APMEN May-June 2016

GETTING THE FINEST QUALITY p32 • SETTING NEW BENCHMARKS p38 May-June 2016

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CO N T E N TS

Asia Pacific Metalworking Equipment News • May - June 2016

METAL CUTTING

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Where The Cut Starts & Ends

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APMEN was invited to the Iscar customer seminar in Tefen, Israel to check out the latest products, innovations and of course a chat with Jacob Harpaz, CEO of Iscar and President of the IMC Group. Syed Shah reports from Israel.

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Getting A Clean Edge:

Competitive Advantages Through Cleanliness

Hard material coatings improve the performance and service life of cutting and metalforming tools. However, these gains are contingent upon good coating adhesion to the substrate and this, in turn, is critically dependent on proper cleaning of the tools. By Doris Schulz.

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Getting The Finest Quality

Haimer’s shrinking technology enriches machining centres with precision. Contributed by Wolfgang Klingauf.

Setting New Benchmarks

One of the most common tools found in the ATC stations of machining centres and multi-tasking machines is the light cutting shoulder mill. This is because, apart from shoulder milling being one of the most prevalent machining operation, the cutters are versatile enough to be used for face milling, slot milling, ramping and more. Contributed by Sandvik Coromant.

GREAT GEAR & SYSTEM

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Press Shop Automation:

Headed For New Frontiers

Thanks to solid experience in the automotive sector and in-depth knowledge of OEM and Tier One manufacturers’ production dynamics, Comau offers robotised solutions for dedicated sheet pressing lines which fully satisfy, and often anticipate, market trends and requirements. By: Marina Zussino.

INDESIGN

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Are You Unintentionally Leaking Your Intellectual Property?

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Creating multiple copies of a document is a common practice when using a file based approach. However, by implementing the Cloud, it does not have to be that way. By John McEleney, CEO, Onshape.

Looking Beyond The Tech

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Exploring new approaches which do help tool shops minimise pains which technology alone cannot help alleviate.

Moving Concepts Forward

These days CAD/CAM is an integral part of metalworking in all sectors and companies are constantly staying one step ahead of the game.

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CO N T E N TS

Asia Pacific Metalworking Equipment News • May - June 2016

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FAST FAB

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Cutting & Weld Preparation:

The Many Faces Of Plasma Cutting

Tex Whiting, consumable sales manager for Hypertherm explains to us about the many forms of plasma cutting under different conditions and how to get the best out of it.

FEATURES

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MES – But Do It In The Right Way

Understanding the proper way of implementing a Manufacturing Execution System (MES) in the context of Industry 4.0 is important to gain the most benefits. By Sascha Graef, MD, MPDV Asia

Intelligent Use Of Non-Productive Time

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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.

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Robots can free up additional capacity for machine tools and increase productivity. By Andreas Schuhbauer, Market Segment Manager for Machine Tools, KUKA Roboter

THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

Industry Endorsements

IoT In Manufacturing:

STARTING THE GROWTH ENGINE

Drawing on a study of 795 executives from a range of sectors in Asia Pacific, Europe and the Americas, Sreenivasa Chakravarti, head innovation and transformation group, manufacturing business unit of Tata Consulting Services shares his insights on strategic decisions involving investing in the Internet of Things (IoT).

EVENTS & EXHIBITION

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EDITOR’S NOTE Asia Pacific Metalworking Equipment News • May - June 2016

Published by:

EASTERN TRADE MEDIA PTE LTD

(a fully owned subsidiary of Eastern Holdings Pte Ltd)

UNITY IN DIVERSITY

Reg No: 199908196C

For the longest time I believed in the whole myopic political and ideological dichotomy of the east and the west. The western media portrayed images of how the west was superior to the east and perpetuated various racial and religious stereotypes. In recent years, more forms of alternative media have emerged championing the cause of those at the brunt of the mentioned stereotypes. Amidst all the confusion of who’s right or wrong, my opinion is that deeper political agendas fuel the various media. You would probably think the last part happened when I went to varsity but no, that was not the case. In fact three university degrees later, I was still quite the myopic fellow believing in state agenda. However, the trade media changed me. The seeds were sown more than 11 years ago but bore fruit perhaps a decade on making me that much wiser in the process.

Recently, I was in Israel for an event by an Israeli cutting tools company, Iscar. I was a little apprehensive at first given my name plus my three hour detention by Ben Gurion airport security but after that, it was just a sublime and amazing trip. People of all ethnicities and religions living in harmony amidst all the warfare and bickering in the other Arab states were just an eye opener. I knew that things were actually not as bad as the media always portrayed it but to see it first hand, that was something else altogether – people of all faiths side by side, working and living in peace.

In the metalworking world, the need for more consolidated business offerings seems to be the trend these days with quite a few M & As happening for the last couple of years. Certain metrology companies are now offering all in one suites for their customers on the manufacturing floor. Everytime I go to a regional or international event, there are always changes to companies in terms of acquisitions.

I suppose that the days of silo-ed products are numbered with increasing costs to upkeep.

Hence customers are looking to more long term cost saving structures to keep afloat with maybe slightly more expensive but more cost efficient (in the long run) consolidated offerings. For instance a metrology provider acquiring CAD/CAM company and offering a suite of products that handles a customer’s operations from scanning to conceptualising.

So how much wiser really am I after all this? Are mergers really the best thing? Is it always better to have unity in diversity? Well, after hearing how mixing whiskey and beer in one night can spoil a good party, I’d take it cautiously.

jeffreypimentel@epl.com.sg

senior editor

Syed Shah

syedshah@epl.com.sg

writer

Ho Peiying

peiying@epl.com.sg business development manager

Randy Teo

randyteo@epl.com.sg

editorial assistant

Sharifah Zainon sharifah@epl.com.sg

graphic designer

Jef Pimentel

circulation executive

Nurulhuda binte Suhaimi nurulhuda@epl.com.sg

contributors Wolfgang Klingauf Tex Whiting Andreas Schuhbauer Sreenivasa Chakravarti Marina Zussino Sascha Graef

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.

Printed in Singapore by Fabulous Printers Pte Ltd MCI (P) No. 047/06/2015 PPS 840/09/2012 (022818) ISSN 0129/5519

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Kenneth Tan executive director

Lum Kum Kuen

Syed Shah Senior Editor

etm

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Trade Media Pte Ltd an Eastern Holdings Ltd company

Head Office & Mailing Address: 12 Hoy Fatt Road #03-01 Bryton House Singapore 159506 Tel: (65) 6379 2888 Fax: (65) 6379 2885

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Lantek Names Juan Jose Colas As Chief Commercial Officer

Toyota Selects EtherCAT As Industrial Ethernet Technology Of Choice Germany: Toyota Motor Corporation has selected EtherCAT as its industrial Ethernet of choice. It will base its new factories worldwide on EtherCAT. General manager of the production engineering innovation division at Toyota Morihiko Ohkura explained the decision: “We have conducted a thorough analysis and evaluation to compare various industrial Ethernet technologies. I believe the performance, determinism and simple wiring characteristics of EtherCAT as well as its openness best fit with the needs of Toyota to evolve production systems with industrial Internet of Things (IoT) concepts.”

The corporation also plans to take an active role within the EtherCAT Technology Group (ETG) and aims to become one of the leading EtherCAT users in the industry.

Executive director of ETG Martin Rostan said: “ETG has always been characterised by active user involvement. Having Toyota on board will strengthen this vital element of engagement and ensure that user requirements are fully met or exceeded by EtherCAT technologies.”

Toyota’s decision to adopt EtherCAT is also attributed to the latest addition to the technology, EtherCAT P, which combines the advantages of EtherCAT with power supply on the same cable. Developed by Beckhoff Automation, the central characteristic of EtherCAT P is that it combines EtherCAT communication with system and peripheral voltage in a single Ethernet cable. EtherCAT P also supports power forwarding through its users.

With EtherCAT P, there is a potential for reducing material and assembly costs as well as space requirements for drag chains, control cabinets and overall machine footprint. The new technology means devices can have access to two 24 V supply voltages with a maximum of 3 A each, undertaken using a traditional 4-wire Ethernet cable.

Mr Morihiko commented: “The concept [of EtherCAT P] to integrate communication and power lines perfectly matches our lean production philosophy. Simply put, the fewer cables, the better.”

United Kingdom: Lantak, a global provider of software solutions for the sheet metal and structural sheet industry, has appointed Juan Jose Colas as its new chief commercial officer. Mr Colas will take a seat on the board of directors and he will be responsible for global commercial strateg y and business development for the corporation. His direct responsibilities, as part of the company’s Strategic Plan 2016-2018, focus on two markets: United Kingdom and France, where Lantak has strong development plans.

Prior to this role, Mr Colas has worked as a commercial director for the industrial machinery business and in the implementation of offshore production in China. He has also occupied CEO positions at an automotive components manufacturing company and in an electronic equipment development and distribution group.

“Juan Jose has successfully managed operations in several countries during the last years. He takes this position at a time when Lantek is well poised for growth and the team worldwide is fully geared to leverage the new market opportunities and contribute to the growth of software solutions for the sheet metal industr y,” said Lantek ’s CEO Alberto Martinez.

On his appointment, Mr Colas shared: “Lantek is a market leader and we have to exploit the oppor tunities that we have in each market to increase our market share, and promote our Lantek Fac tor y concept in each and ever y customer that pursues competitiveness in the sheet metal industry.

Lantek is setting the pace, both technologically and commercially, and is one of the drivers of Industry 4.0.”

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

MHI Group Extends Australia And Oceania Reach Tokyo, Japan: With the aim to strengthen ties with Australia’s governmental institutions and industrial sectors, Mitsubishi Heavy Industries (MHI) Group has launched operations at MHI Australia in Sydney. The new entity also seeks to serve as a base for MHI to develop relationships with Australia’s academic bodies.

The country was selected for its abundant reserves of energy and mineral resources, particularly natural gas and coal, as well as its solid and sustainable economy, which the company recognises as a potential to offer substantial market growth.

Through MHI Australia, the group will focus on developing business opportunities in the energ y and environment industries as well as in diverse fields such as logistics equipment and compressor products for use in natural gas fields. The company also plans to devote its resources to forming close ties with customers and markets within Australia and the Oceania region.

On the inauguration of the new entity in Australia, MHI president and CEO Shunichi Miyanaga said: “With the establishment of MHI Australia, we hope to integrate the MHI Group’s full technological strengths and experience in large-scale project management across a wide spectrum of business areas. Working in lockstep with the advanced initiatives being taken in Australia’s industrial and academic sectors, we will bring new waves of innovation in diverse Australian industries, so that we may grow and prosper together.”

Global Platts China Steel Sentiment Index At Negative Index In May Beijing, China: The latest S&P Global Platts China Steel Sentiment Index (CSSI) has indicated a pessimistic outlook for the construction steel industr y. The CSSI is based on a sur vey of approximately 70 to 85 China-based participants that include traders and steel mills.

Industry participants in the May survey believe prices are set to fall in this month due to weaker domestic demand.

The May index for total new orders dropped 22.14 points to 46.98 from 69.12 in April 2016, recording the weakest reading this year since Februar y. A reading above 50 indicates expectations of an increase or expansion and a reading below 50 indicates a decrease or contraction.

The outlook for domestic orders and expor t orders for steel fell from the previous month by 23.65 points to 47.20 in May and by 4.74 points to 44.44 in May respectively.

Price expectations for long steel product s dropped by 60.00 points to 30.00 from April to May, while pricing prospects of flat steel products decreased by 39.20 points from April to 41.43 in May. Expectations for crude steel production have dropped, falling 3.57 points from April to 57.14, although it has maintained a reading above 50. The only increase in expectation is in steel inventories, with the reading measuring a rise of 31.23 points from the previous month to 67.58 this month.

This month’s pessimism of the cons truc tion s teel indus tr y is a retreat from the surge of optimism in March and April. Paul Bar tholomew, senior managing editor of steel and raw materials for S&P Global Platts, explained: “The big and sudden shif t from optimism to pessimism — particularly in the outlook for construction steel prices — is fur ther indication of how sentiment driven the market has become. Restocking has been a major reason why prices have climbed this year, but steel inventories are tipped to rise while steel production is predicted to stay at current high levels. This could put prices under pressure in the next month or so.”

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Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding. www.gb.schunk.com/Lehmann

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Rising Southeast Asian Countries Poised To Be “New China” Of Manufacturing Japan: According to the 2016 Global Manufacturing Competitiveness Index (GMCI) report from Deloitte Touche Tohmatsu and the US Council on Competitiveness, Malaysia, Thailand, Indonesia and Vietnam are expected to be included in the top 15 nations of manufacturing by 2020, and could represent a “New China” in terms of low-cost labour, agile manufacturing capabilities, favourable demographic profiles, and market and economic growth. Along with the Southeast Asian nations, India was also perceived as a country in Asia to look out for. The group is collectively termed “MITI-V” — “Mighty 5”.

This survey is based on an in-depth analysis of responses from more than 500 chief executive officers and senior leaders at manufacturing companies throughout the world.

“The Southeast Asian countries of Indonesia, Malaysia, Thailand, and Vietnam continue to garner the interest of global manufacturers looking for alternatives to China with the availability of skilled workforce and growing labour productivity, as well as the lower manufacturing labour cost in comparison to China,” said Ng Jiak See, leader of industrial products and services for Deloitte Southeast Asia.

“Other advantages that these countries offer to global manufacturers include numerous tax incentives in the form of tax holidays ranging from three to 10 years, tax exemptions or reduced import duties and reduced duties on capital goods and raw materials used in exportoriented production,” Ms Ng added.

All, but Vietnam, showed a drop in overall competitiveness ranking from 2013 to 2016. However, the MITI-V nations are seen as offering an attractive option for market and economic growth as well as growing the customer bases of manufacturers.

According to the report, CEOs say that advanced manufacturing technologies are a key to unlocking future competitiveness. Predictive analytics, the network connectivity of common objects known as the Internet of Things (IoT), smart products and smart factories that are helping to define Industry 4.0, and advanced materials are viewed by executives as crucial to global manufacturing competitiveness.

Sing apore is al so expec ted to remain a regional leader in manufac turing competitiveness. “Singapore, while considered a relatively high cost manufacturing location in Southeast Asia, is still likely to remain among the most competitive in the region in the future,” said Ms Ng. “With its highly educated workforce, an investmentfriendly business climate, generous R&D incentives, high-quality infrastructure and good governance, the trajectory of Singapore’s manufacturing sector will be one that is propelled by investments in talent and innovation.”

Siemens And Local Motors Partner To Advance The Future Of Manufacturing

Singapore: Tech company Siemens and car manufacturer Local Motors have formed a new partnership to advance the future of manufacturing by optimising the development and large-scale 3D printing of cars. The collaboration combines the power of Siemens’ product lifecycle management (PLM) software technology with Local Motors’ know-how on co-created and 3D-printed vehicles — a process called direct digital manufacturing (DDM).

Through leveraging on Siemens’ expertise in creating digital twins, Local Motors plans to improve productivity in its LM (Local Motors) labs programme, while Siemen wishes to enhance its digital enterprise software suite to support the latest advances in additive manufacturing.

Executive vice president and chief digital officer of Siemens, Helmuth Ludwig, commented on the collaboration: “We recognise the growing importance of additive manufacturing and 3D printing for the global manufacturing industry. That is why we are delighted to partner with companies like Local Motors who are leading the way for large-scale 3D printing. By working closely together, we can help advance this technology so that all manufacturers can better realise innovation.”

Indonesia’s Manufacturing Activity Falls 1.34 Percent In First Quarter Indonesia: According to data from Statistics Indonesia (BPS), Indonesia’s manufacturing activity in the first quarter of 2016 declined 1.34 percent to 3.41 percent, down from a 4.75 percent growth in the fourth quarter of 2015.

The fall is caused by negative growth in the industries of processed tobacco (9.99 percent Q/Q), rubber and plastic (7.66 percent Q/Q), paper and paper products (5.73 percent Q/Q), motor vehicles, trailers and semi-trailers (4.54 percent Q/Q), and electrical equipment (4.13 percent Q/Q).

BPS director general Suryamin commented that the decline of the tobacco industry was caused by a weak harvest rather than a rise in the tobacco tax rate.

While there were several industries that posted expansion, including the industries for wood, wood products and cork, basic metals, transportation equipment, pharmaceutical, and apparel, they were not able to offset the weaker growth in the industries mentioned above.

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Audi Chooses SLM Solutions’ Additive Manufacturing Technology Luebeck, Germany: German automobile manufacturer Audi AG’s Giessenbased department for technical development has purchased an all-in-one SLM 280HL machinery from SLM Solutions, a provider of metal-based additive manufacturing technology. Encompassing a 280 by 280 by 365 cubic millimetre built envelope and a patented multi-beam technology, this 3D printer embodies the laser melting process.

Within Audi AG, this department focuses on developing and testing new casting technologies and materials like light alloys, for the pressurecasting process chain. This contributes to the development of body, chassis and transmission components, involving both the company’s inhouse parts and purchased parts. The Giessen site also has the company’s own casting technology centre where aluminium and magnesium casting alloys are processed, from the pre-development and prototyping stage to the in-house batch production. Additive manufacturing has become an essential part of this division, with a focus on materials, technology and process parameters of 3D printing.

The new SLM 280HL will be primarily used for processing aluminium components. The final goal for this new printer will be the efficient production of topology and process-optimised products in small batches.

SAIL Eyeing 17 Million Tonnes Of Steel Production In FY17 India: Steel Authority of India (SAIL), the country’s largest steel producer, is targeting steel production at 17 million tonnes for FY17 and 20 million tonnes for FY18.

