APMEN Nov-Dec09

Visit APMEN At Metalex Thailand 2009 November-December 2009

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

Taking on today’s challenges means having the right tools and meeting the right partner.

Expect more.

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Experience the new Walter.

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Building Customer

ProFITABILITy

Milling Milling Down Down Production Production Costs Costs with with Winning Winning Combinations Combinations for for Optimal Optimal Productivity Productivity ISCAR JAPAN ISCARShinsenri-Higashimachi JAPAN 1-5-3 1-5-3 Shinsenri-Higashimachi Toyonaka-shi, Osaka 560-0082 Toyonaka-shi, Tel + 81 6 835Osaka 5471 560-0082 Tel + 81 6 835 5472 5471 Fax Fax + 81 6 835 5472 iscar@iscar.co.jp iscar@iscar.co.jp

ISCAR TAIWAN ISCAR 395, DaTAIWAN Duen South Rd. 395, Da Duen Taichung 408 South Rd. Taichung 408 247 31573 Tel +886 (0)4 Tel +886 (0)4 247 31573 Fax 31530 Fax +886 (0)4 247 31530 iscar.taiwan@msa.hinet.net iscar.taiwan@msa.hinet.net

ISCAR THAILAND ISCAR THAILAND 57, 59, 61, 63 Soi 57, 59, 61, 63 Soi Samanchan-Babos Samanchan-Babos Sukhumvit Rd. Phra Khanong, Sukhumvit Phra Khanong, Khlong ToeyRd. Bangkok 10110 Khlong Tel + Toey 66 (2)Bangkok 7136633 10110 Tel + 66 (2) 7136633 Fax 7136632 Fax + 66 (2) 7136632 iscar@iscarthailand.com iscar@iscarthailand.com

ISCAR VIETNAM ISCAR VIETNAM (Representative Office) (Representative Office) Room D 2.8, Etown Building, Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., 364Chi Cong Hoa, Tan Binh Dist., Ho Minh City, Ho Chi City, 519/20 Tel + Minh 84 8 8123 Tel + 84 8 8123 521 519/20 Fax Fax + 84 8 8123 521 iscarvn@hcm.fpt.vn iscarvn@hcm.fpt.vn

CV MULTI TEKNIK CV Balikpapan MULTI TEKNIK JL. Raya JL. Balikpapan Raya No. 28 Jakarta Pusat No. 28 Indonesia Jakarta Pusat 10140 10140+Indonesia Tel 62 21 6307303 Tel + 62 21 6348062 6307303 Fax Fax + 62 21 6348062 multi@centrin.net.id multi@centrin.net.id

SINO TOOLING SYSTEM SINO TOOLING SYSTEM Blk 502, Jurong West Blk 502, Jurong West Ave 1 #03-813 Ave 1 #03-813 Singapore 640502 Singapore 640502 Tel + 65 6566 7668 Tel + 65 6567 6566 7336 7668 Fax Fax + 65 6567 7336 sinotool@singnet.com.sg sinotool@singnet.com.sg

MESCO MESCO Corner Reliance RelianceSt. Corner Brixton Pasig City Brixton St. Pasig City Metro-Manila Philippines Metro-Manila Philippines Tel + 63 2631 1775 Tel + 63 2635 2631 0276 1775 Fax Fax + 63 2635 0276 mesco@mesco.com.ph mesco@mesco.com.ph

ENQUIRY NO 163

Milling Milling Intelligently Intelligently

ENQUIRY NO 157

Contents November - December 2009

ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd, 1100 Lower Delta Road, EPL Building #04-02 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

Thailand Office: Thai Trade & Industry Media Co Ltd. 16/F Italthai Tower, 2034/73 New Petchburi Road, Bangkapi, Huaykwang, Bangkok 10310, Thailand Tel: 66(0) 2716 1722 Fax: 66 (0) 2716 1723

24 FIRST CUT Cutting Metal: The Dry Movement

The issue of using coolant in machining metal is no longer a dry subject especially when economic considerations and usage of exotic materials become more prevalent. By Dr Moshe Goldberg, Iscar

28

Dry & Wet Tools: Applying The Right Pressure

Taking the high-pressure route can reap dividends when machining aerospace materials. Contributed by Jeremy Lim, Sandvik Coromant SEA

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

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

INDUSTRY

Endorsements

32

Which Is Better? Wet Or Dry?

The necessity of cooling lubricants in the cutting tool sector is widely discussed and by weighing their pros and cons, a decision can be made. By Dr Uwe Schleinkofer, Ceratizit

34 TECHNOLOGY UPDATE Computerised Optimisation In Die Casting

The days of trial and error in die-casting seems to be over with the advent of modern simulation packages. By Dr-Ing Ingo Hahn & Dr-Ing Goetz Hartmann, Magma Giessereitechnologie, Germany

36

Maximising Your Mould Design & Manufacturing Process

The design and manufacturing phase of a mould is undoubtedly an important one. By Michael E Neumann

38

From Art To Engineering

In order to stay relevant and profitable, new engineering approaches catered for a production setup have been introduced in mould making. By Joson Ng 2

SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager.

For more subscription information Fax: (65) 6379 2806 Singapore E-mail: irenetow@epl.com.sg

metalworking equipment news Nov-Dec 2009

SPETA

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

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

Taiwan Association of Machinery Industry (TAMI)

JETSTREAM TOOLING

TM

DIRECTED COOLANT STRAIGHT TO THE EDGE.

WORKS BE

ST WITH

NOW FOR MILLING, DTURNING, R AND GROO ILLING VING Answering a call from the aerospace industry to improve the machining of difficult to machine alloys, Seco developed Jetstream Tooling – a revolutionary new solution to the age old problem of delivering coolant precisely to the cutting zone.

Jetstream Tooling works by delivering a concentrated high pressure jet of coolant at high velocity straight to the optimum position close to the cutting edge. This jet of coolant lifts the chip away from the rake face, improving chip control and tool life enabling increased cutting data to be applied – not just in aerospace materials. Jetstream Tooling has been proven to work in nearly all material groups and with a wide choice of coolant pressures..

The future is here, head straight to www.secotools.com Singapore Tel + 65 68412802 Malaysia Tel + 60 3 90591833 Thailand Tel + 66 2 7467 801 Vietnam Tel + 84 8 9144393 Indonesia Tel + 62 21 8088 8122

ENQUIRY NO 174

MILLING NEWS: STEADYLINETM VIBRATION DAMPING HOLDERS

M.I.C.A. (P) No. 233/06/2009

Taking on today’s challenges means having the right tools and meeting the right partner.

M.I.C.A. (P) No. 233/06/2009 • PPS 840/10/2009(028102) • ISSN 0129 5519

40 SOFTWARE & MEASUREMENT

www.equipment-news.com

VOL. 23 NO. 8 NOVEMBER/DECEMBER 2009

• 10 Business News • 87 Product Finder • 91 Exhibition Programmes • 92A Product Enquiry Card

November-December 2009

Expect more.

Engineer what you envision.

Experience the new Walter.

www.walter-tools.com

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Regulars

ASIA PACIFIC METALWORKING EQUIPMENT NEWS

Contents

Visit APMEN At Metalex Thailand 2009

Cover Nov-Dec09~b.indd 2

Making Light Work Of Measurement

From design all the way through to manufacturing, laser beams are shooting for fast and flawless measurements. By Rob Snoeijs, Metris

58 FEATURES

44

Delcam Asian Technical Summit 2009

Shape & Surface Measurements

The art of shape and surface measurements is applied to many modern industrial processes, especially in the fields of reverse engineering, 3D replication, inspection and quality control.

By Augustine Quek

48 FAB & FORM

62

It’s Time To Break The Mould

The financial crisis and stiff competition from neighbouring China has forced a rethink from the Hong Kong mould and die sector.

By Joson Ng

Packing A Quality Punch

There are new set of standards for quality, flexibility and productivity for punching. By Adrian Lim, Trumpf

50

Punch Press Machines: Basic Instinct

A mainstay of the metal working industry, there are a variety of punch press machines to cater to the needed capacity or concept of the product. By Tjut Rostina

66

Thread Production: To Cut, Mill Or Form?

With emerging manufacturing trends introduced into thread production, more consideration time may be needed to decide which production process to adopt. Submitted by Yvonne Ng, Walter AG Singapore

54 INDUSTRY SPOTLIGHT Shipbuilding: Sea Of Opportunities

70

Metalworking processes are a big part of shipbuilding as the industry undergoes the process of renewal.

By Joson Ng

Green By Design

With the 2010 release of SolidWorks, the company has unveiled its intentions to join the green movement. By Derek Rodriguez

74

Metalworking Fluids: Meeting New Regulations

As personnel health and safety continue to drive the development of metalworking fluids, the issues affecting operators are looked at. By Herwig Van Roey, Shell Lubricants

78

EVENTS & EXHIBITION Event Review: Asiamold 2009 Event Review: Metalex Vietnam 2009

• Refer to Advertising Index...

Pg 92

for Advertisers' Enquiry numbers

10/30/09 6:12 PM

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

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

editor’s note

Published by:

Making Metalworking Safer In all industries, safety is a major concern a nd ever y yea r, huge investments are made to ensure that the risks at workplaces are minimised and mitigated. In Singapore, the Workplace Safety and Health Act (WSHA) is formulated to cultivate good safety habits in all individuals and also to instil strong safety culture in workplaces.

In short the WSHA aims to reduce risks at source, inculcate greater ownership of safety and health outcomes by industry and prevent accidents through higher penalties for poor safety management.

Workplace safety to most people should trigger the images of workers wearing safety helmets and gloves or even a mask while working. But in the metalworking world, danger can also come in more subtle ways. Although less of a conventional risk like falling bricks and exploding vessels, the threat of metalworking fluids can cause substantial damage to health

but luckily, there are regulations currently being formulated to make machining even safer.

One such regulation currently in Europe is coming into force in December 1, 2010. It involves the classification, labelling and packaging of potentially hazardous substances.

The new regulations are designed to help improve personnel health and safety in the workplace. For metalworking operators, the levels of certain additives will be minimised to reduce risks during machining.

This calls for reformulation of some Metalworking Fluids (MWFs), setting up an intriguing race for manufacturers to produce safer MWFs with no loss in performance.

The safety issue of MWFs will be discussed in this edition of Asia Pacific Metalworking Equipment News, as we focus on dry and wet machining. Apart from the safety aspect of the MWFs, the performance of the fluid will also be placed under the microscope.

Finally with the year coming to a close, we at APMEN would like to wish all readers happy holidays.

Joson Ng Assistant Editor

6

metalworking equipment news Nov-Dec 2009

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

Reg No: 199908196C

managing director Kenneth Tan assistant editor Joson Ng

josonng@epl.com.sg

advertising sales manager Derick Chia

derickchia@epl.com.sg

assistant sales manager Yessica

yessica@epl.com.sg

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

irenetow@epl.com.sg

contributors Tjut Rostina Jeremy Lim, Adrian Lim Uwe Schleinkofer, Rob Snoeijs Augustine Quek Denis Stephan, Yvonne Ng Herwig Van Roey, Dr Moshe Goldberg Michael E Neumann Derek Rodriguez Dr-Ing Ingo Hahn Dr-Ing Goetz Hartmann board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher.

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

Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 233/06/2009 PPS 840/10/2009 (028102) ISSN 0129/5519

Eastern HOLDINGS Ltd Executive Board

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

etm

Eastern

Trade Media Pte Ltd an Eastern Holdings Ltd company

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

ENQUIRY NO 154

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ENQUIRY NO 161

Businessnews

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Bombardier Sifang Wins Contract To Build 80 High Speed Trains For China

Berlin, Germany: Bombardier Transportation’s Chinese joint venture, Bombardier Sifang (Qingdao) Transportation, has been selected by the Chinese Ministry of Railways (MOR) to supply 80 Zefiro 380 high speed trains (1,120 cars) for the country’s rapidly growing high speed rail network.

The contract, including 20 eight-car trainsets and 60 sixteen-car trainsets, is valued at an estimated CNY 27.4 billion (US$4 billion). The company’s share of the contract is estimated at CNY 13.5 billion. The first train is scheduled for delivery in 2012 with final deliveries expected in 2014.

Valenite To Join Walter

Tübingen, Germany: On January 1, 2010, the US company, Valenite, is to be integrated into the Walter Group. Operating in NAFTA markets, the new 10

metalworking equipment news Nov-Dec 2009

The new trainsets will be an integral part of an evolving high speed rail capability in China, which is developing more than 6,000 km of new high speed lines to create one of the most advanced high speed rail networks in the world. The trains, with maximum operating speeds of 380 kph, are based on the company’s next-generation Zefiro high speed rail technology.

The trains will be manufactured at Bombardier Sifang (Qingdao) Transportation production facilities in Qingdao, China. Engineering will take place in Qingdao and Europe with project management and components provided from sites in Europe and China.

competence brand, Walter Valenite, is set to offer tools with indexable inserts for turning, drilling and milling as well as the special tools of Modco. “By combining our product ranges, we will be able improve our market position in North America on the one hand and our worldwide position in the automotive industry on the other,” explains Peter Witteczek, chairman of Walter's board of directors.

Valenite is to be integrated into the existing organisation of Walter North America. Muff Tanriverdi, president of Walter North America, will be responsible for the new company.

ENQUIRY NO 168

businessnews

Hyundai Heavy Enters US Wind Turbine Market

Seoul, S Korea: Hyundai Heavy Industries signed a contract with Wave Wind, to provide six 1.65 MW wind turbines. The companies also agreed to expand cooperation in the 100 MW capacity wind turbine project.

The wind turbines will be produced in the company’s Gunsan wind turbine factory and installed in Milwaukee, Wisconsin by May 2010.

The rotor diameter is 77 m and hub height is 80 m.

Six wind turbines will generate 10 MW electricity, enough for 5,000 households.

The company has invested KRW105.7 billion (US$89.9 million) to build a 600MW capacity wind turbine manufacturing plant in Gunsan. Covering 132,000 sq m, the plant will be capable of producing 1.65 MW-class wind turbines. The company plans to expand the capacity to 800MW by 2013.

12

metalworking equipment news Nov-Dec 2009

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US Aluminium Industry To Grow Over 5.4% CAGR Come 2013 USA: At present, the US aluminium market is largely driven by automobile, construction, and packaging Industry. Use of aluminium in automobiles will keep on growing with increasing public demand for a greener environment and greater fuel efficiency that has forced policymakers to raise fuel economy standards, cut carbon dioxide emissions and enhance the use of aluminium in automobiles.

It will enable the US aluminium industry to register a steady CAGR of 5.4 percent (in value terms) during 20092013, says RNCOS in its research report ‘US Aluminum Market Analysis’.

Aluminium industry in the US is dominated by the top four players, accounting for nearly 80 percent of the market share, which gives rise to intense rivalry in the industry and calls for new market entrants to balance the aluminium demand-supply mechanism in the country.

According to the report, financial crisis will hamper the aluminium industry's growth rate in 2009 amid slowdown in the country's automobile and construction industry. However, under the government's stimulus plan, US$6.5 billion will be granted to the aluminium sector so that more aluminium power transmission lines could be laid in the country, which will certainly work as a catalyst for triggering the aluminium demand in the country and will provide potential growth opportunities to existing and new market players.

With interest in ‘green’ building increasing in the country, aluminium's role in an array of building and construction applications is poised to grow, which could be attributed to aluminium's recyclability, low weight, durability, and reflectivity. This will further boost the aluminium demand and will help industry to overcome the negative impacts of crisis.

Help Wanted!

• Which is your favourite section?

• Are there any particular technical topics you would like to read about?

• What would you like to see in our future issues?

• Any other comments?

Your opinion matters, please email our editor at: josonng@epl.com.sg

ENQUIRY NO 172

businessnews

Mori Seiki Begins Sales & Service Of DMG Machines In Japan

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MHI To Establish JV In Thailand With EGAT

Robert Montgomery, Nevada, United States

N a g oy a , J a p a n : M or i S e i k i ha s si g ne d a distributorship agreement with the German machine tool manufacturer, Gildemeister for sales/ service activities in Japan, which went into effect as of October 1, 2009.

From that date, Mori Seiki will take responsibility for sales and service activities in Japan, regardless of whether the product is from DMG or Mori Seiki.

Based on the skills and expertise transferred from DMG Nippon, the company will also take care of the servicing of DMG machines in the field and fulfil customers’ requests such as after-sales service, spare parts supply or training.

Gildemeister

Milan EMO The Most Successful Trade Fair For Gildemeister In 2009

Bielefeld, Germany: With order intake of €52.6 million (US$78.5 million) and 254 machines sold, Gildemeister drew a positive balance at EMO 2009 in Milan.

As the largest exhibitor, the company presented 41 exhibits, including seven world premieres, over approximately 1,500 sq m. Its trade fair booth registered 61 percent more trade visitors than the previous EMO in Milan (2003). As a result, 254 machines to a value of €52.6 million were ordered and an additional 1,251 new offers were generated. The innovations on display from the turning and milling technologies, as well as modern automation and software solutions, attracted a lot of attention from the trade visitors.

The orders received at the EMO reinforce the company’s expectations for the fourth quarter; in addition, the first positive impetus for the financial year 2010 has been provided by the newly generated offers.

14

metalworking equipment news Nov-Dec 2009

Tokyo, Japan: Mitsubishi Heavy Industries (MHI), has concluded an agreement with the Electricity Generating Authority of Thailand ( EGAT ) to establish a Joint Venture (JV) company to provide repair services for gas turbine components that are exposed to very high temperatures. The new company will target the launch of a service factory in 2012.

The goals of the partners have meshed favourably.

MHI's aim is to localise repair services in Thailand, where the gas turbine market is thought to have large growth potential, in order to enhance its services, including shortening of delivery times, and to extend its service capability throughout the Asia region, where sharp increases in demand are expected.

EGAT, a major MHI customer, has been looking for ways to reduce maintenance/repair costs and also to cultivate local engineers in this field in an aim to expand into other Asian markets.

The JV, to be known as EGAT Diamond Services, will be capitalised at approximately 600 million bahts (US$18 million), with EGAT, MHI, Mitsubishi Corporation and Ratchaburi Electricity Generating Holding PCL owning shares. The JV will build its repair plant in an industrial park near Bangkok and will initially offer repair services for combustor parts, and progressively expand its operations to turbine blades.

ENQUIRY NO 158

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Nossirom, Germany

UAE’s Steel Consumption To Reach 15 Million Tonnes By 2012

New Delhi, India: According to the report, ‘A UAE Steel Industry Analysis’, despite being affected by the ongoing financial crisis, the steel industry of the country is expected to witness good times ahead.

Various upcoming infrastructure projects will drive the steel demand in the UAE. It is expected that the country’s steel consumption will reach 15 million tonnes by the end of 2012, an increase of around 50 percent from the consumption level of 2007.

