different technologies can be used in 3D scanning devices; ranging from touch trigger probes to 64

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The latest technologies in rapid prototyping reduce cost and usher in the digital age in a big way. By Augustine Quek

Of

optical digitisers to laser scanners.

Each technology comes with its own limitations, advantages and costs. Most 3D scanners offerings now comes with software programs for control, image capturing and even 3D rendering and modelling.

Applications include reverse engineering, inspection, 3D a r c h i v i n g , co m p l e x sh a p e acqu isit ion, me a su re me nt s archiving, damage assessment, digital models and mock-ups, packaging design and rapid prototyping. They can also be classified as either contact or noncontact measurement.

and sculpt modelling. Polygonal modelling uses points in 3D space, called vertices, to connect line segments to form a polygonal mesh.

The majority of 3D models today are built as textured polygonal models due to their flexibility and fast rendering. However, polygons are planar and can only approximate curved surfaces using many polygons. NURBS are mathematical representations of 3D geometry that can accurately describe any shape. NUR BS surfaces are defined by spline curves, which are influenced by weighted control points.

Sculpt modelling, a fairly new method of modelling 3D sculpting,

?

3D Modelling & Visualisation The data obtained from 3D scanners can be used to make 3D models, which are mathematical representations of the real objects.

Programs used to convert such data into models are part of Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).

There are five popular ways to represent a model: polygonal modelling, splines and patches, Non-Uniform Rational B-Splines (NURBS), primitives modelling,

Did You Know?

Research from the Aberdeen Group shows that manufacturers that use digital prototyping build half the number of physical protot ypes as the average manufacturer, get to market 58 days faster than average, and experience 48 percent lower prototyping costs.

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Rapid Prototyping Technologies

Besides 3D printing, there are a few other rapid prototyping techniques around.

Selective Laser Sintering (SLS) technology fuses metal powder into a solid part by melting it locally using a focused laser beam. The laser selectively fuses powdered material by scanning cross-sections g e n e r a te d f r o m a 3 D digital description of the part on the surface of a powder bed.

Af ter each crosssection is scanned, the powder bed is l owe re d by o n e l aye r thickness, a new layer of material is applied on top, and the process is repeated until the part is completed. Even highly complex geometries can be created this way without any tooling. It is a net-shape process,

producing par ts with high accuracy and detail re solution, with good surface quality.

Medical Implants Similarly, Electron Beam Melting (EBM) melts metal powder in a layerby-layer process to build the physical part, using an electron beam in a high vacuum.

This solid freeform fabrication method produces fully dense metal parts directly from metal powder with characteristics of the target material. Since titanium alloys are suitable and widely used with this technology, EBM is also widely used for making medical implants.

Enquiry No. 2507

Marius B, Galati, Romania

3D Modelling In Action Autodesk Productstream software are used by Swiss watches maker Ulysse Nardin to manage design data. As such, it is now easier for other workgroups to work together with the design team. This also allows watch designers to visualise how gears It is now possible to visualise how gears and springs fit with other components with 3D modelling

uses a dense model of subdivided polygon control meshes and stores new locations for the vertex positions through use of a 32bit image map that stores the adjusted locations. This method allows for very detailed reproductions as new topology can be created over existing ones.

One pa r ticula r popula r application for 3D models is in digital prototyping, where designs can be built and tested digitally on a computer without the need for building a physical prototype. 3D models not only give the ability to virtually explore a complete product before it is built, it also enables one to design, iterate, optimise, validate, and visualise products digitally throughout the product development process.

and springs fit with other c o m p o n e n t s a s t h ey design.

It is not only easier to spot and eliminate inter ferences early in the design process; the positions of mechanical parts that integrate with ex ternal por tions of

Reverse Engineering, Rapid Manufacturing Technologies also exist to produce physical models and prototypes using metal from 3D scanned and model data. The entire process from scanning to modelling to 3D printing has typically been part of reverse engineering, rapid prototyping and manufacturing.

Rapid prototyping technologies that use metallic materials include selective laser sintering, electron beam melting and now, 3D printing.

The common feature shared by these technologies is the ability to produce freeform, complexgeometry components directly from a computer-generated model.

