APMEN MayJune 2011

Take Control Of Quality

Make Extreme Metals

Work For You

Who Buys What?

Survey Results On Buying Trends

May-June 2011

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

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Contents

May-June 2011

First Cut

32 Opinion: Don’t Avoid Extreme Metal, Challenge It! When it comes to extreme metals, it is better to embrace than shun.

By Dr Moshe Goldberg, Iscar

34 Tapping Difficult Materials

Conventional tapping applications are slowly becoming a contradiction to cost effective machining and production optimisation. By Andy Hooper, Bilz

Technology Insights

38 Spot Landing For Technology

By using laserform drilling, Mill-Aero Engines has installed an efficient process of machining shaped holes. By Ralph Schiffler, DMG Cooperation Markets

42 Reaming With A New Rhythm Adding speed to reaming helps achieve the required tolerances in surface quality and circularity. By K Ravi Kumar, Komet

Software & Metrology

44 Opinion: The Evolution Of QC Quality control has evolved from an inspection practice to a holistic approach.

By Wu Tek Ming, Tüv Süd PSB

Fab & Form

48 Press Faster & Smarter With Servomotors

Introducing servomotors and compound linkdriven mechanism into presses help bring more punch to productivity. By Dave Tsai, Chin Fong Machine Industrial

50

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metalworking equipment news May-Jun 2011

Industry Focus

Going Deep Into The Oil & Gas Industry APMEN caught up with Dr Lim Beng Siong, senior scientist, PE COI and Anthony Fettig, CEO Unisig at a seminar tailor-made for local companies to understand the use, co-development, support and maintenance of deep hole boring and gun drilling machine for the fast growing oil and gas sector. By Joson Ng

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Contents

May-June 2011 ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

52 Oil & Gas: Adapting To Changes

Contrary to popular beliefs, the oil and gas sector is subjected to changes and embracing technologies enable one to keep up. By Giuseppe Ruffini for Pama S.P.A

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

Features

IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION

56 All Aboard!

RECOMMEND THAT ADVERTISERS

China and South Korea, the two giants in shipbuilding see themselves occasionally trading places in the league of top shipbuilding nations. This healthy competition, fueled by global trade, has plenty of positive impact on metalworking processes like lasercutting. By Mark Johnston

SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

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

INDUSTRY Endorsements

60 Stay In Track

Milling rail track steel is not without its surprises.

Vossloh Laeis in Germany, a company with a tradition in machining rails can keep the material under control by using milling cutters and drilling tools. Contributed

by Yvonne Ng, Walter AG Singapore

SPETA

Federation of Asian Die & Mould Associations (FADMA)

62 Buying Trends 2011

Federation of Malaysian Foundry & Engineering Industry Associations

With advanced economies’ growth prospects brightened in 2010 and regional demand expected to remain strong, the economy of Singapore looks set to grow in a sustainable pace in 2011. As manufacturing is expected to contribute significantly, APMEN conducted a survey on buying trends at the recent MTA in Singapore to gauge market sentiments.

Indian Machine Tool Manufacturing Association (IMTMA)

64 Ten Points On Laser Beam Welding Machine

Here are 10 points to consider before investing in laser beam welding machines.

By Han Kee, Hi-Yew Technology

China Machine Tool & Tool Builders' Association (CMTBA)

66 Events & Exhibition • Special Report: TIMTOS 2011 • Trumpf Showroom Opening Ceremony

Machine Tool Club (MTC)

The opening of its showroom in Singapore is a signal of the company’s ambition and commitment to Southeast Asia. By Joson Ng

Taiwan Association of Machinery Industry (TAMI)

• Event Preview: InterMold Thailand 2011 • Event Preview: MTA Vietnam • Event Review: MTA2011

Regulars 10 80

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83 Exhibition Programmes 84A Product Enquiry Card

Singapore Precision Engineering and Tooling Association (SPETA)

84

Refer to Advertising Index

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For Advertiser's Enquiry Numbers

ENQUIRY NO 089

editor’s note

Fear Not

Published by:

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

Reg No: 199908196C

managing director Kenneth Tan editor Joson Ng

josonng@epl.com.sg

business development manager Randy Teo

randyteo@epl.com.sg

assistant sales manager Kimberly Tian

kimberlytian@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg

People tend to frown when confronted with a problem or when thrust into a new environment. Challenges may feel daunting at first but without them, surely there can be no improvements.

In this issue of Asia Pacific Metalworking Equipment News, we deal with the topic of working with extreme metals. Some people may avoid them but fortune it seems, always favours the brave. Those who invest in better equipment or tools and develop new ways to go about machining those materials are the ones to reap the rewards of their bravery.

In metal cutting, the problem is sometimes down to the lack of awareness and rigid mindsets.

According to Dr Moshe Goldberg from Iscar, when it comes to difficult metals, machining specialists and operators tend to be prejudiced or conservative. They either have inadequate knowledge on how to machine the difficult materials or they are reluctant to adopt new machining strategies or technologies.

Challenges are also aplenty in the oil and gas sector where deep hole gun drilling is faced with unprecedented technical demands. With holes getting smaller and deeper, the machinery, tools and technologies are pushed to the extreme.

I n t hat indust r y, eng ineers sometimes face proprietary alloys that are constructed for specific reasons. As such, there are no instruction books that come with it.

They simply have to ‘feel’ their way into the machining process.

To some, this process of trial and error may seem rudimentary at best, but it sums up the desire to overcome and eventually conquer. Challenges will always be present in metalworking and in life. Some may be lost at first, but we always have a choice to make the best out of a less than ideal situation, that much we should know.

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

irenetow@epl.com.sg

contributors Dr Moshe Goldberg Andy Hooper Ralph Schiffler K Ravi Kumar Wu Tek Ming Dave Tsai Natalia Tee Mark Johnston Han Kee Giuseppe Ruffini Yvonne Ng Dr Huang Xianya board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR

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

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

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

Eastern HOLDINGS Ltd Executive Board

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

Joson Ng Editor

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

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

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Businessnews Gildemeister Successful At CIMT In Beijing

Bielefeld, Germany: With order intake of €45.2 million (US$64.3 million) and 234 machines sold, together with its subsidiary, DMG China, Gildemeister takes positive stock of the CIMT in Beijing. The results confirm the strong demand for machine tools in China.

The biannual event proved to be successful this year with orders to a value of €45.2 million (2009: €22.5 million). As the largest European exhibitor, the company presented 28 exhibits, including five premieres for Asia,

to a Chinese trade public over an area of about 1,500 sq m. At the DMG booth 13,537 trade visitors from 7,390 companies sought information on technologies as well as on industry-focused solutions for the aerospace, automotive, medical and energy sectors.

The complete Ecoline series generated particular interest.

The machines ‘Made in China’ offer access to turning and milling machining to a broad global market segment at entry prices.

Gamesa To Focus On Advanced Materials In Singapore Singapore: Gamesa opened a technology centre in Singapore to focus on advanced materials research. The laboratory begins its work with three important research projects, conducted jointly with the Na nya ng Technological University, the National University of Singapore and the Agency for Science, Technology and Research.

The partnership agreement sig ned with the Na nya ng Technological University enables the company to conduct research projects on wind turbine blade co a t i n g s a n d m e t ho d s fo r incorporating the materials into the company’s manufacturing systems.

A long w it h t he Nat iona l University of Singapore, the company will study methods for monitoring composite materials using embedded sensors and w ill a sse ss their industria l applications.

Meanwhile, in conjunction with the Institute of Materials Research and Engineering, the company will gauge the performance of turbine blades’ carbon fibre polymers after nano-reinforcements are incorporated to lend them added streng th. The company will explore R&D in manufacturing with the Singapore Institute of Manufacturing Technology.

APMEN Online Check out our interview and technical videos Visit us on our website at

www.equipment-news.com 10

metalworking equipment news May-Jun 2011

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Sutton Tools Singapore Pte Ltd, No. 1 Ubi View #03-18, Focus One, SINGAPORE 408555 Phone: +65 67457366 Fax: +65 67455080 Mail: ekoh@sutton.com.au Sutton SuttonTools ToolsSingapore SingaporePte PteLtd, Ltd, www.hoffmann-group.com No. No.11Ubi UbiView View#03-18, #03-18,Focus FocusOne, One,SINGAPORE SINGAPORE408555 408555 Phone: Phone: +65 +65 67457366 67457366 Fax: Fax: +65 +65 67455080 67455080 Sutton Tools Singapore Pte Ltd,

businessnews

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RNCOS: Apparent Finished Steel Consumption To Grow

GM China Announces Five-Year Plan For Continued Success

Marcelo Terraza, Brasilia, Brazil

Demand from the construction industry has driven the growth of apparent finished steel

India: Finished steel consumption is continuously increasing in India with rise in demand from automobile, power, construction, and infrastructure sector (including railways coaches and high capacity bus corridor), according to a research report, ‘Indian Steel Industry Outlook to 2012’.

Finished steel is also getting new applications due to its corrosion resistive property. Moreover, India is having low per capita consumption of steel compared to other countries, which provides enormous potential for growth in the country’s steel consumption.

Additionally, it is expected that the apparent finished steel consumption will grow at a CAGR of around seven percent during FY 2012 - FY 2014.

Metal products are the largest consumer of stainless steel among different industries followed by process industry. Besides, infrastructure accounts for the maximum steel consumption among the industry segments. Moreover, demand from other industries, such as construction, process, and engineering are expected to grow in the coming years on the back of various factors.

Shanghai, China: GM China Group president and MD Kevin Wale shared GM’s five-year plan for continued success in the automaker’s largest market.

According to Mr Wale: “Over the last 15 years, GM has focused on growing all areas of our business in China – from our brands to our product lineup to new business opportunities – both on our own and with our partners. We have recorded many achievements, but we still have a lot more to achieve.”

GM has adopted a multi-brand strategy to meet the differing and constantly changing needs of the market.

It offers a broad portfolio of brands to ensure it brings the right products to its customers at the right time.

Over the next five years, the company will be introducing more than 60 new models and major product upgrades. Its two mainstream brands, Buick and Chevrolet, will account for nearly half.

Lead The Industry In Electrification Electrification has become the overriding trend of the global automotive industry for reducing its century-long dependence on petroleum, according to Mr Wale.

In December 2010, Shanghai GM introduced the Sail battery-electric concept vehicle, which was developed

by Shanghai GM and Pan Asia Techinical Automotive Centre (PATAC). A drivable version will be introduced following Auto Shanghai 2011.

GM also plans to cooperate with its strategic partner SAIC to co-develop a next-generation electric vehicle architecture. It is establishing a battery lab at the GM Advanced Technical Centre to explore battery technologies. It will work with the domestic supply base as well to develop a strong local capability for the provision of high-quality components essential to support the industry’s move to electrification.

Double Annual Sales To Around Five Million Vehicles According to Mr Wale, the company plans to double its sales volume from about 2.35 million units in 2010 to around 5 million units by 2015. The automaker will put a premium on growing sales in a sustainable manner that is integrated with the growth capability.

Hawker Beechcraft Leads In Turboprop Sales Lakeland, USA: Hawker Beechcraft Corp (HBC) continued its leadership in turboprop aircraft sales in 2010 by recording nearly 25 percent of the general aviation industry’s total deliveries in the segment, according to statistics released by the General 12

metalworking equipment news May-Jun 2011

Aviation Manufacturers Association (GAMA) earlier this year.

The company also delivered another 24 military turboprops in 2010, which were not reflected in GAMA’s statistics. Turboprops comprised approximately one

third of the general aviation turbine market last year. HBC has been the industry’s top producer of turboprops for nearly a half century, beginning with the introduction of the King Air series in 1962.

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businessnews

Pratt & Whitney Signs MOU With COMAC

Washington DC, USA: Pratt & Whitney, on behalf of United Technologies Corporation ( UTC), signed a Memorandum of Understanding (MOU) with COMAC, Commercial Aircraft Corporation of China, for cooperation on leadership training for senior executives and mid-level management, project management training and Achieving Competitive Excellence (ACE) training. The training programs, conducted by the Pratt & Whitney Customer Training Centre in collaboration with Hamilton Sundstrand and Sikorsky, provide targeted curriculum for senior executives, mid-level managers and high potential employees. Training is scheduled to begin mid-year.

“We signed this training cooperation MOU with UTC because it offers opportunities for employees at all levels of COMAC to learn critical leadership and technical skills from a trusted and wellrespected OEM,” said assistant president and GM, Human Resources for COMAC, Yan Hua. “In addition to the training offered at our Customer Training Centres in East Hartford and Beijing, China, UTC is working with its university partners to conduct a significant portion of the executive level training created with COMAC,” said Pratt & Whitney VP, Human Resources, Patrick Preux. “We look forward to working together with COMAC to tailor the programs to meet their business needs.”

Toyota Vehicle Production In Malaysia Tops One-Million Mark Selangor, Malaysia: Toyota Motor Corp’s (TMC) Malaysian vehiclemanufacturing company, Assembly Services Sdn Bhd (ASSB), held a ceremony to commemorate production of its one-millionth vehicle.

Attendees at the ceremony included Malaysian International Trade and Industry minister Mustapa Mohamed, ASSB plant director Hideki Omae and UMW Toyota Motor (UMWT) chairman Tan Sri Asmat Kamaludin.

“I am proud to announce that ASSB is the first non-national vehicle manufacturer to achieve the one-million production milestone,” Mr Kamaludin said of the achievement. He went on to reaffirm Toyota's intention to continue to provide high quality products and services.

In 1968, production of the Toyota Corolla began in Malaysia, with cumulative production reaching 500,000 units in 2000. In 2006, exports to Thailand of the Malaysia-produced Hiace began. Plans call for the Camry to start production in 2012.

14

metalworking equipment news May-Jun 2011

www.equipment-news.com

Essar Steel Commissions Production Mill Mumbai, India: Essar Steel has commissioned its Compact Strip Production (CSP) mill with a capacity of 3.5 MTPA. This is a key part of the company’s plans for expanding its steel pro du c t io n c a p ac it y at it s Hazira complex from 4.6 to 10 MTPA. The expansion is being done at a cost Rs 13,500 crores (US$3 billion).

This will be India’s largest flat steel facility at any single lo cat ion a nd a mong t he 10 largest facilities in the world.

It will also be one of the few steel facilities, which are fully integrated and will produce the entire range of flat products.

The total investment in Essar’s Ha zira ste el comple x is R s 30,000 crores.

T he pla nt is c ap able of producing strips of thickness as low as 0.8 mm, which is the thinnest rolled steel in India.

The CSP mill equipped with the advanced level automation system was supplied by SMS Siemag, Germany. The products from the mill have diverse applications in general engineering, hydrocarbon industry, automotive industry and also for LPG, welded tubes and electrical steel. The mill is capable of producing high-strength steels including Dual Phase steel.

As part of this expansion, the compa ny ha s a lready commissioned two iron making units – a blast furnace with a capacity of 1.73 MTPA and a DRI unit of 1.74 MTPA, a Conarc fur nace of 2. 5 M T PA a nd a continuous caster of 1.45 MTPA. Fu r t her, t he compa ny a lso recently commissioned India’s first 5 m wide plate mill with a capacity of 1.5 MTPA and a pipe mill with an annual capacity of 0.6 MTPA

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Delcam Achieves Record Sales & Increased Profits Michael Faes, Switzerland

Birmingham, UK: Delcam has achieved record sales in the year to 31st December, 2010. Sales for the period grew to £36.6 million (US$59.5 million), an increase of 17 percent over the £31.3 million recorded in 2009. Pre-tax profit rose to £2.26 million compared with the £0.59 million last year.

The company continued to increase its investment in software R&D, investing £9.4 million in the period, compared to £8.9 million during 2009. As well as supporting growth in new software sales and enabling the introduction of new products, this investment contributed to an increase in maintenance revenues to £11.6 million, up from £10.2 million in 2009.

Commenting on the results, Delcam chairman, Peter Miles, said: “Our results were driven by improved sales across all of our key markets in Europe, North America and Asia, with the group’s newer territories in Asia showing the largest increases. The marked upturn in sales benefited from our decision to maintain product development and marketing investment during the downturn of 2009.”

On the company’s outlook, he added: “The current indications are that 2011 will see companies in most of our major territories increase their investments in capital equipment and the associated software and, against this backdrop, the business is well placed to benefit.

However this trend may be affected by recent events in Japan and in the Middle East. At this early stage in 2011, the growth in our sales is continuing and, if this remains the case, we are optimistic that our trading results for the coming year will show further improvement over those for the last 12 months.”

Lantek Ends 2010 With A 34 Percent Increase In Turnover Vitoria-Gasteiz, Spain: Lantek, a developer of integrated CAD/ CAM and ERP solutions for the sheet metal sector, recently held its annual conference in which the 2010 results were presented, as well as the corporate strategy for 2011.