The report highlights that the construction boom in the UAE is the major driving force behind the growth of its steel industry. It is expected that in the coming two years, a total of US$392 billion will be spend on

construction activities.

It is noteworthy that UAE’s construction activities are largely concentrated in Dubai, but during the coming years, unprecedented growth in the sector is expected throughout the country, especially in Abu Dhabi.

The country is mainly dependent on imports to fulfill its domestic steel consumption. But re cent ly major ste el compa nie s including state owned Emirate Steel have planned to add major production capacity in the coming yea rs to reduce the countr y’s dependence on imports.

Saving Downtime, A Boost To Machining Productivity S i n g a p o r e : E row a , one of the five Swiss compa nie s, which pa r ticipated in the Swiss-made Precision Grinding Technologies Seminar in Singapore on May 29, 2 0 0 9, showcased their quickc h a n g e p a l l e t i si n g system.

Using aviation as an analogy, Stephan Stephan Neeser Nee ser, director of sales and marketing (worldwide) said: “After 100 years of air-transportation, someone has thought of a cheaper way to fly, and as the low-cost carriers compete and still earn money by cutting down 16

metalworking equipment news Nov-Dec 2009

on ‘downtime’ of airplanes, Erowa’s palletising clamping systems help cutting on downtime of machine tools – providing a key to productivity and profits.”

Similar to other precision machining applications as EDM, milling, turning and wire EDM, the company’s Integrated Tooling System provides quick-change palletising for precision grinding applications on cylindrical grinding machines.

Repeatability accuracies of less than 2 microns (0.002 mm) are achievable over and above the possibility of offline presetting of the work-piece, for boost in productivity. In short, it delivers precise results through simple setup.

The company’s operation in South-east Asia aims at consolidating its position in the metal cutting field through its pursuit in providing high-productivity work-holding systems.

Engineering experts from all industries focus on customers’ needs and satisfaction to supply the best solutions to improve their production.

World Headquarters World Headquarters

304, Yonggye 4-ri, Gachang-myeon, Dalseong-gun, Daegu, 711-864, KorEa / Tel: +82-53-760-7640 / Fax: +82-53-760-7660 Web: http://www.taegutec.com

ENQUIRY NO 162

Taegutec always focus on contributing only the highest level of technology to the automotive, heavy industry and die & mold industries as well as serving dedicated productivity improvement partners for our customers.

businessnews

AMSC & Sinovel Sign A $100 Million Contract Massachusetts, USA: American Superconductor Corp and Beijing-based Sinovel Wind Corp (Sinovel) have signed a contract worth more than $100 million (excluding value added tax) for core electrical components to be utilised in Sinovel’s three megawatt (MW) wind turbines, known as the SL3000.

AMSC expects to begin shipping sets of core components under the new contract in March 2010 and to complete all shipments by the end of calendar year 2011.

This is the second order the company has received from Sinovel for three MW core electrical components and follows an $18 million contract that was signed in early 2008. AMSC’s core electrical components include the company’s PowerModule PM3000W power converter that enable wind turbine operation by controlling power flows, regulating voltage, monitoring system performance and controlling the pitch of wind turbine blades to maximise efficiency.

At the end of calendar year 2008, China had an installed wind power capacity of approximately 12,000 MW (12 gigawatts). In its June 2009 report, industry research firm Emerging Energy Research projected that China’s wind power installed base would exceed 200,000 MW by 2020.

Vestas Receives Order From India Randers, Denmark: Vestas has received an order for 60 units of the V82-1.65 MW wind turbine for a wind power project located in Theni in the state of Tamil Nadu, South India.

The contract comprises supply and commissioning of the turbines, a SCADA system as well as a 10-year service and maintenance agreement.

“This project in Theni is a step forward for us in India. We are thrilled that CLP has chosen Vestas as their wind energy solution provider to help CLP realise their own renewable energy ambitions. This project award is recognition of our long-standing reputation for capability, innovation and competitive strength in this wind energy market,” says Vestas Asia Pacific’s president, Sean Sutton.

The company has been active in India for more than 10 years, and as per 30 June 2009, Vestas had installed more than 2,100 MW of wind power in India.

Shipment of the turbines is scheduled for the fourth quarter of 2009 with expected commissioning to take place in January 2010.

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metalworking equipment news Nov-Dec 2009

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Honda Reaches 25 Million Units In Motorcycle Production In Indonesia Jakarta, Indonesia: PT Astra Honda Motor (AHJ), Honda’s joint venture company in Indonesia responsible for motorcycle production and sales, held a ceremony to commemorate cumulative production of 25 million motorcycles.

The company now has an annual motorcycle production capacity of 3.1 million units, the second largest among all Honda subsidiaries and affiliates worldwide after only Hero Honda in India (with annual production capacity of 4.9 million units).

The total motorcycle market in Indonesia, which is the third largest in the world after China and India, marked an all-time record of approximately 6.2 million units in 2008, a 33 percent increase from 2007.

Delcam Joins Singapore Medical Consortium

Singapore: Delcam’s Singapore-based subsidiary, Delcam South-east Asia, has become a founder member of the MedTech Manufacturing Consortium, which has been set up to accelerate growth of the medical technology industry in the country.

It has been set up by Singapore Institute of Manufacturing Technology and the Workforce Development Agency, which have injected S$10 million (US$7.2 million) into technology and manpower development for the sector over the next five years.

According to the Economic Development Board, the medical technology industry in Singapore doubled its manufacturing output from S$1.5 billion in 2000 to about S$3 billion in 2008. By 2015, the sector aims to reach S$5 billion.

This high level of growth is typical of the rapid expansion in the global healthcare market. It has prompted the company to establish a healthcare division to provide a greater focus on this increasingly important part of its business.

The consortium will offer consultancy services, networking services and a graduate diploma programme.

ENQUIRY NO 019

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OIL & GAS

First Gas From Oyong Phase-2 In Indonesia

Adelaide, Australia: Santos has commenced gas production from the Oyong Phase-2 project located off Madura Island, East Java, Indonesia.

Oyong commenced oil production in September 2007 and has produced over four million barrels to date. Oyong Phase-2 was sanctioned in December 2007 and involves modifications to the offshore facilities and construction of a 60 km pipeline to a new onshore gas processing facility located in East Java. The gas will be

sold to PT Indonesia Power Grati for use in the Grati power station. After an initial ramp-up period, gross gas production rates are expected to be about 50-60 mmscfd during the plateau period.

The Oyong field is located in the Sampang production sharing contract, approximately 70 km from Surabaya in the East Java region of Indonesia. Santos (Sampang) is operator with a 45 percent interest.

Lamnalco Wins Contract With CPC

CNPC & Shandong Government To Construct Gas Pipeline Network

UAE: Lamnalco signed a 10 year contract for integrated marine services with Caspian Pipeline Consortium (CPC). The contract is due to commence mid-2010.

CPC operate the pipeline and related infrastructure linking the oil fields of West Kazakhstan with the marine terminal on the Russian Black Sea coast close to Novorossiysk. Crude Oil export takes place through 2 x Single Buoy Moorings (SBM’s) located around 5 km offshore from the small boat harbour. The CPC terminal commenced operations in 2001 since when it has exported more than 200 m tonnes of crude oil to markets around the world.

The company will provide a turnkey package of services for the complete operation including a permanent on-site dive team for SBM maintenance as well as oil spill response services for the duration of the contract. This will involve the deployment of a modern fleet of 15 vessels including a Multi-purpose Service Vessel (MSV), tugs, line handling boats and boom boats as well as a full IMCA approved dive spread housed on the MSV. 20

metalworking equipment news Nov-Dec 2009

Beijing, China: CNPC and Shandong provincial government signed a cooperation document on jointly establishing the Shandong natural gas pipeline company. On the same day, construction of the TaianWeihai section commenced.

Shandong natural gas pipeline network includes one trunk and six branches, which will run through Taian, Laiwu, Zibo, Weifang, Yantai, Weihai and Rizhao from west to east with a total length of 1,067 km and the trunk length of 659 km. Taian-Qingdao section and QingdaoWeihai section are expected to be operational by June and December 2010 respectively.

Once the pipeline network becomes operational, Shaan-Jing gas pipeline and the second West-East gas pipeline can be linked up with Shandong Province’s pipeline via Ji-Ning pipeline and Taian branch to provide safe and steady gas supplies to the cities along the pipeline, and satisfy the demands of economic development and environmental protection in Jiaodong Peninsula and Jiaozhou Bay Area.

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AEROSPACE

Airbus Foresees Demand For Some 25,000 Aircraft In The Next 20 Years per year or double in the next 15 years. This will require a demand for almost 24,100 new passenger aircraft valued at US$2.9 trillion. With the replacement of some 10,000 older passenger aircraft, the world's passenger aircraft fleet of 100 seats or more will double from some 14,000 today.

Airfreight tonne kilometres (FTKs) is forecast to increasing annually by 5.2 percent. Combined with fleet renewal, this creates a demand for some 3,440 freighters. More than 850 of these are new aircraft valued at US$210 billion, with the remainder converted from passenger aircraft.

The greatest demand for passenger aircraft will be from airlines in Asia-Pacific and emerging markets. The region that includes the People's Republic of China and India accounts for 31 percent of the total, followed by Europe (25 percent) and North America (23 percent). In terms of domestic passenger markets, India (10 percent) and China (7.9 percent) will have the fastest growth over the next 20 years. The largest by volume of traffic, will remain domestic US.

ENQUIRY NO 155

Toulouse, France: Some 25,000 new passenger and freighter aircraft valued at US$3.1 trillion will be delivered from 2009 to 2028, according to Airbus' latest global market forecast. Emerging economies, evolving airline networks, expansion of low cost carriers and the increasing number of mega-cities as well as traffic growth and the replacement of older less efficient aircraft with more eco-efficient airliners are factors driving demand for new aircraft.

Larger aircraft in all size categories are required to help ease aircraft congestion and to accommodate growth on existing routes and to achieve more with less. Compared to timescales for aircraft investment and fleet turnover, economic down cycles are relatively short and a strong underlying demand for air travel will drive growth. In 2009, a decline in Revenue Passenger Kilometres (RPK's) of two percent is expected to be followed by a rise of 4.6 percent in 2010.

The forecast anticipates that in the next 20 years, passenger traffic RPK's will remain resilient to the cyclical effects of the sector and increase by 4.7 percent

Nov-Dec 2009 metalworking equipment news

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AEROSPACE

JTC To Develop Seletar Aero+sPace Singapore: JTC aims to develop the Seletar Aero+sPace (SAP) into a world cla ss aerospace p a rk , sup p o r t i n g Singapore’s vision of becoming a global aviation hub.

The SAP will host a new i nte g rate d aerospace industry Seletar Aero+sPace (SAP ) cluster incorporating aerospace Manufacturing, Repair and Overhaul (MRO); design and manufacturing of aircraft systems and components; business and general aviation activities; and an aviation campus for the training of pilots, aviation professionals and technical personnel.

The 140-hectare (ha) industrial park is expected to contribute S$3.3 billion (US$2.1 billion) annually in value add (one percent of GDP) and create employment for 10,000 people by 2018.

JTC's initiatives to grow the industry in SAP include: - a Business Aviation Complex (BAC) - a General Aviation Centre (GAC), incorporating a hangarage for the parking of aircrafts.

- the Components Manufacturing and MRO Facilities, or CMM in short.

- The Business/General Aviation companies will offer services/products which complement the other aerospace activities at the SAP. Target Market: - Business aviation companies that are providing support services (such as fixed-based operation, supply of aircraft parts, repair cycle management services, chartering and freight forwarding, fleet management and aircraft sales/leasing, and includes the relocation of incumbent business aviation companies).

Components Manufacturing & MRO Facilities (CMMF) Strategic Objectives: - Ready built land-based factories for the aerospace and aerospace supporting companies.

- To offer quick start-up for companies.

Target Market: - Companies involved in the manufacturing of components or the MRO functions, which forms an integral and important part of the aerospace value chain.

General Aviation Centre (GAC)

Business Aviation Complex (BAC)

Business Aviation Complex (BAC) Strategic Objectives: - To relocate incumbent business aviation companies providing supporting services such as fixed-based operation, supplying of aircraft parts, repair cycle management services, chartering and freight forwarding, fleet management, aircraft sales/leasing.

- To offer quick start-up for new entrants into SAP - To provide amenities such as a new food court in the western part of SAP. 22

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General Aviation Centre (GAC) Strategic Objective: - A shared facility and space for line maintenance & parking of smaller aircrafts in the general aviation business.

- A positive outcome for space optimisation that came about from the consultations with the collaborative aerospace community.

- To help individual general aviation company save on investing in fixed infrastructure and hence enjoy long term and substantial operational cost savings.

Target Market: - Companies in general aviation.

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statistics

Worldsteel Short Range Outlook Beijing, China: The World Steel Association (worldsteel) is forecasting that apparent steel use will contract worldwide by -8.6 percent to 1,104 mmt in 2009 after declining by -1.4 percent in 2008. This is an improved figure over the spring forecast issued in April 2009, which predicted a decrease of -14.1 percent.

The improvement is largely due to the exceptionally strong growth in steel demand in China. With signs, from the beginning of the second half of 2009, of a recovery across the world now apparent, global steel demand in 2010 is forecast to grow by 9.2 percent to 1,206 mmt which is a recovery to the level of 2008.

Daniel Novegil, chairman of the worldsteel economics committee said: "The global recovery is stronger than we predicted in April. According to our current forecast, China will rebound 19 percent in 2009 and five percent in 2010. Emerging economies will slow down 17 percent in 2009, to grow 12 percent in 2010. Apparent steel use in developed economies, that contracted 34 percent in 2009, will rebound 15 percent in 2010. Therefore, worldsteel forecasts that global steel demand will return to growth in 2010 but this is expected to be moderate.

As before the financial crisis, the emerging economies, especially China, will be the critical factor in driving world steel demand in the near future.”

Regions EU (27) Other Europe CIS NAFTA Central and South America Africa Middle East Asia and Oceania World BRIC World (excl. BRIC) World (excl. China)

2008 181.283 25.316 48.946 128.955 44.277 26.170 43.055 709.010 1,207.013 553.772 653.241 764.049

2009 122.255 20.813 33.852 82.771 33.455 26.285 38.834 745.471 1,103.735 625.853 477.882 577.493

China’s apparent steel use in 2009 is expected to increase by 18.8 percent to reach 526 mmt. China is expected to account for 47.7 percent of world steel apparent use and excluding China, potential world steel demand would have fallen by -24.4 percent.

Rest Of The World India also remained relatively resilient to the global crisis and apparent steel use is expected to grow by 8.9 percent and 12.1 percent in 2009 and 2010, respectively.

The NAFTA region is expected to show a -35.8 percent decline in apparent steel use in 2009 and then a positive 17.1 percent growth in 2010. Apparent steel demand in the US is likely to fall by -38.7 percent to 60 mmt in 2009 after falling by -8.2 percent in 2008. It should recover to 72 mmt in 2010 with a growth rate of 18.8 percent.

The EU-27 economies were also severely affected by the crisis and the region’s apparent steel use is expected to fall by -32.6 percent in 2009 to 122 mmt. In 2010, the apparent steel use in the EU-27 is expected to grow by 12.4 percent.

Japan will see its apparent steel use decline by -31.3 percent, which is expected to recover by 15.8 percent in 2010 to reach 61 mmt.

2010 137.425 23.817 36.638 96.932 36.685 29.277 42.946 801.866 1,205.585 662.679 542.906 653.032

07/08 -8.2% -10.8% -13.5% -8.2% 6.5% 11.4% 6.9% 1.8% -1.4% 1.6% -3.8% -3.7%

08/09 -32.6% -17.8% -30.8% -35.8% -24.4% 0.4% -9.8% 5.1% -8.6% 13.0% -26.8% -24.4%

09/10 12.4% 14.4% 8.2% 17.1% 9.7% 11.4% 10.6% 7.6% 9.2% 5.9% 13.6% 13.1%

Short range outlook for apparent steel use (2008-2010) in mmt

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The

Dry Movement Cutting Metal:

The issue of using coolant in machining metal is no longer a dry subject especially when economic considerations and usage of exotic materials become more prevalent.

By Dr Moshe Goldberg, marketing technical advisor, Iscar

T

he use of fluids during machining serves several functions, such as effective lubrication and cooling at the tool/workpiece interface, as well as effective flushing of the chips.

Failing to evacuate the chips efficiently can result in subsequent occurrences of re-cutting, which tends to compress the removed material against the freshly machined surface, and to some extent weld the chip fragments to the surface. This can also damage the quality of the surface finish.

In contrast, lubricating fluids are susceptible to bacterial propagation and odour generation, which could cause serious health hazards.

Numerous other drawback s associated with these fluids include the cost of procurement, disposal, maintenance and labour. Stains on the part or contamination can also be problematic.

For flushing purposes, hole making operations require the use of lubrication at the contact point of the drill with the workpiece material, aiming to eject the removed material from the hole.

Lack of fluids will cause the chips to adhere to the hole walls and average roughness of the machined surface might be twice as high when compared to wet operation. Lubricating the interface between the drill head and the walls of the hole can lead to a significant reduction of torque during the operation.

Feeling The Heat In milling and turning, transfer of heat from the cutting zone towards the removed chips is an indicator of positive machining characteristics. Good chip design enables a deflection of 85 percent of the generated heat away from the cutting zone, while the remaining heat flows into the workpiece or dissipates into the tool.

This heat generation phenomenon has a detrimental effect on the cutting tool in terms of

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tool life. During a milling operation, for example, the cutting edges tend to heat and cool as they enter and exit the piece being machined.

These temperature fluctuations create a sequence of expansions and contractions that lead to fatigue stress and thermal cracks.

The introduction of lubricating fluid often makes the situation even worse.

A long-lasting debate amongst research engineers revolves around the question whether cutting fluid actually reaches the zone interfacing between the bottom side of the chip and the cutting tool. If they do, their effect is limited, assuming that they cool only the shearing vicinity. This hot/ cold interaction only intensifies the temperature gradients and increases thermal stress.

Balancing The Books On Wet Machining W i t h r e g a r d to e c o n o m i c considerations, 20 years ago,

Many are turning to dry or nearlydry machining solutions, with the intention to benefit from coolant cost savings or improved tool life

the purchase, management and disposal of lubricating fluids accounted for less than three percent of the production costs.

Today, in comparison, the same operations constitute 16 percent of the cost of the average job.

In line with this significant trend, and with a notion that cutting tools only bear the relatively low cost of three percent on the average, manufacturers are willing

Deep Drills For Milling Centres & Lathe Machines

Iscar has developed long drills for a drilling depth-to-diameter ratio of 7XD and up, to be used on standard horizontal milling centres, turning, and multi-task machines.

Use of supplementary machine and setup can be avoided by using the DR-DH deep drills. They can be used with the existing adaptations, not requiring any special coolant pressure or extra pump capacity. The drills will be available as semi-standard items in the diameter range of 25.4 to 69.5 mm. The company will offer two drill versions, the single and double flute.

