APMEN March 2016 by Eastern Trade Media

ACHIEVING THE DIGITAL EDGE p30 • INNOVATING THE CUT p47 March 2016

PERFORMANCE

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ADVANCED

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THREADING

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PARTING

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Your Tool Advisor Genius ITA recommends the optimal tool based on application parameters and your machine power. 3 tool options, 25 alternatives, cutting data, power consumption, cutting time, metal removal rates, engineering support and more.

Dansk English Français Deutsch Suomi Italiano 日本語 한국어 Nederlands Português Русский Svenska Español-España Tiếng Việt 中文 Български език Српски Magyar Hrvatski Español-México Norsk Polski Româneşte Slovenščina Türkçe Slovenčina Čeština Available for Windows and MAC operating systems, including iPhones and iPads.

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

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

ENQUIRY NO 035

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Asia Pacific Metalworking Equipment News • March 2016

METAL CUTTING

Quantum Leaps And Steady Progress

In today’s ever evolving industrial needs, the evolution of the carbide insert determines the cutting edge advantage. Contributed by Andrei Petrilin, technical manager of indexable milling, and Marcel Elkouby, material science engineer manager, material & coating development, Iscar.

Redefining Productivity:

New Advances In Inserts Technology

Customers always look forward to procuring parts and devices from manufacturers that are reliable in providing quality products that achieve output that does minimal to affect the delivery schedule. Staffan Lundström, product management, parting & grooving, and Bimal Mazumdar, product manager, Sandvik Coromant, explain what it takes to achieve such a status.

GREAT GEAR & SYSTEM

30 34

Achieving The Digital Edge

Within the next decade or so, the machine floor will see connectivity reach new heights with immense amounts of data being driven through networks and on demand – at the touch of a finger. Article contributed by Schaeffler Technologies AG.

Using The Force & The STAR

38 41

APMEN and IAA were granted the opportunity to interview Dr Thomas Liew, executive director, National Metrology Centre; Lee Shih Mean, senior metrologist, National Metrology Centre; Sim Sem Peng, chairman, Malayan Daching; and Elton Tong, service manager, Malayan Daching, on the relationship between Malayan Daching and A*STAR in setting up Singapore’s first 20 MN force measurement facility. By Mark Johnston.

Making The Digital Transformation

Today, intelligent software solutions form the basis of the digital transformation of manufacturing process chains like DMG Mori’s Celos system.

Micromachining:

Getting To The Little Bits

Microcomponent machining of titanium requires micromachining of a special kind and this is usually so for watches and surgical implants. By Syed Shah.

IN DESIGN

Innovating Shopfloor Inspection A Look At The Next Generation CMM

A rapidly changing technological landscape necessitates a leap in the quality of the current crop of Coordinate Measuring Machines (CMM) both in accuracy and the level of automation. Contributed by Nikon.

FAST FAB

Innovating The Cut

Oliver Hergt, editor corporate communications, Bystronic shares with APMEN some highlights from the fields of laser cutting, bending, and software during the Bystronic event in Tianjin had a focus on customers’ increasing requirements for higher productivity.

The High Five In Cutting

As time goes on, the advances of water jetting continues to happen especially in the case of accuracy and more industries are seeing its viability in the market for faster, more accurate cuts. Syed Shah explains.

Enduring power inspired by nature The new GARANT turning grade HB 7020

Robust, sharp-edged and uniquely good! With properties like a shark tooth perfected by evolution, the new GARANT turning grade HB 7020 convinces during comparative tests for machining steel. The multilayer coating system of the GARANT insert makes highest cutting data and maximum reliability possible due to a tailor-made, innovative gradient carbide substrate â&#x20AC;&#x201C; similar to a shark tooth with a hard exterior and an elastic core.

Hoffmann Asia Pacific Tel: +65 6562 8163 Hoffmann Malaysia Hotline: 1800 888469

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

Visit us at

25 - 28 May 2016 PWTC, Kuala Lumpur Malaysia

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CO N T E N TS

Asia Pacific Metalworking Equipment News • March 2016

FEATURES

The Chinese Growth Miracle:

Walking Amongst Giants

China at this point, despite some jitters in the stock markets remained poised to challenge the United States as the world’s top economic superpower. With this, manufacturing in China has seen unprecedented growth but will this economic fairytale sustain? Story contributed by Exxon Mobil.

Putting The Automation On Automotive With articulated robots and advanced software applications that can simulate every stage of production, one company’s robotic solutions help a luxury automotive maker construct their signature models. Contributed by Comau.

It’s About Time:

Evolving Network Standards for the Industrial IoT

In times to come, the manufacturing space will be so interconnected that nothing will escape the eyes of those manning the operations – all in the name of increased efficiency and productivity. By Matej Kranjc, managing director of ASEAN and ANZ, National Instruments.

Efficient And Nimble Service Providers Key To Oil Industry’s Success In The Low Price Environment

The Oil & Gas sector is undergoing much change in recent years. Service providers that are efficient and nimble are seen as a key factor to the oil industry’s success in a low price environment. By Ravi Krishnaswamy, VP & global leader, energy & environment practice, Frost & Sullivan.

Malaysia’s Automation Sector

In this article, we examine a screening of 198 automation vendors in the country, a subset of which was surveyed indepth on their views of their market and contrast these with the latest industrial developments, namely the massive shift in investment growth sectors. By Fabian Teja Boegershausen, manager, and Frederik Junge, visiting analyst, Solidiance.

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ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 12 Hoy Fatt Road #03-01 Bryton House Singapore 159506 Tel: (65) 6379 2888 • Fax: (65) 6379 2885 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 2886 Singapore E-mail: nurulhuda@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

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Versatile milling in focus

When working with mixed production, investing in a versatile milling cutter is always a good idea. CoroMillÂŽ 390, equipped with size 07 inserts, is an extremely flexible concept designed for productive milling in a wide range of operations and materials. Thanks to the small inserts, a higher cutter-teeth density delivers superior productivity. Combine with the insert grade GC1130, produced with Zertivoâ&#x201E;˘ technology, for an added dimension of security and predictability to your steel milling operation.

New CoroMillÂŽ 390. Made for Milling.

ENQUIRY NO 025 sandvik.coromant.com/madeformilling

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

Published by:

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Taking

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Syed Shah

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Face Value

business development manager

Randy Teo

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writer

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Around and about this part of the world, the concept of dignity takes on a whole new level. An extremely sensitive issue, the idea of business in a lot of these parts revolve around the idea of “giving face”. Hard issues on both sides of the bargaining table are never said out loud because that would mean a declaration of “war” to some effect. Hence, carefully chosen words are used to preserve each other’s’ “face” and avoid losing “face”. Ultimately, it’s this form of passive aggressive confrontations and negotiations that lead to some of the biggest deals going down. Likewise in metalworking, there are many issues that are deeper than what is visible to the naked eye. Some may say this issue is only skin deep but in metalworking, such issues have far-reaching sequences that will affect mechanical properties. In surface technologies of metallic material, which sometimes can go into microscopic levels, much is decided in ‘what lies beneath’. For instance, laser surface melting can increase the wear and corrosion resistant of magnesium alloys through increasing the concentration of aluminium content and achieving microstructure refinement in the laser-melted zone. Smaller actions such as these along the cell boundaries has a big consequence since magnesium alloys have been increasingly used in the automobile, communication and aerospace industries owing to their many attractive properties, such as low density, good castability, and high specific strength. On the other hand, there is the image consciousness of the metalworking industry as well, adding the notion of putting the best face forward. These days, the “in-thing” is to be digitally enabled. Walk through any metalworking event and you will see and feel the effects of the Internet of Things (IoT) spewing out from the insides of machine tools. With the automotive industry looking to one day heat up soon after an abysmal few years, we will be looking at the latest cutting edge technologies producing vehicles at rates never seen before. Speaking of face, just in case you have not already noticed in our address and contact column, we have moved to a new office with the same numbers, same great people but a different look (at least externally). So update those address books so that 2016 festive gifts do not go to the wrong building!

circulation executive

Nurulhuda binte Suhaimi nurulhuda@epl.com.sg

contributors

Fabian Teja Boegershausen Matej Kranjc Ravi Krishnaswamy Andrei Petrilin Marcel Elkouby Mark Johnston Oliver Hergt Staffan Lundström Bimal Mazumdar

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

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

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

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

China Is Turning The Tide On Its Manufacturing Downturn

Kobe Steel Looks To Make Cars 20 Percent Lighter

Tokyo, Japan: Kobe Steel devises new method to attach aluminium and steel in automobiles to reduce a car’s weight by 20 percent. Kobe steel has come up with a way to put aluminium and high tensile steel together without the aid of specialised rivets and other fasteners, pieced together using special robots. This technology could potentially reduce a midsize auto’s body weight from 250kg to 200kg. The effort to make vehicles lighter has gained increased momentum recently, thanks to new and stricter emission regulations. In America, the automotive weights of large cars have to be lowered by 15 percent in order to meet 2025 regulation standards. The new method by Kobe is definitely not the pioneering effort by automotive companies to shed weight, but the current methods, including utilising carbon fibre, generally cost far more, up to 10 times as much, than the new method proposed by Kobe. Kobe hopes to apply the technology in new vehicles by 2021.

3D Systems To Demonstrate Leading 3D Solutions For Metalworking Düsseldorf, Germany: 3D systems is expected to show off their leading metalworking solutions at METAV 2016 in Düsseldorf, Germany. 3D Systems will use its booth in Hall 15, booth F35 to demonstrate their featured metalworking solutions by laying out the company’s portfolio of advanced metal fabrication solutions ranging from 3D software and 3D printers to on-demand parts production. The solutions they are presenting include high precision, high throughput direct metal printing, their on demand parts manufacturing, direct scan to CAD workflow integration, CAD inspection, tool design and manufacturing, new production machining software for every manufacturing environment. “We believe in empowering our users to be their most innovative, productive and agile, through an optimised portfolio of products that takes them seamlessly from idea to reality,” said Cathy Lewis, Executive Vice President and chief marketing officer, 3D Systems. “The range, depth and accessibility of our 3D solutions enable our customers to accelerate their designs, improve their products and transform their workflows for faster innovation and optimised results.”

China: China is facing its potentially lowest economic growth in 25 years, not with resignation, but with a rousing call to innovation. The manufacturing market has taken a battering of late as the issue of overproduction proves a hard puzzle to solve, especially with the continued worry of a rapidly lowering Yuen. In the face of these challenges, China has unexpectedly gone on the offensive, pursuing an aggressive route to manufacturing 2.0. Chinese companies have been aggressively buying into businesses, especially those of an automotive nature, in America. A prime example is seen in how Wanxiang Group, which already operates 13 plants in China, is attempting to revive the Fisker, one of the very first electric cars ever produced, under the newly anointed Elux brand. There are numerous other Chinese industries that have taken to investing in western, especially American, tech or automotive companies over the last few years. This outlines China’s ongoing push to invest in as many technologically driven American enterprises as possible. Utilising the knowledge gained from more advanced American companies, especially those that supply par t s , to supplement their local manufacturing sector. China may be shifting focus to a more ser vice oriented economy in the face of falling demands and higher wages, but that does not mean they are relinquishing their manufacturing throne without a f ight, instead, bet on the world’s biggest economy to double down on their most historically successful sector.

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ENQUIRY NO 034

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

Five Important Predictions For The Future Of Metal Printing Technologies Charlottesville, US: SmarTech Markets Publishing, the leading industry analyst firm in additive manufacturing (AM) announced five predictions for AM’s metal printing segment in the coming year. Firstly, metal 3D printing is still in that sweet spot which hits both rising profits and exciting innovations. A team of engineers recently celebrated the start of the New Year by developing a new method of 3D metal printing with the ability to create a more complex and uniform structure. It is these types of innovations that will propel leading AM players to continue on their growth path in 2016. Secondly, the projected boom in popularity of metal 3D printing brings with it slight concerns, specifically the adequacy of supply. Supply of high quality, metal powders that are free of defect might prove insufficient in the face of rising demand in the sector. Thirdly, while companies like Rolls Royce have long been an advocate for AM, although admittedly more in relation to their aviation business, 2016 will just be the year where they put it all together, preferably using AM parts. The aforementioned boom in innovation will undoubtedly lead to new processes in addition to wire-based AM. The most recent leap in AM technology, wire-based is expected to grow substantially in relevance on the back of the aerospace industry. The beauty of which being, the newness of the industry lends itself to as many new competitors springing up as possible. Lastly, If 2014 and 2015 were the years of the large format metal systems, 2016 will be the literal and figurative year of the monkey, with agility and (relative) size priced over the clunky machines of the past. Expect a shift in the market to smaller footprint systems aimed not just at research applications, but for small scale manufacturing as well.

New Ceramic Printing Method Poised To Be A Game changer California, US: The 3D printing innovations just keep on coming The latest milestone featuring a new method to print ceramic micro lattices, the new lattices are both stronger and display less flaws than those made using conventional sintering processes. This breakthrough, made possible by Californian research facility HRL, incidentally founded by airplane legend Howard Hughes, presents a game changer, not only for the 3D printing process but manufacturing industries as well, most notably, the airline sector. The properties exhibited by the new process, including hardness, strength, temperature capability and resistance to both abrasion and corrosion fits in perfectly with the design requirements of making aircrafts. “With our new 3D printing process, we can take full advantage of the many desirable properties of the silicon oxycarbide ceramic” said HRL Sensors and Materials Laboratory senior scientist Dr Tobias Schaedler. The process could potentially free up aircraft manufacturers the same way as more developed segments of 3D printing, such as metal printing, have done, ultimately allowing more efficient manufacturing of ceramic parts that are both stronger and temperature resistant. Senior chemical engineer Zak Eckel, one of two men credited with the invention of the resin (the other being senior chemist Dr Chaoyin Zhou), acknowledges that the new ceramic resin and breakthrough process is a huge leap for ceramic printing. Schaedler himself marvels at the possibilities of their new invention, stating “Everything from large components in jet engines and hypersonic vehicles to intricate parts in microelectromechanical systems and electronic device packaging could be fabricated.”

A member of the UNITED GRINDING Group

Creating Tool Performance

SYSTEM AND SOLUTION PROVIDER FOR TOOL MACHINING SIMTOS

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Manufacturing and resharpening of rotary tools – HSS, CBN or super-hard materials – grinding, EDM, laser or measuring, as well as insert production, WALTER and EWAG offer all technologies from a single source! Together with software and services we provide the best fit for your requirements – you can feel secure with the competence and precision of the experienced partner! www.walter-machines.com www.ewag.com

WALTER EWAG Asia-Pacific Pte. Ltd.

(formerly known as Walter Machines Asia Pacific Pte. Ltd.)

25 International Business Park, #01-53/56 German Centre, Singapore 609916 Tel. +65 65628101 • Fax +65 65628102 ENQUIRY NO 038

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

A P P O I N TM E N TS

Tata Motors Finally Fill Chief Executive Officer Position

Hydrogen Cars Staking Their Claim On The Future Michigan, US: Amidst all the autonomous cars and solar energy powered airplanes, hydrogen is slowly clawing its way back to relevance. It wasn’t long ago that using hydrogen to fuel a car was laughed off by automotive industry experts. Tesla’s co-founder, Elon Musk, called the idea “extremely silly” former US secretary of energy, Steven Chu emphasised the need for four miracles to make hydrogen cars a reality, noting that “saints only need three miracles” Despite the general pessimism from the top minds of the automotive sector, hydrogen has not only survived, but prospered in recent years. Just in 2016 alone, Audi and Mercedes-Benz have either rolled out, the new Audi h-tron Quattro, or are in the midst of producing hydrogen fuelled cars. They join a list of industry heavyweights already dabbling in hydrogen fuelled engines that includes General Motors, BMW, Toyota and Honda. When asked by Mark Brush of Michigan Radio on the reason for utilising hydrogen despite reservations from industry experts, John Mendel, executive vice president of American Honda said “We don’t think they’re silly, we think, you know, hydrogen is still the most abundant element in the universe. And that technology is fast changing.”

India Car Sales Rise By 9.8 Percent New Delhi, India: India is riding on the new wave of automotive sales, as passenger-car sales for 2015 grew at the fastest rate in five years. Amidst the turmoil hacked up by the slowing Chinese economy and the floundering European steel crisis, India has slowly maintained its march to become one of the largest consumer markets in the world. Despite a ban on diesel cars in New Delhi, car sales have never been stronger as they finished 2015 at a five year high. The upsurge in sales is primarily due to the decline in fuel costs, lower interest rates, price incentives by auto makers and an increasingly urban population. The total car sales surpassed two million for the first time in India’s history, a startling recovery from an auto industry that had only recently experienced a 9.9 percent decline in 2013. Despite the positives, Sugato Sen, deputy director general of the industry body, warns of the continued floundering of demand in rural and semiurban areas, caused in no small part to two years of insufficient monsoon rain. In total, SUV’s and minivans experienced a 7.86 percent increase, truck and bus sales enjoyed a near identical 7.6 percent rise, thanks to a 30 percent growth in heavy and medium trucks, which helped offset smaller trucks and buses falling 4.7 percent due to lower demand from semi-urban and rural areas.

Mumbai, India: After two year s of in ter im CEO, Cyrus Mistr y, f illing in for the deceased ex-CEO Karl Slym, Tata Motors f inally found a permanent replacement. Former Airbus and Guenter Butschek Daimler executive, Guenter But schek , is expected to officially take over from Mystry on February 15, serving as both the CEO and the Managing Director, and will oversee the company’s India, Indonesia, South Africa, South Korea and Thailand branches. B o t h t h e C EO a n d MD p o s i t i o n h a d been empty since the previous CEO, Karl Slym, died af ter falling of f a Bangkok hotel. Butschek brings with him, 25 years of experience in Diamler and tenure as the president and CEO of the maker of Mercedes Benz’s China arm. Tata Motors isn’t exactly at their prime, dropping from their vaunted status as India’s undisputed automotive manufacturer to the current six th largest car maker in India, and will be hoping that Butschek will be the catalyst that propels them up India’s automotive ladder. “Tata Motors is going through an exciting yet challenging phase and Butschek’s appointment comes at an opportune moment” said Mistr y. “He brings with him rich global experience of growing organisations and developing new markets.”

The Art of Grinding.

A member of the UNITED GRINDING Group

S121 / S131 / S141 The experts for internal and radius grinding.

Different in size and complexity, but largely the same: The experts for the high-precision internal cylindrical grinding of diameters, cones and radii. The incomparable STUDER-precision is based on the machine bed from Granitan® and the guideway system StuderGuide®. In the development the highest attention was given to the ergonomics in relation to the grinding, the set up as well as the maintenance of the machine. www.studer.com – «The Art of Grinding.»