In 2010, the company saw a 34 percent increase in turnover, €10.58 million (US$15.07 million).

This figure exceeded the forecasts for the year and illustrates the recovery of any ground lost the previous year due to the worldwide financial crisis and the particular difficulties faced by the sheet metal sector.

Of the total turnover achieved

by Lantek in 2010, 84 percent corresponds to the business generated by the international markets as a whole, while 16 percent came from the domestic market.

This shows a slight variation compared with 2009, when the proportion was 80 percent and 20 percent, respectively. This clearly illustrates how important the foreign market is for the company, and is in line with its policy for international expansion, as well as its long-held commitment to emerging markets.

The countries in which Lantek saw most growth in 2010 were China, South Korea, the United States and Brazil. The traditional European markets continue to be an important source of business, although the market growth in Asia and America is increasingly significant.

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metalworking equipment news May-Jun 2011

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The Leica Absolute Tracker AT401 has a unique “All in One” system design that incorporates such needed accessories as built in live video, level to gravity, environmental monitoring and even an integrated IR remote control. By utilizing the integrated Wireless LAN communication the sensor can be used completely wirelessly.

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Hexagon Metrology (Thailand) Ltd. 3 Soi, Bangna-Trad 34, Bangna-Trad Rd. Bangna, Bangna, Bangkok 10260 Tel : +66 2361 3695 to 9 Fax : +66 2746 9607 hexagon.thailand@hexagonmetrology.com

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Shandong Peninsula Blue Economic Zone Presents Opportunities To Singapore Companies

Sanja Gjenero, Zagreb, Croatia

Singapore: The development of the new Shandong Peninsula Blue Economic Zone is slated to bring more business opportunities for Singapore companies in Shandong province. In January 2011, China’s State Council approved the Shandong Peninsula Blue Economic Zone strategy. This will be China’s first marine-themed regional strategy, where Shandong’s 3,100 km of coastline will be optimised by developing its coastal cities and marine-related industries. With strong support from the central government, the Shandong Peninsula Blue Economic Zone is expected to see a wave of new developments and projects.

Singapore and Shandong agreed to explore more economic partnerships in the Blue Economic Zone at the 15th Singapore–Shandong Business Council (SSBC) meeting held in Singapore. The SSBC will also continue to strengthen collaborations in key

areas including urban solutions, logistics, marine and offshore, and tourism infrastructure.

The meeting was chaired by SSBC co-chairmen, Singapore’s Minister of State (MOS) for Trade & Industry, and Manpower Lee Yi Shyan and Shandong’s vice governor Cai Limin. Singapore’s Senior Parliamentary Secretary (SPS) for Trade & Industry, and Information, Communications & the Arts Sam Tan was present.

Bilateral economic relations between Singapore and Shandong have strengthened over the years.

Singapore investments in Shandong, which are mainly concentrated in the cities of Qingdao, Yantai and Weifang spread across the food processing, real estate, manufacturing, chemicals, marine engineering, and electrical and electronic component sectors. Companies in the training and education, urban solutions and agricultural sectors have also engaged in various economic exchanges with potential partners from Shandong.

In 2010, bilateral trade between Singapore and Shandong amounted to US$2.26 billion, an increase of 42.7 percent over 2009. Singapore’s exports to Shandong amounted to US$1.06 billion while imports from Shandong reached US$1.2 billion. (Source: Shandong Department of Commerce) Singapore’s actual Foreign Direct Investments (FDI) in Shandong increased by 46.4 percent from 2009 (US$450 million) to hit US$550 million with 31 projects, in 2010. This made Singapore the third largest investor in Shandong for the last three years. As of end 2010, Singapore’s cumulative actual FDI in Shandong amounted to US$4.33 billion, with a total of 1,268 projects. (Source: Shandong Department of Commerce)

Nissan To Establish New Company Yokohama, Japan: Nissan Motor has decided to establish a new company that will incorporate the operations of its Kyushu Plant in Japan. The name of the new company will be Nissan Motor Kyushu and Yukinobu Kodama will be appointed as president.

The aim of establishing the new company is part of a broader strategy to strengthen Nissan's manufacturing competitiveness in Japan. Since the announcement was made last October, the company has been working in close partnership with the All 18

metalworking equipment news May-Jun 2011

Nissan Motors Workers' Union to conduct a study on establishing a new company for this purpose and both parties have reached an agreement, including working conditions, in the new company.

The auto industry is facing a major turning point. The continued strengthening of the yen against foreign currencies, prolonged globa l economic dow nturn, emergence of competitors from emerging countries, shift in the domestic market to compact cars, and introduction of electricallypowered vehicles due to the

growing concern over energy and environmental issues, has made the market environment as challenging as ever.

In order for the company to grow further as a global automotive company, there is a need to establish a production base in Japan which is globally competitive a nd capable of producing compact vehicles in the future. Establishing this new company is one important step to enable Nissan to maintain its domestic production capacity around one million units.

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Skeleton-Free

Punching How to turn waste into money The work sequences for modern punching machines are highly sophisticated nowadays: fast, process-dependable and often automated. But there are a few exceptions. The sheet skeleton, for example, is a risk for process reliability because parts can get caught on it.

TRUMPF has now introduced an alternative: Skeleton-free processing TRUMPF is the first manufacturer internationally to offer this processing strategy directly on the punching machine and for all possible geometries: Parts no longer get stuck in the sheet skeleton; the operator no longer has to remove the leftover material from the machine table; and sorting is improved due to a turnout underneath the parts chute that automatically separates the finished parts from the scrap.

Costs per part are reduced by about 10 percent Less material is required due to the number of shared split cuts leading to an increase in material efficiency by an average of 10 percent, always having in mind that materials represent the majority of parts costs in punch processing. A great deal of manufacturing energy is saved as well because less sheet metal is used. The new development meets the overall TRUMPF goal of managing resources as sparingly as possible.

Scissor tables, sheet skeleton pallets and removal grippers are a thing of the past All unnecessary material is shredded directly on the machine, sorted out through a parts turnout and collected together with the slugs on a scrap conveyor belt. In the end, all small, well-arranged and easily transported leftovers made of a specific material land in one single container, which makes it much easier for logistics.

The basis of this new development is powerful software with all the right nesting algorithms, combined with the option of rotating parts and leftover pieces with innovative tool technology. This new method relies fully on common split cuts. But extensive programming is no longer needed to make them because the configuration is now

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made by the software TruTops Punch. This enables the sheet layout to be optimized and prepares for the necessary “release strokes.”

The parts are initially processed in sequence and then freely punched prior to discharge or removal. Parts or scrap are rotated using a separating tool with a bi-level stripper to facilitate discharge via the chute. The remaining strips are also completely crushed. The processing time per part stays the same.

TRUMPF TruPunch 3000 (S11) the machine which leads to cost savings The skeleton-free processing will be available on the TruPunch 5000 as well as on the TruPunch 3000 (S11) machine. This new machine will be released in South East Asia this May and features also further advantages.

Because the punching head is not in continuous use in the midsized TruPunch 3000, another innovative feature has been added to the machine: an electric punching head. It’s not only quiet, but – in contrast to the hydraulic version – it uses very little power in standby mode. In punching mode it’s also more efficient, which adds up to power consumption that’s two kilowatts less per hour than other models. And, on top of that, it is more productive. Thanks to its high rotation speed, the electric punching head is very fast when it comes to rotating tools or forming threads. And because the punching hydraulic is no longer necessary, the footprint of the TruPunch 3000 is smaller by five square meters (about 13 percent).

The quality of the processed surfaces is becoming increasingly important so material must be handled as gently as possible. To ensure this, the machine has a parts chute that helps discharge the small cut parts horizontally into the collection container, stacking them evenly. Workpieces measuring up to 500 x 500 mm are discharged scratch-free via the parts flap. The machine can be operated with standard containers to help companies keep additional material logistics uniform throughout their operations and save money.

For further information please contact: TRUMPF Asia Pacific 25 International Business Park #02-28/29 German Centre Singapore 609916 Phone: +65 65718000 Fax: +65 65718001 info@sg.trumpf.com www.sg.trumpf.com

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Otis India Breaks Ground On Expanded Factory Connecticut, USA: Otis Elevator Company (India) (Otis India) will expand its existing elevator factory in Bangalore, India. Once completed in spring 2012, the expanded facility will be three-times the size of the current factory and will include a test tower. The new, 27,500 sq m manufacturing facility will incorporate the company’s technologies from all over the world and is being built to Leadership in

Energy and Environmental Design (LEED) Gold standards.

“Our expanded facility will ensure that Otis India is wellpositioned to support India’s exponential growth with quality, locally produced elevators, while conserving the country’s valuable resources,” said Laurent Bruyère, MD, Otis India.

An expanded factory will enable the company to more

effectively serve an India elevator market that is expected to reach 70,000 units over the next three years. Its Bangalore factor y will also supply the company’s growing portfolio of customers in India. Recently, the company was selected to provide 63 elevators and escalators, as well as its full range of elevator technologies, for Kohinoor Square, an office complex in Mumbai.

Resource-Friendly Car Manufacturing Fraunhofer

Germany: Magnesium instead of steel – this could be an option for lightweight car body parts. A car door made of magnesium is roughly 50 percent lighter. This is one of the exhibits drawn from along the automobile manufacturing chain researched at the Fraunhofer Automobile Production Alliance.

Lighter, more economical, more reasonably priced – that is the motto. If possible, equipped with electric drive. Carmakers have lots of demands to meet.

Researchers are presenting the results of their work at the Hannover Messe in the form of a ‘glass car’.

A Car Door Made Of Magnesium One example is the car door made of magnesium, a development by researchers at the die Fraunhofer Institute for Machine Tools and Forming Technology IWU in Chemnitz. The door weighs just around 4.7 kg. By way of comparison: the version in steel weighs some 10.7 kg.

“Magnesium is available in large quantities worldwide, it can be moulded, and for similar structures – a car door, for instance – it has virtually the same properties as steel. “For example, it has a comparable rigidity,” summarises Sören Scheffler, group manager at IWU. “We have developed specific moulding 22

metalworking equipment news May-Jun 2011

technologies for wrought magnesium alloys. This makes the lightweight material available for future use in series production of car bodies.”

Slide-Ground Tumbled Alloy Wheel Rims The researchers will be presenting a slide-ground tumbled alloy wheel rim. In the process of slidegrinding and tumbling, the wheel rim is moved through a fill of abrasive media moving with a particular frequency. As one would with sand paper, manufacturers begin with coarse abrasive media and replace this with finer and finer abrasives over several steps.

New Adhesive Technologies Car manufacturing can also be optimised through the use of new joining processes. Researchers at the Fraunhofer Institute for Manufacturing Technology and Advanced Research IFAM in Bremen have come up with a gluing process that allows for markedly faster production, such as in the glass front of a headlight. Conventional adhesives need several hours before they are hardened through humidity – and the headlight has to be held in place throughout this period.

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IMF MD Calls For New Global Approaches To Post-Crisis World

Flavio Takemoto, Brazil

Washington DC, USA: Dominique Strauss- Kahn, MD of the International Monetary Fund (IMF), called for a new approach to economic policymaking in the wake of the recent global crisis.

He singled out three areas for improvement: a new approach to macroeconomic and financial sector policies, a new approach to social cohesion, and a new approach to cooperation and multilateralism.

Discussing the current economic situation, Mr StraussKa hn noted that the globa l recovery is unbalanced both between and within countries,

and the global outlook is still beset by uncertainty. He pointed in particular to the Middle East, noting that it is going through an ‘historic transformation’ as citizens are seeking greater freedom, and a fairer distribution of e conom ic opp or tu n it ie s and resources. The immediate challenge for the Middle East, he stated, was “to preserve social cohesion without undermining macroeconomic stability”.

Tu r n i n g t o g l o b a l macroeconomic policies, he argued that policy must go beyond price stability, and look to financial stability, incorporating

macro -prudential tools. The crisis has showed the value of fiscal policy, which had been the ‘neglected child’ of the policy toolkit. Mr Strauss-Kahn also called for more progress with financial sector reform, including across borders, and called for a financial activities tax.

He stressed the virtues of e n ha nce d co op erat ion a nd multilateralism in the post-crisis world, noting that “the great challenges of today all require a collective solution”. He cautioned countries against using currencies or trade restrictions for shortterm gain.

AEROSPACE

MHI Commences Mitsubishi Regional Jet Assembly Work Tokyo & Nagoya, Japan: Mitsubishi Heavy Industries (MHI) and Mitsubishi Aircraft Corp have jointly announced the commencement by MHI of assembly work on the next-generation Mitsubishi Regional Jet (MRJ). Based on an order placed by Mitsubishi Aircraft, which is developing the MRJ, the company began riveting work on the frame structure surrounding the emergency escape hatch for crew in the cockpit roof of the aircraft.

While manufacture of individual parts had already begun last autumn, the start of assembly work indicates that the MRJ project to develop Japan’s first passenger jet is progressing steadily and firmly as 24

metalworking equipment news May-Jun 2011

scheduled. The aircraft’s first flight is slated for 2012.

The start of assembly work on the MRJ signifies that the aircraft’s production mode has now progressed to a new level. Going forward the company, in addition to producing the MRJ’s major components – including the fuselage, wings and empennage – will also engage in final assembly and equipment installation on receipt of the various components currently being produced by the many project partners.

MHI and Mitsubishi Aircraft will continue to devote their efforts toward making the MRJ project a success, aiming to play a significant role in the ongoing development of the global aviation industry.

ENQUIRY NO 067

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AEROSPACE

ST Aerospace Tie-Up Maintenance Contracts In 1Q2011

Colin Kean, Prestwick, UK

Singapore: ST Aerospace has secured new maintenance contracts with a total value of about S$320 million (US$256 million) in the first quarter of 2011. Ranging from three months to 12 months, these contracts for the aircraft maintenance & modification, component total support and engine total support businesses will be carried out at its facilities in the Americas, Asia Pacific and Europe.

The aircraft maintenance & modification business scored new airframe contracts involving line maintenance, base maintenance,

heavy maintenance, passengerto - freighter conversion a nd i n te r i o r r e f u r b i sh m e n t o n various commercial and military aircraft types.

The component total support business secured new component contracts, including maintenanceb y - t h e - h o u r, av i o n i c s a n d mechanical component maintenance, aerostructures and landing gear repair and overhaul.

The engine total support business clinched new engine maintenance contracts, which include on-wing maintenance,

off-wing maintenance, te chnica l ma na gement a nd asset management on various engines types.

In the first three months of t his ye a r, ST Aerospace redelivered 144 aircraft to various customers, for airframe related maintenance and modification work. For PTF conversions alone, it has redelivered a total of five converted freighters in 1Q2011.

Additionally, the company has serviced 58 engines and 11,971 components for both commercial and military customers.

Boeing Celebrates Opening Of New Factory In China Tianjin, China: Boeing and Aviation Industries Corp of China (AVIC) have celebrated the opening of a factory that doubles the footprint of their joint venture, Boeing Tianjin Composites.

The facility will increase Boeing Tianjin Composites’ production capacity by 60 percent and company employment is expected to rise from 700 to more than 1,000 by 2013, the target date for full production. Boeing Tianjin Composites produces components for all of Boeing’s in-production programs including the 737, 7478, 767, 777 and 787. The company invested $21 million to develop the new factory, which was built next to the existing factory in the New Binhai Area of Tianjin.

“Boeing Tianjin’s new factory is an example of winwin collaboration between China and Boeing,” said Ray Conner, VP and GM, Supply Chain Management & Operations, Boeing Commercial Airplanes. “We rely on our Chinese partners to produce quality components for Boeing airplanes, and we are excited to expand this successful joint venture to increase production and employment.”

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metalworking equipment news May-Jun 2011

“The expansion of Boeing Tianijin Composites is just one example of how Chinese companies have an increasing role as our manufacturing partners and collaborators,” said Marc Allen, president of Boeing China. “Through commercial airplane sales, manufacturing, airplane services and research partnerships, we are committed to finding mutually beneficial avenues to advance our long-term relationships in China.”

Building on Boeing’s environmental leadership in manufacturing, Boeing Tianjin Composites’ facility in China is certified to meet the internationally recognised rating of the US Green Building Council ( USGBC) and Leadership in Energ y and Environmental Design (LEED). This rating highlights the company's commitment to use building strategies that improve environmental performance, including energy and water efficiency, greenhouse gas emissions reductions, improved indoor environmental quality and the stewardship of natural resources.

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Apparent Steel Use To Increase By 5.9 Percent – Worldsteel

London, UK: The World Steel Association (worldsteel) released its April 2011 Short Range Outlook (SRO) for 2011 and 2012. It forecasts that apparent steel use will increase by 5.9 percent to 1,359 mmt in 2011, following 13.2 percent growth in 2010. In 2012, it is forecast that world steel demand will grow further by 6.0 percent to reach a new record of 1,441 mmt.