Layerwise shaping and feedstock consolidation, considered as direct fabrication techniques, (eg: powder, wire, ingot, paste, or melt) were adopted to form complex shapes

the watch can also be optimised. Enhancements to designs can also be made by anyone who spots an opportunity. This allows watchmakers to create more innovative watches faster.

Enquiry No. 2508

having full or near-full density without the use of intermediate binders, furnace densification cycles, or secondary infiltration steps. Minimal thermomechanical post-processing or machining are required to obtain a desired geometry, structure, and properties.

3D technologies have already redefined the way companies design and build products. Future developments are likely to be impacted by improvements in computer processing speeds. Faster computers are not only able to produce more complex objects, but also more accurate designs, increase manufacturing speeds which lowers build times. As a result, the rise of 3D technologies in metal products manufacturing is inevitable. MEN Enquiry No. 2509 March 2010 metalworking equipment news

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EVENTs&

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exhibitions

T

he 14th Seoul International Machine Tool Show 2010 (SIMTOS2010) is making its return this year at KINTEX from April 13 – 18. With an exhibition space of 53,541 sq m, the hall is expected to be thronged by some 80,000 visitors. The number of exhibitors stands at some 426, occupying 3,390 booths.

The event aims to showcase metal cutting machines, metal forming machines, CAD/CAM, cutting tools, robots and factory automation and precision measuring machines and instruments.

In terms of machine types, metal cutting machines lead the way, taking up 31 percent of the total number of exhibitors. The next in line are the component/parts exhibitors coming up to 22.7 percent. Exhibitors dealing with toolings round up the top three spots with metalforming machines, industrial robots, automation, measuring equipment, CAD/CAM and other exhibitors making up the full 100 percent.

Event Preview:

SIMTOS 2010

Foreign Exhibitors Among the foreign exhibitors, Germany boasts the largest contingent with 60 companies.

Japan make up the biggest foreign contingent from Asia with 56 companies taking part.

The internationality of the event can be seen with some 20 foreign countries taking part in this year’s event. They come from all corners of the globe including USA, China, Spain, Turkey and Australia, just to name a few.

Show Highlights Although the main focus is expected to go to the exhibits, there are other activities going on concurrently at the venue for visitors of different interest. Among those events is the machine tool symposium by Korea Society of Machine Tool Engineers.

For those who are interested in CNC repair and maintenance, there is a workshop held from April 14 – 15. A seminar on advanced 66

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industrial robot technology will also be conducted for visitors with an eye on automation. Other highlights include machine tool coordinating meeting among Asian MT associations, a CAD/CAM conference and an international machine tool technology seminar.

KINTEX Seoul, South Korea April 13 – 18, 2010 Enquiry No. 2601

ENQUIRY NO 034

EVENTs&exhibitions

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Event Preview:

Intermach 2010

In addition, Sheet Metal Asia 2010, an important sub show at the event, will display sheet metal machinery including hot-stamp presses, watercutting equipment and the latest laser technology – much of it being shown in Asia for the first time.

A

n event that will create opportunities for exhibitors and visitors alike, Intermach 2010 is a platform for business into the whole ASEAN region. It is an event where decision makers gather to meet, talk shop and do business on the spot.

Giving visitors VIP access to many important seminars, conferences and related activities affecting Thai industry, as well as global economic issues – the event allows access to inside information that can provide a big competitive advantage.

What Can You Expect In this year’s event, visitors can expect to see a full display of hightech machinery from the world’s leading international manufacturers

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who will be arriving from over 30 countries. Major country pavilions and displays featuring over 4,000 individual pieces of machinery and equipment will also add internationality to the show.

For those looking to cast their net in the field of business, the business matchmaking opportunities with buyers from the automotive, electronic appliance and electronics industries will be made available.

Other Events Running Concurrently Subcon Thailand runs in conjunction with Intermach and helps manufacturers and suppliers form mutually beneficial partnerships.

Over 300 local and international subcontractors will be at this year’s event, according to the organiser.

Power Of 1 Sanchai Noombunnam, UBM project director for the event says: “The 4th quarter of 2009 showed a strong recovery underway in Thailand for the automotive, subcontracting, electronics and electrical industries.

In 2010, Thailand expects to export around 600,000 cars – an increase of 14 percent over 2009.”