DKSH Technology Pte Ltd · 625 Lorong 4 Toa Payoh #03-00 · Singapore 319519 · robert.puschmann@dksh.com ENQUIRY DKSH Technology Co., Ltd. · 1st Floor, E-town 2 Building, 364 Cong Hoa Street · Tan Binh District, Ho Chi Minh City · Vietnam · alexander.kliegl@dksh.com DKSH (Thailand) Limited · 2106 Fantree 4 Building, Sukhumvit Road · Bangchak, Prakhanong · Bangkok 10260 · Thailand · thanit.s@dksh.com DKSH Technology Sdn. Bhd. · B-11-01, The Ascent, Paradigm, No. 1, Jalan · SS 7/ 26A, Kelana Jaya · 47301 Petaling Jaya, Selangor Darul Ehsan · Malaysia · derrick.ho@dksh.com

NO 029

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

The 2016 Green Car Winners Announced

Tesla Plans To Set Up First Factory In China By 2016 Hong Kong, China: Tesla CEO, Elon Musk recently revealed plans to set up a Tesla factory in China by 2016. Tesla has not enjoyed the smoothest of starts in their quest to repopulate China with a roadful of high tech autonomous driving units. The 2014 sales fell far short of Musk’s heady predictions of China accounting for 35 percent of their total sales, 2015, while better, once again failed to reach expectations. Despite the setback, or perhaps because of it, Tesla has made plans to set up a fully functioning Tesla factory by mid-2016, with Musk expressing his desire to find “a local partner and a location for the plant” by the middle of 2016. While Tesla is known for leaping over boundaries, the timeframe might be a bit too tight, even for them. Forbes contributor, Beterl Schmidt noted that obtaining approvals from a multitude of Chinese government entities “can, and usually does, take years.”

Washington, US: Green Car Journal announced the winners of their 2016 Green Car Awards at the Washington Auto Show. Volvo, Chevrolet and Honda were the big winners at the 2016 Green Car Awards. The trio swept three of the most prestigious prizes up for grabs, with the Volvo XC90 T8 winning the luxury green car of the year, the Chevrolet Malibu Hybrid snatching up the connected green car of the year and Honda’s HR-V earning the distinction of green SUV of the year. Volvo’s XC90 T9 is the industry’s first seven passenger plug-in hybrid SUV, and uses a two litre supercharged and turbocharged Drive-E engine with a rear axle electric motor powered by lithium ion batteries. The Chevrolet Malibu Hybrid features an efficient hybrid powertrain that delivers an estimated 47 combined mpg. Nominated cars included the BMW X5, Lexus RX 450h, and Porsche Cayenne S E-Hybrid among others. The awards are based on components such as safety, quality, functionality, performance, value and other ‘green’ credentials.

Toyota’s Plants Forced To Halt Production

Petrol Car Takes The Spotlight As Diesel Flounders In India New Delhi, India: The Indian government’s ban on diesel cars in New Delhi is expected to pay dividends for KUV100 In December 2015, India’s supreme courts dealt a blow to the already shaky future of diesel cars by banning registrations of diesel cars in New Delhi until the end of March 2016. The measures were enacted to combat the extreme levels of pollution over the capital’s roads. An unintended beneficiary of the drive to clear up the smog might come in the unassuming form of KUV100, a small petrol engine car manufactured by India’s largest SUV maker, Mahindra and Mahindra Limited. “If priced right, the KUV100 should be a best seller” said Basudeb Banerje, an analyst from Mumbai. Petrol cars have increasingly been favoured by India’s people, in large part due to erstwhile government policies of enacting laws against diesel cars and incentivised schemes for those who choose petrol instead. This will be Mahindra’s first petrol car in their stable, as they look to edge their way back to the changing landscape of motor vehicles in India. Another series of stringent emission norms against diesel are expected to be implemented in the near future, which will probably lead to a boost in sales for petrol and electric vehicles. Banerje was optimistic about the future of petrol, saying: “With all the uncertainty around diesel, a petrol model couldn’t have come at a better time for Mahindra.

Aichi, Japan: Toyota released a press statement detailing their plans to temporarily halt auto production due to an explosion at an Aichi manufacturing plant. An explosion that occurred at an Aichi plant on January 8, 2016, has compromised the facilities ability to roll out the assembly line as efficiently, leading to parts shortages. Toyota has therefore decided to impose a factory shutdown from February 8-13, 2016. Toyota is expected to request alternate production lines or source steel from other suppliers. Despite the shutdown only affecting plants in Toyota, the majority of global production is currently concentrated in Japan. Production resumed as planned on February 13. Complete resuming of Aichi plants on the other hand will be expected to resume operations in March this year.

TaeguTec Ltd. World Headquarters 1040 Gachang-ro, Gachang-myeon, Dalseong-gun, Daegu 42936, KOREA +82-53-760-7640 +82-53-768-8055 www.taegutec.com Argentina _ Australia Germany _ Greece _ Norway _ Pakistan South Africa _ Spain

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ENQUIRY NO 028

 4 edges with unique chip breaker  Rigid screw clamping with 3 contact points  Insert indexing from both sides of the holder  Pocket protects unused edges from chips during machining process

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

A P P O I N TM E N TS

Direct Digital Manufacturing Startup Appoints Industry Veteran As General Manager

Open Possibilities For Oil And Gas And Aerospace Industry Singapore: Sandvik Coromant Singapore and Okuma held a joint seminar on the open possibilities for oil and gas and the aerospace industry. A one day seminar on January detailed the possibilities available for the oil, gas and aerospace industry on January 2016. The seminar, held by Sandvik Coromant and Okuma was the first time in 15 years the two companies had held a seminar. The seminar also saw Okuma introducing their latest operation system, OSP Suite, which is equipped with intelligent technology, a thermos friendly concept, machining navi, 5-axis auto tuning system and collision avoidance system. Attendees were later divided into small groups that were allocated around Sandvik Coromant Productivity Centre and introduced to cutting machines and cutting tools.

DeltaWing and DHX Electric Machines Announce Lightweight Engine Georgia, US: Two Georgia based firms announced an agreement to make, use and sell electric motors and components designed for automotive applications. DeltaWing, a transportation and electronics innovation firm, secured worldwide rights to make, use and sell lightweight electric motors and components jointly designed with another Georgia firm, DHX Electric Machines Incorporated. The new engine is 75 percent smaller than average engines, significantly lighter but just as powerful as conventional motors. To combat the thermal losses in high torque electric motors generated in the windings, the new engine uses tiny channels in the windings to dissipate heat and reduce thermal resistance and increase efficiency. “Imagine a light and cool to the touch 20 horsepower motor the size of a 12 ounce can, and one that fits in two hands and puts out 80 or more horsepower.” Said Don Panoz, chairman of Deltawing. “It’s simply a transportation game changer. We’ll use it in our Deltawing road car architecture.”

Atlanta, US: CloudDDM, a company delivering direct digital manufacturing (DDM) services has appointed Gary Fudge, former director for the American branch of Irish Mcor Technologies, a manufacturer of full colour 3D printers, as their General Manager. At Mcor, he was responsible for building a dealer network that went a long way in increasing sales by 700 percent. Prior to that, Fudge had worked at other 3D firms, including Geomagic, a 3D systems company in 2013, and prior to that, Z corporation, a 3D printer company that was eventually acquired by leading 3D printer manufacturer, 3D Systems Corporation, in 2012. “I’ve been working with 3D printing for decades and have witnessed a lot of exciting developments in the field,” said Fudge. “But the technology has yet to realise its potential. The time for that is now. And at this moment, I couldn’t think of a better company to be with than CloudDDM.”

Anglo American Looks To Exit Brazil Barro Alto, Brazil: Less than 10 years after purchasing the US$5.5 billion Baro Alto Mine, Anglo American might be considering selling it off, along with most of their mines in Brazil. Anglo American recently put up their US$1 billion niobium and phosphate business up for sale, a move that would most likely set off a domino effect that ends in their complete withdrawal from Brazil. The mines currently under the most threat from closing down are the Barro Alto nickel mine and the Minas-Rio iron ore complex. The Barro Alto mine, purchased for over US$5 billion has been embroiled in supply shortages and production delays since it opened. The Minas-Rio iron ore complex ran relatively smoother, but the cost of acquiring it, US$4.6 billion, in addition to production costs rising up to US$8.8 billion might lead to their sale as well. The potential exit follows the company’s complete withdrawal from The Middle-East amidst challenging economic times. Chief executive Mark Cutifani had earlier revealed restructuring plans that included layoffs for more than 80,000 of their total workforce.

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

Pressure Transmitter Market Expected To Hit 3.77 Billion By 2020

Doubts Cast Over Malaysia’s Capacity As Bauxite Supplier Pahang, Malaysia: Malaysia’s recent setbacks have fuelled talks that Malaysia might not be the long term solution to fill the bauxite supply gap. Bauxite exports leapt 600 percent from 2014 to 2015, after experiencing a similar leap in bauxite exports from 2013 to 2014. This increase in production has also seen illegal bauxite mining increase substantially over the previous two years. There has been some legislation passed to limit the illegal mining, with the three month moratorium on bauxite mining being the latest, but so far, the Malaysian government have been unable to arrest a single illegal miner. Pahang officials have also been embroiled with claims of corruption and residential dissent, with two more Pahang land and mines department officers recently charged for accepting bribes. The vacuum left by Indonesia’s decision to ban exports of unprocessed ores led to the industry bestowing upon Malaysia the title of primary bauxite exporter, but infrastructural and legalistic shoddiness has cast aspersion over whether Malaysia can keep up their supply. The countries that could pick up the bauxite slack include Australia, the second largest exporter of bauxite ore to China and China itself, whose domestic bauxite mining is beginning to pick up pace.

Dublin, Ireland: Pressure transmitters are expected to stay in high demand even as the global economy stutters. A new market research report on the global trend and forecast of the pressure transmitter market up till 2020 recently published by marketsandmarkets estimated a five percent compound annual growth rate (CAGR) for the pressure transmitter market. The market, estimated to be worth US$3.77 billion by 2020, is expected to benefit mostly from growth in the power, chemical, water and wastewater sectors. The growth will potentially derive from the growing need to optimise resources and cut down on expenses. The multivariable transmitter is expected to experience the highest growth rate among pressure transmitters, primarily due to their ability to measure multiple parameters, thereby reducing total process measurement cost. By producing three measurements from a single instrument, the multivariable transmitter saves on impulse piping, while reducing pipe penetrations. While the most established market for pressure transmitters is found in North America, the bulk of the growth is expected to be driven by the Asia-Pacific region.

Coal Gets Hit By US Moratorium Washington, US: President Obama gave a succinct summary of the failings of the coal industry and outlined the murky future of the sector. A noteworthy snippet from the more than two hour state of the union address came when he touched on his plans for the coal industry. While Obama haven’t shied away from confronting the realities that the coal industry has to face, there was a slight change in tone and content from previous plans to modernise the coal industry. “Rather than subsidise the past, we should invest in the future” President Obama continued “That’s why I’m going to push to change the way we manage our oil and coal resources, so that they better reflect the costs they impose on taxpayers and our planet.” The speech laid the foundation for the recent introduction of the moratorium on new coal leases as a review on coal management is undertaken. More than 30 upcoming coal projects might be scrapped in the face of these new laws. The House GOP has been swift in trying to counteract the President’s regulations, passing a bill that overturned rules designed to protect rivers and streams. Referring to the initiatives proposed by Mr Obama, Republican Alex Mooney decried the fact that the changes “will destroy up to 77,000 coal mining jobs nationwide”. The president has already stated his intention to veto the bill. The National Mining Association (NMA) has already voiced their displeasure earlier during the hearings on the federal coal lease program, with their President and CEO Hal Quinn calling raising the costs of coal that is leased on federal land an “especially foolish idea” America isn’t the only country cutting back on their coal usage. China, by far the number one user of coal, saw its coal consumption drop 5 percent in 2015, with its coal imports plunging 35 percent.

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

A P P O I N TM E N TS

Kennametal Apponts New President and CEO

Lubricant Systems Market Expected To Grow Till 2020 New York, US: A new report on the lubricant systems market predicts 2.14 percent growth in the sector up till 2020. Transparency Market Research, a market research firm that provides market research on current trends and forecasts, released a report on the lubrication systems market. The report predicted that the US$4.367 million market in 2013 will experience a 2.14 percent compound annual growth rate. The main reason for the increase in consumption of lubricant additives is expected to be the constant amendments in emission norms. The automotive industry is going through a period of increasingly stringent emission controls, and is predicted to be the major consumer of lubricant additives. Europe and North America are the two markets expected to impose the most stringent reforms, with the permissible limit for carbon dioxide expected to be set at 95 grams of carbon dioxide per kilometre by 2021 in Europe, down from 130 grams in 2015. Emerging economies might not be subjected to the same standards as more developed countries, but two of the largest car markets, China and India, are also focusing on better emission standards in an attempt to lower pollution in their cities.

Kemper’s Sales Profit Increases By 11 Percent Cheshire, England: For the second year running, Kemper experienced a double digit growth in sales. Kemper built on their strong 2014 foundation, where they recorded a 12 percent growth, by increasing sales profit in 2015 by 11 percent. The primary reason for the jump in profits came from the increase in series devices during 2015. The CEO of Kemper, Björn Kemper, outlined his expectation for the coming year. “Because of the current prevailing political and economic crises, we shall remain cautiously optimistic for the time being. But we are counting on the fact that there is a good chance to open up new markets with our products” Kemper has identified Eastern Europe, especially Poland, as a potential site of growth for their company, and will attempt to make their presence in the region felt by attending three major metal fairs.

Pennsylvania, US: Ron DeFeo, former longtime chairman and CEO of Terex and current Kennametal board member, has been appointed as Kennametal’s new president and CEO. Kennametal turned to long time board member, since 2001, Ron DeFeo to replace outgoing president Donald Nolan, who left his position after a yearlong tenure, to pursue other interests. The hire was viewed by Kennametal chairman Lawrence Stranghoener as “necessary” and emphasised the need for a change in leadership. “Ron is a highly experienced CEO who will bring much wisdom, experience and passion for Kennametal.” “As a 14 year member of the Kennametal board, I know what the company and its people are capable of achieving” DeFeo said. “I’m excited about the potential embedded in Kennametal and with over 20 years of CEO experience, I am excited to get to work on behalf of Kennametal’s employees, customers and shareholders.” Prior to taking up the mantle at Kennametal, DeFeo served as the senior vice president of J.I. Case Company., and managing director of Case Construction Equipment throughout Europe.

Pratt & Whitney Approves Houghton Metalworking Fluid Pennsylvania, US: Houghton’s semi-synthetic metalworking fluid, Hocut 4940 was approved by Pratt & Whitney. Prat t & Whitney approved the use of Houghton’s Hocut 4940 in the production of their aircraft engines and military power units. Specif ically the metalworking f luid is cleared for contact with a variety of aerospace alloys, including aluminium, steel, stainless steels, nickel-based alloys, single-cr ystal nickel alloys, cobalt-based alloys, magnesium, titanium and titanium-based alloys. The fluid is both chlorine free and does not contain either formaldehyde releasers or any other secondary amines. Gary Dukus, Houghton’s business development manager claimed that the metalworking fluid “conforms to all health and environmental regulations”

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

DMG Mori Open House Featured Six World Premieres Pfronten, Germany: DMG Mori’s open house on January 26-30, 2016 hosted the company’s best-sellers and featured six world premieres of their new machines. The 2016 DMG Mori open house event followed in the tradition of previous editions that highlighted their heavy hitters as well as shed new light on their upcoming products. The six world premieres on that day consisted of the CTX gamma 3000 TC 2nd Generation, the largest turn & mill complete machining centre in the CTX TC series, the DMU 160 P duoBLOCK, the DMU 600 G linear, DIXI 125 and the Ultrasonic 20 linear 2nd Generation. Including the six world premieres, there were 90 other exhibits live in operation, and many of their best sellers that include turnmill complete machining, universal milling, XXL parts machining, and new technologies.

High Performance AntiCorrosion Coatings Market Expected To Hit US$18.22 Billion London, England: The high performance anticorrosion coatings market is expected to grow to US$18.22 billion by 2023. Transparency Market Research recently published a repor t that detailed the high performance anti-corrosion coatings market and their forecast for the next seven years. The report underlined a 2014 high of US$11.95 billion, while expecting a compound annual growth rate (CAGR) 4.8 percent between 2015 and 2023, culminating in a US$18.22 billion market by 2023. Like many other metalworking related industries, the anti-corrosion market is currently dominated by western markets such as America. The issue of saturation is expected to kick in the coming year, leading to the expected growth being primarily driven by the Asia-Pacific region. The driving force for future growth seems to be predicated on rising demand from marine, power generation, construction, oil and gas and other industries. The coating is widely used in the oil and gas industry, especially in coating applications.

Boeing Halves Production Of B747s Chicago, US: Boeing continued cuts on their most iconic aircraft, dropping production to only six a year. The Boeing 747 inched a notch closer to a production freeze as Boeing revealed plans to lower production of the aircraft to just six a year. This is even lower than earlier reduction predictions that placed production at 12 a year. The airplane has seen a drastic decline in demand as consumers and airlines both switch over to the newer two engine iterations over the B747’s more traditional four engines. Air France provided the latest blow to the B747 series, retiring their fleet of B747’s in January 2016. Ray Conner, chief executive of Boeing Commercial Airplanes, indicated that while the future for aircraft remained strong, the inertia in the air cargo market had resulted in the slowing demand for the B747-8 freighter, which was expected to produce the most orders for the latest version of their aircraft. He stated: “While we remain confident in the B747-8’s unique value proposition… we’re taking the prudent step to further align production with current market requirements” The remaining orders for the B747’s come primarily from Air Bridge Cargo, one for Cargolux, nine from Korean Airlines and Air Cargo, two for Silk Way Airlines, two for Nippon Cargo and one for Cathay Pacific Cargo.

3D Printing Takes Centre Stage At Aerospace Forum Singapore: The simplification of fuel nozzles proposed by General Electric (GE) proves to be the centrepiece of aerospace forum. The four th Aerospace Technolog y Leadership Forum, held on February 15, saw more than 350 delegates from leading aerospace companies discuss the future of the aerospace industry. The Agency for Science, Technology and Research (A*Star) organised event saw GE bring up their plans to simplify the fuel nozzle, which currently constitutes 18 parts, into one single piece using additive manufacturing. 3D printing has been commonplace for many industrial bigwigs such as Rolls Royce, but airplanes have been riding the trend in marketing more 3D printed engines.