This forecast suggests that by 2012, steel use in the developed world will still be at 14 percent below the 2007 level whereas in the emerging and developing economies, it will be 38 percent above. In 2012, the emerging and developing economies will account for 72 percent of world steel demand in contrast to 61 percent in 2007.

Commenting, Daniel Novegil, chairman of the worldsteel Economics Committee said: “2010 saw a steady recovery of steel demand which began in the second half of 2009 driven by stimulus packages globally, the resilience of emerging economies and an overall market recovery. In 2011, we expect to see a further 5.9 percent growth in world steel demand. Our forecast is based on a stable and steady recovery of the world economy. There are however uncertainties deriving from financial fragilities in Europe, unrest in some oil producing countries in the Middle East and the earthquake in Japan, which could have a negative impact on the recovery and thereby affect steel demand.”

China’s apparent steel use in 2011 is expected to increase by 5.0 percent to 605 mmt following 5.1 percent growth in 2010. Given the pace of steel production in the first quarter of 2011, Chinese apparent steel use could be even higher. However, it is expected that the Chinese government’s efforts to cool down the overheating economy, particularly the real estate sector, will impact Chinese steel demand somewhat later this year. In 2012, Chinese steel demand is expected to maintain 5.0 percent growth, which will bring China’s apparent steel use to 635 mmt.

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metalworking equipment news May-Jun 2011

India is expected to show strong growth in steel use in the coming years due to its strong domestic economy, massive infrastructure needs and expansion of industrial production. In 2011, India’s steel use is forecast to grow by 13.3 percent to reach 68.7 mmt. In 2012, the growth rate is forecast to accelerate further to 14.3 percent.

The rebound in apparent steel use in the US is forecast to continue with growth of 13.0 percent to 90.5 mmt in 2011, reflecting the second round of quantitative easing and new fiscal policy initiatives that gave a boost to economic activities and sentiments in industrial and energy markets.

Construction markets remain at depressed levels.

US are expected to grow by 6.9 percent to 96.7 mmt, bringing it back to 90 percent of the 2007 level. For NAFTA as a whole, apparent steel use will grow by 10.9 percent and 6.3 percent in 2011 and 2012 respectively.

Japan’s steel use was expected to decline by -1.2 percent to 63 mmt in 2011 as stimulus measures expire. However, the forecast was prepared before the natural disaster and it is too early to fully grasp the implications of these recent tragic events. In 2012, apparent steel use in Japan was forecast to remain around 63 mmt, 78 percent of the 2007 level. The impact of the earthquake and tsunami points to a significant downward adjustment in steel use for 2011 and upward adjustment for 2012.

The recovery of steel use in the CIS has been surprisingly healthy due mainly to an unexpectedly strong rebound from steel-using sectors in Russia. As domestic demand and business investment continue to grow healthily in the region, apparent steel use is expected to grow by 7.5 percent to 52.1 mmt in 2011 and then by 8.9 percent to 56.7 mmt in 2012.

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FIRST

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cut

Opinion:

Don’t Avoid Extreme Metal,

Challenge

It!

When it comes to extreme metals, it is better to embrace than shun. By Dr Moshe Goldberg, marketing technical advisor, Iscar

U

nder all circumstances, e x t re m e m a t e r i a l s should be considered as a challenge, rather than a burden, and as a result, should not be avoided or rejected. In most cases the machining solution lies with the cutting tool technologies a n d m a c h i n i n g s t r a t e g y.

Machining extreme materials is an ambiguous term normally referring to machining materials such as Titanium alloys, Inconel, Waspalloy, Hastelloy, Hardox (harden steel), austempered ductile cast iron and more.

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metalworking equipment news May-Jun 2011

In industrial terms, extreme materials are considered to be materials with outstanding mechanical properties, such as an exceptional combination of oxidation resistance, fabricability and high-temperature strength.

These advantageous features are obtained due to alloying or heat treatment processes that subsequently make the machining process of these materials extremely difficult.

These materials are normally the fruit of the development of university laboratories, research institutions

and laboratories commissioned by industry, that aim to develop innovative materials with better mechanical properties, reduced density Dr Moshe Goldberg (weight) or improved corrosion/heat resistance.

The advanced innovative materials have continuously emerged and implemented into the production floor, while gradually replacing existing materials. This trend set ever-growing challenges for cutting tool manufacturers to develop tools that best cooperate with these materials. Therefore, all new materials, following the completion of all stages of development and accreditation, are assessed and trialed by cutting tool manufacturers, with an aim to develop the most suitable machining solution, geometry or strategy.

Awareness Is Key Engineers, machining specialists and operators tend to be prejudiced or conservative when it comes to machining extreme metals.

They either have not got adequate knowledge on how to machine these metals or they are reluctant to adopt new machining strategies or technologies. This lack of awareness or acknowledgment of advanced cutting tool technologies might see some categorise hardened steel up to 65 Hardness Rockwell C as an extreme metal, while in reality an efficient metal removal process can be obtained by using Cubic Boron Nitride (CBN) cutting tools.

Other examples that could represent a challenge in machining are Inconel, Waspalloy, Hastelloy or martensitic stainless steel.

Regarding the first three types of high nickel alloy, here are some machining tips. • Rough turning with the right

firstcut

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• Grooving applications applied on Inconel for instance, can be done by using Iscar JetCut tools with coolant that is fed through the tool and directed in a stream at the cutting edge. The coolant media is pinpointed beneath the chip, at the interface between the tool, workpiece and chip. That constant stream of coolant assists in cooling the vicinity of the shear and the plastic deformation zone, as well as providing lubricity, chip curving, and chip evacuation. • Milling of Inconel and Hastelloy could also be efficiently machined with the right tungsten carbide tools and grades, such as extended flute milling cutters for high productivity, supplemented by whiskers reinforced ceramics that improve the shearing process tremendously.

Finally, martensitic stainless steel is another example w h e re t h e r i g h t s u b s t r a t e composition together with the proper chipbreaker design could overcome any machining obstacles, and as a result, do refrain from categorising it as an extreme metal.

Technological Advances Machining Titanium or Inconel continuously requires placing the focus on restricting generated heat. The key solution stems from technological advancements in this field, in terms of cutting tool materials and advanced coating films.

Various substrates, such as tungsten carbide, CBN, and whiskers reinforced ceramics, provide different characteristics in terms of toughness, hardness and heat conductivity. Coating provides a heat barrier and protection against wear, and so should also be customised per the requirements of each application.

In terms of tooling – the use of extended flute milling cutters exhibits ideal machining characteristics, with high metal removal rates while generating minimum heat.

A potential solution concerning heat could also be applied by machining extreme metals using the high pressure coolant technique. The coolant pressure varies from 70 to 300 bars and in many cases could serve as a great assistance to deform chips and evacuate them, while maintaining a constant control over the generated heat.

Different Handling Approaches There is a clear distinction between different countries, continents and societies in their approach towards solving p ro b l e m s a s s o c i a t e d w i t h machining extreme metals. The working methodologies applied in Germany, Sweden, USA or Japan for instance, are different than the ones used in China, India or Russia.

Some countries apply the most advanced machining solutions, while others remain more conservative and use the traditional style of machining.

Some of these countries are geared up with the right machining capacity, good infrastructure and skilled operators, while others are lagging behind. Whichever way you look at it, it is the consequence of the funding and investment into the industry. MEN Enquiry No. 4001

ENQUIRY NO 100

tungsten carbide grade, constructed upon a sharp positive geometry, positioned at 45 deg approach angle and high pressure coolant, followed by a finishing operation using CBN or whiskers reinforced ceramics would constitute a good machining solution.

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rends in industry are moving towards more dif ficult to machine materials because special alloys with high nickel, silicon or chrome content offer the final product advantages in either performance or visual presentation. Automotive and aerospace companies together with their sub-contractors are especially active in the application of these materials, often called ‘Super Alloys’.

Components with threads are more often than not tapped as a final operation; this operation is seen as most vulnerable because the expensive work piece is all but finished when it comes to the threading process.

Conventional tapping works against the laws of physics for machine utilisation, tap tool life, component security and quality of thread. Yet there are a few simple rules, which can be followed which will enhance all of the negatives already mentioned and turn them into positives.

Factors To Consider Cutting tool applications engineers, machine programmers and production planners will consider machine stability, cutter design, (close pitch or course application) entry and exit angles, cutter approach angle, climb or conventional milling, size of insert and grade among others.

Tooling engineers will look at the colour of the chips, they listen to the machining process and finally analyse the cutting edge to ensure the longevity of the whole machining process. What do we do in the tapping processes?

Too Rigid The drill size is predetermined, as is the depth of thread. The few remaining choices restrict us to what speed is to be run.

That predetermines the feed rate and what coolant can be applied 34

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Tapping Difficult Materials

Conventional tapping applications are slowly becoming a contradiction to cost effective machining and production optimisation. By Andy Hooper, global sales manager, Bilz

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

ENQUIRY NO 096

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

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Under normal circumstances, it is said that the application of synchronised tapping chucks will enhance tap life by 30 percent

and finally the tap material.

Conventional tapping means we have to stop the cutting operation while the cutting tool (the tap) is in cut. This would never be an option in any other machining process because the results would be disastrous but in tapping this is considered normal.

In today’s CNC machining industry, there is a tendency to tap the work-piece utilising a rigid spindle connection set up; that means the tap is clamped in the holder rigidly and the holder is naturally clamped rigidly in the machines spindle. The combination of rigid clamping and stopping the tap in cut sometimes result in failure for both cutting edge and component.

The result is shortened tool life, lack of quality, and costly re-work in an event of a crash. The point being the more difficult to machine a material is, the more vulnerable the application becomes.

Tapping Super Alloys High-risk applications include ‘super alloys’ used in critical aerospace components. Titanium is especially popular for these components. A rigid tapping set up in this environment poses danger for scrapping the component. By applying a tension/compression tap chuck a degree of security is introduced to the process, which will safeguard the investment.

As in all tapping applications where the spindle has to stop or where the tapping depth is 36

metalworking equipment news May-Jun 2011

critically close to the bottom of the drilled hole, there is a possibility that the tap either falls short of its target depth or crashes to the bottom of the drilled hole.

In either case, this can be time consuming and detrimental to the quality of the product.

This is especially true when machining super alloys. Assume the core hole for the tap is drilled too small; the tension/compression tap chuck is spring loaded in one or both axial directions (tapping in and out). This gives an amount of compensation that allows the tap to compress the tap chuck in the event of a small bore or broken drill. As a result, this saves the application from serious damage.

In the event that the hole is not drilled deep enough, by giving a further safety net, a clutch mechanism can also save the application. The tap chuck will compress up to 15 mm. If the tap is allowed to continue to rotate, it would try to strip the thread, the clutch will take over and safeguard the application by simply slipping the tapping assembly. Again, the hole or thread, component and machine are all saved without damage.

The difficult to machine materials are often also hard and in tapping applications it is often found that the tension/compression holders are not used as the tap has no chance to break the surface of the component and therefore only compresses the chuck, which results in no thread.

You can apply a so - called ‘hard start’ tension/compression tap chuck to overcome the first thread. There really is no reason to risk your expensive material and investment in machining for the sake of rigid tapping. The solutions are easy, available and not expensive comparing the risk of conventional tapping methods used.

Small To Medium Batch Runs General engineering applications in the automotive, medical and power generation industry can benefit from the application of synchronised tap chucks. Here too the spindle of the machine runs to zero RPM at the bottom of the bore. The slowing down effect in combination with reducing feed has an effect of non-synchronisation between the RPM of the spindle and the feed rate.

This in turn has the effect of pushing and/or pulling the tap into and naturally out of the bore as the reversing and acceleration of the spindle also gives the same physical demands of the application (resulting in thin or weak threads – you will know that in the event of every first off setup a sample component is submitted to the inspection department for approval.

This is cut and viewed to detect the effect of non-synchronisation, in other words thin threads).

By selecting a synchro chuck, this will allow compensation between the spindle and slowing feed rate. While it cannot be detected, a synchro chuck has a small amount of axial float that allows compensation.

With modern machine tools, this compensation is sufficient to have two major effects on the product and the tap. The product benefits from clean, full form threads and the tap will benefit from extended tool life as the push pulling effect is no longer a factor.

Under normal circumstances, it is said that the application of

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High Volume Runs Automotive and their subcontractors are especially able to benefit from self-reversing tap chucks for applications on materials with higher silicon content and or bimetal and alloyed cast irons from a cycle time and tool life saving point of view.

So far we have discussed the tapping of difficult to machine materials where the spindle stops at the bottom of the hole. If we recall the example on milling optimisation, we talked about

The more difficult to machine a material is, the more vulnerable the application (conventional tapping) becomes. many steps to achieve the best possible result. Now consider a similar end result especially for difficult to machine materials using a self-reversing tap chuck.

A constant feed and speed rate can be employed in a tapping application without stopping and reversing the machine spindle.

Looking at it in another way, the machine spindle remains spinning in a right hand direction while the tapping chuck takes care of the reversal without the time loss due

to the spindle stopping and starting.

The first benefit is easy to see, 0.4 seconds is the average time it takes a machine spindle to stop and change direction. Multiply this by thousands of holes a year and the user quickly sees a major cycle time saving of 29 percent – this figure is dependent upon the depth of thread being machined. But the real benefit comes in the additional tool or tap life. MEN Enquiry No. 4002

ENQUIRY NO 093

synchronised tapping chucks will enhance tap life by 30 percent and if the tap life increases by this amount, the corresponding finish, strength and general quality will also be better for longer. It therefore allows that alloy and all other difficult to machine materials to benefit from even more extended tool life.

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Insights

Spot

Landing For Technology

T

hat laser beam used to machine cooling holes in turbine blades is not new.

This has been the standard practice at MTU (Aero Engine plant) in Munich for years. In addition, the plant has been utilising high tech erosion technologies for quite some time now. Also 3D drilling is not a new subject. Yet 3D drilling with lasers belongs to the less known machining methods for these applications.

Three years have passed since the first prototype was manufactured. Since then the process at the MTU production facilities has evolved into an efficient standard procedure. All new turbines are already fitted with blades, machined with this technology and even the older models are optimised and redesigned respectively.

Taking The Heat Off Why is there a demand for 3D

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By using laserform drilling, Mill-Aero Engines has installed an efficient process of machining shaped holes. By Ralph Schiffler, marketing manager, DMG Cooperation Markets holes at all? After all, cylindrical holes, typically machined with lasers for nearly 20 years, have always fulfilled their cooling purposes with good results up to now. The answer lies simply in the far greater cooling efficiency.

Dr Ing Mark Geisel of the turbine blade production technology division at MTU Aero Engines explains: “The temperatures these turbine blades operate under, come very close to the melting point – normal steel would be destroyed after a few minutes.

Therefore, we use mono-crystalline materials, which are, perhaps, the most demanding materials used presently in machine building. Of course, we direct all our efforts towards maximising turbine engine efficiency to the greatest possible extent. Heat physicists have calculated that integrating a

diffuser, ie: flaring the bore inlet, helps increasing cooling efficiency – essentially because the cooling air distributes itself like a uniform film over the blade.”

This increases the turbine’s overall efficiency by about one percent, which does not sound much at first. However, this one percent represents a temperature difference of about 100 deg C. The real advantage of the enhanced cooling capacity is the higher overall efficiency. If the pertinent reports are to be believed, one quarter of an airliner’s total costs are attributed to fuel – and increasing a turbine’s overall efficiency even by just one percent is a remarkable improvement.

Laser Drilling As mentioned earlier, lasers had already been used for erosion

Onshore. Offshore. We get productivity pumping.

ENQUIRY NO 085

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methods on certain engines. At that time though, the exorbitant tool costs were a constant source of headaches for the production specialists and on the administrative level, every effort was made to weigh the pros and cons of every possible machining strategy.

The upshot was that laser applications (at least on paper) turned out to be the winner in all categories. The theoretical efficiency of laser machining practically demanded implementation in the field.

A group of companies and educational institute came together and their tasks included qualifying a number of questions, drawing up specifications for lasers and components and organising genuine, fixed cycle series production. The procedure was qualified on the basis of a component, now used in the drive for the A380.

There are now six Lasertec 80 Powerdrill units in Munich that operate over three shifts for 3D laser drilling. These are five-axes machines, fitted with linear drives along the X and Y-axes and torque motors in the swivell and rotary axes.

They differ from a conventional laser drill in that they feature two integrated laser sources, one for drilling and the other for erosion.

Dr Geisel says: “Nevertheless we are still by ourselves on an wide terrain. It is also clear to competition that the production costs with conventional machining will be too high over the long run.

