APMEN March 2011

Performance In

Turning

Metrology:

CAD/CAM

Innovations

It Pays To Be Fussy

March 2011

www.equipment-news.com M.I.C.A. (P) No. 133/06/2010

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ENQUIRY NO 157

Contents

March 2011

30

First Cut

Performance In Turning

Turning has gone from a manual process to being computer controlled and automated. To delve deeper into the topic of turning, Asia Pacific Metalworking Equipment News (APMEN) speaks to the experts to gain insights into the world of turning. By Joson Ng

34 Making Turning Difficult Materials Easy

The ability to turn difficult materials easily has wide ranging benefits.

By Dr Moshe Goldberg and Rafi Rabouch, Iscar

38 Getting A Slice Of The Productivity Pie

Only getting the job done is officially out. In today’s ultra competitive manufacturing arena, productivity is key, and cutting tools that improve productivity are the stars.

By Michael E Neumann

41

Technology Insights Gear Lubrication: Tonic For The ‘Heart’

Good lubrication is essential for gearboxes as they prevent a condition known as micropitting. By Michael J Hawkins, ExxonMobil Lubricants & Specialties

42 A Greener Look At Machining Fluids

More than ever, environmentally friendly and cost effective ways of producing work are being searched for, both in machine shops and research laboratories. The need is immediate and governmental policy is being drawn up to reward the environmentally conscious and penalise those that are not. By Mark Johnston

Software & Metrology

44 Virtual Reality: Machine Tool Simulation At Its Best

The most important thing in simulation is whether what is seen on the computer screen in the digital world is the same in the real world. By Vynce Paradise, NX CAM, Siemens PLM Software

48 How Hardware Developments Affect CAM Software Performance

There are many ways in which the latest hardware developments can help CAM users to be more productive. By Peter Dickin, Delcam

52 Opinions: The Future Of Manufacturing, Product Design & Design Tools In Asia

The development of CAD tools has to keep pace with the growth of the metalworking industry in Asia. By Michael Campbell, Creo product development, PTC

Fab & Form 54 A Stamp Of Approval

The production world sees an increase in part orders as the manufacturing sector grows and important industry drivers like automotive and aerospace require precision on a mass scale. By Mark Johnston

4

metalworking equipment news March 2011

Best choice.

User-friendly performance.

Laser | Bending | Waterjet bystronic.com

ENQUIRY NO 172

Contents

March 2011

Industry Focus

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

In parts of Asia where the population is ageing, the medical device market has garnered more attention.

With parts like stents, orthopedic devices and dental implants demanding more from machining processes, Swiss turning is making its mark with its accuracy and rigidity. By Philippe Charles, Tornos

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

56 Swiss Turning For Medical Parts

60 Making Medical Parts, It’s Tough

Demanding materials and complex workpiece geometries – the machining of specialist medical components poses specific demands on the machining tools used. By Michael Fink, Walter AG

62 Robot That Saves Lives

Robotic technologies have proved to be practical in the field of radiation therapy, giving rise to the application of robots in tumour treatment possible, where precision is a must. By Stefanie Senft, Kuka Roboter

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

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

Features

Endorsements

64 Opinions: It Pays To Be

SPETA

Fussy In Metrology

Even with new technologies and challenges coming into the world of metrology, fundamental knowledge, traditional techniques and attention to details are still cornerstones of a good measurement. By Tan Siew Leng, A*STAR

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

Federation of Malaysian Foundry & Engineering Industry Associations

66 The Business Of Going Green

Indian Machine Tool Manufacturing Association (IMTMA)

In the face of environmental, social and governance challenges, CEOs in Asia are increasingly embracing sustainable practices in the playing field. By Teo Lay Lim and Ynse de Boer, Accenture Singapore

70

Multi-Applications Machining: It’s All About Being Versatile Presented in various names like multitasking and integrated machining, they do however point to one concept, ie: accomplishing more than one task in one machine. By Augustine Quek

Regulars 12 79

6

Business News Product Finder

metalworking equipment news March 2011

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

74 Events &

Exhibition • DMG/Mori Seiki (Malaysia) Grand Opening • EMO Press Conference • ASX 2011

83 Exhibition Programmes 84A Product Enquiry Card

Taiwan Association of Machinery Industry (TAMI)

84

Refer to Advertising Index

pg

For Advertiser's Enquiry Numbers

ENQUIRY NO 028

editor’s note

Published by:

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

Reg No: 199908196C

Let’s Go

managing director Kenneth Tan editor Joson Ng

Innovate

josonng@epl.com.sg

business development manager Randy Teo

randyteo@epl.com.sg

advertising sales manager Yessica

yessica@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow

Taking something old and giving it a new lease of life, creating something from very little, thinking out of the box, seeking improvements in an already established product – these are examples and sayings people relate innovation to. The ‘I’ word is an important word in today’s world where a single idea can be a game changer. This is also true in the metalworking environment.

In this issue of Asia Pacific Metalworkin g Eq uipment News (APMEN), stories of innovations dominate. Turning tools for instance will see Seco Tools add to their range of Duratomic grades where atomic orientations were deliberately arranged to produce the desired mechanical performance. In machine tools, Hwacheon relies on flexibility, thermal and mechanical stability for their machines to produce accurate parts with high levels of repeatability.

With companies putting in a sizable amount of their funds into R&D year after year, one might be tempted to put a price tag on R&D. The true fact of the matter is that

certain things are not quantifiable.

In artificial hip joint manufacturing, the R&D efforts invested in a machine tool may result in better surface quality and accuracy on parts, giving possible bragging rights to a particular manufacturer looking to gain more market share. But for the hip transplant patient, it is no longer about numbers; it is much more than that. Therefore it is worthwhile to consider the emotional paycheck innovations bring. The thought of a kneecap replacement patient walking without any pain may be reward aplenty for some.

The journey of innovation is never ending. There is always a better way to turn a part or design a machine. The motivation behind each innovation may vary but the end results are always the same, ie: better products that have benefits that transcend dollars and cents.

irenetow@epl.com.sg

contributors Michael E Neumann Michael J Hawkins Peter Dickin Michael Campbell Philippe Charles Michael Fink Stefanie Senft Tan Siew Leng Teo Lay Lim Ynse De Boer Dr Moshe Goldberg Rafi Rabouch Vynce Paradise Augustine Quek Mark Johnston board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher.

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

Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 133/06/2010 PPS 840/09/2011 (020177) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

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

Joson Ng Editor

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806

8

metalworking equipment news March 2011

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The new generation of Walter Cut tools.

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Because compromise is not an option Because compromise is not an option when it comes to grooving. when it comes to grooving.

Expect more.

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Walter AG Singapore PTE Ltd. Teletech Park, Singapore TIC Tech Centre, Singapore +65-67736180 +65-67736180 service.sg@walter-tools.com service.sg@walter-tools.com www.walter-tools.com www.walter-tools.com

ENQUIRY NO 168

Expect more.

Engineer what you envision.

Experience the new Walter.

Advertorial

www.equipment-news.com

Europe’s number one is exhibiting for the first time at the MTA Singapore Munich, February 2011 – 50,000 quality tools, comprehensive service performance and knowhow that measures up to even the most complex demands: This unique formula has taken the Hoffmann Group forward and made it Europe’s leading system partner for quality tools.

Now for the first time the Munich-based company is inviting visitors at the MTA in Singapore.

The Hoffmann Group will be exhibiting highlights from its 50,000 item portfolio on booth 4E3-05. Experts from the Hoffmann Group and Sutton Tools Singapore, the local partner, will Focused on the essentials: a striking vehicle design, state-of-the-art, high-tech materials and maximum precision during production.

be available throughout the show to guide visitors through the tips and tricks of machining classic and modern materials.

High-performance tools for high-tech materials All lightweight parts of the concept car Roding roadster are cut using GARANT special tools.

Most of these come from the “Black ring” series, which has been developed specifically for fibre composites and graphite materials. A wide range of milling tools with high-performance diamond cuts prevent the material from wearing rapidly. For example, the blank is cut from the mat using a GARANT solid carbide router cutter. The high-performance diamond cut features six cutters and ensures that large, clean chips are produced. The sliding cut of the router cutter presses the component onto the support without placing it under any tension.

The GARANT solid carbide milling cutter, with its patented helical, curved cutting edge, can be used for clean and precise edge milling. The special shape of its cutting edge makes it possible

The Hoffmann GARANT Solid Carbide Milling Cutter 209515 with its patented helical curved cutting edge for super clean and precise edges.

to mill without burrs on the bottom and top edges of the CRP component. The cutting edge pushes and pulls simultaneously to prevent delamination of the component.

The GARANT zero point clamping system The products displayed at the exhibition include some of the most spectacular developments achieved by the Hoffmann Group. Foremost among these is the GARANT zero point clamping system. Thanks to superb precision and very high clamping forces, coupled with extreme ease of use, this tool allows reductions of up to 95% in set-up times, changeover times and nonproductive times. GARANT ZeroClamp is a professional modular system with an enormous variety of uses over a very wide range of tasks including special situations. The system requires only a single type of clamping stud, which guarantees very high modularity: It is suitable for all types of machines and can be adapted quickly and individually to all applications, mastering ever more complex clamping tasks without problems.

The principle of the Hoffmann zero point clamping system GARANT ZeroClamp.

Hoffmann Group Hoffmann GmbH Qualitätswerkzeuge Christian Ossmann Haberlandstraße 55 D-81241 München Tel.: +49/89/8391-498 Fax: +49/89/8391-89 E-Mail: C.Ossmann@hoffmann-group.com www.hoffmann-group.com

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Exclusive premium brand GARANT More 500tools leading brands 50.000than quality The Partner – always by your side MoreSystem than 500 leading brands Exclusive premium GARANT The System Partnerbrand – always by your side ■ Exclusive premium brand GARANT ■ ■ ■ ■ ■ ■ ■

it us: s i v e s Plea 4E3-05 Booth t us: i s i v e Pleas 4E3-05s: th it u s o i v Blo e s P ea 4E3-05 Booth

www.hoffmann-group.com ENQUIRY NO 041

www.hoffmann-group.com ENQUIRY NO 041

Sutton Tools Singapore Pte Ltd, No. 1 Ubi View #03-18, Focus One, SINGAPORE 408555 Phone: +65 67457366 Fax: +65 67455080 Mail: ekoh@sutton.com.au www.hoffmann-group.com Sutton Tools Singapore Pte Ltd, No. 1 Ubi View #03-18, Focus One, SINGAPORE 408555 Phone: +65 67457366 Fax: +65 67455080 Sutton Tools Singapore Pte Ltd,

www.equipment-news.com

Businessnews Siemens Introduces Service For Customised HMI Design

Nuremberg, Germany: The Siemens industry automation division is offering a process for designing customised Simatic Human-MachineInterface (HMI) unit fronts quickly. The service is aimed at machine and plant builders as well as end customers who require HMI units for their machines or plant in a special design.

The first units will be available to the customer seven days after clarification of the design. The industrial-quality operator panels can be customised, eg: with a customer logo, coloured strips, customised text (such as equipment type designations) and displays of photographic quality with a resolution of up to 600 dpi. HMI units can therefore be adapted to the design of the machine or plant more accurately than before. This offer applies to orders of three or more panels.

IndiGo Commits To The Largest Jet Order In Aviation History Toulouse, France: India’s largest low-cost carrier, IndiGo has signed a Memorandum of Understanding for 180 eco-efficient Airbus A320 aircraft of which 150 will be A320neo’s and 30 will be A320s.

It is the largest single firm order number for large jets in commercial aviation history, and also makes IndiGo a launch customer for the A320neo.

The A320neo, available from 2016, incorporates new more efficient engines and large wing tip devices called Sharklets delivering significant fuel savings of up to 15 percent, which represents up to 3,600 tonnes of CO2 annually per aircraft. In addition, the A320neo provides a double-digit reduction in NOx emissions and reduced engine noise.

“This order for industry leading fuel efficient aircraft will allow IndiGo to continue to offer low fares,” said Rakesh Gangwal and Rahul Bhatia, co -founders of IndiGo. “Ordering more A320s was the natural choice to meet India’s growing flying needs. The opportunity to reduce costs and to further improve our environmental performance through the A320neo were key to our decision.”

Total & Partners To Develop The GLNG Project Australia: Total and its partners Santos (operator), Petronas and Kogas announce the sanction of the GLNG project in Australia, representing a 16 billion dollars investment. The GLNG project consists of the development of coal seam gas fields, the construction of a 420 km gas transmission pipeline and of a liquefaction plant of 7.2 million tonnes per year (Mt/y). First 12

metalworking equipment news March 2011

Liquefied Natural Gas (LNG) will be delivered in 2015 and plateau production of the LNG plant is expected to be reached in 2016 for more than 20 years.

“Total is delighted to work alongside Santos in this project, an operator that has demonstrated its expertise in producing coal seam gas since 2002, and to bring its know-how in managing large LNG projects. The involvement

of Petronas and Kogas, main buyers of the produced LNG, also strengthens the project,” declared Yves-Louis Darricarrère, president of exploration and production, Total.

“Through this project, Total increases its presence in Australia and its access to the Asian LNG market, the fastest growing market offering high value prices linked to oil.”

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businessnews

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Hyundai Motor India Clocks Highest Sales Ever New Delhi, India: Hyundai Motor India, the countr y’s second largest car manufacturer and the largest passenger car exporter ended the year on a high note with domestic sales growing by a healthy 23.1 percent while exports saw a decline of 8.5 percent. Cumulative grow th stood at 7.8 percent for the year ending December 2010.

The company’s total sales for December 2010 stood at

47,228 units as against 47,217 units in December 2009 while the cumulative sales almost remained the same. The domestic sales growth however registered a healthy growth of 17.6 percent over 2009 and stood at 26,168 units as compare to 22,252 units for 2009. Exports dipped by 15.6 percent to 21,060 units in 2010 against 24,965 units in 2009.

In calendar year 2010 (Jan –

Dec) the company grew by 7.8 percent cumulatively registering total sales of 603,819 units as against 559,880 units of 2009 with domestic sales surging by 23.1 percent over 2009. Domestic sales accounted for 356,717 units in 2010 as against 289,863 in the year 2009. Overseas sales accounted for 247,102 units as against 270,017 units in 2009, which reflects a decline of 8.5 percent for the calendar year 2010.

Worldwide Semiconductor Revenue Increases 31.5 Percent S i n g a p o r e : A f te r a w o r l d w i d e e c o n o m i c recession, the semiconductor market rallied in 2010 with worldwide revenue reaching a la ndma rk US$30 0. 3 billion in 2010, up 31.5 percent from 2009, according to preliminary results by Gartner.

“In 2010, the semiconductor ma rket wa s driven by pent-up demand as system makers scra mbled a ga inst depleted inventorie s to obtain parts,” said Stephan Ohr, semiconductor research director at Gartner.

It rebounded from a 10 percent revenue decline in 2009. Overall, semiconductor industry revenue grew US$71.9 billion in 2010, the largest single dollar increase for the semiconductor industry in any one year. Only three times in its past – in 1988, 1995 and 2000 – has semiconductor industry revenue grown by more than 30 percent in any one year. In 2010, the industry topped US$300 billion, regarded as a benchmark achievement for the industry.

Intel held the number one vendor position for the 19th consecutive year in 2010, albeit with a slightly smaller share of the market, down to an estimated 13.8 percent from 14.2 percent in 2009. The company saw strong growth in the first half of the year as the PC market stocked up inventory in anticipation of a strong second half of the year, but third quarter growth weakened as consumer sentiment began to flag. Sales of mini-notebooks – a segment for which Intel is almost the exclusive supplier – were particularly disappointing.

Samsung Electronics, Toshiba and Texas Instruments all performed well in 2010 to retain their respective rankings of number two, three and four. Samsung had a strong growth year due 14

metalworking equipment news March 2011

Paolo Ferla, Catania, Italy

to its exposure to the DRAM and NAND flash markets. Memory accounts for over 80 percent of the company’s sales.

Toshiba grew its NAND flash memory business for mobile devices, as well as its A SIC and A SSP device businesses. Texas Instruments had a banner year with the company’s overall semiconductor revenue growing 35.2 percent, and its analogue revenue increasing more than 41 percent.

A new entrant to the top 10 was Renesas Electronics, at number five following the merger of NEC Electronics and Renesas Technology on April 1, 2010. Also in the top 10, Micron Technology rose five places to number eight, largely as a result of its acquisition of Numonyx, which allowed it to capture the last three quarters of the company's sales in calendar 2010.

www.equipment-news.com

businessnews

China Enlists NAG For The Aircraft Manufacturing Industry

Shanghai, China: Shanghai University (part of the consortium to extend the Chinese aerospace industry) announces a partnership with the Numerical Algorithms Group (NAG). The collaboration will utilise a computing platform for key Computational Fluid Dynamics (CFD) research which is essential in order to achieve the civilian aircraft industry targets established in the Chinese government’s ‘Long-term Scientific and Technological Development Plan (2006-2020)’.

The agreement signed by the parties involves the cooperative development of CFD software to be used by the industry. The company will provide development tools, and computational science and engineering technical support and consultations.

“We need a strong, accurate numerical computation engine to lay the basis for the aerospace R & D platform,” said Prof Zhang Wu, the dean of the computer science school and director of the high performance computing centre of Shanghai University. “NAG’s knowledgebase in numerical computation and numerical analysis built over more than four decades, and their leadership in many of the world’s high performance computing centres makes them a valuable partner for the CFD research required. Also, the organisation includes many computational scientists originally trained in China and it is this type of international diversity and cooperation that will facilitate the fast progress needed for this and other industrial development projects in China.”

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Abu Dhabi And Singapore Forge Deeper Economic Ties

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Mike Johnson, Des Moines, IA, United States

Singapore: Singapore and Abu Dhabi have reaffirmed a commitment to strengthen economic ties further.

This took place at the 5th Abu Dhabi-Singapore Joint Forum (ADSJF). The Forum was co-chaired by Lee Yi Shyan, minister of state for trade and industry and His Excellency Khaldoon Khalifa Al Mubarak, chairman of the executive affairs authority of Abu Dhabi.

Singapore’s relations with countries in the Middle East have grown steadily over the years. In recent years, there have been increasing exchanges and mutual visits between the government, corporate and people sector. Expressing his satisfaction at the progress of Singapore’s economic ties with Abu Dhabi, Mr Lee said: “I am pleased that the warm bilateral relationship between Abu Dhabi and Singapore continues to deepen. Through platforms such as this 5th Abu DhabiSingapore Joint Forum, our economic ties with the UAE will continue to grow stronger.”

The economic relationship between Singapore and Abu Dhabi recently reached a new milestone with the conclusion of negotiations for a bilateral Investment Promotion and Protection Agreement (IPPA). This augurs well for the business community as it lays a solid framework where investors from Abu Dhabi and Singapore can benefit from greater certainty by clearly setting out investment norms and protection when investing in another country.

The agreement provides the framework to assure investors of investment protection.