The state-owned company, who has five integrated steel plants, three special plants and one subsidiary in different parts of the country, plans to target 70 percent sales in the northern and eastern regions and increase its presence in “Make in India” sectors such as defence, aerospace and nuclear power. SAIL also plans to sell idle assets and reduce inventories of steel.

These new goals come under the new leadership of PK Singh, the chairman of SAIL, who started his career in the company at the Bokaro Steel Plant in 1980.

The country’s recent finished steel production data saw an increase by 3.2 percent year on year to 7.48 million tonnes in April of the current year.

SAIL posted a rise of 1.8 percent in finished steel production to 859,000 tones.

Schunk Extends Tribos Series For Micromachining Germany: Manufac turer of clamping technolog y and gripping systems Schunk has expanded its range of Tribos polygonal clamping technolog y for more ef f icient results in micromachining.

The Tribos-Mini and Tribos-RM polygonal tool holder series with HSK-E 25, HSK-E 32 and HSK-F 32 interfaces are available from a clamping diameter of 0. 5 mm, a s well as in an ultrafine balanced version with a balancing grade of G 0.3 at 60,000 rpm. This means a possibilit y to achieve even the most demanding specifications in terms of dimensional accuracy and surface finish.

Schunk has also incorporated many of its special solutions in its standard catalogue.

For instance, the Tribos-Mini, which has been designed for high-speed micro applications, is now standardised with 1, 1.5, 2, 3, 4, 6 mm and 1/8 inch diameters, while the diameters for the Tribos-RM are 3, 4, 6, 8, 10, 12 mm and 1/8 inch.

Along with the HSK-A25, -A32, -A40, -E25, -E32 and E40 inter faces that are already available, both mounts will also be available for HSK-E20 and HSK-F32, as well as for BT30 and SK30 interfaces.

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Saudi Aramco’s Oil Output Trending Upwards Dhahran, Saudi Arabia: A growth in demand has led to a slight rising trend for Saudi Aramco’s oil production in 2016.

The state-owned Saudi Arabian petroleum and natural gas company will expand it s capacity in the future if needed, according to chief executive Amin Nasser. For now, its maximum sustainable output capacity is at 12 million barrels per day (bpd), with the nation’s total capacity at 12.5 million bpd.

Mr Nasser added that the expansion of the company’s Khurais oilfield would come in 2018.

The oil giant is currently finalising proposals for its partial privatisation. The company has a team working on the options for the initial public offering (IPO) of less than fivepercent of its value, which include a single domestic listing and a dual listing with a foreign market.

Even after the listing however, Mr Nasser plans to give the Saudi government sole control over Aramco’s oil and gas output levels.

The chief executive also said Aramco was seeking to expand globally via joint ventures in Asia and North America. “We are looking at the current market status that, even though challenging, is an excellent opportunity for grow th,” Nasser said, adding that he was looking at opportunities in the United States, India, Indonesia, Vietnam and China.

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Rolls-Royce Wins US$1.2 Billion Order From Garuda Indonesia United Kingdom: Rolls Royce has won an order worth US$1.2 billion from airline Garuda Indonesia for its Trent 7000 engines for 14 Airbus A330neo aircrafts. These engines are set to be manufactured in plants in Derby and Singapore and are scheduled to enter service in 2017. The Trent 7000 is the exclusive power plant for the Airbus A330neo aircraft, and is the seventh member of the Trent family of large engines by Rolls Royce.

The order was upgraded from an existing one for seven A330-300 aircrafts powered by Trent 700 engines. The deal was inked in London by Garuda Indonesia CEO Arif Wibowo, Airbus COO Tom Williams, and Rolls Royce president of civil aerospace Eric Schulz, and witnessed by Prime Minister David Cameron and President Joko Widodo.

Commenting on the signed deal, Mr Schulz said: “Indonesia has great economic prospects and we are committed to supporting its future growth in air travel. This year marks the 20th anniversary since we first provided Trent engines to Garuda Indonesia and we are proud to power this latest expansion to their fleet with the very latest member of our Trent engine family. In creating this family, we have benefited from UK investment in innovation across materials, aerodynamics, noise, control systems and manufacturing technologies.”

PAL Cements Purchase Agreement With Airbus Philippines: Philippine Airlines (PAL) has finalised a purchase agreement with Airbus for an order of six A350-900s with another six purchase options.

The contract firms up a Memorandum of Understanding announced earlier this year during the Singapore Airshow.

The A350 XWB, the newest member of the Airbus widebody planes, is set to become the PAL’s flagship for its future long haul fleet. It features a modern aerodynamic design, carbon fibre fuselage and wings and fuelefficient Rolls-Royce Trent XWB engines. The airline will operate the aircraft on nonstop flights to the US and on services to new destinations in Europe.

Remarking on the conclusion of the agreement, president and COO of PAL Jaime J. Bautista said: “With the A350, we will introduce a whole new level of comfort for long haul flights, with more personal space in all classes, a quieter cabin and the very latest on-board amenities. At the same time we will benefit from the A350’s enhanced efficiency and ability to fly nonstop on our longest sector from New York to Manila.”

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Kobe Steel To Manufacture Aluminium Extrusions In Kentucky Tokyo, Japan: With over 20 years of experience supplying aluminium bumper materials to Japanese automakers, Kobe Steel now plans to dip into the North American automotive sector with a new plant that produces and sells aluminium extrusions in Kentucky. The new business will operate through a company called Kobelco Aluminum Products & Extrusions Inc. (KPEX) and will make bumper materials for cars and car frame materials.

The new plant will have an integrated production facility, with operations ranging from melting to fabrication. Fabrication will begin in late 2017, and the melting to extrusion processes will start in 2018.

KPEX’s conception is stemmed from North America’s position as the second largest automotive market in the world. Car production in the region is predicted to grow in the future. Higher Corporate Average Fuel Economy (CAFE) standards for 2025 have also accelerated the need to lighten car bodies, and aluminium extrusions are seen as an effective way to reduce the weight of cars.

Delayed Rail Line In Sino-Singapore Tianjin Eco-city Finally Launched Singapore: The long-awaited Z4 rail line, which will run through the Sino-Singapore Tianjin Ecocity, was launched with a ceremony participated

by Singapore’s national development minister Lawrence Wong and China’s housing and urbanrural development minister Chen Zhenggao.

The semi-express rail line is expected to be completed by 2020, and will connect to the Beijing-Tianjin intercity railway extension, linking the Eco-city to Beijing, Tianjin City and the rest of the Tianjin Binhai New Area.

Launched in 2007, Tianjin Eco-city is a bilateral, national-level joint venture between the governments of China and Singapore with the goal of becoming a role model of sustainable cities. “ The Z4 rail line is a much-awaited development. The improved rail connectivity will provide a further boost to the Eco-city’s growth.

This will allow the Eco-city to become a model satellite city, serving the surrounding regions with its efficient administration, business-friendly policies and conducive living environment,” said Mr Wong.

DB Plans To Sell Minority Shares In Arriva And Schenker Germany: As part of restructuring efforts, German rail company Deutsche Bahn (DB) will develop a plan to sell a minority stake in its international passenger business DB Arriva and logistics subsidiary DB Schenker. Its supervisory board will pass a final resolution later this year.

Board chairman Utz-Hellmuth Felcht said: “If we don’t take action, the group’s debt will increase substantially by 2020. A third-party equity interest limits the level of debt and creates financial scope necessary to continue the quality and investment campaign in Germany.”

Between 2016 and 2020, the company plans to invest €55 billion (US$62.7 billion), where 90 percent will be spent on rail operations in Germany.

Previously a two-tiered holding structure, DB Group will also merge with DB Mobility Logistics as part of the restructuring plans.

More Train Services In Victoria Victoria, Australia: The government of Victoria in Australia set aside AU$131 million (US$96.3 million) from its 2016-2017 state budget to increase train services to Geelong and the South West Coast.

Regional train services for Geelong will grow by an additional 54 every week, including four off-peak daily trains and 26 during the weekends.

There will also be more weekday and Sunday services on the Warrnambool line, including 50 weekly.

The budget also provides AU$3 million to develop a business case for the duplication of line between South Geelong and Waurn Ponds.

This move is part of the state government’s AU$1.3 billion investment to better regional train services, which includes AU$280 million for 27 new VLocity carriages, AU$141 million for critical maintenance and AU$198 million to rebuild V/Line.

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BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Kennametal Named “World’s Most Ethical Company” United States: Kennametal, a supplier of tooling and engineered components, was named as a “World’s Most Ethical Company” by the Ethisphere Institute, an organisation which defines and advances the standards of ethical business practices. This marks the fifth consecutive year that the corporation has received the distinction. Kennametal is also one of only two companies in the machine tools and accessories category honoured this year.

The award recognises organisations that excel in three areas: promoting ethical business standards and practices internally, enabling managers and employees to make good choices, and shaping future industry standards by introducing tomorrow’s best practices today.

“At Kennametal, ethics and integrity make up the foundation of our culture and are a crucial part of our business success,” said president and CEO Ron De Feo. “It is thanks to our 12,000 team members worldwide that we have been awarded this honour for the fifth year in a row. Their unwavering commitment to operating with the highest ethical standards has always been at the core of Kennametal’s success, and is essential to our future.”

DMG Mori Introduces High-tech Machines Jonkoping, Sweden: A series of high-tech machines

by DMG Mori was presented at the Elmia Machine Tools trade fair. Among them were Celos, a user interface that can be expanded with new apps and updates as a solution to Industry 4.0. Celos can be used with smart devices and networks all machines within a manufacturing organisation to simplify the process from an idea to a finished product. Presently, 16 apps help the operator prepare, optimise and process production jobs by minimising errors and enabling consistent administration, documentation and visualisation of order, and process and machine data.

Also on showcase was the Ecomill 800 V vertical machining centre with the Slimline multitouch control. As part of the manufacturer’s Ecoline series, it is based on a C-frame cast iron bed for optimal stiffness and vibration characteristics to ensure the highest precision.

It is coupled with the 19-inch Slimline multitouch control that comes with a 45-degree swivel range.

Other machines on display include the NHX 4000 2nd Generation, a compact horizontal machining centre as well as the turn-mill machining centre CTX beta 800 TC.

Alstom To Provide Five Trainsets For Melbourne Rail Melbourne, Australia: Alstom is set to supply five additional X’Trapolis trainsets for Melbourne’s suburban rail network, following the order for five trains placed by the Public Transport Victoria in June last year that are currently in production. The first batch will be delivered in September 2016.

The six-car X’Trapolis trainsets will enhance the network’s capacity and will be produced in Ballarat.

Noting on the new order from Public Transport Victoria, managing director of Alstom Australia and New Zealand Mark Coxon said: “This will not only secure the manufacturing pipeline in Victoria well into 2017, but also provide additional transport capacity to the residents of Melbourne’s area and allow them to commute on-board reliable, comfortable and environmental-friendly mode of transport.”

Opportunities To Reduce Costs Presented At EMW’s “Innovation Day” Germany: Some 100 delegates visited the Handwerkskammer Koblenz in Rheinland-Pfalz, Germany as part of welding machine manufacturer EWM’s first “Innovation Day”. They were introduced to the new forcearc puls welding process as well as other offerings by the manufacturer through a series of talks and welding demonstrations.

The key highlight of the event was the presentation on the forcearc puls welding process. Its wide applicability, low heat input and higher welding speeds were shown to translate to more cost savings and higher productivity for its users.

Opportunities to reduce costs were also the focus of other talks. Boyan Ivanov, head of process engineering at EWM, reported on the commercial benefits of the new welding process and the potential savings from fillet welding. His colleague Hassan Lakhnati, director of the Technology and Mechanisation Centre in Weinheim, talked about the efficiency benefits of EWM’s technology when applied in mechanised welding in equipment and pipe construction. And Benedict Menningen, responsible for EWM’s software service, showed how modern software can be used to implement continuous quality assurance during welding.

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22

BUSINESS NEWS Asia Pacific Metalworking Equipment News • May - June 2016

Bosch To Open Office In Tehran Germany: Auto parts supplier Bosch Group is opening a new liaison office in Tehran and will employ around 50 associates in the Iranian capital by the end of the year.

Bosch Europe, Middle East and Africa board member Uwe Raschke said: “The country’s potential is tremendous. We expect to see the Iranian economy grow by just under five percent this year. The medium term is also highly promising.”

Bosch estimates that the Iranian government plans to invest more than US$40 billion in local infrastructure, including airports, rail networks and energy supply.

“We can support the country’s modernisation process with a wide range of products and solutions, including mechanical engineering applications, solutions for connecting infrastructure and energy and building technology, as well as household appliances and power tools,” added Raschke.

This year, Bosch says more than one million vehicles are expected to be produced locally in Iran, an estimated nine percent increase from last year. The country’s archaic fleet also means that the need for investment is high, especially in the commercial-vehicle segment.

In addition to its liaison office in Iran, Bosch has also recently opened a sales office in Lahore, Pakistan’s second-largest city, and a new regional headquarters in Istanbul last year.

Kemppi Strengthens Presence In Asia Pacific With New Appointment And Exhibition At Metaltech Malaysia: Arne Dittmar has been appointed as the Asia Pacific director of Kemppi Oy and general manager of Kemppi Welding Solutions Sdn Bhd, Malaysia. In his new role, Mr Dittmar will focus on establishing the Kemppi presence in Malaysia and to intensify the cooperation with Kemppi’s Malaysian and Singaporean customers.

Mr Dit tmar comes to Kemppi from an indus trial machiner y manufacturer, where he was responsible for strategy and marketing. He also has experiences in global key-account management and project sales as well as in sales of premium priced high-quality industrial equipment.

In addition to the new appointment, Kemppi is expanding its presence in the region through an exhibition at the Metaltech 2016 event held in Kuala Lumpur.

The manufacturer presented on a range of new products for automated welding, suitable for industries such as automotive, shipbuilding, oil and gas, and tube and pipe manufacturing. One of the highlights was a new robotic welder with functions that aim to deliver faster and more accurate welding performance for a wide range of applications.

Heimatec Shares Its Knowledge In Bangkok Bangkok, Thailand: Distributors from China, Malaysia, India, Korea, Japan, Indonesia, Thailand and Japan gathered for the Heimatec’s 3rd distributor meeting in Bangkok, Thailand.

During the meeting, distributors were then updated with the latest Heimatec product developments which is also important because of the need to synchronise and upgrade their individual produc t knowledge. President Martin Krieger opened the meeting to welcome par ticipant s. Preben Hansen (president , Heimatec, USA), Anshuman Tambe (managing director, Heimatec India) and Andreas Meyele (sales manager, Heimatec GmbH) presented detailed product information and introduced new, interesting applications for the various industries. The event was concluded with a dinner wit h par t icipant s t ak ing aw ay new information about Heimatec’s latest product offerings.

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METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

Where The Cut

STARTS & ENDS APMEN was invited to the Iscar customer seminar in Tefen, Israel to check out the latest products, innovations and of course a chat with Jacob Harpaz, CEO of Iscar and President of the IMC Group. Syed Shah reports from Israel.

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I

scar which is ac tually shor t for Israel Carbide is headquartered in the northern Israeli community of Tefen is known as International Metalworking, or IMC. When billionaire U.S. investor Warren Buffett bought out the remainder 20 percent of Iscar from the Wertheimer family for about US$2 billion, the Berkshire Hathaway completed the full transfer of ownership of the Israeli cutting tools firm from the Wertheimer family. Even before the purchase, Iscar was already proving itself to be up there amongst its competitors as being a premium provider of cutting tools, especially for the metalworking world.

The company was founded in 1952 by Stef Wertheimer in the Western Galilee town of Nahariya and moved in 1982 to the Tefen Industrial Zone, about 20 kilometres away. In 1984 Stef gave the leadership to his son Eitan Wertheimer who then passed the CEO’s seat to Jacob Harpaz in 1995. Jacob then went on to serve as chairman and later president.

Eitan validated Jacob’s leadership praising him saying that the executive team together with Jacob would continue the vision started out by Stef when he first started the company and with positive profit revenues in the last few years, I have no doubt that this trend will continue into the future.

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

Standing Out Amongst The Rest Interestingly enough, thanks to the usual dose of misinformation of common mainstream media channels, the Middle East has been often portrayed as a place that is not very good for business and living. Back in Singapore, religious stalwarts of the Abrahamic faiths often mention of Israel and how they would love to at least do a pilgrimage there once in their lives. Until I had done business and trade reporting, I had only known Israel for its famous Jaffa oranges!

But this one trip alone made it clear that Israel is more than just a holy city or wonderful fruits, truly, it is the heartbeat of business in the Middle East.

That aside, there are many incredibly successful Israeli companies and Iscar has by far been one of the most successful in terms of its offerings in the metal cutting arena. All over in Asia, their carbide inserts and grades are seen in many heavy and lucrative industries here in Southeast Asia and the Asia Pacific.

The automotive industry which continues to dominate a large part of Southeast Asia’s GDP (Gross Domestic Product) regularly are in need of cutting tools and timely innovations to them as demands get higher and expectations for superior low cost products increase.

Giri Drori, business development manager, Iscar, explained over dinner on the first seminar day that Iscar’s plan in the Asia Pacific region is to “continue to grow with the industry while committing to superior service in terms of technical support round the clock”. “I believe that every year with our innovations, we set the bar higher for not only the competition in the market, but also for ourselves in the areas of milling, turning and drilling. We look to not only capture the market but also the heart of the market because with that belief in us, only then can we show how much our customers mean to us with innovations that make every difference to helping their businesses.”