At some time or another, somebody else is certainly going to aim for the same goal.”

First, the laser drill drills the basic cylindrical hole. Then, the part moves underneath the erosion laser to ‘laser out’ the funnel-shaped cavity. Dr Geisel says: “The technology of laser erosion is well-known in the cutting tool industry, which means it certainly isn’t new.”

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But there are substantial differences. In tooling, bigger geometries are lasered out.

As for blades, a complex, 3D

component, there are hundreds of shaped holes to generate – up to 400 and every one of them individually.

The Truth About Laser Q: What are the reasons for the increasing use of laser technology in material processing? Can you highlight the important applications of laser micromachining in various manufacturing processes?

A: The development and improvement of laser technology within the last years led to a reduction of costs and size of laser machines. Therefore the attractiveness compared to alternative machining such as EDM, grinding and etching has risen greatly due to lower cycle times, no tool wear and a large range of applications.

Q: Please elaborate on the various types of industrial lasers and their properties in the gas and solid-state lasers that made them suitable for laser micromachining.

A: The main laser types on the market are fibre, Vanadat, Nd:YAG, Picosecond and CO2 Lasers. For laser shaping, short pulsed and ultra short-pulsed lasers in the nanosecond and picosecond range are used. These lasers mostly vaporate the material and are able to achieve a very good surface finish. For fine cutting applications, fibre lasers and pulsed Nd:YAG lasers are used, depending on the application. The possibility for coolant hole drilling are pulsed YAG Lasers. For holes up to 20 mm depth, lasers with an average power of up to 500 W are used.

Q: Can you please tell us more about the precision and performance of the drilling rates of laser micromachining used in the manufacturing industry?

A: A typical nozzle guide vane of an aircraft engine with approximately 250 coolant holes can be drilled in less than 15 minutes. The positioning accuracy of the Lasertec machines lies within 10 µm.

Q: Please highlight the materials and industrial sectors that have benefited most with laser micromachining?

A: The target of our fine cutting machines is to produce intricate geometries from sheet metals and even 3D parts for the watch industry and the medical industry and other high precision applications.

Q: With most of the economies of the world recovering, what is your outlook for the future growth and demand for laser micromachining in global and Asia Pacific markets? What will be the key growth drivers for this technology?

A: Tremendous progress and the high speed development of laser sources in the last two years have opened new applications for laser micro machining. There will be a double-digit growth for laser precision applications over the next three to five years. Especially in Asia, there is a high potential of replacing conventional processes by laser technology. The key growth drivers will be further development in the laser technology and the laser machine and development of applications.

Enquiry No. 4101

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That means the biggest challenge is the exact positioning of the blades underneath the laser beam. It becomes more difficult, when one considers that even such precise raw castings have inherent tolerance deviations, resulting in further problems vis-à-vis the laser’s beam focus.

Implementing Laser The greatest challenge of all for process control is how to implement series production. Dr Geisel says: “We are required to produce quickly, also to recoup our investments with productivity. We have given highly detailed thoughts on process control.”

Owing to each turbine blade’s individuality, it is impossible to pin down a general value for the time needed to laser machine a blade. The background is a whole chain of cause and effect, from a

consistent CAD/CAM strategy to the corresponding logistics work. Not least of all, it is also the qualifications of the machine operators.

Dr Geisel says: “The process is highly complex and has to be mastered. There are many facts coming together that must be understood, eg: that more than one zero point must be taken into consideration for each workpiece and sensor. Without qualified personnel it will not work – and that is something you have to know as well.”

But this ultimately holds true for all sophisticated production methods and all the more so in the world of aerospace. But just to return to erosion drilling – is it not a more precise method when it comes down to it? Dr Geisel’s answer: “Yes, erosion can be better. Even today we have applications that require it. In this case, the selection criteria

is not precision, but the aspect ratio. We cannot seriously consider using lasers for some aspect ratios.

Laser erosion, on the other hand, exhibits accuracy that is good down to a few microns and that’s perfectly adequate. We work with precisions on the scale of 10 μm with fast fixed cycles corresponding to genuine series production. Under these series conditions we are far superior to any other method, even where production quality is concerned.”

Dr Geisel dispels all doubts as to whether this combination of laser drilling and laser erosion, ie: 3D laser drilling, should now be regarded as a standard method, even though for some time yet erosion will continue to uphold its right to exist for a handful of special applications, even at MTU. MEN Enquiry No. 4102

APMen_ASIEN_3406147_EMO Hannover 2011 18.03.11 13:36 Seite 1

INFO: VDW – Generalkommissariat EMO Hannover 2011 Verein Deutscher Werkzeugmaschinenfabriken e.V. Corneliusstrasse 4, 60325 Frankfurt am Main, GERMANY Tel. +49 69 756081- 0, Fax +49 69 756081-74 emo@vdw.de · www.emo-hannover.de

ENQUIRY NO 062

The world of metalworking

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Reaming With A

New

Rhythm

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Adding speed to reaming helps achieve the required tolerances in surface quality and circularity. By K Ravi Kumar, GM (Asia Pacific), Komet

raditionally precision holes are machined through several processes such as fine boring, grinding, honing, polishing, super finishing and reaming. Among all these processes; reaming plays a vital role in reaching required tolerance; surface quality and other geometrical accuracies.

The conventional reaming process is always a slow process and machining times are quite high, so generally for finishing operations, the most opted process is grinding or honing. Manufacturing technology has evolved over the times with the introduction of CNC machine tools that offers high spindle speeds, linear feeds and flexibility. This results in the higher demand of high performance cutting tools.

High-Speed Reaming Technology has helped us move ahead from conventional reaming to high-speed reaming in order to get better results. High-speed cutting

Figure 1: Highspeed reaming performs at very high speed and feed rates 42

metalworking equipment news May-Jun 2011

drastically reduces the cycle time; improves surface finish; delivers better cost per component all cumulating to better productivity.

As visible from figure 1 where conventional reaming operates at low speed and feed rates; highspeed reaming performs at very high-speed and feed rates.

The cutting edge of a reamer is as illustrated in figure 2. The whole high-speed reaming technology depends on how these details in micron levels are prepared and maintained consistently for consistent performance of the reaming tool.

It is not just the cutting edge alone that brings the high performance while reaming. The vital role is to choose the right cutting material and the newest coatings. The cutting materials are sub-micron carbide substrate, which is suitable for all kinds of work piece material to be machined together with TiN, DBG-N coatings. The other harder substrates are DST which offers higher wear

resistance to ream in all kinds of steel, stainless steel and nodular iron.

DST being the hardest substrate can operate at a cutting speeds of Vc= 100 to 300 m/min with guaranteed longer tool life. With the additional DBG-N coating on DST cutting material, the performance of the reamer can be further enhanced to extend the tool life. DST being a harder substrate than carbide; means it is also brittle in nature and therefore not recommended for reaming with interrupted conditions.

Reaming Aluminium A l u m i n i u m i s i n c re a s i n g l y becoming a component material in the manufacturing industries like aerospace and automotive parts.

They are of high volume production and need high performance tools to ensure the consistent quality levels and process capability. Figure 3 represents aluminium machining with various cutting materials.

It is clear that most of the cutting materials are not stable in terms of performance while the Poly Crystal Diamond (PCD) is the cutting material we can rely on for the higher process consistency of machining bores. The main reason for the other cutting materials not being able to perform is that aluminium has the affinity for builtup edge with carbide. PCD however, does not have any affinity for a builtup edge. This gives PCD the longest consistency in performance and enables endless tool life.

Application Areas Of PCD Tools The major application areas of PCD tools are machining aluminium and non-ferrous materials in automotive and aerospace industry. Today the

Figure 2: The cutting edge of a reamer

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Figure 3: Aluminium machining with various cutting materials

edge cool and assists better chip evacuation while machining to increase wear resistance.

Finally, it helps avoid or delay the process of built-up edge.

The coolant recommendations are water- based soluble oil with six to eight percent mixture and coolant pressure at a minimum of 10 bar.

Other innovative tool concepts

like reaming with indexable inserts, coating technologies and special chip breaking geometries for machining soft materials will benefit modern machines used across the industries like automotive, power generation, aerospace and machine builders to keep up with the new rhythm of high-speed reaming. MEN Enquiry No. 4103

Conditions For High Speed Reaming Precision bore machining with high-speed reaming technology requires cer tain machining conditions to be fulfilled to enable use of optimum cutting data that achieve excellent surface quality, circularity, cylindricity even at the end of tool life.

The basic conditions are to ensure the right alignment from the machine spindle to the work piece, and the true running of the reamer, which means that the runout on the cutting edge must be less than 0.003. With a compensation adaptor system, it is even possible to eliminate misalignment of spindle to ensure the true running of the reamer.

The inner coolant supply for high-speed reaming is a very important factor as it lubricates the cutting edge; circular land and chip face to increase the tool life. It also reduces heat generation and kveeps the cutting

ENQUIRY NO 094

trend is that most of the automotive parts, especially the engines and transmission parts of the car is made out of aluminium with silicon content of 8 to 13 percent. Automotive part production operating in high volume means there is demand of high process capability without any quality deviations.

PCD reaming technology offers benefits to hold the high quality levels of the parts with tool life in the range of 2,000 to 5,000 m of cutting length.

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Metrology

the success of a company cannot depend on ISO 9000 alone; other business considerations have to be included.

Opinion:

The

Evolution

QC

Of

Quality control has evolved from an inspection practice to a holistic approach. By Wu Tek Ming, senior VP, management services, Tüv Süd PSB

Q

ua lity Control (QC ) is a thing of a past. It started in the 60s when people were talking about control in every stage of a production process. Back then, QC meant doing an inspection on a finished product to ensure it conforms to a certain specification.

In the 70s, the industry evolved into Quality Assurance (QA), or more importantly, the philosophy behind it, ie: quality is the responsibility of everyone, not just the inspector’s per se. This brought about the wave of training in quality awareness and quality tools.

Nowadays, quality is a given.

Without it, a company can stop production as quality is a journey, and the journey is the destination – it is a continuous process.

The quality systems of today emphasise on the holistic approach, resulting in the term ‘Total Quality Management System’ (TQM). As such, quality does not equate to the number of staff you have or the complexities of the technology. An SME with 10 people can implement a simpler TQM but the concept and approach will be the same as that implemented by an MNC. The company must have a system that is less human dependable where you can ensure the product produced at any one time meets the requirement.

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Management System In the modern industrialised era, Management Systems (MS) like ISO9000 and ISO14000 are becoming a commonplace and even a must for some industries. The metalworking industry is no exception. Although it is comprehensive, the system alone cannot guarantee success in an organisation. Take ISO9000 as an example, it is a tool, an enabler.

It helps create a system for people to follow. As such, it helps you to achieve your targets. However, if there is a fundamental flaw in the product design, MS cannot help mask that fact.

The system defines quality principles and so staff training and their understanding are key success factors. A pertinent point to note about MS is it is not product certification (eg: testing on durability or reliability). It is an organisation structure that is supported by process procedures and resources.

At times, it may be an irony as MS does not define the product quality, ie: product quality is specified by the producers. For example, if the producer specifies a loose reliability parameter, the company may still achieve ISO 9000 certification if there are no obvious signals to indicate customer complaints, product recall or huge scrap cost. As such,

Question Of Implementation The success or fa ilure of a QC program depends on implementation. As such, the top management plays a very big role.

Sometimes, the quality movement may not be well communicated downwards for various reasons.

The enterprise could be too large, the management is pressurised by the bottom line and the training program is not well-defined.

In some parts of ASEAN, the companies have good plans but the implementation is weak. Using ISO9000 as an analogy, in the management system, there is PDCA – Plan Do Check Action. The amount of effort put into ‘P’ and ‘D’ must be the same otherwise there will be no benefits.

In other parts of the region, staff mobility is also an issue.

Taking Singapore as an example, where a considerable number of its workforce is transient in nature, it is difficult for the management to commit to training its workforce. That is why in quality awards, the first thing we look at is top management’s commitment, ie: to see if they walk the talk. In addition, effective training is essential, you must be able to apply what you learn from classrooms.

The last point is related to infrastructure and language, which may pose a challenge to countries like Cambodia or Vietnam. As the quality principles and tools are developed mainly f rom t he E n g l ish sp e a k i n g regions, it would be difficult for the locals in these countries to fully understand the concept and their applications. This could impede their quest for quality improvement.

Enquiry No. 4201

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ERP and PLM: The right balance for competitive advantage.

Learn how to strike the right balance. PTC invites you to read the PLM-ERP papers in our PLM Resource Center: PTC.com/go/erp-plm Š 2011 Parametric Technology Corporation (PTC). PTC and the PTC logo are trademarks or registered trademarks of PTC. All other product or company names are property of their respective owners.

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Too many companies suffer from an imbalance between the management of business operations and the control of product development processes.

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Failure Analysis:

Uncovering The

Truth

When failure happens, thorough investigation is conducted to locate the root cause.

By Dr Huang Xianya, VP & chief consultant of Inspection & Failure Analysis Centre, TĂźv SĂźd PSB A defect of few micrometres in a screw or other key metal component may seem insignificant, but under some conditions, it may lead to major failures. Real-life examples include breakdown of ship engines, oil refinery devices, boiler tubes, heart operation equipment, roller coasters and aircraft turbine engines. From an economical perspective, these incidents are equivalent to losses in millions of dollars in terms of profits and damage costs.

As such, it is important to conduct thorough checks on the products before distribution. However, in many cases, these minor fatigue cracks are undetected, escaping many hands in the manufacturing line. Therefore, when a breakdown happens, Failure Analysis (FA) engineers are often called in to conduct detailed investigations.

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Uncovering The Root Cause Of The Failure FA involves studying the failed sample from various angles including chemical composition, mate rial, me chanical proper ties and microstructure. Two steel plates made of the same grade m ay ex hib it dif fe re nt qu a litie s ( ie: concentration of impurities is higher in one of the plates). Site visits are also conducted to gather first-hand information like interviewing the workers.

Furthermore, FA engineers identify and understand the root cause of the failed location. This is done through examination of the fracture locations, features of the fracture as well as the crack properties.

Often, failure is a result of material, environment, manufacturing process,

manpower or management. For example, a particular type of tension insulator may work in France, but will fail in a tropical country such as Singapore.

Indeed, it is even possible to predict potential failures based on a detailed surface analyses of the fractures, which eventually help customers to prevent catastrophic failures.

Improving FA Looking forward, it would be beneficial to have a database of past FA cases so as to enhance investigation and predict possible failure mechanics. This not only helps new FA engineers, but experienced engineers will also be able to better utilise the information.

Lastly, FA engineers should possess qualities like moral integrity and logical scientific thinking, with the ability to apply theories on actual practical breakdowns.

Moral integrity is especially important as customers or external parties may challenge the FA engineers’ explanation.

Ultimately, the purpose of FA is to help customers ward off future failures as well as improving the design of the product and manufacturing processes.

Enquiry No. 4202

Failure Of Aircraft Engine

Failure Of Ship-Lifting System

Having investigated more than 150 aerospace cases, more than 40 cases are aircraft engine failures. One example is the failure of an aircraft engine High-Pressure Turbine (HPT) blade. A loud noise emerged from the engine after an aircraft flew for half an hour. Upon checking, it was discovered that many HPT blades were damaged.

After thorough investigation, our team found out that one of the turbine blades was primarily damaged and caused damage to other turbines. In particular, an irregular-shaped cooling hole initiated high-cycle fatigue cracking and led to the final rupture of the turbine blade. We further identified that the abnormality of this cooling hole could be attributed to improper EDM manufacturing process.

Another case is a found crack on a modified welded steel beam of a ship-lifting system in a shipyard. Detailed FA investigation uncovered three stages of crack development.

First, a 1 mm hot crack was formed at the weld toe during or just after the welding process.

The FeO oxide layer on the crack walls implies that it was formed due to high temperature.

Second, the crack propagated sideways under the high residual stresses through stress corrosion cracking mechanism, because no post-weld heat treatment had been done for the beam. Some yellow primer paint detected in this part of the crack evidenced that the beam had been exposed to open air for many weeks before being painted.

Third, the crack turned perpendicular to the applied main stress, indicating that the beam, ie: the system, was put under stress. Clear features of hydrogen-induced cracking were detected in the late half of the third part of the crack suggesting that the cathodic protection system of the ship-lifting system started working after sometime, but its parameters were set up inadequately. All above inferences were confirmed by the customer to be consistent with the facts.

Therefore, it was recommended that all other welds of the modification project of all 50 beams must be inspected for similar cracks using NDT. A few days later, the results of the NDT showed more than 40 percent of the welds already had cracks. A catastrophic accident was avoided through a thorough FA investigation. MEN

Enquiry No. 4203

Enquiry No. 4204

metalworking equipment news May-Jun 2011

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

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

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

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

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

MMC Hardmetal (Thailand) Co.,Ltd.