“The IPPA will be a good addition to our existing GCC-Singapore Free Trade Agreement. It will also help boost bilateral investment between Singapore and Abu Dhabi. I look forward to the official signing of the IPPA soon,” said Mr Lee. The UAE is Singapore’s second largest trading partner from the Middle East. Trade between Singapore and the UAE has more than tripled since 2002. In 2010, total trade between Singapore and the UAE increased by more than 19 percent from 2009 to reach S$13.9 billion (US$10.8 billion). To-date, Singapore companies have secured up to S$10.17 billion worth of projects in the UAE. Abu Dhabi is also Singapore’s most significant economic partner within the UAE. 16

metalworking equipment news March 2011

Gretchen Jezerc

Kennametal has appointed Gretchen W Jezerc to the position of VP, global product management.

With leadership experience in marketing for a number of global manufacturing companies, Ms Jezerc has strategised, developed, and implemented successful marketing programs for such companies as Philips Respironics, PPG Industries, and Whirlpool Corporation.

Delcam Establishes Manufacturing Services Subsidiary Paul Wilkinson

Birmingham, UK: Delcam has converted its Professional Services Group into an independent subsidiary, Delcam Professional Services (DPS), as the first stage in a significant expansion planned for its process development activities. The subsidiary also includes the company’s former tooling services division, which has been renamed as the Delcam Advanced Manufacturing Facility.

The primary focus of DPS will continue to be working with clients, mainly in the aerospace and power generation industries, to improve their manufacturing processes by increasing productivity, improving accuracy and shortening lead times. In particular, this will be achieved through the use of adaptive machining. Paul Wilkinson, the current head of the professional services group, has been appointed GM of the new subsidiary.

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SHI Signs US$1.08 Billion Contract For Two Units Of Drill Ships

Luiz Fernando Pilz, Sao Paulo, SP, Brazil

South Korea: Samsung Heavy Industries (SHI) had signed a contract to build two units of drill ships for Seadrill, a Norwegian firm. The contract amount is US$1.08 billion.

With the marine energy development boom, drill ships orders have been active. In 2006 and the three years that followed, approximately 14 units of drill ships were ordered per year, but the market has suffered from sluggish demand since the financial crisis. The number

of drill ships ordered in 2009 was two.

SHI received an order for large drill ships for the first time in 2010, and its success was attributed to its compliance with the tightened safety standards that have been applied since the oil spill accident in the Gulf of Mexico, as well as its highest score in the areas of safety and eco-friendliness, which includes its technology to minimise volatile organic components.

Industry experts believe that the global oil price has recovered to US$86, which is the pre-crisis level, in two years, and SHI contract for large drill ships signal the recovery of the marine energy development market.

IEA has upwardly adjusted the average daily oil demand estimates, and investment organisations such as JP Morgan and Bank of America released an outlook for the global oil price of US$100 per barrel. As South Korean shipbuilders are dominating the marine energy development market, the recent market conditions can be interpreted as favourable for South Korean shipbuilders.

The company had already delivered three units of the same class of drill ship to Seadrill, so it expects that it will be able to accelerate the design process and save costs. The company is highly likely to receive additional orders, as the drill shipbuilding contract includes options for two units of additional ships. An ‘option’ is a conditional contract between a shipper and a shipbuilder, under which a shipper shall place a future order with a shipbuilder it has previously contracted with.

IE Singapore Introduces An Assistance Program Singapore: To encourage more Singapore-based companies to participate in the Tianjin Ecocity, International Enterprise ( IE ) Singapore is offering a Tia njin Eco - cit y A ssista nce Program ( TA P Program) for Singap ore compa n ie s. T h is wa s a nnounced by Senior Minister of State (SM S ) for N a t io n a l D e v e l op m e nt a n d Education Grace Fu. SMS Grace Fu is the vice chairman of the Singapore -Tia njin Economic and Trade Council (STETC).

T h e TA P p r o g r a m h a s been put together to address common concerns raised by companies. These include the lack of market awareness as 18

metalworking equipment news March 2011

well a s the initia l outlay of efforts and expenses required to set up a presence in the Ecocity. With the TAP program, Singapore -ba sed compa nies can now enjoy a grant of up to S $15 0 , 0 0 0 ( U S $116 , 0 0 0 ) to l o o k a t (i) s e t t i n g u p a physical presence in Eco-city, (ii) developing key staff’s inm a r ke t e x p e r t i s e a n d ( i i i) penetrating the local market The Tia njin Eco - cit y ha s attracted some RMB 1.19 billion (e st imate d S$231. 2 m illion) wor t h of i nve st me nt s f rom Singapore-based companies as of December 2010. This makes up 46 percent of the Eco-city’s total commercial investments.

From Ja nua r y – O c tob er 2010, bilateral trade between Singapore and Tianjin amounted to US$1.37 billion, (- 4 . 6 p e r c e n t). E x p o r t s to Tianjin accounted for US$0.87 bi l l ion (+3 9. 3 p e rce nt) a nd imports from Tianjin accounted f o r U S $ 0 . 5 b i l l i o n (- 3 8 . 5 p e rce nt). D u r i n g t he s a m e p e r i o d , S i n ga p o re’s a c t u a l Foreig n Dire ct I nve st ment s (FDI ) in Tianjin hit US$ 0.28 billion with 19 projects. As of end October 2010, Singapore’s cumulative actual FDI in Tianjin amounted to US$ 3.41 billion with a total of 178 projects.

(Source: Tianjin Commission of Commerce)

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2011 Global Automotive Assembly To Exceed 75 Million Units And Surpass 93 Million Units By 2015

Detroit, USA: PwC’s Autofacts has forecasted the 2011 global light vehicle assembly to exceed 75 million units, a new industry peak. Although some uncertainties persist in various regional economies, the baseline global assembly estimate is reflective of: • Continued mature market recovery volume in North America, the EU, and developed Asia-Pacific (Japan, South Korea, and Australia).

• New organic growth in emerging automotive markets primarily within developing Asia-Pacific (China, India, and ASEAN), South America, and Eastern Europe, which are forecasted to contribute more than 70 percent of global assembly volume growth from 2010-2015.

• Increased demand for premium brands, estimated to increase by 9.2 percent in 2011 versus a growth rate of 5.9 percent for non-premium brands.

“Unlike the past, vehicle assembly volumes are increasing due to natural market recovery as opposed to artificial stimulus such as automaker incentives and

government intervention,” explained Anthony Pratt, senior automotive analyst, PwC’s Autofacts.

“Automakers who took a bitter pill by making difficult decisions to make significant cost reductions throughout their organisation are reaping the benefits.

This is evident for companies who are achieving profitable growth.”

China remains the number one automotive sales market after surpassing the US in January 2009. In 2011, Autofacts forecasts China’s vehicle assembly volume to reach more than 15 million units, an increase from 14 million units in 2010. However, the growth rate is expected to plateau as the government ends tax incentives for small cars and attempts to suppress asset price bubble concerns.

Instead of China’s tremendous sales increase of 31 percent year-over-year recorded in 2010, Autofacts expects a 20 percent rise. With gross domestic product (GDP) per capita in China exceeding the $7,500 threshold, when sales tend to surge, Autofacts does not envision the possibility of single-digit growth in the short-term.

“China is the poster child for stimulus driven market performance,” continued Mr Pratt. “We expect sales in the first half of 2011 to slow as a result of pull ahead incentives.”

Due to booming global demand, premium automotive manufacturers are facing capacity constraints. This is a major concern given that a future China market of 40 million units would double the size of the world premium brand market.

Furthermore, premium brand assembly growth is forecasted to increase by more than 50 percent by 2017, while non-premium segments are anticipated to grow by 36 percent during the same period. This may be counter-intuitive considering the significant growth-taking place in low cost segments in emerging markets.

Nissan: Leading Sales Growth In China Among Japanese Automakers China: Nissan (China) Investment (NCIC) has announced its sales performance including Infiniti for the whole year of 2010. With 1,023,638 units sold in the China market, a 35.5 percent sales grow th compa red to a yea r before, Infiniti division sales doubled with 11,513 units sold.

In the year of 2010 Nissan’s sales in China became the largest over those in US and Japan.

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metalworking equipment news March 2011

“This has been a productive year for Nissan in China,” said Takashi Nishibayashi, president of Nissan (China) Investment.

“With the product lineup expanding continuously and our increasing investment in China, Nissan will manage to keep our strong momentum in this booming market.”

Dongfeng Nissan Passenger Vehicle Company ( DF L PV ),

under the ma nagement of Dongfeng Motor (DFL), Nissan’s joint venture in China, set a record sales at 660,610 units, a 27.3 percent increase compared to the year of 2009. Zhengzhou Nissan Motor (ZNA), also under the management of DFL, made a great contribution to this growth.

It achieved sales of 100,100 units with a significant 78.6 percent year-on-year growth rate.

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BCA: Promising Outlook For Construction Sector In 2011 Herman Brinkman, Amsterdam, Noord-Holland, Netherlands

Singapore: Riding on strong economic growth, Singapore’s construction demand1 increased by 14 percent year-on-year from S$22.5 billion (US$17.4 billion) in 2009 to S$25.7 billion in 2010. For 2011, Singapore’s construction demand is projected to reach between S$22 billion and S$28 billion, reflecting a continued and sustained workload.

For 2011, public sector demand for construction is likely to strengthen to between S$12 billion and S$15 billion, contributing about 55 percent to the overall construction demand. The rebound is anticipated to mainly come from growth in public sector institutional construction demand as well as stronger public sector civil engineering construction demand led by Land Transport Authority 's (LTA) Downtown MRT Line Stage three contracts.

The private sector construction demand is expected to moderate from the preceding year’s level of S$17.4 billion to between S$10 billion and S$13 billion in 2011, reflecting more cautious industry sentiments among developers amidst a more moderate economic outlook.

Private sector residential construction demand is projected to moderate to between S$5.1 billion and S$6.1 billion from 2010’s contracts of S$7.7 billion.

Private sector commercial construction demand is likely to be backed by a buoyant office space demand and vibrant retail sector, while high-specification buildings will dominate the private sector industrial construction sector.

To facilitate the industry in project and resource planning for the medium term, Building and Construction Authority (BCA) has been providing the construction demand forecast beyond the immediate year on a rolling basis since 2009. For 2012 and 2013, the average construction demand is projected to range between S$19 billion and S$26 billion2 per annum. The public sector construction demand is likely to reach between S$9 billion and S$12 billion per year in 2012 to 2013, with about 65 percent of the total demand coming from building projects while the remaining 35 percent from civil engineering projects.

The total construction output3 (payment made for work done) is estimated to moderate from a record high of S$31 billion in 2009 to about S$27 billion in 2010, as a result of the completion of a number of major projects including the two integrated resorts.

In view of the moderation in construction demand since 2009, the level of on-site construction activity or output is projected to range from S$24 billion to S$26 billion in 2011 and from S$20 billion to S$27 billion per year in 2012-13.

Footnotes: 1. Construction demand is measured by total value of construction contracts awarded. All construction demand figures stated here exclude reclamation projects.

2. Demand forecast beyond the immediate one year will be done on a rolling basis to take into account subsequent changes in economic outlook and other pertinent factors.

3. Construction output is measured by total value of certified progress payments.

New Plants Launch Full-Scale Operation Tokyo, Japan: Two new plants belonging to two Joint Ventures (JV) between Mitsubishi Heavy Industries (MHI) and Larsen & Toubro L imited ( L &T ) of India, created to manufacture supercritical-pressure coal-fired boilers and steam turbines/ generators respectively, have been completed and launched 22

metalworking equipment news March 2011

full-scale operations.

The two JVs were established to respond to India’s strong electricity demand, which is sharply increasing along with the country’s robust economic growth, through the manufacture and supply of high-efficiency coal-fired power generation equipment.

Spurred by the launch of the two plants’ full-scale operations, going forward MHI, together with its two JVs and L&T, will further strengthen its marketing activities for high-efficiency supercriticalpressure boilers and turbines in the Indian market, where construction of many new thermal power plants is planned.

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Connectivity ICs Critical For Growth In Handset Semiconductor Markets

Kulo T, Fukuoka, Japan

Singapore: The total revenue delivered by handset semiconductor shipments is forecast to increase approximately 5.5 percent, says ABI Research. The trend is expected to continue through the next three years, resulting in a total estimated revenue growth of 12 percent in 2013.

Industry analyst Celia Bo notes: “The increasing shipment rates of handset processors and connectivity chips are the major engines driving handset semiconductor market growth.”

Qualcomm, MediaTek, and TI account for approximately 80 percent of all shipments in the handset chipset market. Qualcomm maintains a leading market position, especially in the high-end smartphone segment.

The majority of MediaTek’s shipments are 2.5G and 2.75G chipsets for the company’s low-cost solution. The company is set to continue gaining a greater share of the low- to mid-priced chipset market. TI has been gradually stepping out of the 2.5G and 2.75G chipset market since the end of 2008, with shipments declining in 2010 and virtually cease in 2012.

“Connectivity chips will play a critical role in driving handset semiconductor market growth in the next five years,” adds ABI Research principal analyst Peter Cooney. “The total revenue from handset Bluetooth, GPS, and Wi-Fi chipsets is forecast to grow more than 15 percent year, and is estimated to hit US$3.5 billion in 2015.”

BHEL Bags Orders From Indian Railways New Delhi, India: Bharat Heavy Electricals Limited (BHEL) has secured two orders from Indian Railways for the development, ma nufacture a nd supply of 3-Phase IGBT-based propulsion systems for Electric Locomotives and AC EMUs. Cumulatively valued Rs 3,000 million ($US66 million), the orders for 40 sets for 1400 HP AC EMUs (Electric Multiple Units) and 30 sets for 6000 HP Electric Locomotives, have been bagged.

In the recent past, across the world, the trend has been to switch over from conventional DC drives to 3-Phase AC drives based on Insulated Gate Bipolar Transistor (IGBT) technology which provides advantages like lesser power losses, better control ability, higher performance and reliability.

These orders give the company an opportunity to supply the system within the shortest possible time to Indian Railways in order to become the established supplier for this technology. Both BHEL and Indian Railways will benefit from this as the company will be able to offer products, system and services indigenously eliminating dependance on costly imports and ensuring long term sustenance.

Ford To Invest US$400 Million In Vehicle Production Plant Kansas City, USA: Ford Motor Company has plans to build a new vehicle at its Kansas City Assembly Plant in Missouri after Ford Escape production moves to Ford’s Louisville Assembly Plant and retooling of the Kansas City facility is complete.

Ford will invest US$400 million in the Kansas City plant to install a new body shop, new tooling and other upgrades. In addition, 24

metalworking equipment news March 2011

the company has committed to retain 3,750 full-time jobs at the plant – consistent with current employment levels. This includes the positions required to assemble the Ford F-150, which will continue to be built at the facility on a separate line.

“This investment and promise of a new vehicle to be built in Kansas City reinforces Ford’s commitment to US manufacturing

and American jobs,” said Mark Fields, Ford president of the Americas. “Investing in our plants, products and people is critical to Ford’s ability to compete with the best in the business.”

Kansas City Assembly Plant is the fourth North American facility the company is retooling for production of new vehicles that are at the heart of a lineup of cars, trucks and utilities.

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Yamaha Gained Momentum In 2010 thereby registering a growth of 69.7 percent. In domestic markets, the company almost doubled last year’s sales, with 26,567 units in December 2010. The export figures stood at 8,272 units in December 2010 while 6,917 motorcycles were exported in December 2009.

“We are pleased with our achievements this year, wherein we have been able to strengthen our brand image and cement our place in the hearts of our customers. Along with achieving several milestones, the year was marked by various initiatives to enhance our relationship with our customers,” said Hiroyuki Suzuki, CEO & MD, India Yamaha Motor.

Stainless Steel Consumption Set For Growth

Nossirom, Germany

India: Indian steel industry has registered a rapid progress on the back of strong fundamentals during the past few years. The industry is getting all essentials element, which will lead to growth in near future.

Rising demand for steel from the government backed infrastructure construction projects (including railways coaches and high capacity bus corridor) kept the industry momentum going. Moreover, with various industrial sector investments and infrastructural developments, it is expected that the steel consumption will grow at a CAGR of around 7.5 percent during FY 2009 - FY 2013.

According to a research ‘India Steel Industry Outlook to 2012’, among various different industries, metal products are the largest consumer of stainless steel followed by process industry. Besides, demand from other industries like, construction, process, and engineering are expected to grow in the coming years on the back of various factors.

Even during the tough economic conditions, industrial consumption succeeded to sustain its positive growth momentum on the strong fundamentals of domestic demand from construction, automobile, and infrastructure sectors.

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New Delhi, India: India Yamaha Motor rode at a brisk pace in 2010 backed by new product offerings and marketing initiatives. The company clocked sales of 350,264 motorcycles in 2010 as compared to 267,895 motorcycles in 2009, a growth of 30.7 percent over last year. The domestic market recorded sales of 258,987 units in 2010 as compared to 218,625 units in 2009, a growth of 18.5 percent while in export markets, a growth of 85 percent was achieved with the sale of 91,277 motorcycles in 2010, compared to 49,270 units in 2009.

In December alone, the company sold 34,839 units compared to 20,529 units in December 2009,

March 2011 metalworking equipment news

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Italian Machine Tools, Robots And Automation Manufacturing Industry Saw An Increase Of 3.3 Percent In Production In 2010

Italy: In 2010, the Italian machine tools, robots and automation manufacturing industry has taken the road to recovery; but the recovery, just as forecasts for 2011 confirm, is a rocky road.

As shown in the preliminary data calculated by the studies department of the organisation, in 2010, the Italian production sector grew to €4,230 million (US$5,641 million), indicating an increase of 3.3 percent compared to the previous year.

The cautious trend reversal, which has enabled manufacturers to recover less than a tenth of the ground lost in 2009 when production fell by 30 percent is an expression of the apathy that has affected almost every market for about two years.

As confirmation of this, exports of Italian machine tools only grew by 3.1 percent in 2010 to €2,605 million.

According to the calculations from the department on ISTAT data, relating to the first nine months of the year, the main outlet market for the Italian suppliers sector is China, which has knocked Germany off the top spot. The US is in third place, followed by France, India, Russia, Iran, Brazil, Spain and Poland.

With an increase of 13.3 percent over the period January-September 2009, sales of Italian machine tools in China exceeded €270 million; China now accounts for 15.9 percent of Italian exports in the sector. In light of the drop in sales in traditional outlet markets for Italian products such as Germany, the US and France, Italian manufacturers have seen sales in India (+83.8 percent), Russia (+16.4 percent), Iran (+312.5 percent) and Brazil (+47.7 percent) all rise.

On the domestic market, consumption grew by 6.5 percent to €2.485 million, stimulated and supported, in the first part of year, by Tremonti-Ter. Italian manufacturers benefited from the recovery of demand, as confirmed by the data relating to deliveries on the domestic market which grew by 3.8 percent, to €1,625 26

metalworking equipment news March 2011

million. Imports were also up (+12.1 percent) but the absolute value is still very low.

The export/production ratio is stable compared to 2009 with a result of 61.6 percent.

The 2011 forecasts show a trend for improvement that is still rather weak. Production will grow by nine percent, to €4,610 million compared to 2010. A positive sign characterises the cross-border sales which are expected to grow by 7.1 percent and will reach €2,790 million.