The contingent of participants that were present was an international bunch with the largest number of them coming from the United States. Kicking off the program on day one was Jacob Harpaz who stressed on Iscar’s goal to provide customers with the latest technologies to bring down costs. “The new products create magic for our customers by improving technology and lowering production costs. Iscar’s strategic philosophy is ongoing R&D that drives our business growth. As soon as we introduce to the market our newest tooling families, another team from the R&D division focuses on designing tools that will compete with these latest tools. We basically never stop innovating.” Coincidentally, Jacob is a man from

Iscar has by far been one of the most successful Israeli businesses in terms of its offerings in the metal cutting arena.

the ground, who has worked producing these tools on the ground and has risen to the position he is at now.

Taking A Stroll Through Production Excellence On both days of the seminar, we were treated to tours of the Iscar facilities and taken through the processes on how different tools were manufactured. Each cutting device goes through an extremely stringent checking process right down to the last millimetre. A very interesting innovation seen in the production process was the use of smart robots at one part of their facility to transport parts and pieces from one part of the shop floor to the next.

Moreover, Iscar takes the security of its production know how very seriously especially at some portions of the installation where engineers were required to surrender their mobile devices. This is done to 1) protect the engineers from accidentally causing an accident that may endanger lives and 2) ensure accuracy

The bar is set higher every year to challenge themselves to produce even better products for their customers.

25

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METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

A Five Star Performer Following the successful introduction of the Penta 24 and Penta 34 inserts, Iscar has recently introduced the latest evolution of the renowned Penta family.

Some of the tools on display as the demonstrations were going on.

As the Penta prefix suggests, Iscar’s advanced new parting insert boast 5 cutting edges. Penta IQ-Grip inserts, available in 2 and 3 mm widths,

Walking along in one of the groups while touring the facility.

are ideal for parting up to a 40 mm part diameter or up to a 20 mm depth of cut.

An innovative dovetail wedge clamping system ensures ver y stable Penta IQ-Grip inser t clamping, secure edge indexing and rapid inser t replacement. In addition, the robust structure enables the application of high machining parameters, resulting in much reduced cutting time.

As well as delivering significant performance advantages, Penta IQ-Grip provides excellent

In the facility checks on each step of the process was taken extremely seriously with extra care taken to monitor defects.

straightness and surface finish characteristics in parting applications.

Penta IQ-Grip outclasses all other self/

in their work because in such a business, the margin for error is near to zero.

The many demonstrations include those that showcased their hole making, gripping and turning systems as well as the introduction of new grades – all designed and made to increase cost efficiency in customers’ plants. There were countless very good demonstrations across all product ranges that definitely convinced the contingent about making further investments in Iscar products.

At the end of the seminar days, participants were taken to dive into Israel’s rich history that predates many civilisations today. Participants even dined at a port that was named after Julius Caesar (most famous dictator of Rome) called Caesaerea with the couple of thousand year old preserved ruins all around us. In the end Iscar gave the participants not only the good news that in the ever increasing challenging economy, new cost saving innovations were available, but also a side of the beautiful country of Israel that not many will get to see in their lifetimes.

screw clamping mechanisms currently available.

Also, when compared to competitors’ parting inserts that have more than 2 cutting edges, Penta IQ-Grip provides double the depth of cut.

The new Penta IQ-Grip is able to outperform other manufacturers’ single, double or triplee dg e d in s er t s for g r o ov ing and p ar t ing applications.

Penta IQ-GRIP assures prolonged insert tool life, at least double that of single, double or triple ended parting inserts. Penta IQ-Grip inserts are available in 3 sizes for parting: D22 (up to 22mm part dia), D32 (up to 32mm part dia), and D40 (up to 40mm part dia).

D22 and D32 mm sizes can also be used on Swiss-type and small CNC machine tools.

All inserts feature C- and J-type chipformers to accommodate a wide variety of machining and material applications. Penta IQ-Grip is produced from grade IC808G; a hard, fine grain substrate with excellent chipping resistance, whilst a TiAlN PVD coating provides impressive wear resistance.

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

industry. Currently we hold the number two

What are the functioning departments of Iscar?

position within the metalworking industry.

Iscar has several divisions of which the most

continue to innovate and add value to the

dominant is the production division. The

How much revenue of Iscar comes from the Asia Pacific?

processes are all in-house to enable a high

Well we have TaeguTec in Korea and Tungaloy

demanded by the market. In essence Iscar

in Japan and these companies serve mainly

manufactures tools and inserts from scratch,

that area just like Ingersoll serves customers

i.e. from raw materials to the finished product;

in Europe mainly. I would say roughly about

with the highest level of quality assurance.

level of competence and quality assurance

a third comes from the Asian market. As driver behind how well the heavy industries

What are your thoughts on the role of R&D in your company?

like the automotive sector, does. With that,

I believe that R&D is the thing that drives the

how things go in that market will determine

company and I would like to think that I am

how well our sales in the metal cutting and

still the force behind it, giving the direction

removal tools does, really. It is true to say

and vision to Iscar and the IMC Group. We

that with the current downturn of the global

are doing is investing up to six percent of

economy, the consumption of machine tools

our total revenue in R&D, which mind you,

Has the vision shifted from Stef (Wertheimer’s) to somewhat something of yours or has that ethos remained?

is down in that area.

is quite a sizeable portion dedicated to a

mentioned earlier, China is still the main

A Chat With Jacob Harpaz, CEO of Iscar & President of IMC Group

B u t h o w e v e r, w e a r e c o n s t a n t l y

single area. Initially, upon acquiring more

watching other markets and India, which

companies, they were replicating some of the

We have a very unique company culture and

previously was rather dormant , in my

existing tools so thus there was potentially

I had the pleasure of working very closely

opinion, it ha s awakened and we are

some duplication in our offering but because

with Stef and then his son Eitan, later on,

looking to explore that market more keenly.

I was overseeing the processes, I insisted

in different roles – from an engineer to

What goes on in the ASEAN region for the

that there be innovations so as to have

that of a sales manager and then serving

demand in cut ting tools, let ’s say the

useful differentiation amongst the different

with the executive management. Even after

automotive industry in Thailand – that is

offerings – it was a chance to step up and give

the sale to Warren Buffet, I can assure you

very much dependant on the major markets

more to our existing customers. Hence I would

that the original philosophy of the company

like China, India and Japan. So if it is slow in

like to say that we are always very aware of

remains the same. We are proud to say that

these major markets, then things do slow

the existing market offerings and with our

because of our very strong work culture, we

down in these markets too.

aggressive marketing strategy, we look to

have a very high percentage of people that

always be staying ahead of the competition.

honestly if you do ask them about the sale

What is considered as the top product among Iscar tools?

on what we put on the table to offer our

of the company, they would tell you that it

Machining intelligently is Iscar’s way of

customers. If you look around the industries

was work as usual.

thinking to promote new tool developments

that we serve, you will know that the people

for increased productivity. Our customers

there (in those industries) rely and trust

What are the future directions of cutting tools development, and what are the market expectations in the next two to three years?

know that they can rely on us as the

our brand. In return, I think it is our duty,

bottleneck opener of the metalworking

above and beyond just simply the money

industry. The many milestones that Iscar

to deliver a continuous, innovative product

has created over the past 40 years are

line to serve their needs. This would mean

The rapid increase of manufacturing in

legacies within their era, always just slightly

consistent cost reductions as the market

China and India is the main catalyst for US,

ahead of their time. Iscar’s renowned trade

conditions get more challenging and to always

European, and Japanese manufacturers to

names such as Self-Grip, Tang-Grip, Helimill,

try and stay ahead of their competition. You

search for more efficient production methods

TangMill, HeliTang, Multi-Master, ChamDrill

could say that in more than some senses

in order to compete with them. Iscar (the

and SumoCham paved the way for the new IQ

that we are our customers’ partner like an

IMC group) has given special attention to

products which were recently launched. Our

ongoing relationship. At our end, that thing

fast growing markets in the Far East and Asia

focus is to constantly reduce machining

alone keeps the sales robust and I would

by building modern production facilities in

costs, with the R&D team concentrating on

like to think that about half of our sales

those regions. This is in order to be close

tool developments characterized by more

are based on that goodwill that has been

to the customers and provide them with

complicated and accurate shapes. The

carefully cultivated over the years. Like you

the same quality of tools that we provide

new High QLine products such as Penta-IQ,

will always hear our product engineers and

our customers all around the world – with

Dove IQ Grip, Tang-Grip IQ, Heli IQMill 390,

sales managers say: our customers can and

dedicated sales and engineering personnel

and Dove IQ Turn can be applied to faster

will always know that we are reliable around

in each country. Iscar sees itself as being its

metalworking applications and have already

the clock to assist them with their problems,

own number one competitor and strives to

proven their ability to cut production costs.

eliminating as much downtime as possible.

have stayed for twenty years or more and

At the end of the day we pride ourselves

27

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

Photo Credits: Dürr Ecoclean

28

GETTING A

CLEAN EDGE

Competitive Advantages Through Cleanliness Hard material coatings improve the performance and service life of cutting and metalforming tools. However, these gains are contingent upon good coating adhesion to the substrate and this, in turn, is critically dependent on proper cleaning of the tools. By Doris Schulz.

R 4002

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educed tool costs, increased productivity, improved precision and extended maintenance inter vals – these are objectives which top the priorit y list of manufac turing companies today. The service life and production reliability of metalforming and cutting tools such as indexable inserts, drill bits and milling

cutters are key parameters for performance optimisation and hence, safeguarding the user’s competitive edge.

In order to minimise wear, tool s are often surface-coated with a hard material such as titanium, aluminium, zirconium, or diamond-like carbon (DLC). The coatings are deposited in the micron gauge range

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

To minimise wear, the surfaces of metalforming and cutting tools such as indexable inserts and drills are often coated with a hard material.

Proper coating needs an extremely clean surface.

by means of a PVD, PACVD or CVD process.

On a cutting tool, a hard material coating ensures a longer service life while reducing the formation of built-up edges. In the case of punching and metalforming dies it can reduce unwanted effects such as abrasive wear and cold welding.

A Ready-To-Coat Surface Standard Is Essential For the hard layer to deliver its beneficial effects, it is critical that the coating material is perfectly matched to the application and that the tool itself has a proper surface finish. Any particulate or film-forming residue is bound to degrade the coating-tosubstrate adhesion.

“In order to attain an adequate level of cleanliness in a cost-efficient and processreliable manner, one mus t consider the en t ir e t o o l mak in g p r o ce s s . O t h er w i s e , contaminants will be carried over through the manufacturing chain and can then be removed only through an intense effort at the final cleaning stage, or not at all,” comments Volker Lehmann, managing director of UCM AG. When Is Cleaning To Be Performed?

Tools such as indexable inserts, which are often made of hard metals, are ground upon leaving the sintering furnace. Grinding commonly involves the use of machining fluids, the residue of which must then be removed. “This is typically done with the aid of hydrocarbons, i.e., solvents which effectively remove nonpolar contaminants such as oils while exhibiting a good material compatibility,” Volker Lehmann explains.

Dürr Ecoclean’s product portfolio comprises solvent-based cleaning systems for this purpose which can be adapted to individual cleanliness, throughput and part geometry needs by selecting a suitable machine size, process technology, fluid treatment and drying system. One important factor is the system’s ability to handle the incoming oil loads, which may be substantial at times. The equipment must therefore have fluid treatment systems which ensure high degreasing performance of the solvent in multi-shift operation.

If the indexable inserts are polished as well, this operation must be followed by another cleaning step. This should be performed directly after the polishing cycle to prevent polishing paste residue from drying into a difficult to remove film on the part surface. The preferred solution here is a multi-chamber

Final cleaning before deposition of the coating is commonly performed in multi-chamber systems with the aid of ultrasound.

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Sufficient tool cleanliness requires a coherent design of the overall cleaning process, not just an individual machine.

In tool cleaning, solventbased systems are typically used downstream of grinding operations involving machining fluids.

system in which intermediate cleaning is performed with an aqueous medium.

The advantage is that parts can be run through the cleaning system immediately in a single layer so that the polishing paste will be fully removed without residue. A common subsequent step before coating is alumina blasting, i.e., surface finishing of the product using a fine-grained aluminium oxide.

Complete Development Of The Cleaning Process Next, the parts move on to the final cleaning stage which takes place in multi-chamber systems with the aid of ultrasound. The objective of this cleaning step, on the one hand, is to remove all residue from the part and to dry each product to a stain-free finish. On the other

hand, an aqueous cleaning process must always be designed to minimise the so-called cobalt leaching effect, i.e., the dissolution of cobalt from the hard metal. “Especially for the final cleaning operation, it will normally be necessary to develop an overall process in which aqueous media as well as parameters such as temperature, utilisation of ultrasound and treatment cycle times are perfectly matched to the parts being cleaned,�

Volker Lehmann notes. The associated cleaning trials are performed by UCM at its own Technology Center under production conditions. The frequent problem of part carrier marks being inflicted on indexable inserts during cleaning is also resolved at this stage.

At the equipment engineering level, a consistently high level of part cleanliness is ensured by the four-sided overflow developed by UCM. The cleaning or rinsing fluid enters each tank from below, then rises up and flows out over the rim on all sides. As a result, a permanent flow is generated in the tanks which ensure an intense treatment of each part.

At the same time, removed residue and particles are discharged from the tanks and filtered immediately so that no re-contamination will take place when the parts are lifted out or transferred. In order to obtain a stain-free surface, moisture is blown off the part before the actual drying cycle commences.

Thus, proper cleaning after each processing step is a key contributor to an optimised coating quality and can provide a competitive advantage to toolmakers and coating contractors.

ENQUIRY NO 085

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

Starrag

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GETTING THE

FINEST QUALITY S Haimer’s shrinking technology enriches machining centres with precision.

Contributed

by Wolfgang Klingauf.

Editorial

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tarrag’s machining centers has served the aerospace indus tr y for quite awhile now in providing supplies for machine engine component s such as turbine blades and blisks. Almost no other machine supplier understands the requirements in such detail as Starrag does and can offer turnkey solutions including the right software, clamping fixtures, tool holders and peripheral accessories from one single source. At the same time, it is very important for the Swiss company that external suppliers also provide the best quality possible. This is why they rely on the shrink fit chucks and shrink fit machines made by Haimer.

The company is mainly focused on the aerospace and energy industry and offers 5-axis machining centers capable of high metal removal rates in order to produce highly precise turbine blades, impellers, blisks and other structurally complex parts.

Since the beginning of the 20th century the aerospace industry has been the core mar ke t for machine to ol s pro duce d by the company. Even at that time they were able to distinguish themselves from other products and brands through their rigid and robust design and their high technological standard.

Therefore it is no surprise that in the 1960s the company was regarded as one of the pioneers in the area of 5-axis simultaneous machining. A know-how advantage that is clearly visible in their current high quality product portfolio which includes machine types such as the STC and BTP series for titanium machining. Furthermore, machining centres that are specialised in blisk cutting and the LX series are part of the portfolio and were especially designed for the highly precise, efficient and simultaneous 5-axis machining of turbine blades.

METAL CUTTING

Starrag

Asia Pacific Metalworking Equipment News • May - June 2016

Haimer

Haimer

As a long-time partner of the aircraft industry the Starrag Group has the necessary competence to come up with precise turnkey solutions for the production of turbine elements. One standard element of such complete systems is the Haimer shrinking technology.

Starrag uses Haimer power shrink chucks for demanding roughing and finishing processes.

Patrick Rutishauser (head of application eng ineering ) ex pl ains : “ Technolog ic ally speaking, our machines are of premium quality.

They are known for their high performance capacity and precision. Furthermore, we offer our customers additional value regarding the application.” Starrag considers itself to be a technology partner of its end users and is capable of designing and realising complete processes. “When a customer approaches us with a component he needs 10,000 pieces of, we design the complete system for him and supply the machine including sof tware, clamping fixtures, tool holders as well as peripheral components and machines.”

Such an additional offer is only possible after many decades of experience regarding the development of machine tools, CAM systems and special tools – and because of the application know-how which Starrag is able to acquire during the production of prototype and small series turbine blades. One area Mr Rutishauser is responsible for: “My tasks include technology and software development for so-called single blade applications. In my team, application engineers work hand in hand with CAM-Software developers. This way we can provide our endusers with exactly what they need without taking any detours or wasting time.”

Experiences From The Production Plant His co-workers are able to gain important experiences at the CPE (Center of Production Excellence), the Starrag application centre in Rorschacherberg, where they test and optimise demanding, and new machining processes. The hall which has a surface of about 2000 sq m is equipped with the new 4 and 5-axis Starrag machining centres. There, the application team is able to per form various applications ranging from heavy duty cutting of highly solid titanium alloy up to high speed cutting of light metal.

Mr Rutishauser emphasises: “We work on rotating parts, complex cubic work pieces, as well as free-formed flow surfaces – we do all of this under production conditions. We also produce prototype and small series for our customers. This entails developing a drawing and quality production at reasonable costs in the market.” This is certainly an advantage, as the application specialist suggests, because that way you acquire valuable knowledge about the machine requirements and you can find out more about the integral machining process right down to the smallest detail. “It is different from customer demonstrations where you usually overlook minor details,“ Rutishauser explains.

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In order to shrink tools Starrag has a Haimer power clamp NG (left) at its CPE and a power clamp premium. Both machines are equipped with a patented double coil which adapts itself to the length and diameter of the shrink fit chuck.