Riding on the wave of optimism, a strategy has been developed to help increase business opportunities as Mr Noombunnam concludes: “We have been working hard with the Thai Board of Investment (BOI), the co-organiser of Subcon Thailand, and other government agencies to develop our strategy, ‘The Power of 1’ – is focused on helping Intermach customers increase business opportunities with major manufacturers in Thailand and other countries.”

BITEC Bangkok, Thailand May 13 – 16, 2010 Enquiry No. 2602

EVENTs&exhibitions

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Event Preview:

Medtech Manufacturing 2010 growing purchasing power will fuel the demand for better quality healthcare systems and solutions.

This growing market in Asia presents a window of opportunity for medical technology companies to venture into new frontiers and new geographies.

M

edtech manufacturing 2010 will be held in Suntec Singapore from March 18 – 19, 2010. Organised by SPETA in collaboration with IE Singapore and SPRING Singapore, the inaugural event will play host to some 50 exhibitors.

The exhibitors hail from industries specialising in optics, plastics processing technology, precision metal finishing technology and machine tools, just to name a few.

The profile of visitors ranges from heads of quality control, technical procurement managers, medical packaging designers and medical equipment procurers amongst others.

Conference & Other Highlights Jointly organised by Singapore Institute of Manufacturing Technology and SPETA, the conference focuses in manufacturing opportunities and challenges, manufacturing of medical device and emerging technologies for medical devices fabrication.

Another highlight of the event is the Global-Asia Trade Exchange (GATE). It is a procurement event in Asia that seeks to connect global buyers and regional suppliers in 70

metalworking equipment news March 2010

the electronics and precision engineering industry. GATE was first launched in 2004 by International Enterprise (IE) Singapore, as a platform for Singapore companies to meet with key global procurement decision makers from global OEMs. GATE 10 caters specifically to buyers from the medical technology industry. It is a global buyer- centric platform that allows international buyers to source for a wide range of products and services from end-to-end precision engineering and electronics solutions such as product design and development, prototype testing, production and assembly, to supply chain and distribution services.

Through a process of prequalification, this businessmatching event is designed to be focused and targeted such that buyers will be matched with the most suitable suppliers based on their requirements.

Accelerating Medical Technology Innovation In Asia Asia presents new growth opportunities with a growing base of ageing population and rising affluence. In 2050, the United Nations expects Asia’s population aged 60 to grow beyond 100 million.

Alongside this development, Asians’

Key Global Manufacturing Site Today, 30 global medical technology companies have invested in commercial-scale manufacturing plants in Singapore. They develop and manufacture a wide range of medical products, such as contact lenses, scientific analytical equipment, implantables, syringes, stents, catheters and hearing aids as well as research instruments.

In research tools and diagnostics instruments, Singapore is one of the leading global sites that supplies 70 percent of the world’s micro-arrays and 50 percent of the global demand for Polymerase Chain Reaction (PCR) instruments.

Indeed, as companies seek to outsource their manufacturing activities to electronic manufacturing ser vices and precision engineering companies, they can tap on the capabilities and expertise of our local suppliers.

These suppliers adhere to strict standards of IP protection and regulatory requirements stipulated

by US FDA and European EMEA. They have also received ISO 13485 certification and have established a strong track record amongst leading medical technology corporations.

Suntec Singapore Singapore March 18 – 19, 2010 Enquiry No. 2603

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Event Review:

Automechanika Shanghai

T

he fifth edition of Automechanika Shanghai was held from December 9 – 11, 2009 at the Shanghai New International Expo Centre, China.

Exhibitor numbers increased by nearly 22 percent to 2,414 from 24 countries and regions, compared to the 2008 event. Showing an even larger increase were the visitor numbers with 38,551 visitors from 132 countries and regions attending the show. This is an increase of nearly 25 percent compared to the previous show.

Automechanika Shanghai has further confirmed its position as an international show with 29 percent of the visitors coming from overseas, compared to 16 percent in 2008.

The top 10 visitor countries and regions outside China were (greatest first) Taiwan, South Korea, Malaysia, Iran, Japan, Russia, Turkey, India, the United States and Hong Kong.

Business Opportunities Heads of sourcing and procurement departments from 15 companies including China, France, Italy, Japan, New Zealand, South Africa and UAE attended the Automechanika Matchmaking Forum to meet one-onone with suppliers.