Enquiry No. 8001

to accept slightly shorter tool life at the expense of eliminating the cost of buying and maintaining lubricating fluids.

Consequently, a growing number of manufacturers are turning to dry or nearly- dry machining solutions, with the intention to benefit from coolant cost savings or improved tool life.

Dr y machining refers to machining without any fluids, while near-dry machining or MinimumQuantity Lubrication (MQL) is the use of a minute amount of fluid that is applied directly to the cutting edge (either internally or externally).

T he ne a r- dr y machining features fluid vaporisation during the process, leaving dry chips.

The practice of dry or near-dry machining has already proved in numerous machining case studies that much faster cutting conditions can be successfully applied.

Substrate & Coatings The method of dry/near- dry machining has been recognised

by Iscar in the past few years. The company supports the adoption of green machining techniques, with the added value benefits of cost reduction. As a result, the latest technology of cutting tool materials, such as advanced coated carbide, ceramics, cermets, Cubic Boron Nitride (CBN), and Polycrystalline Diamond (PCD) has Nov-Dec 2009 metalworking equipment news

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been developed.

The submicron grain structure of the solid carbide substrate provides the retention of cutting edge integrity, even at high cutting temperatures, while accommodating a sufficient sof tening ef fe ct to combat deformation and resist cratering.

The high cutting temperatures, which occur during dry machining tend to slightly soften the carbide structure, which in turn increase its toughness, prevent any potential chipping and prolong tool life.

Using Polycrystalline Boron Nitride (PCBN) cutting tools also provides a successful alternative to dr y machining. Abra sive technology features PCBN tools for turning, boring and milling applications in a form of brazetipped or solid PCBN inserts.

The PCBN features a close resemblance to diamond hardness with a considerable amount of abrasion resistance, combining both a high degree of toughness and hot hardness. All of these properties make PCBN the most suitable cutting tool materials for machining hardened steels, cast irons and super alloys.

Dry Machining Is Good But… In conclusion, despite the growing popularity of dry machining and MQL methods, machining some materials essentially requires the use of cutting fluids. Machining aluminium has to be carried out with the use of high-pressure coolant for the prevention of built up edge phenomenon.

In addition, machining high temperature and nickel based alloys also requires the use of copious amounts of coolant for the prevention of strain hardening of the sub-surface layers. Deficiencies such as chipbreaking, exhibited when machining stainless steel, can be solved by the use of a coolant stream. MEN Enquiry No. 8002 26

metalworking equipment news Nov-Dec 2009

Wet Machining Fights Back Even though dry machining has its benefits, machining certain materials require a softer touch – coolant.

High-Pressure Coolant (HPC) is used particularly for exotic and stainless steel materials. High pressure creates a localised stream of coolant at pressure that eliminates the formation of vapour and assists chip breaking into small segments.

The combination of coolant Directing the coolant at high pressure (70-140 bar) right to the cutting zone is the key precisely targeting the cutting zone provides advantages that are not available with conventional flood coolant. The coolant is delivered with enough force to reach the cutting zone as a liquid, not a vapour.

In the liquid phase, it actually lubricates the cutting process as it quenches the molten chip, shattering it into smaller, more manageable pieces. Also, because of its internal flow path, HPC keeps the entire spindle, tool, insert and workpiece cooler, leading to much longer tool and equipment life. In that sense, it works like the cooling system in an automobile engine.

Another benefit is that delivering coolant close to the secondary shear zone improves machinability of the material under high speed conditions.

Higher pressure coolant, directed right at the cutting zone, creates smaller, more manageable chips, whether the material is titanium, inconel or steel.

Take Aim, Don’t Flood Directing the coolant right to the cutting zone is the key. This is the ‘laser’ approach to coolant deployment, not the ‘floodlight’ approach.

At the extreme cutting rates involved with today’s HPC turning, high pressure coolant flow is an integral part of the cutting process. Besides prevention of overheating and thermal shock in the cutting zone, the coolant contributes a ‘water-jet cutting’ effect, which actually enhances cutting action.

HPC tools are custom designed to operate at these extreme pressure and cutting rates. They deliver a higher performance level than their conventional internal coolant counterparts made for lower pressure service.

High-Pressure Coolant HPC systems deliver numerous production benefits:

• Increased productivity - High pressure coolant removes heat and deflects chips from work surfaces, allowing for higher feed rates and faster spindle speeds.

• Higher quality - More efficient chip removal, higher feed rates, faster spindle speeds, and reduced tool wear in turn boost part quality and surface finish.

• Longer tool life - High pressure coolant eliminates heat and chips and reduces tool wear.

Enquiry No. 8003

The Art of Grinding.

There are more than 100 000 000 000 grinding possibilities.

At STUDER you can always find the perfect solution.

High precision, productivity and a long machine tool life are typical of our solutions for cylindrical grinding and Combination-Machining. As the Market and Technology Leader, STUDER stands for top Swiss Quality for Hardware, Software, System-Integration and Service. If the need is for universal and flexible or high production solutions, for small or large batches, we have a solution for everyone.

Munger Machine Tool Pte Ltd. Tel: +65 6764 63 88 Fax: +65 6764 33 18 E-mail: mungermachine@pacific.net.sg MMT Thailand Tel: +66 2 391 9953 Fax: +66 2 712 3973 MMT Malaysia Tel: +60 12 326 6309 Fax: +60 3 7980 4744

Fritz Studer AG CH-3602 Thun (Switzerland) Telephone +41-33-439 11 11 路 Telefax +41-33-439 11 12 www.studer.com

ENQUIRY NO 159

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Dry & Wet Tools:

Applying The

Right

Taking the high-pressure route can reap dividends when machining aerospace materials. Contributed by Jeremy Lim, marketing communications, Sandvik Coromant SEA

T

he role of coolants in machining aerospace parts is undergoing somewhat of an evolution. Machine shops have for many years used coolants by directing tubes, which flood the machining zone, particularly on the materials that need coolant to be machined.

But now, by applying coolant at high pressure accurately into the machining zone, new advantages are being made available. Broad access to this technology has been made possible by higher coolant-supply capacity of many CNC machines as well as by new tooling concepts.

Turning Up The Pressure Based on research, precisely directed jets of coolant up to a high pressure (100 – 1,000 bar) became part of the cutting tool used to machine materials that were demanding with regards to machinability and chip control.

The coolant jets forced their way in, forming a fluid wedge between the chip and cutting edge.

The contact length was shortened with a lowering of the temperature at the machining zone. Another interesting result was how the curl of chip could be influenced,

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improving the control of the chip and in some cases even leading to chip breaking.

For a number of applications, the tool became the solution for machining materials with poor machinability and/or troublesome swarf. A lot was learnt about the effect of coolant-pressure distribution a nd coola ntnozzle size.

By varying the jet data, a variable chip-former was achieved and it became possible to guide stringy chips in a desired direction and even improve the length of chips.

Installations were made on a limited scale to solve problems particularly in the oil, aerospace and ball bearing industries. The tool, however, needs dedicated installation with special tool holders and has been mainly used in vertical turning machines.

Embracing HPC Many modern CNC machines have coolant supplies at pressures of 70 to 100 bar as standard or option with capable tanks and pumps. This is sufficient to incorporate High Pressure Coolant (HPC), which makes a noticeable difference to performance and results on more commonly used machining centres,

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If coolants are applied effectively, they can make a difference in modern machining HPC can make a difference with regard to chip formation and tool wear

turning centres, vertical lathes and multi-task machines. Standard equipment is sufficient with easy channelling of coolant to where the jet is applied.

An essential basis for HPC machining are modular tools, partly to ensure quick tool changes for minimising machine stoppages but also to efficiently secure coolant connections and channels from the machine to cutting edge.

Taking reference from modular quick-change tooling system, today’s standard high-pressure coolant tooling system, designed with internal coolant supply, is also suited as the means with which to supply coolant at high pressure. It is an established ISO standard and option on many CNC-machines with stationary and rotating tools.

A milling cutter for HPC has through-coolant and is equipped with nozzles positioned and directed depending upon the tool type and the application it is intended for. Channels are connected to the machine tool or extra pump equipment for supplying coolant at pressures of around 70 bar.

This supply is widely available today and although the pressure i nvolve d is not u lt ra h ig h as in special applications, the scope is certainly sufficient for improvements on performance and results.

Turning With Coolant Modern turning tools adopt HPC for turning. It is equipped to give accurate coolant jets with laminar parallel flow. The jets give rise to a hydraulic wedge between insert and chip, affecting the chip form and flow and reducing temperature in the machining zone.

Employing nozzles, mounted close to t he cut t i n g e dge , accurately projecting the highvelocity jets, forces the chip off the insert face, cools and breaks the chips into smaller lengths, helping

to evacuate them.

Benefits in finishing operations have been established even at lower pressures, down to 10 bars in material including steel, stainless steel, aluminium, as well as titanium and heat resistant super alloys.

Apart from higher security brought about by better chip control, HPC can bring about a considerable improvement of tool-life and a potential for higher cutting speed. By applying HPC, 50 percent tool-life increases can often be the result.

Cutting speed affects the temperature and tool wear, more than any other factor. Increasing the cutting speed in titanium outside the more limited machinability window reduces the tool-life dramatically.

But when the feed is increased on a similar scale, a smaller reduction in tool-life is typical.

This often makes the feed an attractive route to improved metal removal rate with low effect on tool-life. However, high feed is not always an option in these machines because of higher cutting forces as well as the effect on chip control.

Here Comes The Jet Era If coolants are to be applied effectively and make a difference in modern machining they need more frequently to be applied as jets at high pressure, in sufficient volume and directed correctly. Just having a stream of coolant or even flooding the machining zone with coolant is not enough any more.

Qualified application of High Pressure Coolant (HPC) can, on the other hand, make a distinct difference as regards to: • Chip formation • Distribution of heat • Smearing of work piece material on the cutting edge • Surface integrity • Tool wear The application of HPC can make a difference to machining especially for stainless steel and low-carbon steel. But it is when machining the more demanding materials, such as titanium alloys and heat resistant super alloys, that the practice makes a dramatic difference.

Enquiry No. 8004

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Employing nozzles, mounted close to the cutting edge and accurately projecting the high-velocity jets can force the chip off the insert face

The effect of HPC can therefore provide a potential to raise performance by way of higher cutting speeds without the usual rise in temperature and loss in toollife. For ISO S classified materials, a 20 percent increase in cutting speed can be achieved while maintaining the same cutting length.

Internal turning is also an area where HPC can provide an important role to help ensure good chip formation, as well as improving shearing properties in demanding materials such as titanium.

In this way the concept adds higher security and longer toollife to boring operations. When machining relatively large, deep holes with boring bars, such as in landing gear components, modular tooling at the back as well as the front end of the tool can be advantageous.

HPC For Milling The effect HPC gives through the coolant jet can also be an advantage in milling. With numerous inserts making up each long radialedge, coolant nozzles have been positioned to provide the benefits of high-pressure jets for each insert.

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depth capability of the cutter is not used, plugs can be used instead of nozzles, in that way avoiding wasted coolant pressure through unnecessary jets. The nozzles at the inserts cutting at the end-face are positioned to also assist chip evacuation, avoiding the re-cutting of chips particularly in cavities.

To ensure the right values for coolant flow and pressure, a dedicated calculator is used to best apply HPC for the cutter with inputs of flow rate and pressure in the machine, along with cutting data, axial cutting depth and tool specifics.

The calculator arrives at the size of nozzles that will optimise the effect and can reduce flow requirement while keeping up a high-pressure flow of coolant through selected holes.

Titanium is chemically reactive and as such is prone to work piece material welding onto the cutting edge during machining. This phenomenon is often a problem as it affects tool-life particularly through causing re-cutting of chips and chip-jamming of hardened chips. HPC can often be a solution to prevent welding onto the edge when machining titanium and other

smearing materials.

Va r iat io n i n co mp o ne nt surface integrity is affected by the temperature and forces generated during machining. Coolant certainly plays its part in controlling the temperature and consequently HPC has been shown to provide a more reliable surface result.

Optimising Operations Turning tool with HPC capabilities has the ability to force a fluid wedge into the machining zone, especially in operations classified as medium to finish turning. The chip thickness is more controllable and the fluid wedge easier to apply than in roughing operations.

Application of high pressure machining should not be seen as means with which to compensate shor tcomings due to other application factors – such as unsuitable insert, instability and incorrect cutting data.

HPC is an optimiser when operations are correctly established basically. The concept will provide the means for shorter cycle times, improved component quality consistency and higher process security in turning and milling.

The need to optimise various machining operations, especially when chip formation and the effects of demanding materials are prominent; make HPC an attractive option, especially as it is available readily on machines today.

The rising population of multi-task machines along with new-generation vertical turning machines has highlighted the benefits of machining with highpressure coolant especially from the chip control point of view.

The disturbance due to swarf accumulation is critica l a s these machines are to a rising extent used by machine shops making aerospace components in demanding materials. MEN Enquiry No. 8005

High Precision Precision Toolholders Toolholders High

C5/C6/C8 C5/C6/C8

The modular tooling system of turning and rotating tool holders strengthens the performance of Machining Machining && Turning Turning Center Center

Turning Tools Tools Turning

Rotating Tools Tools Rotating

ENQUIRY NO 169

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?

Wet Dry

Which Is Better?

Or

The necessity of cooling lubricants in the cutting tool sector is widely discussed and by weighing their pros and cons, a decision can be made. By Dr Uwe Schleinkofer, head of the development department, cutting tools, Ceratizit

W

et or dry? This is a frequently asked question with regard to machining processes. Dry machining is desirable but cannot be applied to all work piece materials. Wet machining is then applied and emulsion and/or oil is used as a cooling lubricant. Increased tool life, reduced material adhesion on the cutting edge and improved surface quality of the work piece are the result.

The problem: due to the high temperatures in the machining process, cooling lubricants evaporate and cause chemical reactions; and the disposal of contaminated chips and liquids means additional costs and effort. For decades the industry has strived to reduce the coolant quantity or to apply dry machining.

Aerospace Industry: Machining With Minimum Lubrication It was 20 years ago that the coolant quantity in the field of aluminium machining began to decrease. The aerospace industry took the initiative and started machining with minimum quantity lubrication. In this method the mixture of air and liquid was sprayed in the direction of the cutting edge.

The result was virtually dry chips, extremely low coolant consumption and acceptable tool life combined with high cutting speed. At the beginning of this development the challenge was to create an air-liquid mixture, a so-called aerosol, and its transport to the spindle, to the adapter and the tool holder through the coolant holes. The special design of the coolant holes and the coolant exit holes in the direction of the cutting

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edge further optimised this technology.

Ceratizit is one of the suppliers for HSC tools in the aerospace sector. When developing these tools the machining of aerospace components made of high - tensile a luminium a lloys for minimum qua ntity lubrication wa s the main focus.

The result – the tools are suitable for wet machining, minimum quantity lubrication and dry machining. They combine developed carbide with positive chip groove geometry, ‘microfinish’ treated inserts and the special tool geometry.

When turning aluminium wheels, the company developed a coated carbide grade characterised by its surface morphology designed to reduce adhesion of the work piece material. The reason for this is the graphite top layers, which reduce the friction of the chips during the process. When using air-cooling, this grade produces good surface quality of the work piece and long tool life.

Challenges & Solutions To Dry Turning Dry turning of steel at high speed represented another big challenge. The main problems in this context were the high temperatures during the machining processes (up to 1,200 Deg C on the cutting edge) and the adhesion of the work piece material to the cutting material in the cutting edge area.

In order to prevent plastic deformation of the carbide at high temperatures, special carbide compositions with a low share of cobalt binder and an increased share of cubic carbides such as TaC, NbC,

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Coating is important and it affects heat resistance and subsequently the reliability of the tool

High-pressure coolant applications for the control of chip formation may enhance the performance of cutting tools

TiC and ZrC are developed.

There are certain grades developed for dry turning of steel and cast iron. In order to achieve this, much attention must be placed on the substrate to ensure toughness and heat resistance.

Apart from substrate properties, coating is also important. Some coating produces heat resistance even at temperatures above 1,000 Deg C or with the frequently occurring hard casting skin and varying depths of cut in cast iron machining. This coating consists of titaniumcarbonitride and an multi-layer aluminium oxide coating with a special nano-level structure.

The new surface finish provides the inserts with a metallic shine but, more importantly, improves the protection to the cutting edges against chipping and makes wear detection notably easier for the customer.

This surface treatment also influences the friction of the chips in a positive way and reduces adhesion of the work piece material on the cutting edge.

Super Alloys & Titanium To date, materials like high alloyed steel, super alloys and in particular titanium have ‘defended themselves’ successfully against dry machining. It is not even possible to reduce the coolant or lubricant quantity.

Therefore phenomena like swarf adhesion, chip evacuation and chemical reactions between cutting material and work piece have to be analysed.

For the production of titanium components the tool design has been adapted. Large chip flutes and coolant holes for optimised chip evacuation, specifically shaped chip grooves of the inserts ensured notable

increases in performance, ie: higher chip removal rates when wet machining. Until now dry machining tests of titanium at high chip removal rates have failed due to high temperatures, material adhesion and chemical reactions.

The PVD coating generation intelligently adapts to the various types of stress during machining. High temperatures influence the friction through controlled phase reactions within the coating, while the special coating morphology has a positive influence on the chip flow.

High-pressure coolant applications for the control of chip formation also may enhance the performance of cutting tools in the future, particularly with materials where chip formation and evacuation are problematic.

At present coolant pressures, up to 300 bar are applied with promising results. New developments in the field of cooling lubricants will ensure that wet machining is applied also in the future, particularly in situations where very close tolerances are required due to thermal expansion.

Dry machining? The answer is yes and no. There are very successful applications in dry machining, even high-performance applications. Nevertheless there are application fields where cooling and lubrication will remain indispensable in the near future. MEN Enquiry No. 8006

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update

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he simulation of die filling and solidification p ro ce s s e s w a s f i r s t applied in fou ndr ie s more than 20 years ago. Although casting simulation is still a young technology, it has gained wide acceptance.

More than 150 foundries in Germany use simulation programs.

They use simulation mainly as a tool for testing the quality of castings for new or modified equipment.

Fou nd r y si mu lat ion c a n quantify experience and therefore only test a ‘state’, whereas the conclusions from the calculations and improvements require the hands of an expert. Continuous improvement and optimisation is a succession of trials and errors, both in reality and in simulation.

In recent years, response time of simulation software has improved and now integrates parallel process computers. Combining simulation software with an optimisation program makes it possible to automatically analyse calculated variants with regard to the defined target criteria, to create new variants and to analyse them in the same way. The vision of automatic computer- a ssisted solution finding for casting problems has become a reality.

Optimising By ‘OneDimensional Search’ Each foundry has a number of processes that are subjected to constant improvement. This is driven by the necessity to improve the quality of castings or to cut the costs of production.