8th Floor Regent House Building, 183 Rajdamri Road, Lumipini, Pathumwan, Bangkok 10330, THAILAND Tel: 66-2651-9800 Fax: 66-2651-9803 Home page or contact our regional distribution centres below.

Singapore (Representative office) 33 Ubi Avenue 3, #05-14 Vertex, Singapore, 408868 Tel: 65-6634-8250 Fax: 65-6634-8257

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fab&form

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Press Faster & Smarter With

Servomotors

Introducing servomotors and compound link-driven mechanism into presses help bring more punch to productivity. By Dave Tsai, sales engineering executive, Chin Fong Machine Industrial

M

echa nical press machines have become smarter and faster with numerical cont rol of ser vomotor a nd compound link-driven mechanism designs introduced into modern presses. They are for materials like light alloy (magnesium, aluminium and lithium alloy) and various forming technologies like fine blanking, flow control forming and die heating.

The application and development of mechanical press is over hundred years. With the demand of high-speed production, press stamping has emerged as one of the best solutions. However, the quality level of stamping product has become higher with the booming economy and better living standard. As such, stamping product needs to have variety, high quality and short life cycle.

When it comes to energy saving, carbon reduction cars and 3C products, (Computer,

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metalworking equipment news May-Jun 2011

communications and consumable electronic products) are required to be lightweight, high strength and constructed in recyclable metal like light alloy or high-tension steel.

Servo Press The introduction of servo driven press machine overturns the limited stamping motion curve, which is generated by flywheel inertia from conventional press machine. The feature of programmable stamping speed and curve can precisely match any forming process.

The slide (press ram) motion of conventional crank type press machine is a simple harmonic motion with constant velocity. In every stamping cycle, too fast a slide speed would have problems like metal forming difficulty, serious breakthrough in blanking, loud noise and die damages.

Compound-Link Sheet Metal Forging Press It has been a while since the link-

driven mechanism is used on the mechanical press machine.

The non-constant speed slide motion can approach forming area quickly, go through the forming process slowly and exit quickly, resulting in an increase in production rate.

For example, the forming speed of some workpiece is 10 M/min and its conversion speed is 25 Stroke Per Minute (SPM) on conventional crank press. It means 25 pieces are made per minute in progressive stamping die. Using link-driven press can shorten the non-forming period when the forming speed of 10 M/min remains unchanged.

With higher speed at non-forming area, link-driven press can reach 35 SPM, resulting in a 40 percent increase in production rate.

Knuckle-joint mechanism is widely used on cold forging press machine. Its slide motion could stop the slide briefly at the bottom dead centre, which extends the plastic forming time and reduces non-forming period. Such slow speed during forming is very suitable for drawing, coining, blanking processes.

Compound-link sheet metal forging press combines the advantages of link-driven and knuckle-joint mechanisms to create a slide motion curve which is able to extend the forming time from 180 to 240 deg crank angle.

This slide motion is suitable for complex sheet metal forging, fine blanking, near-net shaping, and compound stamping. It also prevents spring-back of materials, resulting in better forming and productivity. Finally, the slow speed for forming raises die lifespan and product accuracy.

Intelligent LinkDriven Servo Press Slide motion curve on conventional press is limited by fixed mechanism. When the same press works on product in different shape or material, the

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It brings more benefit tha n conventional stamping. Linkdriven servo press uses the link mechanism in the same machine space to create bigger stamping capacity from smaller servomotor.

It also integrates intelligent servo control system for better market acceptance. MEN Enquiry No. 4301

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Hot Issues Magnesium alloy is lightweight and has high hardness. It is used in high-end 3C electronic products and car parts. The temperature of this material needs to be raised to 200 - 300 deg C for best forming condition.

However, this material absorbs and releases heat very quickly.

The temperature cannot be controlled well by heating the material beforehand as such, the stamping yield is low. The die heating motion curve in servo press could make the slide to

clamp and heat the material by preheat dies for few seconds to reach ideal forming temperature, then stamp with low slide speed.

It can prevent material breakage.

The design of compound of link-drive and knuckle joint mechanism changes the slide motion curve to solve the problem of productivity, material springback and compound stamping.

©

user could only change the SPM for another slide speed to adapt to different stamping conditions.

However, the actual operation b e co me s d i f f ic u lt b e c au se o f t h e co mp l e x fa c to r s o f stamping. The servo press is driven by servomotor; the slide motion cur ve is changeable and controllable to be used on different kinds of stamping conditions by programming.

Genera l ser vo press is directly driven by servomotor, the capacity of the servomotor is very high. It makes the price of servo press expensive and it is not easy to source for big servomotor. The press maker already developed link-driven servo press with WATT VI type link- driven mecha nism a nd decelerating gears to reduce 75 percent motor torque and 6 0 p erce nt motor c apacit y requirement compared to direct driven servo press.

In another words, smaller servomotor uses link- driven me c h a n i sm to e n la r g e t he torque output to reach the same stamping capacity. The operators could choose build-in intelligent slide motion curves for different sta mping conditions. The advanced user could program the motion curve freely for more complex usages to increase product accuracy.

May-Jun 2011 metalworking equipment news

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Focus

Going Deep Into The Oil & Gas Industry APMEN caught up with Dr Lim Beng Siong, senior scientist, PE COI and Anthony Fettig, CEO Unisig at a seminar tailor-made for local companies to understand the use, co-development, support and maintenance of deep hole boring and gun drilling machine for the fast growing oil and gas sector.

By Joson Ng What is your personal take on the oil and gas industry in this region?

Dr Lim Beng Siong: For oil and gas in this particular region I think most of the jobs are moving over from other parts of the world to this region largely because of cost and proximity. As such, there is a big tendency to move the new parts or more complex parts here. If you bring in more complex parts, there are more difficult holes to drill, and therefore you need more advanced machines to produce them.

Anthony Fettig: What we find are our customers do not necessary move production but they duplicate it. To achieve service proximity, for example, they have production in Houston for complex product and they want to have the same production capability in Singapore or elsewhere in Asia so they can respond quickly to their customers who have rigs in this region. As a result, there is definitely a push to have similar technology or advancing technologies that are available in the US in Singapore.

What is the future technological trend in deep hole drilling in the oil and gas sector?

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metalworking equipment news May-Jun 2011

LBS: Most of the tools will be equipped with sensors. These sensors could be gamma ray sensors or magnetic resonance imaging sensors. When you incorporate these sensors you must have wiring to send power and another set of wires to pick up the status. Sometimes beside the sensors, they even have a tiny hole that acts as a flow line.

This hole becomes a chamber t o m e a s u re p re s s u re a n d temperature. When we need to incorporate these features, it becomes very challenging.

We see that in this part of the world, there will be more operators requiring intelligent tools, those that can measure the profile of the terrain and carry out data logging while drilling is taking place.

AF: The holes are getting smaller and deeper. The machinery and tools we are using get pushed to a greater extreme. As such, we always try to build a machine

such that the tool is the limitation because when people buy a machine, they expect to use it for 20 to 30 years.

Exotic materials like Inconel and Titanium; do they change the game in deep hole drilling?

AF: We commonly drill super alloy or proprietary alloys. For proprietary alloys, they are constructed for specific reasons, for example, some are designed to undergo high elongation before breaking. As a result, they are more difficult to work with and in addition, there is no instruction book that comes with the material, so our customers have to use our machine to ‘feel’ their way into the machining process. As such, our machine must be sensitive to allow the engineers to determine the best cutting parameter on the material with very little information to start with.

Enquiry No. 4401

More On Deep Hole Gun Drilling In the oil & gas sector, deep gun drilled holes are created on extremely hard and corrosion resistant, nickel and chrome-based alloys to serve as safety, control, wire-lines and flow-line holes to allow for effective command, control and communications between the down-hole tools with the surface control crew.

To facilitate communication between surface and the down-hole tools, companies need to create high aspects ratio holes of 700 that are of 5 m deep Ă— 7 mm in diameter to accommodate flow and wire lines. Many of these down-hole tools are now equipped with highly sensitive instruments such as gamma rays, X-rays and magnetic resonance imaging that requires an added layer of protection using non-magnetic materials such as Inconel 718, Incoly and K-Monel. MEN

Enquiry No. 4402

INNOVATIVE BAND SAW BLADES FOR YOUR REQUIREMENTS OF TODAY AND TOMORROW Customised band saw blades and support for higher efficiency With more than 50 years of experience in the development and production of high-performance tools, WIKUS is Europe‘s largest manufacturer of band saw blades and global technology leader in metal sawing.

Precision band saw blades from WIKUS represent innovation and productivity with the objective of higher efficiency for the customer.

WIKUS is offering you: · Innovative band saw blades, optimised for all kinds of sawing tasks · Competent and individual customer service in the entire sawing process · Cutting tests directly on location of the customer

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Made in Spangenberg, made in Germany.

ENQUIRY NO 098

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T Oil & Gas:

Adapting To

Changes

Contrary to popular beliefs, the oil and gas sector is subjected to changes and embracing technologies enable one to keep up. By Giuseppe Ruffini for Pama S.P.A

DIFFICULTY: The old mindset sees the oil and gas sector as an industry with a minimal need for change and innovation

SOLUTION: Adopting a new philosophy that places a focus on technology

CONCLUSION: A reduction of processing time (for heavy milling of carbon steel) by up to 50 percent

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metalworking equipment news May-Jun 2011

he Trieste-based (Italy) company Orion is one that deals directly with those who design and make plants for extracting oil and gas, according to its VP, Mr Croci.

In fact, it is the manufacturer of large valves for the oil sector.

They can weigh up to 100 tonnes.

In a dynamic market situation, those that have to commission an oil plant today will ask their partners to come up with the right solution quickly and at a compatible cost. Besides all this, those who work for the prime contractor of such a plant must develop a tailored product in a very short time frame imposed by the market.

None of this can be invented or guessed, it is instead the result of knowing how to be ready in time and looking beyond what already exists. They are the most useful and functional tools for the job.

With that said, the company embarked on a drive to reduce the weight of its products while guaranteeing the same level of safety. The company also places attention on the environment, leading to the implementation of the so-called ‘green’ valve (or low-emission).

The notion of the oil and gas sector being not susceptible to great changes has been found to be untrue and the company is required to know how to guess the expectations of a strong expansion in its market, face the topic of technological innovation and placing it as the central of its competitive strategies.

The Need For Technology “The group’s investments are aimed at anticipating market trends and gathering all the signals of new things to come in order to be ready to face new challenges,” says Mr Croci.

It offers valves, flanges, fittings and tie-rods when the project is still ‘on paper’ (ie: the products are mostly born and created

For enquiries or space booking : Indonesia mtt@ecmi.cc +62 21 781 8954 +62 21 7884 1726 ENQUIRY NO 101

Overseas overseas@ecmi.cc +65 628 55507 +65 628 44355

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t rke rge a M e ere Conv est h W ers il Lat s d e e Lea to Unvhnologi lutions

o Tec vide S tives o rna ery d Pr to & Alte eet Ev g Nee M in to actur f nu Ma

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Embracing technology results in shorter time in milling and turning operations

together with the plant for which they are meant for, integrating all the variables and requirements that each single project calls for and needs).

This requires a certain amount of technological skills, expertise and knowledge on how to develop innovative methods. As such, the company also nurture designing skills inside its own walls and equips itself with computerised calculation technologies. (eg: CAD and finite element programs) At the same time, the company’s st rateg y define s impor ta nt investment as a catalyst for improvement in production. It aimed at reducing production times (up to 50 percent). In addition, it focuses on high precision and at maintaining plant performance constant over time.

Case Study Within this growth and development logic, there are technological tendencies and investments in production assets and machinery.

This resulted in the choice to introduce technology. In this case a Pama Speedram 2000 boring and milling machine.

“With the machine,” explains Mr Halupca, the Orion production manager, “we are on our way to 54

metalworking equipment news May-Jun 2011

reducing machining times. This solution was opted for after a lengthy comparison with similar systems; we carefully assessed all the technical-qualitative aspects of what we were being offered.”

Just one consideration would be enough to justify the whole investment: “With Pama Speedram 2000 boring and milling machine, we achieved the same milling/ turning results seen in typical technologies for the valve sector far quicker,” he says.

According to Mr Halupca, bigger pieces that were traditionally tooled by a lathe and milling machine took at least 45 to 50 hours whereas they do the same work in less than half the time.

This result wa s possible because of a versatile production plant: Speedram 2000 boring and milling machine featuring integral hydrostatic guideways, a 160 mm spindle and a 60 kW power, equipped with two high load bearing capacity rotating tables (40 and 25 tonnes respectively), a head attachment magazine and a largecapacity tool magazine to allow flexibility of use for heavy removal roughing and high accuracy finishing work.

Other considerations pushed the company to adopt the Pama boring

and milling machine. One of the main factors is flexibility that is linked to the specific configuration of the plant that allows the piece to be finished in just the one set-up. That meant no picking up work pieces again or completing the process of machining on other machines. Another factor that is anything but negligible is the plant’s capacity, which allows certain machining operations, such as roughing, for instance, to be performed during unmanned times.

Other key success factors of the solution are linked to removal and production capacity.

M r H a l u p c a c o n c l u d e s: “In carbon steel heavy milling operations, where cutting speeds are 220 - 250 m/min and feedrates ra nge 8 0 0 - 1, 50 0 mm/min, about 100 kg/min of material are removed. Under such conditions the advantage we have is reducing working times by 50 percent: the Speedram machine is stable, it does not vibrate, the inserts do not wear abnormally and the power absorbed is about 60 – 70 percent of the power available. In terms of precision, on valve bodies weighing about 1,500 kg, we can obtain a repeatability of 5/100 mm on a maximum span of 2.5 m.” MEN Enquiry No. 4403

ENQUIRY NO 080

A N

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M M

N T E NR T E NR T E R E E

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All Aboard!

China and South Korea, the two giants in shipbuilding see themselves occasionally trading places in the league of top shipbuilding nations. This healthy competition, fueled by global trade, has plenty of positive impact on metalworking processes like laser-cutting.

By Mark Johnston

Rennett Stowe, USA

S

hips are a necessary part of global trade as commodities are moved from one port to another. Shipping to this day remains the largest sector for transport. It is the bedrock of global trade, importing and exporting raw materials and finished goods between countries and continents.

The importance of shipping on global affairs makes the shipping industry big. It involves huge capital, wide workforce and technology. Eastern shipyards dominate the shipbuilding industry. In 2008, four of the top five shipbuilding nations were in Asia. South Korea produced more ships in 2008 than the rest of the world combined.

However, the growth of China has been rapid and in 2009, it overtook South Korea to become the number one shipbuilding nation in the world.

China with its extensive facility expansion the

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construction of new green field shipyards, cheap labour, technological innovation and the Chinese government policy of ‘Home building for home demand’, has all resulted in persistent and rapid growth even during the global financial crises which badly affected the global shipbuilding industry as a whole. In Q1 of 2010, South Korea overtook China to again become the leading shipbuilding nation.

Ship Construction The typical process flow used in shipyards starts with marking the plate, then cutting the hull and internal structure, and finally the ship-block construction. To mark the plates for cutting, a plate printing system is used which includes a specialised machine that marks one large plate at a time.

Shipbuilding uses a CNC oxy-fuel/plasma/laser

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Benefits Of Laser-Cutting The benefits of using a laser over more traditional methods of cutting are many. They are quick and yet precise making them highly attractive. They work by using a focused beam of light to cut or etch materials.

The width of the cut achieved (by laser-cutting) is known as the kerf width and is 1/8 that of plasma cutting. There is also less heat distortion because of its focused energy and precision. This has many advantages, namely making subsequent assembly and welding easier by reducing fitting adjustments and welding failure.

An important factor in the laser cutting process is material quality prior to cutting. It is important that the plates being cut are prepared and smoothed to avoid complications and improve final cut quality and later assembly.

The cutting quality can also be affected by the type of plate being used, ie: high tensile plates. Surface coating should be kept under 20 microns as anything more would affect the cut quality of the laser.

Laser-Welding The type of welding technology used is key to shipbuilding for a number of reasons. The right technology will increase productivity, reduce shipbuilding cycle, lower manufacturing costs, and improve manufacturing quality.

Welding technology ranks high in importance during manufacture of the hull accounting for about 40 percent of the total working hours while the cost of manufacturing the welded hull is about 30 to 50 percent of the total cost.

The arc welding processes are cheap and reliable although it suffers several limitations which are important in the shipbuilding industry. The thermal process of the arc weld creates a wide heat-affected zone, and as a result, the plates can be buckled and

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cutting machines and portable cutting machines. In welding, heating touch, portable welding machines and more recently laser welding and laser-hybrid welding are used.