Stronger increase (12 percent) in manufactures’ deliveries on the domestic market which will reach €1,820 million, as they are propped up by the recovery of consumption, which is expected to grow by 11.5 percent, to €2,770 million.

“Despite the main economic indicators marking an increase the recovery seen in 2010 and forecast for 2011 still appears to be quite weak,” said Mr Giancarlo Losma, president of UCIMU-Sistemi Per Produrre.

“What really worries Italian machine tools manufacturers is the weakness of the domestic market and the European area in general. According to a recent survey by the association, more than 25 percent of machine stock installed in Italy, and also in Europe, is more than 20 years old. Updating the current production systems in our facilities is therefore a necessary requirement to prevent the loss of competitiveness of our manufacture compared with that offered by foreign competitors, above all, those from the Asian area.”

“In other words, we must create the conditions in Europe because the whole production system has gone back to absorbing technology. In this respect we reaffirm the need to introduce a system of incentives for the destruction of obsolete machinery that could be financed with the Eurobonds guaranteed by the gold reserves of the countries in the area,” added Mr Losma.

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Performance

Turning Turning has gone from a manual process to being computer controlled and automated. To delve deeper into the topic of turning, Asia Pacific Metalworking Equipment News (APMEN) speaks to the experts to gain insights into the world of turning. By Joson Ng

Jordanhill School D&T Dept

In

Cutting Tools: Seco Tools

I

n turning, where a single point cutting tool is involved, plenty have been done to make sure the tool performs to a high standard. As such, much research has gone into making a modern turning tool capable of making precise parts in a productivity manner. Though there is only a single point of contact, other aspects like tool holding, coating, geometry and substrate contribute immensely to a successful turning operation.

In cutting tools, coating is one area where extra performance can be coaxed. For Seco Tools, it is one area they have looked into and will continue to do so in order to break new grounds in turning.

“Back in 2010, we developed more products in Duratomic, a coating technology that was first launched in 2007. We have added to the technology where through manipulation of the atomic structure, it is possible to provide higher levels of toughness and wear

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metalworking equipment news March 2011

resistance,” says Kenneth Barkman, MD, Seco Tools Singapore.

M r Ba rk ma n state s w it h improved toughness, it is possible to run parts at higher cutting speeds without having to worry about tool breakage. As the name of the coating suggests, much of its secrets lie deep down in the atomic level.

Says Mr Barkman: “In this technology, the atomic structure is finer, and direction plays a part.

We can influence the properties of the coating by organising the atoms in a certain way.”

Drawing an analogy, Pavel Hajman, president (Asia Pacific) and senior VP of group business development says: “Similar to forging steel, the reason you bend steel in many directions is to make it much tougher.”

Other Factors To Consider “Though coating is important, it is the combination with the substrate that gives the performance. You

cannot formulate a coating and put it on any surface and expect it to work,” says Mr Barkman.

I n addit ion, fac tors l i ke coolant pressure and toolholding are critical to good turning performance. He says: “There are holders for high-pressure coolant where we aim the coolant directly at the cutting zone. The coola nt pressure should be around 50 – 70 bar for best results albeit even at standard coolant pressure the system shows good improvements. Heat removal during cutting and chip control enhances tool life and allows for higher cutting speeds. Surface finishing is also improved as chip evacuation is better and shorter chips are produced.”

Mr Barkman also reveals that in 2011, another 500 different types of products in turning and grooving will be making their debut. Some of them will feature the HD (heavyduty) holder. In it, carbide pin seating will ensure the stable sitting

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of inserts, ensuring the cutting edge location is kept constant.

The range of turning products at the company is testament to the R&D efforts, which according to Mr Hajman is an ongoing process because as far as the turning process goes, there are still plenty of room for improvements. With its R&D efforts, which is valued at some three to four percent of the company’s annual turnover, new grades for hardened steel, the TH1000 and TH1500, are now available for materials up to 55 HRC hardness.

He concludes: “We continue to invest in the development of turning tools as we still see further potential for development. The interesting question here is what comes after the cemented carbide cutting tool because I think someday metal will be cut in a different way.”

Enquiry No. 2001

Pavel Hajman (L) and Kenneth Barkman believe there are further potential for developments in turning

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Visions For The Future Pavel Hajman “The trend is generally towards more and more multi-edged tools, ie: more cutting edges per inserts, resulting in better economy.”

Kenneth Barkman “The cutting tool industry will see more machining of composite materials. While traditional materials like steel will still be around, the trend is unsurprisingly, to cut faster, with better surface finishes at lower cost.

The real competition is in R&D.”

www.equipment-news.com

Pavel Hajman’s Take: Seco Tools To Grow In Asia In terms of absolute value we believe we will outperform our results in 2010 but a slightly lower rate in percentage than in 2010, which was a fantastic year for us.

Globally we were up 24 percent by the third quarter in 2010. In Asia, we managed some 40 percent growth in the same period. We do not think we will grow this fast this year but we think we will still achieve double digits, no doubt about that.

With an investment of some 10 percent of our annual turnover in capital expenditure like new machines and factories, we are setting our sights at markets in Vietnam, Indonesia and Thailand this year. In addition, we will continue to invest in the two fastest growing markets that is China and India. On a regional basis, we have increased our number of staff by 20 percent last year and we plan to do the same this year.

Growth can also be in the form of acquisitions. Our acquisition strategy is global and the same anywhere in the world. We have to make sure that every acquired company adds value to us – be it complimentary product line we do not have at the moment and will take too long for us to develop ourselves, added market presence or sales channel structure. I do expect that we will accomplish an acquisition in Asia in the next two years.

Enquiry No. 2002

Machine Tools: Hwacheon Machine Tool

T

“

he machine tool manufacturers are always in a technology race with the cutting tools makers.

Sometimes they are ahead and we have to play catch-up and sometimes it is the other way around,” says Klaus Ludwig, VP of Hwacheon Machine Tool, Korea.

In order to stay in this race, an essential fuel is innovation. When it comes to turning technology, the company has driven its development endeavours on four fronts, they are, flexibility, thermal control, environmental protection (control) and software control.

Flexibility & Versatility “In our T2 Series where the machine handles mainly more complex parts, innovation comes in the form of adaptability. The machine is designed for customer manufacturing complex parts. The more complex and accurate the part needs to be, the better the machine will prove its capability. It is designed as a modular system so the machine can be adapted to the

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“The machine tool manufacturers are always in a technology race with the cutting tools makers.”

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manufacturing needs of the user,” he says.

Using the basic model of the T2 machine as an example, he says: “The basic machine comes as a full three axis turning centre with a single spindle, a turn mill turret with 12 stations and a fully operational c-axis. Users can also adopt a secondary spindle, not a sub spindle but an equivalent unit to the main spindle. It is therefore possible to have two main spindles. In addition, there is an option to add a second turret so the number of tools goes up to 24. A y-axis can be added to the upper turret as well.

In total, the machine can have up to eight axes.”

The company plans to showcase its technology at Intermold in South Korea where it will also introduce four to five new machines. Of which, one is a vertical turning machine and two are horizontal turning machines. Mr Ludwig says the machines will illustrate the concept of flexibility that will cater to industry’s demands.

Thermal Control According to Mr Ludwig, the accuracy of a turning machine is mainly attributed to a solid basic construction and built. In order to keep it thermally stable during machining, it is important to control the temperature throughout the machine in order to maintain mechanical stability.

Using T2 to illustrate the point, he says: “We have integrated a cooling system to the main as well as the second spindle. In addition, each turret has their cooling system. We design the machine in such a way such that if there is any expansion due to a temperature gradient across the machine, the expansion will be symmetrical. It is important for the machine to be expanding or contracting symmetrically. This provides consistent accuracy and safe operation.”

Green Movement Environmental protection is playing a bigger part in machine tool manufacturing. Mr Ludwig says: “The VT950 and 1150, a medium size vertical turning centre’s lubrication system was designed in a way whereby the oil from guide way do not mix with coolants used for cutting. A drainage system is also designed to drain and filter oil.”

“The future trend in green designs will focus on chip disposal and ways to minimise the amount of coolant used in the machine,” he adds.

The Soft Touch Optimisation is something that Mr Ludwig believes will happen more in the future. He says: “Software in the future will be even more optimised to improve the quality of the machine and its performance. Software programs will be supporting the function of the machine, ie: they can optimised the cutting process in monitoring the necessary torque and power on the spindle. The complex system of internal automatic control will find itself on turning machines for the first time. We have also developed several software

programs to maintain temperature in the machine in order to control thermal expansion on the spindle setup. As such, we have managed thermal expansion of less than a micron in some cases,” he says.

Driving innovation is the company’s R& D department, which has access to 15 percent of the company’s annual turnover worldwide. In addition to its efforts in the development centre, ideas are tapped from other sources, as the company is also a manufacturer of automotive parts. For Mr Ludwig, it gives them another edge in the drive for innovation.

He concludes: “We ma ke cylinder blocks and heads as well as crankshafts for the South Korean auto industry in big quantity. We know how to produce parts and what is required to achieve it. This helps us in our machine designs.

With Hyundai and Kia Motors the single biggest customer worldwide for us using a total of close to 4,000 of our machines, we have constant feedback on what they need and what is required.”

Enquiry No. 2003

What's Coming Up? Klaus’ Thoughts Software & Hardware The trend in turning and machining products in the next two years will see software programs go hand-in-hand with the mechanics. Once a mould maker myself, I know how important it is to have a good software to support equally good mechanics. Some people use software to compensate the weakness of the mechanics. Though this works for a short while, but it cannot work for long. The weak point of the mechanics will always come out sooner or later.

Intuitive Machines Machine tools that are intuitive in nature so as once the button is pushed, it will do everything resulting in minimum operator input.

A Korean Wave For Machine Tools Last year has seen strong recovery from 2009. In 2011, we will try to grow 30 35 percent. Be it consumer products or machine tools, made in Korea products have seen breakthroughs in technology and consumption. We have also set up an international business unit where we will be looking to develop intuitive machines and expand our current business on an international scale. MEN

Enquiry No. 2004

March 2011 metalworking equipment news

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T

he turning of stainless steels, superalloys and other ‘difficult’ materials grows less difficult all the time, as a result of equipment improvements and refinements in High Pressure Coolant (HPC) machining practices. In many such applications with flood or low-pressure coolant and advanced tooling, throughput gains of 20 percent or more are reported, together with a doubling of edge life.

In addition, when the pressure is up to the 70-300 bar range, potential gains are increased by another big step. In fact, with proper HPC practices and tooling, a routine order-of-magnitude gains in edge life and/or hourly output can be expected.

Here are some recent improvements for turning the exotic superalloys, stainless steels and titanium materials.

• A drop-in in retooling of a rough turning operation on 316L stainless steel extended tool life from four to nearly 10 parts per edge, despite running the part 20 percent faster. The job ran with conventional flood coolant.

• Likewise, turning of hard superalloys has been improved with a whisker-reinforced ceramic insert that performs well even in roughing applications. Indeed, these inserts have enabled eight to 10-fold improvements in roughing and semi-finishing removal rates compared with carbide inserts. The new ceramic insert has withstood cutting speeds high enough to heat and soften hard materials such as Stellite, and performed reliably enough to permit unattended turning of superalloys.

Controlling Heat, Managing Chips Such gains stem mainly from better control of heat and chip 34

metalworking equipment news March 2011

Making Turning Difficult Materials

Easy The ability to turn difficult materials easily has wide ranging benefits. By Dr Moshe Goldberg marketing technical advisor and Rafi Rabouch, turning product manager, Iscar formation in these gummy, longchipping nickel and cobalt-based alloys, made possible through advanced insert design.

Even without HPC, the driving strategy in insert design for these materials is to provide a very sharp edge, slippery, heat resistant coatings and aggressive chipbreakers.

That combination quickly breaks up the chip and propels it away from the insert and cutting zone before it can adhere to the cutting edge, overheat the insert or clutter up the tool-workpiece interface with chips that create recutting conditions.

Chips can be much harder and more brittle than the base metal, compounding the damage caused by recutting. With HPC in the picture, coolant (boiling point 350 deg C) remains in the liquid phase, thereby maintaining its lubricity, cooling power and chip-flushing capacity.

Moreover, the flow rate under true HPC conditions is high enough to create a ‘hydraulic

wedge’ in the cutting zone, significantly reducing friction and all its consequences.

Tools For The Times There are technologies in tooling that makes turning difficult materials less difficult. Inserts that bring high-positive, helical-edge, high-feed and double-sided benefits to turning of stainless steel, nickel based alloys and titanium usually feature sharp edge and aggressive chipformers that make a difference in gummy materials.

The helical edge creates a more gentle entry and exit and helps reduce breakout at those points in a cut. Throughput and edge life aside, their high rake angle has also proven to reduce power requirements by 10 percent.

Unlike most ceramic inserts, a particular whiskered ceramic grade handles roughing, semi-finishing cuts on superalloys. The extrahard basic alumina insert provides extreme wear resistance in hard materials, and the SiC whiskers add the shock resistance.

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HPC is well proven among the aerospace, powergen and turbomachinery industries

The insert can withstand machining heat well enough to last at speeds that soften the metal in the cutting zone.

Turbomachinery manufacturers report substantial improvements with the IW7 over other ceramics in Inconel 718 and Waspalloy.

Turn Up The Pressure While many have all heard about the promise of high pressure coolant (HPC) machining, they may have shied away from it because of the added equipment cost and uncertainties of an ‘untried’ technology.

A look at the se issue s reveal that the technique is well proven among the aerospace, powergen and turbomachinery industries. On one ha nd, experienced practitioners report two and three -fold gains in machining rate with no loss in edge life. Others mainly concerned about edge life, report up to sevenfold improvements at equal removal rates.

These are actual results on ID and OD work on titanium and Inconel turbomachinery parts, titanium airframe parts and a variety of stainless steel components.

As far as the notion of added equipment cost and availability is concerned, this was true in the early years, but not now. When

first introduced in the ‘50s, there were no spindles fast enough or coolant pumps powerful enough to make the process workable on the shop floor.

However, today most machine tool providers routinely offer optional high-speed spindles and high-pressure pumps. High speed machining is more the norm than the exception in industries that must contend with stainless steel and superalloys.

HPC-Ready Tooling Now ‘HPC-ready’ tooling has become more widely available.

While providing the geometries

and physical properties tailored to particular difficult-to-machine materials, true HPC tooling also features the means to deliver coolant through the tool and discharges it in a tight, laserlike stream, aimed directly into the cutting and secondary shear zones.

This is critical because at the zones, it cools, lubricates, creates the hydraulic wedge effect and quenches the chips so they break up into compact, manageable curls. On its passage from reservoir to cutting zone, the coolant also lowers the temperature of tool and insert.

True HPC tooling is specifically designed for 70-300 bar pressures.

They are important for optimal performance.

They can pinpoint the stream as it leaves the tool and in addition, the orifice diameter in HPC delivers the correct pressure at the exit point. It is like the difference between true power washing and spraying with a garden hose.

Better answers, including today’s HPC machining, are more readily available. Solutions for handling difficult-to -machine materials can improve your productivity in a big way.

Enquiry No. 2005

Benefiting From Experience Here are some tips from experienced HPC practitioners.

• Use carbide tooling. Ceramic and CBN tools do not deliver the same degree of improvement in the HPC realm.

• Direct the coolant through the tool. Do not take a ‘flood coolant approach’ with a HPC coolant stream.

• If more cooling power is needed, (ie: the coolant is vaporising or chips are not flushing well enough) turn up the flow rate, not the pressure. This way is far more cost effective.

• For coolant requirements, a good rule of thumb is 0.5 gpm/horsepower. For example, a cut requiring 10 hp will need 5 gpm to achieve the high pressure effect. MEN

Enquiry No. 2006

March 2011 metalworking equipment news

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Providing for

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

Years in the Making

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

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

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

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

Setting Solid Edge apart from other

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

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

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

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

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

In Solid Edge ST3, both synchronous and

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

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

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

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

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

www.equipment-news.com

Three weeks of design… all done in a day?

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

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

Experience in person how Solid Edge has fulfilled the vision of synchronous technology with the release of ST3. Current and future Solid Edge users are welcome. Join a Solid Edge ST 3 launch and Design competition on 15th March 2011, Tuesday, 0900-1500 in Marina Mandarin Singapore. Call ECSS at phone No: +65 6295 3566 or email: sales@ecss.com.sg

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

ENQUIRY NO 042 March 2011 metalworking equipment news

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Getting A Slice

Productivity Pie Only getting the job done is officially out. In today’s ultra competitive manufacturing arena, productivity is key, and cutting tools that improve productivity are the stars.

By Michael E Neumann

I

n machining, cutting tools are called upon to remove material from the part in question. In the market today, there are many cutting tools, which serve different purposes.

From turning to milling, cutting tools can operate under single point or multi point contacts. A typical example of single point contact sees a turning operation on a lathe.

In addition to the point of contact, factors like geometry, hardness and the ability for a cutting tool to withstand heat are also important considerations.

Hardness of a cutting tool is directly related to the material of the tool. Tool steels – low end, low cost equal low tool life. HSS provides better hardness and wear resistance. Cobalt upon HSS results in cutting speed 25 percent higher.

During machining, the power introduced often finds itself generated into heat energy. A cutting tool compresses the metal directly in contact in front of it. This eventually results in deformation and shearing of the metal. Chips are produced. They are continuous,

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discontinuous and continuous with a built-up edge.

Combination Tools The ability to cut in a productive manner may be a plus in the days gone by; it has become an absolute essential in order to stay competitive in today’s manufacturing climate. For certain cutting operations, special tools are required. They are often designed to cover several different machining steps. As such, they are optimised for the required machining process in order to guarantee the best conditions for a precise, economical high volume production of precision parts.

Inline with improving productivity, it can be achieved by reducing the number of tool changes, giving rise to combination tools as sensible alternatives to special tools. In addition, the repeated setting of subsequent tools increases the quality of the work pieces being machined. The distinguishing feature is that several machining operations are integrated in one single tool.

According to Mikron Tool, such cutting tools guarantee process reliability and are first choice to achieve significant cost savings in production. With an optimal design of the cutting tools, a reduction of the costs per piece of 30 percent and more can be achieved.

A productive tool solution is more beneficial compared to the savings made with a cheap solution. In order to assure an advantageous price/performance ratio, it is important for the tool manufacturer to make special cutting tools in minimum batch sizes of 5 to 10 tools.

Shape & Coating Rule The geometry of a cutting tool is also a factor in productivity, particularly for inserts. Central to a high feed is the lead angle. In Ingersoll’s SP6H/SP6N S-Max face mills, high-feed is made possible by a 80 deg lead angle for a (5x) chip thinning factor.

Staying with cutting, in band sawing, the push for productivity is in evident as well. According to a paper by Chuck Wahr, director of marketing, (band

SocjosenPG, Poland

Of The

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saw blades and fluids) Lenox, the proliferation of exotic, hard-tocut metals have forced band saw blade manufacturers to develop longer lasting blades that will not only cut through these tougher materials, but cut through them quickly. The need for longer lasting, fast and precise cutting band saw blades has never been more imperative.