Basically, a simple optimisation method called ‘one-dimensional search’ is applied. After a number of successive trials, tests and improvements should produce an acceptable result, although it is not known whether this is the genuine absolute optimum.

Therefore, runner optimisation means that a first variant of the casting technique is designed based 34

metalworking equipment news Nov-Dec 2009

Computerised Optimisation In

Die Casting The days of trial and error in die-casting seems to be over with the advent of modern simulation packages.

By Dr-Ing Ingo Hahn & Dr-Ing Goetz Hartmann, Magma Giessereitechnologie, Germany

on experience, then the casting is inspected and if a problem occurs, the technique is modified (again empirically).

This process is repeated until the quality of the casting and/or the cost efficiency of the process is acceptable. In foundry practice, the effectiveness of this optimisation approach ha s substa ntia lly improved in recent years. Today, trials are often not carried out in reality using pattern, die and casted prototype, but virtually by means of simulating the casting process.

A New Way Of Optimisation Automatic computer ised optimisation represents a new approach to solve difficulties in the manufacturing process.

Magmasoft simulation calculations with varying process parameters and die layouts are used as an experimental ground. For this, the simulation program was integrated into an optimisation loop that runs without user interaction after optimisation targets and degrees of

freedom were defined.

To have a positive impact on the optimisation targets, manufacturing variables (eg: casting conditions, materials, die temperature, shot curves, spray conditions) and geometries (eg: runner design, gate dimensioning, position and dimension of cooling channels) can be varied. Manufacturing restrictions (eg: cycle times, die concept) can be taken into account.

The Magmafrontier optimisation tool is based on genetic algorithms.

The first generation of variants is defined as DOE (design of experiments) – using the example of statistical experimental design.

The ‘trial and error’ method is now transferred to the computer.

The next generation of casting p ro ce s s si mu l a t io n m a ke s proposals for optimum parameter combinations or the best possible layout. This will be explained with the following examples covering important process development areas for die-casting.

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Figure 1: The layout of a runner of a six-cavity die is obtained as a result of arranging the cavities on as little space as possible

Figure 2: Solidification of a die casting takes the longest where the walls are thick. As this area cannot be squeezed sufficiently, local squeezing is a solution

Figure 3: Illustration of a feeding criterion: (Right) Design by computer optimisation – no shrinkage cavities. (Left) Design of similar dimensions where not all shrinkage cavities were avoided

Homogenising Die Filling Most small castings are produced in multiple-cavity dies. To produce products of uniform quality and to allow smooth filling of the die, the cavities should all be filled at the same time and local flow peaks should be avoided.

In this example, six castings are poured simultaneously (Figure 1).

Normally, the courses of the cross sections of the six runners are designed by the engineer based on experience and proven tables.

In our case, this is provided by the optimisation program.

A parametric 3D model of the geometry is introduced in Magmasoft for this purpose. The filling time for each die cavity is known after the simulation. This is the time span from when the plunger begins to move until the complete filling of the cavity. The target function for the optimisation program is to make the deviations between the filling times of the die cavities as small as possible by selecting certain runner cross sections.

Apart from the homogeneous filling process of all cavities, oxides in the castings should also be avoided in this example. As a result of the simulated die filling, the intensity with which the melt is exposed to air can also be analysed as local distribution across the filled die cavity. On this basis, calculated reduction of oxide formation in the cavities was defined as the second

target function of the optimisation program.

way of obtaining good quality in spite of this is local squeezing.

The case described is that of dimensioning a squeezing system for the forced feeding of the critical area of a casting (Figure 2). If they do not work from the beginning, such systems must be optimised by trial and error, which is expensive.

The optimisation program finally finds a variant that ensures optimal product quality at the critical material accumulation with minimum squeezer volume (Figure 3). It becomes clear how critical a design of this kind can be and why it is so difficult to design local squeezer systems correctly.

Minimising Gas Porosity Avoiding gas porosity is one of the central tasks in designing the die casting technique. During the whole die filling process, the melt should fill the runners and gates completely to avoid the entrapment of air in the cavities.

Problems with gas pores were encountered in the critical area of the ring circumference during the production of an ensemble of four piston rings. The task of automatic optimisation was to eliminate the pore risk. For this purpose, the geometries of gates and overflow tabs were to be optimised.

Ta k ing adva nta ge of the available symmetry, the pouring system and castings were modelled – the gates and overflow tabs were designed parametrically. For each variant, the simulation shows the distribution of air in the cavity at the end of filling. The purpose of optimisation was to keep the air entrapment in the critical area of the piston ring as low as possible.

360 variants were simulated.

The improvement allows the to-be-machined area of the piston ring free of pores and consequently ensures high product quality.

Optimised Squeezing Shrinkage cav ities that a re surrounded by thin walls can often not be removed by squeezing. One

Trial & Error No More The examples described above illustrate that the automatic optimisation of casting techniques based on simulation is also entering the casting practice. Elimination of trial and error gives the expert the opportunity to improve processes at highest quality and maximum cost effectiveness.

The sensitivities of the impacts and interactions of the process parameters to the final casting quality of process conditions can be learned. Hardly exhausted, the pool of available possibilities comes in the form of the next generation of simulating casting processes. MEN Enquiry No. 8101 Nov-Dec 2009 metalworking equipment news

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Maximising Your Mould Design & Manufacturing Process The design and manufacturing phase of a mould is undoubtedly an important one. Using software programs can go a long way in making sure that designers get all the assistance they need while undergoing this task.

By Michael E Neumann

preview of runner system according to input sketch or sketches. In addition, it is possible to make parameter modification according to segment, path or on complete sketch. The program also comes with automatic sink definition.

Gate features on the other hand have automatic penetration calculation and display, complete pa ra meter a nd or ie ntat ion control and the ability to calculate penetration height and area.

Furthermore, it gives warning when gates exceed runner boundaries.

T

he world of moulding is vast and classifying them is not exactly a n ea sy ta sk. Throw in the fluid nature of changing technologies, considering the take up rate, and the successful implementation certainly makes things more complicated.

Though a well-established process, some may consider it an art form. In certain parts of the world, that may well be the case but in the more industrialised corner of the globe, the influx of technology into this field is well worth looking into.

Mould Design When it comes to mould design today there is no running away from CAD software programs. Arguably, 36

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the advent of software programs in this field has probably wrestled some impetus of mould designing from traditional mould makers to the design engineers.

With the momentum of change behind them, the design engineers can look forward to more software programs to help them in their daily routine.

Now R&B, a developer of the computer-aided mould design technology has added new runner and gate modules to their software MoldWorks 2009 SP0.

The runner features include

Software Programs Integration Adding new innovative features is one way, there lies another path for improvement, ie: integration.

It is not uncommon to see software programs of different manufacturers partnering each other to bring the level of usability to greater heights.

Moldex3D eXplorer, a 3D integrated tool for designers to perceive different part design and mould design options during early stage is supporting Pro/Engineer to improve the design process for the users.

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“Most of our users are using the software for designing precision parts with complicated wall thickness variations. Moldex3D’s true 3D simulation capabilities will provide more accurate simulation results,” says Mike Campbell, senior VP of product management, PTC. “The 3D parallel computing capability is now extended to support CAD users directly. Upfront CAE becomes straightforward for every CAD user,” says Dr Venny Yang, president of CoreTech System.

In the past, designers and moulders have to come together to discuss various moulding conditions after CAD graphics are completed. Now, the software can bridge the gap between these two professions because it provides designers the necessary insights on how to produce good quality products.

Designers now can check welding line, air trap, flow balance, and decide gate location and gate number during the design phase.

It can also simulate true 3D flow to provide the inner temperature and pressure of cavity. Moulders then can visualise moulding requirements to further optimise products.

In terms of performance, the product supports parallel computing technolog y. It is capable of reaching the maximum acceleration by fully utilising each core of the modern CPU architecture. After analyses are done, report generator then enables users to share reports with the product design team, clients, suppliers, and the moulders.

Mould Making Similar to the design phase, a big part of mould making involves the usage of CAM software programs.

Although the initial financial outlay may be considerable but in the long run, the benefits can justify the spending.

Dynamic, based in Menomonee Falls, Wisconsin, is a mould builder providing assistance in product

design, in-house mould design and verification of critical mould dimensions. With its Delcam software, the company can produce a multi-cavity cap mould much more quickly.

“Rest machining with the software is a time-saver,” says Randy Lee Meissner, CNC department supervisor. “This alone has easily saved us upward of 25 percent to 50 percent on our cavity machining cycle times, cutting down roughing times particularly, so we can move quickly to the finished mould.

With PowerMill, the tool is always in the cut, removing the unwanted material, with no air cutting. You’re always on the steel,” he adds.

“When the programmers want to edit paths, they can do it quickly.

They can pick any part of a toolpath, delete it and still have the rest of the toolpath intact. The new toolpath only needs to be calculated for the relevant area, not for the whole part. That’s a big time-saver for us,” says Mr Meissner.

Upstream from PowerMill in the programming department is PowerShape. With it, Dynamic programmers analyse imported models for damaged, duplicated or missing surfaces, inspect draft angles, and visualise hard-to-mould regions. They can also repair, replace or modify surface or solid models, and add textures, logos and complex embossed reliefs.

F ro m m o u l d de si g n to manufacture, software programs have made their presence felt and results have shown that improvement of moulding technologies is almost synonymous with the improvements made in design and manufacturing software. It will be no surprise that individual companies will continue to invest in software programs to maximise their mould designing and manufacturing process. MEN Enquiry No. 8102

Moulding has made inroads into the automotive and telecommunications industries Barunpatro, India

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update

Art To Engineering

From

In order to stay relevant and profitable, new engineering approaches catered for a production setup have been introduced in mould making. By Joson Ng

T

echnology is key in all industries. Even in the mould making industry, traditionally dominated by skilled craftsmen, there is a shift in focus in recent years to embrace technologies. For Amura Precision Tooling, a company specialised in ma nufacturing precision moulds used in industries like telecommunications, computer, electronics, medical and aerospace, this journey started some four years ago.

Says AT Ta n, ma rketing director, Amura: “Right now in mould and die making, we are adopting the production concept.

We started this initiative some four years ago as we decided not to continue on the well-travelled path of having a skilled worker to do everything.”

The philosophy of using advanced machines is there for all to see as Mr Tan explains: “We machine everything precisely according to drawing. We have 38

metalworking equipment news Nov-Dec 2009

“We have replaced senior craftsmen with technicians who machine the parts to size and assemble them separately, part by part. We feel this is faster and more efficient.”

- AT Tan replaced senior craftsmen with technicians who machine the parts to size and assemble them separately, part by part. We feel this is faster and more efficient.”

Controlled Approach ‘From art to engineering.’ That is something very much on Mr Tan’s mind. His decision to shift the production philosophy appears to have paid dividends as right now, tolerances around the figure of 20 microns can be achieved, according to him.

His commitment to moulding technologies is evident in the amount he has invested in modern

machiner ie s a nd computer software.

“We typically invest in Japanese machine tools a nd through government support, we are able to invest in 3D software programs.

The introduction of software in our industry has transferred the control of mould making to design and process control engineers – a far cry from the past when we used to employ master craftsmen from Hong Kong,” he says.

The Mould & Die Survival Guide Speed, according to Mr Tan, is essential for survival. In order to

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Future Plans With years of experience in the field of mould and die making and its technologies, Mr Tan is in a good position to give his take on the market outlook of his industry and he duly obliged when asked.

“In Singapore, the situation is not as rosy compared to other countries in the region. As such, we have to venture outwards. We are currently looking very closely at Vietnam because they are opening up. The business opportunity there is attractive. They have a lot of MNCs from Japan, Europe, the US, South Korea and Taiwan.

Their scale is also bigger than Singapore. In fact, we have had an office there for over a year now.

For me, the next stop is Vietnam as mould making in China is very competitive. Having said that, we do have a partner to take care of

the China market,” he says.

A lthough his assessment of Singapore is not as positive compared to Vietnam, Mr Tan admits that there is a shining light in Singapore still – the aerospace industry.

“Granted, our main customers are from Japan and mostly deal with office automation, automotive

and electronics. However, we are venturing into the aerospace industry. We are currently making some fixturing for our customers in that field and in addition, we have a tie-up with one of them to receive training and get certified for more complex jobs,” he concludes. MEN Enquiry No. 8103

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maintain competitiveness, quality moulds must be made in the shortest lead-time. He feels with an open market with information readily available on the Internet, it is easy to source for suppliers, bringing his company up against the mould makers overseas, especially China.

Mr Tan however has a few tricks up his sleeve to make sure he has an advantage over his competitors.

“I have a tool room in Singapore but I collaborate with my partner and our design centre in China in order to bring the cost down. Some 50 engineers who run the design centre 24/7 generate mould designs for us. The designs are then sent to our manufacturing facility in Singapore,” he says.

Although speed is important, the accuracy of the part is also the essence of a mould. “Big emphasis is on measurement as we place a check after every processing step.

Using equipment like CMM, scope, non-contact measuring and digital gauging, we follow process plans through – consistent with our engineering approach,” he adds.

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measurement

Making

Light Work Of Measurement

From design all the way through to manufacturing, laser beams are shooting for fast and flawless measurements.

By Rob Snoeijs, senior editorial writer, Metris

D

imensional error margins that compound too enthusia stically throughout the parts assembly process introduce lengthy corrective actions and poor product quality. To avoid this, accurate and efficient 3D scanning solutions keep a close eye on component and assembly geometry until the final product is proofed.

T he use of touch probe measurement in part-to - CAD comparison and reverse engineering applications offers accurate results, but faces limitations in terms of inspection throughput and freeform inspection capability.

Digital point cloud acquisition a nd g raphic a na lysis drive process-driven development and manufacturing as well as quick straightforward checks for quality control and troubleshooting.

Touch Probing No Longer The Gold Standard For decades, the use of traditional touch probes on CMMs has been the gold standard for component

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inspection and verification.

However, the time-consuming process becomes an even bigger drain on a quality department’s valuable resources. Metrology engineers are charged with increasingly complex freeform part surfaces that take an exceptionally longer time to thoroughly inspect.

3D Laser scanning – matured over the last 10 years – is on the verge of revolutionising metalworking industries across automotive, aerospace and other markets. Quickly and accurately digitising freeform surfaces was the first niche application for laser scanning probes, a technology that uses a single laser.

During operation, 3D laser scanners basically beam a laser on the surface of the part being inspected. As the laser is swept back and forth, it appears as a line on the part surface. A digital camera incorporated in the scan probe digitises the projected laser line shape non-stop under a fixed angle.

Real-time digital data processing keeps track of the precise location

of the projected laser line as it is moved across the part surface.

This results in a continuous stream of 3D surface measurement points, appending data to a socalled point cloud. Graphic representations of this point cloud instantly highlight CAD deviations a nd su r face i r re g u la r it ie s, eliminating potential anomalies that remain unnoticed through touch probing.

Faster Process & Better Geometric Insight Laser scanners are fast, accurate, and can collect thousands of measurement points a second, making 3D laser scanners suitable for digitising freeform shapes.

A suspension part or a wheel rim – each individual die or mould component can be checked to ensure geometry specifications are actually met. Laser scanners play an important role in tackling dimensional problems related to casted metal shrinkage and spring back issues of sheet metal, for example.

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Scanner Innovations Drive High Process Efficiency Innovations in laser scanning technology and point cloud processing software establish a streamlined process that increases productivity in every stage of the development process.

Instead of numerous indexing head rotations and multiple CMM axes displacements that are needed to operate a touch probe, a laser scanner performs inspection along straightforward linear and polygon motion paths. Every second pinched off from the inspection cycle is multiplied by the number of cycles you run on the CMM, adding up to time savings.

Simplified motion paths of the CMM scanner also means more straightforward off-line CMM programming. This compares favourably with tactile inspection where elaborated programming effort is required to define a rather lengthy sequence of touch sensor movements and measurements.

Multi Laser Scanner Technology Despite numerous advantages, single-laser scanners unfortunately st r uggle when t r y ing to measure critical features, such as circles and slots. As a result, tool changes between a laser probe and conventional touch probes are required to complete freeform surface and geometric feature inspection.

In the metalworking industry, fa st a nd f lawle ss a ssembly is realised through accurate placement of features that are used to connect the product’s constituent parts. Fast and indepth inspection of 3D features is essential in speeding up the assembly process and increasing the quality of the final product.

Car manufacturers slash preproduction body geometry verification using laser scanner, point cloud and virtual assembly technology

Smart automated scanner path programming capability guarantees full surface coverage and enables you to start scanning within minutes after loading the CAD file. Cross scanners with full 3D view digitise the entire surface of parts and all features. Digital analysis using graphic comparison charts provide instant geometric insight.

Automotive Industry As an example, leading automotive OEMs digitise sheet metal and other body parts and virtually assemble vehicle bodies in software. These car manufacturers slash pre-production body geometry verification using latestgeneration laser scanner, point cloud and virtual assembly technology. They not just reduce the time required to evaluate physical prototypes, but also eliminate the need for costly specialty verification tooling.

Before Manufacturing In the pre-production stage, metrology engineers scan sheet metal and castings as well as composite and plastic parts. After acquiring data at 20 micron accuracy, they filter the resulting point cloud and analyse geometry against nominal CAD data. They rely on digital graphic reports to evaluate part geometry, and streamline supplier interaction with regards to adjusting moulding and stamping equipment.

After digitising individual parts, engineers align and virtually assemble sheet metal, interior, exterior and chassis components in software in order to build a complete virtual vehicle body. Even before body parts are physically assembled, this geometric verification approach already provides insight into potential fitting issues.

Enquiry No. 8201

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Laser scanners can collect measurement points quickly, making them suitable for digitising freeform shapes

When using a multi-laser instead of a single-laser scanner, the timeconsuming issue of switching back and forth between probes, and often between software packages, is eliminated. A multi-laser scanner is a one-scanner-fits-all-applications that quickly digitises complex surfaces and accurately measures deep into critical features.

Comp a re d to a sc a n ne r with a single laser, a scanner with three lasers incorporated in a cross-pattern configuration simultaneously captures the part surface from three different angles.

With lasers being swept in three directions, the number of points measured on the edges of a circular feature, for example, roughly increases threefold.

This has a major impact on the accuracy of extracting the feature’s precise location, size and roundness, regardless of the scanning direction. It makes much more sense to increase feature extraction accuracy by fitting geometric features through hundreds of points, rather thanrelying on a handful of tactile inspection points.

Ideally, geometric feedback regarding features is incorporated into g raphic pa r t- to - CA D comparison charts, structured according to geometric dimensioning and tolerancing (GD&T) standards.

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Cross Scanning Thanks to its multi-directional laser sweeps, a cross scanner is the bestsuited probe for automotive gap and flush inspection. Quite unique is that no probe reorientation is required along the spline in between doors, fenders, hood and trunk lid. A single scan path is sufficient to capture the full 3D curvature of the spacing gaps, sourcing data for assembly quality verification and aerodynamic performance analysis.