Because of the reinforced wall thickness in the clamping area and other constructive features the Haimer heavy duty shrink chucks are able to reach very high clamping forces and can be used for roughing processes with big tools.

The Importance Of Tool Handling Starrag has known for a long time that “tool holding” is a very important issue when it comes to high precision machining. After all, they were using a high speed spindle (30,000 rpm) at their headquarters in Rorschacherberg even 20 years ago. At that time, the cutting tools were usually clamped with Weldon or Whistle-Notch holders and collet chucks which, however, led to many problems because of the insufficient run-out accuracy they provide. At high rotational speeds even small deviations can lead to poor milling results, an inferior surface quality, as well as tool and spindle wear. Also the geometry of these tool holders has many interfering contours which make it impossible to reach deep cavities with minimally clamped tools.

Based on their testing of different tool holding systems, it was concluded that it was necessary to use shrink fit chucks, which due to their rotationally symmetric clamping body, have less inter fering contours and a high run-out accuracy. During the initial test s with the new clamping technolog y, Starrag had to overcome some weaknesses; at that time the chucks were heated up with hot air which was very time consuming and placed great strain on the material.

About 15 year s ago, in search of a solution, the Starrag specialists came across Haimer GmbH in Igenhausen who today is the European market leader in the area of tool holding technolog y. Mr Rutishauser emphasises: “Haimer professionalised the shrinking technolog y. Even back then the company offered a large selection of tool holders and a shrinking machine with an induc tive coil and cooling bodies which were very easy to handle for anybody. Until today Haimer has kept on further developing it s shrink ing technolog y – tool holder s and machines – and at the same time was always able to stay true to its high quality requirements. When it comes to shrinking technolog y we appreciate the possibility of clamping tool s with shor t projec tion lengths and of course the slim contours in comparison to other clamping systems.”

The Importance Of Details It is not without reason why the company

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

philosophy of Haimer is “Qualit y wins”.

Behind this concept there is the idea to only produce in the home town of Igenhausen near Augsburg in Bavaria, where the precision can be kept under control 100 percent of the time. There, all shrink fit chucks, even the standard ones, are made out of heat resistant steal and are f ine balanced (at G2. 5 at 25,000 rpm < 1 gmm unbalance).

The functional surfaces are machined and grounded extremely accurately and the taper tolerance is much more precise compared to the relative norm.

For spe cial machining re quiremen t s special shrink fit chucks are required. For e x ample , t he P o w er Shr ink C huc k s ar e suitable for 130 special high speed or high precision milling applications. The patented design combines a low tendency towards vibrations with a high rigidity and a slim design on top. This special construc tion m a ke s i t p o s s ib l e f o r t h e o p e r a t o r t o increase the cutting depth and the feed and thus reach a higher cutting volume while still maintaining a good surface quality.

The heav y dut y shrink chuck s are

especially designed for heav y machining with large cutting tools and they feature a reinforced wall thickness at the clamping area, a very rigid outer contour and patented expansion grooves in the clamping bore.

This way, high clamping forces which can be compared to those of milling chucks can be reached. The portfolio of shrink fit chucks is

Patrik Rutishauser, head of application engineering, is convinced of the Haimer shrink fit chucks and machines: “Haimer professionalised the shrinking process.”

ENQUIRY NO 050

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METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

strong cutting forces. At this point, a high runout accuracy and the balancing quality are of importance. The Haimer Power Shrink Chucks are ideally suited for both processes and if the cutting gets even tougher we simply switch to Heavy Duty Chucks.”

In terms of the shrink fit chuck quality the best is required for Starrag. This is due to the fact that during the roughing and finishing machining of titanium and other hard-tocut materials, the cutting forces can be very ag gressive on the inter face between the machine spindle and the tool holder.

“In the end, the key element is the part quality. It has to be perfect starting from the very beginning, because even the titanium blanks cost a small fortune. We are convinced that the tool holder quality is absolutely essential for the part quality,” Mr Rutishauser explains. This is especially true regarding the surface quality, which constitutes an important factor. This is due to the fact that the turbine blades need a very precise structure in order to be very energy efficient. Nowadays it is possible to get the desired structure through milling and without any additional regrinding.

High-end solutions for professional shrinking and cooling: the Haimer power clamp premium offers a spacious working area, easy handling and linear guided cooling bodies with temperature monitoring.

Starrag has the optional length pre-setting integrated into its machine.

Close to the shrinking station you can find the Haimer balancing machine tool dynamic preset, a combination solution to balance and measure tool holders and tools.

completed with the small Mini Shrink Chucks.

These are one-piece shrink fit chucks with an extremely slim design and a three-degree outer contour – designed for mould making.

Difficult Material, High Surface Requirements For Mr Rutishauser, this variety of shrink fit holder designs works as an advantage. He explains: “During the blade production made of extrusion profiles there are generally two procedures. First, it starts with a rough cutting process. During this process it is important that the chuck operates with a damping component in order to achieve a high cutting depth and feeds and to remove as much material as possible in one production stage. During the finishing process, however, there aren’t any

Ensuring Fast And Easy Tool Clamping In order to shrink tools, Starrag has a power clamp profi Plus NG in its CPE with which you can shrink all HSS and solid carbide tools with shank tolerance h6 and diameter 3mm up to 50mm within a matter of seconds. It is equipped with a patented double coil technology which means that the coil adapts itself to the length and diameter of the shrink fit chuck. During the shrinking process only the shrinking area is heated which reduces the heating and cooling time (via contact cooling) significantly.

In addition there is a high end solution for professional shrinking and cooling: a Power Clamp Premium machine that offers a spacious work surface, easy handling and linear guided cooling bodies with temperature monitoring.

The machine has an integrated length presetting – holding lengths exactly within 0.02 mm – since tools always have to be shrunk to a precisely defined overhang length.

“Haimer shrink fit chucks are part of our standard equipment, because they offer the best conditions for process reliable cutting which people expect from us,” Mr Rutishauser explains. “We don’t just use these products at our CPE, but we also sell them together with our own systems. Therefore it is important that the quality of the products always remains high.

With Haimer we feel secure. I can’t remember a single incident where a tool holder was the reason for a customer complaint.”

ENQUIRY NO 040

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METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

SETTING

NEW BENCHMARKS One of the most common tools found in the ATC stations of machining centres and multi-tasking machines is the light cutting shoulder mill. This is because, apart from shoulder milling being one of the most prevalent machining operation, the cutters are versatile enough to be used for face milling, slot milling, ramping and more. Contributed by Sandvik Coromant.

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T

he CoroMill 390 from Sandvik Coromant has for a long time been seen a s an ef fec tive square shoulder end mill, and now the company is extending this successful concept with the addition of the smaller 07 inser t size. This becomes the first choice for small diameter, light cutting applications on low powered

machines, where it offers impressive levels of versatility and productivity The objec tive for the design and development team wa s clear, to create an ex tremely versatile cutter for produc tive milling in a wide range of operations and materials. The solution had to offer troublefree, reliable milling per formance, as well as easy-to-use inser t clamping to increase process security. The result: CoroMill 390 tools with size 07 inserts, a product that has close synergies with two other innovations: the Coromant EH modular system and the new steel milling grade GC1130.

Inputs Through Market Research As with all innovations, each is designed to

METAL CUTTING Asia Pacific Metalworking Equipment News • May - June 2016

address genuine machining challenges highlighted through extensive market research and customer feedback. Mixed production machine shop face the daily uncer tainty of not knowing what jobs will come through the door next.

This scenario, with dif ferent components and materials, means that having an optimised tool for each component feature is unfeasible. Instead, a set of tools is required that allows machine shops to produce whatever component are needed.

Having the CoroMill 390 family of cutters, par ticularly with the ex tended 07 inser t size, can be the dif ference between being able to ser vice the needs of customers and having to turn down a new order due to lack of capability to produce the components.

The concept of “producing more with less”– an increasingly prevalent industr y trend – is facilitated further by multi-purpose end milling cutters capable of delivering top level per formance. Here, investing in the modular system Coromant EH when choosing the coupling type will result in optimised tool holding options with a limited inventory.

The coupling is self-centring and facilitates quick and accurate cut ter head exchange, which saves cost s in regard to eliminating the need for additional, dedicated tool assemblies. This is of course vital for shops using small machining centres with a limited number of stations in the ATC unit. Fur thermore, the shor t tool assembly of an integrated machine adapter and cutter head with Coromant EH coupling gives high productivity when the gauge line is critical.

Modular systems, which allow users to achieve the required reach and accessibility with a series of different shanks and adapters, will also help reduce the number of tool changes required. Fac tors such as these help ensure consistent prof itability, which is the bedrock of machine shop operations the world over.

Cylindrical shanks are a flexible solution suitable for numerous tool holding options.

On mult i-t a sk ing machine s , under sized shanks can be used in different leng ths and materials for stability and clearance when milling with long overhangs. The combined modularity of Coromant Capto and EH offers accessibility for hard-to-reach features. The versatility of CoroMill 390 is also favourable when the number of tool positions is limited on turning centres with driven tool holders.

Of course, there is a common viewpoint that versatile tools are good at many things but not great at specif ic operations. Aware

The cutters have been designed as the ideal choice for mixed production, as well as when a square shoulder end mill for a specific component feature is required.

The solution had to offer trouble-free, reliable milling performance, as well as easy-to-use insert clamping to increase process security.

of this, the company set about ref ining the per formance of the new CoroMill 390 end mills to ensure they achieve the highest levels in many dif ferent machining tasks.

The cut ter s have been designed a s t he ideal choice for mixed production, as well as when a square shoulder end mill for a specif ic component feature is required.

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METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

Having the CoroMill 390 family of cutters, particularly with the extended 07 insert size, can be the difference between being able to service the needs of customers and having to turn down a new order due to lack of capability to produce the components.

The coupling is self-centring and facilitates quick and accurate cutter head exchange, which saves costs in regard to eliminating the need for additional, dedicated tool assemblies.

When it comes to face milling, the goal for machine shops is usually high metal removal rates with good surface finish â&#x20AC;&#x201C; an ambitious combination that is not easy to achieve.

The cutters have been designed as the ideal choice for mixed production, as well as when a square shoulder end mill for a specific component feature is required.

Elevated Performance Levels So, what technical features underpin such elevated per formance levels? Well, f irstly the end mill cutter bodies are produced in a new material with increased heat resistance. Secondly, par t s of the range have been optimised with dif ferential pitch for applications that are par ticularly prone to vibration.

Process security also featured highly on the agenda when developing CoroMill 390 inser ts. With this in mind, the light cutting geometries and high performance grades of this cutter concept are designed to give secure milling in all material groups. For steel milling, the new f irst choice inser t grade is GC1130, which is produced with technolog y known as Zer tivo. The grade of fers a new level of process securit y thank s to long and predictable tool life with a clean and intact edge.

The objective for modern machine shops is to deliver secure milling in operations

such as pocket milling, where one of the major challenges is ensuring the ef f icient and secure opening of cavities. Here, the t ypical solution would be to use helical interpolation and linear ramping to create pocket s from a solid workpiece, but this requires strong inser t face geometr y. As a consequence, inser ts that can adhere the stress caused by steep ramping or demanding interpolation, giving a low vibration process with even tool life are required.

In shoulder milling operations, closetolerance inser t s and an exac t inser t position help produce shoulders without steps. The smooth cutting action of inser t limits radial cutting forces which provides machining with minimal bending and good wall perpendicularity.

Slot milling offers a set of different challenges, typically centred on chip evacuation and vibration. Indeed, these issues are exacerbated when milling with large engagements as vibration of ten accelerates tool wear. Here, light cutting geometr y in combination with a cutter featuring optimised differential pitch can take care of this issue and of fer a low vibration milling process.

METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

In a cus tomer example involving slot milling, a subcontractorâ&#x20AC;&#x2122;s productivity was limited by it s end mill as the two-inser t cutter could only manage a cutting depth of two millimetres. However, when switching to a CoroMill 390 cutter with three size 07 inser ts, the cutting depth was increased to three millimetres. Fur thermore, cutting speed could be increased by 33 percent, and spindle feed speed by 50 percent. The upshot was a gain in productivity equal to 225 percent. As a bonus, the burr formation caused by the previous tool was nowhere to be seen when milling with the new cutter.

For key slot milling , specif ically, the CoroMill 390 cutter with size 07 inser ts is available in dimensions designed purposely for key slots. With a tool diameter 0.3 mm smaller t han t he slot wid t h, a sui t able amount of stock is lef t for the subsequent f inishing operation.

When it comes to face milling, the goal for machine shops is usually high metal removal rates with good sur face f inish â&#x20AC;&#x201C; an ambitious combination that is not easy to achieve. For this reason the company has

designed geometries for milling with low cutting forces, which prove ideal for facing sur faces that demand a shiny f inish and close tolerances.

Process Security To further improve process security in all types of milling operations, a new torque key is delivered with each cutter. Its built-in spring functionality makes it easy to mount inserts with correct clamping force, giving reliable and consistent tool life. Maintaining the process security theme, the cutters also offer internal coolant in operations where chips tend to get stuck, for example slots, and for machining of materials where elevated temperatures are undesirable.

In short, the insert is equipped with size 07 inserts for small diameters offers capability that is ideally matched to component features that have a cutting depth of up to 5.8 mm. The smaller inserts deliver higher cutterteeth density, giving superior output in many different milling operations. In combination with the new steel milling grade GC1130, productivity can be optimised.

To further improve process security in all types of milling operations, a new torque key is delivered with each cutter.

ENQUIRY NO 067

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GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • May - June 2016

Press Shop Automation:

Headed For

NEW FRONTIERS Thanks to solid experience in the automotive sector and in-depth knowledge of OEM and Tier One manufacturers’ production dynamics, Comau offers robotised solutions for dedicated sheet pressing lines which fully satisfy, and often anticipate, market trends and requirements. By Marina Zussino.

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GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • May - June 2016

The Comau NJ110-3.0 and NJ130-3.7 Press Boosters are the “special version” of the robots in the NJ family, designed and created specifically to interlock press-to-press systems.

M

eeting the needs of the market, not only by interpreting them, but by anticipating its requirement s and trends . This is the linchpin of Comau’s sales strateg y in the area of robotised press-to-press solutions for the Automotive sector. A way of working that the Turin-based multinational, now par t of the FCA group, achieves thanks to long-standing experience in the automotive sector and in industrial press line automation for sheet pressing processes intended for major vehicle manufacturers and Tier Ones. Comau’s know-how is so well established that it can design and install automatic robotised systems in press shops, complete with turnkey systems, in any par t of the world.

T hi s e x p er t i s e i s al s o e x pr e s s e d in the form of the manufac turing centre of excellence in Poland, where the next generations of dedicated industrial robots are conceived and designed, with ever greater per formance, as well as new solutions for automating and optimising lines.

Standardising To Optimise “Thanks to the opening of a centre of excellence based in Tychy, Poland, Comau develops robotised press interlocking solutions able to guarantee maximum technical and operational performance for any client in any country,”

declares Roberto Dudda, press line automation segment manager at Comau. “The Comau Poland plant designs and creates complete press-to-press systems, all internally, with robotised solutions and accessories for the most complete lines possible, thus making them more productive and efficient.”

The guarantee provided by a dedicated specialist centre is the competitive advantage required to bring the market a range of s tandardised produc t s, which can be adapted to the operating requirements of any company, without necessitating a new design studio per client, with resulting – and net – decrease in system production cos t s and simplif ied ins t allation of the lines: “A considerable value added for an application sector such as press interlocking lines for sheet pressing, where it’s often the demand for ever shor ter star t-up times that makes the dif ference.”

The Right Product For The Market “Comau benef its from solid, long-standing experience in the sector of cold sheet forming for the automotive sector,” explains Mr Dudda. “The high productivity of the pressto-press lines is also ensured by the use of anthropomorphic robots. This is how we offer the market special machines with ever great per formance.

In contrast to standard robot versions,

The guarantee provided by a dedicated specialist centre is the competitive advantage required to bring the market a range of standardised products.

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Their capacity can be as high as 130 kg, with wrist torque of up to 125 kgm and a reach of up to 3,700 mm, suitable for operation even in ver y large spaces between presses: “In automated pressing lines, it’s impor t ant to have a manipulator robot that minimises the press interlocking time, thus ensuring that optimal line rhy thm is achieved. Reducing the c ycle times permits boosted system per formance, making them more productive. The Press Booster robot s are charac terised by light yet robust mechanics, with a 30 percent weight reduction compared to the previous models.

So they’re more flexible and ensure lower energ y consumption,” Mr Dudda explains.

Thanks to the new process simulate software, it is possible to simulate Comau robotised solutions in 3D.

Press-topress system operators frequently have to manage the movement of heavy sheet metal pieces at a rapid pace at end of line.

the specific press booster models for these applications guarantee a good rhy thm of production, efficient press interlocking and better execution of all in-line operations that require great flexibility and a high degree of precision in operation, such as sheet picking, sheet centring, washing, storing the f inished pieces and so on.”

The Comau NJ110-3.0 and NJ130-3.7 Press Boosters are the “special version” of the robots in the NJ family, designed and created specifically to interlock press-to-press systems. These machines are characterised by dedicated on-board equipment, 600 V ventilated motors, controlled by digit al drives, and special reduction gears on some spindles. They guarantee high-speed operation, achieving a rhy thm of up to 16 pieces per minute for the line.

Intuitive Software The Key In creating press-to-press systems for sheet pressing, the company can also take pride in making a dedicated software application available, SMART IP, capable of optimising workflow on operating lines. It can be used to calculate the robots’ cycle times, as well as synchronise their operation with that of the presses flawlessly. The result?