Coating in this case is the answer. Band saw blade manufacturers initially did not enjoy good success when they tried to transfer the coating process used for tools to band saw blades. One of the issues involves achieving an even and consistent protective layer.

This requires more surface preparation and without it eventually results in the blade’s s p e e d a nd accuracy being compromised.

Coating allows band saw blades to last longer, cut faster and with more precision

Cory LaFlamme, Canada

Multi Sigma 8x24 Multispindle automatic lathe with parallel numerical control.

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ENQUIRY NO 026

A HIGH OUTPUT SOLUTION FOR YOUR MOST DEMANDING AUTOMOTIVE APPLICATIONS - UP TO 30 ppm

March 2011 metalworking equipment news

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An AlTin coated carbide blade from Lenox called Armor CT Black is an example of blades that deliver the performance that band saw operators need.

This blade has allowed band saw operators to realise productivity in var ying applications. For example, traditional blades typically cut a 6-inch round

of 17-4PH in approximately 25 minutes. The blade allows users to accomplish this same cut in 40 to 50 seconds. This type of performance advantage has fundamentally changed the way some steel ser vice centres operate. MEN Enquiry No. 2007

Electromagnetic Fields As Cutting Tools

Ivan Ivanov

They also found that simply coating existing tooth geometries does not guarantee success.

To take full advantage of the benefits offered by coatings, manufacturers must design tooth forms, which support coatings and maximise their benefit in each application.

For instance, if the blade does not have the beam strength necessary to support an aggressive feed rate, then a well-coated tooth form will not demonstrate any benefit. Beam strength is directly correlated to gullet size and shape. Balancing the relationship between coatings and sawing dynamics is crucial to realising a blade’s true benefit.

With the emergence of 3D CAD software programs, refining tooth geometr y is nowhere near as difficult as it once was.

The time and cost with fieldtesting of prototypes is virtually eliminated and the virtual results are reliable as well.

The tester can estimate chip loads, mechanical stresses, thermal distribution and chip morphology before the design is prototyped, then Finite Element Analysis (FEA) technology can simulate the stresses that a blade might encounter during the cut. Engineers are using these new tools to perfect the ability to manufacture tooth forms, which work with coatings to enhance the durability and life of the cutting edge.

After creating a tooth form capable of supporting the benefits of a coating, then it must actually be coated. Careful attention to chemistry, blade preparation, application technique and fixturing has made second-generation coatings truly beneficial to the performance of a band saw blade.

Coatings now bond with the tooth edge, protecting the teeth from heat and abrasion so that blades can endure higher speed and feed rates and last much longer than ever before.

www.equipment-news.com

The demand for stable bodywork for vehicles has resulted in the usage of high-strength steels.

Processing these steels have posed quite a challenge and as a result, opened the door to a new steel-cutting process.

By Fraunhofer

The high strength of the steels that are used in the automotive industry, though effective in protecting the passengers in an event of an accident, has thrown up challenges in machining. For example, when automobile manufacturers have to punch holes in them for cable routing.

One possible alternative is to use lasers as cutters, but they require a great deal of energy, which makes the entire process time-consuming and costly.

Working together with a number of partners including Volkswagen, researchers at the Fraunhofer Institute for Machine Tools and Forming Technology IWU in Chemnitz have come up with another way to make holes in press-hardened steel bodywork. Dr Verena Kräusel, head of department at the IWU, explains: “The new method is based on Electromagnetic Pulse Technology (EMPT), which was previously used primarily to expand or neck aluminium tubes. We’ve modified it to cut even hard steels. Whereas a laser takes around 1.4 seconds to cut a hole, EMPT can do the job in approximately 200 milliseconds – our method is up to seven times faster.”

Apart from speed, another advantage is that the process produces no burr. As a result, there is no need for a finishing process. Stamping presses become obsolete.

The pulse generators comprise a coil, a capacitor battery, a charging device and high-current switches. When the switch closes, the capacitors discharge via the coil within a matter of microseconds, producing a high pulsed current.

The coil converts the energy stored in the capacitors into magnetic energy.

To be able to use this process to cut steel, the researchers had to modify the coil to ensure the resulting electromagnetic field is strong enough: the pressure with which the field hits the steel must be so high that it forcibly expels the material from the sheet. “The impact pressure on the steel is approximately 3,500 bar, which equates to the weight of three small cars on a single fingernail,” says Dr Kräusel. MEN

Enquiry No. 2008

technology

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Gear Lubrication:

Insights

Tonic ‘Heart’ For The

Good lubrication is essential for gearboxes as they prevent a condition known as micropitting. By Michael J Hawkins, global brand manager, ExxonMobil Lubricants & Specialties

G

earboxes deliver a vital source of power transmission and, for many industrial businesses, represent the heart of production. Today, advancements in technology have enabled designers to decrease the footprint of gearboxes while maintaining the same – or even higher – power transmission capabilities.

Compared to previous models, these newer, high performance units typically require lubricants that offer more comprehensive protection. If a gearbox is not properly maintained with the appropriate lubricant, there is the potential for the ‘heart’ to break, or experience a condition known as micropitting.

Common Symptoms A common sign of inadequate gear lubrication, micropitting is surface fatigue that is mainly observed in gears. That however, can also occur in rolling element bearings.

Micropitting causes destructive wear that can occur within the first few hours of operation. If left uncontrolled, it can cause a reduction in gear tooth profile accuracy, gear breakage and, over time, lead to system failure.

Micropitting on gears may not only lead to problems with gears, but with bearings and seals as well.

The main concern with micropitting is that this wear – which is often overlooked – can cause the shape of the gear teeth to change. To this end, it is critical that a company select a gear lubricant that can supply long-lasting protection for all the components.

The Smooth Remedy The selection of the appropriate viscosity grade is the first and most important step in choosing a lubricant. Under extreme conditions, simply increasing the ISO viscosity grade of the oil is not necessarily preferred. Instead, choose a highperformance synthetic lubricant that features a balanced formulation and is designed to deliver long-lasting wear and corrosion protection.

In addition, look for a product that has been endorsed by major gearbox OEMs and meets the industr y’s most demanding specifications, such as DIN 51517 Part 3 and AGMA 9005 E02.

For example, Mobilgear SHC XMP Series lubricants are designed to provide equipment protection, oil life and problem-free operation.

The combination of premium synthetic base fluids, a naturally high viscosity index and additive system help the lubricants deliver good performance under severe high and low-temperature operating conditions.

Additionally, the synthetic base stocks have inherently low traction properties that result in low fluid friction in the load zone of nonconforming surfaces, reducing fluid friction which produces lower operating temperatures and promotes improved gear efficiency.

Finally, they have good EP, oxidation and thermal properties and resistance to shock loading, all of which can enhance gearbox p e r f o r m a n c e a n d i m p ro v e productivity – and promote longer life for the ‘heart’ of your facility. MEN Enquiry No. 2101 March 2011 metalworking equipment news

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Greener Look At

Machining Fluids

M o r e t h a n e v e r, environmentally friendly and cost effective ways of producing work are being searched for, both in machine shops and research laboratories.

The need is immediate a n d g o v e r n m e nt a l policy is being drawn up to reward the environmentally conscious and penalise those that are not.

By Mark Johnston

M

achining is a dynamic process that generates heat and disturbances on a work surface. Specially formulated fluids are used to cool the tool and the work surface, so further distortions of the workpiece do not occur.

Cutting fluids are divided into four categories, straight, soluble, semi-synthetic and synthetic. Each has its own advantages and uses; for example, straight oils have the poorest cooling characteristics of all four fluids but has the best lubrication properties.

Soluble oil are widely used in varied industries as they are the least expensive but provide good lubrication and heat performance. Semisynthetic fluids in terms of cost and heat transfer performance lie between soluble oil and synthetic fluids. Overall, 42

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Piskedi, Turkey

synthetic fluids provide the best cooling performance of all the fluids.

The Choice Of Coolant A coolant has different purposes and the correct choice in coolant selection should be made depending on the nature of the machining operation. A more oil based coolant would be better suited at low cutting speeds, and a more water based cooling fluid would be more appropriate at higher cutting speeds.

Other important functions of a cooling fluid are to flush chips away from the work surface and protect it from corrosion.

The effects of choosing the right coolant for a machining operation are that the tool will have a longer life and the workpiece will have reduced thermal deformation from the heat generated by the machining process. In some applications, a better surface

finish can also be expected with ease of chip and swarf handling.

Vegetable-based raw materials are considered the greenest choice for coolants, but have several problems which need to be addressed for wide spread adoption as a green coolant. They offer better lubricity than mineral based but are more affected by sump life issues. They also have issues with availability, volatility and seasonality of supply. As well as oxidation instability, biological issues and societal concerns surround genetically modified vegetable sources.

Biological growth is also a problem which vegetable based oils may be more prone to. So, although a vegetable based oil may have started out as a green alternative, the end result when it comes to disposal or reuse is not. Green coolants are normally used in concentrated form and delivered to work surface in very small amounts.

In conventional coolant use, the cost is considered 15 percent that of the life-cycle operational cost of the machining process. Breaking this down, costs associated with procurement, filtration, separation and disposal of the machining fluid can be seen. Traditionally, the disposal cost is seen, in many circumstances, as higher than the initial coolant procurement.

Minimum Quantity Lubricant (MQL) is seen as a solution in saving overall cost and contributing to a greener process by using less coolant more effectively in the machining process.

Minimum Quantity For Maximum Quality MQL, as the name suggests, is all about using the minimum quantity of lubricant to achieve comparable results to traditional coolant delivery methods. The result of this being much lower coolant costs with a greater environmental impact while increasing safety for

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Alternative Comparison As discussed earlier, implementing MQL in a machining operation increases tool life and surface

finish. This is achieved through abolishing silicon particle content in the coolant.

In the case of aluminium, where 13 percent contains silicon, and comparing this to a wet machining operation, filtration is only effective to a point. Only particles larger than 40-micron in size are removed, while those particles smaller than 40-microns are allowed to pass through into the system to get recycled with the coolant.

Changing the order of machining operations can have a significant affect on improving the production of heat during the machining process relaxing the expected requirement of the coolant. In the traditional wet machining method, roughing happens first followed by finishing.

In MQL, this process is very optimised, reducing roughing to what is essential to distress the part. This method means the part can then be finished before the workpiece heats up.

Solving Problems By using less coolant during the machining operation a number of issues arise, related to heat, tool life and chip removal, which need to be addressed for an effective system to operate. In the case of heat dissipation, a coolant is normally required as an effective means to dissipate the heat, so a different approach is needed.

So for MQL to work effectively, a number of system modifications need to be made based around this concept. An appropriately designed tool with lubricant ducts and fine grain control over the oil/air mixture will not affect part quality and perform better than wet machining. The system can provide an economical and ecological alternative to wet machining, where usage of such systems are increasing. MEN Enquiry No. 2102

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machine operators.

A surprising facet of MQL is it enables a greater tool life and a better surface finish than wet machining, despite wet machining being deployed for better results in these two same areas. The reason why it achieves better results than wet machining is two fold, one being you can set the specific coolant amount needed for the machining operation being used, be it milling, drilling, or cutting and two, contamination of silicon particles in the cutting fluid can be avoided and as a result, better surface finish in the workpiece is observed.

In an MQL designed system, it is possible to deliver precise amounts of lubrication to the tool bit and workpiece allowing targeted optimisation for each machining operation. This is important as it saves costs, has a positive environmental impact and is safer for machine operators as less lubrication is used and it is optimised for each machining operation in use.

The lubricant is sprayed onto the surface being worked by mixing oil with air. This is difficult initially as demixing was done at higher speeds. This problem however has been resolved and modern systems are now as effective as wet operations at maintaining lubricity.

The short distance between where the oil/air mixture exists and the cutting surface enables optimal cooling and lubrication in the machining operation. In a process where several holes need to be machined, the coolant spray is switched off between operations. Through the optimal use of coolant application, the swarf that is generated through the machining operation stays dry.

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Metrology

Virtual Reality:

Machine Tool Simulation

At Its Best

The most important thing in simulation is whether what is seen on the computer screen in the digital world is the same in the real world. By Vynce Paradise, marketing director, NX CAM, Siemens PLM Software

I

n the drive to become more efficient and, as a hoped-for result, win new business, more and more shops are investing in advanced machine tools. Whether it is simply to perfect their already existing capabilities or to add to their portfolio by machining more complex, high value parts, the demand is there, and the advanced nature of these machine tools can make machine tool simulation a real necessity for the NC programmer, not just useful as a program validation tool.

W hile the evolution of machining simulation has resulted in most CAM systems now offering some simulation capability, it is safe to say that not all systems were created equal. They do 44

metalworking equipment news March 2011

not all operate in quite the same way and the difference can be important when the programmer really needs to be sure that what he or she sees happening in the digital world will actually happen on the machine tool.

As the old saying goes, ‘the right tool for the right job’ and in order to ensure that you have the right process for the job at hand, it is important to understand the differences in machine tool simulation.

The Basic Level What CAM systems have done for years – and still do today – is the most basic level of simulation, known as ‘tool path verification’.

This drives a representation of the

cutting tool over a 3D representation (model) of the stock material to verify the tool path relative to the stock. Tool path verification can be done without any representation of the machine tool present.

In standard milling or turning operations, this level of validation of the intended tool path is often more than adequate. With automatic material removal options selected, the speed of today’s PCs coupled with advances in software algorithms can make this level of tool path verification look quite impressive. It does the job of proving out the internal tool path. The user can simply read the internal definition of the tool path that specifies exactly where the tool is relative to the surface being machined.

Getting The Whole Picture When the machine tools become more advanced, with multiple degrees of freedom in their basic motion or with multi-tasking capabilities, a different simulation becomes necessary.

It needs to understand and to show what the proposed tool path data will do once the controller and the machine tool see it, so that we can see the motion of the machine tool as a complete system and not just the motion of the cutting tool relative to the stock.

The most basic capability for any CAM vendor to create is software that looks at the internal tool path definition, very similar to that used for basic tool path verification. This is known as ‘internal tool path-driven machine tool simulation’ and the software turns this into a form of generic motion output that is linked to the axes of a 3D machine tool software (CAD) model.

This approach is fairly easy and, more importantly, it can be relatively generic. At this stage in the software chain, the

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motion definitions are relatively independent from the make and model of the final target machine tool and controller, and most CAM vendors will likely utilise a generic third-party plug-in application that takes care of the 3D kinematics and motion display to build out their machine tool simulation solutions.

The Post Processor Effect Putting it mildly, the post processor is an important part of the overall CNC system and, in most cases, the only way post processors pass on their data to the machine tool controller is by way of the well known ‘G and M codes’.

The issue here is that at one level, G and M codes are standardised and universal. However, like all standards, they become extended and interpreted in many different ways by each controller maker and machine tool builder.

Since in most ca se s t he controller only has these codes and the attached numerical values associated with them, the exact way in which the codes are interpreted is crucial.

If the system is to simulate the motion of the machine tool properly or completely, it needs to read from the output of the post processor (the data that is sent to the controller). For a job of this magnitude, the software that deals with internal tool path-based simulation drivers is simply not advanced enough.

G-Code Driven Machine Tool Simulation Needless to say, in order to provide a simulation that is driven by the output of the post processor, the system needs software that is able to interpret the G and M codes as well as other controller specific commands and associated data fields. In doing so, it turns the information into corresponding motion inputs for each axis or controllable device on the machine tool.

Automate offline CMM programming by working in the context of a 3D solid model environment that includes the machine and the part

To be able to do this, detailed knowledge of the specific target machine tool and controller is necessary, even down to the expected target configuration of that machine for a specific customer.

This is effectively a reverse engineering of what the post processor created, ideally done in the same way that the machine tool controller does this task. The outcome is a 3D simulation that is driven by the same G and M codes that will go to the machine tool to cut the real part.

The post processor may also add other actions that it deems as logical, but was not present at the earlier internal tool path stage and this software can also see those actions.

What results out of this is a more realistic, more complete simulation of what the machine tool will actually do. In the confined, complex environments of ma ny adva nced machine tools, especially those with true, simultaneous multi-tasking capabilities, this is critical.

There are ways in which you can check if your CAM system is capable of doing G-code driven machine tool simulation. One test is to see if it has any capability to read in and simulate an NC program from an external source, for example,

one that was created or modified by hand, or from the machine tool, and written in G and M codes.

If successful, it means that your system has the ability to reverse engineer these codes for the given machine and controller and is therefore capable of doing G-code driven machine tool simulation – at least for the target machine considered in the test.

More generally CAM packages that offer G-code driven simulation will usually display the G-code data in a scrolling window, line by line as the simulation is running.

In terms of standalone software packages that offer late stage validation of the G and M codes, there are some very good ones out in the market.

These software solutions can read in the output from the CAM systems and use the data in exactly the manner you need. While many machine shops have invested in them, the downside of this type of external machine tool simulation software is that it requires an investment over and above what you have already paid for your CAM software. Also, it generally means that the 3D models of machines, tools and fixtures and of the stock and the part itself have to be copied from the CAM system and duplicated in the standalone simulation package.

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NX CMM Inspection Programming is complete with simulation and collision avoidance to help you validate CMM programming decisions

Getting It Right Beyond cost, there are other issues that arise from using separate applications for G-code driven simulation as an add-on to your CAM system. For example, when it comes to synchronising the separate elements of multi-channel machine tools, the programmer will want to see exactly where key elements of the machine tool, tool holders and cutting tools will be at any given instance.

This is especially the case at the stage where the programmer is using the software to add ‘wait’ and ‘sync’ codes to the program operation sequence. These codes that manage the multiple machining sequences like traffic signals controlling the flow of cars at a busy intersection are critical in ensuring that multi-tasking machines do not become ‘multi-collision’ machines.

For synchronisation to be reliable precision is a necessity and exact times per operation or NC block are mandatory.

The system needs to be able to calculate the exact times and exact representation of the controller capabilities, along with the axis parameters (acceleration, maximum speed, jerk limits and exact stop windows) and a generic 46

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machine tool simulation can only provide rough values. These are far from sufficient when we are looking at fast moving equipment and tiny clearances, where a programmer is utilising the full machine tool capabilities.

Some programmers will add these ‘sync and wait’ codes by hand to the output of their CAM systems post processors and then use their external, third-party machine tool simulation packages to test the whole thing.

Of course, if they see issues they either have to do some local, manual editing of the G and M codes or they go back into their CAM systems and run through the sequence again, on a kind of trial and error basis.

Ideally, shops should have all of that capability available inside the CAM system when the programmer is synchronising the overall set of operations.

In fact, what is ideally required is the complete integration of the post processor capability with internal ‘G-code driven’ machine tool simulation. Having that combination linked directly to the synchronisation functions inside the CAM system means that the NC programmer has it all at their fingertips in the same software.

The Next Step There is no denying that G and M code-driven simulation is a big improvement from basic internal tool path driven simulation, however, it is still dependant on how well the software interprets those codes and what motion algorithms are applied to try and match what the machine controller and machine tool will do with them.