BUSINESS NEWS Asia Pacific Metalworking Equipment News • March 2016

Rio Tinto Not Slowing Down Iron Ore Shipments

Melbourne, Australia: Despite plummeting iron ore prices, Rio Tinto isn’t slowing down on production any time soon. Iron ore prices have f latlined from a 2011 peak, falling more than 75 percent since then, landing in at below US$40 a tonne. Even with the dreary outlook, Rio Tinto isn’t slowing down their production anytime soon. The iron ore producer reported an 11 percent rise in annual iron ore shipments, while announcing plans to ship 350 million tonnes in 2016. Their unorthodox supply tactics might be actually working, with many expecting the company to maintain or even raise its dividends for the next 12 months. Their bullish attitude on the supply side hasn’t come without its fair share of hardships. The company have recently gone on a global pay freeze, with stricter expense management and cutting what it spends on consultants and contractors. Chief executive Sam Walsh sees the global carnage on the iron ore market could prove an ideal opportunity for the company to widen the gap between other competitors who have decided to halt or cut down on their iron ore productions, stating: “Rio Tinto can thrive when others falter.”

Gold Proving To Be Silver Lining For World Economy

Nevada, US: Gold has been on a steady decline for the past few years, but the rebound is well and truly away. Gold has been on a tear recently, experiencing their first sustained price recovery in years, climbing up 13 percent this year, and seven percent in February alone. The projected hike in gold comes about due to a curious intersection of factors coming together, with the prices of precious metals rallying coinciding with increased demand from a populous ravaged by market turmoil. The effects of strengthening gold is already beginning to be felt, with Tahoe Resources acquiring Lake Shore Gold in a US$680 million deal. While gold firms are expected to continue consolidation and divestment in their near future plans, the rise of gold is definitely promising news for miners in the long term.

Milacron’s Coolant Approved By Bombardier Ohio, US: Bombardier has approved of Milacron’s Cimcool brand’s Cimperial 861. Milacron, a company that manufactures and distributes plastic processing equipment, has received approval from Canada’s answer to Boeing, Bombardier for use of its hybrid lucidity, semi-synthetic metalworking fluid. One of the main positives of the product as mentioned by Milacron’s aerospace business manager, Kyle Walker is “The hybrid combination of InSol technology in semi synthetic metalworking fluid” that helps to deliver cooling and lubricity directly to the point of cut. The company, which just last year went public on the New York Stock Exchange (NYSE), recently saw its stocks dip 4.28 percent to US$13.21.

Aluminium Systems Projected To Grow In The Coming Years US: A new report by marketsandmarkets highlighted some encouraging signs for the aluminium systems market from 2015-2020. Then aluminium systems market is considered by many to be a ripe sector for growth, in particular due to the expected economic leaps the Asia Pacific region is expected to make in the next few years. The Asia-Pacific region in 2014 accounted for the largest share, in terms of volume, of the aluminium systems market, coming in at 17151.5 kilotonnes. North America also performed strongly, accounting for a total of 25 percent of the market share. The growth till 2020 will be mainly focused on the Asia-Pacific region though, with expected compound annual growth rates (CAGR) of 5.65 percent expected until 2020, leading ultimately to a US$147.13 billion share. Going forward, the market’s growth will be propelled by mainly an increasing demand from the end-use industry and technological advancements. Another intangible factor that might play into the expanding aluminium systems market could be the shift in attitude from the consumers themselves.

Peru’s Largest Copper Mine Completes First Shipment Las Bambas, Peru: Peru’s largest copper mine, completed its first shipment to China. China backed, Australian based mining company MMG has officially started shifting copper in their gigantic Las Bambas mine, shipping over 10,000 tonnes of copper concentrate to China. The US$10 billion mine located in Apurimac is expected to produce over 500,000 tonnes of copper, or more than a third of Peru’s national production, and could propel the country into becoming the world’s second largest producer of copper, right behind Chile. It will also produce silver, gold and molybdenum over its mine life. Despite making up over half of Peru’s exports, mining has taken a few hits over the years, with environmentalists and community leaders staunchly rejecting the construction of the Las Bambas mine. Copper is currently trading at a six year low, but experts predict that the surge in production will result in a net profit for Peru.

ENQUIRY NO 030

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

Quantum Leaps And Steady Progress In todayâ&#x20AC;&#x2122;s ever evolving industrial needs, the evolution of the carbide insert determines the cutting edge advantage. Contributed by Andrei Petrilin, technical manager of indexable milling, and Marcel Elkouby, material science engineer manager, material & coating development, Iscar.

Editorial

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emented carbide is a hard material that is used extensively in cutting tools that are intended for machining. Within an industrial context, references to carbide or tungsten carbide usually refer to this cemented composite. Carbide cutters deliver many advantages. In the vast majority of cases, they provide a better surface finish on the machined part, and allow faster machining when compared to the use of high-speed steel (HSS) cutters. In

addition, carbide tools are able to withstand higher temperatures at the cutter-workpiece inter face than standard high-speed steel tools, which is the principal reason for their faster machining capability. Carbide usually provides superior performance for the cutting of tough materials such as high alloyed steel or stainless steel, as well as in situations where other cutting tools would wear away faster, such as when performing highquantity, extended production runs.

METAL CUTTING Asia Pacific Metalworking Equipment News • March 2016

At the same time, progress in science and technology has significantly impacted on the manufacturing process of inserts.

Industries use of cemented carbide for cutting metals began in the 1930s. Since that time carbide has become by far the most popular material for the production of cutting tools. While some tools that feature relatively small sizes are wholly produced from carbide; others use carbide in the cutting area only. Originally the cutting area consisted of a carbide tip that was brazed or soldered to a tool body. However, in the 1940s cutting tool manufacturers began to produce cutting tools with the advantage of replaceable carbide segments that were mechanically mounted on to the tools body. This clever innovation and the use of mechanical clamping, which provides much greater strength compared with to the previously brazed connections, are now recognised as memorable milestones, not only in the area of tool manufacturing, but also in advancing the efficiency of all metalworking industries. This major development led to impressive improvements in productivity within the area of machining operations. It was immediately possible to increase the load on the tool and to intensify operational metal removal rates. In addition to this cost effective method ensuring the simple and economical replacement of the cutting element when worn or in case of breakage, it allowed the manufacturing of cutting segment and the tool bodies to be divided. Depending on the shape of the inserts used, they could be quickly indexed ensuring the rapid change of a worn cutting corner by several methods, such as rotating the insert on its axis or by flipping it upside down. Initially the new cutting segments were known by several names, such as throwaway tips, interchangeable inserts, replaceable inserts, however, today the more widespread, generic term indexable inserts is used.

The technology used in the manufacturing of the indexable inser t s is based on powder metallurg y, comprising of several manufacturing processes as follows:

Fig. 1 - The milling insert H690 TNKX 1005 features marked difference in height of the inserts’ corners

- preparing carbide powder (mixing) - pressing the powder (compacting) - sintering compact - post-sintering processing - coating In principal these stages have remained unchanged over many decades. Although, at the same time, progress in science and technology has significantly impacted on the manufacturing process of inserts. In the past, inserts were produced by the use of manual machines. Hence, the application of various complex powder metallurgical processes was very difficult or even impossible to perform. The introduction of more progressive industrial equipment, featuring advanced automation and computer control, made the technological processes more stable, controllable and reliable. Consequently, the mechanical properties of manufactured inserts became more uniform, predictable and repeatable; these factors allowed dramatic improvements in terms of the accuracy of sintered inserts by reducing production tolerances. Today, a typical insert production press is a highly engineered device that is computer controlled. A moveable punch can be made from several “sub punches”, each operated separately. Some press designs encompass multi-axial pressing options. The remarkable progress in press technolog y enables the production of complex shaped inserts that are characterised by variable corner heights (Fig. 1). This capability enables the realisation of optimal cut ting geometr y, which

This major development led to impressive improvements in productivity within the area of machining operations.

METAL CUTTING Asia Pacific Metalworking Equipment News • March 2016

Fig. 2 - The nanolayer structure of the coating of the IC807 carbide grade (SEM image)

PVD coatings performed a gigantic step in overcoming the complex problems that prevented progress within the field of nanotechnology.

guarantees not only smooth and stable machining but also the increased accuracy of a machined surface. Additionally, the advantages provided by the use of modern CAD/CAM systems make it possible to improve the design and the shaping parts of pressing die sets. Also, the ability to simulate the pressing processes related to new sintered products, when they are at the beginning of their design stages, allows further design amendments and enhancements to be made. Advanced new techniques, related to sintering insert masters, improves process quality. Gradient sintering of multi-carbide substrate ensures a thin upper layer that feature high cobalt content. This gradient layer produces an excellent barrier against the development of cracks and guarantees increased resistance to brittleness and fracturing. Today, substrates of this type are commonly used in tools intended for turning operations. Until the 1980s carbide grades were uncoated. In order to make grades more universal and applicable to machining various engineering materials, tool manufacturers invented grades that contained various additives. The adoption of coating technologies has dramatically changed the world of machining; now the vast majority of carbide grades are coated. The addition of this new technology permitted the grades to focus on cutting specific material groups. The substrates contained fewer additives; therefore their structures became more uniform and stable, which further improved control during production. The introducing of coated carbides and on-going developments in this area by companies like Iscar, has enabled signif icant increase in cutting speeds. For example 30 years ago, when turning gray cast iron the cutting speed used was approximately 100 m/min for inser t s which were made from Iscar’s IC20 (uncoated carbide grade). Today, the coated IC5005 allows speed values of up

to 600 m/min. In another case, the milling of martensitic stainless steel during the same years was performed at about 80 m/min for IC50M (uncoated carbide grade), now 300 m/min is the acceptable value when using IC 5500 (coated grade). These impressive numbers provide an excellent illustration of how coated carbides have allowed leaps in progress to be made in the area of cutting speeds. Coating technology continues to develop in two principal directions - Chemical Vapor Deposition (CVD) and Physical Vapour Deposition (PVD). The main result of progress within the area of CVD was the introduction of Alumina ceramic coatings. This allows machining at elevated speeds due to its excellent temperature isolation properties, high hardness and chemical stability at high temperatures. PVD coatings were introduced during the late 1980s. PVD coatings per formed a gigantic step in overcoming the complex problems that prevented progress within the field of nanotechnology. PVD coatings brought a new class of wear-resistant nano layered coatings. Such coatings (Fig. 2) are a combination of layers having a thickness of up to 50 nm (nanometers) and demonstrate significant increases in the strength of the coating compared to conventional methods. Modern technology allows both methods – CVD and PVD – to be combined for insert coatings, as a means of controlling coating proper ties. In par ticular, ISCAR’s carbide grade DT 7150 features a tough substrate and a dual MT CVD and TiAlN PVD coating. This was originally developed to improve the productive machining of special-purpose hard cast iron. Another major advancement in inser t technolog y relates to post-coating treatment s. For instance, Iscar developed Sumotec, a treatment method for the already coated surface of an insert. The advanced post-coating technology delivers improved streng th and wear resistance to carbide grades, enabling higher productivity. In CVD coatings, due to the difference in thermal expansion coefficients between the substrate and the coating layers, internal tensile stresses are produced. Also, PVD coatings feature sur face droplet s. These factors negatively affect a coating and therefore shorten insert tool life. Applying Sumotec post-coating technologies considerably reduces and even removes these unwanted defects and results in increasing the tool life of the grade, also greater productivity (Fig. 3 and 4).

METAL CUTTING Asia Pacific Metalworking Equipment News • March 2016

Fig. 3 - SEM image of CVD coating’s surface before (left) and after (right) Sumotec post coating treatment

Fig. 5 - The structure of Iscar grade IC6025, which was designed especially for turning ISO M materials

Fig. 4 - The effect of Sumotectreatment on a PVD coated surface: a- untreated surface, b- treated surface

Continuous development s in carbide inser t technolog y have initiated several areas of development. Advanced methods of pressing and sintering, coating processes and post-coating treatments, new options for surface treatment and optimisation of cutting geometr y are intended for manufacturing indexable inserts to meet the requirements of efficient machining dictated by modern metalworking industries. Iscar’s recently developed grade IC6025 is intended specifically for turning materials related to ISO M group (austenitic and duplex stainless steel). The grade coating is a multi-layered coating that features post-coated treatment. The grade enabled signif icant improvement s in produc tivity related to turning materials in the aerospace industry (Fig.5). Among the very latest advanced carbide grades, Iscar has developed the IC806 grade for turning and grooving high temperature alloys. The IC806 grade is a new complementary Sumotec PVD coated grade for machining high temperature alloys, especially Inconel 718. This new grade for Inconel 718 machining belong s to a family of nickel ba sed super alloys that are used extensively for applications where the ability to withstand high temperatures and high corrosion resistance properties are required. The material

is widely used in the aerospace industry, in components that are placed in the hot section of the engine, and is also used in various oil industry sectors. The microstructure of Inconel 718 consists of an austenitic structure possessing high tensile and yield strength. The major problems encountered when machining Inconel 718 are characterised by very high temperatures on the cutting edge of the insert, this is due to the abrasive elements in the materials composition (high nickel content of 50-55 percent and chrome 17-21 percent), which can cause high wear rates, chipping, notching and inser t breakage. These factors contribute to reduced tool life and high deformation of the cutting edge even at low cutting speeds. Another complexity associated with Inconel is its tendency to become malformed; this is due to its metallurgical sensitivity to residual stresses and self-hardening effects during cutting operations. The aim is to effectively machine this unique material, and has therefore successfully developed the IC806. This is a submicron grade with TiAlN and Iscar’s Sumotec coating resulting in superior wear resistant properties. IC806 has a hard submicron substrate with PVD coating and a special post coating treatment that provides substantially improved tool life and better reliability.

Modern technology allows both methods – CVD and PVD – to be combined for insert coatings.

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

Redefining Productivity:

New Advances

In Inserts Technology

Customers always look forward to procuring parts and devices from manufacturers that are reliable in providing quality products that achieve output that does minimal to affect the delivery schedule. Staffan LundstrĂśm, product management, parting & grooving, and Bimal Mazumdar, product manager, Sandvik Coromant, explain what it takes to achieve such a status.

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2002

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s the metal cutting industry becomes more and more competitive, machine shops are continually looking for ways to deliver market differentiation. In combination with stricter environmental requirements, machining operations are becoming increasingly automated to ensure energy efficiency and streamlined production with a minimum of waste, interruptions and late deliveries. The automotive industry is not just at the forefront when it comes to automated manufacturing processes, but leads with its willingness to communicate the amount of energy required to produce each vehicle. Cutting force in component machining operations is just one part of that equation, while recycling, scrap and number

Sandvik Coromantâ&#x20AC;&#x2122;s Inveio coating has unidirectional crystals and a uniform crystal growth direction. Every crystal of the alumina coating layer is lined-up in the same direction (shown as a uniform yellow color of the alumina crystals in the image).

of inserts used, are other parameters that have to be included. Maximising Output The objective for tooling suppliers is to design premium cutting tools that can handle ever greater speeds, feeds and depths of cut, in order to maximise output. However, production planning today is far more holistic than it has been historically. In fact, increasing the cutting data by 30 percent in a certain operation is no longer sufficient. As a result, demands for sustainable manufacturing along with automated, unmanned production call for a completely new understanding of productivity. Market surveys indicate that the majority of machine shops place process security and the

METAL CUTTING

4325 has the ability to run at higher cutting data than almost all other P25 grades - productivity by metal cutting efficiency

Metal cutting efficiency - cm3/min

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

t uc

it y

Productivity throughout the large and varied P25 area is to some extent an individual measure, depending upon the type of production. But generally it is a combination of machining efficiency, often measured in metal removal rate, and machine tool utilisation, in pieces machined per hour. For the cutting edge, this comes down to the good old values of cutting data and tool life.

10-200% increase in tool life has been seen with 4325 (average > 30%) - productivity increased machine utilisation

Machine utilisation - %

Sandvikâ&#x20AC;&#x2122;s Inveio coating is an innovation in tool material technology that fundamentally changes the coated insert. It has uni-directional crystal orientation achieved through the new CVDprocess, presenting a stronger, uniform structure of the coating. New properties emerge that are advantageous for withstanding the forces and temperatures of the cutting-zone, giving a much more durable insert contact-surface.

potential to run unmanned at the top of their wish lists, followed closely by higher metal removal rates. In truth, the ultimate aim is to combine all three ambitions. Steel turning in the ISO P25 material classification is the backbone of operations at machine shops around the world, which makes it a good focus area for the purposes of this article. The P25 category covers the whole range, from unalloyed to high alloy steels, from soft and sticky to hard and abrasive, and from low specification to high. Of course, machinability differs considerably from steel type to steel type, particularly as the material comes in workpiece variants that include forgings, castings, bar, tube, rolled, drawn, untreated, hardened, tempered and pre-machined. Factors To Consider To maximise output, the selected insert for each type of steel must balance a number of factors. These include durable and predictable tool life, which will lead to fewer stops for insert changes, as well as high reliability for limited or unmanned supervision, guaranteed surface quality throughout the life of the insert, and a broad application area. The latter entails sourcing an insert that can deliver excellent performance

The edge-line of the GC4325 insert is more resilient, giving improved predictability of the insert capability. Controllable, continuous tool wear provide a combination of very high process security, long toollife and potential for higher cutting speed.

in continuous and interrupted machining, and from finishing to roughing, in a wide variety of steels. In turn, this will reduce tooling inventory, handling and storage costs. The ability to machine a multitude steel with different hardness properties is also vital. With this in mind, the condition of the edge-line is particularly important as it can help achieve the highest possible process security and repeatability, reduce the need for supervision and thus boost the potential to run unmanned. In short, the edge-line must possess the necessary hardness to resist any plastic deformation induced by extreme temperatures in the cutting zone.

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

Turning in the ISO P25 area Turning in the ISO P25 area.

towards the top surface. Controlled crystals give a substantially stronger edge line that endures high temperatures and intermittent conditions, for longer. Most importantly for manufacturers, machining processes and tool life become predictable, while as an additional benefit, the technology ensures a high proportion of recycled carbide material is utilised.

The complete assortment of new insert grades for steel turning and cast iron milling with Inveio technology includes GC4325, GC4315 and GC3330.