The applications of lasers have taken more prominence in shipyards because of its clear advantages over other methods of metalworking used, both in cutting and in welding. The CO2 laser cutting machine is gaining a good reputation in the shipbuilding industry and has many advantages in reduction of labour, reduction in welding time and cost, and it reduces secondary processes after cutting.

There was a concern in the industry that laser-cutting adoption would be difficult given the complicated requirements of bevel cutting. However this has changed with new cutting procedures for laser bevel cutting and its programming system.

May-Jun 2011 metalworking equipment news

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Features

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warped. This led to an unpredictable situation in which the subsequent assembly and joining process may not fit as tightly as desired. As a result, plates had to be flattened and large gaps caused by warping and shrinkage had to be filled.

High power density is what makes laser welding so desirable offering distinct advantages over traditional methods. The advantages would be high-speed seam welding, low distortion, single-pass welding in large thickness, easy automation, and positive effects on the working environment. Laser welding has experienced a huge uptake across the industry because of these reasons.

It is unlikely that properties like speed, heat input, and environmental aspects of the arc welding process will be improved further. This is due to the physics of the processes and the distortions seen in arc welding. By replacing the arc welding process with the laser welding process holds many advantages such as low distortion, high speed, and natural automation.

However by introducing a hybrid welding system, such as laser/MAG (GMAW), ie: laser/ (Gas Metal Arc Welding), instead of pure laser welding then the advantages of both approaches can be harnessed. It increases the ability to bridge a gap and provides a significant increase in speed when welding a w ide gap, g iv ing excellent weld properties overall.

So by using both laser and arc in conjunction with each other the combination results in an increase in both weld penetration depth and welding speed.

Market Analysis The shipbuilding industry has faced hard times in recent years and was badly affected by the global financial crisis, which saw the decline of sea-borne trade leading to an over-capacity of ships globally. A report from Bharat Book Bureau shows the orders on the global shipbuilding scene declined dramatically over the 2008 - 2009 time scale with a pickup only now seen in 2010.

The financial crisis hit all areas of shipping. With

scrapping volume hitting record levels in particular the dry bulk vessel segment despite falling vessel prices, which saw a 20 to 30 percent year-onyear decline. The biggest shipbuilding nations in particular have seen dramatic falls in their orderbook over the 2008-2009 timeframe.

In South Korea a nd Japa n, governments restructured shipyards facing financial problems and offered them monetary and non-monetary incentives to bolster the industry’s outlook.

Globally, Asian shipyards dominate the industry holding 95.1 percent of the total global orderbook.

In 2008 South Korea held 37 percent of the global orderbook, the highest in the industry, with China and Japan holding 36.1 and 16.8 percent respectively.

The 5th ranked nation, India, held 1.44 percent of the global orderbook with 2.2 mn CGT of vessels on order as on December 31, 2009. The shipbuilders in India are known to specialise in offshore vessels.

They have however diversify their order base with the expansion of shipyards to construct bigger vessels such as dry bulk carriers.

In contrast to their peers in South Korea and China, no major instance of order cancellation took place during the 2009 calendar year in the Indian shipbuilding industry. The most likely reason for this is that no speculative orders were being placed through the Indian yards with the majority of orders being repetitive clients.

CARE Research expects that during the 2010-2013 timeframe the global shipping fleet will be over-capacity based on a mix of factors such as world fleet size, world GDP – current prices and the historical trend of seaborne trade.

The company also expects that demand will increase for second-hand vessels as compared to newbuilds despite a 20 to 30 percent year-on-year price decline for new-build vessels. Relatively lower prices of second-hand vessels with a younger fleet to offer is expected to drive this increased demand.

Enquiry No. 4501

Shipbuilding: The Trend Is Towards China China is on its way up. The s h i p b u i l d i n g m a r ke t i s b e i n g seen as a major strategic move by the Chinese government and has been growing steadily with strong growth now expected with the end of the financial crisis of 2008-2009. The country was less affected by the financial crisis than

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its competitors. It was in large part through major government initiatives that were implemented, designed to cushion Chinese shipbuilding from the recession and allowing it to grow further.

The countr y briefly took the number one spot in December 2009, overtaking its competitor South

Korea before it regained ground and took back its position as number one during Q1 of 2010. Chinese ships have a cost advantage. With current rate of growth it is predicted that China will be the market leader by 2015. MEN

Enquiry No. 4502

Features

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Stay In

Track

Milling rail track steel is not without its surprises. Vossloh Laeis in Germany, a company with a tradition in machining rails can keep the material under control by using milling cutters and drilling tools. Contributed by Yvonne Ng, marketing manager, Walter AG Singapore

A

nyone thinking of points for trains, trams or the underground, does not automatically think of milling machines – curved or straight pieces for track coming directly from the rolling mill. Tongues and hearts, as they are called by the experts, are a different story.

These parts are milled from solid material. Tongues are used for turning the points, hearts are the centerpieces at crossings.

Vossloh Laeis manufactures such parts. In addition, they have a patent for hearts and crossings made from block material. The advantage of this design is that no bolts are needed.

Other terms used require explanation to enable the reader to follow the discussions with these points specialists. There are flat bottom rails and grooved rails. A conventional rail system uses flat bottom rails, trams and many industrial lines use grooved rails. The differences in size are enormous because of the different axles bases and the smallest possible radii of curvature.

Meeting The Standard Flat-bottom points are 30 - 40 m in length and about three times as 60

metalworking equipment news May-Jun 2011

long as grooved-rail points. There are however many variants of grooved rails in terms of width and gradient. Common widths are 36, 32 and 23 mm and common gradients are 1:4 and 1:6. Although all types of rail are machined at Vossloh Laeis, the large majority is made up of grooved rails and constitutes some 80 percent.

The reason for this is that the National German Rail operator machines the majority of its own rails; alternatively, the popularity of local tram systems is increasing.

From the machining point of view, the steel used for the rails is something special. The loads experienced during normal service are enormous. The goal being aimed for in producing rails is the service life, which should be as long as possible. This is why the tensile strength is so important and common values for this are 700 to 1,300 N/mm2. At the lower end of the tensile strength range is the ‘standard’ rail steel with the type designations S700, S800, S900 among others. (The number indicates the tensile strength).

The resistivity of the material is attributable to the relatively high carbon content, the rolling process and any applicable tempering

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Right Tool For The Job In the case of milling cutters, it is the precision tools from Walter, which are used. Face milling and porcupine cutters are the most prolific. Also used are beveled inclination cutters for the grooves.

These are tools for generating special forms, which can process the rail grooves in a single operation. The use of these types of tools has continually increased ever since the company launched the Xtra·tec series, for example the face mill milling cutter F4033 with eight cutting edges per indexable insert. The cutting tool material most used is the universal Tiger·tec cutting material WKP35.

“This cutting material unites high hardness with toughness and is suitable both for a wide spectrum of materials as well

a s fo r v a r i a b l e m a c h i n i n g conditions,” explains Josef Alt, engineering consultant at the cutting tool maker.

The machining process itself is dry roughing. The tolerances lie in the range +/- 0.1 mm. Rail ca rriage s r un on clea ra nce tolerances. Mr Bartzen explains: “Our requirements do not justify using ground precision indexable inserts and we therefore use types sintered over the circumference with a stable geometry. What we need are long tool lives. If for example we were milling grooves with a depth of 40 to 50 mm in curved track 10 m in length and the cutter broke, the machine operator would have to come off the curve and interrupt machining.”

Other Challenges Met Normally rails need few holes, however, for a large job from a client in Vancouver/Canada the situation is different. The rails are fishplated at the ends, numerous holes with diameters 19, 26, 28.5 a nd 30 mm a re therefore required. Boring is in the centre of the rail web, ie: in a normally soft area. However on this job the top of the rail is hardened; the hardness reaches as far as the web area.

“The HSS drills which we would nor ma lly use a re rendered useless here a fter about 15 drilling operations,” reports Mr Bartzen.

“Years ago when there was only standard rail steel like S800, the machining was easier and more predictable,” resumes Mr Bartzen: “today we have numerous different materials and also very high strengths.

Almost every order has different machining requirements.

Without robust, universa l varying machining conditions, this is not possible.” MEN Enquiry No. 4503

ENQUIRY NO 103

process. Besides standard rail steel, there are also high-end steel grades and these are designated by the name given by manufacturer.

In the Vossloh concern this highgrade material is called Cogidur and has a tensile strength of 1,300 N/mm2, which is right at the top of the strength scale. For cost reasons, Cogidur is used for rails in a welded sandwich construction with ST52 as the substructure.

Minor differences are in the composition, differences (100 N/mm2 are not uncommon) in the tensile strength due to rolling, on request hardened CrNi heads welded-on, different resting conditions on the machine table – these are all factors making life difficult for milling cutters and drilling tools.

“Whereas machining the one block might be easy, the next block can be much more difficult without there being any apparent reason for this,” explains Stephan Bartzen, who is responsible for component engineering at Vossloh Laeis. In view of such variable conditions, the points specialists at the company have to depend on robust tools.

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Features

www.equipment-news.com

Buying Trends 2011 With advanced economies’ growth prospects brightened in 2010 and regional demand expected to remain strong, the economy of Singapore looks set to grow in a sustainable pace in 2011. As manufacturing is expected to contribute significantly, APMEN conducted a survey on buying trends at the recent MTA in Singapore to gauge market sentiments.

Out of 512 visitors surveyed…

172 (24%) CNC Machining Centre 145 (20%) Cutting Tools

366 (71%) Sourcing For Machine/ Tool/Equipment

97 (13%) CNC Lathe

Sourcing For Machine/Tool/ Equipment

67 (9%) Vertical Machining

56 (8%) Metrology Equipment 52 (7%) Sheet Metal

87 (17%) Looking For Business Opportunities

59 (12%) Gather Market Trends

Size Of Investment

47 (6%) EDM

111 (33%) Metal Jobshop

(Singapore Dollars) 119 (33%) 50,000-100,000

109 (30%) 10,000-50,000

94 (26%) 100,000-500,000

33 (5%) Horizontal Machining

118 (35%) Mould & Die Manufacturing

76 (22%) Agents/ Distributor

40 (11%) >500,000

58 (8%) Software Programs

Company’s Operation

22 (6%) 14 (4%) Education Foundries Institutes

Size Of Company

Surveyee’s Role In Company

(Number Of Employees)

56 (11%) 51-100

100 (16%) Manufacturing

103 (17%) Management 158 (25%) Engineering

91 (15%) Sales 222 (44%) >100

148 (29%) 11-50

63 (10%) Marketing

56 (9%) Purchasing

33 (5%) Research 76 (15%) 1-10

18 (3%) Education

For more information on new product offerings from various machine tool, cutting tool, software and metrology equipment makers, view our video interviews at www.equipment-news.com MEN Enquiry No. 4504

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ENQUIRY NO 024

Features

1 What Laser Parameters Should I Set For The Material I Want To Weld?

Laser beam welding involves melting a particular metal within milliseconds. Therefore it is important to know how much power should be configured and the optimal beam size to be used for a 0.4 mm welding rod.

For the aerospace industry, a wide variety of aluminium c o m p o s i te s , t i t a n i u m a n d stainless steel are used. However, the welding for all these materials differ to a great extent and is dependent on each welding facility to fulfill the requirements for their end customer.

2 Where Do I Get My Laser Materials?

You can easily get welding rods ranging from 0.8 mm and above cheaply and readily.

By now we all know that material from each country uses a different classification code with different allowance.

By far, the strictest is the aerospace industry that adheres to a protocol of using approved sources of wires with flagged tips for tracking every single electrode that was used in the process.

3 Do I Have Any Skilled Welders?

Many TIG welders go through con si ste nt a nd cont i nuou s practice for years, to familiarise the different positions of welding.

In the aerospace industry, we classify welds in different classes and ensure that the qualification of the welders meets the requirement of the welding permitted. All welders go through tough and rigorous qualification tests that includes X ray and destructive mechanical bends to test the weld integrity and ensure adherence to standards such as AWS D17.1 – specification for fusion welding for aerospace applications.

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www.equipment-news.com

10 Points On Laser Beam Welding Machine

Here are 10 pertinent points to consider before investing in laser beam welding machines. By Han Kee, project manager, Hi-Yew Technology 4 What Is The Work Piece Or Product That I Want To Weld?

A laser machine comes in all sizes and prices with different specifications. If there is a need to weld a big work piece, there is probably a need to invest in a robotic arm concept machine.

When welding a small work piece, do find out the different rules and regulations required to comply with a class four open laser systems and also check if a class one closed system is applicable.

Another pertinent point to note is fixturing. What fixtures to use and its storage should be considered as some aerospace production parts are low in volume and orders may only be repeated several years ahead in the future.

5 Laws And Regulations In Singapore, NEA is the governing body for laser machines. Any doctor, nurse or user of laser machines must be registered with the NEA (Doctors are presumed to know how to use lasers).

NEA requires each company to register their laser machines with them, as well as a license to be issued to be user of the machine.

It is important to note the

implications of the law for laser applications. In addition, the permitted users need to be aware of the safety rules and functions in operating the laser machine.

6 Laser Technology

By Manufacturers Different manufacturers use different patented terms to enhance the potential of their laser machines. Without the basic knowledge of laser technology (how does the laser form and how does it aid welding?), it is difficult for people to evaluate terms coined by manufacturers.

H o w e v e r, t h i s m a y b e overcome by a physical test and experimentation with the machines from different manufacturers.

7 Service Support And Maintenance Some of the pertinent points to note here is the service support and maintenance networks available in your country. Issues like spare parts availability, installation procedures, and the testing implementations should be evaluated.

Each laser machine is required to change its source (eg: lamps and diodes) regularly. It works in a concept similar to our fluorescent

features

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lamp, except that it is much more expensive. This has to be taken into consideration.

8 Laser Machine Quality Testing Process Every country has its own climate conditions – humility, temperature in the day and temperature at night.

However, this test may not be valid. Testing processes held in Europe do not yield the same results as test processes held in Singapore. The average temperature of the cooling water in a laser machine may be around 28 deg C in European countries, but the same experiment may reach 39 deg C in Singapore.

This is because of the humility in the air, as well as the temperature in temperate countries. As we all know, machines function well in a dry and cold environment and best kept in an air-conditioned room.

However, it is relatively expensive to replicate similar conditions in a tropical country.

For the aerospace industry, all materials and composites are required to withstand high temperature and tolerances under different conditions and environments. All maintenance must be performed as instructed in the aircraft manual without failure.

9 Quality Check And Shipment Process Before a laser machine is sold, it is assumed to have gone through testing at the manufacturers’ site by observing the beam quality with a viewer, before it is shipped to the customer’s place.

This beam quality is best when the mirrors being used in altering the beam is kept still. Unfortunately, most of the shipping process inevitably caused some movements

QUICK VISION

in one of these mirrors, causing lower beam quality and poor welding ability once the machine is first installed on site.

This can be easily overcomed by having a technical laser engineer to perform the laser beam alignment process upon installation. However, that depends on the engineer having the required tools as well as the knowledge required to align the laser beam.

10 Selection Of Laser Beam Microscope Visual is important when it comes to welding. What you see is what you weld. A spotlight visual system, as well as an LED visual system can aid in this process as the effects of an LED light and spotlight lighting produces different visual impacts on the work piece to be welded. MEN Enquiry No. 4505

th i w Touch Probe

➤ Higher brightness Ceramic packages Ceramic packages

➠ Conventional Vision machine

New QV

➤ Reduced Flare Resin surfaces Resin surfaces

Touch probe with Auto-Change Rack Rack

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White

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New QV

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MALAYSIA Tel: (60)3-7845 9318 Fax: (60)3-7845 9346

THAILAND Tel: (66)2-521 6130 Fax: (66)2-521 6136

INDONESIA Tel: (62)21-898 0841 Fax: (62)21-898 0842

VIETNAM Tel: (84)8-3517 4561 Fax: (84)8-3517 4582

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Conventional Vision machine

➤ Advanced Green

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exhibitions

Special Report:

TIMTOS2011

The six-day TIMTOS 2011 at the Exhibition Hall 1, 2, 3 of Taipei World Trade Centre (TWTC) and the Nangang Exhibition Centre wrapped up on March 6, 2011 as the largest trade show in Taiwan’s history, achieving its ‘double 5,000’ goals by attracting a record number of overseas buyers and exhibitors.

A

total of 928 companies from 20 countries exhibited at the Taipei International Machine Tool Show (TIMTOS). With it, a total of 5,071 international buyers resulted in a new growth of 18.9 percent over the previous show in 2009. The number of booths utilised topped 5,000, a new record in the history of the exhibition.