Another advantage of a cross scanner is its ability to scan deep into the bore of a hole, the flanges of a notch, or pockets of complex freeform surfaces. Full 3D capture of features such as holes and slots can be accomplished with a single scan path, thereby eliminating the need for multiple scanner positions and reducing the cycle time to inspect a part.

In addition, feature extraction

Cross scanner technology matches the performance levels required to drive virtual body verification

becomes much more accurate because fillets and chamfers can be ignored as part of the point cloud processing calculation. A cross scanner not just captures all 3D details of slots, notches and edges, but is also able to scan specialised geometric features, including connection pins, welded bolts and T-studs.

Leading car manufacturers use cross scanners and point cloud processing software to automate the inspection of a socalled christmas trees. These metal features are automatically welded on sheet metal surfaces to support efficient and robust connection between body parts using screws.

The use of a cross scanner sp e e d s up c h r i s t m a s t re e measurement because it captures feature geometry all around in one go. Scanning these features obsoletes the time-consuming procedure of mounting cylindrical extensions on the features to obtain valid tactile measurement.

The standoff distance of a cross scanner is important too.

For specimens with a somewhat flat geometry, a shorter distance between scanner and part works well. But a longer standoff distance comes in handy when inspecting clamped parts, as the scanner simply scans over the clamps without having to adapt scanner motion.

Probably the biggest advantage of increased standoff and higher

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The concept of digital inspection streamlines metrology operations, saving time and money

field-of-view depth is that the scanner gains optimum access to cavity surfaces in body-inwhite structures. This is why long standoff cross scanners are used a lot on horizontal-arm CMM in automotive assembly plants.

Scanner Standoff & Field-OfView Depth The cross scanner concept with long standoff distance and field-of-view depth results in time savings when inspecting automotive castings.

This simplifies scanner motion when digitising engine blocks, cylinder heads and gearbox covers.

To take a full 3D scan of one side of such a specimen, the scanner is moved along parallel motion paths without indexing the CMM head.

W it h suc h l i m ite d CM M overhead, the scanner captures the complete surface, including full 3D characteristics of ribs, holes, flanges and pockets, at record speed. One hour is sufficient to set

up and inspect cast driveline parts, whereas detailed tactile inspection easily lasts more than a day.

The outcome of laser scanning is a part-to-CAD comparison chart that with colour-coded areas marking local geometry deviation.

Regardless whether inspecting prototype samples, pre-production batches or serial-produced parts, a cross scanner traces part shrinking issues or degrading production mould geometry. In the aerospace industry, cross

Metris: Digital Laser Scanning Automate scanning jobs with a digital LC60D laser scanner on a new or retrofitted CMM. Thanks to fast image acquisition, wide laser stripe and higher point resolution, the scanner by Metris reaches up to 75,000 non-interpolated points per second.

Benefit from this scanning speed to digitise freeform parts faster, or boost the number of features you can capture in the same time frame. Linear and polygon scanner motion paths also means more straightforward off-line CMM programming.

The LC60D’s Enhanced Sensor Performance (ESP3) functionality obsoletes manual scanner adjustment altogether. From a technical viewpoint, the all-digital scanner automatically adapts laser intensity and camera sensitivity pointper-point to account for local surface colour and reflectivity variations.

Enquiry No. 8202

scanners are used to inspect the geometry of larger milled precision parts made of steel, aluminium or composite material.

Digital Inspection A trend in manufacturing that is gaining importance is the shift towards a digital inspection process. Compared to executing digital inspection directly on the physical part, the digital inspection approach allows parts to be digitised first, after which inspection can occur on the acquired digital model data.

As such, the digital inspection process – from measurement preparation to final report – takes advantage of the typical automation and flexibility benefits of a digital approach. The concept of digital inspection streamlines metrology operations and embeds them into the CAD-centric design-throughmanufacturing process, saving time and money.

As the complete digital copy of the test part remains available, full flexibility is offered to run other or more detailed analysis at any time and place.

This illustrates how computerintegrated metrology provides the touch with reality, by inserting dig ita l duplicate s of pa r ts, prototypes and products upstream in the digital workflow. As a result, product quality increases and throughput time decreases – all achieved with fewer resources. MEN Enquiry No. 8203 Nov-Dec 2009 metalworking equipment news

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& Surface

Measurements

The art of shape and surface measurements is applied to many modern industrial processes, especially in the fields of reverse engineering, 3D replication, inspection and quality control.

By Augustine Quek

Today’s Technology As a result, industrial applications today need an accurate and rapid measurement of 3D shaped objects that requires creating accurate 3D data models of complex surfaces and objects.

In many cases, this is achieved by performing measurement on the object’s surfaces and then constructing 3D point clouds that correspond to the object’s surface.

The point cloud can be overlaid on a CAD model, creating a visual ‘map’ of the surface, showing the degree of deviation from nominal in different colours. Solid models can now be created from the surface profiles, making 3D measurements even more important.

There are many measurement instruments that can make such 3D measurements, including hand tools, Coordinate-Measurement Machine (CMM), and optical comparators. 3D measurements 44

metalworking equipment news Nov-Dec 2009

can be broadly classified as either contact or non-contact.

Non-Contact Measurement There are a variety of noncontact measurements available on the market. The four most popular types are optical comparators, microscopes, v ideos a nd laser systems.

Optical comparators utilise traditional optics to magnify and project the image of an object onto a glass screen. This type of optical inspection instrument is very popular and is also the least expensive method of optical noncontact inspection in use today.

The optical comparator also offers the greatest versatility in regard to parts that can be inspected. Lightweight parts as well as parts weighing hundreds of pounds can be inspected on many available instruments.

Nikon’s V series is suitable for very small parts to large industrial systems. The V-12B series incorporates a four-step condenser lens that can magnify up to 500x, while the V-20B has a field of view that can be adjusted from 100 mm to 5 mm.

Optica l compa rators a re available in a wide variety of styles and configurations from manufacturers. Projection screen sizes from 10” to 80” are available, though 12” to 30” are typical. Other features include horizontal or

Ilker, Izmir,Turkey

T

here is no time to waste in determining various 3D features of a part and whether it is within a certain range of tolerance.

First of all, the accuracy in the measurement scheme needs to be adequate in order to eliminate measurement errors.

Measurement errors can lead to erroneous inspection that results in an acceptable part being rejected and a defective part being accepted.

vertical light path configurations, profile and surface illumination systems, various stage travel options, magnifications from 5x to 200x and digital readout options from a basic two-axis display to fully computerised automatic CNC systems.

Viewing Under A Microscope Inspection microscopes utilise traditional optics to magnify a desired detail. Many inspection

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microscopes today are coupled with a video or laser system for automated inspection, as they are suited to inspect lightweight and or flat parts.

For insta nce, Vision Engineering’s Falcon 300 is a 3-axis non-contact video microscope system that uses high-resolution colour CCD ca mera w it h a 5-position indexed zoom and iris aperture control.

Another example is the Mitaka Kohki’s NH-3SP laser probe 3D surface metrology instrument and MitakaMap surface analysis software. It measures geometry and roughness with vertical resolution of 1 nm, a lateral resolution of 10 nm, and is accurate on slopes of up to 80 deg.

The software can also analyse depth distribution, bearing ratio, functional volume, 3D motifs, grains and particles, dimensions, isotropy and directionality.

Video & Laser Measurements Video systems utilise a magnification lens and camera.

Some 1,300x in magnification can be achieved with the developments in camera and computer technology.

F u r t h e r m o r e , c o m p u te r manipulation and storage of the image is possible due to image digitisation process utilised by video systems. Lastly, a video inspection system can actually print out a pictorial view of the part being inspected for documentation purposes as long as there is a printer and driver.

A u to m a te d v i d e o - b a s e d measuring now allows multiple edge-to-edge measurements to be made, such as those on stamping lines producing pressed metals components. Video systems can also measure the position, diameter, depth and profile of apertures on lower volume, complex work pieces, such as those from drilling and machining processes.

Although video systems are typically more expensive than optical comparators and are less flexible in the size and weight of parts inspected, they have the advantage of being smaller and more compact, and better suited for relatively lightweight and flat parts.

An example of vision-based shape measurement is the Airon’s Tubeinspect HS 3D tube measuring system, which uses ten digital

cameras with higher resolutions. A spatial reference point field made from glass, especially stable with respect to shape and temperature, is located in the measuring cell.

The compa ny claims the measuring system can resort to reference points in different spatial planes, which reach a measurement precision of up to 50 micron for tube geometries.

Other development in noncontact mea surement instruments comes in the form of laser inspection instruments.

Accuracy and repeatability within +/-.000001 under certain conditions can be expected. This type of instrument reflects a laser beam from a detail being inspected and determines distances using time delay calculations.

A laser scanner, for instance, projects a line of several hundred points on the work surface. These points are reflected from the surface to a solid-state camera chip.

Each line is processed as a profile of the surface at that machine position. The data is collected at tens of thousands of point per second. This allows some features (such as holes and small slots) to be

ENQUIRY NO 166

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measured in a single pass, whereas spot lasers and tactile probes require multiple measurements.

L a s e r s c a n a l s o re co rd horizontal and vertical angles, and distances using an interferometer all at the same time. This permits the calculation of x, y, z values for any point from one position. Lasers do not require multiple instruments to read a single point to generate its coordinate values, and can use the coordinate transformation to relate different sets of point measurements to a common reference frame.

L a ser mea surements a re appropriate for sheet metal, soft bodied parts that can be deformed by a touch probe and other inspection applications where throughput and speed of measurement take priority.

Spencer Ritenour, United States

Contact Measurement Nevertheless, tactile probing of geometries and surfaces is still widely used. This is because evaluation of optically hidden surfaces and parts such as water jackets, cooling holes, deep pockets and cylinders, full-field noncontact measurements may not pick up as much details as point-based touch probes.

Most touch probes incorporate the sa me ba sic mecha nica l functions regardless of style. The touch probe system includes some form of spring-loaded device to

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sense contact, a hard-wired or wireless system for feedback to the CNC control, compensation for overshoot, calibration and recording of position, usually on a software program.

During measurement, the stylus of the probe will be deflected upon contact with a measurement point.

The contact switch internal to the probe will be turned on and activates a signal that is sent to the CNC control, commanding that axis motion be halted.

For probes that have a hardwired system for feedback to the CNC control, there would be two wires that run from the probe to the control to form an electric circuit.

Probing Issues The latest development in current probe technology incorporates a radio transmitter and receiver. The transmitter, mounted in the probe itself, is activated the instant the stylus is deflected, and sends a signal to the receiver which relays the signal to the CNC control.

However, there will always be a certain amount of overshoot while axis motion decelerates to a halted condition. That amount will be determined by the rate of motion (feedrate), the response time of the servomotor, and the mass and weight of the related machine components.

These factors are usually calibrated into the routines used when probing to compensate for the overshoots. Other factors like thermal deviation, wear and tear on the machine, and variations in the material being measured also directly affect the overshoot amount. After the signal is sent and received, the machine’s current position (in X, Y, and Z) can be recorded.

Depending on what the probe The measuring solutions of today must keep pace with ever demanding manufacturing process in order to measure complicated parts

is doing, this recorded position is used within the program.

For example, Hommel-Etamic Ro u n d s c a n c a n d e te r m i n e roundness and straightness as well as the roughness (Rz) value and the linear free forms in connecting rod diameters, as it combines automatic measurement of form, cylindricity and roughness characteristics in one measuring instrument.

The ‘Multi’ Approach Given t he va r ious benefits and drawbacks for each type of measurement, multi-sensor measurements are now increasingly popular. These instruments combine two or more types of sensors, utilising the advantages unique to each measurement technique in the measurement process.

In Kreon’s Solano 3D laser scanner, it has been integrated with a contact probe to provide an enhanced collection of up to 40,000 points per second with an accuracy of 50 micrometer. It also provides sufficient data for its scan-to-CAD comparison with colour-coded visualisation of deviations, and gap and flush measurement.

Shape and surface metrology is becoming more important in today’s industrial environment. The rapid growth of extensive computer 3D modelling in manufacturing processes means an increasing number of objects are being used to build theoretical surface models and contour maps.

From the theoretical models, new objects will be manufactured.

3D measurement has become the key connection between the physical and virtual worlds.

Furthermore, when measurement, validation and optimisation are part of the growth of digital manufacturing, 3D measurements will eventually become an integral part of future industries. MEN Enquiry No. 8204

Spreading our wings into aerospace and medical industries.

In the niche market of aerospace and medical device manufacturing, you need to have the technical capabilities and know-how to get started. Thereafter, you need certification to be qualified.

But what do you do to get exposure?

Reaching target audience is our specialty.

Let APMEN knock on the doors for you.

For advertisement enquiries, please contact: Derick Chia Advertising Sales Manager derickchia@epl.com.sg • (65) 9237 8983 • (65) 6361 9792

Fab& Form

E

limination of scratches during punching a nd forming – that is an old requirement for punching machines. With an active die that works like a second punching head from beneath, it is possible to fulfil this requirement.

Although brush tables with pneumatic raisable loading and unloading units already helped produce workpieces with minimal scratches in the past, an ‘active die’ option now completely minimises the danger of scratches. Especially when processing surface-treated or galvanised material, zincor sheet metal and aluminium customers are asking for high quality standards.

Many of the parts are used in applications where they are visible, so eliminating scratches and burrs is very important and cost effective.

The combination of active die and roller deburring has resulted in a new standard of quality for coated and soft materials like zincor or aluminium, because follow-up processes like hand deburring due to scratches can be eliminated.

Both run-times and scrap can be noticeably reduced in this manner.

Downtimes can be reduced as well, because employees no longer need to search for the causes of scratches during the fabrication process.

The Scratch Eliminator Adjustable in height, the active die is installed below the worktable.

The matrice is retracted so that it does not touch the sheet while it is being positioned or moved on the machine. This prevents scratches on the backside of the metal.

Now the sheet metal lies flat with the worktable, which means it can be machined closer to the clamps, as it does not camber up when being processed. That reduces the area that cannot be processed and cuts material costs. Moreover, this active die simplifies programming because it is no longer a disturbing contour that would have to be taken into account when calculating the 48

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Punch Packing A Quality

There are new set of standards for quality, flexibility and productivity for punching. By Adrian Lim, sales manager, Trumpf

fab&form

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positioning path.

The active die also gives users greater leeway in processing. With this option, larger and deeper areas can be formed using entirely new tools. What is more, forming in the upward and downward directions can be completed in a single setting. That is because the active die functions like a second punching head enables active forming from below.

The sequence, is as follows: the machine positions the sheet metal with the matrice retracted. Once the plate has reached the desired position, the punching head secures the workpiece from above whereupon the matrice executes its active forming stroke from below.

Finally the punching head and the active die retract into their original positions before the sheet metal is repositioned. As a result, production processes run completely without danger of scratches.

The mobile die is especially useful when it comes to forming.

Many applications include forming in both directions, tapping threads at the same time. There is no

longer a need for detours to protect these threads and extrusions from collisions, because the die can simply be lowered out of the way.

The movable die also expands the forming possibilities of a machine since the total distance between the table and punch can be used.

In addition to the larger tools that can now be used, the active forming stroke from below increases the machine flexibility – even marking from underneath is now possible.

T he ac t ive die b e come s therefore a further purchase c r i te r i o n f o r s h e e t m e t a l companies. Beside this technology, which is affecting the quality of products, major requirements for modern punching machines are productivity and flexibility.

Productivity Of Punching Machines Productivity can be measured at the end in cost per part. The number of strokes per minute and the speed of the axis are well known parameters to measure at least one significant portion of productivity.

Today’s punching machines are able to operate with up to 1,400

Roller deburring tools help reduce follow-up work of removing burrs, shorten parts run-time, particularly with coated metal

With the integration of punching tools which allow bending, additional manual work can be eliminated

strokes per minute.

Productivity can be expressed as well with fewer and faster tool changes. Conventional punching machines even with electric punching heads need about 150 s to complete one part. Using modern machines, a reduction by 30 percent is possible. Machines with 1,400 strokes per minute and high-speed axis can cut down the time even to 60 s or more than 50 percent of the value.

But productivity is more than just comparing number of strokes or travel speed of axis. By incorporating additional functions into the punching process such as tapping, bending of laches or roller beading or deburring. It is now possible to avoid additional manufacturing steps after ‘only’ punching holes and therefore increasing the value add of the punching technology inside the whole manufacturing process.

Especially with deburring, an additional work step in one set-up saves set-up times and production time downstream. It is further to highlight that one could gain a higher and reproducable quality of burr-free parts, not to forget the greater work safety when handling the parts.

Using multiple tools in one tool boosts the productivity further due to tool change within a multitool of 0.3 s. It is possible to integrate 10 tools into one whereby each of the individual tools can rotate a full 360 deg.

With the integration of punching tools, which allows bending on a punching machine, an additional manual work step downstream the process chain can be eliminated.

The forming strokes take place in very quick succession with the possibility for both inside a nd outside contours. This ‘punching’ function can be used in combination with extrusions and thread forming. MEN Enquiry No. 8301 October 2009 metalworking equipment news

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Punch Press Machines:

Basic Instinct A mainstay of the metal working industry, there are a variety of punch press machines to cater to the needed capacity or concept of the product. By Tjut Rostina

P

unching is the process of forming metal components using a punch. The punch is usually the upper member of the complete die assembly and is mounted on the slide or in a die set for alignment (except in the inverted die).

The illustration in Fig 1 shows how the work piece remains and the punched part falls out as scrap, when the punch enters the die.

Depending on the size of production, a user can choose between a manual operation that utilises a single die set, or a CNC operated system to carry out the process.

Pressed For Variety The machines are normally driven by electric motors. A crank, a toggle, or a cam mechanism effects the conversion of the drive shaft from the rotary motion to the reciprocation of the ram.

As there are varied power demands, energy is stored between strokes by attaching a flywheel to the drive shaft when the machine is in idle mode. The energy is then delivered to the shaft during the operation, and by doing so, reduces the required capacity of 50

metalworking equipment news October 2009

Ilker, Izmir, Turkey

Fig 1

the driving motor.

There are various types of punch presses, and one of them is the hydraulic press. The press is made up of a cylinder, which is fitted with a sliding piston. Force is then exerted on the confined liquid, compressing the stationary anvil or baseplate.

With this action, the liquid is pumped into the cylinder. The machines is available in a variety of sizes and capacities, and can handle less than a tonne or go up

to over 10,000 tonnes.

Mechanical punch presses are driven by a rotary motor and screw, toggle, or lever. For lightduty applications, operators can consider utilising the air-driven punch presses. Manual presses are powered by hand, in a setup that includes a screw, lever or some other mechanism.