T h e wo rd ‘si mu l a t io n’ encapsulates what we want to achieve, which is to realistically copy exactly what the machine tool controller will do with these G and M codes and the attached data fields. What is important to remember is that all controllers have software inside their boxes –

sophisticated algorithms used to interpret data coming at them from CAM package post processors – and no two controllers are exactly alike in this area.

If you really want to simulate the true motion of the machine tool, you need to have a good way of replicating what the specific controller software will do with a given sequence of G and M codes. In order to do that, you would obtain a version of the software that is in the real machine tool controller and then plug that into the machine tool simulation package.

In that way, software from the controller manufacture can be used to interpret the G and M codes in the virtual, digital world of the CAM system. This would deliver ‘controller driven machine tool simulation’. In fact, for both the CAM system or for the shop floor based simulator, controller driven simulation can take machine tool simulation to a whole new level of completeness and accuracy.

In Summary A CAM software package may have the coolest looking 3D simulation, complete with metallic and reflective surfaces on 3D models.

However, what is important is whether what is seen on the computer screen in the digital world is the same as what will really happen when the start button is pressed on the real machine.

To deliver the best results, most advanced machine tools may need a G-code driver in the CAM system’s internal machine tool simulator.

To maximise the value of a machine tool investment, ‘controller driven simulation’ is no longer an option, but a necessity, whether it is inside your CAM system for your programming task or out on the shop floor inside a standalone machine tool simulator for the ultimate in virtual machine tool prove out. MEN Enquiry No. 2201

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How

Hardware

Developments Affect

CAM Software

Performance

There are many ways in which the latest hardware developments can help CAM users to be more productive. By Peter Dickin, marketing manager, Delcam

W

ith most new releases of CAM software, the developer will focus on the latest machining strategies that are available in the system. Over the past two years, however, promotional material for new versions has been full of claims about the ability to support the latest hardware developments, such as parallel processing and multi-threading.

The key change in computer hardware has been the move from single-processor computers to multiprocessor equipment. After many years of steadily increasing processor speeds, there has been a step change in processing power through the much wider introduction of multi-processor equipment. Many laptops for home use now come with dual processors, while equipment for commercial use will often include four, eight or even more processors.

As with all computer developments, the increased number of processors has come alongside continuing falls in the price of the equipment. Computing power that would have been impossibly expensive 10 years ago is now very affordable even for smaller companies.

Benefits Of Multiple Processors There are two main benefits from multi-processor computers; background processing and parallel processing (also called multi-threading). Background processing allows the user to prepare, simulate or edit one toolpath in the foreground, while simultaneously calculating other toolpaths in the background. In fact, this technology can work on any hardware but the 48

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benefits are only really apparent on multi-processor equipment.

The ability to prepare data in the foreground while calculating toolpaths in the background eliminates the need for the user to wait for each calculation to be completed before preparation work can start on the next operation. For example, it is no longer necessary to wait for a complete roughing path to be produced before work starts on programming the rest-roughing operation. Similarly, the user can be setting the parameters needed to machine one area of a part, while toolpaths are being calculated in the background for machining a second area with a different strategy.

Productivity is also increased because the computer can continue with a series of calculations during the user’s breaks or even overnight.

Calculations can be queued by the operator and the software will automatically start the next operation as soon as each toolpath is generated. This approach can be also used with single-processor equipment but the benefits are again much greater with computers having two or more processors.

With parallel processing, the computer can perform different parts of a single complex calculation at the same time. Essentially, this divides the processing of this operation over all of the processors in the CPU chip. Clearly, this ‘spreading the load’ between multiple processors allows calculation times to be reduced significantly.

The extent of the savings will depend on the size and complexity of the part being machined and on the

programming strategies being used. Tests at Delcam indicate that a dual core computer will perform raster machining calculations in around 55 percent of the time taken by a single core machine. A quad core machine will complete the calculation in around 35 percent of the time and an eight-core machine in around 25 percent of the time.

The ultimate benefit comes from applying both these technologies at the same time, with parallel processing being used for both the foreground and background operations.

It might be expected that the benefits would continue to increase exponentially as more and more processors are added to the computer but this is not the case. This is because the computer must use some of its capacity to manage the allocation of the different parts of the calculation between the different processors. This process becomes more complex, and so takes more capacity, as the number of processors increases.

The optimum number of processors for most machining calculations will be eight.

Coping With Complexity There are, of course, obvious benefits in being able to reduce calculation times and waiting times. User productivity can be increased significantly, reducing any downtime where machine tools are waiting for NC data and minimising lead times. These benefits are most important for companies that are using the latest generation of machine tools, like five-axis machines and mill-turn equipment.

For both types of equipment, the main advantage is the ability to complete the manufacture of more complex parts in a single operation. With a five-axis machine, this is possible because of the ability to change the angle of approach of the cutting tool, for example, when machining undercuts or drilling holes at a series of different angles. With a turn-mill machine, operations can be carried out on a single piece of equipment that would otherwise need a series of lathes and mills.

The ability to produce parts in one operation obviously saves time compared to performing the job in a series of set-ups. Labour costs can be reduced because there is no need to relocate the part on the machine or to transfer it between different machines.

In many cases, multiple set-ups means multiple fixtures so moving to a single set-up reduces the time and cost of making fixtures. Furthermore, with multiple set-ups, there is always a possibility of incorrect alignment each time the part is moved. By machining parts in a single set-up, there are fewer opportunities for error, so quality and consistency should improve.

The problem with this more advanced equipment

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is that calculating toolpaths for their operation is more complicated than for simple lathes or threeaxis machines. Not only are there more options to consider but the software will need to undertake more comprehensive checking to ensure that collisions will not occur.

For example, many CAM systems now include some sort of automatic collision avoidance during five-axis machining. The software will change the tool axis automatically when collisions might occur, tilting the cutter away from the obstacle by the specified tolerance and then returning the cutting angle to the value set for the overall toolpath once the obstacle has been cleared.

More sophisticated systems will even incorporate a look-ahead distance as part of this capability in order to ensure a smooth transition when toolaxis changes are required. This all involves extra calculation and checking, making the extra speed of modern hardware an even bigger benefit.

Stock Models Another intensive computation involves the production of stock models during the overall machining process. Of course, all CAM systems require the user to describe the shape of the stock at the start of the operation and most allow arbitrary shapes to be used, for example when finish machining a casting.

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The most detailed simulations can predict the surface quality in the final part

The complexity of the latest mill-turn machines makes simulation essential to ensure safe operation on the machine

The latest CAM software produces a model of the material still remaining on the part as each machining stage is completed. They can be used by the system to ensure that the cutter is never asked to remove more material than it can safely cut. At the same time, the stock models also ensure that toolpaths are not produced where there is no material remaining so the machine tool is never left cutting air.

The options to optimise tool loading will help overcome a constant conflict for programmers. On the one hand, they want to maximise productivity by setting feed-rates as fast as their machines will allow; on the other hand, they need to ensure safe speeds that will not break the tool. The need for safe machining has, of course, become more critical as a growing number of companies are introducing lights-out, unmanned operation overnight or during weekends.

Simulation Work As mentioned above, the ability to undertake background processing means that tasks that might have been considered too time-consuming ca n now be completed in the back ground, simultaneous with other programming work.

An important aspect of this capability is the ability to undertake more simulation of the machining process.

This aspect of programming has also benefited from the better quality of the graphics that can be provided in the latest computer hardware. These improvements 50

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have made it possible for software developers to generate accurate, three-dimensional models of a wide range of machine tools and to then simulate the complete machining process. It is even possible to give an indication of the surface quality of the part.

Being able to prove out the program on the computer gives a very high confidence that it will work successfully on the machine tool. Warnings are displayed whenever there is any possibility of a collision, either between the machine and the job or between any parts of the machine itself.

Any potential problems can be eliminated before the program is issued to the shop floor so minimising the chance of collisions during machining. It is, of course, much cheaper to find mistakes on the computer than on the machine tool, where there is a risk of scrapping the part, breaking the cutter or damaging the machine.

Providing Good Support This article has shown the many ways in which the latest hardware developments can help the CAM user to be more productive. As mentioned, despite the improved capabilities, computer hardware is still becoming cheaper than ever.

An investment of a few thousand dollars in a better CAM system and the hardware to allow it to operate at its peak efficiency can give huge benefits to companies, especially those using more sophisticated machine tools. MEN Enquiry No. 2202

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Opinions:

Michael Campbell

The Future Of

Manufacturing, Product Design Design Tools

&

In Asia

The development of CAD tools has to keep pace with the growth of the metalworking industry in Asia. By Michael Campbell, divisional VP, Creo product development, PTC

M

ost analysts agree that the metalworking industries in Asia can look forward to continued growth in the coming years – especially those that provide high-value, high-precision work. These companies are gaining experience, investing in automated processes, and becoming adept at manufacturing complex products.

I predict this trend towards improved production methods will lead to still another trend: As Asian companies become more competitive at pumping out goods for others, they will also become better positioned to develop products of their own.

That is not just because Asia is building up the capacity to produce sophisticated products; it is also building up the talent.

Schools a re producing a generation of designers throughout Asia. For example, China produces at least twice as many engineers

as the US annually, and that number is growing. Some of these new designers study for two-year vocational engineering degrees, others receive alternative technical certificates, and some have obtained four-year degrees equal to those for engineers in the United States and Europe.

Asian manufacturers who typically work with designs and 3D data from the US, Europe, and Japan, can now find design professionals in their own backyard.

S c h o o l e d d e si g n e r s a r e not the only skilled workers manufacturers might tap for product development. Another source of talent is the technical wo r ke r s w h o h av e h e lp e d automate manufacturing recently.

While these people have typically been experts in manufacturing, they could provide valuable skills upfront in product design too.

A sia’s re su lt ing pro duc t development teams will have

As Asian companies become more competitive at pumping out goods for others, they will also become better positioned to develop products of their own.

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a mix of skills, experience, and needs. You might find companies with handful of experienced skilled design engineers, some with the skills but little practical ex perience, a nd some w ith significant experience, but lacking deep design skills.

S o h ow w i l l C A D to o l s complement these new teams and businesses? Typically, companies end up with a patchwork of CAD tools to address diverse team needs and skills. We have often seen a single company deploy 2D, 3D direct, and 3D parametric tools from multiple vendors at once.

I n e v i t a b l y, t h e s e t o o l s introduce new headaches for the company, like IP management and interoperability challenges.

And of course, all those software suppliers and applications need to be supported by IT, increasing cost and complexity.

With that, I would like to offer one final prediction for product development: As manufacturing becomes more diverse a nd sophisticated, we will see its software become less complicated, offering true multi-paradigm design modes that let users design in 2D, 3D direct, or 3D parametric seamlessly. MEN Enquiry No. 2203

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

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Form

A

Stamp Of Approval

The production world sees an increase in part orders as the manufacturing sector grows and important industry drivers like automotive and aerospace require precision on a mass scale. By Mark Johnston

T

here are four operations associated with stamping, ie: blanking, piercing, forming and drawing. Their objective, to give the exact shape and parameters to metal products.

This is critical for precision industries with tight fitting parts.

Once the metal is inserted into the machine, it is moulded into the exact shape pre-determined by the customer beforehand, by submitting a schematic of the defined shape. It is possible that a client does not know what their final product will look like, and may produce a vague idea of its purpose. However, the majority of metal stamping producers have designing capabilities to aid in the final product design requirements.

The Defined Categories The application range of metal stamping machines is impressive given a fairly targeted operational construct. With manual and computerised operations available today, the speeds and capabilities produced by these machines allow the construction of simple geometries and highly complex shapes. The range becomes wide along with price points to match.

There are two categories for metal stamping machines, mechanical and hydraulic. In a mechanical press the energy is stored in a mechanical flywheel, which is transferred to the punch and then to the workpiece. The presses range from 20 tonnes to 6,000 tonnes in size and 5 to 500 mm in strokes, with 20 to 1,500 strokes per minute in speed. They are tailored more for high-speed blanking, shallow drawing and the manufacture of precision parts.

In the case of the hydraulic press, the energy is delivered through hydraulic means. Hydraulic presses

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can range from 20 to 10,000 tonnes with strokes varying from 10 mm to 800 mm. Some advantages of a hydraulic press is an ability to deliver full force at point in the stroke, another is variable tonnage with overload protection and also adjustable stroke and speed.

Applications for hydraulic presses are deep-drawing, compound die action, eg: blanking with forming or coining, low speed high tonnage blanking, and force forming rather than displacement forming.

Extending The Traditional Approach Metal stamping technology is seen as a natural extension of more traditional methods of machining like die casting, fabricating, and forging processes used in the past to mould and shape metals.

Modern stamping technology is considered more cost effective than comparative techniques for shaping and forming metals. Once the metal is stamped into its pre-determined shape, it can then be plated with nickel, tin, or another metallic element for protection against corrosion.

Turbulent Times For The Auto Sector The automotive industry where stamping is popularly used, has seen turbulent times in recent years. The American automotive market has seen a demand for light trucks and Sport Utility Vehicles (SUVs) go down hill as high petroleum cost and the environmentally conscious topped off economic woes in the face of a global recession. According to IBISWorld Industry Reports, the automotive market has seen its sales in the light-vehicle sector cut by 37.9 percent from 2007 to 2009, resulting in a steep decline of revenue.

Stamping technology in the auto sector caters to the modular nature of each vehicle, producing hubs,

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Stamping is critical for precision industries like the aerospace industry where tight fitting parts are required The automotive industry is an important driver for the stamping process

Andrei Dimofte, Aachen

Drivers Of Demand As mentioned, speed and efficiency are categories for advancements in stamping technology, as well as accuracy and agility of the stamping presses. Demand for presses follows demand in the market segments that use stamped products. In the case of the automotive sector, demand for stamping machines will follow demand for automotive vehicles.

The demand itself occurs through the combination of several macro-economic factors including population growth, consumer confidence, discretionary spends, interest rates, credit availability, employment and the price of fuel. The metal stamping industry as a whole has seen slow growth over the previous three decades, likely due to a lack of capital, a slow down of capitalisation, and reduction in labour productivity.

Looking ahead, slow growth is likely to continue in developed markets with the bigger companies indicating cutbacks over several locations.

Looking To The Future The market research report on automotive stampings indicates that as of 2009, 56 percent of the global market is held by Asia-Pacific and Europe. Showing market resilience, and looking ahead in the medium to long-term, the outlook for developing nations is seen as encouraging. The global industry in automotive stampings for developing nations will see the sharpest growth, with China especially, seeing the greatest gains.

In any market going through a turbulent period, companies need to innovate in the market either with direct relevance in a particular sector or innovating through several markets or segments. The issue with stamping technology is its pace of innovation and ultimately stamping companies need to be technology innovators, a low-cost producer, or assembler of mechanical or electrical components.

Nico Nelson, Sydney, Australia

Innovations of note in the stamping industry include substitution with low-grade materials, use of environment-friendly lubricants, laying out behaviour of alloys and metals when subjected to pressurisation (between the die and punch), use of alternate materials for both dies and component parts. Other innovations of note in the stamping sector include a new sheet metal stamping technologies that aim to improve accuracy of the stamped parts to less than 1 mm tolerances and a decrease in design, production and test time for sheet metal dies. MEN Enquiry No. 2301

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fenders, and internal drive components for new vehicles as well as the replacement of parts. The components produced from stamping are of great importance to the overall feel, look, integrity and the performance capacity of the vehicle.

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Focus

Swiss Turning For Medical Parts

4. Diagnostics (point- of- care testing instruments) 5. Wound care (staples, suture anchors, and clips) 6 . D e n t a l (e q u i p m e n t a n d implants) segments all have parts that can be efficiently and profitably machined on a Swiss turning centre Machining Processes Advanced applications focusing on special machining processes use Swiss turned parts and devices for the medical market.

Here are some excerpts.

In parts of Asia where the population is ageing, the medical device market has garnered more attention. With parts like stents, orthopedic devices and dental implants demanding more from machining processes, Swiss turning is making its mark with its accuracy and rigidity. By Philippe Charles, medical segment manager, Tornos

T

he ‘Swiss- ty pe’ lathe is known for its ‘sliding headstock’ style of lathe machining. It utilises a standard single-point lathe turning tool placed very close to a ‘guide bushing’. By feeding the material through the bushing and past the tool, rigidity is achieved throughout the turning process.

This allows for the machining of long, slender diameters with high efficiency because the cutting conditions are kept at a maximum regardless of the part length. Chatter and taper are largely eliminated, and in general, very tight tolerances can be held with customary ground barstock.

This method means, in general, all the material can be removed in a single pass. Depths of cut

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can be larger than one might think practical, but the rigidity of the Swiss-type process not only makes it possible, but efficient.

Machining Health The medical sector includes several segments. All of them can be served using Swiss turning machining processes. Here are some examples: 1. Inter ventional cardiolog y devices (stents, catheters, and surgical tools) 2. Orthopedic devices (bone screws, implants, and joint replacement) 3. Minimally invasive surgical dev ice s a nd equipment (laparoscopic devices)

• Machining PEEK PEEK (polytheretherketone) is not a traditiona l ba r stock material. It is a strong thermoplastic material with potential for a vast variety of different applications in the medical parts market.

Machining conventional medical grade PEEK requires carbide-cutting tools. However, carbon-fibre-reinforced PEEK takes diamond tools.

• Micro Machining Micro machining, another type of Swiss turning useful for medical parts, requires a proper mindset in terms of part and tool handling, inspection, and secondary operations. When micro machining medical parts, there are a few musts: 1. Machine accuracy: even with the best tooling, if your position locations are not accurate, you are fighting a losing battle. It is important to re-qualify your tool positions and update the database.

2. Run-out: run-out that might seem fine for a standard size part could likely spell disaster in micro machining.

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Ma in/pickoff collets a nd guidebush need to be ‘XP’ (extra precision). And ER style collets need ‘UP’ (ultra precision).

3. High frequency spindles: essential for drilling or milling tiny features into parts and achieving the desired finishes, accuracy and tool life. For example, drilling a 0.2 mm hole in stainless, you will need 11,500 rpm. But if the tool is TiN coated (Titanium nitride – a hard ceramic material often used as a non-toxic exterior for medical implants), you need 19,000 rpm.

S ome spi nd le s (suc h as those from IBAG, NSK, Mey rat a nd ot hers) ca n reach speeds in excess of 150 K. Spindles can be mounted various ways in the machine to me e t sp e ci f ic ne e d s.

These parts include features created with high frequency spindles and spindles that are mounted in holders.

to the final shape except that it is ground with clearance. The tool axis is typically inclined 1 deg from the work axis. As the broach rotates, it is pressed against the work. Due to the 1 deg incline, the leading edge of the tool ‘wobbles’ with respect to the work. Tornos offers these guidelines:

• Internal Broaching Another key machining process for medical parts manufacture is internal broaching. It is important to purchase the proper broaching tools.

I n prepa rat ion for t he broaching process, it is necessary to make a pilot hole. Depending on the configuration, it may be necessary to remove material for the corners with a small end mill.

A 90 deg chamfer on the hole is also necessary. This prevents t he point s from chipping upon entering the cut. It also allows the broach to follow the centreline. Depending on the chip size, deburring passes may be required.