In 2011, the overall production value of Taiwan’s machine tool industry is expected to grow by 10 to 15 percent year-on-year, making the machine tool industry one of the ‘one-trillion-dollar-value industries’.

Total export value of the machine tool industry bucked the trend of financial downturn by reaching US$3 billion in 2010, an increase of 70 percent year-onyear. Hsu Hsiu-Tsang, chairman of TAMI, estimated that with the global economy recovery, TIMTOS was likely to help create business opportunities worth US$2 billion.

Int’l Buyers Buyer representation was strongest from Japan since Taiwanese manufacturers have grown adept at offering products with quality

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that nearly match that of Japanese goods. Secondly, Taiwan-made machine tools and components are more competitive in price due to the appreciation of Japanese Yen. Thirdly, the potential business opportunities provided by the signing of the cross-strait Economic Cooperation Framework Agreement (ECFA) has encouraged many Japanese companies to establish cooperation with Taiwanese manufacturers.

China ranked second in the total number of visiting buyers.

The event was the first machine tool exhibition held after the release of the Early Harvest List stated in the ECFA, resulting in the

upward spike in the number of Chinese buyers. Other countries included Malaysia, South Korea, India, Thailand, US, Turkey, Singapore and Russia.

Tech Seminars & Trade Meetings During the exhibition, experts from Industrial Technology Research Institute, Precision Machinery Research & Development Centre (PMC), Institute for Information Industry (III) and TÜV Rheinland Taiwan offered six seminars, including ‘Control System for New Generation Intelligent Factory Technical Presentation’, ‘Safety of Machinery-Issues for Mechanical and Electrical Safety and Electromagnetic Compatibility in EU’, and ‘Alliance of R&D for High Speed Machining Centre Research and Development Exhibition’. The events received responses from more than 200 participants in the industry.

In addition, TAITRA invited 12 leading international buyers from seven countries for the ‘TIMTOS 2011 Trade Meeting’. A total of 51 exhibitors participated in 71 sessions of the meeting, reporting on-site transactions of US$280,000 and follow-up orders projected at the value of US$4.52 million.

TWTC Halls 1,2,3 & Nangang Exhibition Centre Taipei, Taiwan March 1- 6, 2011 Enquiry No. 4601

Export Figures The Taiwanese machine tools industry has been actively exporting their products to locations worldwide in recent years. In his opening address, Dr Chih-Kang Wang, chairman of TAITRA presented the export figures to highlight Taiwan’s performance last year.

He said: “Between January and October of last year (2010), the total export value of Taiwanese machine tools reached US$2.3 billion, a 68.4 percent growth compared to the same period in 2009.”

For components, he revealed the total export value between January and October last year (2010) was US$627 million, marking a 98 percent growth when compared to the same period form 2009.

Enquiry No. 4602

EVENTs&exhibitions

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ECFA: View From The Other Side Opinions From China Buyers At The Show (Zeng Weier, president, Fujian Welder Science and Technology and Jian Ding-Fen, VP Fujian Chanqing Precision Machinery)

Mr Jian The market demand for machining centres in China is nearly 100,000 units per year. We believe, once the ECFA begins taking full effect, the manufacturers on both sides of the Taiwan Strait will benefit, and we hope to find good business partners during this visit, creating a win-win situation for all.

One of our main purposes of visiting this show is to evaluate the present situation of Taiwan’s machine tool business for our next machine procurement program. At the same time, we are studying the possibilities of finding strategic partners to cooperate with China; especially in terms of the production of high performance machines, such as high-speed hard milling and 5-axis milling machines.

Enquiry No. 4603

ECFA: Opportunities Or Challenges?

The signing of the Economic Cooperation Mr Lu predicted a good 10 Framework Agreement (EFCA) between years ahead Taiwan and China has been widely heralded for Taiwanese machine tool as the main headline of 2010 for the Taiwanese builders machine tool industry.

Echoing this sentiment, John Hsu, the chairman of Taiwan Association of Machinery Industry (TAMI) said: “The signing of ECFA not only brings new business opportunities and greatly encourages exchange and cooperation, it also forms a complementary and mutually beneficial relationship between Taiwan and mainland China.”

Alan Lu, the chairman of the machine tool committee of TAMI, though agreeing that ECFA brings good opportunities, offered another view. He said: “It is a good chance (the signing of ECFA) for us but also a challenge particularly in the near future.”

One of the challenges includes the need to undergo the process of product differentiation. In this area however, Mr Lu is feeling positive. “We are really well prepared and we can look forward to a golden 10 years,” he said.

Though the signing of ECFA looks set to promote even more growth and partnership with China, Mr Lu is quick to suggest the need to develop new markets.

“Of course we do not want to put all our eggs in one basket. Newly developed markets like Russia, Turkey and Brazil are also very interesting to us,” he said. “ However, market development is not easy. We have to learn the cultures and business rules of the countries,” he added.

Enquiry No. 4605

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

Smart Hybrid Finishing

Dah Lih: Focus Is Key New OptiRough Toolpath

New Dynamic Milling Techniques

Easier Multiaxis Machining Mr Chuang

Enquiry No. 4604

New Plunge Turn Toolpath

Mastercam Machine Simulation

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

Techtown Pte Ltd

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

ENQUIRY NO 083

Displaying four machines including the DMV-2000 multi-axes vertical machining centre at TIMTOS, the company focuses on making milling machines according to David Chuang, the MD. With exports to China, Turkey and Brazil, the company is expecting to manufacture about 50 to 60 machines in a month to satisfy the demand.

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SOCO: All About Tubes & Pipes

Mr Lo is constantly on the lookout to improve his products

The SLS2-400 double crank press by Seyi, with a capacity of 400 tonnes, is suitable for precision progressive die applications.

SOCO produces tube-manufacturing equipment, which is the company’s core business. As tubes are regularly used in the manufacturing of cars, (exhaust, air conditioning unit and seat frame) a big part of the company’s customer base is in the automotive industry according to Kyle Lo, CEO and MD of SOCO. Even with tube cutting, finishing and bending machines in its product range, Mr Lo is constantly on the lookout to improve his products. Laser, for him, is the answer. He said: “I think laser is the future for a number of things. For instance, sheet metal cutting is a good example.”

Laser however cannot be a direct substitute for traditional saw blade cutting. He said: “The traditional machine is still faster. Laser is good in terms of flexibility but not always for high volume production. It is good for parts requiring many complex operations.”

Going forward, Mr Lo sees carbide blades and all electric machines to be more popular in the cutting and bending arena respectively. Driving this push will be the R&D department, which employs some 15 percent of the company’s workforce.

Enquiry No. 4607

Hiwin: Smooth Flowing

Luren: Driven By Development The company invests some eight to nine percent of their annual turnover into R&D according to Mr Chen

A producer of gear cutting tools, Luren invests some eight to nine percent of their annual turnover into R&D according to Chuck Chen, the president of the company. Targeting a turnover of NT700 million in 2011, a substantial increase from NT560 million last year, the company looks set to add to their product range in TIMTOS, which includes the LFG-3540, a CNC gear profile grinding machine.

Enquiry No. 4608 Combining engineering with music, the piano robot.

Manufacturer of ballscrews, linear guideways among other products, Hiwin was recently at TIMTOS where it showcased its product including the new NC SynchMotion ballscrew. The product achieves better energy efficiency by reducing friction. Other pertinent features include noise and vibration reduction.

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metalworking equipment news May-Jun 2011

Jade Chen, the director of sales and marketing of Chin Fong Machine presenting his machines which included the iLS1160, a servo press that can achieve multi-stage forming process requirement.

EVENTs&exhibitions

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Trumpf Showroom Opening Ceremony

Mr Kienast felt Asia is an important part of the company’s global sales strategy

Dr Laubscher introduced the TruPunch 3000 which made its debut in this region at MTA Malaysia

The opening of its showroom in Singapore is a signal of the company’s ambition and commitment to Southeast Asia. By Joson Ng

T

rumpf recently opened its showroom in Singapore where some 100 participants gathered to discuss the challenges and solutions in the metalworking industry of the future. Graced

by Jörg Kienast, director of international sales, the event also featured a short presentation on the company’s latest technology

by Dr Hans-Peter Laubscher, MD of Trumpf Asia Pacific.

In his opening speech, Mr Kienast talked about the company’s presence in Asia and how important it is to stay engaged in this region.

He said: “Trumpf’s subsidiary in Singapore was founded in 1995 and since then, there are further 14 subsidiaries in Asia. By the end of our current fiscal year, we would have 800 people working in our subsidiaries in Asia.”

By any accounts, the number of people looks set to increase as Mr Kienast explained the company’s long-term plans in Asia.

“Over in our headquarter, we recently shaped our Asian market strategy which will see us maintain our presence in the Chinese market

and expand outside it because we feel even though China is booming, the economic affairs in the Tiger states (Taiwan, Hong Kong, South Korea and Singapore) are still very healthy. That is why we plan to invest further in those countries,” he said.

Continuing, he also touched on the company’s willingness to play a role in improving the sheet metal industry in ASEAN. Said Mr Kienast: “In Singapore, we see many sheet metal job shops moving away from mass production and into more valued-added engineering work.

This is where Trumpf can support in terms of innovative products.”

Trends & Opportunities Noticing a trend, which is in sharp contrast to their European counterparts, technical knowledge is often confined to a handful of specialised engineers and the management team of sheet metalworking companies in the ASEAN region.

With that, Mr Kienast sees an opportunity for his company to help widen the knowledge base by offering training to machine operators and shop floor staff.

New Technologies & Discussions Taking the oppor tunity to introduce their technology at the opening, Dr Laubscher introduced the TruPunch 3000 to the crowd.

He said: “This machine is designed for punching without limits.

Problem in sheet metal punching today is the skeleton. The idea of the machine is not to be faster (ie: not to increase hit per stroke per min). It is to reduce waste and be more resource friendly. As such, it is possible to achieve waste reduction in materials. In other words, more parts can be made from the same sheet.”

In the three days that followed the opening ceremony, the facility hosted technical workshops and machine demonstrations where the participants came together for knowledge exchange. The topics in discussions were TruServices – enhance efficiency, punching – skeleton-free production, laser 2D – CO2 vs fibre laser, laser technology – choose the right laser and bending – productivity and profitability.

Enquiry No. 4609 May-Jun 2011 metalworking equipment news

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Event Preview:

InterMold Thailand 2011

I

n response to the continuous 18-month growth on the automotive manufacturing industry, as well as Thailand Automotive Institute’s (TAI) prediction that a significant number of investments will be made by major automakers and auto parts makers in 2011, mould makers and related industrialists are planning to invest more on new technology acquisitions and factory expansions.

It is revealed by Automotive Industrial Club (AIC) that in February 2011 alone, there were approximately 150,000 units of automobiles produced (17.9 percent growth Year-on-Year) with approximately 77,2000 units sold domestically (42.5 percent growth YoY), and approximately 80,600 units exported (8.9 percent growth YoY). Also, the expansion of Thai automotive industry has been growing for 18 consecutive months.

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To sugarcoat the good news, TAI recently predicted a collective investment from both automakers and auto parts makers to be as high as approximately THB 100 billion (US$3.3 billion).

Technologies For Industrialists To keep up with this momentum of automotive growth, mould makers and all related manufacturing

industrialists would invest on new technologies to boost their productivity and capitalise on this growing business opportunity to increase more annual revenue.

Trusted by manufacturing industrialists for 19 years as being the show for mould and die manufacturing machinery, InterMold Thailand 2011 will be a platform for related industrialists to select the right technologies from 370 brands, 16 countries, and many opportunities to enhance their business achievements.

The show will create opportunities for all related industrialists to propel their business to higher achievements by demonstrating live performance of the manufacturing technologies, so mould makers can adopt the right technologies to increase productivity and strengthen competitiveness.

InterMold is part of the Manufacturing Expo 2011, which synergises the show with three other major shows for the manufacturing sectors, where over 38,000 manufacturers from a wide range of industrial sectors will enter the show to touch base with 1,500 brands from 25 countries.

BITEC Bangkok, Thailand June 23 – 26, 2011 Enquiry No. 4610

Other Programs Mould & Die Forum 2011 A forum will be conducted by industrial gurus where participants can expand their horizon with the latest insights on runner and gating design for plastic injection moulds, industrial technologies for mould & die, and the development and technologies for lost-foam casting.

Business Matchmaking Program There will also be a business-inducing activity where technology providers and mould makers with the right buying/selling demands are connected together to facilitate their market expansion in ASEAN region.

Enquiry No. 4611

ENQUIRY NO 082

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ENQUIRY NO 106

EVENTs&exhibitions

M

TA Vietnam will return to Ho Chi Minh City from July 5 - 8 at the Saigon Exhibition & Convention Center (SECC), and will feature a projected 350 exhibitors from 23 countries and regions. In a survey of last year’s visitors, about 90 percent indicated that they will return for this event as they left the show gaining valuable knowledge and new business contacts.

The show saw more than 6,900 trade professionals who took the opportunity to network with key industry players and review the latest machine tools and solutions available from around the world. These included 70 group delegations from local and foreign manufacturing enterprises. The 2010 edition had more than 340 international exhibitors, which was a 40 percent increase from 2009.

The Financial Beat Of Vietnam MTA Vietnam aims to support Vietnam’s manufacturing needs as the sector grows. The country’s Foreign Investment Agency, under the Ministry of Planning and Investment, announced that for the first quarter of 2011 the 74

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Event Preview:

MTA Vietnam manufacturing and processing sector attracted US$1.55 billion of Foreign Direct Investment (FDI), which accounted for 65 percent of the total registered capital.

In 2010, the sector ranked second in terms of attracting FDI – up from a third ranking in 2009 with a 127 percent increase in registered capital.

With Vietnam’s manufacturing industry progressing as a result of government initiatives, World Trade Organization’s (WTO) commitments and industrial liberalisation, the country is set to become industrialised by 2020. It is expected to be a major manufacturing hub in Southeast Asia because of an enhanced business environment due to increased trade, investment cooperation and low labour costs.

An International Affair “As Vietnam’s manufacturing sector progresses, the show is

set to serve the industry with a quality exhibition that provides quality supply from our exhibitors to buyers. The event will provide an essential platform for industry professionals to network, explore business opportunities, and gather knowledge about the latest trends and development today,” said William Lim, project director for MTA Vietnam from the show’s organiser, Singapore Exhibition Services.

An international event, there will be 12 group pavilions from China, Germany, Italy, Japan, South Korea (2), Singapore, Taiwan (2), Thailand, Turkey and the United Kingdom. Exhibitors will hail from 23 countries and regions.

Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam July 5 – 8, 2011 Enquiry No. 4612

EVENTs&exhibitions

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MTA 2011 O Event Review:

ver 13,400 trade visitors, exhibiting staff, conference delegates and speakers, and members of the press participated in MTA2011, Asia’s precision engineering trade exhibition and business forum. The event drew to a close at Singapore Expo on 26 March 2011. Visitors to this international trade event arrived from almost 50 countries and regions to network and source for machine tools and precision engineering technologies available in the global market.

With the manufacturing sector in

the region currently in good health, industry players were looking for the latest technology and knowhow to reduce dependence on the mass production of uncomplicated components and standardised products as demand for such output can be highly volatile. The show was designed to help the industry move up the manufacturing value chain into high value sectors which is imperative to long term growth.

The buyers who came to the show saw an array of machine tools and technologies, serving the traditional precision engineering

base and also specifically for the strategic growth sectors of Aerospace, Medical Technology and Oil & Gas. William Lim, the show’s project director at SES, said: “We are glad that exhibitors and visitors alike have found many opportunities at the show to network, strengthen professional relationships, and close business deals. The many transactions that have taken place at the show affirm MTA’s strong reputation as Asia’s sourcing ground for the latest in manufacturing equipment and technology.” MTA2013 will return from March 27 - 30, 2013 at Singapore Expo.

Singapore Expo Singapore March 23 – 26, 2011 Enquiry No. 4613

The best kinematic performance on the sliding headstock market EvoDECO 16a / 16e • New design and increased rigidity • Optimized performance • Productivity gains • Motorized spindle at 12,000 rpm • Thermal performance optimized

www. tornos.com

TORNOS TECHNOLOGIES ASIA LTD Unit 4, G/F, Transport City Building 1-7 Shing Wan Road, Tai Wai Shatin, N.T., HONG KONG Tel. +852 2691 2633 Fax +852 2691 2133 asiapacific.contact@tornos.ch

TORNOS S.A. THAILAND REPRESENTATIVE OFFICE Tel. +66 2746 8840-1 Fax +66 2746 8842 thailand.contact@tornos.com

TORNOS TECHNOLOGIES ASIA LTD MALAYSIA REPRESENTATIVE OFFICE Tel. +6 (04) 642 6562 & 6563 Fax +6 (04) 642 6561 malaysia.contact@tornos.com

ENQUIRY NO 086

• Up to 10 axes (+2 C Axes)

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Precision Engineering Business Forum 2011

Complementing MTA 2011 was the forum, which returned for a second edition this year. The event was attended by local and overseas delegates to gather information on the developments of the aerospace, medical technology, oil & gas and surface finishing sectors.