Punch Press Parameters Typical parameters of punch presses include size of working

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Punching Of

All parts should be tight and the punch to die alignment suitable in order to punch a good hole

Another Kind Higher output is possible through rotary punching technology in continuous production lines. By Denis Stephan, sales & marketing director, Schober

R

Mario Alberto Magallanes Trejo, Mexico

area, working force, and its capacity.

Other features of this equipment, such as productivity, which are characterised by the speed of strokes, speed of movement without shock, maximum weight of workpiece and power consumption.

With mechanical punch presses, working force is the ability of the main shaft to bend.

Understanding The Die-Set The die-set is made up of a ‘male’ punch and ‘female’ dies. When these two parts are pressed together with a metal sheet between them, it cuts a hole in the sheet. The hole would be cut in the form of a predetermined shape, and its size depends on the diameter of the die.

In setting up the punch and die set, the American Punch Company advises that all parts should be tight, the punch to die alignment is suitable, and that the punch to die clearance is accurate with reference to material thickness. Normally, the die size is punch size plus 1/32 or 1/16.

The punch performance is dependent on several factors, and it is important to recognise the problems early. For this, operators have to pay attention to problems

that may come up, and the methods to correct them.

For this, the company adds that some problems that may come up are as follows: • A loose coupling nut, which can lead to chipping or cracking. This is because the punch can shift during the process and leads to chipping or cracking.

• A misalignment of the punch and die will result in a non-uniform clearance.

• Improper clearance between the punch and die.

• Uneven stripping pressures.

For precision gaging presses or controlled presses, the electrical knockout punch and die sets is an option that can be considered.

The set ha s a n inver ted configuration, with the die fitted into the punch adapter, and the punch in the die adapter. With the offset in the up position, disruptions when repositioning the piece part can be eliminated.

Enquiry No. 8302

otary punching technology was successfully introduced many decades ago in the paper, film and foil converting industr y. O ver the yea rs it has gained recognition in the continuous metal converting industry because it provides a number of valuable advantages.

They are higher output and efficiency, more environmentally friendly, better quality and precision, process reliability and production stability.

How Does It Work?

Rotary punching incorporates two cylinders. The upper one, featuring the male portion of the design to be punched and the bottom one that features the female portion of the design.

The individual and exchangeable punches and dies are mounted respectfully into the punch and die cylinders. The proper phasing between the tools is achieved by the use of alignment pins and the use of hardened and ground antibacklash format gears.

Rotary punching provides for a shearing cut. Therefore, the punching forces involved are considerably lower than what is required for conventional punching.

As the material is fed through the rotating tools, the punches enter and exit the die at an angle resulting in a shearing action. The October 2009 metalworking equipment news

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slugs are removed through the centre of the die cylinder and then disposed off.

Round holes, squares, oblongs or rectangles can be punched on to continuous fed metal foil using rotary punching technology.

Module Design & Drive Configuration Despite the fact that the punching forces are considerably lower due to the shearing or scissor cut effect, rotary punching still requires special design considerations.

They include special bearing assembly designs, high-precision hardened and ground gearing as well as heavy duty and precision module design. The punching module can be geared up with an existing line shaft or can be powered via servo-drive.

Normally, the circumference speed of the punching tool is identical with the linear speed of the material to be punched. The punch spacing is fixed. The length of the pattern or patterns to be punched, the line speed that needs to be achieved and the thickness of the material to be punched will determine the diameter of the punching tools.

However, more variability and

Rotary punching and forming cylinder

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Rotary punching process can result in noise and vibration reduction since the material rolling through the rotary punch is being sheared progressively

flexibility is achieved when the unit is servo-driven and controlled by programmable logic controllers.

This scenario makes it possible to vary hole positions on the fly. The only time the punching tool rotates in synchronisation with the web speed is when they are actually punching. Otherwise, the rotary unit is accelerating or decelerating to position the next punch.

Advantages Of Rotary Punching The rotary punching process can be used either inline as a punching unit, in combination with roll forming lines or as a stand alone rotary punching machine.

Much higher productivity (up to five times) has been achieved by integrating the rotary punching process in the roll forming line.

This speed increase now makes it possible to combine production areas like press rooms and a roll forming departments.

Con se que nt ly, e x te n sive handling and transporting is greatly reduced or illuminated.

Additionally, the whole process becomes more ‘operator friendly’.

The rotary punching process provides further advantages.

They are noise and vibration

reduction since the material rolling through the rotary punch is being sheared progressively. This smooth operation illuminates the requirement for noise insulating cabinets and foundations can be lighter because of greatly reduced vibration.

Due to the compact design and because the material is fed directly into the punching tool, no loops before and after are required. In addition, floor space could be reduced drastically. In instances that a module can be mounted directly inside the roll forming machine, no additional space is needed at all.

Moreover, you enjoy shorter make ready times because the tools are pre-set on the bench.

Making the change over time to a new product or a new pattern significantly less because you are just interchanging the punching cassettes. Change over time could be reduced to a few minutes.

Higher output due to the continuous process (material feeding) converting speeds up to 100 m/min can be achieved. This is about five times higher than the conventional punching system. MEN Enquiry No. 8303

look

closer

Do you think all measuring systems are identical? That is not true.

Look closer at SmartScope速 dimensional measuring systems form Optical Gaging Products (OGP速), and you will see the difference. OGP is the world leader in video and multisensory metrology, and our machines can measure a variety of parts with optical, laser, touch probe, and micro-sensor technology.

With tens of thousands of OGP systems installed in more than 65 countries, manufacturers everywhere rely in OGP systems and trust us for expert advice and service, for innovation, for productivity, and for reliability. See for yourself how OGP can help you solve your measurement challenges.

ShapeGrabber a fully automated industrial 3D scanners that inspect whole part in minutes. It is ideal for rigorous, full surface 3D quality control and is easy to use even without CAD training.

Optical Gaging (S) Pte Ltd www.smartscope.com.sg

21 Tannery Road, Singapore 347733 Tel: (65) 6741 8880 Fax: (65) 6741 8998

Email: sales_epl@smartscope.com.sg

Singapore . Malaysia . Thailand . Indonesia . Philippines . Vietnam . Hong Kong . Taiwan . South China . India . Australia . New Zealand

ENQUIRY NO 112

industry

Andy Muir, Glasgow, Strathclyde, UK

www.equipment-news.com

spotlight

Shipbuilding:

Sea Of

Opportunities

Metalworking processes are a big part of shipbuilding as the industry undergoes the process of renewal. By Joson Ng

W

he n Ch r i stophe r Columbus made his first voyage to the new world in 1492, he was travelling in a carrack, a sailing ship. A lot has changed since then.

In shipbuilding, metal, especially steel has overtaken wood as the main material for construction.

The modern shipping industry is large. This industry involves huge capital, wide workforce and technology. The process of shipbuilding is also lengthy in terms of time taken and there are many other auxilary industries

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associated with shipbuilding. As such, from the technology point of view, modern shipbuilding has adopted new techniques and methods to make the process a more efficient one. The industry also saw most activities transferred to Asia with South Korea emerging as the powerhouse of shipbuilding.

Shipbuilding Capital According to Korea Times, South Korea has retained its number one position in shipbuilding nation in terms of new orders, order backlogs and volume of vessels built in 2008.

ENQUIRY NO 175

industryspotlight

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Michael Broxton, San Francisco, USA

The relationship between metalworking and shipbuilding is a very close-knit one

Home to seven of the world’s top 10 shipyards, some 17.5 million compensated gross tonnes in new orders were won last year, accounting for 41.1 percent of all global new orders. Chinese shipbuilders took the second spot with orders totalling 14.9 million Compensated Gross Tonnes (CGTs) last year, outpacing Japanese rivals, which won a combined 4.89 million CGTs. Clarkson, a London-based market researcher said that South Korean shipbuilders’ combined order backlogs totalled 67.7 million CGTs, making up nearly 35.8 percent of 189.2 million CGTs in global backlogs. China followed with 60.73 million CGTs. The (Metal) Work To Sea Worthiness Like anywhere else in the world, with metal as the chief building material for ships, the relationship bet ween meta lwork ing a nd shipbuilding is a very close-knit one. Not just that, improvements in metalworking also created benefits in shipbuilding.

For instance, weld seam facing 56

metalworking equipment news Nov-Dec 2009

tools can reduce or eliminate the need for manual grinding of weld reinforcements on the DDG 1000 class of ships (military vessel), according to a press release from Navy Metalworking Centre.

The manual weld removal is slow, which increases shipbuilding costs, and the repetitive nature of hand grinding causes frequent injuries (eg: carpal tunnel, eye, back) and costly medical expenses.

The cost savings from using weld seam facing technology for removal of butt welds alone on DDG 1000 is estimated at US$750,000 per hull.

The preproduction tools remove the weld automatically at a minimum rate of 20 feet per hour versus the current rate of three feet per hour. The tool is capable of removing the majority of weld reinforcement height with minimal or no further hand grinding.

Apart from grinding, tube bending is a lso one of the metalworking processes commonly deployed in shipbuilding. With tubes in today’s shipyard ranging up to 220 mm in diameter and 12 mm in wall thickness, a variety of large CNC bending machines are

required to support the demands of the ship building industry.

Bending tubes with thick wall requires applying pressures down the column of the pipe while bending. This is done in order to prevent unnecessary wall thinning of the pipe wall on the various types of material used.

Though machining is heavily featured in the construction of marine engines and shipbuilding, metrology is also a big part of this industry. As such, structural analysis is an important step before commissioning a ship.

These simulations incorporate pressures cause by waves and the movement of the ship as well as the hydrostatic pressure applied to the ship. Climatic conditions are taken into considerations as well.

In addition, stress concentrations are studied using a finite element analysis model to complement structural analysis.

Whether is it design, assembly, pre-outfitting or other shipbuilding processes, metalworking has a stake every step of the way. MEN Enquiry No. 8401

ENQUIRY NO 089

features

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Delcam Asian Technical Summit 2009

H Live demonstrations were one of the highlights of the technical summit

eld from September 8 – 11, 2009 in Gyeongju, South Korea, the Delcam Asian Technical Summit provided the platform for users and manufacturers to come face to face for meaningful technical exchanges.

The participants were treated to presentations pertaining to products. There were also live demonstrations to promote better understanding of the products on show. They included DentCAD, DentMill, PowerMill, PartMaker, Fe a t u r e C A M , A r t C A M a n d PowerInspect amongst others.

In addition to presentations from the Delcam personnel, the company also invited guest speakers from HP, Intel, MTEC and Lee Ming Institute of Technology.

T he technica l summit was however not just about presentations. A big part was dedicated to plant visits. This year, the delegates visited the Hyundai car factory and SL Corp.

Joint Session With Korean User Group On the final day of the summit, a session with the user group was organised at the venue. Some 1,000 users attended the event, making it the biggest turnout so far.

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Delcam Asian Technical Summit 2009

Some 1,000 users attended the conference

During the event, Clive Martell, MD, Delcam shared the company’s strategy for success. Posting sales growth from 2000 to 2008, he used it as a backdrop and went on to speak about expanding customer base from the mould and die industry to the medical and dental sector.

Mr Martell also touched on the firm partnership the company enjoys w ith metrolog y a nd machine tool makers.

Success and growth go hand in hand and Mr Martell captured the imagination of many when he explained the new business areas of the company.

He also told the audience that the company is the third-largest CAM supplier to the aerospace industry and it is the only mainstream CADCAM company offering a solution for orthotics. Lastly, he revealed the planned new releases, which included PowerShape with Parasolid along with others.

Hyundai Hotel Gyeongju, South Korea September 8 – 11, 2009 Enquiry No. 8501

The company also invited guest speakers from the industry and educational institutes

In The Pink Of Health Delcam has recently gained its 30,000th customer, the German toolmaker Werkzeugbau Laichingen. Coincidentally, the order was again for six seats of the FeatureCAM feature-based CAM system, the same as that placed during 2008 by the 25,000th customer, JR Automation Technologies.

Following hot on the heels of this news is the announcement that the company has maintained its R&D expenditure during the first half of 2009 despite feeling the effects of the global economic downturn. The company invested over £4.7 million (US$7.7 million) in R&D during the period, a small increase from the £4.5 million invested in the first half of 2008. This strategy is in marked contrast with some other suppliers in the CAM market, which have cut their investment in development as their sales have fallen.

Despite the fall in sales and its continued high levels of R&D expenditure, the company remained profitable. Pre-tax tax profit for the first six months of 2009 was £0.3 million, against £1.4 million in the first half of 2008. Net cash at the end of the period was £5.8 million. This financial strength leaves Delcam well placed to take full advantage of any improvement in market conditions. MEN Enquiry No. 8502

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Delcam Asian Technical Summit 2009

One-On-One With

Peter Dickin

Speaking to Asia Pacific Metalworking Equipment News on the sidelines of the Delcam Asian Technical Summit, Peter Dickin, marketing manager shares his thoughts on the event and also some future plans. By Joson Ng

H

eld in the historic district o f G ye o n g ju , S out h Korea, the Delcam Asian Summit can be mistaken for a company retreat. That is of course not the case and business is very much on the agenda as Mr Dickin explains the objective of the technical summit.

“We invited two groups of people – the journalists and our customers. In terms of the output, we haven’t seen that yet as it is far too early. The hope is to receive exposure in the media and also for customers to buy more software.

No one has got their checkbooks out as yet but I am sure they will,” he says.

Marketing 2010 The marketing strategies for 2010 will not include any drastic changes. However, there are some interesting twists. A very relaxed Mr Dickin says: “In terms of marketing strategy, we would be putting a little more emphasis on the healthcare industry. In addition, we would like to build on our novelty of the year, which is the Delcam TV. We plan to increase the amount of video

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coverage for next year.”

Although these new pursuits are refreshing and exciting, he has not turned his back on traditional marketing, particularly in the engineering sector.

“Just because we are doing more in healthcare doesn’t mean we are doing less in the traditional fields.

We will carry on our traditional ma rketing progra mmes like advertisements and editorials.

Also, we will be participating in exhibitions and newer media,” he adds.

Organising a technical summit in Asia on an annual basis speaks volumes of the company’s focus in this region and when asked if there is a shift eastward in the marketing direction, Mr Dickin is quick to point out that comprehensive coverage is the name of the game.

“We have a big focus on Asia anyway. There will be no real increase from our current efforts as we are very strongly represented in Asia already. We want to be successful everywhere, we are definitely not putting less efforts anywhere else to concentrate on this region,” he says.

Calling On The Lion City In keeping with the philosophy of equal representation in all four corners of the globe, Delcam has established a Professional Services Group in Singapore, following the group’s successes in the UK and Europe.

The office will provide process development and prototyping services based on the company’s range of CADCAM software. A similar focus on helping companies with the manufacture and repair of aerospace components will be the main priority, although the Singapore team will also provide its services to other industries.

The reputation of the city-state as a MRO hub is only one of the reasons why the company set up

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base here.

“Apart from being the MRO hub, there is also no language problem. Centrally located in Asia, it is easy from the transportation point of view, making it a place with potential for a lot of business because of the big focus they have in aerospace. You have companies like Rolls Royce and Pratt and Whitney investing heavily in Singapore. We need to be there to support them,” Mr Dickin notes.

Making It Work With a wide array of products in their portfolio, the company relies on product testing and more importantly customer feedbacks to maintain quality.

“We have formal events like the users meeting, which is held during this summit. A lot of feedback can also be gained in less formal ways (eg: support desk). We have our second tier of support staff based in Asia, the UK and the US. If the local sales can’t solve the problem, these are the people who will provide assistance. We get constant feedback on the way users are using the software and the problem they face. All data are fed back to development teams,” he says.

The Asian Summit was also a platform for the company’s ma nagers ba sed in va rious countries to come together and formulate the general direction in product development in the coming year.

“I think for machining side, there is a lot of work on multithreading to take advantage of more powerful multi-processor computers. On top of that, we are looking at higher end machines and so we will focus on mill turn machines and five-axis machines,” he says.

On the design side of things, a lot of attention will be placed on Parasolid integration, according to the marketing manager.

Not about to get carried away, he says: “We are not going to

believe the software will be perfect when we release it. Yes, we test it comprehensively at Delcam but there are things you will miss.

Luckily we have 30,000 customers using our product, they are going to find things we haven’t. Consolidating that feedback however, is going to be the key.”

Up Close & Personal A veteran in the field of CAM software, Mr Dickin can be forgiven for taking things easy but the truth is far from it. When queried to describe his management style, he says: “I try to encourage people to do the best they can. I believe in leading by example. Do the best job you can, hopefully you can inspire people.”

With this dedication, he expects the same from the members of his team as he adds: “People who are enthusiastic, keen and willing to go a bit further – they are the people I look for in my team.”

From personal management to personal favourite, we put Mr Dickin on the spot by asking him to pick a favourite product in the company. With his marketing hat firmly on, he proceeded to pick two.

“There are two of them. I picked them because I feel they will generate big benefits for our

business. The first product would be PowerShape because it gives us two large benefits in terms of robust solid model and easy data transfer with other design software. I think with the improvement in solid modelling together with the knowhow we have in surface modelling and triangle capability, we have a good product. The other will be our dental product. The dental industry is a rapidly growing one, making it an exciting opportunity for us,” he says.

Conclusion & Next Stop Back commenting on the summit, he feels that the event has gone well. There is no time to relax, as planning has already started for next year’s meeting, which will take place near the Pune headquarters of Delcam’s Indian subsidiary.

“We haven’t held the Summit in India before even though our organisation there has the largest staff in our Asian subsidiaries and Joint Ventures,” explains Mr Dickin. “The year 2010 marks the tenth anniversary of the founding of Delcam India so we will make the Summit part of those celebrations.” MEN Enquiry No. 8503

With some 25 to 30 percent of annual turnover invested in R&D, Mr Dickin says this figure is one of the highest in the industry, setting them apart from other manufacturers

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TimeTo

The Mould

The financial crisis and stiff competition from neighbouring China has forced a rethink from the Hong Kong mould and die sector. By Joson Ng

H

ong Kong SAR, one of the leading financial centres in Asia, has long had the reputation of bridging the East and the West. Quietly powering on in the background is its manufacturing sector, which also includes the mould and die industry.

In order to understand more about this industry in the former British colony, Asia Pacif ic Metalworking Equipment News speaks to Edward Lai, honorary chairman, Hong Kong Mould and Die Council on the current situation in the industry, how has it been affected by the global downturn and also his take on the future.

“At the moment, we are quite seriously hit. I think for those companies that used to be active in the export business are quite affected. What we learned is that many new projects have been on hold for a whole year. Customers are just holding off their new product launch. Actually in Hong Kong, there is almost no mould and die manufacturing activities. Most of the companies have shifted their manufacturing facilities to China.

As we are located in the southern part of China, we are looking at this situation with interest,” he says.

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Moving Out Of The SAR Due to geographical and financial reasons, it is no surprise that comp a n ie s have made t he journey up north. Very much in the know, Mr Lai explains the mechanics of the industry in the mainland and the challenges for Hong Kong companies.