Interlocking and piece loading/unloading operations which are ever more ef f icient and feature a better rhy thm of production.

“Thanks to this specif ic sof tware, developed for press line management, we can optimise the productivity of the systems, and make the work easier for operators at the same time,” clarif ies Mr Dudda. “Smar t IP has simplif ied programming modes, permitting the correct operation of the line to be monitored, as well as instant display of it s produc tivit y. Las tly, it check s the operation of the interlocking robot s and promptly advises operators of any anomalies in the process, thus avoiding production stand-by.”

Also, thanks to the new process simulate sof tware, it is possible to simulate Comau robotised solutions in 3D. This application simplif ies the planning for the layout of a complete line, simulating its arrangement and operation with great precision. On the basis of the client’s specif ic requirements, process simulate permits fur ther improvement to the line’s rhy thm, optimising the layout of presses, robots and equipment.

Automatic Racking Optimises Processes Press-to-press system operators frequently have to manage the movement of heav y sheet metal pieces at a rapid pace at end of line. To make automatic pressing lines more efficient and safe, Comau offers the market

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • May - June 2016

ENQUIRY NO 082

In practice, the sheets of metal come out of an oven at 950 deg C approximately, are picked and positioned in the press for the drawing phase and simultaneously cooled using moulds with a water circuit that lowers the temperature of the sheet to 250 deg C. automatic racking solutions in which the storage of the processed material in dedicated containers at end of line is managed by several anthropomorphic robots with no human assistance.

“Automatic unloading systems permit companies to facilitate and optimise the entire flow of production on the lines. The use of anthropomorphic robots, flexible and precise, in the end-of-line racking stations and with the assistance of inspection systems has considerable advantages.

They permit the movement of elements of dif ferent sizes in dedicated containers and simple handling of finished pieces, steel or aluminium, of different weights and dimensions. They also mean that more precise and satisfac tor y positioning of component s in the storage containers can be guaranteed, arranging them in such a way that they’re ready to be sent directly to the welding line for the following stages of processing,” Mr Dudda says.

Designed For Hot Forming The automotive market increasingly adopts new materials capable of ensuring the production of stronger and lighter structural components for motor vehicles.

This specif ic aspec t means that companies have to develop and adopt new industrial pressing processes: “The market is requesting a reduction in motor vehicle weights. This demand has led to the use of new materials to make specif ic structural vehicle par ts. Boron steel, for example, can guarantee better mechanical proper ties than those of the raw materials commonly used in the automotive industr y. On the other hand, it requires particular pressing processes, called hot forming,” says mr Dudda In practice, the sheets of metal come out of an oven at 950 deg C approximately, are picked and positioned in the press for the drawing phase and simultaneously cooled using moulds with a water circuit that lowers the temperature of the sheet to 250 deg C. “This particular, sudden reduc tion in temperature let s us press and harden the sheet, making it more resistant and rigid than a component made using conventional steel with greater thickness and weight, but results in the need for dedicated pressing lines.”

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We are the technology leader in metal sawing machines and storage systems. As your competent partner, we create additional value that can clearly be seen.

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Saws. Storage. And More.

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Presses usually have a long operating life, so it’s often possible in the automotive sector to optimise old or unused lines to provide them with new roles.

The latest trend in the hot-forming sector is the use of electric multi-ovens with several levels, instead of gas ovens, with a single tunnel oven. The former are compact, can be stacked on top of one another and managed individually, permit ting a considerable saving in terms of energ y and space, and allow the creation of a more eff icient line layout. Gas ovens, on the other hand, require more ser vicing and constant maintenance of the temperature, even when not in use.

Retrofitting: Making The Difference Comau’s consolidated know-how in pressshop automation applications can also be seen in the series of ser vices that it of fers, enabling clients to make their production lines more ef f icient. “Many clients request automation for press lines that are already in operation, to readapt and make complete with robotised solutions that make them more ef f icient,” explains Mr Dudda again.

“For this reason, Comau of fers the market dedicated retrof it ting ser vices, which it provides independently or in par tnership with other companies.”

Presses usually have a long operating life, so it’s of ten possible in the automotive sector to optimise old or unused lines to provide them with new roles . This is achieved through the addition of anthropomorphic robots and industrial automation solutions that make the production procedure more ef f icient.

“Restyling and the enhancement of existing pressing lines, with the introduction of automation systems, permits optimised system processing times, with a distinctly rapid return on investment,” concludes Mr Dudda. In this respect, a retrof it operation on an old manual pressing line that was carried out at a company in Turkey is signif icant.

Thanks to the adoption of Press Booster anthropomorphic robots and an automatic mould switching system, it was possible to increase the pace of production from four par t s per minute to 12 par t s per minute, boost the reliability of the line and reduce the time necessar y to change the mould on the presses at each change in production from an hour to just 15 minutes. This resulted in more flexible production, with an improved rhy thm, on batches with a lower volume. It was also a change that resulted in lower production costs however, due to the use of fewer machine operators, and the elimination of a second old manual line, sold to a third par ty.

Smart Press Booster: A Special Range NJ 100 3.2, which can bear a load of 100 kg at the wrist and has a reach of 3.2 metres, featuring special reduction gears that make it a faster robot than the standard models and NJ 130 3.7, which can also be fitted in a shelf version.

The high productivity of the Comau lines is also ensured by the use of dedicated Press Booster robots. Two models are currently available on the market, though new extensions to the range are currently at the design stage: NJ 100 3.2, which can bear a load of 100 kilograms at the wrist and has a reach of 3.2 metres, featuring special reduction gears that make it a faster robot than the standard models and NJ 130 3.7, which can also be fitted in a shelf version. All Comau press boosters are characterised by a light yet robust mechanical structure, high structural rigidity and the possibility of fitting a vast range of accessories to boost their operating performance still further.

Thanks to a seventh motorised spindle – Flexifeeder – the robot’s flange can move directly over the piece to be moved, guaranteeing fast, stable transfer even with large components. The increased flexibility obtained thanks to the use of an additional axis permits optimised robotic motion, speeding up the transfer of the piece from one press to the next. Last but not least, it allows the planning of a more compact line layout, with a further decrease in cycle times.

ENQUIRY NO 016

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IN DESIGN Asia Pacific Metalworking Equipment News • May - June 2016

Creating multiple copies of a document is a common practice when using a file based approach.

However, by implementing the Cloud, it does not have to be that way. By John McEleney, CEO, Onshape.

Editorial

Got a Question?

Make An Enquiry.

ENQUIRY NUMBER

4201

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

Are You Unintentionally

LEAKING YOUR INTELLECTUAL PROPERTY?

A

re copies of your propriet ar y designs on multiple computers in multiple locations – with partners, manufac turers, vendors and supplier s? D o you have an inad ver ten t leakage problem without even knowing it?

Odds are ex tremely high that both your answers are a screaming “YES!” A s John Rousseau, who leads the operations team at Onshape, puts it, here is one scenario where you could confidently say you have no security problem: “Keeping your data on a desktop machine in a physically secure room with no network connection, no other users, and no other

software (except a traditional CAD package) would be very secure,” he writes. “However, it is also not very realistic, and it is not the way most CAD users work today.”

The way the mos t securit y-sav v y companies control data today is they put physical fences around their of f ices and virtual fences with firewalls and other cybersafeguards. So how do people communicate and share proprietar y information inside their company and with outside partners and suppliers?

The Way Engineers Share Work Today All of the existing CAD systems today are file-

IN DESIGN Asia Pacific Metalworking Equipment News • May - June 2016

based systems. Here are the most common ways that CAD users share things right now: •

Email files

•

Put them in elaborate Product Data Management (PDM) systems, which require CAD users to check out files from “the vault”

•

Put them on an FTP site

•

Use a storage service like Dropbox or Google Drive

Let us look at what happens with email.

First of all, email is not so secure because it is going over the public Internet. So I send my supplier a part for them to make a mold for that part. When the supplier gets my message in their inbox, I have no idea if their security protocols match my security protocols. They may not have the same firewalls as I do. So I have no idea how easily somebody can hack into their system and access their email.

So your of f ice may follow ver y tight practices and be at the forefront of data security – but your partners may not be. Now that you have emailed them, they have a copy of your design in their email server (Copy 1). You literally have no idea what they have done with that file. They may simply download it to their local computer (Copy 2). Or they may forward it to another one of their email accounts (Copy 3). Maybe they send it off to another computer or co-worker (Copy 4). Or they may copy it over on a thumb drive (Copy 5) to bring home.

Your 3D CAD model already has five clones and it is not even time for lunch yet.

Copies of your IP multiply like rabbits and once they are out in the wild, you have no idea where they live or who has access to them. You have no way to trace what happened to your intellectual property.

These same unintended scenarios play out no matter whether you use email, an FTP site, PDM or Dropbox. It is not the email’s fault or Dropbox’s fault. It is much more of a function of you using a file-based approach – anytime you share, it means copies, copies, copies – versus a database-driven approach.

A CAD System That Makes No Copies Let us contrast this chaos with how a modern CAD system should work. Let us say your data resides in the cloud under your control. You can share that information to any number of people, but you can assign different levels of

Everytime you share a traditional CAD file, you inadvertently create uncontrolled copies of your IP.

When you are done working together on a project, you can remove any of those permissions.

privilege rights. You can allow people just to view it. Or view and comment, or you can give them full editing rights.

When you are done working together on a project, you can remove any of those permissions. You cannot do that when you send an email. The only thing you can do is say, “Please delete the file.” Guess what? They might say, “Yeah, I deleted it,” but maybe they still have a copy that they did not even realise.

Copies also create version control problems.

Perhaps you have even experienced this when collaborating on a Word document with a coworker. You are emailing versions back and forth and you keep renaming the files so you know which one is the latest version. Within no time, your desktop may look like a clutter of the same document in different versions.

In the word processing world, Google solved the version control problem with Google Docs, allowing everyone to instantly access the latest version without muddling through pas t editions – all while neatly archiving every incremental change.

Onshape does the same thing for the design process. Because your CAD system and your CAD data live in the same central place in the cloud, you will always only have one version of the truth. And controlling who has access to that truth dramatically increases the odds that your company secrets will stay secrets.

In the word processing world, Google solved the version control problem with Google Docs, allowing everyone to instantly access the latest version without muddling through past editions.

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LOOKING BEYOND THE TECH Exploring new approaches which help tool shops minimise pains which technology alone cannot help alleviate.

Editorial

Article adapted from the whitepaper Tool Shop Optimisation: Why Technology is Not Enough by Cimatron Tech.

Got a Question?

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ENQUIRY NUMBER

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L

ike many manufacturing sectors, the tooling industry continues to experience mounting global competition, placing ongoing business and operational challenges on tool shops across the industry.

Those that thought these challenges were temporary in nature have either gone out of business or realised that “change is here to stay.”

According to a survey conducted by CIMdata, delivery, quality, and cost are the top three challenges facing tooling companies, according to, an industry research firm. These findings prompted Cimatron, a provider of CAD/CAM solutions to establish a task force to dig deeper into the causes and identify new approaches

that would help tool shops eliminate or minimise these pains.

This is work-in-process just like any practical framework. It is continuously used and honed as more tool shops are engaging in this effort.

The Usual Issues Faced In talking with tool shop executives, it became apparent that many do not take the time to analyse their business processes. Working in a highly competitive environment, firefighting has become the standard mode of operations at most shops. When faced with a challenge, the common reaction is to grab for the most immediate solution – be it purchasing a new machine, extending business hours, outsourcing, or adding a new, detached software solution.

As a result, many of these solutions fail to address the root causes of the problem at hand.

More than 50 percent of tool shops polled in the CIMdata survey indicated that their first priority was to implement advanced technology. The Cimatron analysis revealed that many of these implementations failed to solve the problems for which they were acquired, as the following examples show: •

Facing the need to expedite delivery times, a tool shop invested a significant amount of money to purchase additional machines.

While the investment helped speed up machining, it created new bottlenecks

IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

This is work-inprocess just like any practical framework.

throughout the process and ultimately fell short of reducing overall delivery times. â&#x20AC;˘

Another tool shop that had trouble meeting delivery times began outsourcing their design work. Not only did the outsourcing increase their cost, the need for greater communication between parties negated any improvement in delivery times.

Investment in technology alone failed to delivery the expected results. It became clear that tool shops needed to look for other ways to improve operational results and examine the entire business processes.

Tool Shop Optimisation The starting point in any improvement is a clear understanding of the business goals. In its analysis process, the Cimatron team has come across a set of goals that have been close to universal across the companies interviewed: increase productivity, shorten delivery times, reduce costs, and increase customer satisfaction as well as employee motivation.

The more dif f icult ques tion was how to get there. To help tool shops with this undertaking, the company developed an eightstep methodology: 1. Identify the best process and flow: All too often, companies invest in new technology or software, but oftentimes this merely moves bottlenecks from one area to another or creates other burdens in translation, as seen in the case studies above. The first step is to establish a streamlined process that covers all deliverables and milestones â&#x20AC;&#x201C; from the initial price quote to the finished product.

Inputs and outputs for each step in the

process must be clearly identified, along with quality expectations and the value added to the finished product. Only once the entire process has been laid out can specific technologies and methods be considered for individual tasks; these would be evaluated based on their impact on the entire process, not just the task at hand.

2. S t r e a m l i n e i n t e r n a l a n d e x t e r n a l communications: Direct data transfer with the customer and among the design team, shop floor and purchasing not only saves time by minimising the need for multiple data translations, it also increases data reliability, reduces errors and repeat work and minimises engineering changes.

To get started, minimise the use of printed documents, with the eventual goal of operating as a paperless company.

3. Implement 3D design and manufacturing: Striving towards concurrent processes, implementation of 3D data minimises downtime and eliminates the level of redundancy caused by manually entering

Facing the need to expedite delivery times, a tool shop invested a significant amount of money to purchase additional machines.

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include a contingency plan for unplanned events such as fluctuations in the shop’s workload. To shield customers from any negative impact during the implementation, maintaining and even improving delivery times throughout the transition should be a priority.

6. Acknowledge the cost of change: The cost of change must also be acknowledged and quantif ied: What will be the loss of produc tivity during the initial implementation? When is it gained back?

At what point does productivity surpass previous levels through the optimisation?

The starting point in any improvement is a clear understanding of the business goals.

7. Get buy-in: The optimisation plan results in a more streamlined operational approach, usually with fewer steps in the tool making process. Resistance to change is natural, so getting all parties involved in the process early on is crucial to its success.

Direct data transfer with the customer and among the design team, shop floor and purchasing increases data reliability, reduces errors and repeat work and minimises engineering changes.

8. Measure results: Measuring success is an important part of the optimisation process.

Using this approach, the company has been able to help tool shops achieve tangible and measurable results, with over 30 percent increase in productivity and up to 50 percent design cost reduction.

The cost of change must also be acknowledged and quantified.

data into the machines, as is the case with 2D design work.

4. Re-examine outsourcing: Including your out sourced ac tivities in your process design may reveal opportunities to bring work back in-house and reduce costs, eliminate communication obstacles, and speed up delivery times in order to be more competitive.

If certain activities must be outsourced, focus on improving the communication process with these partners and better integrating them into the overall process.

5. Plan for success: A solid implementation plan is the key to the success of the entire process. The implementation plan should consider all factors and constraints and

Case Study I: PTA Corporation With facilities in Connecticut and Colorado, PTA is in plastic injection moulding, providing a set of services from design to tooling, manufacturing, and assembly. The company has always been known for speed-to-market; nonetheless, to maintain its leadership position, it has had to adapt to changes in customer demands, including lead-time reduction.

Until recently, the company was using different applications for each department, forcing extensive need for translating geometry back and forth between different platforms, which made the process very time-consuming and non-cohesive.

Implementing a unified process and software platform across different departments and offices has enhanced PTA’s design capabilities and improved overall communications. With everything done in the same software – design, NC, and electrodes – operations are streamlined, resulting in shorter delivery time.

In addition to improving communication between departments, the company has also improved their external communications. They are able to work more efficiently with their customers in the design process and provide them with better feedback.

IN DESIGN Asia Pacific Metalworking Equipment News • May - June 2016

Quoting is another area that PTA identified for process improvement. The company’s project managers simulate a split of how a part will fit into the tool to analyse drafts before going to the designers.

Working on a recent project provided a concrete example of how valuable 3D capabilities are. The project comprised a package of over 20 tools. The majority of parts were overmoulded, building one mould for a solid substrate and another to overmould an elastomer on top of that substrate.

Working in solids provides 3D visualisations, which helped the mould makers plan out their job much faster than they were able to in the past.

Case Study II: Cam Tool And Engineering Cam Tool & Engineering is a small tool and die shop facing increased competition from larger tool shops and overseas manufacturers. The company knew that in order to remain successful, they would have to remove all bottlenecks from their operations by streamlining their processes and employing the latest technologies.

The company launched an effort to improve operations in his shop. Both the equipment and

software, including a Makino vertical machining centre and the CimatronE software solution.

These new capabilities have enabled Cam Tool to operate more efficiently. For example, a job which previously required 90 percent burning could be done without any electrodes — everything was cut — generating time and cost savings.

Similar process improvements have been realised on the design side, where a project that took 177 hours now takes about 55 hours to complete. These savings translate to faster deliver y times that give the company an advantage over overseas manufacturers.

Streamlining the entire process, which owner Craig Mog refers to as “Screen to Machine” brings Cam Tool additional benefits. The ability to read customers’ files and do the design, NC and electrodes all within the same software means there is nothing lost in translation, which makes the entire process efficient and cost effective.