Dubai company Dynatrade specialises in a diverse range of automotive products such as tyres, batteries and vehicle parts.

Manager, V Rajkumar was very satisfied with the event: “This is the first time that I’ve participated in the matchmaking event,” he says. “Since there are too many companies at the show, the matchmaking forum is like a shortcut for me to quickly make contact with the leading suppliers.”

Latest Industry Topics Other industry events at the show included the fifth International Forum and Showcase

of Service Outsourcing in the Manufacturing Industry.

Other events included the Automechanika Academy which was attended by many prominent industry speakers who explored the latest topics.

In 2010, Automechanika Shanghai will become a four day event, instead of a three day event, running from December 8 – 11, 2010.

Jason Cao explains: “As the show is becoming bigger and

bigger, we see the need for an extra show day. We also received feedback from exhibitors and visitors who wanted to extend the show by one day to further maximise their benefits and opportunities.”

Shanghai New International Expo Centre Shanghai, China December 9 – 11, 2009 Enquiry No. 2604 March 2010 metalworking equipment news

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EVENTs&exhibitions

Event Review:

Singapore Airshow 2010

A

siaâ&#x20AC;&#x2122;s largest and one of the top three aerospace and defence exhibitions in the world, played host to industry bigwigs, international government and military delegations, providing them a platform to network and make key announcements.

As the global economy recovers from the recent downturn and the aviation industry is on a slow upswing, the biennial event saw deals and announcements at the show worth about US$10 billion over the first three days. To date, trade visitorship has already exceeded 30,000, which is higher than the inaugural show in 2008.

Overseas visitors have more than doubled from 25 percent to more than 50 percent. There was also a notable growth in the total number of countries/regions represented, with the count moving up from 113 in 2008 to 119 this year.

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metalworking equipment news March 2010

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In terms of exhibitors, there was representation from more than 60 countries/regions

EVENTs&exhibitions

In terms of exhibitors, there was representation from more than 60 countries/regions. Singapore Airshow attracted high-level foreign dignitaries from around the world. The total number of foreign delegations grew from 240 from 61 countries in 2008 to over 250 delegations coming from close to 80 countries this year.

“As the first major airshow taking place at the beginning of the year, the Singapore Airshow is in a position to gauge the pulse of the industry.

Although aviation as a whole has taken a hit due to the economic downturn, it is promising that we have witnessed large transactions and major announcements this week, and we look forward to the market picking up further as the industry rides the upturn. For the next Singapore Airshow in February 2012, we have already more than 60 percent of the exhibition space taken up. We are committed to delivering another iconic and strategic event,” says Jimmy Lau, MD of Singapore Airshow & Events.

Changi Exhibition Centre Singapore February 2 – 7, 2010 Enquiry No. 2605

Military aircraft were also part of the draw of the show

March 2010 metalworking equipment news

73

EVENTs&exhibitions

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Aviation Industry: Into A Greener Future

A*STAR’s Institute of Chemical and Engineering Sciences (ICES) is entering into a collaborative project with EADS, a global leader in aerospace and defence, to investigate the conversion of algae oil to kerosene for jet fuel.

The objective of this 12-month collaboration is to assess the potential for microalgae to be a renewable source of fuel for aircraft and to investigate the conversion of algae oil to kerosene for use as jet fuel.

Air transportation is a vital contributor to global economic grow th. The aviation sector accounts for 2 to 3 percent of manmade CO2 emissions, and although this may be a small proportion, EADS recognises that growth in air

transportation must be sustainable.

There is significant interest across multiple sectors in the potential of microalgae as an energy source. They have the potential to produce nearly 90,000 litres of oil per hectare per year.

Mi c r o a l g a e g row r a p i dl y (doubling in biomass in as little as a few hours), require limited nutrients to thrive, but technological breakthroughs are needed for them to become viable. Some microalgae contains high levels of oil content which can be used as the feedstock for making jet fuel, for example by separation of fatty acids, hydrogenation and hydrocracking.

Enquiry No. 2606

Bombardier, Bodycote, Rösler, Addvalue Technologies Join A*STAR’s Aerospace Programme The Agency for Science, Te c h n o l o g y a n d R e s e a r c h (A*STAR) has inducted four new members namely Bombardier, Bodycote, Rösler and a local SME, Addvalue Technologies, into its Aerospace Programme.