“For us, the situation has been difficult compared to 15 or 20 years ago. We have been transferring quite a bit of know-how, technology, skill and management to the Chinese companies and now they are taking up the business we used

to enjoy,” he says.

“In China, we have to look into another aspect that is the domestic market. Unfortunately, most of the Hong Kong companies are unable to penetrate quite well into the market. For instance, in the automotive industry, most of the suppliers are local Chinese companies,” he adds.

Though technically the same country but as Mr Lai mentions, the companies are facing stiff challenges in the mainland. He explains why.

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“To a certain extent, we are regarded as foreign investors. In addition, they know the country much better than us. They know where to find resources. Moreover, there are quite a lot of government initiatives to assist small Chinese companies,” he says.

When the going gets tough, the tough gets going. The council has looked elsewhere to ensure the competiveness of their members – trade promotion.

Mr Lai says: “One good example is participation in exhibitions. For this year, we have applied funding from the Hong Kong government.

In Asiamold exhibition, we have a Hong Kong pavilion. To help our members, we offer special price for booth rental.”

The council is not stopping there. Mr Lai also tells us that they would organise another pavilion at Euromold as he feels it is a good

chance to touch base with many European based customers.

Places Of Action The mould and die industry stretches far and wide. Well represented in many countries, the progress varies greatly. Using his wealth of experience, Mr Lai helps us narrow down the search for the areas of activities.

“In terms of country, it is China.

In the country itself as a whole, the last several years has been dominated by the automotive industry. There has been a lot of investment in automotive. There are about six to seven million cars produced in a year just for the domestic market. The next step is exporting. Some are starting their export business. I can tell soon the automotive industry in China is really going to take off. It should benefit the mould and die industry

as more models will be produced,” he notes.

Although aerospace is also taking off in a big way, Mr Lai feels that it will not be as benefiting to industries in the southern part of China.

Elsewhere in healthcare, he sees some activities especially in the SAR but it should be monopolised by foreign companies for now.

“Initially the mould should probably still be imported from outside. There are a lot of joint ventures in China with Japanese and US firms. Many of them still want to use the same tooling they have been using in their own country.

Some countries are shipping used moulds to China,” he says.

Hitting Fast Forward We ask Mr Lai to look ahead into 2010 and give us his take on the industry. He says: “I hope the

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“I think whoever can survive till today can make it all the way through this downturn. Business should be better by the beginning of next year.”

-Edward Lai

Mr Lai feels participation in trade events help boost competitiveness of their members

worst is over. We do see some kind of recovery, as it is not as bad as few months ago. There are more projects going on now although we are still experiencing some very steep price correction.

In addition, there are not enough orders. I think whoever can survive till today can make it all the way through this downturn. Business should be better by the beginning of next year.”

With his positive take on the economy still ringing in the background, we ask him what are the niche market the Hong Kong mould and die sector is moving into for 2010.

“One of it is medical and the other is food and beverage packaging,” he says. As far as product innovations go, more focus will be on design.

He expects to see more companies incorporating design services in addition to prototyping and production, making themselves a one stop mould and die solutions provider. “This will be the best way to fight for survival,” he concludes.

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Innovation To The Rescue Difficult times call for support and a helping hand. The Hong Kong Mould and Die Council responded – using innovation.

“We are celebrating our 20th anniversary this year. With some 180 company members and most of them in mould making, we organise several types of activities every year. For instance, we conduct six to seven seminars annually. In addition, we go for study missions around the Guandong area. They are mostly factory visits so our members can study the advanced manufacturing on show,” Mr Lai says.

Although the activities largely served an educational purpose, they go a long way in helping members stay relevant and these are just a number of ways the council assists their members.

Automating Mould Making Another way is to get their members involved in trade shows and exhibitions. Not contented with just displaying products and services in a booth, the council came up with some novel ideas in the last Asiamold.

“During Asiamold last year. We organised an automation workshop.

With five machines, we basically setup a mini factory in the middle of the exhibition hall. It shows the process flow – raw material coming into the process and leaving as finished product with no human intervention.

It is all automated,” he explains.

The idea behind this is to demonstrate to the industry that mould making can be automated. For many, it was an eye opener and the partners in Germany are interested in doing the same thing at this year’s Euromold, according to Mr Lai. MEN Enquiry No. 8505

28. – 31. March 2007 · Hall 6/Booth 6H1-01 Date of Exhibition: 18-21 Nov 2009 Booth no: B175

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Thread Production:

To

?

Cut , MillOrForm With emerging manufacturing trends introduced into thread production, more consideration time may be needed to decide which production process to adopt. Submitted by Yvonne Ng, marketing manager, Walter AG Singapore

I

n themselves, female threads are hardly rocket science - or so it appears. But given evertighter production deadlines, time-honoured processes lose their apparent triviality.

The high cutting parameters in modern thread production processes place extreme strain on the core-hole drill, in particular with stainless, acid-resistant steels and materials that are difficult to machine (ISO-M, ISO-S materials).

Very high temperatures can develop on the cutting edges, which causes the material to harden.

Lower-quality drills tend to wear more quickly, exacerbating this effect. The subsequent tap meets greater resistance, and its useful life is reduced.

This also affects the surface finish quality and gauge accuracy of the finished thread. Ultimately, it is a matter of the quality of the threading tool. The great importance of boring the core hole is often disregarded when assessing a situation.

Thread Cutting “It’s not our intention to reinvent thread cutting,” says Timo Mager, threading product manager, Walter.

“As thread cutting comprises two separate processes, we want to offer the best tools for both in the form of

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a complete solution,” he adds.

T h e X·t r e m e Plu s s o l i d carbide drill and the ECO-HT tap represent that for the production of female threads, according to the product manager. In comparison with standard tools they reduce processing times by up to 50 percent; this applies to both operations, drilling and thread cutting. They also have an above-average tool life and process reliability.

Solid carbide is increasingly being used for taps. “One aspect of the development work at Walter Prototyp has been aimed at introducing to the market solid carbide taps for steel machining with tensile strengths of up to approximately 1,200 N/mm 2 ,” says Josef Giessler, development manager for rotating tools at Walter Prototyp.

The maximum cutting speeds of these threading tools are 60m/min.

By way of comparison, speeds of 20m/min are usual for HSS-E taps; the tool life is as much as eight times higher.

A New Emerging Trend Most female threads are still

produced by thread cutting, but the alternative methods of thread milling and thread forming are gaining ground. “We are seeing a trend towards these technologies a nd a re ou r se l ve s ma k i n g developments in these directions,” confirms Mr Giessler.

T h re ad m il l i n g re qu i re s modern machines and complex programming. The programming itself represents a bit of an obstacle to many machinists. The machine control modules are generally not sufficient.

Walter has a way of dealing with this. It provides in addition, a machining strategy in the form of the NC program, together with the TEC/CCS cutting data software.

This saves programming time and increases reliability.

Threadforming requires a particularly precise coordination of the core-hole drill with the threading tool. The precision of the drilled hole is in the region of 0.05mm (eg: for M6, core-hole drill is 5.55±0.05 mm).

As the technology is only considered for appropriate materials that can be cold formed,

ENQUIRY NO 177

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the range of application is more limited. The problem of hardening is also a factor here.

When forming, temperatures often build up sharply, which can change the forming properties of the material. However, the central question for the user is often not a technological one. Less common hole diameters can create procurement problems for tool managers.

Says Mr Mager: “We have a range of drills that includes not only all diameters for thread cutting and milling, but also for forming.”

Software Solutions An important element, widely proven in practice, is the TEC/CCS software mentioned before. The system represents an information pool for both technological and commercial questions. Machinists save time and can work more independently, as the answers to many questions can be obtained immediately.

In the current version, the subjects of drilling (TEC module) and threading (CCS module) are interlinked. Based on this interconnection, users can find the combination of drilling and threading tools and are also given the costs per thread.

Moreover, the indiv idua l threading technologies can be compared directly in terms of t he i r e co no m ic e f f ic ie nc y.

After inputting the machining assignment, the material and the cooling lubrication method, the cutting data are also listed.

“The cutting data for drills and threading tools provided by the software are worked out in detail by us under normal conditions encountered in practice,” explains Mr Giessler.

“The same applies to the coolant recommendations. We test all the coolants readily available on the market and on the basis of our experience suggest two particularly suitable and environmentally68

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Software programs are used to help optimise cutting

Solid carbide orbital thread mill produces precision threads right down to the root

friendly oils for thread cutting and threadforming,” he adds.

In general only emulsions are used these days, although there are exceptions, for example for threadforming with high-tensile materials. In these cases the high temperatures require special cutting oils.

The product manager concludes: “By using the recommended tool combinations and cutting data, machinists will always be on the right track. In other words, the known problems relating to bore hardening are minimised.” MEN Enquiry No. 8506

Compact Technological Overview Walter have introduced manuals in pocket-book format, designed to answer questions that frequently arise in practice.

The manual for threading entitled ‘The prefect thread’ contains a condensed overview of the tools with information on performance and dimensions, but also provides a whole range of general technological information, illustrated with diagrams and sketches.

Subjects covered include cutting data, chip formation, lubrication, quality assurance and more.

Enquiry No. 8507

10-Day Special Service For Drills “If drilling and reaming tools have to be adjusted with great precision to the subsequent threading job, sooner or later a special tool is called for,” says Peter Müller, development manager for rotating tools/drills, Walter Titex.

This relates not only to unusual intermediate diameters, which are required every so often in threadforming, depending on the material, but also in particular to special lengths, drills with countersinking or step drills.

Walter offers the 10-day rapid delivery service CAT express for special drilling tools of this kind. “This service is especially useful for users who have short-deadline orders and need a special tool quickly for a small- to medium-sized series. The service is based on fullyautomated design mechanisms with associated work plan generation,” adds Mr Müller.

Enquiry No. 8508

ENQUIRY NO 156

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Green By

With the 2010 release of SolidWorks, the company has unveiled its intentions to join the green movement. By Derek Rodriguez

W

ith the 2010 release of SolidWorks, the company has made available to users many new features. Ved Narayan, VP, Asia Pacific Operations of Dassault Systemes SolidWorks Corp, explains the company’s philosophy towards product de si g n: “ We wa nt to ma ke products that are easier to use, robust, and affordable so people can literally take it out of the box, start using it, and get productive.”

According to Mr Narayan, his favourite new feature is SolidWorks SustainabilityXpress. He says: “It resonates with what is going on in the world today and what customers are demanding. Many companies today are really taking the initiative to make their products environmentally friendly or green or sustainable.”

C o n t i n u e s M r N a r ay a n : “That is happening more for the manufacturing side, but if you look from a market perspective, the regulations that are coming, people are talking about greenhouse gas

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emissions and carbon taxes. France is going to have carbon taxes implemented as early as next year (2010). It has an impact on business for people. If you are going to pay more for taxes it’s going to affect your profit margin. So they have to take that initiative to really start thinking and incorporating products and materials for that.”

Design For Sustainability This green direction, claims Mr Narayan, is a natural progression and is not just a one-off thing.

Rather, it is a process that will continue to be built upon.

Making sense of the need for green design, Mr Narayan says: “If you truly see the whole lifecycle assessment, the biggest influence on the whole overall sustainability for your green product that you can have, is at the design phase.”

Painting an example, Mr Narayan adds: “People talk about designing a green house, people talk about designing a solar energy panel.

You can do that design but how do

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SolidWorks Innovation Day SolidWorks partners and end users in Singapore gathered at Swissotel Merchant Court on October 9, 2009, to witness the unveiling of the latest version of the company’s CAD software.

Organiser and reseller Advanced Technology Enterprise’s (ATE) MD, Isaac Chong introduced the software and talked about the new sustainability feature offered with SolidWorks 2010.

According to Mr Chong, sustainable design would be able to help on three levels: environmental, social, and economical. The advantages of sustainable design are minimised material usage, improved material choices, the ability to design for ease of disassembly, minimised energy consumption and product reuse or recycling.

Dr Lee Hui Mien, assistant research scientist with the sustainability and technology assessment section of SIMTech (Singapore Institute of Manufacturing Technology) further elaborated on the need for sustainable product development.

Dr Lee pointed out that it can bring economic incentives such as a lower cost of production. Corporate social responsibility is another factor to consider, as is improving the environmental performance of the product.

Declaring that “clean energy is the hottest topic in product manufacturing today”, Sharon Toh, GM, South Asia, SolidWorks set out to convince product designers of their crucial role to play in sustainability.

She identified the important metrics to measure (when considering environmental impact) as carbon footprint, energy consumed, air acidification and water eutrophication.

Swissotel Merchant Court Singapore October 9, 2009 Enquiry No. 8509

Did You Know?

Research by the Aberdeen Group found that 56 percent of manufacturers globally have already deployed some form of a design for greener products strate gy, with another 26 percent planning to adopt a similar strategy over the next two years.

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you know the material you use for that itself is green enough in the first place?”

“That’s where the advantage of SustainabilityXpress comes in.

It will help you choose a material that will give you the same strength, same functionality, but with a lesser impact on greenhouse, energy consumption, air pollution and water pollution.” “ We a re a lso going a nd educating our customers on the design process. How can we make our design modular for re u se ; e du c at i n g not o n l y with respect to the way you can use a material but also the way you can design a product.”

Keeping Ahead With Technology Speaking about the company’s business model, Mr Narayan reveals that it is 100 percent indirect. The compa ny ha s partners and resellers who are authorised by them both in their skill sets and capabilities, whether it relates to product usage, training or demonstration.

This allows the company to focus on its R&D. Discloses Mr Narayan: “On average, we spend more than 20 percent of the company’s revenue on R&D. In fact, in the downturn, the only budget which wa s not cut interna lly wa s the R&D budget. This is the perfect time to build products because when the economy bounces back, you have that edge.”

In fact, the field testing of the programme started some months back. Mr Narayan declares: “Since the product preview in January 2009, we have been testing the product in multiple stages. One is quality assessment, this is a built in process. In every stage of coding there is testing going on. We start from the initial stages so every time we submit back coding it has already been tested.”

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A Virtual 3D Experience Attendees chose from over 40 different sessions from an action-packed agenda at the first SolidWorks Innovation Day virtual event. Speakers included CAD industry veterans, SolidWorks key executives, and product and technical experts. Topics ranged from CAD technology to product innovation trends to sustainable design for the future and how the company addresses the vertical industries’ needs.

Keynote speakers included SolidWorks CEO, Jeff Ray and SolidWorks group executive and co-founder, Jon Hirschtick.

SolidWorks initiated the virtual event to complement the offline SolidWorks Innovation Day events and to unite its network of over one million users with one another and the rest of the SolidWorks community.

This virtual event was available in three languages, English, Simplified Chinese, and Korean. Attendees were able to connect and chat with one another real-time if they were online at the same time by leveraging on the social networking tools available on this platform. Allowing users around the world to share will fuel creativity and drive the design industry forward through collaborative innovation.

Enquiry No. 8511

SolidWorks 2010: Working Smarter & Faster SolidWorks 2010 CAD software improves designers’ and engineers’ productivity with a range of capabilities.

A configuration publisher lets users publish a model configurator interface to the 3D ContentCentral service – a Web-based marketplace for 3D parts, assemblies, and other content – to enable simple selection of model alternatives.

SolidWorks Simulation Premium provides tools to validate design decisions and uncover hidden problems before they affect production.

The 2010 version adds capabilities like event-based motion simulation, which mimics the way machines really work, as well as proximity sensors and automatic edgeweld sizing.

SolidWorks Enterprise PDM software includes new productivity features for preparing models and drawings for distribution.

SolidWorks Sustainability software makes sustainable design accessible. It helps users determine the carbon footprint, energy consumption, and air/water impacts in a product design’s raw material sourcing, manufacture, use, and disposal. An assembly visualisation tool colour-codes parts based on their total environmental impact.

Configuration support in the software also lets users compare multiple design iterations for sustainability concerns.

Included with every license of SolidWorks software, SolidWorks SustainabilityXpress helps users immediately determine the environmental impact of any part. The sustainability products include an environmental impact dashboard, customisable reports, and a tool to find alternative materials to compare and improve the sustainability of a part. MEN Enquiry No. 8512

ENQUIRY NO 058

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Metalworking Fluids:

Meeting

New

Regulations

As personnel health and safety continue to drive the development of metalworking fluids, the issues affecting operators and how they can effectively manage HSSE requirements and performance demands are looked at.

By Herwig Van Roey, global technical expert, water miscible fluids, Shell Lubricants

I

n January 2009, European regulations came into force introducing a new scheme for the Classification, Labelling and Packaging (CLP) of potentially hazardous substances. It was originally intended that from June 1, 2009, it would be mandatory for companies manufacturing, supplying and using chemical substances such as Metalworking Fluids (MWFs) to comply with the new regulations.

However, the date changed and is now set for December 1, 2010, when it will become a legal requirement for companies operating in EU member states to comply with CLP regulation.

The new reg ulations a re d e si g n e d to h e lp i mp rov e personnel health and safety in the workplace. For metalworking operators, this will lead to the reformulation of some MWFs as levels of certain additives will be

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minimised to reduce potential HSSE risks during processes such as cutting and forming.

This reformulation could compromise fluid performance, resulting in reduced fluid life, shorter maintenance intervals and lower levels of equipment efficiency.

Essentially, maintenance and fluid costs could increase, along with the risk of unscheduled stoppages.

Meeting The Regulations With the right technical knowledge and understanding, MWFs can be developed to meet regulatory requirements, while also offering enhanced performance properties.

Shell Lubricants have reformulated part of its range of MWFs and

continue to improve substance formulations in accordance with CLP regulation.

This is helping operators to promote better HSSE practices and maintain production capabilities well in advance of the mandatory compliance date in December 2010.

Boric Acid One of the components of water miscible MWFs that has generated much debate is boric acid. It has been used extensively for a number of years in MWFs due to its corrosion protection, long life, pH and buffering properties.

However, there are concerns that it can potentially cause infertility in males and harm unborn children

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in the long-term. To reduce these potential risks, CLP regulation will require MWFs to contain less than 5.5 percent boric acid for them not to be labelled as containing boric acid.

As boric acid is soluble in water, it is difficult to remove from waste water and remains active in biological treatments. Therefore, it can pose a potential environmental risk in addition to a threat to personnel health.

To help operators improve personnel health and safety, and environmental compliance, MWF companies have developed fluid technology that contains less than 5.5 percent boric acid as well as boron free fluids that still offer optimal performance.

Secondary Amines The secondary amines present in MWFs can react with nitrites and cause the formation of nitrosamines. As some of these have proven carcinogenic properties, it is therefore preferable to choose a supplier offering secondary amines free technology.

The presence of contaminants can increase and speed-up the

growth of bacteria and fungi in water miscible MWFs. There are growing concerns on the possible adverse health effects of microbial life by direct skin contact or inhalation.

Contaminants could include small particles of metal or alloys such as chips from the tool or machined part, tramp oils used to lubricate other parts of the equipment including hydraulics and gear boxes, and cleaning products used during finishing and general facilities management.