As a result, the company has reduced the number of steps involved in their tool making processes, allowing them to cut costs and reduce delivery times while improving accuracy and expanding their product offerings.

These savings translate to faster delivery times that give the company an advantage over overseas manufacturers.

ENQUIRY NO 045

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Moving Concepts

These days CAD/CAM is an integral part of metalworking in all sectors and companies are constantly staying one step ahead of the game.

Editorial

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FORWARD P opul ar and e x t en si vel y u s e d in automotive and aerospace industry, Computer-Aided Design (C AD) has gained not just economic importance, but also opened the door for more computerised solutions into the manufacturing industries.

The program is used to present important information like dimensions and tolerances found in engineering or technical drawings.

Able to display in 2D and more recently 3D format, the technology is moving forward to reflect the advancements of today.

In the manufacturing spectrum, efficiency and productivity are of utmost importance. This gives rise to the need for a computer based tool that helps engineers and machinists alike to manufacture parts.

Computer-Aided Manufac turing (C AM) frequently incorporates CAD into the manufacturing process in order to create a faster, more precise and consistent production process. Benefits like waste minimisation and energy conservation are often synonymous with the usage of CAM. Collectively, CAD/CAM can be classified as computer-aided technologies. Often used in the context of a software tool covering a number of engineering functions, they can further evolve into many different aspects of product lifecycle management, including design and analysis using finite element analysis.

Getting The Edge In Metalworking The recent advances in metalworking are aplen t y. From CNC s y s tem s in machine tools to orbital drilling in composite, many innovations have been applied to satisfy the stringent requirements. In order to sustain these initiatives, much attention must surely be put on the design and manufacturing of these products.

Seen as an integrated operation these days, the usage of CAD/CAM enables manufacturing processes to be considered at the product design stage. Analysis of design data is allowed.

As such, the designer can assess a design through different angles and explore different possibilities and make better predictions.

For instance in sheet metalworking, 3D CAD has been applied as it is important to understand the parameters for the unfolding process. Programs can help in producing a more accurate part as parameters like bend allowances and geometr y are taken into consideration.

Apart from improving accuracy, transfer of information is also easy â&#x20AC;&#x201C; they are received through network, and NC data are produced from that to supply to working machine.

Importing drawing files directly into software can both save time and reduce cost s. In addition, data can be stored in digitalised form.

IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

Innovate & Improving Complexities Through Accuracy The accurac y and complexit y of modern par t s have placed added s train on manufac turers and designers alike.

With such great expec t ations come the integration of C AD/C AM into mainstream manufacturing and design processes. Not only that, improvements have to be made on this particular front so perhaps it is of no surprise that CAD/CAM solutions providers are all operating in full swing, coming up with various programs to complement the existing range of products.

There are providers of integrated CAD/ CAM solutions for mould, tool and die makers as well as manufacturers of discrete parts, like Cimatron.

Its integrated solutions allow design and NC programming to take place in the same environment eliminating the need for data translation, preventing errors and saving time was ted trans ferring f iles from one application to another.

Elsewhere there are companies that do feature-based machining sof t ware. That includes enhancements from 2D drilling and wire EDM, to five-axis milling and mill-turn operations.

Automation within the program gives faster programming than other CAM systems.

These developments are support for multithreading when generating 3D toolpaths.

They allow calculations to be spread across multiple cores in dual- or quad-core computers. Average time savings are around 25 percent on a dual-core PC. Improved algorithms have been introduced within the user interface to speed up the editing of features and to reduce the time needed to switch between machinetool set-ups, while more efficient handling of stock models will reduce the memor y required, so as to improve performance.

Fur ther development yields a programming option that combines drilling and milling functionality that will allow more efficient hole creation on machines fitted with automatic tool changing. It generates roughing and finishing toolpaths to produce any holes for which the appropriate drill is not loaded, using the existing tooling within the machineâ&#x20AC;&#x2122;s crib.

It is evident that advances in this field can directly affect the people on the ground.

Companies that do not have automatic tool changing on their machines will benefit from this improvement. In some cases, it will be possible to use a combination of drilling and

In the manufacturing spectrum, efficiency and productivity are of utmost importance.

From CNC systems in machine tools to orbital drilling in composite, many innovations have been applied to satisfy the stringent requirements.

milling with a single cutter to generate all the holes in the part. This could then allow the complete sequence to be run without the machine needing to be manned.

Other options include a spiral finishing opt ion t hat g ives f a s ter machining and impr o v e d s ur f ace f ini s h w i t h no d w ell mar k s , and au tomat ic re s t roug hing to minimise air cutting when applying a series of progressively smaller roughing cutters.

In addition, a 3D chamfer can be added to a part, even when this is not shown in the model, for de-burring and similar clean-up operations.

Fa s ter machining and bet ter sur face finish are possible now. The product has the same ability to redistribute the points within any toolpath to enable fas ter, smoother machining. Similarly, the program can now under t ake tool-a xis smoothing to avoid sudden changes in orientation of the cutter during five-axis machining.

Other options include a spiral finishing option that gives faster machining and improved surface finish with no dwell marks, and automatic rest roughing to minimise air cutting when applying a series of progressivelysmaller roughing cutters.

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Improved algorithms have been introduced within the user interface to speed up the editing of features and to reduce the time needed to switch between machine-tool set-ups.

The accuracy and complexity of modern parts have placed added strain on manufacturers and designers alike.

Visual programming enhancements include visualisation of specific move paths before and after a selected feature, visualisation and animation of the machine’s working volume within the model view, and translucent clearance plane visualisation.

Machining simulation has also been made faster and more accurate, in particular for simultaneous five-axis machining. In addition, a dual-view option allows a part to be viewed from two-different angles simultaneously.

This is helpful when simulating the production of large or complex parts.

The Stuff That Inspects The advances in CAD/CAM is not contained in production, it is also present in inspection as well. There are companies that have CAD products that allow feature measurement/ inspec tion and C AD-to-par t comparison.

Comparisons of measured par t s to engineering design files are possible.

Advancements in technology allow multi-

par t inspection, including large f iles. The engine link s multiple measurement f iles to a single C AD f ile, instead of each f ile containing the entire CAD par t data. The handling capability also enables the users to deal with entire CAD files, rather than slice them up into separate sections.

Staying on inspection there are products t ha t ar e u s e d pr imar il y on au t oma t e d coordinate measuring machines. A feature is “protected mode execution”, a “run-only” mode with password protection against all editing or changing of the program or reports.

This mode is useful for companies that have a library of programs and wishes for operators to run them and interac t with them without being allowed to alter them in any way. This is of particular relevance for companies with medical cer tif ication requirements, such as FDA. Visual programming enhancement s in c lu d e v i s ual i s a t io n o f s p e c i f ic m o v e paths before and after a selected feature, visualisation and animation of the machine’s working volume within the model view, and translucent clearance plane visualisation.

Additionally the grid view is expanded to allow point s to be def ined at any cross section automatically.

A d v an ce s al s o co m e in t h e f o r m o f measurement capabilities for non-contact 3D laser probes. They include the display of laser stripes, measured features, and measured point s. A laser hole and cone auto-feature measurement are also added.

From design to manufacture and finally to inspection, the advances in CAD/CAM is already here and it is safe to say the future will only get brighter.

The 12th International Manufacturing Machinery, Factory andManufacturing Supplies Exhibition The 12thEquipment International Machinery, Factory Equipment and Supplies Exhibition

3 - 6 August 2016 3 - 6 August 2016 Grand City Convention & Exhibition Centre . Surabaya . Indonesia Grand City Convention & Exhibition Centre . Surabaya . Indonesia

With the support of...

With the support of...

Association of Metalworked and Machinery

Indonesian Automotive Parts & Componenst Industries Association

Indonesian Machine Tool Industries Association

Federation of Indonesia Metalworks & Machinery Industries Association

Indonesian Mould & Dies Industry Association

Association of Metalworked and Machinery

Indonesian Automotive Parts & Componenst Industries Association

Indonesian Machine Tool Industries Association

Federation of Indonesia Metalworks & Machinery Industries Association

Indonesian Mould & Dies Industry Association

For further information please contact the office closest to you: For further information please contact you: Maysia Stephanie Carolyn Leethe office closest to Leonie Brooker

PT. Pamerindo Indonesia International Expo Management Pte Ltd Maysia Stephanie Carolyn Jakarta, Indonesia Singapore Lee PT. Indonesia International Tel: Pamerindo +62 (0) 21 2525 320 Tel: +65 6233Expo 6777Management Pte Ltd Jakarta, Singapore Fax: +62Indonesia (0) 21 2525 482 Fax: +65 6233 6768 Tel: +62maysia@pamerindo.com (0) 21 2525 320 Tel: +65carolyn@iemallworld.com 6233 6777 Email: Email: Fax: +62 (0) 21 2525 482 Fax: +65 6233 6768 Email: maysia@pamerindo.com Email: carolyn@iemallworld.com www.ManufacturingSurabaya.com

www.ManufacturingSurabaya.com

Overseas Exhibition Services Ltd Leonie Brooker London, United Kingdom Overseas Services Ltd Tel: +44 (0)Exhibition 20 7840 2134 London, Fax: +44United (0) 20 Kingdom 7840 2111 Tel: +44lbrooker@oesallworld.com (0) 20 7840 2134 Email: Fax: +44 (0) 20 7840 2111 Email: lbrooker@oesallworld.com ENQUIRY NO 084

Organised by Organised by

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FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

Cutting & Weld Preparation:

THE MANY FACES Tex Whiting, consumable sales manager for Hypertherm explains to us about the many forms of plasma cutting under different conditions and how to get the best out of it.

Editorial

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P

Of Plasma Cutting

lasma cutting is a thermal cutting process in which a beam of ionised gas heats an electrically conductive metal beyond its melting point and flushes molten metal through the kerf of the cut. The electrical arc is produced between the electrode (negative potential) in the torch and the workpiece (positive potential) being cut by ionising a beam of pressurised gas at a temperature between 14,000 degrees and 26,000 degrees Fahrenheit.

The ionised gas (plasma) is constricted and focused through a nozzle, which produces a dense plasma arc that melts and severs various types of metal. This is the principal process for both manual and mechanised plasma cutting systems.

Manual Systems Manual plasma cutting systems are moderately small power supplies that use a hand-held plasma torch for cutting various types of metals. These systems are manoeuvrable, versatile, and can be used for a variety of cutting applications. These power supplies have a range of cutting capabilities that is based on the output amperage of the cutting system. Power

supplies commonly are rated as low as seven to 25 amps and as high as 30 to 100 amps.

Some power supplies, however, allow for hand-held cutting of up to 200 amps, but this is not typical. Manual plasma systems normally use shop air as the plasma gas and/ or shield gas, and they are designed so that they can be used with several incoming voltages. The input voltage is between 120 and 600, utilising either one-phase or three-phase power transmission.

Manual plasma cutting systems generally are used by fabricating shops that handle thin metal, factory maintenance, farm maintenance, welding repair centres, metal service centres (scrap and dismantling applications), construction work (such as buildings and bridges), commercial ship manufacturing, trailer manufacturing, auto repair work, and artwork.

Typically, they are used in light-metal applications for trimming excess material.

A typical 12-amp hand-held torch will cut a maximum of 3/16-inch material at approximately 15 inches per minute (IPM). A typical 100-amp, hand-held torch cuts a maximum of 1 1/4 inches material at approximately 20 IPM.

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ May - June 2016

Plasma cutting is a thermal cutting process in which a beam of ionised gas heats an electrically conductive metal beyond its melting point and flushes molten metal through the kerf of the cut.

The input voltage is between 120 and 600, utilising either one-phase or three-phase power transmission.

Generally, a manual system is chosen based on the thickness of the material to be cut and the desired cutting speed. A system that delivers high cutting amperage cuts faster. However, when cutting at high amperages, it becomes increasingly difficult to control cut quality.

Mechanised Systems Mechanised plasma cutting systems generally are significantly larger then manual plasma systems and are used in conjunction with cutting tables, including a water table or downdraft table with a gantry system that runs on various drives and motors. Also, mechanised systems have a CNC and a torch height control (THC), which may include initial height sensing and voltage control.

Mechanised plasma cutting systems can be incorporated into a punch press, laser cutting, or robotic cutting system. The size of a mechanised plasma cutting configuration is based on the table and gantry being used. Tables may be smaller than four by eight feet or larger than 48 by 120 feet. These systems are not easily maneuverer, so all of their components should be considered, along with the layout of the facility, before installation.

Power Requirements Typical power supplies have a maximum amperage range of 100 to 400 for oxygen cutting and 100 to 600 for nitrogen cutting. Many systems have intricate cutting capabilities at lower amperage ranges, such as 15 to 50. Some

systems allow for nitrogen cutting at 1,000 amps and higher, but they are not common.

The incoming voltage for mechanised plasma systems is 200 and 600 with a three-phase power transmission.

Gas Requirements Commonly used gases are compressed air, oxygen, nitrogen, and a mixture of argon/ hydrogen for cutting mild steel, stainless steel, aluminium, and various exotic materials.

Combinations of these gases are used as the plasma gas and assist gas. For example, for cutting mild steel, it is not uncommon to use nitrogen as the plasma cutting start gas, oxygen as the plasma cutting gas, and compressed air as the assist gas.

Mechanised plasma cutting systems can be incorporated into a punch press, laser cutting, or robotic cutting system.

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two other types of gas occasionally used in the plasma cutting process. Plasma and assist gases are only two of the critical choices that need to be taken into consideration when installing or using a mechanised plasma system.

Gas tanks are available for purchase or rent, and they are offered in many different sizes, which means an area needs to be created to store them. A substantial amount of wiring and plumbing for gas and coolant is involved with the installation of a mechanised plasma system. Beyond the mechanised plasma system itself, a table, gantry, CNC, and THC will need to be chosen. OEMs generally offer an array of equipment choices that are adequate for any cutting application.

Generally, a manual system is chosen based on the thickness of the material to be cut and the desired cutting speed.

What Mechanised Process Makes Sense?

Because of the complexity involved in selecting a mechanised plasma cut ting process, a substantial amount of time should be set aside to research various system configurations and criteria. Consider: • • • • •

Plasma and assist gases are only two of the critical choices that need to be taken into consideration when installing or using a mechanised plasma system.

Compressed air is the most commonly used gas, as both a plasma gas and an assist gas.

Oxygen is used for mild steel (carbon steel) because it produces high-quality cuts in the material up to 1 1/4 inches thick. Oxygen also can be used as the plasma gas for stainless steel and aluminium cutting, but it produces a rough-looking cut. Nitrogen is suitable as a plasma gas and assist gas as it produces excellent cut quality on almost every type of metal. It is used for high-current applications, cutting metal up to three inches thick, and as the assist gas when cutting with nitrogen and argon/hydrogen plasma gas.

Compressed air is the most commonly used gas, as both a plasma gas and an assist gas. It works relatively well for low-current cutting applications in metals up to one inch thick, leaving an oxidised cutting surface. It is used as the assist gas when cutting with air, nitrogen, or oxygen plasma gas.

An argon/hydrogen mix usually is the plasma gas of choice for cutting stainless steel and aluminium. It provides a high-quality cut, and it is required for mechanised cutting of material thicker than three inches carbon dioxide also can be used as an assist gas when cutting with nitrogen plasma because it cuts most metals and provides good cut quality.

Nitrogen/hydrogen and CH4 methane are

Types of parts to be cut.

Number of production pieces cut per batch.

Desired cut quality and speed.

Cost of consumables.

Overall operating cost of the configuration (including consumables, electricity, gas, and labour).

The size, shape, and quantit y of the production par ts may dictate the type of CNC, table, and gantry required. For example, production parts that are small and intricate may require a gantry with a specialised drive package.

The rack-and-pinion drives, servomotors, drive amplifiers, and encoders used on the gantry determine the cut quality and speed capability of the plasma system.

The cutting speed and cut quality also depend on the plasma system, the CNC, and the gases selected. A mechanised system that has current ramping and gas flow ramping at the beginning and end of the cut will increase consumable life. Furthermore, a CNC with high storage capacity, a variety of programming capabilities (such as freezing the height of the torch at the end of the cut), and fast processing speed (input/output communication) will lead to a decrease in operational downtime and an increase in cutting speed and accuracy.

Ultimately, the decision to purchase or upgrade a mechanised plasma system or use a manual process should be based on the facts.

Faced with such a decision, a fabricator should consider size, shape, and thickness of the material being cut.

ENQUIRY NO 074

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Understanding the proper way of implementing a Manufacturing Execution System (MES) in the context of Industry 4.0 is important to gain the most benefits. By Sascha Graef, managing director, MPDV Asia

MES – But Do It In The Right Way

A

n increasing demand for a quality Manufacturing Execution System (ME S) f o r In du s t r y 4 . 0 c le ar l y manifests itself. The functions and proper ties an MES system must have are detailed in the VDI guideline 5600. But is that relevant for Industry 4.0? The Future Concept MES 4.0 casts a light on the issue.

Recommended action in order to prepare for Industry 4.0 could be: “Introduce an MES!” But which one? Which properties and functions must an MES have in order to be a central information and data platform?

VDI 5600 Guideline – Relevance For Industry 4.0 Looking into relevant standards like the VDI guideline 5600 (VDI = Association of German Engineers), published in 2007, gives an indication that apart from a wide range of functions, basic features like “Horizontal Integration” and “Realtime Capability” must be guaranteed. This also

applies to industry 4.0. Therefore, MES systems already play an essential role in the practical implementation of Industry 4.0.