• Rotary Broaching Wobble (or rotary) broaching uses a tool with a similar shape MTA 2011(S)_APMEN_Sept10 FA.indd 1

1. If the tool is inclined 1 deg, the sides of the tool must have a clearance angle of at least 1 deg.

2. Ideally, the tool advances at the same rate it cuts. For example, a 0.5” diameter tool should advance at 0.022 per rev. (1/2 x sin (1 deg) = feed)

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2. The setting gauge locates inserts at the proper angle prior to locking them into the head

Gun drilling allows cannulated bone screws to be made efficiently from solid bar stock

3. The cutter head is mounted into the thread whirling unit 4. The thread whirling unit is mounted in the machine at the proper helix angle by means of a graduated scale 5. Tools rotate at very high speeds 6. Part rotation depends on left hand or right hand threads

3. In general, wobble broaches do not cut as accurately as the punch broach so its use should be determined by the application.

• Thread Whirling Thread whirling, is generally used for cutting specia l for m t h re ad s i n d i f f icu ltto -machine materials with fa r fewer limitations tha n other thread cutting options.

I t i s o f te n u se d for b o ne screws due to their typical cha llenges: long leng th to diameter ratio; deep, high helix buttress thread forms; a nd ex treme difference s between major a nd minor diameters.

ID thread whirling is suitable for producing clean, burr-free thread contours. No residual chips are created and it is possible to thread right to the bottom of a hole.

Thread whirling can 58

metalworking equipment news March 2011

produce threads as small as M1.4. Alternatives to thread whirling include: die head (which does not work with materials like titanium); thread milling (which requires preturning, special cutters, and in some cases, special supports); single point turning (good for short screws – but long screws need support), thread rolling (which requires accurate preturning and does not work on ‘buttress’ style threads of hard materials), and grinding (which cannot be done on a Swiss turning machine). Some special considerations with thread whirling are: 1. The circular inserts used in a thread whirler are custom ground. If a customer does not have the means or desire to re-sharpen the circular inserts, they can opt for a cutter he ad t hat u se s indexable inserts

• Special Work Holding As more and more work is sent overseas, the remaining work takes experienced and knowledgeable people to process jobs in ways that are efficient and reliable.

Specially designed work holding is a key component to success in the medical market.

Step collets can be bored in the machine – resulting in better concentricity and timesavings.

This collet allows customer to balance work between main and counter operations improving productivity and profit.

• Gun Drilling Cannulated (or hollow) bone screws contain a space that allows bone marrow to grow and facilitates the insertion of guide pins for bone screws used in fracture fixation. With increases in cannulated bone screw orders, many shops are purchasing cannulated material.

This represents a large expense for the company due to the limited use of the hollow bar stock and the need to carry larger inventory. An alternative is gun drilling which allows these types of medical screws to be made efficiently from solid bar stock with:

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1. High drilling quality

metal at your service

2. Good chip removal 3. High process reliability 4. Minimum run out

6. Reduced need for cannulated material Enquiry No. 2401

Medical Device Market: Money To Be Made Despite the fact that Asia represents 60 percent of the world’s population, its healthcare expenditure constitutes only 15 percent of the global healthcare expenditure. As such, the potential is huge. With a yearly growth of 6.2 percent, it is expected that the total healthcare expenditure for Asia will exceed US$1 trillion by 2012.

While some parts of Asia are experiencing high population growth, other countries such as Japan and China are facing the problem of an accelerated ageing population.

For instance, Japan is estimated to have 22 percent of its population above 65 years old by 2012 as compared to 20.6 percent in 2007. Its neighbour China will have 248 million of its citizens over the age of 60 by 2020.

With the current Asian lifestyle, the prevalence of chronic diseases such as diabetes, cancer, obesity and cardiovascular diseases has increased significantly. Other diseases that threaten the region include auto-immune diseases, infectious diseases and neurological disorders.

Accelerated ageing population and increasing prevalence of chronic diseases are the key drivers that contribute towards the increase in total healthcare expenditure on medical devices in the region.

Medical tourism is a very important factor too, with an increasing number of countries joining the lucrative market. Singapore, for instance, estimates that it will soon achieve its target of 1 million medical tourists a year, thanks to the increasing numbers of visitors from Middle Eastern countries.

Beyond the growing demand for healthcare, its rising costs is another reason why the medical sector is an attractive new business arena for those involved in manufacturing. Insurers and healthcare providers are creating pressure to reduce costs by increasing productivity – and this spells opportunity for manufacturers of innovative medical parts and devices. MEN

Enquiry No. 2402

Brütsch Rüegger Metals Ltd., your Swiss-based supplier for European high quality steel products: ●

hot rolled and cold drawn bars and profiles

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hot rolled and cold drawn seamless tubes

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sheet metals and plates

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precision cylinder tubes and chromed bars

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Metalshop most advanced e-shop in the industry and competence centre  www.brr.ch

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Brütsch/Rüegger Metals Ltd. PO Box | CH-8105 Regensdorf | Switzerland Phone +41 44 871 34 34 | Fax +41 44 871 34 99 info@brr.ch | www.brr.ch

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5. Good length to diameter ratio

March 2011 metalworking equipment news

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Making Medical Parts,

It’s Tough

Demanding materials and complex workpiece geometries – the machining of specialist medical components poses specific demands on the machining tools used. By Michael Fink, manager, product marketing for Rotary Tools, Walter AG

M

edical components such as implants and artificial limbs play an important role in the success of surgical interventions.

They help surgeons to achieve excellent results. If, however, the surgeon uses deficient instruments, this will, in serious cases, endanger the health of the patient.

The tools used to manufacture such components make a decisive contribution to their quality. As such, manufacture of implants and workpieces also represents a greater challenge, eg: devices for repairing a cranium or bone fracture.

Precision: The Highest Imperative For tight tolerances, as is often the case in the medical industry, selecting the right tool requires a lot of intuition and comprehensive expertise. On the one hand, it is important, even when drilling the smallest of holes, to reduce friction-using lubricant, and to reliably dissipate the heat and dispose the swarf.

On the other, cutting tools that are both sharp and smoothrunning are essential for burr-free production of high-end medical engineering products, so that the required high surface quality can be attained. The tools used most often for this are boring tools made of HSS or solid carbide.

Demanding materials such as titanium, stainless steels, precious metals or even composites can be machined using drills.

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Turning Tools For Producing Implants Typical applications for turning tools are small components such as bone screws and implants that require maximum precision.

Carbide indexable inserts are used predominantly on multispindle machines.

For maximum process stability, the combination of coating and a fine grain substrate provides maximum process stability.

Other benefits of the temperature-resistant Al2O3 coating include maximum hot hardness and with it the highest level of wear resistance. In addition, the sharp cutting edges ensure burr-free components as well as a reduction in built-up edges.

Combination Solutions As in every other sector, companies

Walter: New Geometries To Parting Off Operations

in the medical industry are finding themselves subjected to ever-increasing cost pressure.

For a company to survive on the competitive international stage, it needs to produce top quality and maintain cost efficiency in its manufacturing processes.

When it comes to implants, which are normally made of highalloy steel, titanium or titanium alloys, the particular material and often complex geometry of the workpiece present a particular challenge in terms of the precision required. The typically small batch sizes of many smaller companies are an additional obstacle in the path towards achieving maximum productivity.

The solution in this case is multi-purpose tools. Whereas three standard tools would have been required before, only one is needed now, which saves two out of three processes. The bottom line is a reduction in costs for the manufacturer. The disadvantage is that such combination solutions are not normally in the standard tool catalogue range. This problem can however be mitigated with an online system called the ‘CATexpress’ service whereby information are collected online and production begins after the order is received. MEN Enquiry No. 2403

Walter Cut is the tooling system for grooving, parting off and recessing from Walter. Developments have seen new geometries for the main field of application in parting off operations. As a result, geometry trio CF6, CF5 and CE4 are developed for those applications.

CF6 provides a sharp and positively designed cutting edge for low feed rates, and CE4 is trimmed to bring maximum stability and high feed rates. CF5 geometry is a recent development for the medium feed range. This chip breaker closes the gap between the two mentioned above. With the CF5, approximately 60 percent of all parting off applications could be covered.

Enquiry No. 2404

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Robot That Saves Lives

Robotic technologies have proved to be practical in the field of radiation therapy, giving rise to the application of robots in tumour treatment possible, where precision is a must. By Stefanie Senft, Kuka Roboter

University Medical Center Heidelberg

I

n ion-beam therapy, highpre cision t re at me nt of tumours is made possible with the aid of robots.

In Heidelberg Universit y Hospital, an annual total of up to 1,300 tumour patients were treated with ion beams. In clinical studies, the success of this therapy was demonstrated by cure rates of up to 90 percent.

In the ion - be a m therapy centre, a particle beam of carbon ions is directed with millimeter accuracy at the patient’s tumour, thereby optimally protecting adjacent tissue.

Flexible Patient Positioning With Robot Robots are utilised at the centre whenever a patient needs to be precisely positioned: first during treatment planning, then during position verification, and later during irradiation.

With its six degrees of freedom, the robot is able to move the 62

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patients with complete flexibility.

This is not possible with the tables employed in conventional radiation therapy.

A floor-mounted robot moves the patient on a treatment table with sub-millimeter accuracy into a calculated position relative to the radiation source.

A second, ceiling-mounted robot additionally guides an X-ray C-arm around the patient.

During this procedure, X-ray images are taken in order to pinpoint the current position of the tumour. If the tumour is not in the exact target position calculated previously, the image data are used to generate an offset vector for the patient positioning robot. The positioning of the tumor can then be corrected.

Only when the exact position is reached is the ion beam enabled for the tumour treatment. The positioning robot is equipped with the safe operation system, which enables the robot to monitor independently the predefined

spatial boundaries. Further special safety devices and anticollision systems guarantee the safe operation of the system to ensure the safety of the patient at all times.

Administering Precision For the robot manufacturer, the greatest challenge was to implement the required degree of precision – potentially a matter of life and death for the patient. “To achieve this, we had to adapt a large number of the robot’s components,” comments Ralph Berke, manager of medical technology.

“The robot arm positions the patient with an accuracy greater than 0.5 mm, and the machine can then correct the position in steps of 0.1 mm.” The robotic application makes it possible to achieve an high patient throughput rate.

Further facilities based on the Heidelberg model are to follow in other places. MEN Enquiry No. 2405

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It Pays To Be Fussy In

Metrology

Even with new technologies and challenges coming into the world of metrology, fundamental knowledge, traditional techniques and attention to details are still cornerstones of a good measurement. By Tan Siew Leng, head & principal metrologist, optical metrology department, National Metrology Centre, A*STAR

T

he field of metrology is a unique science of measurement where not many people like to be involved in. This is probably due to a kind of ‘prerequisite’. Metrologists are very particular about getting a measuring job done properly and correctly, ie: we are fussy people.

To day, one of t he ma i n challenges we have is how to meet the industry’s requirements. In the industries, metrology is like a hidden ‘infrastructure’ people take for granted without knowing its importance.

The ‘In’ Measurement Lately, the trend in metrology is in shop floor measurement, whereby the product manufacturers carry out the measurements by themselves without sending some of the equipment or parts out. In order to do so, they have to equip themselves with some calibration facilities.

This brings us to the point of making measurements that ‘measure up’. When there are rapid technological advances, it is tough to keep pace.

In order to support today’s industrie s’ requirements, there is a ne e d to ma ke accurate and traceable

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measurements. This is an important concept of measurement, ie: your measurement must be able to be traced to a reliable standard.

As such, this involves standard maintenance.

I n add it ion , I t h i n k t he world is moving towards in situ measurements. This can be directly attributed to today’s manufacturing environment, where there is a need to keep things moving, resulting in the increasing demand for inprocess inspections.

Another emerging trend is to see people involved in product designing adopt some metrology concept during the design stage. The reason for saying this is at times, a problem we faced is the inability to reach certain areas on a part while we are carrying out inspection. One good example would be the MEMS (Microelectromechanical systems) parts. As they are small, certain areas are fairly inaccessible. As such, some voices in the metrology fraternity have been advocating inspection before assembly.

Old Vs New With the influx of laser measurement in the field of metrology, the usage of laser has come under increasing spotlight. There are two ways of using laser – either for accuracy enhancement or as a source. I would say the main reason for people to use laser is to increase accuracy and also to provide a direct traceability to the SI metre.

Using laser, there is a possibility

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Though the equipment are all accurate and reliable, they each have their own characteristics

Some voices in the metrology fraternity have been advocating inspection before assembly. of increasing accuracy in quite a number of order. However, the measurement can be very sensitive to changes in the refractive index of the air which is affected by fluctuations in air temperature, air draught humidity and pressure.

Though the ‘new’ way of noncontact measurement promises to bring improvements in accuracy, the traditional contact measurements still have their benefits. Measuring an inner structure using CMM, for instance, may have difficulty in accessibility by optical means due to limited depth of view and long contact probe may have to be used.

In addition to this example, there is also another reason why traditional techniques are important in metrology. Manual calculations can be a perfect tool to countercheck the values generated by computer software programs. This is becoming more of a pertinent point as in recent years, we have seen more automation, ie: computers and software programs are slowly taking over more calculations in measurement.

In the science of measurement, we are worried that by relying too much on the computer, we lose sense of the measurement.

I have seen people accepting results computers churn out without questioning its validity.

This is evident when I carry out accreditation work on secondary laboratories. When we ask the personnel in the laboratories to carry out an interpretation, they were unable to do so as they solely depend on their programs for calculation. My advice for them is to know what they are looking for.

They must have a good sense of the final value; therefore they must ascertain the number is sensible before accepting it.

In order to make sure the

computers are generating accurate calculations, we are moving towards validation of software.

To do that, the operators must know the algorithms responsible for a particular calculation and carry out a manual calculation to countercheck. Apart from software programs, even spreadsheets need to be validated. Simple things like rounding up and down (a figure) can be very deceiving.

Western Accuracy, Eastern Detail In our centre, we have various measuring equipment from all over the world. Though they are all reliable and accurate, they each have their peculiar characteristics.

The machines we have here are mostly from Japan, Europe and the US. All these countries are leaders in producing measuring equipment.

Take CMMs for example, it is interesting to note that Europeanmade CMMs are constructed based on high precision technique. As such, the whole system is more robust. Japanese-made CMMs however, relies on software compensation so as to bring the values back to the order of accuracy they are looking for. As such, they are often more price-competitive.

S t ay i n g w it h J a p a n e s e metrology products, it is worth noting that in terms of supporting software programs, they are more user-friendly as they use a lot of graphical aids in their presentation. At the end of the day, the equipments each has their pros and cons. The important thing is to apply the rule of common sense and question the validity of your measurements so you can give a meaningful figure with a certain amount of confidence. MEN Enquiry No. 2501 March 2011 metalworking equipment news

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Features

Asian Perspectives More APAC CEOs than in any other region of the world (98 percent) se e su sta inabilit y as either important or ver y important to their company’s future success. In fact, 57 percent of APAC executives perceive sustainability issues to be ‘very important’ to their future success, a slightly higher proportion than the global average of 54 percent.

In the words of Hirokazu Hashimoto, president and director of the Japanese technolog y company Anritsu Corporation: “Sustainability issues are critically important for our company’s future.” According to Zhongshu 66

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The

Business Of

Going Green

In the face of environmental, social and governance challenges, CEOs in Asia are increasingly embracing sustainable practices in the playing field. By Teo Lay Lim, country MD; Ynse de Boer, senior manager, sustainability services, Accenture Singapore

Alessandro Paiva, Brazil

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EOs around the world are starting to see the shape of an era of sustainability coming into view. In the face of rising global competition, technological change and one of the most serious economic downturns in nearly a century, corporate commitment to the principles of sustainability remains strong throughout the world: 93 percent of CEOs see sustainability as important to their company’s future success.

There has been a fundamental shift since the last Global Compact survey in 2007. Then, sustainability was just emerging on the periphery of business issues, an increasing concern that was beginning to reshape the rules of competition.

Three years later, sustainability is top of mind for CEOs around the world.

A lthough env ironmenta l, social and governance challenges continue to grow and CEOs wrestle with competing strategic priorities, sustainable business practices and products are opening up new markets and sources of demand; driving new business models and sources of innovation; changing industry cost structures; and beginning to permeate the business from corporate strategy to all elements of operations.

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Zhou, president of China Minmetals Corp: “Sustainable development is a basic guarantee for our company’s survival and development.”

Although many factors contribute to this strong APAC support of sustainability, one important element is what one business leader termed the ‘lens of proximity’ of sustainability issues. That is, corporations and the public alike in emerging economies see sustainability in personal, local and immediate terms. Examples are access to clean water, more direct dependence on the natural environment – and therefore perceive their future success to be more directly threatened by environmental degradation. For example, APAC CEOs emphasise more than their global counterparts the importance of access to clean water and sanitation, as well as achieving food security and alleviating hunger, as key sustainability issues.

Many CEOs are concerned about the damaged reputation of business in the wake of the recent financial crisis and economic downturn, and these business leaders appreciate the scale of the challenge in reestablishing confidence in the corporate community. According to PM Telang, MD of Tata Motors: “The concept of ‘trusteeship’ is vital, both as a management philosophy and as a principle of governance.”

Driving Motivation A message that comes through from APAC executives is that the urgency to act on sustainability has shifted from a moral to a business case.

In some respects, the economic downturn has been a prime cause of this move to drive sustainability initiatives based on business goals.

During a time of economic hardship, businesses have been forced to examine closely how their sustainability activity delivers core business value, measured in terms such as cost reduction and revenue growth. Among APAC CEOs, 80 percent believe that the downturn has led their company

to align sustainability more closely with their core business – a number exceeding the global percentage of 73 percent.

These regional CEOs are also more likely to see solid business returns from sustainability as a key driver. For example, 57 percent of APAC CEOs cite ‘cost reduction and efficiency’ from sustainability as an important opportunity over the next five years, compared with only 46 percent globally.

As one business leader pointed out: “If managing a business sustainably is about using resources efficiently, then it serves the cost agenda as well.”

APAC executives are especially focused on consumers as a key value driver – buyers who will create a viable marketplace for sustainable products and services.

One finding of the research is that 66 percent of APAC executives named ‘consumers’ as a stakeholder group having the greatest impact on sustainability initiatives, compared to 58 percent globally.

It is likely that the emphasis on consumer demand expressed

by APAC CEOs reflects the fact that most of these companies are global in nature. So executives see consumer demand in terms of the global customer, not only the local one. As Carlos Ghosn, CEO of the Renault-Nissan Alliance, said: “We want to make the most eco-friendly choice a good economic solution for consumers as well.”

Turning To Alternatives Executives are cautiously hopeful that they can see significant new sources of growth in ‘green’ products and services: As growth slows in traditional markets, companies are turning their attention toward new propositions that tap into new waves of demand. For example, Nissan is investing in a portfolio of green products, including clean diesels, efficient internal combustion engines and hybrids.

The centre-piece of its product

strategy is the zero-emission vehicle.