Furthermore, although it might sound obvious, the insert coating must adhere tightly to the substrate. If the coating fails to stick, the exposed substrate deteriorates rapidly. A chipped or broken insert can result in production stoppages and unacceptable scrap. Throughout the years, leading cutting tool suppliers have strived continuously to offer insert coating properties that offer evergreater levels of adhesion, toughness and wear properties, predominantly by optimising the microstructure and post-treatment processes. Among the most significant breakthrough in recent years is Inveioâ&#x201E;˘, from Sandvik Coromant, which uses advanced material science to align the direction of crystals in the coating. In conventional CVD coatings, the direction of crystal growth is random, but this latest breakthrough manages to control the crystals so that every one is lined-up in the same direction,

Proven Technology Many are already experiencing the advantages of aligned crystals, including Bajaj Motors of Agra, India, a supply chain partner to major automotive OEMs that include Tata, Suzuki, Nissan and Renault. Customers of Bajaj require excellent quality at the lowest possible cost and just in time delivery. Due to the high volume of components, itâ&#x20AC;&#x2122;s impossible to measure and check every one. As a result, the tools and suppliers selected by the company are evaluated carefully prior to adoption. So, what does a new coating have to do with a more holistic way of evaluating productivity? From what is known now, quite a lot. At Bajaj, which is producing steel components in their millions every year to customers that require outstanding quality at low prices, the pressure is on. High machine utilisation is crucial and the company needs to trust that every component will meet close tolerance demands. Exploiting the aforementioned benefits of coated inserts featuring crystal orientation technology, Bajaj Motors is finding it can improve productivity and reduce its cost per component substantially.

ENQUIRY NO 018

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

Achieving The

Digital Edge

I Editorial

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n recent decades and years, the main aims of “mechatronisation” of subsystems and rolling bearings have been high level s of func tional integration, high power density, downsizing and reducing the number of components and interfaces. With Industr y 4.0, the scope has widened: Communicative products and the digitalisation of component s which provide completely new additional functions are a new point of focus. Amongst other things, the aim is to have a real time view of production. The performance and quality of production machines are fundamentally and definitively determined by the bearing supports. Data on the current condition as well as the future behaviour of subsystems supported by bearings, such as spindles, guidance systems, rotary and swivel axes are a fundamental basis for the required real time view. In its role as supplier and development par tner for technical drive component s,

S c hae f f ler i s p ur s uin g a dig i t al i s a t ion s trateg y across all produc t groups with the aim of providing data from the most diverse of processes via sensors, networking and analysis in order to be able to of fer customers clear-cut added value. Schaeffler’s activities in the f ield of machine tool digitalisation provide the whole sector with the potential to conver t oppor tunities and overcome challenges through close collaboration between manufacturer, supplier and user. Schaef f ler and Deckel Maho P fronten have developed the “Machine tool s 4.0” concept based on a specif ic inves tment project together with other par tners which connects existing technolog y, from sensors to the cloud, to new digitised components and represents a real step towards digitised production. Two prototypes have been built based on the four th generation of the DMC 80 FD duoBLOCK machining centre.

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

Building on a specific investment project, Schaeffler and Deckel Maho Pfronten are in the process developing what they coin as “Machine tool 4.0” which connects existing technology, from sensors to the cloud, to new digitised components and represents a real step towards digitised production.

One will be put into volume production in the precision bearing cell at Schaef fler’s plant in Höchstadt. The second prototype was seen at the DMG Mori booth at EMO 2015. This is in pursuit of a specif ic digitalisation strateg y with the aim of providing data from the most diverse of processes via sensors, networking and analysis. As a user of machine tools, this Industr y 4.0 initiative ha s a direc t relevance in Schaef fler’s own production. The company ’s ac tivities in the f ield of machine tool digitalization provide the whole sector with the potential to conver t oppor tunities and overcome challenges through close collaboration between manufacturer, supplier and user. Bearing Supports As Data Sources Bearing suppor ts are decisive components for machine tool per formance as they are decisive not only for the functional capacity of the machine but also for the quality of the work piece. Data which can be attributed to the current condition as well as the future behaviour of components become an impor tant source of information for the machine operator.

At times, it could advantageous or, in fact, the only sensible option, to integrate the sensor directly into components as this is the only point at which some parameters can be determined. Existing sensors can be used or suitable equipment retrof it ted. At times, it could advantageous or, in fact, the only sensible option, to integrate the sensor directly into components as this is the only point at which some parameters can be determined. The prototypes for this innovative project have additional sensors integrated into nearly all the bearing positions relevant to the machining process in order to measure vibration, forces, temperatures and pressures and obtain the best possible information on the condition of the machine. Making a machine ready for analy tics means being able to assess the recorded data, saving it and drawing conclusions from them. In order to make all data accessible, the machine is provided with an internal network to which all additional sensors, actuators and evaluation units are connected. A

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

available without having to connect to the network. Calculations can be completed in the cloud via web services or apps.

The possibilities offered by digitalisation are not limited to manufacturing machines. The production environment also benefits from a continuous flow of data in the value chain.

gateway provides a link to the cloud. In order to ensure data can be exchanged with the machine’s control system, Profibus is integrated into the programmable logic controller (PLC) for time-critical and process data and the open platform communications unified architecture (OPC UA) protocol is used for further information from the human machine interface (HMI). The data from the machine are saved locally in the gateway and copied into the cloud. This ensures the machine’s data history is

Analysing The Data Analysis of large volumes of data has assumed a new sig nif ic ance compared to exis ting data analysis, which principally has a 1:1 ratio as far as output is concerned. This assumes that, in addition to the actual measured values, pat terns occur in a suf f iciently large number of measured values/data which can be correlated with other data. These provide a new level of quality in terms of what they can reveal with respect to, for example, the bearings’ condition and therefore machine condition (dat abased added value). The patterns can be automatically recognised by suitable algorithms and any necessar y recommended actions carried out. Decentralised functional units are required which can operate both autonomously and as an integral par t of the network. This allows local intelligence to assess the dat a locally. Additional evaluations which require more computing power can be retrieved from the cloud. An analytical

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

Representation of the system architecture of a digitised machine tool.

evaluation based on data from all connected machines is carried out in the cloud and not locally on the machine. S c hae f f le r i s t h e r e f o r e d e s i g nin g a horizontal network along the value-added chain, similar to the ver tical integration of sensors into the cloud, in order to learn how complexity and requirements for products and services can be accommodated in production. Integration Into Production The possibilities of fered by digitalisation are not limited to manufacturing machines. The manufac turing environment can also benef it from a continuous f low of data. This avoids isolated solutions which could require manual intervention. Vertical integration is also required to connect to the enterprise resource planning (ERP) system for automatic order processing. Manufacturing An important element in “big data” is an unambiguous identification of individual components. To this end, a marking unit is integrated which gives each component a unique code using a data matrix code. This stays with the components throughout the manufacturing process and forms part of the unit ID. This allows the component’s history to be analysed and provides traceability. Process Determining the forces on the tool centre point (TCP) allows fur ther optimisation of the machine loading as well as the process itself: Displacement at the TCP due to loads that occur during machining can be determined using a mathematical model and potential correction measures can be fed back to the control system in real time. The actual ma-

chining forces occurring can be determined in advance using machining simulations. These form a nominal value which may not deviate outside a predetermined range as this would indicate an unacceptable condition. Energy In addition to measuring actual energy usage and assigning this to each machining stage, it is also possible to determine future energy demands through process simulation. When combined with existing data, a more accurate prediction of energy requirements can be produced which allows demand-driven purchasing of energy as well as production planning by minimising energy peaks across the business. Condition of the machine The condition of the machine is recorded using cla s sic vibr at ion monitoring processes. The condition of the lubricant is also measured and evaluated at different points. D emand- dr i ven lubr ic a t ion g uar an t e e s functional capacity as well as careful use of resources without influencing machine performance. It is also possible to provide a relative prediction of the further development of the bearing condition. Maintenance Load collec tives in the machine can be clearly understood by classifying the machining processes. For example, a nominal residual service life of the bearing position can be calculated online using the Schaeffler bearing calculation program Bearinx via a web service. The aim is to use simulations of planned machining tasks and the resultant foreseeable operating life of the individual components to control production in such a way as to allow essential maintenance to be planned in advance in order to maximise machine availability.

Schaeffler is therefore designing a horizontal network along the value-added chain, similar to the vertical integration of sensors into the cloud.

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

Using The Force & The STAR

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ingapore in the past lacked the measurement capability to handle many of the heavy industry requirements that are necessary today. Until now that is. With the opening of Malayan Daching’s new force measuring instruments testing and calibration laboratory.

A s Singapore’s f ir s t accredited force measurement laboratory with the capability to test and calibrate force measuring instruments of up to 20 Mega-Newtons (MN) which is coincidentally among the highest worldwide opens, credible and accurate force calibration continues to be of great impor tance to the industr y. What APMEN and IAA understands is that aside from Singapore, only China and Germany has facility of such testing and calibrating capability. Force measurement is widely applied in many industrial sectors in the form of force transducers, or otherwise known as loadcells, for a variety of purposes including: • • • • • • • •

Aerospace Industry – weighing aircrafts Automotive Industry – truck scale weighing Rail Transport – train weighing, lifting jacks Civil Engineering – soil & concrete testing Marine Industry – lifting devices, jacks Oil & Gas – pipe bending tests Mechanical Testing – material failure Others – loadcells used in electronic balances for weighing

It is essential for accuracy in force measurement s as it brings about safety (high forces are commonly used in industries, hence accurate measurements is crucial to ensure safety), quality assurance (accurate

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

mea surement s would meet the requirements for operational or service standards set by the industry) cost savings(accurate measurements may lead to compensation, legal costs and liabilities); and most likely enhanced competitiveness of the company and the industry. Setting Up Of The Laboratory Set up with the support of A*Star’s National Metrology Centre (NMC) and Spring Singapore; like any such facility accreditation is important to give customers greater confidence in the laboratory’s test and calibration results and reports. Accreditation has been achieved for this facility under the Singapore Accreditation Council – Singapore Laboratory Accreditation Scheme (SAC-SINGLAS). Before, this facility’s highest measurement capability available offered by A*STAR was 2 MN. Now with this new facility applications such as those in heavy industries like oil & gas, marine and offshore, construction, or heavy engineering are now able to calibrate up to 20 MN locally rather than sending overseas, which is both time consuming and costly. Produc tivity is also expec ted to increase by more than 50 per cent, with workers being freed up for deployment of other tasks. As the custodian of the national measurement standards in Singapore, NMC has the expertise and experience in providing metrological support to the industry. NMC is represented in various international forums, for instance Metre Convention, International Committee for Weights and Measures (CIPM), Asia Pacific Metrology Programme (APMP), and has the extensive network with national metrology institutes around the world. With this facility, industries such as oil and gas, marine and offshore, construction, or heavy engineering can now calibrate 20MN force transducers locally, instead of sending overseas, which is the current practice among these indus tries. This cut s down time required for calibration from two to four weeks to about one week. Productivity is also expected to increase by more than 50 per cent, with workers being freed up for deployment of other tasks. Automating For Accuracy “To effectively make use of such equipment and to ensure accuracy it is necessar y to employ automation within the system,” said Elton Tong, service manager, Malayan Daching,. He continued, “In regards to control, for us to exert a 20 MN force, it takes a while and if you

do it the manual way the chances are you may not even control too well.” ontinuing, he said, “There is three stages of control. Firstly, if you want to go to 20 MN, the first stage of this would be to go to say 18 MN in a short time. Once we reach 90 percent of our full capacity we then lower down into a medium control, which is a bit slower, but still fast enough to go to perhaps 95 percent. However, once we reach the top five percent towards our target we have this fine tuning to go up to 20 MN. These are the control mechanisms that we have.” “When we reach the target force that we want we have an automated system where we capture the reading once it reaches the target force. This process needs to be automated as our eyes will not be able to tell the exact force because once it reaches 20 MN the reading of this unit is always fluctuating. If you want to look at 20 MN exactly and take the reading chances are you will miss it by a fair bit. What we did was to have a capture system so when the indicator master shows 20 MN it will capture the units reading. On top of that, there are also some controls related to the methodology on how not to overshoot your target range,” added Mr Tong. Additionally, the company developed customised software to enable the testing and calibrating of high capacity force measuring instruments, load cells and hydraulic cylinders. With a fully computerised system, the entire calibration process will be automated. Lee Shih Mean, senior metrologist (Mechanical Metrology) added: “One example of this is that when the force you are taking is a set point. In the case of taking a measurement

from left: Lee Shih Mean, senior metrologist, National Metrology Centre Dr Thomas Liew, executive director, National Metrology Centre, Sim Sem Peng, chairman, Malayan Daching; and Elton Tong, service manager, Malayan Daching.

“There is three stages of control. Firstly, if you want to go to 20 MN, the first stage of this would be to go to say 18 MN in a short time. Once we reach 90 percent of our full capacity we then lower down into a medium control, which is a bit slower, but still fast enough to go to perhaps 95 percent.”

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

to ensure that the measurement machine that is constructed is measuring the force accurately, i.e.: traceable to national measurement standards or SI standards. That is our key role.”

National Metrology Centre’s Lever Amplified Force Standard 2 MN.

“We are the national measurement institute within Singapore, so what we offer is the measurement science knowledge and also our understanding of measurement standards and references.”

we do not want the force to overshoot and then come back down. In terms of control, it is easier to control when you overshoot and then when you come down you let it hit the set point before you increase the force. This would be considered normal control. However, we do not want that to happen here, we want to go up and then increase slowly and then hit a set target before you go up to the next point. There should not be any kind of decreasing force when it is in an increasing phase. This is the advice we give people. Collaboration With A*STAR When asked more about the collaboration with A*STAR, Dr Thomas Liew, executive director of the National Metrology Centre, remarked: “We are the national measurement institute within Singapore, so what we of fer is the measurement science knowledge and also our understanding of measurement standards and references. We used this knowledge to work with Malayan Daching to develop this new machine that is capable of 20 MN. I would say, regionally, this is a one of its kind facility and is an expansion of our Singapore measurement capability, which has gone from 2 MN to now 20 MN.” He further explained: “We used our measurement knowledge to help in the selection of reference cells for this machine. We also useour capability as a measurement authority

Operating Procedure Mr Tong explained more on what is expected once a company contacts them and wants to make use of their new measurement capabilities: “If say a customer or client calls in for an enquiry the first thing we do is assess their equipment, for instance, what kind of equipment do they have? What is the capacity? Is it within our scope in terms of facilities and also the size of the load cell or the hydraulic jacks, and whether it can fit into our calibration frame? After we establish the suitability of the request, then we will talk to them more on the specification, such as what kind of accuracy they need, and what kind of sensitivity they need.” “If they are ok with our scope then we will probably go into a little bit more detail on what kind of indicators do they have, because if you have a load cell, the load cell will signal to an indicator. We need to understand how we can work with this indicator, and then if everything is fine and the engineers are happy then the job will be done,” he added. Integration With Existing Capabilities Mr Tong expanded on the issue of integration and how this new service fits in with the company’s existing capabilities: “This new capability is a separate offering compared to what we previously had. From weighing of physical test kits to more measurement of load cells. We are ISO/IEC 17025 accredited since 1988 so our quality manual we can still make use of the same quality system that we have been using and then on top of that our engineers who have all trained in the weighing business (the weighing calibration part), for them to learn on the new calibration for load cell force measurement is quite an easy transition. It impacts their productivity because for calibration we do not have every day where they are fully booked and they are fully utilised so with this new calibration services it is easier for them to work with us a bit and increase their time on work so I think that is a good increase.” To meet the strict requirements of ISO 376 and ISO 7500-1, the team dedicated six months (instead of the usual two to three months) to develop and troubleshoot a customised software that is able to control the calibration process to an accuracy level of 5 ppm (parts per million).

ENQUIRY NO 040

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

Today, intelligent software solutions form the basis of the digital transformation of manufacturing process chains like DMG Mori’s Celos system.

Editorial

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Making The

Digital Transformation T he topic “Industry 4.0” is dominating the discussion of the future like no other, even in the sector of machine tool construction. Metal removing machine tools companies like DMG Mori suppor ts its customers seeking to transform their business to having the digital edge with the app-based Celos system and other intelligent software solutions. The digital change is also taking place in machine tool construction with increasing momentum. This in turn means that software is also becoming more and more important, even in the manufacturing environment. That is why companies in the branch are keeping a close eye on the developments and are fully aware that the foundations for Industry 4.0 must be laid in everyday manufacturing now and in the near future.

Digitalising With Ease The app-based Celos system was presented around three years ago and has been consistently been updated ever since. Using this uniform user interface for machine and office PC, employees in shop floor and job scheduling can manage, document and visualise job order, process and machine data. With an open architecture, the system allows the exchange of information with higher-level structures in addition to its effects in the shop floor area. So the system offers customers complete integration of their machines in the company organisation while simultaneously creating today the interface of metal cutting production in the cyber-physical production system of the future. The benefits in day-to-day operation have indicated a 30 percent time saving in tooling times and 50

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

percent lower time and effort for the calculation of technology values or the search for important information. And what is more, the “Control APP” in the system enables the continued use of existing programmes, so employees can go on working in their familiar programming and control environments. Machine Tool 4.0 – In a collaboration project “Machine Tool 4.0” DMG Mori and Schaeffler Technologies have taken the DMC 80 FD duoBLOCK mill-turn center as an example and have integrated more than 60 additional sensors in total in critical components of the machine. Vibrations, forces and temperatures are continuously recorded during operation by these sensors and then collected, processed and saved in a special evaluation unit. The benefits for users are twofold. Firstly, process parameters are visualised in the Celos system with the aid of the “Condition Analyser”, so analyses of the performance and status of the machine can be undertaken in realtime. Secondly the data collected are brought together in a superordinate cloud architecture as well as undergoing cross-machine and cross-plant evaluation with the aid of special algorithms. Specifically, this enables a qualified forecast of potential events of damage, for example on the spindle, from the submitted status data based on empirically determined “behavioural patterns”. So taken all together these functions and functionalities constitute an intelligent early warning system that optimises service and maintenance intervals, prevents unscheduled machine downtimes and significantly increases machine availability. The Machine Tool 4.0 is therefore an excellent example of how data can be determined from the symbiosis of mechanics, electronics and information technology and then used to generate real qualitative added value for the customer. DMG Mori process chain – a key component of software strategy The DMG Mori process chain is a prime example of a successful digital transformation and a practical link from the virtual to the real world. This is substantiated by both numerous successful customer applications and by the competence partnership between Deckel Maho Seebach GmbH and the Porsche LMP1 team. The background of this cooperation is the premium partnership between DMG MORI and the Porsche Motorsport Team. Porsche has won the drivers’ as well

The app-based Celos system is a key building block in the customeroriented digitalisation strategy of DMG Mori.

as the manufacturers’ classification in the recently finished season of the World Endurance Championship. The Porsche 919 CNC Motorsport Center in Seebach produces among other things comple x pump housing s f rom dif ferent materials and technically demanding fixing elements in mini-series. The developers from the racing team supply the necessary CAD data, while the machining experts in Seebach are responsible for the entire process through to the finished workpiece: starting with the processing of the CAD data and CAM programming with the NX CAM and on to 1:1 simulation on the DMG Mori Virtual Machine and right on through to the high-precision finishing on our high-tech machines. Based on the virtualised process chain machining centers can be optimised in advance thus allowing perfect planning, effective prevention of collisions and a reduction of setup time to an absolute minimum. In

Celos enables smooth entry into the future of metal cutting production, because this takes place gradually.