Including the new members, there are now 18 companies in the consortium, of which seven are local companies.

The Aerospace Programme,

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metalworking equipment news March 2010

l a u n c h e d i n 2 0 0 7, i s a n ongoing and proactive industry engagement effort that enables members to partake in aerospace R&D by leveraging on the agency’s scientific know-how and resources, and is helmed by industry giants. It has invested a total of S$18M on 16 projects to date.

Enquiry No. 2607

www.equipment-news.com

ProductFinder Extensible CAD Technologies: Easy Assess Program

Cognex 3D-Locate delivers accurate, real-time, threedimensional p o s i t i o n information that enables automation equipment to work with a wider variety of parts, including item s t hat a re stacked or tilted.

Using the software can improve vision performance for challenging applications such as logistics and robotguided de-palletising and precision assembly, and it can eliminate the need for expensive mechanical fixtures or measurement devices. The software can also be used in combination with Cognex code reading, gauging, and inspection tools.

Extensible CAD Te c h nolo g ie s, providers of CA D a nd PL M productivity sof t wa re , ha s released the Office2PDM. The program is an add-in for Microsoft Office that brings the document management functions of SolidWorks Enterprise PDM directly into Microsoft Word, Excel and PowerPoint.

The product provides access to common Enterprise PDM functions as well as timely access to document status information, all without requiring users to open up a separate interface. It enables SolidWorks Enterprise PDM users to access Enterprise PDM directly through their Microsoft Office environment by way of a simple and intuitive ribbon interface as well as an easy to use task pane.

Enquiry No. 2701

Enquiry No. 2702

ENQUIRY NO 050

Cognex: 3D Vision Software

March 2010 metalworking equipment news

75

productfinder

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Iscar: Inserts With PB Chipformer

Master Chemical: Low Cost Metalworking Fluid

I sc a r ha s developed Penta 34 inserts with a PB chipformer. The PB chipformer features a single cavity with a positive rake, neutral shoulder angle, and a honed edge. It is actually a C-type chipformer with a different frontal edge.

The chipformer is designed for machining sof t materials. It is a solution for parting bearing steel and other very ductile materials. It can be used at low feed: 0.03 to 0.10 mm/rev. The combination of the chipformer and IC908 grade provides good chipbreaking and tool life results. The insert is available in a 1.5 to 3.0 mm width range, made from the IC908 PVD coated grade.

Master Chemical has developed a low-cost and low-odour semisynthetic metalworking fluid. Trim SC520 uses a proven EP-additive package to control built-up edge and improve tool life. It performs well in multimetal, multi-operational job shops.

The fluid has the wetting and cooling characteristics necessary for good machining results on high-speed milling and turning operations. It provides sufficient lubricity to do downthe- hole operations in aluminium, cast iron, and most steels, including many stainless steels.

It controls chip welding on soft, gummy materials like aluminium and will reject tramp oils rapidly which will help provide good sump life in ‘stand-alone’ machine tools.

Enquiry No. 2703

Enquiry No. 2705

Leica Microsystems: Digital Microscopes

76

Mate: 5-In-1 Tooling Kit

A generation of digital microscopes – Leica DVM5000, DVM3000, and DVM2000, has been developed

by Leica Microsystems. With the DVM line, the microscopic image is displayed directly on a highresolution monitor. The zoom optics reach difficultto-access surfaces for nondestructive inspection of even the largest stationary parts, which could only be examined with great effort using traditional microscope techniques.

Leica digital microscopes not only feature highquality optics, they also offer a variety of quantitative analysis options – whether 2D analysis or advanced 3D surface measurements.

The EasyMark 5-In-1 tooling kit from Mate Precision Tooling allows fast and rel iable met ho d for marking fabricated parts in five different ways during the punching process.

It is a thick turret application tooling system for machines w ithout a bottom stroke forming feature. Using the programming software in a CNC punch press, this tool system can be set up to automatically perform any of five marking operations.

The operations include writing numbers, dates and other identifying information on a part surface, etching the sheet metal surface with permanent marking information, cut or scribe protective film on sheet metal surfaces, create cone-shaped indentations (centre point down) on the part surface and perform high-speed dot-matrix marking.