The company has successfully entered this market with the LEAF, a car that produces no carbondioxide emissions, uses advanced aerodynamic technologies and has a driving range of 100 miles on a single charge of its electric motor.

The LEAF had 13,000 pre-orders in just over one month in the US and Japan alone, with more than 56,000 orders globally.

The survey found belief in an era of sustainable business – one in which sustainability is more than an aspiration or a separate initiative, but something fully integrated into the strategy and operations of a company.

Ben Earwicker, USA

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While sustainability has become part and parcel of how many businesses operate, it has yet to permeate the organisation into all elements of core business – that is, into capabilities, processes and systems

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Mike Canon, Austria

Tata Steel company provides electricity, fuel, drinking water, and cooking gas free of charge to a community in West Bokaro, India

The past three years represent a significant mindset shift in how UN Global Compact CEOs think about the role of sustainability in strategy and operations. It was found that 96 percent of CEOs in APAC – identical to the global figure – compared to just 72 percent globally in 2007, now believe that environmental, social and governance issues should be fully integrated into the strategy and operations of a company.

CEOs are also confident about the progress that they have made toward this era of sustainability.

For example, the most significant performance gap lies in the integration of sustainability issues into supply chains. Although 82 percent of APAC executives believe that they should be integrating sustainability throughout their supply chain, just 53 percent believe that this has been achieved within their company.

Business Of Assimilation The second most significant performance gap appears in the integration of sustainability issues into the strategy and operations of subsidiaries. While there is widespread acceptance of the need to embed these issues into subsidiaries (88 percent in APAC) just 62 percent of APAC executives believe that they currently meet this ambition.

Given the opportunities and challenges that sustainability presents to Asia Pacific businesses, it has been observed that, while 68

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su st a i nabi l it y ha s b e come part and parcel of how many businesses operate, it has yet to permeate the organisation into all elements of core business – that is, into capabilities, processes and systems. In particular, the difficulty of implementation, especially across supply chains and subsidiaries, is a significant barrier to the full integration of sustainability.

Although the outline of another era of integrated or embedded sustainability is becoming clear, the means to get there and the timing of the journey are uncertain. Multiple stakeholders across industries and national boundaries will need to work in concert.

What are the conditions most important to enabling that tipping point to be reached? Among CEOs in the Asia Pacific region, the top two answers were related to education and government: educational systems that produce effective talent, as well as government action that provides clear support for sustainability.

APAC companies are committed to training their manager-level employees as a means of embedding sustainability objectives into operations. There are 69 percent of APAC CEOs who state that they are already engaging in the additional training of managers to enable them to address sustainability issues.

Authoritative Action Among business leaders in APAC, 88 percent believe that clearer direction from governments will be a critical impetus toward reaching a tipping point on embedded sustainability. These executives also express a greater belief than their global peers that they must proactively engage with policy makers, and demonstrate public support for global integration and open markets.

It was also found among APAC executives that a commitment to partnering with local communities exists. In the words of Jamshed J Irani, director of Tata Steel: “Corporate social responsibility is an investment. Long-term community inve stment a nd partnership has contributed to operational viability and stability in challenging environments.”

Tata Steel sought to create a stable environment for business in West Bokaro, India, investing in local community infrastructure to support the scale of operations. West Bokaro Mines, first established in 1948, now contributes approximately 4.5 million tonnes annually to the company’s production capacity.

To su sta i n t h is level of production the company requires advanced support services for engineering and heavy equipment like dumpers and excavators.

Since the area in which the mine is located is underdeveloped, the company has to be self sufficient in many of its activities.

It was observed that there is a sense of optimism among many of the CEOs pertaining to operating in the area of broader social responsibility. In a number of ways, businesses should be able to couple both business value and societal value.

In doing so, businesses will be better able to reassert a stronger, more positive and influential role in society. MEN Enquiry No. 2502

ENQUIRY NO 171

Features

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Multi-Applications Machining:

It’s All About

Being Versatile

T

oday’s manufacturing industry operates and thrives in a marketplace where fabrication and delivery of complex parts must satisfy the bottom line and ensure quality and precision. As supplier relationships shift from country to country and business activities flows through different regions in search of reduced labour costs, being competitive now require expertise and investment in multiapplications machining.

As the name suggests, multiapplications machining do more than a single machining task in a single setup. Conventionally, most complex parts required multiple setups on multiple machines, which impose high labour costs for setup, part transfer, and inspection for the additional operations. Even moving and storing incomplete parts around the floor represents unnecessary cost.

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Presented in various names like multitasking and integrated machining, they do however point to one concept, ie: accomplishing more than one task in one machine.

By Augustine Quek The development of multiple operations on one machine was made possible by the invention of Numerical Control (NC), or computerised machining. NC has enabled many mechanical motions to be automated with fewer labour and parts.

Over the past few years, machines have evolved from e ssentia lly tur ning centre s with some milling capability, or conversely, machining centres with a rotary table for basic turning operations. Offerings now include unique machine configurations that combine processes ranging from turning and milling to grinding, inspection to assembly, among other operations.

Cutting Tools In the cutting tools segment, inserts with different shapes can give a face mill a different dimension, ie: multi-application enabled. The ability to adapt to many operations result from the consolidation of multiple applications within one face mill. In Valenite’s V490 multiapplication face mill, its secure insert retention is designed for precise indexing, making the cutter suited for steels, stainless steels and cast iron.

The octagon insert is effective for low cutting force milling with eight indexes; the square insert is suited for 90 -deg shoulder machining with a depth of cut

features

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The development of multiple operations on one machine was made possible by the invention of numerical control

Software has also advanced with multitasking

Curtis Palmer, USA Steve Jurvetson, USA

ranging to 12 mm; while the round insert is designed for rough face milling and shallow profile machining, according to the company.

Elsewhere, Coromant Capto, from Sandvik Coromant, is an open tool system designed for multi-task machining. The tool system makes it possible to have only one system that covers all metal cutting operations. The same coupling from the system can fit all machines.

The adaptors, in long and short versions, make it possible to extend the coupling size of a smaller tool and the total length, as well as reduce the coupling size of a larger tool a nd/or extend the total length for better accessibility. Its mini turret can hold three standard shank tools in one position in the magazine.

Machine Tools Like their cutting tool counterparts, machine tools makers are also looking into avenues to produce machines capable of multitasking.

For example, Mori Seiki’s line of multitasking machine tools includes the SuperMiller 400, which features a tilt/rotary table that provides five-axis machining capability as well as turning to

1,500 rpm on the A axis. The machine’s tilting B axis moves vertically over a range of -20 to +110 deg using a roller gear drive.

A 12,000-rpm, BT40 spindle and 30-tool ATC are standard, and the machine has primary axis travels of 600, 425, and 450 mm in X, Y, and Z, respectively.

As machine variations have multiplied, machine builders are modifying their marketing pitches to reflect the differences among their products. For example, multitasking is sometimes used intercha ngeably with multia ppl ic at io n s to e mph a si se flex ibility a nd combined machining functionality.

A few companies prefer the term ‘integrated machining’.

This is because while multitasking implies performing multiple operations on a part simultaneously, for example, screw machining or multiple spindles, multi-application refers to operating on a part with one process at a time, sequentially, within the same machine.

For example, a grinder with both OD and ID grinding capabilities could multitask by doing both at the same time. Therefore, some companies are even redefining terms, or coining new ones to

describe the technology.

The term ‘multi - tool simultaneous machining’ can be applied to the Cincom M20/32 from Swiss-based Citizen. It is a Windows-based NC multiapplications machine that unites the high-speed performance of a gang tool and the multiple functions of a turret. It has 2-spindles and 3-tool posts with a multi-axis/multiline control system.

This allows it to control 13 programmable axes, A-axis for robotic arm, and perform front and back work simultaneously. The turret tool post allows multiple tools to be mounted in one tool holder on one turret station, decreasing tool change times.

A term called ‘ültratasking’, is used at Mazak Corp to reflect integration of a wider variety of processes into a single machine platform. This is because as the concept of multitasking is already being accepted by the majority of manufacturers, they are also looking beyond milling, drilling, and tapping and adding other functions like hobbing, polishing, and grinding to the workpiece while it is in the machine.

This concept can be seen in Mazak’s Integrex, which merged a turning centre with a full-function March 2011 metalworking equipment news

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Features

machining centre to create a machine tool, which is capable of producing complicated finished parts in a single setup. This machine enables the processing of round parts with secondary op erat ions, f u lly pr ismat ic parts from solid or castings, or sculptured parts.

There a re a lso severa l configurations for this machine.

The single spindle with tailstock and B/Y-axis ATC – style turret configuration allows for turning and complex milling on and off centre line including helical features.

The single spindle with sub spindle instead of the tailstock enable s automat ic t ra n sfer o f t he f i r s t op e ra t io n a n d completed part to the second spindle for second operation and completion of the part.

Lastly, adding a second drum turret to configurations above provides the ability to cut with two tools simultaneously on the same part in the first or second spindle or working one tool from one tool carrier on the part in the first spindle and a different tool from the second tool carrier on the part in the second spindle.

Software Programs Software has also advanced with multitasking. Pro/Engineer Prismatic and Multi- Surface Milling is an example, which automates many programming tasks through integration with 2D and 3D CAD/CAM operations.

It features 2-axis prismatic part toolpath generation, multi-surface 3-axis milling toolpath generation and automatic drilling. Its high speed machining features helical spline approaches and exits and slope-based finishing while its hole making features a large variety of cycle types with custom cycles definition and simulation. It is also scalable to include 4-axis wire EDM and multi-axis milling (5-axis) and turning.

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The Road Ahead Multi - application machine s eliminate multiple setups, part transfers and part handling. As a result, they eliminate the human errors and out-of-tolerance error accumulation associated with multiple setups. They also reduce multiple inspections as raw material that enters the machine comes out as finished parts. Therefore, the use of multi-application equipment can support lean manufacturing initiatives as the reductions that define lean occur when setting

up a machine once for several operations.

Multitasking machines probably make up the most dynamic segment of the machine-tool industry. Still a small portion of overall machine sales, multitasking technology is gaining in importance as more users realise the benefits of single-setup machining of complex parts. This occurs as the machines are built with ever increasing capabilities and decreasing complexity in usage.

Enquiry No. 2503

In The Pipeline In the future, multi-applications machining may not just cut or shape work pieces but may also measure its working depth before operations. A pending patent for multi-function CNC cutting/milling machine includes not only a cutting tool for cutting a workpiece, but also two lasers for depth measurement.

A feeder selectively feeds a gas or fluid through a longitudinal passage of the cutting tool to the workpiece to carry away cutting chips from the workpiece, a first laser beam and a second laser beam respectively projects through the passage of the cutting tool onto the workpiece, and a detection control device receives the reflective light wave of the second laser beam reflected by the workpiece for measuring the working depth of the cutting tool.

Enquiry No. 2504

Okuma: Vertical Machining Centre The MU-400VA is a vertical machining centre developed by Okuma with major components b a s e d o n t h e c o m p a n y ’s MB-V series. A rotary table is mounted on a trunnion table, for the additional two axes that make this VMC a 5-axis machining centre.

The rotary table is ø400 mm in diameter, can take workpieces up to ø600 mm, 400 mm high, and weigh 300 kg. The VMC also comes equipped with the ‘Thermo-Friendly Concept’. It includes thermally symmetric designing, with box-building (building block), thermally balanced structures that control thermal deformation.

‘Machining Navi’ is included in the VMC to improve machining efficiency. It is an optimum cutting condition search function that supports the aggressive use of higher spindle speeds in stable zones. MEN

Enquiry No. 2505

Held Inconjunction with :

The 4th Indonesian International Automotive Components, Spare Parts & Accessories Exhibition

Indonesia’s Outsource Engineering & Manufacturing Event for the Automotive, Electronics, ICT, Mould & Die, Machinery, Metalworks, Plastics and Supporting Industries

ENQUIRY NO 159

For enquiries or space booking : Indonesia mtt@ecmi.cc +62 21 781 8954 +62 21 7884 1726

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exhibitions

S

ituated at the heart of the industrial area in Kuala Lumpur, Malaysia, the DMG/Mori Seiki technology centre was declared opened by YB Dato’ Mukhriz Bin Tun Dr Mahathir, deputy minister of ministry of international trade and industry on Jan 17, 2011.

In his speech, YB Dato’ Mukhriz shared with the crowd Malaysia’s initiatives in promoting the transfer of technology. Of which, it includes an investment tax allowance of 50 percent on qualifying capital expenditure incurred within a period of five years to be offset against 50 percent of statutory income for each year of assessment.

New Facility The RM2 million (US$653,000) centre has a total space of 1,200 sq m, a showroom space of almost 200 sq m plus a separate training area and machine service and repair facilities.

In addition, the technology and application centre offers beginner and advanced courses in CNC and CAD/CAM metalworking technology.

A product lineup worth up to some €1.2 million (US$1.6 million) was presented in the showroom on the opening day. It ranges from Eco machines for cost-effective entry into the field of standard machines to high-tech machines for complex machining jobs.

Visitors at the centre on the opening day also attended a HSC seminar and a presentation on cutting tools by partner Sumitomo Electric Hardmetal. At the seminar, the attendees’ knowledge on HSC and tool coating were enhanced.

In total, some 350 visitors from over 270 companies attended the event over four days. With the infrastructures now firmly set in place, TQ Lim, GM of DMG/ Mori Seiki Malaysia said: “We plan to increase our market share to 20 percent in the next two to three years.”

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Event Review:

DMG/Mori Seiki (Malaysia) Grand Opening

On a separate note, Jens Hardenacke, CEO of the cooperation markets from the DMG side, revealed to APMEN that DMG and Mori Seiki will present the first jointly developed machine (horizontal machine) in the next EMO show.

Industrialisation In Malaysia The establishment of the technology centre is one of the many that has happened in Malaysia, very much in line with the nation’s strategy of attracting high end, high yield and innovative industry requiring skilled labours.

YB Dato’ Mukhriz revealed the country is trying to move away from the low cost labour-intensive type of industries. For him, the

process should start sooner, rather than later.

“We aim to be an industrialised country by year 2020. As it is only nine years away, there is not much time. As such, Malaysia is very aggressive in moulding itself as an investment destination for the manufacturing sector,” he said.

The figures have shown the nation is moving in its intended direction. “We have exceeded our RM1 trillion mark for trade as of November 2010. We have also been maintaining a trade surplus for 157 months consecutively since November 1997,” he concluded.

Enquiry No. 2601

ENQUIRY NO 024

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Event Preview:

Spotlight On EMO Christoph Miller (L) at the press conference with Martin Thiem.

E

MO Hannover is pushing its publicity campaign in their build up to the main event to be held from September 19 - 24, 2011. The stage is set and the preparations are in mid swing following a series of press conferences held across Asia recently. The marketing campaign arrived in Malaysia with a press conference hosted in KL to potential visitors, exhibitors and of course regional press. The presenters were Christoph Miller, MD of EMO Hannover and Martin Thiem, senior VP of Deutsche Messe.

The event is sponsored by Cecimo, the European committee for cooperation of the machine tool industries is marketed as an event to meet qualified experts and decision makers from all over the world.

The Press Conference The press conference was well attended by a cross section of Malaysian machine tool manufacturers and those with an interest in exhibiting at Hannover. It started with an introduction of the 76

metalworking equipment news March 2011

speakers before Mr Miller started his presentation, followed by Mr Thiem.

Mr Miller talked about the state of this year’s show, quoting statistics on venue capacity and past successes of the show. He also looked at industry trends and analysed demographics that attended the show. Mr Thiem on the other hand presented on the logistics of catering for a show of this scale, as well as delving into more detail concerning their broader role in organising trade fairs worldwide.

The State Of Hannover At the time of the press conference, Mr Miller stated that 1,500 exhibitors had registered, covering a surface area of 140,000 sq m net. This year the organisers are expecting almost the same number of visitors in line with the global up-swing.

The size is not the only attractive feature of the show however, the relative high calibre of visitors that attends the trade show is well regarded. A visitor survey by EMO Hannover suggests that four fifths of all visitors to the

trade show have decision making capacity for their company.

On the other hand, a big focus at this years event is sustainable manufacturing solutions aimed at showcasing new developments to reduce energy consumption.

This Years Success In 2009, the global economy say a sharp decline, with a return to growth seen in 2010, and further growth by economists is predicted through 2011. Current forecasts see a 20 percent rise in machine tool use in 2011, with Europe and America catching up with Asia in this sector. In the Malaysia market, the gross domestic product shrank by 1.7 percent in 2009 but grew in 2010 and further growth is expected through 2011.

When asked about differences this year at EMO, Mr Miller had this to say: “There will not be that big of a difference, we will see the same exhibitors of course, but you will see the latest developments from our exhibitors and it will be interesting to see and learn how our exhibitors and visitors passed the economic crisis. At the show you will be able to meet with the entire industry, it is a networking event.”

During the last EMO Hannover, nearly 400 visitors from Malaysia went to Hannover with the organisers looking to increase numbers further with increased marketing efforts and 60 press conferences worldwide. When Mr Miller was asked what potential the show has for the Malaysian economy, Mr Miller stated: “I can tell you that Germany have sold machine tools to Malaysia worth about e25 million (US$34.6 million) in 2009, ranking number six, with Japan first, after Taiwan, South Korea, China and the US.” Hilton Kuala Lumpur, Malaysia January 17, 2011 Enquiry No. 2602

3rd 3rdInternational InternationalWire, Wire,Cable, Cable,Tube Tube&&Pipe PipeTrade TradeFairs Fairsfor forSoutheast SoutheastAsia Asia 3rd International Wire, Cable, Tube & Pipe Trade Fairs for Southeast Asia 3rd International Wire, Cable, Tube & Pipe Trade Fairs for Southeast Asia

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13 13 15 15 Sept Sept 2011 2011 13 -- 15 Sept 2011 13 2011 BITEC, BITEC, Bangkok Bangkok BITEC, Bangkok BITEC, Bangkok Bangkok BangkokInternational InternationalTrade Trade&&Exhibition ExhibitionCentre Centre Bangkok International Trade & Exhibition Centre Bangkok International Trade & Exhibition Centre

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wire wire Southeast Southeast ASIA ASIA 2011 2011 wire Southeast ASIA 2011

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•

Organized Organized Organized by: by:by:

Supported by : :by : Supported Supported bySoutheast wire & Tube ASIA 2011 IWMA - -International IWMA IWMA - International International Wire &&Machinery Wire Wire & Machinery Machinery Supported by : Association Association Association Italian Wire Machinery IWMA - International Italian Italian Wire Wire Machinery Machinery Manufacturers Wire & Machinery Malaysian Iron &Iron Steel Spring Manufacturers Manufacturers Malaysian Malaysian Iron & Steel & Steel Japan Japan Japan Spring Spring Association (ACIMAF) Association Association Industry Federation Association Association (ACIMAF) (ACIMAF) Italian Wire Machinery Manufacturers Manufacturers Association Association Industry Industry Federation Federation Manufacturers Manufacturers Malaysian Iron & Steel Japan Spring IWCEA International IWCEA IWCEA - International - InternationalAssociation (ACIMAF) Industry Federation Manufacturers Association Wire & Cable WireWire & Cable & Cable Industry Partner Association : Messe Düsseldorf / Organizer of Exhibitors Association Industry Industry Partner Partner Association Association : : Messe Messe Düsseldorf Düsseldorf / Organizer / Organizer of of IWCEA - International Exhibitors Exhibitors Association Association • Austrian Wire and Cable Machinery & Cable Austrian • Manufacturers Austrian WireWire Wire and Association Cable and Cable Machinery Machinery (VÖDKM-AWCMA) Industry Partner Association : Messe Düsseldorf / Organizer of Manufacturers Manufacturers Association Association (VÖDKM-AWCMA) (VÖDKM-AWCMA) Exhibitors Association • International Wire and Cable Exhibitors

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

Philippines Metalcasting Technology Promotion Steel Wire Association Philippines Philippines Metalcasting Technology Technology Promotion Promotion Steel WireWire Association Association Association, IncMetalcasting Association (Thailand-Japan) ofSteel Malaysia Association, Association, Inc Inc Association Association (Thailand-Japan) (Thailand-Japan) of Malaysia of Malaysia Philippines Metalcasting Technology Promotion Steel Wire Association Association, Inc Association (Thailand-Japan) of Malaysia

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Event Preview:

Aerospace Supplier Exchange

T

he Aerospace Supplier Exchange (ASX) is back from April 27 – 29, 2011 in Singapore and would be held at the Sands Expo and Convention Centre, Marina Bay Sands.