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

The DMG Mori process chain is a prime example of a successful digital transformation and a practical link from the virtual to the real world.

PC-version of Celos: The uniform user interface at the machine and in the office enables employees in shop floor and job scheduling to manage, document and visualise job order, process and machine data.

Workshop-oriented programming is still of great importance, especially in single item production and the production of small and medium-sized quantities. 24 exclusive DMG Mori technology cycles enable 60 percent faster direct programming on the machine via a dialog. Outstanding examples here include various cycles for gear cutting or gearwheel production.

other words, the importance of the DMG Mori Virtual Machine is comparable to that of the racing simulator for the pilots. It enables a 1:1 simulation under real conditions â&#x20AC;&#x201C; including machine kinematics and control. The result is a high degree of safety and speed in the (exciting) real world.

The Software Offensive In Workshop Programming Workshop-oriented programming is still of great importance especially in single item production and the production of small and medium-sized quantities â&#x20AC;&#x201C; and it will remain just as important for a long time to come. Whereby working with cycles is now state of the art and standard cycles for turning, milling and drilling have long been included in the performance range of modern controls. Based on its decades of application experience DMG Mori currently has 24 technology cycles for the fields of turning / turning-milling or rather milling / milling-turning in its portfolio. These enable the operator in the workshop to programme complex machining him/ herself up to 60 percent faster directly on the machine via a dialog using parameterised context menus. Examples here include the machining of free-form surfaces using 5-axis inter-polation or various cycles for gear cutting or gearwheel production. Other cycle highlights include the machine protection control for the protection of machines, workpiece and tool, the 3D quickset toolkit for checking and correcting the kinematic accuracy of 4 and 5-axis machines or the application tuning cycle for the process-oriented tuning of feed drives at the push of a button in relation to the table load. The machine tool manufacturer sees optimum integration of employee potential as the key success factor in the implementation of new production principles. This applies above all to the operation of machine tools due to the complex tasks this involves.

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

Micromachining:

Getting To

The Little Bits

Microcomponent machining of titanium requires micromachining of a special kind and this is usually so for watches and surgical implants. By Syed Shah.

icromachining is a technology for fabricating micro-components of sizes ranging millimetres to micrometres, the latter commonly referred to as microns. Today, miniature components are manufactured and put together to form complex micro assemblies, magnifying the need for micromachining. Many manufacturers have been dealing with these miniature components for several decades; in this case, the watch-making industry and the production of surgical implants. Hence, this technology is not as new as it thought to be. The wealth of experience and expertise gathered in this area is advantageous to the selection of materials and production processes.

Getting The Materials Sorted Titanium, silicon nitride ceramics and nivarox alloy are commonly used in making micromachining parts. The suitability for both titanium and silicon nitride ceramic as surgical implants is dictated by the fact that they are biocompatible. According to the medical perspective, it means that they are chemically inert and do not have any reaction with various bodily fluids. As such, these materials are often used to either replace organ or tissue or function together with living tissue. Nivarox alloy, on the other hand, can be found in both watch-making and medical applications, even though it is more commonly found in watches. This steel alloy is compounded with

Editorial

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

Many manufacturers have been dealing with these miniature components for several decades; in thi s case, the watch-making industry and the production of surgical implants.

cobalt, nickel, chromium and small amounts of titanium or beryllium. When used in making watch components, the alloy reduces errors due to temperature variation; hence it is commonly made as nivarox springs.

Skeletal loads are more evenly shared between bone and implant, leading to a lower incidence of bone degradation

Getting The Right Metal â&#x20AC;&#x201C; Titanium Specifically to titanium, there are two other beneficial properties. They are high strengthto-weight ratio and corrosion resistance. In its unalloyed state, titanium is as strong as steel but 45 percent lighter. Coupled these with its non-toxic state and non-ferromagnetic properties, which allow patients to be safely examined with MRIs and NMRIs, makes titanium a suitable choice for the medical industry. Titanium is used in surgical implements and implants such as hip balls and sockets that can stay in place for up to 20 years. With metal-onmetal implants, both the ball and the socket of the hip joint are replaced with a metal prosthesis, with a metal spacer placed in between. Therefore, metal-on-metal implants do not wear out as quickly as the usual metal-on-plastic implants. The metal and plastic implants wear at a rate of about 0.1 mm each year whereas the metal-on-metal implants wear at a rate of about 0.01 mm each year, about 10 times less than metal and plastic. In addition, since titanium is able to osseointegrate, explaining why they are used in orthopaedic implant applications. Skeletal loads are more evenly shared between bone and implant, leading to a lower incidence of bone degradation due to periprosthetic bone fractures. However, titaniumâ&#x20AC;&#x2122;s stiffness is still more than that of the bone so adjacent bone bears a greatly reduced load and may deteriorate.

Micro Cutting Micro cutting, particularly micro milling, and laser micromachining are some of the micromachining processes. In order for micro cutting to take place, the cutting speeds must be and feeds to remove material at an acceptable rate must be increased, requiring specialised high-speed spindles. In addition, cold air guns and misters are preferred to flood coolant in cooling during cutting. Another aspect to consider is the end mill selection as it is important to maintain tool life and fixturing. The tool bit for micro milling should follow a diameter as small as 0.1 mm with a highspeed spindle rotating at 20,000 to 150,000 rpm. It is capable of milling steel, brass and aluminium with depth of cut at about 30 microns and feed rates of 120 to 240 mm per min to provide surface quality finishes as good as 0.2 microns. In spite of micro milling being applied in manufacturing biomedical components, one common problem that many users have identified is the breakage of the tool bit, which is usually caused by the amount of force associated with removing material at the particulate level. During the process of removing metal, specific energy required increases as the chip thickness decreases. As such, the micro tool bit is subjected to greater resistance as the depth of cut decreases, as if the workpiece material becomes harder during micro machining. The resistance force is strong enough to exceed the bending strength limit of the tool bit before the tool experiences any wear and tear. As such, the edge radius of the tool bit has to be larger than the chip thickness.

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

Titanium is used in surgical implements and implants such as hip balls and sockets that can stay in place for up to 20 years.

Moreover, the micro cut ting machine should have high tolerance as small vibrations are amplified relative to the tool diameter as tool diameter is reduced. Such vibrations not only cause reduced precision, but can also fracture end mills. Makino tackles this problem by producing the direct tool-change type spindle. It reduces the total run-out caused by tool holder variation by eliminating the use of a tool holder. The method of cooling and lubricating the spindle also has an impact on the spindle growth and movement during the machining process. Makinoâ&#x20AC;&#x2122;s spindle core cooling and under race lubrication system, Spindle Core Cooling, is used to suppress spindle thermal distor tion. It circulates the temperaturecontrolled cooling oil through the centre of the rotating spindle, cooling the liquid from the inside. Also, with under race lubrication, the cooling oil circulates through the spindle flows through holes in the inner bearing races to lubricate the bearings. Laser Micromachining Laser cutting process is carried out by a Computer Numerical control (CNC) moving a tiny focused laser beam along the surface of a workpiece. This process is not only non-contact, it is also flexible and free from vibration. The sharp focusing of a laser beam coupled with high power density at the focus makes it an attractive tool for cutting materials at the micron level. Laser micromachining encompasses varied functions including micro cutting and micro drilling. Unlike established fabrication technologies, laser micromachining provides optimum

preconditions for the required quality and precision. For laser cutting of implants, foils and wires can be cut on the 10-micron scale. Foils and tubes can also be machined with cutting widths of below 20 microns. Continuous Wave (CW) lasers or pulsed solid-state lasers can be used for micro welding, leading to a production of cochlear implants. Picosecond lasers offer quality in laser micromachining by cold ablation, a cold removal of thin material layers, without mechanical force, wear-and-tear and thermal damages. The power of the lasers ranges from 6W to 50W and is based on a 50MHz mode locked oscillator, which generates approximately 10 picosecondpulse-train and a subsequent power amplifier. The combination of high pulse power and high repetition rate produces high average power. Furthermore, its pumping technology allows the lasers to exhibit beam pointing and focus location stability, a prerequisite for high-precision micromachining. To sum it all, micromachining has been in the industry for several decades as companies began dealing with making parts for the watches. It is important for manufacturers to know that the materials used for making microcomponents should be strong enough to withstand constant cutting and drilling. In the process of manufacturing surgical implants, materials used should be biocompatible and has high resistance to wear. In addition to having expertise on the suitable materials, manufacturers should also be aware of the plethora of micromachining processes, ranging from micro cutting to laser micromachining as well as cold clamping to hold parts.

Micromachining has been in the industry for several decades as companies began dealing with making parts for the watches.

IN DESIGN Asia Pacific Metalworking Equipment News • March 2016

Innovating Shopfloor Inspection A Look At The Next Generation CMM A rapidly changing technological landscape necessitates a leap in the quality of the current crop of Coordinate Measuring Machines (CMM) both in accuracy and the level of automation. Contributed by Nikon.

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n today ’s inspec tion methods during automotive assembly, it is important for automotive assembly plants to continuously monitor process quality during the manufacturing process. Locations of holes, slots, studs, welding lines and other features need to be measured on the vehicles in Body in White (BIW) assembly. Flush and gap of doors and other hangers also need to be monitored and verified. These inspections ensure that vehicles are built within the stringent tolerances set by automotive manufacturers. These measurements in the past have been primarily performed offline by either horizontal arm CMMs or on the production line using dozens of sensors individually aimed at each of the features that are to be inspected. Although CMMs provide highly accurate absolute measurements, they tend to be slow

and require an expensive metrology lab which limits their use to offline applications. A large amount of time is required to remove the vehicle from the line, fixture and align it on the CMM and then perform the time-consuming measurements. At best, two vehicles can be inspected per shift on a CMM. This is a very small sample considering that over 1,000 vehicles can be built each day in a single automotive plant. Traditional inline systems can have over 100 fixed sensors. These fixed sensors are demanding to install and maintain and do not provide ‘absolute measurements’ of the features in the car’s coordinate system. In addition, most assembly lines now are ‘flexible’, meaning that they can produce more than one type of vehicle. Fixed sensors cannot be used between different vehicles styles; every vehicle requires it’s own custom set of sensors. Recently inline inspection systems have been moving towards robotic based solutions which are f lexible but rely on the robot for positional accuracy which limits their performance.

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

The Laser Radar Nikonâ&#x20AC;&#x2122;s Laser Radar provides a unique alternative to the shortcomings of the traditional inspection methods. The device per forms automated, highly accurate, cont ac tless measurements by using a focused laser that is controlled by precision azimuth and elevation drives. To perform a measurement, the device only needs a fraction of the laserâ&#x20AC;&#x2122;s signal to be returned giving it the ability to measure almost any surface, including highly reflective bare body panels as well as shiny painted surfaces. This robust measurement ability means that the device can be used for both BIW and end of line flush and gap inspections on finished cars. In addition, the device also has a large measurement range (up to 50 m for the MV350), allowing it to easily measure objects that have the size of cars, trucks, and other large vehicles. Line Side Inspection Laser Radar inspection stations can be installed line side. A station consists of one or more laser radars mounted on 6-axis industrial robots. This type of robot is common

place in automotive production facilities, is very robust and can easily handle the payload of the device. The robots are used to automatically reposition the device so it can inspect areas that are hidden from the line-of-sight of a single device location. For example the door frame or other body panels could be blocking the line-of-sight to some features on the floor pan; repositioning the device to an alternate location will make these features visible again without the need for multiple sensors. After the robot repositions the Laser Radar, the device automatically measures alignment points on the vehicle or pallet. This occurs each time the robot moves the Laser Radar,

End-of-line flush & gap measurements

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IN DESIGN Asia Pacific Metalworking Equipment News • March 2016

Dual horizontal arm setup for body-inwhite inspection

Features such as holes, slots, pins, studs can be quickly inspected using the Laser Radar

In each robot position, the Laser Radar can inspect dozens of features

In addition, most assembly lines now are ‘flexible’, meaning that they can produce more than one type of vehicle.

guaranteeing that all measurement s are collected in vehicle coordinates and ensuring measurement accuracy is independent of the robots ability to repeatedly position the device. In each location the device can measure dozens of features on the vehicle. These measurements are pre-programmed in the inspection software directly from the vehicle’s CAD model. After the initial programming, data collection and reporting is fully automated. Unique inspection scripts can also be written for each vehicle style and model made on the production line making the inspection station completely flexible. Adding vehicle styles in the future only requires re-programming of the inspection plan and does not require any physical changes or new hardware. The interaction of the device, robot, and analysis software are fully integrated; the inspections are completely automated and do not require manual intervention during runtime, improving both the speed and quality of the measurements over traditional methods. Bringing Accuracy To A New Level The Laser Radar is a programmable contactless measurement system and has an

Dimensions and location of features are measured in absolute coordinates

accuracy <0.1mm over the volume of a car. It can be fully automated and can directly mea sure holes, s tuds, bolt s, along with many other features accurately from a large standoff, eliminating the risk of ‘crashing’ into the vehicle. The device measures up to 2,000 points / second making it suitable to not only measure features but also scan sur faces. The ability to offline program the device makes it ideal for inline inspections; different vehicle models on the same assembly line are simply a new inspection program.

FAST FAB Asia Pacific Metalworking Equipment News • March 2016

Innovating The Cut Oliver Hergt, editor corporate communications, Bystronic shares with APMEN some highlights from the fields of laser cutting, bending, and software during the Bystronic event in Tianjin had a focus on customers’ increasing requirements for higher productivity.

uring the event in Tianjin, China, Bystronic presented upcoming trends and innovations where customers’ requirement s was the focus. “We want our machines and process solutions to enable users to be cost-effective, efficient, and fast – from the offer right through to the delivery of the manufactured parts”, Norbert Seo, Bystronic senior vice president market division Asia and Australia, explains.

Thus customers got to see how they can rely on Swiss quality and innovations in the fields of laser cutting, bending, and software. One of the innovations that were unveiled during the open house at the Chinese development and production location in Tianjin was the new BySmart Fiber laser cutting system. The machine enables a fast entry into fiber laser technology. With the Xcite, Bystronic presented a versatile press brake that allows bent

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

Simple operation: Operators control the entire cutting process using a 22-inch touch screen with just a few swipes of the finger.

Swiss-quality performance package: The new BySmart Fiber enables the fast entry into fiber laser cutting.

parts to be produced fast and cost-effectively. With the process software, it was proven that the cutting and bending process steps can be handled simply and efficiently within a unified software environment. Laser Cutting With A Difference With the B y Smar t Fiber, a la ser cut ting device, users can launch directly into fibre laser technology without detours or lengthy preparations. The newly developed machine platform implements outstanding cutting results with just a few operating steps. To achieve this, the machineâ&#x20AC;&#x2122;s per formance package focuses on the core benefits of a fibre laser which is using a simple and cost effective method.

In the thin range of sheet thicknesses, the BySmar t Fiber uses the full potential of fibre laser technology. Here the machine significantly speeds up the cutting process compared to a CO2 laser. But the machine also proves its qualities in the thicker sheet metal range. In addition, users benefit from comparably low operating costs and maintenance requirements. Hence, for users whose range of applications lies in the thin and medium material range, this means: faster cutting processes, lower costs, and higher profits with every cut part. On the BySmart Fiber, operators control the cutting process using a 22-inch touch screen. With the ByVision user inter face, the user controls the operations with using swipes of the finger: upload cutting plans, start the process, and the machine then gets going. The user interface then accesses an extensive database that includes the parameters for all the common types of sheet metal. Taking the material, sheet thickness, and part geometry into account, it generates the ideal cutting process. Taking Bending A Step Further In todayâ&#x20AC;&#x2122;s increasingly demanding work floor, the introduction of Xcite press brake looks to enable fast and efficient bending processes. The Xcite 80 E is essentially an electrically driven press brake. It is the fast and economical way to high-quality bent parts. In

FAST FAB Asia Pacific Metalworking Equipment News • March 2016

BySoft 7 provides viable solutions for successful sheet processing.

concrete terms it bends some two and a half times faster than a hydraulic press brake. Using the Fast Bend safety system the tool can be positioned very close to the metal sheet without the operator being placed in any danger. Only then does the machine switch over to bending speed. The Xcite press brakes look to achieve new height s of accurac y. Thank s to B ystronic’s proprietary “force dynamic drive” it bends to within a high tolerance of plus/ minus 25 arc minutes and with a simply incredible repeatability of plus/minus 0.0025 millimetres. Behind the force dynamic drive there lies the interaction between a special mounting of the lower beam and the unique drive system of the upper beam. T he B y S o f t 7 s o f t w are g uide s us er s through sheet metal processing with simple programming of cut ting and bending processes. This software solution supports users in all the process steps associated with the cutting and bending of sheet metal parts. Hence the software essentially creates a potential competitive advantage for the user. The sof t ware solution will be constantly updated, in order to already fulfil the constant changing requirements of modern sheet metal processing. Thus, customers can benefit from innovative software and constant updates. With it, users work in a process-oriented, fast, and intuitive manner. BySoft 7 is structured in such a manner

where even someone who is first time user, will not find much difficulty in handling it. In addition, the software simplifies the processes in the manufacturing stage – designing of parts, creating cutting plans, generating bending programs, simulating bending sequences and much more. Everything runs automatically and based on validated data. It consists of four modules: flat processing, tube processing, bending, and the “plant manager”. The plant manager is a unique tool that both plans and monitors all cutting processes for the customer. In addition, it makes all the relevant machine and production data available, and hence ensures a maximum level of transparency in the fields of sheet metal and tube processing.

The electrically driven Xcite reportedly bends two and a half time times faster than a hydraulic press brake.

FAST FAB Asia Pacific Metalworking Equipment News • March 2016

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The High Five In Cutting

aterjet cutting has long been making inroads into every area of manufacturing and engineering. New materials often demand waterjet cutting – in fact it is pretty much the standard in many production lines now. With single and multiple head five-axis waterjet cutting available on a single machine, the technology is now one that is accessible, and it would literally be competitive disadvantage to not be in possession of it. Waterjet is opening doors – forgings are being replaced with parts nested into sheet material effortlessly cut into the most complex of shapes. Castings are being scanned and flashing trimmed, eliminating multiple tedious steps and labour. Near net shape cutting of everything from complex blades to helical rack and pinion to accurate cutting of composites, laminates of high nickel alloys, glass and phenolics, plastics, ceramics, armour plating of most every make and composition are easy.