Enquiry No. 2704

Enquiry No. 2706

metalworking equipment news March 2010

productfinder

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Mikron Tool: Back Chamfering Without Re-Clamping

Mori Seiki: High-Precision VMC

Mikron Tool has developed a milling cutter, which is designed for back chamfer milling of contours and bores in small dimensions. Compared to other products available on the market it has up to 50 percent more teeth, according to the company.

The toolmaker claims this results in better surface quality at high cutting speeds. Used for the smallest holes and micro machining, starting from diameter 0.4 mm and depths of 5 x d, where it can be optimally used, the main applications can be found in the watch industry, medical engineering and automotive.

Mori Seiki has expanded its NV Series by adding the NV7000 with a table size of 1,700 mm x 760 mm and Y-axis travel of 760 mm. The VMC features a high-rigidity structure, which has been inherited from the MV Series, as well as versatility and simplicity equivalent to those of the DuraVertical Series. The machine is also equipped with the operating system, MAPPS IV. The machine improves rigidity by increasing the width of guideways 2.4 times wider than the conventional machine. It offers good damping performance with the use of slideways in all axes.

Enquiry No. 2707

Enquiry No. 2708

CAD/CAM SYSTEMS Mastercam X4 is here, delivering dozens of new tools based on input from users like you. From dramatically finer machine finishes and efficient dynamic milling to fast multi-core computer processing, Mastercam X4 provides maximum productivity at a great value. Find out how the world’s most widelyused CAM software* can maximise your shop’s machining.

See Mastercam X4 in action at www.mastercam.com/X4

Techtown Pte Ltd

www.techtown.com.sg • info@techtown.com.sg Tel: +65 6741 3318 • Fax: +65 6741 0181

ENQUIRY NO 044

ENQUIRY NO 017

*Source: CIMdata, Inc. 2009

March 2010 metalworking equipment news

77

productfinder

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Stäubli: High Speed Machining Robot

Widia: Combining Modular & Solid-Carbide Drills

Stäubli Robotics, manufacturers of advanced industrial and cleanroom robots, has developed a machining robot, the RX170 HSM (High Speed Machining).

The robot features several te c h n o l o g i c a l innovations. This robot has a Fischer Precision high-speed spindle integrated directly into its forearm, an adaptation that enhances rigidity. In addition, the harness containing the unit’s power supply, cooling system and lubrication is completely inside the arm, with no external ducting.

The robot‘s pressurisation also enables it to operate in difficult and wet conditions.

The Widia Victory Top Drill M1 Modular Drill gives users the best of both worlds by combining t he e conomic benefits of modular drilling s y ste m s w it h mac h i n i n g performance and hole quality comparable to solid-carbide tools.

Available over a standard diameter range of 8.00 to 20.99 mm, and in length/diameter ratios of 3× and 5×, drill bodies come in either flanged-shank (metric) or round-shank (inch) configurations.

They feature solid coupling for consistent performance from insert to insert and easy insert changes on the machine due to a front-clamping mechanism.

Enquiry No. 2709

Witte: Vacuum Clamping System

Sentry Protection Products: Portable Versatile Bollard

78

Enquiry No. 2711

Machine shop, foundry and metalworking plant managers and material handling supervisors seeking simple ways to demarcate plant walk-through paths can now use a portable, versatile bollard from Sentry Protection Products.

The Sentr y Gua rd Po s t , a re - de si g n of t he t radit iona l bollard for a wide range of both indoor and outdoor applications.

The lightweight product is 1,219 mm, tapering from 125 x 125 mm, with a 355 mm diameter round base. Each side of the post has a 63 x 500 mm inset available to place reflective tape or other signage.

Watertight and hollow, the product can be filled with ballast (eg: sand or water) to increase stability. It can also be attached with fasteners into a floor, dock, or any other flat base.

Flip-Pod vacuum system was conceived for clamping large work pieces in wood, aluminium or plastic parts for different manufacturing processes. These plates can also be modular and by joining them together, for instance with a guiderail system, a larger clamping surface can be achieved.

This vacuum system by Witte comprises of a base chuck with integrated Flip-Pods elements in a preselected layout. Non-active pods remain inside the chuck, only Flip Pods required according to work piece contour and geometry are flipped over and thereby activated.