Status Quo Current MES market reviews show that the market is quite diversif ied but only a few systems fulf il the requirements of the VDI 5600 guideline. Many systems have already implemented online capabilit y but make sacrifices in their functional range and their horizontal integration. Many suppliers only partly cover the tasks and must supplement ot her func t ions wit h ex ternal produc t s from par tners. More and more suppliers ex tend their own por t folio of func tions which verif ies the relevance of VDI 5600.

Avoiding inter faces, which is an essential requirement for horizont al integ r at ion, is normally not covered by increasing the number of functions.

Horizontal integration, which is defined in the VDI 5600 guideline, plays a central role even in the “VDI House for Industry 4.0.”

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No matter which manufacturing processes are presented by the MES in any culture or country, a modular, horizontally integrated MES solution fulfils all the requirements

MES systems are plentiful but a broad range of functions and a complete horizontal integration is only supplied with a few systems. (source: MPDV).

“Everything Under One Roof”: Horizontal Integration For the Future Concept MES 4.0 ‘Horizontal Integration’ is connecting all functions and data across the value chain and covering all tasks of an MES. Essential characteristics of the horizontal integration are avoiding interfaces and the modular structure of an overall system.

It goes to show that in the workplace order pos t ing s (BDE) a s well a s qualit y inspections (CAQ) are carried out in the same shop floor collection terminal. Ideally both func tions are represented in comparable dialog ue s . T his make s it ea sier for t he operator as the modules function on the same basis. The operator saves time as there is no need to go to a specif ic inspection station.

It also makes it simpler for the adminis tration of an ME S s y s tem if the modules come from one software house. This is especially illustrated when the software is maintained and is considerably important concer ning t he li fe c ycle managemen t .

Typically in using complex software systems, not only small updates and error corrections routinely occur but also release and version

changes. Thereby core software changes are also carried out. A horizontally integrated system can be used after a version change instantly as the modules and the functions are linked. This means the customer has time and cost savings.

Horizontal integration is a requirement for the modular structure of an MES solution.

That eases the successive introduction of the system which is significant for mediumsized companies. Also users can decide for themselves which functions are sufficient for their application case and can align their selection to their requirements. The software can be extended at any time. No mat ter which manu f ac tur ing proce s s e s

Integrative data management – all collected data stored in a central database (source: MPDV).

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Shop floor data collection and quality management in one system. (source: MPDV).

requirement to stay competitive – especially considering Industry 4.0.

Here are some examples from real life: Keeping On Top Of Energy Costs In times of ever increasing energy costs and complex cost relief models, manufacturing companies need tools to collect and evaluate energy consumption. An integrated MES can correlate energy data with other information from produc tion, ie: processed orders or machine status. Instantly energy intensive production steps or energy guzzling machine ar e d e t e c t e d . O p t imi s e d p l annin g l ike avoiding peak times is one of the principal activities. In order to achieve the requested integrated solution relevant data from all areas must be linked.

Consumption Correlation — to know exactly how much energy is consumed with every order. (source: MPDV)

Shop Floor Scheduling provides you with a multidimensional production planning and control (source: MPDV).

are presented by the MES in any culture or country, a modular, horizontally integrated MES solution fulfils all the requirements.

D e spi te t hat f ac t , s ever al supplier s campaign with “Indus tr y 4.0 compliant ” products. If it is envisaged to use the system in the long term, horizontal integration is essential.

Further Exploit Data: Correlating Evaluations E s p e c ial l y r e le v an t f o r In du s t r y 4 . 0 i s t hat s y s tems , incorpor at ing integ r at ive management , can proces s and evaluate data across all areas. The more complex manufacturing environments are, the more signif icant correlating evaluations are in order to obser ve and operate processes efficiently. Only context-relating correlation of data can supply valuable information and therefore knowledge. Only by collec ting comprehensive knowledge, processes can be optimised. This in turn is an important

Quality Made By MES The product quality is also significant in the era of Industry 4.0. By using an integrated ME S inspec tion plans can be created simult aneously to produc tion order s .

When log ging an order at the shop f loor terminal the equivalent inspection order is instantly available. After a defined interval (based on time or cycle) due inspections are automatically identified and displayed on the shop floor terminal. Automatically collected quantities and the machine status can be evaluated.

To further increase automation of quality inspec t ion, collec ted proce s s dat a c an be used (ie: temperature, pressure, f low velocit y, etc) which are now available if machines are connected. Therefore, quality levels improve.

Preventive Maintenance An MES solution manages all produc tion resources in one system containing apart from machinery also tools and other production

FEATURES Asia Pacific Metalworking Equipment News • May - June 2016

aids. A common database can plan and evaluate all resources across all sectors. Planning an order in the shop floor scheduling, it is straight away apparent which tools are available or if the tool needs maintenance during utilisation period. The central collection of cycles and utilisation times enables preventative and needs-orientated maintenance. Therefore, utilisation of tools increases and idle times are reduced.

From Planning To Controlling Systems, organised in a decentralised manner as required for Industry 4.0, require standards and to a certain extent planning or controlling.

Direct connection to the shop floor enables the switch from true planning to a precisely accurate production control. Unforeseen events are detected instantly and the responsible members of staff can react in real time. If a machine breaks down, the graphical planning module in the MES system checks if there are alternatives available and how it affects the orders overall. The fully integrated MES solution can, apart from planning availability of tools and machines, also make allowances for

resources like personnel, material stocks and energy consumption. Transparency achieved with the system safeguards the ability to react in production.

Prospects: The Future Is Here The future vision, illustrated by Industry 4.0, seems to be more tangible with the realisation of the Future Concept MES 4.0. Growing networks which are presented by the horizontal integration of the MES environment, central data retention and the correctness of data are increasingly in the focus of production IT. Technical innovations ensure that obstacles are not insurmountable and successively disappear.

Technical progress is unstoppable and therefore, the number of self-regulating systems at work is rising. An unrestricted access to relevant data is more important than ever. This goes to show that a Manufacturing Execution System (MES) is not only suitable to support Industry 4.0 but a necessary requirement.

It is also necessary for an MES to comply with the VDI 5600 guideline — completely. Remember not every system offered on the market is worthy being called an MES.

Technical innovations ensure that obstacles are not insurmountable and successively disappear.

ENQUIRY NO 077

PERFECT VERSATILITY The HBP410-723G Mitre Cutting Bandsaw Behringer GmbH · 74912 Kirchardt Phone +49 72 66 207-0 info@behringer.net www.behringer.net

BEHRINGER and BEHRINGER EISELE - world leading producers of high-performance band- and circular sawing systems offer a wide range for every kind of metal - including stainless and special alloys.

BEHRINGER‘s mitre cutting bandsaw HBP410-723G grows in step with requirements. The models are designed to cut sectional steel and solid metal materials. An extensive range of peripheral devices, such as infeed, outfeed and measuring systems, offer versatile possibilities.

Use the potential of innovative HighPerformance Band- and Circular Saws of BEHRINGER and BEHRINGER EISELE. Experience machines and solutions for high precision and profitability. True to the motto „RED HOT EFFICIENCY“.

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INTELLIGENT USE

Of Non-Productive Time

Robots can free up additional capacity for machine tools and increase productivity.

By Andreas Schuhbauer, market segment manager for machine tools, Kuka Roboter.

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A

ccording to an industry study from 2013, German machine tool operators see their greatest challenges in ever-shor ter deliver y times and the increasing complexity of the components to be machined. At the same time, quality requirements are rising and prices are falling.

The measures that companies are taking to meet these challenges include investment in machining centres, in milling machines and lathes as well as in automation. The focus is shif ting increasingly onto robot-based automation — for good reason.

In the past, machine tool and mechanical engineering companies assumed that the automation of machine tools was only suitable for mass production. Manufacturers with batch sizes of 100 or with components that have long throughput times in excess of 90 seconds have only rarely been taken into account. However, the new challenges are gradually leading to a rethink. Outsourcing to countries with a

lower wage level is increasingly reaching its limits in terms of the need for short supply chains, the hiring of specialist personnel and quality control. The degree of automation in the industry, when compared to other sectors, is currently at a lowly 1.5 percent — but the pressure to automate is building.

Higher Robot Performance At A Lower Price Automation using robots can be the right answer here. Robots work with a very high degree of precision — even with complex and heav y component s , t he rejec t r ate is practically zero. They can work around the clock, and their performance is just as good after 24 hours as in the first minutes.

In heavily automated produc tion shif t s, they improve the capacity utilisation of the machines and reduce the unit labour costs.

Beyond this, unlike wages, the costs for robots have decreased continuously — while their performance has increased at the same time.

FEATURES Asia Pacific Metalworking Equipment News • May - June 2016

Versatile Helpers For Handling, Machining And Assembly Already today, robots load machine tools quickly and precisely with blanks and then remove the machined par t s . During the operating time of the machine tool, the robot can use non-productive time effectively and carry out tasks such as drilling, brushing and deburring. This reduces the spindle runtime per part. On components requiring intensive machining, the robot can al so carr y out roughing, leaving the machine to take care of the smoothing alone.

Where productivity is concerned, every second counts. About 20 percent of all machine tools can be operated more eff iciently in conjunction with robots. It is true that a robot cell can double the investment costs for a machine tool. However, the payback period is often only two years — even with an extensive range of parts.

Robots Are Helping To Build Kuka Robots In Augsburg At Kuka Roboter in Augsburg, six robot-based solutions are in use. In the case of long

machining times, the robot can be gainfully employed between the loading cycles. For example, a robot of the KR Quantec series is deployed in the machining area (where parts of the in-line wrists for Kuka robots of the same series are manufactured) to make use of the non-productive times of an automated machine tool. It not only loads the “DMC80 U duo Block” machining centre from Deckel Maho with blanks and unloads the machined parts from the machine, but also machines the sixth side of the workpiece and then deburrs it.

About 20 percent of all machine tools can be operated more efficiently in conjunction with robots.

ENQUIRY NO 049

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Robots load machine tools quickly and precisely with blanks and then remove the machined parts.

The automation system is designed in such a way that it can be simply adapted to changing production procedures.

All the machining steps that are required in production of the workpiece are carried out entirely in the new cell. The automation system is designed in such a way that it can be simply adapted to changing production procedures. The result: Kuka is now producing about 4,500 more parts per year than before the automation.

The use of robots in two further machining centres at Augsburg has resulted in an average increase in productivity of more than 15 percent.

Since 2013, DMG Mori machine tools have been manufacturing 14 components from castings and sawn sections that are then installed in the adjacent robot assembly shop. A KR 150 R2700 extra robot loads and unloads the machine

tools. Once a layer of the pallet has been completely filled with machined components, the robot picks up the suction gripper and takes a cardboard slipsheet from another pallet. It then sets it down on the completed layer of finished parts. Once the carriages on the supply conveyors are empty, the robot places them on the return conveyor.

The robot-ba sed solution allows the company to machine a large number of different components and to flexibly adapt the batch sizes to the quantities required.

This automation solution is characterised by its high degree of flexibility in the smallest of spaces. Thanks to the buf fering of the components, a maximum unmanned runtime of eight hours is made possible. Kuka has managed to reduce the costs per part while also increasing the operating hours â&#x20AC;&#x201D; without the need for additional resources.

In the Burkhardt and Weber machining centre at Kuka in Augsburg, the machine is loaded and unloaded by a KR 500 robot that also processes the workpieces, measuring up to 1.5 metres in length, during otherwise non-productive time. The result: productivity has increased by 10 percent. Compared with a conventional solution, the company has since been able to machine 300 more components e ac h y e ar. T h e g r e a t er pr o duc t i v i t y i s attributable to the fact that system operation is 70 percent unmanned and additionally that night shifts run in fully automated mode.

Whereas, in the past, each system required one dedicated operator per shift, automation enables staggered working practices.

The operator no longer has to carry out the time-consuming loading of the workpieces directly into the fixture, but places them on

FEATURES Asia Pacific Metalworking Equipment News • May - June 2016

Six-axis robots are suitable for machining and handling tasks directly at the CNC machine.

the simply-designed locations of the material feeder to the robot. The material feeders are designed as two-axis positioners and are implemented in the robot controller as axes seven and eight. The two material feeders can each carry eight parts. This is enough to keep the system running in unmanned operation for eight hours. Prior to automation, it took up to 15 minutes to clamp a workpiece. The robot now only requires two minutes. The precise alignment of the workpiece, which was physically strenuous for the operator, is dispensed with by the robotic loading, which also eliminates the risk of damaging the expensive clamping equipment during loading and unloading with the crane. Beyond this, downstream tasks, such as deburring the machined workpieces, no longer have to be performed since this task is also carried out by the robot. The company expects a payback period of no more than 2.6 years. If non-productive times can be more effectively utilised — for example, by drilling holes on the link arm and rotating column — this period might be even shorter.

Simple Operation Guaranteed Six-axis robots are suitable for machining and handling tasks directly at the CNC machine.

In order to keep training requirements to a minimum, machine tool manufacturers must pay attention to the ease of operating the robots.

The central user interface of the company’s robot on the Sinumerik-CNC opens up the possibility of seamlessly integrating robots into machine concepts and production processes using the KR C4 controller, for instance. This minimises the training requirement for employees since the operator control panel of the machine

tool makes it possible to display, operate and program the company’s robots in the same system that the user is familiar with from using the machine tool.

Conclusion The examples make it clear : there is potential for productivity increases in every manufacturing step. The use of modern robots allows the potential of machine tools to be tapped through a wide variety of automated processes — such as marking and measuring workpieces, as well as quality control in the machine during the manufacturing process.

Performance can be fully maximised especially if the robot is linked to multiple machines.

Six-axis robots are suitable for machining and handling tasks directly at the CNC machine.

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IoT In Manufacturing:

STARTING THE GROWTH ENGINE

Drawing on a study of 795 executives from a range of sectors in Asia Pacific, Europe and the Americas, Sreenivasa Chakravarti, head innovation and transformation group, manufacturing business unit of Tata Consulting Services shares his insights on strategic decisions involving investing in the Internet of Things (IoT).

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T

he Internet of Things (IoT) has the potent ial to deliver subs t ant ial revenue gain to manufacturers, but where should you focus your efforts and what decisions are the most important?

Manufacturing companies already invest heavily in IoT initiatives, spending more

than most other industries, including hightechnology, energy and utilities. According to a study by Tata Consulting Services, The Internet of Things: TCS Global Trend Study 2015 - A Manufacturing Industry Perspective, manufacturers spent an average of US$108.2 million on IoT in 2015, and they are expected

FEATURES Asia Pacific Metalworking Equipment News • May - June 2016

to spend 11 percent more in 2018.

What’s more, they are also achieving a good return on this investment. Manufacturing firms reported a 19.7 percent revenue increase in 2014 over 2013 in the areas of the business that implemented an IoT initiative – the highest of any industry in the study. By 2018, the average anticipated impact of IoT on total revenue will be 20.4 percent, much more than the 16.3 percent which is the average impact for all industries.

Most Valuable Strategic Focus The study also looked at what IoT strategies have the mos t value for manufac turers.

Many companies are using IoT to monitor the flow of raw materials and finished products through their supply chain: 48 percent of manufacturers in the survey were doing this.

Beyond this , IoT deployment s in the sector have focused primarily on tracking how produc t s are per forming. Jus t over a quar ter (26.4 percent) of respondent s monitored produc t s in the f ield to make maintenance services more proactive. With customer-specific information and remote diag nosis c ap abili t ie s , te chnicians c an provide faster and more efficient service.

From a more macro point of view, this data can help f irms identif y – and f ix – produc t problems before cus tomers are aware of them. Plus, it can be used by the R&D te am to improve e x is t ing produc t features.

To go further and gain a higher level of return, manufacturers will next use IoT to evolve their business models and identify and pursue new business opportunities.

Evolving Business Models Manufac turer s have embraced busines s model changes as a key consequence of IoT. All but 18 percent of the 140 manufacturing leaders surveyed in the study had evolved some aspect of their business model as a result of IoT work.

These changes are set to accelerate. By 2020, firms expect to use IoT to increase their ser vice business (49.3 percent), generate more revenue from customer usage data (26 .4 percent), and re supply cus tomer s directly through automated re-orders (20.7 percent).

F o r e x amp le , t h e “r a z o r-an d blades”model, where a business of fers a one-time produc t at low cos t and earns repeat busines s from complement ar y products, takes on new meaning in the IoT era. IoT connectivity can turn almost any

digital device into a service, as innovative manufactures of home printers, e-readers and wearable health tech are showing.

Manufacturing companies already invest heavily in Internet of Things (IoT) initiatives, spending more than most other industries.

New Business Opportunities Traditionally, many businesses have relied on customer surveys and feedback to discover how customers use their products. Others have trusted experience and intuition. With IoT you can finally delve more deeply into produc t usage and gain real insight into customers’ actual experience.

Analysing your IoT data is likely to reveal areas where customers need help or more func tionalit y. If some customers are not using the produc t s as you intended and designed, it could also present a different view of customer segmentation. With product monitoring data at your fingertips, you can analyse, learn and adjust accordingly.

A s an example, a manufac turer could create a service that aggregates data from a plant’s sensors and other devices to help the customer maximise productivity. Or you might leverage your IoT data to let you, or your customer, of fer your produc t s on a pay-by-use basis.

Automotive manufacturers are taking a novel approach to this oppor tunity. Some are now producing fully feature-loaded cars that can be turned on remotely for a f inite period of time. This function stems from the enhanced understanding of usage pattern, which allows customers to pay per use for features that they would not have paid up-front for at the time of the initial product purchase.

Analysing your IoT data is likely to reveal areas where customers need help or more functionality.