And this is no longer limited to flat, plane cutting. If you can imagine it, waterjet can probably be used to cut it. The principles of waterjet cutting are fairly simple. In a nutshell, water at pressure of 60,000 psi or more is channelled to a cutting head through sheathed, 0.25” diameter autofrataged stainless steel tubing that in short lengths is not flexible. Abrasive is fed to the cutting head where the water pressure, as it transitions from potential energy to kinetic energy, accelerates the abrasive grains to over 2,200 miles per hour in a nozzle that is 3” long. Accuracy – Spot On In years past, when multi-dimensional waterjetting was new, the understanding was that there would be a sacrif ice in tolerances. This is no longer the case. With advances in engineering of the nozzles and orifices used, the width of the waterjet stream is now predictable to 0.0005”, allowing manu-

FAST FAB Asia Pacific Metalworking Equipment News • March 2016

Waterjet is opening doors – forgings are being replaced with parts nested into sheet material effortlessly cut into the most complex of shapes.

facturers to support demands for precision five-axis parts. Key to creating an accurate f ive-a xis mechanism is the ability to measure the results. As such, a 3D spatial laser tracker is employed to measure the actual mechanisms and correct for any ‘real world’ inaccuracies that crop up in the manufacturing processes or from material properties. Standard laser interferometers are incapable of measuring all of the parts once they are assembled and operating in space. Once a f inal mechanism is measured, the data can be used to electronically compensate, on the fly, for any repeatable errors that occur, pushing the envelope on accuracy to new bounds. High Pressure Water Imagine your finger is the nozzle in a cutting head. Now wave it around and notice how flexible your wrist, elbow and shoulder are, not to mention the muscles as they twist and flex. So how do you get high pressure water bolted to a fixed position on the face of the Z carriage to the fixed position of the cutting head mounted on the other end of an ‘arm’ that twists, spirals and rotates? Any additional forces generated in flexing the high-pressure tubing will typically cause variations in positional and repeatable

In years past, when multidimensional water-jetting was new, the understanding was that there would be a sacrifice in tolerances.

tolerances. Coiling the high-pressure tubing to reduce these forces normally shows unacceptable results in laser tracking. By direc ting the high-pressure tubing through the centre of rotary actuators, it is possible to virtually eliminate varying torsion, sheer and moment loads on the cutting head. The combination of swivels and routing the 0.25” high-pressure tubing means no coiling is necessary. There is no wind up of the high-pressure tubing often associated with five-axis waterjet cutting and lengths of the high-pressure tubing are short. All high pressure tubing eventually fatigues and fails, releasing high-pressure

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

In waterjet cutting, one has to presume materials will move through the redistribution of stresses as material is cut.

hose. This reduces the leng th of the path the abrasive travels from the mini hopper to the cutting head. An ingenious swivel system allows the abrasive to be passed through the centre of the motor, collected and directed back into a flexible hose. The result is seamless delivery of garnet to the cutting head no matter what the cutting head position or angle of attack. Bulky tubing and awkward mechanisms subject to pinching, clogs and blockages are reduced into a simple straight path from abrasive hopper to cutting head.

Any additional forces generated in flexing the high-pressure tubing will typically cause variations in positional and repeatable tolerances.

water from hairline fractures. It is important to design a mechanism that fails in a safe manner and is easily repaired. Getting Abrasive To The Cutting Head The abrasive, which is typically garnet ranging from 150 to 50 mesh, is fed into the waterjet stream three to four inches above the tip of the nozzle. There is a way to direc t the abrasive through the middle of the actuator without any wind up of the 3/8â&#x20AC;? abrasive resistant

Covering All Angles Any five-axis programming revolves around a common mandate that the part does not change position while cutting. Fixturing for a five-axis mill is often substantial to ensure the part does not move. In waterjet cutting, one has to presume materials will move through the redistribution of stresses as material is cut. A spring assisted, self-locating crash sensor has a low voltage signal passed through the foot which when interrupted detects a crash. The height sensor is pneumatically controlled and can take periodic samples of the location of the material or continuously ride on the material. The analog feedback allows adjustment s to be registered and responded to. What is most impressive is the height and crash sensor can be deployed to work while the head is cutting at angles approaching 50 degrees off the vertical.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

The Chinese Growth Miracle:

Walking Amongst Giants

hina has well-established its position as a manufacturing powerhouse in modern history. China was ranked seventh in the 1980s in the global manufacturing sector, trailing behind Italy. In 2011, they became the world’s largest producer of manufactured goods, overtaking the United States, allowing for double digit growth of the country’s GDP per capita

over the last decade according to data by The World Bank. China is able to achieve this in a few decades as compared to the 150 years the United Kingdom took with their industrialisation efforts. China’s astonishing growth in the manufacturing sector is attributed by the economy’s macroeconomic factors such as the economic liberalisation policies after 1978

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FEATURES Asia Pacific Metalworking Equipment News • March 2016

The adoption of technology and innovation has led China’s modern economy to shift their focus on innovation and high tech services, moving away from being too reliant on their low-end, labour-intensive methods.

The rising competition from cheaper manufacturing plants in the region such as Vietnam and India and the move towards automation have also contributed to the slow manufacturing growth in China.

with an open door policy and its subsequent confirmation in 1992. This led to a substantial increase in FDI (Foreign Direct Investment) of an estimated value of US$83 billion in 2007. The manufacturing sector is a very important pillar for the country’s economic growth and transformation. The industry serves as a main channel for employment around the country and a symbol of progress and international competitiveness. One is unable to separate the image of production lines and factories from the country. China has developed a comprehensive and optimised manufacturing industry with excellent infrastructure and a large and highly-skilled workforce to be the world’s largest manufacturer. It is therefore imperative that the sector remains prosperous in ensuring China’s market leadership in the global supply chain. The sector is also the backbone of the country’s economy and it is impor tant they remain ahead of the game and continuously improve themselves in order contribute growth to the country’s GDP. Potential Roadblocks Today, China faces new challenges in manufacturing due to a myriad of factors. The slow economic growth, risings costs of business and more complex value chains have caused the decline of China’s exports, which leads us to question if the country can still maintain its position as a leader in low-cost manufacturing. The rising competition from cheaper manufacturing plants in the region such as Vietnam and India and the move towards automation have also contributed to the slow manufacturing growth in China. The industry is losing momentum fast,

experiencing the sharpest drop in the last six years. The Caixin/Markit manufacturing purchasing managers’ index (PMI) slipped to 47.3 in August 2015, the lowest reading since March 2009 and a further decrease from 47.8 in July 2015. A print above 50 indicates an expansion in activity while one below points to a contraction. To counter the slow growth rate of the manufacturing sector, China has recently implemented new measures to improve the industry’s productivity. This includes a government scheme through policies, subsidies and incentives to persuade manufacturers to move towards highend manufacturing. Chinese manufacturers have sought to upgrade their skills and capabilities, with a distinct focus on higher technological capabilities according to The Economist. Precision Machining Industry With the move towards modernising production capacity in the country, companies are moving upstream in the value chain to produce mid to high-end products to meet global demand. This causes a shift in improved production methods and an increased investment in high-tech machinery. Chinese manufacturers are seeing the need to switch their machinery to more complex CNC machine tools capable of automated tool swapping and workpiece loading and dis tribution. This will allow manufacturers to produce precision machined products that will result in higher margins and production value. The adoption of technology and innovation has led China’s modern economy to shift their focus on innovation and high tech services, moving away from being too reliant on their low-end, labour-intensive methods. This

FEATURES Asia Pacific Metalworking Equipment News • March 2016

has paved the way for the country’s industrial zones to be upgraded with automation, workforce skills training and new production methods according to The Economist. Shenzhen: China’s Silicon Valley Shenzhen is a southern Chinese city known to be China’s “Silicon Valley for hardware”, a prominent manufacturing city. The city was built with the purpose to cater to electronics and hardware manufacturing. Shenzhen was the first city to

undergo China’s Special Economic Zone policy that practices market capitalism “guided by the ideals of Chinese socialism.” Soon, the city was booming to become an international port and a manufacturing centre focused at the profitable electronics industry. The city has created a modern and collaborative environment for manufacturers to work and learn from each other. This allows companies to stay nimble and competitive due to the endless flow of information and support.

Lubricating It Right: Shenzhen Yihe Mould Shenzhen Yihe Mould is a high-tech manufacturing company that produces hardware punching press par ts and precision punching-press moulds. The company is an example of a hightech manufacturer that benefitted from the talent, innovation and marketing influence of the southern Chinese megacity. The company utilises about 40 units of the Mori Seiki CL 200 CNC machining centres for their precision machined products. The CNC machines’ slideways used a third party brand of oil as a lubricant. The oil had poor adhesive properties, causing it to leak into the cutting fluid system of the machines. This leakage produced a foul odour in a very short time, which resulted in an unpleasant working Additionally, the oil caused stick-slip chatter in the machine that produces a stop-start jerking pattern.

environment for employees on the production floor. Additionally, the oil caused stick-slip chatter in the machine that produces a stop-start jerking pattern. Consequently, there has been a drop in operational accuracy, a component highly important in producing precision punching press parts and moulds. This decline in productivity levels due to the oil used caused at the company to have lower product quality and high oil consumption rate for the CNC machining centres, incurring higher manufacturing costs. After conducting customer feedback and an on-site investigation, ExxonMobil recommended that they switch to Mobil Vactra Oil No. 2 for their CNC machine’s slideway lubrication.

Adhesive properties prevent the removal of lubricants from critical surfaces. Its controlled frictional characteristics helps eliminate stick slip, which improves the product qualification ratio and effective production of their manufacturing output.

This product is a slideway lubricant that is recommended for horizontal slideways on small to medium size machine tools. It reduces slideway oil leakage into the cutting fluid system, therefore preventing the formation of strong odours on the production floor. This creates a safer and improved working environment for the company’s employees. Adhesive properties prevent the removal of lubricants from critical surfaces. Its controlled frictional characteristics helps eliminate stick slip, which improves the product qualification ratio and effective production of their manufacturing output. In addition, the oil has coolant separability properties that reduce slideway oil and cutting fluid discharge, enhancing the service life and performance of both the lubricant and coolant. Shenzhen Yihe Mould was also provided with complementary services such as equipment system inspection, cutting fluid proposal and a clinic seminar in order to ensure optimum results for the company. Since making the switch, the company has seen the consumption of slideway oil reduced by 10 percent, which in turn caused a reduction in cutting fluid consumption by 12 percent annually. The product qualification ratio of their precision punching press parts and moulds has also improved significantly after the switch. All in all, the company has achieved an annual saving of US$11,890 after since making the switch to the new lubricant. The Mobil Vactra Oil numbered series are premium-quality slideway lubricants that are formulated to handle accuracy requirements, aqueous coolant separability, and equipment protection of precision machine tools. Its anti-corrosion properties reduce the deterioration of sliding surfaces in the presence of water and aqueous coolants during production. The series is specifically designed to meet the stringent needs to slideways, therefore providing an additional margin of machinery protection.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Putting The

Automation

On Automotive

With articulated robots and advanced software applications that can simulate every stage of production, one company’s robotic solutions help a luxury automotive maker construct their signature models. Contributed by Comau.

I 2402

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nternationally known for it s famous Trident, the Maserati brand is located in Bologna, Italy. Today, it operates in more than 40 countries around the world and continues to play a key role in the history and culture of sports cars. The brand has made its presence as a high end car model around the globe and the processes that

have been involved in its construction is an intricate one – something that requires a high amount of precision to achieve. Within The Production Line Maserati’s old Bertone plant in Grugliasco (Italy), which has been re-named the Avvocato Giovanni Agnelli Plant, is the place where

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Maserati Quattroporte is one of the two models of the italian prestigious cars produced in the Torino’s plant.

two of its most popular models, the Quattroporte and the Ghibli, are manufactured. Here, the production process starts at the sheet metal department and the bodyshop assembly lines. “The Grugliasco plant has a production capacity of 50,000 vehicles per year,” explains the plant manager Alberto Filippini. “We currently make 150 vehicles a day over two working periods. The cycle time of the sheet metal working phase is of around 316 seconds. This means that the line can build nine bodies per hour,” he continued. The main feature of the line is its flexibility, as Renzo Novara, who is responsible for the sheet metal working depar tment, explains, “Depending on the produc tion needs, it is possible to program the line to automatically determine whether the piece is for the Quattroporte or Ghibli.” According to him, this is important because the bodies of the two models differ substantially in

A detail of the Maserati Quattroporte.

terms of the length of the chassis and the related components. There is a need for a great amount of flexibility of the line – this means that it is able to produce one of the two models, or both, in a continuous flow, according to the requests.

One of the Comau Smart NJ4 robots (the “Spot Welding Machine”) involved in the welding process of the Maserati cars.

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

Robots spot welding on one hand and, on the other hand, insert subcomponents (brake hoses, underbody parts, wiring, etc.) and all the closing elements such as side and top clamp brackets, rivets and Tucker studs.

Once the automatic cycle is started, each chassis is processed in sequence by the various industrial robots.

To better understand why this level of flexibility is strategic for a high end automotive company, it is necessary to examine the line configuration in more detail. The first section of the sheet metal working line is where the high-streng th steel and die-

The robots allow Maserati to perform the complex operations of BIW - Body in White with extreme precision.

cast aluminum component s, all of which have been fully tested and controlled, are received and hand assembled to build the so-called body. This element consis t s of the front framework (upon which the engine and all the related mechanical component s are mounted), the central floor (the first row of seats, tunnel, etc.) and the back framework (the second row of seats and trunk). After the frame is finished, it moves to the second sec tion where the process is fully automated by 86 robots (82 of which are made by Comau). These robots perform a wide range of operations including, welding, par t handling, riveting, Tucker s tud installation, roller hemming (the process of folding the flanges of the metal sheets), and more. The strength of the line, according to Mr Novara, is largely due to robots such as the ones by Comau which can perform the complex operations of bodyshop line with extreme precision.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Live Tools for machining centers

Once the automatic cycle is started, each chassis is processed in sequence by the various industrial robots. These robots perform spot welding on one hand while inser ting subcomponent s (brake hoses, underbody parts, wiring, etc.) as well as the closing elements such as side and top clamp brackets, rivets and Tucker studs. Once completed, the chassis goes into to the section where the body is added. This operation is performed in ‘double layer’, or better, in ‘parallel’. In a f irst station, the skeleton, which is the internal part of the side, is fastened, while in the subsequent phase, the socalled ‘outer skin’ is added. This cutting-edge technology improves accessibilit y and facilitates the operations performed by the robots in the welding stages and in the positioning of the references and clamping elements. In addition, the technology minimises the number of slots, which makes the vehicle quieter and more stable. The Comau robots have a double function in this section. They weld, and by changing the robot head, they also perform the other activities that are needed to complete the assembly according to predetermined sequences. Such ac tivities include handling and positioning of the different pieces, spreading the semi-structural adhesive on the chassis, and more. Mr Novara explains the process in more det ail . “In the ‘double layer ’ stations, where the body is composed, the line can handle both the long chassis of the Quattropor te and the shor ter Ghibli chassis. In other words, it is here that the line proves its flexibility, given that it is able to produce both car models according to the reques t s , in a continuous f low and without interruptions. Af ter the assembly of the outer skin for the sides, each piece continues to the sheet metal working phase for the measurement and verification operations.” In summary, the whole process involves the a ssembly of par t s and subgroups through the insertion of 4,785 welding spot s for each model. Of these, 1,083 are per formed in advance and 3,702

are made during the sheet metal working phase (1,025 of which are done by hand and 2,677 are performed automatically). On the line, 190 rivets and 243 arc-welded studs are also applied for each model. Finally, almost 79 metres of semi-structural adhesive are spread, 66 metres of which by means of the robot and 13 meters manually. Af ter the sheet metal working phase, each body is sent to the painting and final assembly sec tions. “Before being put on the market,” Filippini adds, “every vehicle is

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FEATURES Asia Pacific Metalworking Equipment News • March 2016

A view of the production process automated with Comau’s robots.

Maserati leverages Comau’s robotic solutions to build the bodies of two of the company’s most luxurious automobiles, the Quattroporte and the Ghibli.

carefully controlled and verified using simulation based on specific test benchmarks, and with a complete road test that covers a distance of 40km.” The Robotic Factor In the Grugliasco plant, Maserati applied 82 Comau robots of various types, including articulated and multi-axis, specifically designed to ensure a reduced footprint , a larger working area, and high-precision movement and positioning, while covering all payload categories and applications. More specifically, the robots are available in different ‘wrist’ versions: the ‘standard wrist’ version with external dressing, and the ‘hollow wrist’ version, in which the welding equipment is housed inside the forearm. Hollow wrist robots feature a reduced footprint, as the various cables for the welding guns, air flow, and other the cables run inside the robot arm to reach the head. This is why the robot is called ‘hollow wrist’.

Before the lines were set up, Comau and Maserati collaborated to develop specif ic software applications to provide accurate, detailed offline simulation of each stage in the production line. Thanks to that, Maserati was able to verify the entire sheet metal working process in a virtual way, before it was actually implemented. This enabled the company to anticipate and correct mistakes and significantly reduce operating times and costs. Mr Novara said, “The Comau robots are technologically advanced, high-performing, and easy to maintain. They are also reliable, flexible and specifically tailored to suit all our applications.” He went on to mention that these robots can be employed in low and medium frequency lines, such as in the Grugliasco plant where body is produced in slightly more than five minutes, as easily as in high-frequency lines, such as the plants in Melfi, Cassino and Pernambuco, in Brazil, where the cycle time of each body is around 50 seconds.