Enquiry No. 2710

Enquiry No. 2712

metalworking equipment news March 2010

Exhibition Programmes March

18 – 19 MedTech Manufacturing 2010 Suntec Singapore SPETA medtech@speta.org www.medtech-mfg.com

24 – 27 INAPA 2010

JIExpo Jakarta, Indonesia Global Expo Management www.inapa-exhibition.net/contact_us.php www.inapa-exhibition.net

25 – 26 China Commercial Aircraft Summit 2010

InterContinental Pudong Shanghai Shanghai, China Oppland jennyx@opplandcorp.com www.opplandcorp.com/aero/index.htm

April 13 – 18 SIMTOS

KINTEX Seoul, S Korea KOMMA kate@komma.org www.simtos.org

14 – 17 Intermold 2010

Intex Osaka Osaka, Japan Japan Die and Mold Industry Association iminfo@itp.gr.jp www.itp.gr.jp/im/english/index.html

19 – 23 Hannover Messe Exhibition Grounds Hannover, Germany Deutsche Messe www.hannovermesse.de

2010

21 – 24 Japan Int’l Welding Show 2010

Tokyo Big Sight Tokyo, Japan Japan Welding Engineering Society info@weldingshow.jp www.weldingshow.jp/english

May

5–9 MTA Malaysia 2010 Putra World Trade Centre Kuala Lumpur, Malaysia Malaysian Exhibition Services enquiry@mesallworld.com www.mta-asia.com

5–9 Metaltech 2010

Putra World Trade Centre Kuala Lumpur, Malaysia Trade-Link Exhibition Services info@tradelink.com.my www.tradelink.com.my/metaltech

8 – 11 MT Duo

Taipei World Trade Center (TWTC) Exhibition Hall Taipei, Taiwan TAITRA & TAMI mt@taitra.org.tw www.mtduo.com.tw

13 – 15 Subcon Thailand 2010 BITEC Bangkok, Thailand UBM Asia (Thailand) sanchai@cmpthailand.com www.subconthailand.com

13 – 16 Intermach 2010

BITEC Bangkok, Thailand UBM Asia (Thailand) intermach@intermachshow.com www.intermachshow.com

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13 – 16 Sheet Metal Asia 2010 BITEC Bangkok, Thailand UBM Asia (Thailand) intermach@intermachshow.com www.intermachshow.com

20 - 22 Vietnam Manufacturing Expo 2010

ICE Hanoi Hanoi, Vietnam Reed Tradex vietnammanufacturingexpo@reedtradex.co.th www.vietnammanufacturingexpo.com

June

2–5 Manufacturing Surabaya 2010

Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo www.manufacturingsurabaya.com

24 – 27 Automotive Manufacturing 2010 BITEC Bangkok, Thailand Reed Tradex rtdx@reedtradex.co.th www.automanexpo.com

24 – 27 Intermold Thailand 2010 BITEC Bangkok, Thailand Reed Tradex rtdx@reedtradex.co.th www.intermoldthailand.com

July

6–9 MTA Vietnam 2010

Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam events@sesallworld.com www.mtavietnam.com March 2010 metalworking equipment news

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advertising index

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

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4T TECHNOLOGIES PTE LTD

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CNC Machining Milling Gear Cutting Grinding Stamping Shearing

❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310

EDM/ECM Inspection/Measuring/Testing Design with CAD/CAM Drilling/Boring Tapping/Threading Lapping/Honing

❑ 313 Forging ❑ 316 Rolling ❑ 319 Die Casting ❑ 322 Welding ❑ 302 Turning ❑ 305 Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 Others (Please specify)

YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122

Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg.

Dies & Moulds mfg.

Motor Vehicles Parts

❑ 123 ❑ 160 ❑ 180 ❑ 200 ❑ 224 ❑ 078

Shipbuilding Design & Consultancy Services Govt bodies, Trade Assns, Exhibitions Cos. Agent/Distributor/Trader of Machine Tools & Accessories Mechanical, Fabrication and all other metal engineering works Others (Please specify)_____________________________________

JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt

❑ 028 Testing & Inspection ❑ 030 Sales & Marketing ❑ 027 Others (Please specify)

❑ 022 Production Engineering ❑ 024 Quality Control/Assurance

❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

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ENQUIRY NO 136

Our complete portfolio.

Your complete satisfaction.

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.

ENQUIRY NO 160

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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