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By 2018, the average anticipated impact of IoT on total revenue will be 20.4 percent, much more than the 16.3 percent which is the average impact for all industries.

3. Integ r ate t he IoT dat a from sensor s and ot her dig i t al dev ice s wi t h your enterprise systems. Connecting the IoT initiative to enterprise s ys tems that support management decisions will help executives gain a deeper understanding of the business.

With product monitoring data at your fingertips, you can analyse, learn and adjust accordingly.

Most Effective Operational Success Factors But how can you make sure that you can effectively turn IoT data into business insight and improved profitability? Our study identified five operational success factors:

4. Support cultural change. You will need to empower managers and workers to change the way they think about customers, produc t s and processes. The insight s provided by IoT-based systems will reveal the truth about product usage, but they will not benefit the business unless your team is able to use them to guide decisions and change the way things are done. Support from the C-suite is mandatory for the cultural change necessary to get the most from IoT.

1. Focus on core application areas. The world of connected devices presents a vast number of possibilities for manufacturers. To avoid diluting the effectiveness of your IoT efforts, we recommend focusing on operational excellence and the customer experience.

5. Determine what technologies and capabilities to develop internally and which you will need external support for. IoT deployments are complex, requiring expertise in hardware, software, networking and analytics, among other disciplines. It makes sense to develop internal talent where it will deliver the most value, and to look for competent partners and solutions providers for the rest.

2. Decide what data to capture from the IoT. There is no shortage of data to be had, but not all of it is created equal. The data must be relevant to the IoT initiative and your desired outcome, whether that is product improvement or better customer service.

With the potential to help firms improve their competitiveness, IoT-driven opportunities are exploding in the manufacturing sector. Now is the ideal time for you to take advantage of the technology to enhance the customer experience and improve operations.

Increased amount of thought content to help you drive your business.

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EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • May - June 2016

Event Preview:

MTA Vietnam M Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City July 5 – 8, 2016 Editorial

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TA Vietnam, the International Precision Engineering, Machine Tools and Metalworking Exhibition, will return from 5 to 8 July 2016 at the Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam. Into its 14th edition, MTA Vietnam is the premier gateway for Vietnam’s industrial manufacturers to be kept up to date with the most progressive machines, technologies and innovations available in the global marketplace for precision engineering and industrial manufacturing.

The event is a platform where international and local companies assemble to source for the latest state-of-the-art innovations, seek new business opportunities and expand their professional network. With Vietnam’s economic growth on the rise and the establishment of the ASEAN Economic Community (AEC) in 2015, opportunities abound and MTA Vietnam 2016 is a specialised event not to be missed.

First launched in 2005, MTA Vietnam has gradually expanded over the years to become Vietnam’s most comprehensive manufacturing technology trade event. MTA Vietnam 2016 will once again bring together many industry leaders and professionals working in the high-value sectors of precision engineering and manufacturing.

Exhibiting companies will include more than 360 international and local participants from

20 countries/regions looking to partner with and supply technology to local manufacturers, dis t r ibu t or s and re t ailer s . To da t e , 13 international group pavilions, comprising Germany, Japan, Korea, Singapore, Taiwan and Thailand, have confirmed their participation in MTA Vietnam 2016. A broad range of cutting edge technologies, applications and systems catering to the manufacturing industry will be showcased on the exhibition floor.

Held alongside MTA Vietnam 2016, a full roster of educational sessions, conferences and seminars will also be hosted throughout the show. Featuring an impressive line-up of speakers from local and regional organisations, the conferences contribute to help delegates expand their knowledge bank, stay relevant and up-to-date with the current trends and issues facing the manufacturing industry.

“For manufacturers requiring precision engineering equipment and metal forming machinery for manufacturing, MTA Vietnam is the ‘go-to’ event, with consistently the highest number of machines on display in an exhibition hall. As with previous years, strong support has come from Germany and other Asian countries with significant presence of many national pavilions,” said BT Tee, deputy chief, Vietnam representative office, Singapore Exhibition Services, the organiser of MTA Hanoi 2016.

PRODUCT FINDER Asia Pacific Metalworking Equipment News • May - June 2016

ENQUIRY NO 044

ECH METALSTIA 2016

MALAY

Hall 2 061 Booth 2

Behringer: HBP410-923G Bandsaw Machine Artesyn Embedded Technologies: vATCA-7490 Server Blade

The ATCA-7490 is designed for computer-intensive tasks such as deep packet inspection (DPI), firewalls, intrusion prevention and data encryption or decryption.

On-board load balancing and f iltering func tions, hardware accelerated crypto engines and powerful server CPUs combine with multiple 10/40/100G Ethernet switch interfaces provide a line-rate processing engine.

It comprises two Intel Xeon processors with up to 40 CPU cores per board. Data paths to main memory and I/O are optimised by the use of DDR4 and PCIe Gen 3 protocols.

Memory capacity can scale up to 512 GB. Combining an open source operating system, such as Red Hat Enterprise Linux or CentOS, with OpenStack, the ATCA-7490 resources are accessible and sharable in cloud environments.

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B e h r i n g e r ’s H B P41 0 923G bandsaw machine is designed to cut sec tional s teel and s olid me t al materials as well as comparable plastics. Suitable for a wide range of different sawing operations, it has a cutting range of 410 mm in round material and 700 x 400 mm (900 x 400 mm) in flat stock, as well as a bilateral mitre from 45 degrees on the right to 30 degrees on the left.

The unit can be swivelled to the required position with a simple rotation movement. The pivot point is located at the intersection between the bandsaw blade and the material contact edge, ensuring that the measurement reference line remains constant.

Its dual-column saw frame guidance system is effective in vibration-damping—convenient for cutting materials with widely different cross-sections. It also features a fully automatic saw frame height adjustment facility depending on the material height, and saw lowering in rapid traverse.

Editorial

Got a Question? Make An Enquiry.

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

ENQUIRY NUMBER

4602

75

76

PRODUCT FINDER Asia Pacific Metalworking Equipment News • May - June 2016

DMG Mori: Lasertec 65 3D Milling Machine

To enable generative manufacturing, the Lasertec 65 3D milling machine from DMG Mori is equipped with a 2-kW diode laser for laser deposition welding. The five-axis mechanism features a monoblock design, making it a stable to carry out precise milling operations.

In contrast to laser melting in a powder bed, the laser deposition welding of the machine enables large parts to be manufactured using a metal powder nozzle. With a deposition rate of up to 1 kg per hour, this process is up to 10 times faster than the laser generation of parts in a powder bed.

Editorial

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

ENQUIRY NUMBER

4603

Faro: Focus3D X 130/330 HDR 3D Laser Scanner

Faro’s new 3D laser scanners with high dynamic range photography (HDR) produce detailed images in bright and dark lighting conditions and feature extended colour resolution of up to 170 megapixels per scan. While typical digital images cover a contrast range of 255-to-1, the new FARO laser scanners capture brightness ranges of up to 4 billion-to-1.

To maximise the capabilities of the laser scanners, Faro has also launched version 6 of the Faro Scene software. It has a solid-surface rendering technology that eliminates the need for fur ther data processing in visualisation applications.

Editorial

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ENQUIRY NUMBER

4604

Holroyd: 8EX CNC Rotor Milling Machine

Part of Holroyd’s EX series, the 8EX milling machine is capable of milling profiles of up to 850 mm in diameter.

The series is designed to maximise high sur face speeds demanded by the latest cutting technologies. EX machines also cut a full-depth groove by traversing the cutting tool through the material at the relevant helix angle, while rotating the component in the C axis. Accurate synchronisation between the axes is maintained via CNC, with digital drive technology controlling all axis movements.

Majority of heat generated is transferred to the swarf chips, enabling the cutting head to remove a substantial amount of material in one step.

Editorial

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ENQUIRY NUMBER

4605

Nord Drivesystems: Industrial Gear Unit With 190 kNm output torque

Nord Drivesystems extends its industrial gear unit range by adding a new size with 190 kNm output torque. The series now comprises nine sizes and covers torques from 25 kNm to 250 kNm. Featuring a single-piece Unicase housing, it achieves a longer bearing life than gear casings manufactured from jointed parts and ensure efficient power transmission and high tolerance for load peaks and jolts.

It can be assembled as two or three-stage helical inline or helical bevel gearboxes with nominal transmission ratios from 7.1:1 to 400:1, or even up to 30,000:1 with an auxiliary primary stage. The input and output direction can also be freely selected.

Editorial

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ENQUIRY NUMBER

4606

PRODUCT FINDER Asia Pacific Metalworking Equipment News • May - June 2016

ENQUIRY NO 061

Efficient, versatile and easy to use Featuring a bar capacitiy of 25.4 mm diameter, the Tornos Swiss GT 26 is a Swiss-type lathe equipped with six linear axes and two C axes.

Versatility, high performance in value-added operations, and ability to work with or without a guide bush make the Swiss GT 26 a comprehensive bar turning solution.

Discover more : www.tornos.com

Your advanced machining solution

CH H EC TE ALLT TA ME ET M 016 2 6 1 IA 0 S 2 Y A L A

M

HHall 22 1 h 2200661 BBooootth

Swiss GT 26

We keep you turning

ENQUIRY NO 072

ARNO® - Drilling System ARNO Product expansion Drilling With the new AKB5 we have added drills with drill depth potential up to 5 x D. Furthermore we now offer drills up to 55 mm diameter in the AKB2 and AKB3 range.

Renishaw: FixtureBuilder 3D-modelling Software

Fix tureBuilder is a 3D-modelling sof t ware package designed to allow the offline creation and documentation of fixturing setups. Easy to use, the FixtureBuilder features well-organised component libraries, an intelligent “dragand-drop” function, a quick manipulation of parts and a user-friendly constraint mechanism.

The software’s full CAD compatibility and the availability of custom libraries also contribute to its ease of use. A key highlight is its “Build it” function that automates the production of work instructions and bill of materials for every fixture setup, ensuring compliance with quality standards while assisting with product ordering.

Editorial

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ENQUIRY NUMBER

4607

With the multifunctional SHARKCUT® tool you can drill and turn.

The tool produces a flat bottom in the hole and is, depending on version, suitable for drilling, boring, turning and facing.

The tool is available from 4 – 50 mm and depending on diameter and application supplied as either solid carbide, one, two or three fluted indexable tool. No matter which version, this tool can prove most cost efficient.

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

www.arno.com.sg

77

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PRODUCT FINDER Asia Pacific Metalworking Equipment News • May - June 2016

Rofin: CombiLine Basic Laser Workstation

R o f i n ’s C o m b i L i n e Basic laser workstation present s a technical solution for laser marking.

The standalone workstation comes equipped with a working chamber, an integrated marker and employs a smart operation technology.

A motorised door provides easy access to the spacious chamber, while a motorised z-axis positions the marking head to house different workpiece heights. All components are controlled by an integrated computer system which can be operated via a 15-inch touch screen.

Both simple and complex marking layouts can be achieve with the Visual Laser Marker, Rofin’s laser marking software.

The software supports matrix codes, bar codes, and serial numbers, among others.

Editorial

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ENQUIRY NUMBER

4608

Schaeffler: MTKUSE Telescopic Actuator

Schaeffler has developed the MTKUSE telescopic actuator for secondary axes such as in pick-and-place applications or for tool transfer. Three precision linear ball bearing and guideway assemblies are arranged on top of one another, making the possible travel distance more than twice that of the basic actuator.

The linear unit can extend in both directions. A geared servomotor is mounted on the outside of the aluminium profile and drives the actuator via a rack and pinion drive.

Servomotors from other manufacturers, low backlash precision planetary gearboxes, end switches and distance measuring systems can be fitted on request.

Editorial

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ENQUIRY NUMBER

4610

Seco: Jabro-HFM JHF980 Solid-carbide End Mill

Seco has expanded the highfeed machining applicability of its Jabro-HFM JHF980 solidcarbide end mill with new 4- and 5-flute options.

High-feed machining pairs shallow axial depths of cut with accelerated table feed rates for increased metal removal. In addition, cutting forces are directed axially into the spindle, thereby stabilising the operation, minimising vibration and lessening wear on the machine tool.

The end mill also features an ultrafine carbide grade and a monolayer Tiain coating, which insulates the cutter and transfers heat into the chips. The coating helps lower operating costs by eliminating the need for coolant in hightemperature situations.

Cutting diameters for the 4-flute JHF980 range from 2 mm to 6 mm, while the 5-flute version spans 8 mm to 12 mm. Both cutters are available in 1.5xD, 5xD and 7xD lengths.

Editorial

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ENQUIRY NUMBER

4609

ZWSoft: CADbro 3D CAD Viewer

CADbro supports over 20 major 3D CAD and neutral formats, including the likes of Catia, NX, Creo/ProE, SolidWorks and Parasolid, allowing users to easily access and interact with 3D CAD data without expensive licenses. Additionally, the viewer has also incorporated smart commands to detect open edges and perform quick healing when required.

The viewer comes with 3D annotating functionalities, allowing even periodic users to add dimensions, tolerance, symbols, or texts directly to the 3D models. Packed with diversified query and analysis tools, it allows users to take measurements to estimate and quote accurately while also verifying the manufacturability of product structure and assembly.

CADbro has also incorporated flexible editing technologies, like Direct Edit, Curve Creating and Shape/Part Transfer, making it possible for users to make tweaks on 3D CAD models.

Editorial

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ENQUIRY NUMBER

4611

EXHIBITION PROGRAMMES 2016 Asia Pacific Metalworking Equipment News • April 2016

JUNE 22 – 25

OCTOBER 6–8

23 - 27

Bangkok International Trade & Exhibition Centre (BITEC)

District 7, Ho Chi Minh City, Vietnam Reed Tradex

Greater Taichung International Expo Center

Manufacturing Expo 2016, Metalex Vietnam 2016 Intermold Thailand 2016, Saigon Exhibition & Convention Center (SECC) Nepcon Thailand 2016 799 Nguyen Van Linh Parkway, 88 Bangna-Trad Road (Km.1), Bangna Bangkok 10260, Thailand Reed Tradex Company

25 – 27 JULY 5–8

MTA Vietnam 2016

Saigon Exhibition & Convention Center (SECC)

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

Indometal 2016

Jakarta International Expo (JIExpo)

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

25 – 29

Euro Blech 2016

AUGUST 3–6

Manufacturing Surabaya 2016

Grand City Convention & Exhibition Centre

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

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

NOVEMBER 23 – 26

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

NOVEMBER 30 – DECEMBER 3

Manufacturing Indonesia 2016

Jakarta International Expo (JIExpo)

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

13 – 15

Indometal 2016

Jakarta International Expo (JIExpo) Gedung Pusat Niaga Lt. 1 Arena PRJ Kemayoran Jakarta 10620 Indonesia Messe Dusseldorf Asia

Metalex Thailand 2016

Bangkok International Trade & Exhibition Centre (BITEC)

SEPTEMBER 22 – 24

88 Bangna-Trad Road (Km.1), Bangna, Bangkok 10260, Thailand Reed Tradex

Manufacturing Myanmar 2016

Myanmar Event Park

Shin Saw Pu Rd, Yangon, Myanmar Singapore Exhibition Services

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

The Editor (APMEN)

Eastern Trade Media

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

79

80

ADVERTISING INDEX Asia Pacific Metalworking Equipment News â&#x20AC;¢ May - June 2016

Page Number

Enquiry Number

AGMACHINE TECHNO CO LTD

75

044

ARNO WERKZEUGE S.E.A. PTE LTD

77

072

BEHRINGER GMBH

65

077

BENIGN ENTERPRISE CO LTD

21

076

BYSTRONIC PTE LTD

05

079

COMPRO PRECISION MACHINERY CO LTD

67

049

DEES HYDRAULIC INDUSTRIAL CO LTD

53

045

EXXON MOBIL ASIA

15

081

FRITZ STUDER AG

13

068

HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD

03

073

HWACHEON ASIA PACIFIC PTE LTD

09

070

ISCAR LTD

IFC

075

KASTO MASCHINENBAU GMBH & CO KG

45

067

KENNAMETAL INC

BC

031

MESSE DUSSELDORF ASIA (INDOMETAL 2016)

31

085

OKUMA CORPORATION

IBC

069

PT PAMERINDO INDONESIA (MANUFACTURING SURABAYA 2016)

57

084

RE-ATLANTIS ENTERPRISE CO LTD

41

067

REED TRADEX COMPANY (METALEX VIETNAM 2016)

61

074

SCHUNK INTEC PTE LTD

11

078

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA VIETNAM 2016)

47

016

TAIWAN TAKISAWA CO LTD

35

050

TORNOS TECHNOLOGIES ASIA LTD

77

061

TRADE LINK ITE SDN BHD (METALTECH 2016)

37

040

TUNGALOY SINGAPORE (PTE) LTD

01

086

WALTER AG SINGAPORE PTE LTD

07

071

WALTER EWAG ASIA PACIFIC PTE LTD

19

038

WENZEL ASIA PTE LTD

FC

083

WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG

17

064

YIH CHUAN MACHINERY INDUSTRY CO LTD

23

080

ADVERTISER

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ASIA PACIFIC METALWORKING

No. 4 2016

The Engineering Journal For Manufacturing,Automation & Quality Control

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ENQUIRY NO 069

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

Face Grooving

Grooving

Deep Grooving

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

Cut-Off

Side Turning

Beyond Evolution EASY kits are currently

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

B 0 1KG L1C 116 - P 3

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

kennametal.com/BeyondEvolution

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

Only available through participating distributors.

www.kennametal.com

ENQUIRY NO 031

Chamfering

Profiling

Facing