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FEATURES Asia Pacific Metalworking Equipment News • March 2016

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It’s About Time:

Evolving Network Standards

for the Industrial IoT

Editorial

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he Industrial Internet of Things (IIoT) promises a world of smarter, hyperconnected devices and infrastructure where manufacturing machines, transportation systems, and the electrical grid will be outfitted with embedded sensing, processing, control, and analysis capabilities. Once net-

worked together, they’ll create a smart network of systems that shares data between devices across and across enterprises in the cloud. To support the new capabilities of IIoTenabled infrastructure, designers and end users alike need reliable, remote, and secure access to smart, leading edge devices.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Rise of Internet Connected Devices

2000

6.1 Billion People 200 Million Devices

2003

6.3 Billion People 500 Million Devices

Network technologies must evolve to satisfy the requirements of these next-generation industrial systems and radically advance the way we operate our machines, electrical grids, and transportation systems. Existing IT networks are defined by IEEE 802 standards, which specify requirements for different Ethernet layers and functions and ensure interoperability between devices. It defines standards and protocols for wired local area networks (WLAN), metropolitan area networks (MAN) and wireless networks; defines characteristics, operating procedures, protocols and services for networks that carry variable sized packets and specifies the development and handling of compatible devices and equipment. Today’s hyper-connected world relies on IEEE 802 Network Standards to carry out daily tasks for both work and leisure. For example, computer, smartphone, e-book reader and gaming systems are just a few of the devices containing interfaces compliant with the suite of network interoperability standards developed by the IEEE 802 LAN/MAN Standards Committee (LMSC). Just imagine all the activities we undertake on these devices and what we couldn’t do without them. Today, industrial suppliers, IT vendors, and silicon providers are collaborating within IEEE 802 and the recently formed AVnu Alliance to update standard Ethernet protocols and provide bounded, low-latency data transfer for timecritical data in IIoT applications, because the IIoT adds stricter requirements to its local networks for latency, determinism and bandwidth. Time Sensitive Network Industry consortiums are now working to address this challenge using a standard called TSN (Time Sensitive Network), a real-time Ethernet solution that will become part of the open platform communications architecture in the future. Its development was originally created for in-car applications that required fast realtime communication. Ethernet has been used

2010

6.9 Billion People 12.5 Billion Devices

2015

7.3 Billion People 25 Billion Devices

for automotive applications since 2008, mostly as a method for diagnostics communication and data download. Increasingly, the large bandwidth Ethernet provides compared to other automotive invehicle networking technologies makes it an obvious choice for emerging applications such as camera-vision systems and infotainment systems. There is also a huge potential for Ethernet to be used for backbone network communication throughout the vehicle. This could even include safety critical applications which enable piloted and autonomous driving - a major trend in the automotive industry today. The IEEE has now adopted it as the IEEE802.1 standard. This development brings real-time Ethernet capability to chip level to enable cost-effective edge processing solutions to be added to instruments and devices to give them real time Ethernet capability. The AVnu Alliance, working with member companies such as Broadcom, Cisco, Intel, and NI, will drive the creation of an interoperable ecosystem through certification, similar to the way the Wi-Fi Alliance certifies products and devices to be compatible with the IEEE 802.11 standard. With further development of the IEEE TSN related set of standards, it might be possible to mimic real-time communication performance and some of the safety-related features provided by the combination of both ARINC664 and SAE AS6802, which are applied in critical aerospace applications for example. Ethernet may also have great potential for use in the energ y industr y. These applications will require 802.1 to work with other organisations to help create complete standards solutions for the issues they face, such as energy efficiency. Ethernet could be part of the ecosystem that provides better overall solutions. The new TSN standard will provide numerous benefits, but notably it would improve bandwidth, security, interoperability and latency and syn-

2020

7.7 Billion People 50 Billion Devices There has been a marked increase of interconnected devices and that number will be set to increase right through to 2020 and beyond.

Today’s hyperconnected world relies on IEEE 802 Network Standards to carry out daily tasks for both work and leisure.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Industrial and Consumer Internet of Things SMART

SMART

Phone

Factory

Grid

Wearable

Connectivity Data Analytics

Machine

Appliances

City

Home

Car Based on Moor Insights & Strategy’s report “Segmenting the Internet of Things (IoT)”

As IIoT adoption continues, increased amounts of data and widely distributed networks will require new standards for sharing and transferring critical information.

chronisation, over today’s standard and specialty Ethernet protocols. Bandwidth: Large data sets from advanced sensing applications such as machine vision, 3D scanning, and power analysis can put a strain on network bandwidth. Proprietary Ethernet derivatives commonly used for industrial control today are limited to 100 Mb of bandwidth and half-duplex communication. TSN will embrace standard Ethernet rates (1 Gb, 10 Gb, and 400 Gb versions are in the works) and support full-duplex communication. Security: Most of the lower-level field buses used today achieve security through air gap and obscurity. They are influenced by the automotive industry, for which air-gapped and closed CAN networks carry all the control and operational data. But recent security breaches have exposed the need to fully extend security into the critical lower levels of control infrastructure. TSN protects critical control traffic and incorporates top-tier IT security provisions. Segmentation, performance protection, and temporal composability can add multiple levels of defense to the security framework. Interoperability: By using standard Ethernet component s, TSN can integrate seamlessly with existing brownfield applications and standard IT traffic

to improve ease of use. In addition, TSN inherits many features of existing Ethernet, such as HTTP interfaces and web services, which enable the remote diagnostics, visualisation, and repair features common in IIoT systems. As an added benefit, leveraging standard Ethernet chip sets drives component cost down by virtue of high-volume, commercial silicon, especially compared with specialty Ethernet variants that are centred on lower-volume, ASIC-based implementations. Latency and Synchronisation: TSN prioritises the low-latency communication required for fast system response and closed-loop control applications. It can achieve deterministic transfer times on the order of tens of microseconds and time synchronisation between nodes down to tens of nanoseconds. To ensure reliable delivery of this time-critical traffic, TSN provides automated configurations for high-reliability data paths, where packets are duplicated and merged to provide lossless path redundancy. As IIoT adoption continues, increased amounts of data and widely distributed networks will require new standards for sharing and transferring critical information. Just as an ambulance or fire engine receives priority among other traffic during an emergency, the TSN standard ensures that critical, time-sensitive data is delivered on time, over standard network infrastructure. Welcome to life in the fast lane with the IIoT.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Efficient And Nimble Service Providers Key To Oil Industry’s Success In The Low Price Environment The Oil & Gas sector is undergoing much change in recent years. Service providers that are efficient and nimble are seen as a key factor to the oil industry’s success in a low price environment. By Ravi Krishnaswamy, VP & global leader, energy & environment practice, Frost & Sullivan.

t is more than a year since the oil prices have started to go south and with Brent crude prices hovering below US$50 per barrel since August 2015, the question that is being asked is, “Is this the new normal?”. Unfortunately oil prices are significantly impacted by geopolitical events & speculation and not always demand-supply driven, as such making it unpredictable. From a sharp decline in October 2008 postLehman Brothers collapse, oil recovered ground fairly quickly for a global financial crisis of such

a magnitude. Oil above US$90 per barrel seemed to be the norm from December 2010 till about the third quarter of 2014, when it started collapsing again. This time around it seems to be more of a long term shift in direction brought about by a combination of factors, the primary one being supply glut. Nonetheless there are several significant factors and trends that will determine the future direction of oil prices. China: The impact of China on the global oil price movements occurs from two different

Editorial

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

Maintaining open shipping lanes is important for controlling costs in the oil industry.

Sustained low oil prices will create political and economic instability in these countries.

perspectives; one is the more obvious economic growth concerns and the other is the less visible strategic intent. In the recent months, China seems to have emerged as a proxy for the global economy. Even the US Federal Reserve has cited concerns about growth in China and its impact on a wider global economy, as one of the reasons for holding off interest rate hike. Chinaâ&#x20AC;&#x2122;s crude oil demand has been falling and is likely to reach an annual growth rate of 2.3 percent by year end, down from 5.6 percent growth at end of June 2015, according to International Energy Agency (IEA) projections. Reasons cited include weak car sales, slowdown in industrial activity, property price correction, and so on. However what has ac ted as a counter balance to this declining demand is Chinaâ&#x20AC;&#x2122;s purchase of crude oil from the spot market to boost its strategic oil stockpiles. According to IEA, China has a capacity of 218.9 barrels oil storage which it is filling fast by buying in the international market whenever the price dips. Role of the Organisation of the Petroleum Exporting Countries (OPEC): The position of OPEC and the role of Saudi Arabia as swing producer have come under intense scrutiny in the recent months. In order to maintain its market share, this bloc of oil exporting countries, mainly Saudi Arabia, have been pumping more oil, to the discontent of Venezuela and Algeria. Even though Saudi Arabia may stand to lose more than US$90 billion annually if the oil stays below US$60/barrel, they may still pull on, albeit with reduced foreign exchange reserves. While the rich Gulf States can survive long low oil prices, other member states like Iraq, Libya, Venezuela, Algeria and Nigeria all need oil to be at US$80/ barrel or more to support their budgets. Sus-

tained low oil prices will create political and economic instability in these countries and Saudi Arabia may end up losing its clout among the grouping. Whether OPEC will still be relevant or not is a different issue. Iran: Once the sanctions are lifted, Iran will compete in the international market and start entering into long term contracts, beyond its traditional customers India and China. Iran has the ability to ramp up production to at least 1.5 million barrels per day (mbpd) by end of 2016. Saudi Arabia and Iran could potentially engage in a price war to gain market share, as such further choking the oil prices. Shale Future: Many industry players like Saudi Arabia estimated that shale oil will not be sustainable below US$70. Contrary to the expectations shale oil production in the US has not collapsed, but some producers remained viable even as WTI prices reached US$40/barrel. US Energy Information Administration (EIA) data suggests that the production in October is forecast to be 5.21 mbpd as compared to 5.29 mbpd in September. However the drop in October is likely to be less than previous months, suggesting that shale is holding ground. Improvements in technology and production process have resulted in better well yields, in terms of rig efficiency. What could impact the long term viability of shale gas in the US is the financial performance of the companies involved. The capital markets poured billions into the shale industry at the height of low interest rates and three digit oil prices. However with the reversal of these trends, the capital markets will be forced to cut their exposure to shale industry, as such resulting in industry consolidation and survival of the

FEATURES Asia Pacific Metalworking Equipment News • March 2016

more efficient and financially disciplined operators. Shale will continue to play a major role in the oil supply industry, even though a shakeout in the short to medium term is inevitable. Mergers & Acquisitions: The low oil prices have forced the US players to consolidate and emerge more nimble and efficient. Major merger and acquisition activities have been announced both by operators and service companies. Shell’s US$70 billion acquisition of BG Group and Noble Energy’s US$1.2 billion acquisition of Rosetta Resources will provide the acquirers eventual access to more reserves. However the proposed merger of Halliburton and Baker Hughes has interesting effects on the service industry as a whole. These two companies may be forced to shed some of their businesses to pass through regulatory scrutiny. This gives opportunity to equipment makers like GE and Siemens, who are waiting to expand their footprint further in the oil & gas services industry. Schlumberger’s proposed acquisition of Cameron also signifies the importance of having end to end service offerings, keeping in tune with the current industry climate of cost pressures. A more efficient and nimble services industry will help to keep the production costs low. US Crude Oil Exports: The US government severely restricts export of crude oil, except to Canada, from North Slope in Alaska and some exports from California. Crude oil swap deal agreed with Mexico in August, raised expectations of a broader easing of these export restrictions by the US government. While EIA has done a detailed study on the effect of removing these restrictions, there is no indication whatsoever that the government is making any such move. If indeed there is even a limited easing of such regulations, then the difference between the US benchmark West Texas Intermediate (WTI) prices and global benchmark bent prices, will determine the attractiveness of US crude in international markets. If the current WTI-brent spread of US$6-8 per barrel still prevails, then the supply dynamics will not see any significant alteration and will be guided purely by market forces. However it does not look likely the US government is in any urgency to change the policy. Oil prices have always proven to be elastic in nature. Whenever the prices have remained very high for a prolonged period, the consumers tend to adjust their usage patterns thus reducing the overall demand which causes prices to drop. Similarly prolonged low prices have resulted in inefficient and uneconomical assets to cease operations, as such lowering the supply and

increasing the prices. A summary of the above trends indicate that Brent crude oil is likely to remain in the US$45-US$65 range till end 2017, before making any further recovery. A short term dip or spike is still possible, depending on some geopolitical shocks. However in the long run, this elastic phenomenon, which has so far ensured that oil prices stay in a wide price band, could be under threat by some of the mega trends which are upsetting several other industries too: • Disruptive technologies including digitisation of the upstream operations with Internet of Things (IoT) and Big Data and energy efficient demand side technologies like electric vehicles, highly fuel efficient engines, intelligent mobility, LED lighting and so on, are all bringing down the overall cost of production and demand for oil, at the same time. • Business models transformation including the massive growth of sharing economy with the advent of startups like Uber will eventually challenge the overall demand dynamics of crude oil in the long run. While the oil industry will continue to devise strategies to stay viable in the current pricing environment, it still needs to mindful of the fundamental transformation which may have just been underway and have profound long term implications.

The low oil prices have forced the US players to consolidate and emerge more nimble and efficient.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Malaysia’s

Automation Sector In this article, we examine a screening of 198 automation vendors in the country, a subset of which was surveyed in-depth on their views of their market and contrast these with the latest industrial developments, namely the massive shift in investment growth sectors. By Fabian Teja Boegershausen, manager, and Frederik Junge, visiting analyst, Solidiance.

Editorial

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he former core production sectors of Malaysia — Oil & Gas, Palm Oil, Electronics and Automotive — are facing world market plunge, rising cost and increased competition from the neighbouring markets, especially with the reduced trade barriers of the ASEAN Economic Community (AEC) coming into effect since 2015. Although investments were still up in 2014, they are massively changing their focus away from oil & gas, automotive and other former key sectors, and towards, for instance, chemicals and refinement of petroleum.

Industrial automation vendors question about where the remaining opportunities are and which factors will affect a move in the market. Our survey shows that firms radically turn away from the once ‘land of milk and honey’ in the oil & gas as well as their ‘bread and butter’ business in manufacturing sectors, and instead see the future in processing industries such as chemicals and food processing. Firms also see a rising relevance of the aftersales business and believe that positive impulses could also come from the IT industry.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Sector specific data partially confirms the future potential seen by vendors in their newly preferred areas, yet also leave a lot of questions open. At this point, it is hard to predict how industrial investments and demands for automation will turn out in 2015 and beyond. What is clear is that there is not going to be a broad rebound of industrial growth across sectors, but vendors must pro-actively seek for the ‘pockets of opportunity’ and prepare to offer their products and services outside of their comfort zones. Economic And Investment Trends Malaysia is one of the most developed nations in ASEAN and has shown in the past a solid, industrial growth. It has developed essentially in four main industrial sectors: •

Oil & gas — large reserve fields, mostly raw exports.

•

Palm oil — large plantations, mostly raw exports.

•

Electronics — the biggest technically manufactured export.

•

Automotive — for the domestic market only.

In recent years, the technical manufacturing, both in electronics and automotive, has slowed down. Producers and vendors of automation goods and services must ask themselves which sectors in Malaysia can open future opportunities and still hold potential for growth at this point. There are some sectors which may hold this potential, especially one much discussed recently that is the chemicals and petrochemicals sector, which now overlaps with the petroleum/ downstream industry. There is an evident shift in the Malaysian economy as downstream processing, petrochemicals, and chemicals, see an apparent

surge in investments, while top sectors such as transport and oil & gas are falling in investments. The strong increase in downstream processing and petrochemicals are mainly due to super large projects such as the RAPID integrated refinery and petrochemicals project worth US$16 billion (invested over several years). Electricals and Electronics appear stable while other sectors form a mixed picture. A strong increase is also in the production of basic metals, such as foundry projects. Buildings and construction could not be recognised here due to unrepeated reporting of investments. Other manufacturing sectors in total amount to roughly US$4.3 billion worth of investments. Approved investments were ~US$74 billion in 2014. The main driver remains to be the service sector with almost ~ US$47 billion of investment. Notably, in 2014, the domestic investment had more impact to the economy, accounting

Firms also see a rising relevance of the aftersales business and believe that positive impulses could also come from the IT industry.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Broadly, the vendors’ expectations are in line with the growth of investments, yet some sectors, such as F&B, are out of line.

The vendors’ expectations are in line with the growth of investments, yet some sectors, such as F&B, are out of line.

for 72.6 percent, whilst the remaining 27.4 percent accounted for foreign investments. The investments recovered moderately fast after the economic crisis in 2008 and continued to increase over the last years. Automation Vendor Survey Malaysia’s Automation Vendor Landscape The activities of automaton firms have been focused so far on some of the technical industrial sectors such as electronics and automotive, plus key processing industries. About 80 percent of Malaysian automation firms build their headquarters in Kuala Lumpur and Selangor region. Automation firms in non-central regions tend to be focused heavily on technical know-how and products suited for the local industries, eg: electronics in the north region The divide between firms giving a positive and negative outlook sentiment reflects the change of the automation landscape. Firms are either clearly positive — as they are betting on the right sectors — or negative as their industry focus cannot capture the current opportunities.

business outlook and future industrial priorities. Based on the survey, the vendors had radically turned away from some of the previous high profile sectors and bet on previous side-lines of the business plus keep a few sectors in a middle-field of preference. The industries were grouped into three clusters: 1. ‘New hopes’, as these sectors appear to have suddenly high expectations in them. 2. ‘Solid bets’, sectors that had performed well in the past and could be at least stable in coming years. 3. ‘Fallen from grace’, large sectors, once hailed motors of growth, seem to have lost their importance here. While future investments are hard to predict in these sectors, recent investment records seem to confirm that the new focus is on chemicals, while the decline in coming investments, for instance, in oil & gas, is evident shown by the low oil price.

Business Outlook Of Automation Vendors The aftersales market is becoming more significant to the vendors. Especially in partially decreasing markets, maintenance and service are important business areas. The availability of (local) engineering experts will be one of the main issues of the automation industry while cyber security and the access to spare parts may be an upcoming challenge as well.

Production automation: Refers to the automation of discrete ‘step wise’ productions such as in loaves of bread baked, number of chips tested, bottles of beers filled, and so on.

The New Priorities For Automation Vendors Solidiance screened over than 190 automation vendors with 10 in-depth interviews on their

Product complexity: Refers to the variables that must be accounted for in the automation and hence increase the cost of automation.

Process automation: Refers to the automation of continuous ‘flowing’ processes for fluids, gases as in chemical processes, fermentation of beverages or air cooling, and so on.