The event, a biennial conference and exhibition aimed for all tier three and four companies in the Asia-Pacific, will serve as the platform for the sourcing needs of buyers from the tier one and two suppliers, OEMs and MROs. The conference topics are already generating growing interest especially with heightened sentiments of industry players on business growth expected with the continued strengthening of many Asian economies this coming year. The booming markets are continuing to exert pressure on the supply of both cargo and passenger airplanes.

Par t of this growth can be attributed to the growing economies and demands of China, India and other ASEAN countries, causing air traffic, aircraft fleet and aerospace MRO revenues to rise.

Keynote Speakers The two-day conference will 78

metalworking equipment news March 2011

address aerospace trends and growth perspectives on day one.

Three conference keynotes kick off the first day’s deliberations. Pierre Steffen, VP, Airbus China, (China) will speak on ‘Growth in Aircraft Manufacturing Activities in Asia, especially China & Japan, and its impact on the Region’.

The director of ST Aerospace Supplies (Singapore), Long See Kong will discuss ‘Building Bridges for Commercial Suppliers to Support the Defence Industry’.

And rounding up the keynotes on day one is Wong Su-Yen, MD, ASEAN, Mercer (Singapore), who will highlight ‘AAIS Singapore Aerospace Manpower Study’.

Some of the topics for the first day also include, offsets policies in the modern aerospace market, R&D and new technologies impacting indigenous markets, clean energy and its applicability in today’s growing market, infrastructure needs of a growing aerospace hub and risk mitigating in aerospace business.

Day two with a planned focus on aerospace operations and supplier management, promises to keep the heat on the excitement generated on the first day with issues such

as ‘Globalisation and its Impact on Supplier Management’ by David Stewart, principal, Aerostrategy (UK), ‘Effective Supplier Development Policies and how they have Evolved’ by Steven Pearson, MD, Sales and Support Services, Asia Pacific, NORDAM (Singapore), ‘Moving from Customer Service to Customer Satisfaction – Challenges in the Aerospace Industry’, by Fergus Lopes, GM, Aerospace Component Engineering Services (Singapore).

Important topics that are not to be missed touches on issues like developing a global distribution network, what OEMs look for in potential suppliers further to quality requirements, overview and current landscape of the global aerospace MRO market, next generation MRO technologyaerospace composite/materials, rise of the aerospace industry in China and India and how it affects the global MRO market.

Strong Support ASX 2011 would once again deliver opportunities to local suppliers, especially in meeting key aerospace procurement decision makers from overseas.

Singapore based suppliers will also especially benefit from the Hosted Buyers Program – a B2B matchmaking program managed by IE Singapore and the Association of Aerospace Industries (Singapore).

The event has support from regional industry associations and relevant organisations like Civil Aviation Authority of Singapore, Agency for Science, Technology and Research, EDB Singapore, IE Singapore, Singapore Exhibition & Convention Bureau, Spring Singapore and the Singapore Tourism Board.

Sands Expo Singapore April 27 – 29, 2011 Enquiry No. 2603

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ProductFinder

Carl Zeiss: Gear Wheel Measuring Machine

Ceratizit: Clamping Wedge For Crankshaft Milling

Carl Zeiss has developed the DuraMax Gear, a shopfloor gear wheel measuring machine. The key features of the CMM are its suitability for a rough production environment, high permissible temperature fluctuations, proven measuring software, and its small footprint.

The machine is suited for process control on the production floor, for quick in-between inspections of small workpieces and for testing volume parts directly in production. Because of its accuracy, it is also suitable for many requirements in gear wheel measuring technology.

The X-Lock cassette clamping from Ceratizit has improved crankshaft milling. It maintains closer tolerances and can be positioned with a precision of a few microns. The main attraction of the milling cutter is a self-centring clamping wedge, which serves both to pull the cassette back against the location faces and as a drive dog.

On the one hand this minimises vibration, which results in improved tool life of the crankshaft milling cutters. On the other hand the clamping device enables a considerably more flexible design of the crankshaft milling cutters even at the construction stage.

Enquiry No. 2701

Enquiry No. 2702

MTA2011 23 to 26 March • Booth: 3A3-05

MTT Expo 2011 25 to 28 May • Booth: A2-633

Smart Hybrid Finishing

New OptiRough Toolpath

New Dynamic Milling Techniques

Easier Multiaxis Machining

New Plunge Turn Toolpath

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

Techtown Pte Ltd

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

ENQUIRY NO 042

ENQUIRY NO 166

Mastercam Machine Simulation

March 2011 metalworking equipment news

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Esco: Clamping End Prep Tool

Grieve: Inert Atmosphere Box Furnace

Esco C-Hog Millhog OD clamping end prep tool is up to three times faster than ID clamping weld end prep tools for beveling, facing, and boring alloyed small bore heavy-wall steam header tubes.

Featuring a la rge steel reinforced solid aluminium clamp, w it h b l o c k s fo r gripping 12.7 mm to 63.5 mm tubes, this tool mounts to the outside of these hard tubes and sets up quickly. Equipped with an attached wrench, the tool is suitable for tube squaring and ‘J’ prepping for orbital welding.

Number 954 is an electricallyhe ate d 1,0 93 deg C inert atmosphere heavy-duty box furnace from Grieve. Some 57 kW are installed in nickel chrome wire coils, supported by vacuum-formed ceramic fibre, to heat the load.

Workspace dimensions are 30” wide x 48” deep x 30” high. The unit is equipped with a roof-mounted heat-resisting alloy recirculating fan, powered by a 1-HP motor with V-belt drive and a motor-operated vertical lift door.

This furnace also features inert atmosphere construction, consisting of a continuously welded outer shell, high temperature door gasket, sealed heater terminal boxes, inert atmosphere inlet, inert atmosphere outlet and inert atmosphere flowmeter.

Enquiry No. 2703

Enquiry No. 2705

Flow: 3D Waterjet Cutting Technology

Haas Automation: Dual-Spindle Turning Centres

Dynamic Waterjet X D integ rate s 3D functionality with Dynamic Waterjet – giving accuracy, speed, and flexibility. The waterjet cutting machine offers beveling and up to 60 degrees of motion. This functionality provides added versatility and allows for easy cutting of complex parts in 3D. Users can cut up to two to four times faster, to precision and tight corner geometry. It automatically compensates for stream lag and taper, natural occurrences of the waterjet process. Its articulated wrist allows the cutting head to tilt in any direction, compensating for waterjet stream imperfections using the FlowXpert software suite, without the necessity of operator participation using the SmartStream technology.

The Haas DS-30 series dual-spindle turning centres provide the ability to turn both ends of a part in a single setup to minimise part handling, increase throughput, and reduce work-in-process. The opposed spindles offer fully synchronised turning for clean part-off, and allow on-the-fly part pass-off to reduce cycle times.

The DS machines are available in standard and super speed configurations. The standard DS-30 has a maximum cutting capacity of 21” x 26”, and is equipped with a 12-station BOT turret.

The Super Speed DS-30SS has a maximum cutting capacity of 16” x 26”, and is equipped with a 24-station hybrid BOT/VDI turret.

Enquiry No. 2704

Enquiry No. 2706

metalworking equipment news March 2011

productfinder

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Iscar: Chipbreaking Inserts Improve ID Grooving

Mate: Tooling Systems For Salvagnini Punch Presses

Iscar has developed a line of improved Cut-Grip grooving inserts for ID grooving that features the N-type chipformer that has proven effective in OD turning of problematic metals.

Internal groovers with the chipformer are available for diameters down to 22 mm. In OD grooving applications, the N-type chipformer has performed in numerous automotive parts. Several tier-one suppliers report that the tool begins to reliably break up chips at feed rates as low as 0.05 mm/rev.

The expanded line includes double-ended GINI inserts for ID turning and grooving and new sizes of GIMN 302 inserts in grade IC907.

Mate offers a complete range of Salvagnini Style Type II and Type III tooling. The high-speed steel punches, dies and strippers compliment the punching system.

Manufactured from powdered metal-based highspeed steel, the punches provide long tool life under punching conditions. They have abrasion resistance, anti-galling properties, plus hot and red hardness.

Perforating strippers are fully guided with a design that supports the punch point throughout the punching cycle. They are made of high strength tool steel that will not deform or break.

Enquiry No. 2707

Enquiry No. 2708

AMAZING TECHNOLOGIES

3D Multi-Axis Laser Cutter and SERVO Bender (NO hyd.oil)

Axial Forming • Chipless Metal-Forming Process Innovative Spline Forming Technology No Chip, No Scrap, No Cutting, Save Material & Process

PLEASE CONTACT

Creative Machinery Enterprise

Block 3015 Ubi Road 1 #04-214. Singapore 408704 Tel: +65 6746 5959 Fax: +65 6745 7163 Email: sales88creative@gmail.com

ENQUIRY NO 040

ENQUIRY NO 048

Application for: • Automotive • Aerospace • Medical Industries

March 2011 metalworking equipment news

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Mori Seiki: Integrated Mill Turn Centre

The NTX2000 is a compact integrated mill turn centre with a maximum workpiece size of diameter 660 mm x 1,540 mm. This machine is suitable for complex and high-precision machining, which is required to cut parts used in the aerospace, medical equipment and semiconductor industries.

The machine uses the company’s original DDM (Direct Drive Motor), ORC (Octagonal Ram Construction) and BMT (Built-in Motor Turret) technologies, offering high-precision complete machining on small to medium sized parts.

Finally, the standard distance between centres is 1,500 mm, the machine width has been shortened by 1,000 mm and the installation area has been reduced by approximately 30 percent from conventional machines.

PTC has developed its vision and strategy for the next generation of design solutions. Creo is a scalable suite of interoperable design apps that help companies unlock the full potential within product development.

It will deliver easier to use design apps for everyone involved in product development, spanning the entire process, and addressing a broad set of needs and roles.

These purpose-built applications will deliver the right capabilities to get the job done through the technology of AnyRole Apps.

Creo helps manufactures unlock the potential within product development, enabling more people to participate earlier and more fully in the product development process, improving creativity, teamwork, efficiency, and value.

Enquiry No. 2709

Enquiry No. 2711

MMC: Face Mill For Cast Iron Machining

Mitsubishi Materials Corp has developed a face milling range that offers the opportunity to achieve high performance milling of general cast irons, the VOX400 face milling series.

The series has been designed around the concept of overall stability in mind, as a result, enabling it to cover a wide range of cast iron milling applications.

In addition to the efficiency savings due to the increased stability, the SONX geometry inserts also offer the customer the use of eight effective cutting edges. Released with a CVD coated carbide tool grade, MC5020, the tool is available in both coarse and fine pitch types from diameter 63 to 250 mm.

Enquiry No. 2710 82

PTC: Design Solutions To Solve Chronic Challenges

metalworking equipment news March 2011

SolidCAM: Functional Adaptive Technology

The basic goal of the iMachining strategy is to use ‘ideal’ cutting conditions and to keep the tool cutting angle within limits, resulting in a constant tool load as much as possible. When it is not possible, especially in lead in and lead out from cut, the algorithm of the software modifies cutting conditions according to the tool path.

The user can select from eight levels of machining aggressiveness in order to take full advantage of the state of his CNC machine and set up, realising his full productivity potential. Recommended values for cutting are calculated and shown to the user – these values can be modified by the user.

Enquiry No. 2712

Exhibition Programmes 2011 March

16 – 20 Intermold Korea 2011 KINTEX South Korea KODMIC koreamold@koreamold.com www.intermoldkorea.com

23 – 26 MTA 2011

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

23 – 26 INAPA 2011

Jakarta International Expo Jakarta, Indonesia PT GEM Indonesia info@gem-indonesia.net www.inapa-exhibition.net

April

4–8 Hannover Messe 2011 Exhibition Grounds Hannover, Germany Deutsche Messe www.hannovermesse.de

27 – 29 ASX 2011

Sands Expo & Convention Centre Singapore IIR Exhibitions michelle.tan@iirx.com.sg www.aerosupplierx.com

May

4–8 Metaltech 2011 PWTC Kuala Lumpur, Malaysia Trade-Link Group info@tradelink.com.my www.tradelink.com.my

4–8 MTA Malaysia 2011 PWTC Kuala Lumpur, Malaysia MES enquiry@mesallworld.com www.mtamalaysia.com

19 – 21 Subcon 2011

BITEC Bangkok, Thailand UBM Asia (Thailand) sanchai@cmpthailand.com www.subconthailand.com

19 – 22 Sheet Metal Asia 2011 BITEC Bangkok, Thailand UBM Asia (Thailand) info@sheetmetal-asia.com www.sheetmetal-asia.com

19 – 22 Intermach 2011

BITEC Bangkok, Thailand UBM Asia (Thailand) intermach@intermachshow.com www.intermachshow.com

25 – 28 MTT Expo 2011

Jakarta International Expo Jakarta, Indonesia ECMI mtt@ecmi.cc www.mtt-indonesia.com

June

8 – 11 Manufacturing Surabaya 2011

July

5–8 MTA Vietnam 2011

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

September

13 – 15 Wire Southeast Asia 2011 BITEC Bangkok, Thailand Messe Duesseldorf Asia wire@mda.com.sg www.tube-southeastasia.com

13 – 15 Tube Southeast Asia 2011 BITEC Bangkok, Thailand Messe Duesseldorf Asia wire@mda.com.sg www.wire-southeastasia.com

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

October

Grand City Convention & Exhibition Centre 6 – 8 Surabaya, Indonesia Metalex Vietnam PT Pamerindo SECC info@pamerindo.com Ho Chi Minh City, Vietnam www.manufacturingsurabaya.com Reed Tradex contactcenter@reedtradex.co.th 23 – 26 www.metalexvietnam.com

Automotive Manufacturing 2011 BITEC Bangkok, Thailand Reed Tradex automan@reedtradex.co.th www.automanexpo.com

23 – 26 Intermold Thailand 2011 BITEC Bangkok, Thailand Reed Tradex intermold@reedtradex.co.th www.intermoldthailand.com

March 2011 metalworking equipment news

83

advertising index

Advertiser

Enquiry No.

4T TECHNOLOGIES PTE LTD

25

020

AGATHON AG

49

037

BENZ GMBH WERKZEUGSYSTEME

43

047

BRUDERER PRESSES (FAR EAST) PTE LTD

23

028

BRUTSCH-RUEGGER METALS

59

162

BYSTRONIC PTE LTD

05

172

CREATIVE MACHINERY ENTERPRISE

81

048

DEES HYDRAULIC INDUSTRIAL CO LTD

79

043

DELCAM PLC (INTERNATIONAL DIVISION)

07

028

DMG ASIA PTE LTD

21

036

ECMI SERVICES PTE LTD (MTT EXPO 2011)

73

159

FRITZ STUDER AG

19

032

HAAS AUTOMATION INC

13

023

HOFFMANN GMBH

10

041

HONG CHEK CO (PTE) LIMITED

31

045

HWACHEON ASIA PACIFIC PTE LTD

27

035

IIR EXHIBITIONS PTE LTD (ASX 2011)

61

044

FC/IFC

034/033

KENNAMETAL INC

BC / 02 / 28

135 / 157 / 137

LMT ASIA PTE LTD

53

46

MALAYSIAN EXHIBITION SERVICES SDN BHD (MTA Malaysia 2011)

69

171

MAWEA INDUSTRIES SDN BHD

81

040

MESSE DUSSELDORF ASIA (WIRE/TUBE SOUTH-EAST ASIA 2011)

77

031

MMC HARDMETAL (THAILAND) CO LTD

47

030

NATIONAL INSTRUMENTS

17

038

SECO TOOLS (S.E.A) PTE LTD

01

001

SIEMENS PLM SOFTWARE (SG) PTE LTD

36

042

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2011)

57

118

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2011)

75

024

SUTTON TOOLS PTY LTD

15

039

TECHTOWN PTE LTD

79

166

TORNOS TECHNOLOGIES ASIA LTD

39

027

TRADE-LINK EXHIBITION SERVICES SDN BHD (Metaltech 2011)

63

173

TRAVERS TOOL CO., LTD

55

132

UBM ASIA (THAILAND) CO LTD (INTERMACH 2011)

51

9

WALTER AG SINGAPORE PTE LTD

09

168

YAMAZAKI MAZAK SINGAPORE PTE LTD

IBC

29

ISCAR LTD

84

Page No.

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metalworking equipment news March 2011

ASIA PACIFIC METALWORKING

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The Engineering Journal For Manufacturing,Automation & Quality Control

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❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

INTEGREX e -V II

INTEGREX Revolutionary Multi-tasking Machines

Efficiency

SERIES

Accuracy

Machining concept for the future - The Integrex

High accuracy C-axis positioning

Higher productivity thanks to powerful, high speed spindle

Productivity

e - V II Series

Max. workpiece size Ă˜3500 mm x 1800 mm

Machine Interference Prevention

INTELLIGENT SAFETY SHIELD

Function for safe operation during machine setup and manual operation Verbal Message System (Patent Pending)

MAZAK VOICE ADVISOR

Verbal support for machine setup and safe condition confirmation Minimized Vibration

ACTIVE VIBRATION CONTROL

Minimized vibration function for high-speed, high accuracy machining and longer tool life Heat Displacement Control (Patent Pending)

INTELLIGENT THERMAL SHIELD

Unique Mazak heat displacement compensation system TelMazak : +65 6862 1131 Fax : +65Pte 6861Ltd 9284 Singapore TelEmail : +65 :6862 1131 Fax : +65 6861 9284 marketing@mazak.com.sg Email : marketing@mazak.com.sg Website : www.mazak.com Website: www.mazak.com

ENQUIRY NO 029

Our complete portfolio.

Your complete satisfaction.

ENQUIRY NO 135

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

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

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