By Mark Johnston and Natalia Tee

Growing The Precision Engineering Industry Dr John Young, director, Singapore Institute of Manufacturing Technology, talked about the opportunities present in the precision engineering industry in Singapore.

Dr John Young shared at the forum the opportunities and drivers to enhance growth in the Precision Engineering (PE) industry in Singapore. He said: “Many Multi-National Corporations (MNCs) seek local partners in terms of outsourcing and localisation in manufacturing processes as they want to focus on their core businesses in product innovation.” Besides the pull factor, the local government encourages local companies to increase provision of value-added services like niche PE solutions.

Medical technology is one of the important fastest-growing industries in Singapore, which holds many opportunities for PE growth. Currently, this industry has contributed more than S$3 billion in manufacturing output.

Dr Young elaborated that the Singapore population older than 65 years old is set to double to 20 percent in 2020. This means that demands will increase for the next 10 to 20 years. In addition, a more educated elderly cohort demands more sustainable chronic care solutions, resulting in an ever-growing market for innovative and high-grade devices such as cardiovascular and orthopaedics applications.

Enquiry No. 4614

Additive Manufacturing – The Future Pillar In PE Lukasz Pienkowski, sales manager APAC, Atoms Optical Measuring, shared the benefits of applying additive manufacturing in the PE industry.

At the forum, Mr Pienkowski spoke about the potential growth of applying additive manufacturing in the PE field. He said: “This technology involves building of layers. For example, if you have a piece of metal slice, you build layers until you get a 3D model.” This technology is able to build a compact model using strong metals like titanium and gold.

In comparing between machining and additive manufacturing, he elaborated that the cost of machining increases with the removal of materials and the complexity of process. On the contrary, additive manufacturing part cost is mostly independent of batch size. This indicates that companies can produce as many prototypical products as possible. Manufacturing more parts in a tray can also enhance speed of production.

Finally, he talked about the flexible nature of the technology. He said: “It is possible to create a bone joinery implant in which the exterior is made of titanium, a biocompatible metal, while the interior is a honeycomb structure.”

Enquiry No. 4615

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Mr Pienkowski shared the potential growth of applying additive manufacturing in the PE field

ENQUIRY NO 091

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Enhance Manufacturing Capabilities Of Suppliers For Greater Competitiveness Daniel Bouric, technical m a n a g e r, T h a l e s Aerospace, is currently responsible for a range of business-to-business electronic equipment ranging from radars to airborne and ground, to cockpit devices and flight components for IT networks and defence and space.

Mr Bouric’s presentation aimed to give an insight into ways to enhance the manufacturing capabilities of Southeast Asia’s suppliers to achieve greater competitiveness.

His presentation touched on a few key points, namely: specificity of equipments in terms of process family requirements; process efficiency improvement to reach the level of performance and competitiveness; configuration and traceability management; knowledge about stringent rules or standards for hardware, coatings, and chemicals; proficiency to raise consistent technical reports as proof of qualification.

The speaker stated that the design teams in his company are developed according to French, European, or ISO standards. Unfortunately, these standards are not always in use in Southeast Asia. Also, suppliers of materials or chemicals do not have a proof of compliance to the standards used during product qualification. It is important for the company to attain qualification and change processes to adapt to locally known standards.

In aerospace, it is preferred to keep a process or definition with its own imperfection and risks rather than go for something new without knowing the risk. Of course, that does not mean that no change is allowed but rather risk analysis is mandatory.

Enquiry No. 4616

Aerospace & Defence Applications For Fuse Deposition Modelling Bill Macy, application development lead, manufacturing solutions group, Stratasys presented on Fuse Deposition Modelling (FDM) at the precision engineering forum at MTA 2011. As Mr Macy explained, FDM is an additive manufacturing process that builds parts in layers, so it builds it one layer at a time as an additive process. This particular additive manufacturing process takes advantage of the properties of thermal plastics.

“The FDM system has more than 20 years as a prototyping tool. In the industry, additive manufacturing is traditionally seen in prototyping. It allows you to take these prototypes into a shop and use them to actually functionally test your part and design.”

The system takes CAM model into the software and takes layers of that model out and then allows special processing to those. There are ways where CAD model can be manipulated to optimise strength, weight and build times in order to generate more affordable parts.

In conclusion, Mr Macy shared his thoughts on the advantages on the technology. He said: “The benefits of the FDM system are that it provides a variety of strong materials that allow the matching of application to the material properties. This means that we’re not just talking about prototypes anymore, but about engineered tools, engineered parts that go into the final product. There are of course other benefits, including software advantages, allowing you to build a void within the volume of the parts but still maintain structural integrity.

Other advantages include, no operator, scalability, and environmental benefits.”

Enquiry No. 4617

78

metalworking equipment news May-Jun 2011

PE Industry Technologies In Singapore Riding on Singapore’s strong 10.5 percent annual grow th by the manufacturing sector in 2010, the Singapore Institute of Manufacturing Technology (SIMTech), aims to help the PE in du s tr y s oa r to g re ate r heights by equipping the industry with innovative and advanced technological c a p a b i l i t i e s to m i g r a te i n to t h e specialised industries.

Oil & Gas Initiative The oil & gas initiative develops and equips the PE companies with the critical processes needed to produce high value oilfield equipment products, tools and components. The initiative aims to develop indigenous deep-hole gun drilling capabilities on exotic materials to attract a new range of high performance and corrosion resistant oilfield equipment manufacturers to Singapore.

Twenty two companies – including oilfield equipment manufacturers, equipment builders, gun drill manufacturers and sensors/lubricant manufacturers are participating in an international gun drilling benchmarking project led by SIMTech with participants from the USA, Germany, UK, Japan and Singapore.

Aerospace Initiative Taking a multinational corporation-led approach, a research consortium is formed by aerospace multinational and local companies to create niche capabilities in component and MRO manufacturing and non-destructive testing. Aerospace companies are a ble to c a pit a lis e on SIMTe ch’s facilties including CT X-ray for internal structure measurement, residual stress measurement system, material characterisation, robotic automation, ultra precision machining and cutter design to develop advanced manufacturing solutions. MEN

Enquiry No. 4618

productfinder

ENQUIRY NO 072

www.equipment-news.com

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

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

Fax: +886-2-2601-8936

E-mail: sales@spc.com.tw

www.deesgroup.com.tw

ENQUIRY NO 057

ENQUIRY NO 040

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

May-Jun 2011 metalworking equipment news

79

ProductFinder

80

www.equipment-news.com

DMG: Next Generation Five-Axis Milling

Komet: Modular Reaming

With its footprint of 11.6 sq m, DMU 85 monoBlock

by DMG ensures that there will be room in any workspace. The three-axis version can accommodate workpieces that are up to 1,200 mm long and weigh 2,000 kg. The five-axis machine supports a 1,040 mm diameter and a workpiece weight of up to 1,500 kg. For such workpiece dimensions in particular, the machine’s accessibility presents benefits as it offers top loading above the table centre.

Travel distances also support these dimensions: 850 mm in X and Y direction, and 650 mm in Z direction.

The milling machine’s rigidity and stability allows machining performance and precision. The swivel rotary table’s 45-size roller guides produces a level of stability. In conjunction with its SK50/HSK-A100 tool holder, the machine supports heavy machining with 288 Nm / 44 kW.

Komet group through its reaming brand Dihart has introduced a modular reaming tool system Reamax TS with integrated concentricity adjustment (DAH zero), which ensures precision concentricity with precision of < 3 μm.

These side clamping reamers are available from diameter 18 to 65 mm and depths up to 5 × D with DBF and DBC coatings with speeds of 500 m/min.

Enquiry No. 4701

Enquiry No. 4703

Hypertherm: Enhanced Durability

Mori Seiki: Evolved Cell Control System

Hypertherm has developed the Duramax torch series that includes more durability and longer consumable life, while using their existing Powermax systems.

Designed with durability in mind, they can withstand impacts five times greater than the previous generation of torches and are more heat resistant.

The torches use a conical flow nozzle and spring electrode for longer consumable life. Testing shows an up to 55 percent increase in the life of the Duramax consumables, which translates into a 30 percent savings on consumable costs.

The retrofit torches are available in an ergonomic, 75-degree (HRT) hand torch (right) or a 15-inch fulllength (MRT) machine torch (left).

Mori Seiki has developed MCCLPS III, the version of its cell control system. It is designed to provide efficient operation and management of the company’s pallet transfer systems. Pallet transfer systems include LPP (Linear Pallet Pool), CPP (Carrier Pallet Pool), RPP (Round Pallet Pool) and AWC (Automatic Workpiece Changer).

With a range of functions from job/order data management, machining program management, material/fixture/ tool management, system status monitoring to variety of production reporting, the system maximises operating efficiency of customers’ pallet transfer systems. It is available in three versions to suit a range of uses.

Enquiry No. 4702

Enquiry No. 4704

metalworking equipment news May-Jun 2011

productfinder

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Objet: Advanced Materials For 3D Printing

STANDARD GUIDING ELEMENTS THAT ARE ANYTHING BUT STANDARD: High-precision standard and special design guiding elements.

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

ENQUIRY NO 037

Enquiry No. 4705

PURE BRED EFFICIENCY FOR TOOLING DESIGNS.

ENQUIRY NO 073

Objet Geometries has developed three advanced materials, an ABS-like digital material (RGD5160 -DM), a clear transparent material (Objet VeroClear), and the Objet VeroWhitePlus.

The ABS-like material is a high-impact, high-temperatureresistant material suitable for manufacturers and engineers looking to functionally simulate products made of ABS-grade engineering plastics.

The clear material provides clear optical and visual transparency combined with dimensional stability enabling designers to simulate PMMA in glass-like applications such as lighting cases, lenses and cosmetics containers. Finally, the VeroWhitePlus is suitable for fit and form testing for a range of industries and for validating model design.

May-Jun 2011 metalworking equipment news

81

productfinder

www.equipment-news.com

Schaeffler: High-Performance Spindle Bearings

82

Tornos: Enhanced Kinematics

The FAG spindle bearings of series RS combine the speed capability of the HS high-speed series w ith the robust ne ss and load capacity of bearings with large balls (B spindle bearings).

The frictionoptimised inter na l design a nd uniform 20 - degree contact angle have resulted in maximum speed capabilit y, high load capacity and minimal sensitivity to operational and environmental influences.

As such, the series open up new possibilities when it comes to designing high-speed spindles for high machining forces. Their improved speed capability allows a more cost-effective realisation of high-speed operation.

Tornos has developed the successor of its Deco 13. The EvoDeco 16 presents all the benefits of its predecessor, plus a number of enhancements and features, taking advantages of new technologies.

The powered main spindle and counter spindle are identical with torques and power notably increased compared with the Deco 13. The machine features 10 axes (plus 2 C axes) for the ‘a’ version and eight axes (plus 2 C axes) for the ‘e’ version.

The machine includes all the drive systems for the rotating tools, the C axes, interpolation in polar coordinates and automatic central cyclical lubrication.

For short parts, it can also work without a guide bush.

Enquiry No. 4706

Enquiry No. 4708

Seco: Solid Drills For Composite Materials

Witte: Cool Clamping Method

Seco Tools have developed two geometries for drilling of composites and composite stacks. Designed to produce high quality holes in a highly productive environment, C1 and C2 have optimised point geometries to improve and secure the hole quality.

The Dura diamond coating achieves higher cutting data and extended tool life when compared to conventional TiCN/TiAlN coated tools.

The C1 geometry is designed for a variety of composite materials. The main feature is the point angle design, which is developed to reduce the axial forces and minimise splintering or delamination of the work piece. The C2 geometry has been designed to provide optimum results when drilling stacked materials.

For complicated applications with intricate, thin walled components it is not so much the machining process which is a challenge but more the correct method of holding the parts. Where flat large surfaces are concerned, vacuum clamping technology is often the best method.

The Ice Vice chuck developed by Witte Germany is available in standard dimensions of 75 x 140 x 300 mm (clamping surface 100 x 150 mm). For operation only a compressed air supply of six to eight bar is required and air consumption amounts to approximately 25 m³/h.

Freezing and thawing – corresponding to clamping and releasing – is done with a simple on/off switch.

Integrated mufflers ensure a comfortable reduction in operating noise level.

Enquiry No. 4707

Enquiry No. 4709

metalworking equipment news May-Jun 2011

Exhibition Programmes 2011 May

June

4–8 Metaltech 2011

8 – 11 Manufacturing Surabaya 2011

PWTC Kuala Lumpur, Malaysia Trade-Link Group info@tradelink.com.my www.tradelink.com.my

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

23 – 26 Intermold Thailand 2011

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

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

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

BITEC Bangkok, Thailand Reed Tradex intermold@reedtradex.co.th www.intermoldthailand.com

July

5–8 MTA Vietnam 2011

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

25 – 28 MTT Expo 2011

23 – 26 Automotive Manufacturing 2011 BITEC Bangkok, Thailand Reed Tradex automan@reedtradex.co.th www.automanexpo.com

19 – 21 Subcon 2011

19 – 22 Intermach 2011

Grand City Convention & Exhibition Centre Surabaya, Indonesia PT Pamerindo info@pamerindo.com www.manufacturingsurabaya.com

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

September 13 – 15 Wire Southeast Asia 2011

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

APMEN goes on the road...

Visit our booth at: • Intermach • MTT Expo • Manufacturing Surabaya • InterMold

• MTA Vietnam • Wire & Tube • Vietnam Manufacturing Expo

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

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

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

October 6–8 Metalex Vietnam

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

November 16 – 19 Metalex

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

Nov 30 – Dec 3 Manufacturing Indonesia 2011

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

• Metalex Vietnam • Metalex

www.equipment-news.com May-Jun 2011 metalworking equipment news

83

advertising index

Advertiser 4T TECHNOLOGIES PTE LTD

33

Enquiry No.

AGATHON AG

81

037

23

027

BRUTSCH-RUEGGER METALS

57

162

BYSTRONIC PTE LTD

05

097

DEES HYDRAULIC INDUSTRIAL CO LTD

79

057

DELCAM PLC (INTERNATIONAL DIVISION)

07

089

DMG ASIA PACIFIC PTE LTD

FC

089

ECMI SERVICES PTE LTD (MTT EXPO 2011)

53

101

EMO 2011

41

062

EXXON MOBIL ASIA PACIFIC

35

085

Flow asia corporation

37

093

HAAS AUTOMATION INC

13

081

Hexagon metrology asia pacific pte ltd

17

105

HOFFMANN GMBH

11

051

HONG CHEK CO (PTE) LIMITED

45

078

Hurco (s.e.asia) pte ltd

19

151

ISCAR LTD

IFC

088

BC / 02 /30

135 / 157 / 137

81

073

KENNAMETAL INC

MAWEA INDUSTRIES SDN BHD

79

040

MESSE DUSSELDORF ASIA

71

082

Mitutoyo asia pacific pte ltd

65

102

MMC HARDMETAL (THAILAND) CO LTD

47

053

Newell rubbermaid (m) sdn bhd

29

065

OBJET GEOMETRIES AP LIMITED

25

067

OPTICAL GAGING (s) PTE LTD

27

060

PAMA SPA

49

099

PARAMETRIC TECHNOLOGY (SHANGHAI) SOFTWARE CO LTD

45

087

PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA SURABAYA 2011)

55

080

REED TRADEX COMPANY (INTERMOLD THAILAND 2011)

59

121

REED TRADEX COMPANY (METALEX THAILAND 2011)

77

091

REED TRADEX COMPANY (METALEX VIETNAM 2011)

73

106

REED TRADEX COMPANY (VIETNAM MANUFACTURING EXPO 2011)

72

090

SECO TOOLS (S.E.A) PTE LTD

01

001

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2011)

63

024

SOLIDCAM LTD

43

094

TECHTOWN PTE LTD

67

083

TORNOS TECHNOLOGIES ASIA LTD

75

086

15 / 20

104 / 095

39

096

TRUMPF PTE LTD TUNGALOY SINGAPORE (PTE) lTD WALTER AG SINGAPORE PTE LTD

09

168

WENZEL ASIA PACIFIC PTE LTD

61

103

WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG

51

098

YAMAZAKI MAZAK SINGAPORE PTE LTD

IBC

092

Yih chuan machinery industry co ltd

79

072

metalworking equipment news May-Jun 2011

ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing,Automation & Quality Control

100

BRUDERER PRESSES (FAR EAST) PTE LTD

LICO MACHINERY CO LTS

80

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