FEATURES Asia Pacific Metalworking Equipment News • March 2016

Risk reduction: Refers to reduction of risk for human life and product liability, effectively reducing company risk and cost of capital. Savings potential: Refers to lowered production cost ie: by reducing downtimes and labour, allowing faster amortisation of the investment. Conclusions And Outlook Broadly, the vendors’ expectations are in line with the growth of investments, yet some sectors, such as F&B, are out of line. Automation Vendor Priorities Vs. Investment Trends In 2014, certain sector investments showed significant faster growth than others. This is, to a large degree, in line with the new priorities of the automation vendors. This is at least likely for petroleum and petrochemicals due to the state driven ‘super’ projects that will continue. Also, the chemical sector has had a significant increase. For food processing, however, the data seems to contradict as investments here are falling. This can be explained, for instance, by either very new trends coming up just in 2015 or perceptions unrelated to the investment trend. The neutral-to-positive stance of the vendors on electronics make sense in light of the data as well, as investment growth here is stable. The automation vendor survey was not able to cover basic metals as a potential sector. While the super heavy processes of this industry only partially fall under classical manufacturing automation, this could indeed be an interesting field for future development. Sector Opportunities — Vendors’ priorities make sense on a broad level, but may need a reality check

While the new priorities of vendors on chemicals and petrochemicals against former top fields such as automotive and oil & gas make sense, their optimism needs to be validated. On food and beverage, the flaming political announcements are not backed by hard investment data and the fantastic investment surge in petroleum and petrochemicals is driven by a few large projects. Future Industrial Outlook — Trends are likely to continue in key sectors The government and joint-venture driven investment s in processing industries are likely to continue at least for the next three to four years. In the classical sectors such as oil & gas, upstream recover y is likely due af ter two to three years when global economic conditions favour higher energy prices. The local transport industry will have to restructure if ever to recover. Export sectors such as electronics will likely be stable as innovation from regional headquarters plus growing global technolog y market s and stable domestic conditions will favor investments. How To Win In The Market — The fac tual market access will count more than ever in the automation industry The growth in chemicals as well as petroleum and petrochemicals are dominated by super projects. This means that few decision makers will steer massive project volumes. Some companies will emerge as winners while many others will miss out. Similarly, in small and not (yet) growing sectors like F&B, the access and presence in the underdeveloped market will decide who wins when the sector takes off.

While future investments are hard to predict in these sectors, recent investment records seem to confirm that the new focus is on chemicals, while the decline in coming investments, for instance, in oil & gas, is evident shown by the low oil price.

ADVERTORIAL Asia Pacific Metalworking Equipment News • March 2016

Mr Norbert Seo, Senior Vice President Market Division Asia & Australia, Bystronic

The BySprint Fibre Press

Reliable technology and machinery is needed to meet growing demands and manufacturers should be technologically prepared.

Seizing The Cutting Edge

Opportunity The Thai government has already conned 2016 “The Year of Investment In Thailand”. It looks to recover and expand its core industries like the automotive sector while embracing new technologies from international companies like Bystronic to achieve that. ENQUIRY NO 041

he government of Thailand’s main policy is to attract foreign investors to invest in the country by offering a range of special privileges. These include exemptions for corporate income tax and lower import duties on machinery. Thailand also expects to welcome some 20 infrastructure projects worth nearly 1.8 million baht. These will cover roads, air transport and maritime operations throughout the country and all will be underway before 2018. Recently, the Ford Motor Company announced that the company is committing an additional US$186 million to expand its Thai manufacturing factory in Rayong. With these new investment projects, reliable technology and machinery is needed to meet growing demands and manufacturers should be technologically prepared. It is necessary for manufacturers to invest in machinery that can meet this challenging business growth and increased flexibility as demanded by new and complex work orders. Amongst the many renowned international brands that will be featuring their latest products for the region at INTERMACH 2016 & SHEET

METAL ASIA 2016, one stand out is sheet metal processing specialist, Bystronic, who has been a long believer in the potential of the region. Commenting on their activities here, Mr Norbert Seo, Senior Vice President Market Division Asia & Australia, Bystronic mentioned that markets here are important to Bystronic because of close relationships to customers in this region. “Thus we support our customers with our concept of successful sheet metal processing: World Class Manufacturing. This means we bring our customers to the top. We provide solutions which optimise the entire process chain: order management, programming, cutting with fibre laser, CO2-laser and waterjet technology, bending and automation.” Bystronic has an excellent track record of impressing at this show. There they will be presenting the BySprint Fiber with 4kW. Mr Seo says, “We will also present the right press brake for this fast cutting system: the Xact. We want to show our visitors how they can make their business more efficient: by reducing costs, speeding up processes and getting more profit.” “INTERMACH 2016 & SHEET METAL ASIA 2016 presents itself as an important event of the industry in this area. This is the perfect opportunity to show our latest products and to present our concept of successful sheet metal processing to our customers and interested visitors,” Mr Seo concluded. With a sizeable booth size of 200 sqm at Hall 101 booth #T2 of SHEET METAL ASIA 2016, they look to be having a successful show this year together with the rest of the participants.

ENQUIRY NO 036

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

600 UK: Colchester Magnum Lathe

600 UK introduced a new central lathe to their portfolio, the Colchester Magnum. The new lathe is available with either the 660 or 800mm swing over bed options, possesses centre distances of up to 4,000 mm and comes equipped with spindle bore options of up to 230mm. The lathe is designed to complement any heavy metal Editorial Got a Question? turning requirement. Make An Enquiry. The central lathe, one of three ENQUIRY NUMBER new Colchester and Harrison lathes, due to its ability to withstand any turning requirement is also capable Turn to page 80a to enquire or log on to: of fast, heavy metal removal, allied to www.equipment-news.com precision finishing.

2501

Beumer: Rota-Sorter

Beumer has released the new Rota-Sorter, their newest sortation system to their portfolio. The system is able to handle different types of items such as bags, polypacks or packages. The machine uses a discharge technology which helps transport light, flat items of 120 x 60 x 5 millimetres to 1,200 x 800 x 800 millimetres and up to 31.5 kilograms on one line. Editorial Got a Question? The sorter contains only a handMake An Enquiry. ful of moving parts and requires no ENQUIRY NUMBER complicated electronics and only a few sensors. The modular system also allows for flexibility, as the Turn to page 80a to enquire or log on to: discharge systems are able to be www.equipment-news.com mounted in multiple places.

2503

Delcam: PowerMILL CAM System Behringer Eisele: HCS 150E

Behringer introduced the HCS 150 E, a compact system entry package consisting of an automatic high performance circular saw for steels with a loading magazine for round material and optional rectangular profiles. The saw is suitable for solid materials and pipes to a diameter of 150 millimeters. The wide standard speed regulating range of 25 to 215 r/min allows Editorial Got a Question? for a varied scope of applications Make An Enquiry. with a basic equipment setup. ENQUIRY NUMBER The saw drive is based on a combination of zero backlash, inhouse manufactured worm gear Turn to page 80a to enquire or log on to: unit and frequency-controlled 15kW www.equipment-news.com main drive.

2502

Delcam released the PowerMILL 2016, a CAM system for highspeed and five-axis machining. The main improvement in the newest CAM system is the ability to mirror complete machining projects in one operation and to automatically maintain the machining characteristics, whereas the previous version could only mirror individual toolpaths. The automatic mirroring saves time when tooling is needed to produce right and left Editorial Got a Question? hand versions of a par t. It also Make An Enquiry. allows quicker programming of ENQUIRY NUMBER machining moulds for symmetrical objects due to the ability to program one half of the core and then Turn to page 80a to enquire or log on to: mirror the toolpaths to generate www.equipment-news.com the complete program.

2504

ENQUIRY NO 016

PRODUCT FINDER Asia Pacific Metalworking Equipment News • March 2016

ESPRIT: Espritcam.com

ESPRIT revamped its corporate website, showcasing a new 3D-style logo that updates the company’s original logo. The new website is multi-platform compatible and features clearer navigation for users from different industries. It is also available in nine languages and allows users an instant experience of ESPRIT software with educational videos on the homepage itself. The website also features extensive information on products that is catalogued based Editorial Got a Question? on industry, machine tool, or type Make An Enquiry. of machining operation consum- ENQUIRY NUMBER ers wish to perform. The product page also highlights their compatibility with machine tool builders, Turn to page 80a to enquire or log on to: enhanced customer support and www.equipment-news.com factory-certified post processors.

2505

Fives: Cransfield Precision TTG

Fives launched the Cransfield Precision, their latest high precision machine that provides a stiff, thermally stable foundation to cater for a wider variety of machining processes. The machine uses stacked linear axes as the primary motion control system, it also coordinates two rotary axes and a short linear axis. The combination of rotary and linear axes produces a relative motion between tool and workpiece Editorial over a working area. Got a Question? The design provides a common Make An Enquiry. platform for multiple machine con- ENQUIRY NUMBER figurations and processes, including O/D grinding, I/D grinding, profile grinding, milling, polishing, hard Turn to page 80a to enquire or log on to: turning, diamond turning dicing and www.equipment-news.com in-situ metrology.

2506

Haas: DT-2 and DM-2

Haas expanded its product line with the DT-2 and DM-2, high-speed, lean-style machining centres that offer the same acceleration rates, axis speeds and shot tool change times as their smaller predecessors, while offering an additional eight inches of X-axis travel and table length. The two centres are nearly identical in specifications, with the exception of spindle taper Editorial Got a Question? and tool changer. Both machines Make An Enquiry. offer a 28” x 16” x 15.5” work cube ENQUIRY NUMBER and a 34” x 15” T-slot table. The two products also allow for high-speed rigid tapping up Turn to page 80a to enquire or log on to: to 5000rpm, with four times the www.equipment-news.com retract speed.

2507

Precision Technologies Group: Zenith 400

Precision Technologies Group introduced their newest profile grinder, the Zenith 400, the first machine to offer three grinding wheel options: aluminium oxide, ultra hard plated CBN and vitrified, dressable CBN. The profile grinder also offers an increased level of versatility, mainly by combining a 420mm diameter grinding capability, with a maximum component load of 700kg. The helical prof ile grinding Editorial Got a Question? machine al so of fers increased Make An Enquiry. s t o c k r e m o v a l r a t e s a n d ENQUIRY NUMBER aggressive semi finishing, and like the aforementioned emphasis on versatility, production rates and Turn to page 80a to enquire or log on to: accuracies are tailored to each www.equipment-news.com customer’s needs.

2508

PRODUCT FINDER Asia Pacific Metalworking Equipment News • March 2016

ENQUIRY NO 033 ENQUIRY NO 033

ENTER THE UPPER CLASS The HCS 90 E Circular Saw Behringer GmbH · 74912 Kirchardt Phone (0 72 66) 207-0 info@behringer.net www.behringer.net

Behringer and Behringer Eisele - world leading producers of high-performance band- and circular sawing systems offer a wide range for every kind of metal - inclunding stainless and special alloys. Volume cuts with maximum yield and quality are the strengths of the HCS 90E high performance automatic circular saw from Behringer Eisele. Use the potential of innovative High-Performance Band- and Circular Saws of BEHRINGER and BEHRINGER EISELE. Experience machines and solutions for high precision and profitability. True to the motto „RED HOT EFFICIENCY“.

ENQUIRY NO 023 033 Behringer.indd 1

ARNO®-FE-Milling System

Renishaw: H20 Laser Encoder System

Renishaw has upgraded their H20 laser encoder system. An upgrade to the elec tronic design means that the system can now achieve a maximum speed of two m/s, double the previous iterations speed of one m/s. The laser encoder system has retained their precision, delivering accuracy of ±1 µm/m for axis leng ths up to 60m. The system is expected to be useful in sectors like the aerospace industr y, Editorial Got a Question? where there is a need for large Make An Enquiry. machine tools with accurate en- ENQUIRY NUMBER coder systems. The system also provides real time position feedback with subTurn to page 80a to enquire or log on to: micron resolution through both www.equipment-news.com analogue and digital quadrature.

2509

The new FE system from ARNO® Werkzeuge in diameter range 16 – 80 mm will offer a solution for square shoulder (90°), slot milling and high feed milling simply by changing the insert. The twisted helix insert ensures a soft entry and exit of the component material. The extremely positive insert positioning guarantees soft cutting action. The milling cutter has during tests provided excellent surface finish results. FE analysed (Finite – Element – analysed) swarf chambers have been accordingly optimized and an effective 90° shoulder, up to 8 mm depth is achieved with the available square shoulder inserts with radius 0.8 mm from the initial product range. Five geometries with six PVD coated grades and a variety of different cutting edge designs for almost all materials are available for selection.

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

www.arno.com.sg

28/2/16 3:13 pm

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

Sandvik Coromant: CoroTap 100-KM

Sandvik released the CoroTap 100-KM, a tapping tool aimed at making a difference for a wider variety of cast iron machining. The new tapping tool features an increased number of flutes on each cutting edge. A black Chamfer has also been added to the let the tap thread deeper, with thread and Editorial chamfer relied being provided. Got a Question? The new tapping tool also uses Make An Enquiry. a new grade, the D210, to of fer ENQUIRY NUMBER more wear resistance. The grade is a combination of powder steel substrate with high hardness and Turn to page 80a to enquire or log on to: titanium aluminium nitride with www.equipment-news.com multi-layer clothing.

2510

Schaeffler: HLE-A-XL

Schaeffler introduced a new version of the fully hydrostatic compact guidance system, the HLE-A-XL. The updated system is a result of second generation INA linear technology combining with integral pressure sensors. The pressure pockets of the saddle plate are filled with a sliding material to prevent crash situations; the sliding material is also replaced with a special bronze coating to ensure very high emergency running characteristics. Piezoresistive pressure sen- Editorial Got a Question? sors are used in the latest version Make An Enquiry. of the guidance system, and its ENQUIRY NUMBER sealed sys tem with integrated pressure control combines the guidance and damping within the Turn to page 80a to enquire or log on to: design envelope of a monorail www.equipment-news.com guidance system.

2511

Schuler: Servoline

Servoline has made available their press line, Servoline, in different configurations and speeds. The production rate, depending on the manufactured parts and the features of the line, ranges from 12 all the way up till 23 strokes per minute. The 12 and 14 iteration are designed for customers who only require a medium production volume. For higher volume production, the 16 version Editorial Got a Question? offers more advanced technology Make An Enquiry. and performance. One of the newest ENQUIRY NUMBER designs, the Servoline 18 is able to cope with maximum volumes. The updated 23 design offers Turn to page 80a to enquire or log on to: the same capabilities of the 18 with www.equipment-news.com an enhanced 23 strokes per minute.

2512

Seco: T-Style Inserts

Seco introduced inserts with T-style edge preparations to the line. The insert features free-cutting and sharp geometry, the inserts bring stability and durability to the machining of nickel-based superalloys. The Insert is available in 20 degree chambers that range from 0.05 mm to 0.1 mm in width, and their sharp, negative reinforced cutting edges help absorb some of the high cutting force and pressure that would Editorial Got a Question? have been placed on the machine Make An Enquiry. setups and workpieces. ENQUIRY NUMBER These inserts also help lower the risk of workpiece deformation, especially in thin-walled compoTurn to page 80a to enquire or log on to: nents, while extending tool life by www.equipment-news.com reducing excessive vibrations.

2513

EXHIBITION PROGRAMMES 2016 Asia Pacific Metalworking Equipment News • March 2016

MARCH 30 – 31

JULY 5–8

Singapore EXPO Hall 1B

Saigon Exhibition & Convention Center (SECC)

IoT Asia 2016

1 Expo Drive, 486150, Singapore Singex Exhibition Ventures

APRIL 6–8

Manufacturing Expo Hanoi 2016

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

91 Tran Hung Dao Steet, Hanoi, Vietnam Reed Tradex

APRIL 26 – 28

MTA Hanoi 2016

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

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

MAY 11 – 14

Intermach Thailand 2016, Sheetmetal 2016, Subcon 2016 UBM ASIA (Thailand) Co Ltd. 503/23 K.S.L. Tower, 14th Floor Sri Ayuthaya Road, Kwaeng Thanon Phayathai, Khet Rajathewee, Bangkok 10400, Thailand UBM (Thailand) Co Ltd

25 – 28

Metaltech 2016

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

JUNE 22 – 25

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

MTA Vietnam 2016

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

AUGUST 3–6

Manufacturing Surabaya 2016

Grand City Convention & Exhibition Centre

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

SEPTEMBER 22 – 24 Manufacturing Myanmar 2016

Myanmar Event Park

Shin Saw Pu Rd, Yangon, Myanmar Singapore Exhibition Services

OCTOBER 6–8

Metalex Vietnam 2016 Saigon Exhibition & Convention Center (SECC)

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

25 – 27

25 – 29

Euro Blech 2016

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

NOVEMBER 23 – 26

Metalex Thailand 2016

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

23 - 27

Taiwan International Machine Tool Show (TMTS)

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

NOVEMBER 30 – DECEMBER 3

Manufacturing Indonesia 2016

Jakarta International Expo (JIExpo)

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

Indometal 2016

Jakarta International Expo (JIExpo)

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

To be considered for inclusion in the Exhibition Programmes, send details of event to:

The Editor (APMEN)

Eastern Trade Media

12 Hoy Fatt Road, #03-01 Bryton House Singapore 159506 Email: syedshah@epl.com.sg Tel: (65) 6379 2888 Fax: (65) 6379 2885

ADVERTISING INDEX Asia Pacific Metalworking Equipment News • March 2016

Page Number.

Enquiry Number

ARNO WERKZEUGE S.E.A. PTE LTD

023

BEHRINGER GMBH

033

BENIGN ENTERPRISE CO LTD

030

FRITZ STUDER AG

029

HEIMATEC GMBH

027

HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD

026

FC/IFC

039

KENNAMETAL INC

031

OKUMA CORPORATION

IBC

032

REED TRADEX COMPANY (INTERMOLD 2016)

037

RENISHAW (HONG KONG) LTD

034

Advertiser

ISCAR LTD

SANDVIK SOUTH EAST ASIA PTE LTD

025

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA HANOI 2016)

018

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2016)

016

TAEGUTEC CO

028

TRADELINK ITE SDN BHD (METALTECH 2016)

040

TUNGALOY SINGAPORE (PTE) LTD

035

UBM ASIA (THAILAND) CO LTD (ADVERTORIAL)

041

UBM ASIA (THAILAND) CO LTD (INTERMACH 2016)

036

WALTER AG SINGAPORE PTE LTD

024

WALTER EWAG ASIA PACIFIC PTE LTD

038

ZWCAD SOFTWARE CO LTD

022

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

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ASIA PACIFIC METALWORKING

No. 2 2016

The Engineering Journal For Manufacturing,Automation & Quality Control

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ENQUIRY NO 032

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

Face Grooving

Grooving

Deep Grooving

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

Cut-Off

Side Turning

Beyond Evolution EASY kits are currently

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

B 0 1KG L1C 116 - P 3

+65 6572 4465 / 66 (SGP) 02 203 5800 (THA) 03 55699080 (MYS)

kennametal.com/BeyondEvolution

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

www.kennametal.com

ENQUIRY NO 031

Chamfering

Profiling

Facing