The contamination can degrade e mu lsion s a nd cha nge t he properties of the MWFs, which can lead to the formation of potentially hazardous components.

Formaldehyde Donor Biocides Formaldehyde donor biocides are often used to control the growth of bacteria in MWFs. The environmental impact of these substances is relatively low as it is rapidly broken down by sunlight or by bacteria present in soil or water and is quickly metabolised by normally-functioning cells.

Therefore, it does not often accumulate above extremely

Micro tapping test for water miscible cutting fluids

low, non-toxic levels. However, laboratory tests have shown that the long-term inhalation of formaldehyde donor biocides could be responsible for producing malignant tumours in nasal cavities.

Health Risks MWFs can pose a threat to personnel health through inhalation and direct skin contact. High operating speeds, fluid pressures and MWF contamination can cause misting during machining.

This increases the risk of toxic vapours being inhaled by personnel and can lead to respiratory issues such as asthma and bronchitis.

Vapours can also be inhaled during improper MWF application, handling and storage.

Skin contact with MWFs can be caused by fluids flinging-off tools and parts due to high operating speeds, fluids splashing during manual application, leaks and drips from lubricant system hoses and during maintenance and cleaning practices. Personnel may come into contact with MWFs when draining fluids, setting tools and changing work pieces.

Similarly, contact can occur through cloths and work clothes becoming soaked in MWFs during operation. There are concerns that skin exposure could cause conditions such as dermatitis, acne, folliculitis and some cancers.

There are a number of solutions to reducing potential HSSE risks associated with the content of certain MWFs including ventilation and filtration systems, training, equipment guards, protective clothing and adding biocides to MWFs to reduce bacterial growth.

In addition, reducing equipment operating speeds and feed rates can also lessen the risk of misting and direct skin contact with MWFs. While all of these can prove effective, one of the most practical and cost-effective solutions – opting for low toxic MWFs – is often overlooked.

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Extensive tests were carried out to maintain and in some cases improve the performance of metalworking fluid while meeting the new regulations

Safer & High Performing MWFs In the past, some low toxic MWFs such as boron and amine free alternatives have not been able to meet all equipment performance requirements and operational demands. This has led to issues such as reduced sump life and lower corrosion protection. To overcome these challenges, Shell Lubricants is working in partnership with customers to develop a comprehensive range of advanced MWFs. Combining lubricants expertise with an in-depth understanding of everyday operating conditions is driving the development of fluids that help operators meet operational demands and legislative requirements.

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metalworking equipment news Nov-Dec 2009

and other biocides.

As well as helping to reduce potential HSSE risks and complying with CLP regulation, the MWFs offer performance properties including: stability to promote long sump life and reduce the presence of tank side additives and growth of bacteria, corrosion protection, separation of tramp oils to reduce contamination, low foaming characteristics and high levels of detergency to promote effective cleaning and reduce degreasing requirements.

Furthermore, MWF technology including carefully selected base oils, anti-misting additives and esters reduces the potential risk of misting and associated risk of inhalation of vapours. The MWFs have been developed for machining a wide range of materials and can be used in hard and soft water applications.

Preparing For Change Metalworking operators are becoming increasingly concerned about personnel health and safety risks, and are looking for solutions to manage these risks.

M W F te chnolog y is now available and provides a practical and effective solution to enhancing HSSE, which in turn, can help satisfy market demand and legislative requirements for better working practices.

Acting now and using the transitional period will not only help metalworking operators ensure compliance in time for the mandatory date, it could help them to better promote HSSE and gain advantage in an increasingly competitive marketplace.

Investing in high performance, low toxic MWFs as a first step can also help to reduce the need for wider adaptation of production facilities, while enhancing overall efficiency a nd profitabilit y through lower maintena nce costs, longer equipment life and increased uptime. MEN Enquiry No. 8513

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ENQUIRY NO 176

EVENTs&

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exhibitions

Event Review:

Asiamold 2009

H

aving received 10,468 visitors from 38 countries and regions over the course of the three-day fair period from September 16 – 18, 2009, Asiamold 2009 was declared a success. This reflected an increase of 8.4 percent in the attendance figure achieved last year.

The third edition of the event successfully reinforced its position as a trade exhibition in southern China for mould-making and tooling, design and application.

This was achieved by following the example set by its sister event – EuroMold in adopting the fair concept ‘from design to prototyping to series production’, which ensured

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metalworking equipment news Nov-Dec 2009

the fair organiser received positive feedback from exhibitors and visitors alike.

Gateway To Southern China’s Mould & Die Market The global recession has barely impacted the popularity of the event.

Participation of both international and domestic exhibitors at the 2009 event was up respectively by 10 and six percent on last year. In total, 298 brands from 12 countries and regions flocked to Guangzhou to showcase their latest in machinery, equipment and products.

Covering a display area of 20,000 sq m, this year’s exhibition also featured a Hong Kong pavilion

organised by the Hong Kong Mould and Die Council, a metal manufacturing pavilion organised by the Hong Kong Metal Manufacturers Association, a Singapore pavilion orga nised by the Singapore Precision Engineering and Tooling Association and a EuroMold pavilion organised by DEMAT. International Appeal Receiving 1,233 international visitors, an increase of 15.6 percent on the year before, many of which senior decision makers in purchasing, design and R&D, exhibitors were also impressed with the calibre and internationality of the 2009 attendees.

ENQUIRY NO 129

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Some 1,200 international visitors made the trip to Asiamold

Interview With The Organiser

Phoebe Lu, account manager, Century Step Precision Molds observed: “The visitor flow this year was diversified and comprehensive.

This included delegations from Brazil, Germany, Iran, Malaysia, Singapore, the UK and the US, as well as agents, distributors, fellow suppliers and direct clients from the automotive and communications industries.”

With visitors from 38 countries and regions of which the top 10 by visitor volume were from China, Hong Kong, Iran, Malaysia, India, the US, Japan, Brazil, Taiwan and Russia, Asiamold enables exhibitors to expand their customer base.

The international reputation enjoyed by Asiamold is reflected in the increase in attendance of overseas visitor delegations. This year, five delegations attended the exhibition from Brazil, Germany, 80

metalworking equipment news Nov-Dec 2009

Iran, Malaysia and Singapore.

Two buyer delegations were also organised by the American Chamber of Commerce and the British Chamber of Commerce.

Each of these delegations had between 20 to 30 delegates.

Seminars & Workshops The event also featured a range of technolog ie s a nd fr inge programmes. Under the Hong Kong Pavilion, an advanced moulding workshop was set-up to demonstrate the manufacturing processes of mould and die equipment.

To assist exhibition attendees gain the latest industrial knowledge and market updates, experts from a diverse range of backgrounds delivered more than 20 sessions of technical talks and presentations.

Enquiry No. 8601

Held at the Poly World Trade Centre Expo, Guangzhou, China, the third edition of Asiamold featured some 298 exhibitors over three days.

Asia Pacific Metalworking Equipment News was there to talk to the organisers to find out the objectives of the show as well as the health of the mould and die industry in China.

“The aim of this event is to provide a platform for mould makers for business networking. We feel this is particularly beneficial for Asian mould makers from Taiwan, South Korea and the SEA nations as they rely heavily on exports to overseas countries,” says Louis Leung, deputy GM, Guangzhou Guangya Messe Frankfurt.

Highlights Of The Event With many exhibitions dedicated to mould and die in the region and also around the world, we asked Mr Leung, what is the highlight of the show and how does it stand out amongst others.

“In my personal opinion, it is the fact that we focus on mould design.

Other shows of the same genre may choose to emphasize on relevant machine tools, casting injection machines and stamping machines.

They focus more on machines and equipment but we choose to focus on the design and engineering aspect because mould design is very important particularly for the mould manufacturers,” he says.

According to him, some 75 percent of exhibitors are mould makers and there are no

ENQUIRY NO 165

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other shows in the region that concentrate this much on the mould makers.

This direction taken by the organisers looks set to continue according to Mr Leung. “Mould design will be the main theme of Asiamold for the next two to three years. We will showcase mould design that caters for the production needs of manufacturers.

We are developing this event into a sourcing centre for manufacturers.

Our ultimate objective is to provide a large platform for them. As such, we are targeting 50,000 to 60,000 sq m of exhibition space in the future,” he adds.

Challenges For Organisers Planning an event for a few thousand people over the period of three days is no easy task. In addition, marketing it is also a tough process. Many organisers use internationality as a selling point but that can also be a challenge as well as many foreign visitors or buyers may be hindered by the language barrier.

Even with a healthy number of visitors coming from Brazil and India this year, language is not a concern for Mr Leung from the organiser’s point of view as he explains: “We offer translating services in advance. But basically this barrier can be overcomed.

Furthermore, the exhibitors have English, German and Japanese speaking staff available. Anyway, most inter nat iona l v isitors generally speak English and sometimes they have a Chinese staff with them so language is not a problem,” he notes.

Every event organisers’ dream is to have government support but as far as Mr Leung is concern, he feels that they need more support from the associations itself and he got his wish for the event this year.

“In our exhibition we have supp or t f rom t he relev a nt

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Louis Leung, deputy GM, Guangzhou Guangya Messe Frankfurt

Experts delivered more than 20 sessions of technical talks

associations from the mould and die industry. In terms of government support, it is always welcomed but at the moment, the government policy is a little different in Guangzhou compared to Shenzhen. For example over there, you can expect some subsidies. However Guangzhou continues to be attractive to us because of the infrastructure and also the airport here makes it convenient for international visitors,” he says.

Mould & Die Industry 2010 Of all the major economies, China is arguably less affected by the global economic slowdown thanks to its massive domestic demand. Although not entirely spared by the downturn, there is certain optimism and it is evident in the thinking and plans of the event organisers.

Mr Leung says: “The economy we believe should recover soon and as such, we are still quite positive.

There are still production needs and new product developments.

We feel that the opportunities

for mould makers are good so we a re optimistic for ne x t year’s Asiamold.”

Still looking to the future, we asked where the ‘hot spots’ for the mould and die industry are and using Hong Kong as an example, he says: “They used to focus a lot on the US and Canada. But there is a shift in focus to Europe, particularly Germany and France. In the future, some 50 percent of focus will move from the US to Europe. They would prefer to spread out than put all their eggs in one basket. Not forgetting China, domestic demand would be very significant. As such, the hot spots would be China and Europe in the future.”

Poly World Trade Center Expo (Pazhou) Guangzhou, China September 16 – 18, 2009 Enquiry No. 8602

ENQUIRY NO 164

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Event Review:

Metalex Vietnam 2009

E

xhibitors were satisfied with the quality of business opportunities and the organisation of Metalex Vietnam 2009 as it closed on a high note. In addition, visitors were happy about the new machine tools and metalworking technologies they experienced and obtained at the event.

A total of 6,659 Vietnamese industrialists from across the country and trade missions from many countries attended the event.

They discovered new technologies, learned new knowledge, and expanded their business networks.

Speeding Ahead With New Technologies A t t h e s h o w, V i e t n a m e s e manufacturing industrialists purchased new technologies to improve their production efficiency and made the investment to save cost and increase business

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metalworking equipment news Nov-Dec 2009

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ENQUIRY NO 170

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sustainability. And that adds into the acceleration of the advancement of Vietnamese manufacturing industry.

The show’s official opening ceremony was attended by highranking executives from both local and overseas organisations and associations. Also, manufacturing professionals attended the show and got connected with both their existing and potential business partners. The show is a good place for an individual to expand his or her manufacturing business network in Vietnam.

Technical Upgrades In addition to over 1,000 items of new technologies that 500 brands from 25 countries brought to exhibit in the show, visitors also gained first-hand experiences with new high-technology innovations in ‘HiTech Zone’ in which technologies from China, Japan, S Korea, and Taiwan were showcased. And in the zone, ‘Motoman’, an intelligent industrial robot showed off its capability to weld and cut metals with laser in ‘Robot Demonstration’.

During the show, conference and technology presentation sessions were conducted to provide new knowledge and introduction to new technologies to delegates. Speakers hailed from Thai Tool and Die Industry Association, Department of Industrial Promotion (Thailand) and private sectors.

The topics range from ‘Mould and Die Development for Japanese Industry’, ‘Precision Workholding for Quality Parts’ Manufacturing’ and many more. Finally, organiser Reed Tradex have also announced that the next Metalex Vietnam will be held from October 7 – 9, 2010 in Ho Chi Minh City.

A total of 6,659 visitors attended the event

Speakers from other countries were invited to conduct technical presentations

Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam October 8 – 10, 2009 Enquiry No. 8603 86

metalworking equipment news Nov-Dec 2009

Live demonstrations never fail to capture the imagination of the visitors

www.equipment-news.com

product finder

Adcole: Software Upgrade

CNC Software: Dynamic Machining

Adcole has developed a software upgrade that can be retrofitted to all existing windows gauges in the field to allow a customer’s entire supply chain to have the same measurement and processing capabilities.

The 1200 CrankshaftCamshaft Gage software upgrade features measurement parameters like thr ust face tota l runout, asperity removal a nd chatter a na lysis.

In addition, the postprocessing function include 3D colour mapping and analysis options such as cylindricity report plots. The upgrade package requires no modification to their current measurement sequences.

CNC Software has released Ma sterca m X4. It provides expanded machining flexibility and an increased emphasis on speed and automation with a suite of new toolpaths and techniques, including dynamic machining cutting motion.

Dynamic Machining creates a constantly adapting toolpath that delivers more consistent cutting conditions and allows use of the entire tool flute length, saving both time and money. The toolpath is designed to take a full depth cut in, often eliminating the need for multiple depth cuts.

Enquiry No. 8701

Enquiry No. 8702

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

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

maximise your shop’s machining.

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

Visit us at

Hall 106 , Booth 6B16 19 - 22 November 2009

Hall A, Stand 3403 2 - 5 December 2009

ENQUIRY NO 171

*Source: CIMdata, Inc. 2009

Nov-Dec 2009 metalworking equipment news

87

productfinder

www.equipment-news.com

Esco Tool: Welding End Prep Tool

A welding end prep tool for bevelling heavy-wall pipes in offshore platforms and pipelines where the weld is critical because of high-pressure requirements is available from Esco Tool.

The Millhog dictator ID clamping welding end prep tool is designed for use on heavy-wall pipes up to 508 mm diameter that are made of stainless steel, super duplex, P91 and other hard alloys.

Delivering 553 kgf-m of torque, it is equipped with a standard pneumatic motor and has dual-opposed tapered roller bearings for rigidity.

Enquiry No. 8703

Kennametal: Shrink-Fit System

As part of its complete tooling solution from the spindle face to the cutting edge, Kennametal has developed its shrink-fit toolholding system for machining centres and multi-tasking machines.

The shrink-fit program is split in two lines. With the GP (General Purpose) line, carbide, HSS, and steel shanks can be accommodated with clamping torques suitable for most general engineering, die and mould and automotive.

For heavy roughing operations the HT (High Torque) line is recommended.

Enquiry No. 8705

Husky: Temperature Controller For Wide Applications Husk y Injection Molding Systems have expanded its line of Altanium temperature controllers with the introduction of A lta n iu m Ne o2 controllers.

It is designed o n a p l a t f o r m to prov ide two to 24 zones of control and is equipped with 15 amps per zone, making it flexible enough to handle a wide variety of applications. The desig n combines functionality and control with an intuitive and simple user interface.

The controllers are able to store up to 24 mould setups internally and support external storage through a USB key, allowing for faster, more accurate start-ups.

Enquiry No. 8704 88

metalworking equipment news Nov-Dec 2009

Mate Precision Tooling: ABS Tooling For Punch Presses

The AMX ABS tooling with lubrication features and high speed steel is designed to extend tool life while ensuring quality punching. Mate’s punches and strippers are compatible with Amada ABS assemblies and holders, offering customers a replacement tooling alternative.

Operating benefits of the Mate AMX ABS tooling include internal lubrication within the punch guide and external lubrication between the punch guide and the turret bore.

The lubrication functions are computer controlled within the turret press and can be programmed and regulated according to punching requirements.

Enquiry No. 8706

productfinder

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Mori Seiki: High Performance Operating System

NUM: Tool Head Solution For Cutting Machinery

The fourth-generation of MAPPS, the operating system, has been developed by Mori Seiki. The system allows customers to use a common operating method, regardless of model.

It has been supporting machining processes of customers worldwide with its interface and automatic conversational programming function.

The main features are improved userintuitive hardware and interface. Its vertical soft-keys can be used as option buttons or shortcut keys to display the information users like to view.

CNC vendor NUM has developed a ready-integrated pan-and-tilt tool head solution for plasma, laser and waterjet cutting machinery applications. Called NUMcut, it extends the capability of machinery from 2D to 3D applications, with multi-axis interpolation.

A mechanical design provides the versatility of movement and stiffness required to implement precision cutting motion, but with the advantages of low mass, and the elimination of cabling runs that need to flex with the tool head movement.

Enquiry No. 8707

Enquiry No. 8708

Precision Measurement Equipment Since 1959

Excellent Technology and Outstanding Products

Micro-Vu Corporation designs and manufactures a broad line of measuring machines including Automated Vision Systems, Manual Video Systems, and Optical Comparators.These non-contact and contact measurement system use video and touch probe inputs to perform high precision 2D and 3D measurements.

Excel

We offer advanced Structure Design Concepts.

Spectra

Exeptionally High Rigidity and Stability.

To ensure the best Structural Rigidity and Stability, the major casting parts of the machine are analysed by advanced “Filter Element Analysis”.

SMG Technologies

Matrix Vertex Vector

SMG Technologies Pte Ltd No. 7 Toh Guan Road East #08-01/17, Alpha Industrial Building Singapore 608599 Ph: (65) 65622093 sales@smgtech.com.sg www.smgtech.com.sg

Henko Machine Tools Pte Ltd No.23 Kaki Bukit Industrial Terrace, Singapore 416103 Tel: +65 6846 4666 • Fax: +65 6846 4555

Dahlih Machinery Industry Co Ltd No: 3, Kung-Yeh Lane Fengcheng Road, Nanshih Tsun, Wufeng Shiang, Taichung Hsien 413 Taiwan Ph: (886) 4-23334567 www.Dahlih.com.tw

BME Industries (M) Sdn Bhd D-G-2 & D-1-2 Persiaran Relau Sungai Ara, 11900 Bayan Lepas Penang Tel: +604 640 8686 Mobile: +6016 440 0618

Henko Machine Tools (Thailand) Co Ltd 26/357 Moo 18, Tumbol Klongnuang Amper Klongnuang Pathumthani Province Thailand 12120 Tel: +66 2908 1131 Mobile: +66 860 423 383

恒科商贸（上海）有限公司 上海市徐汇区沪闵路8075 号红梅商务大厦613 室邮编200233 电话: +86 21 5418 4811 手机：+86 1360 164 1618

For enquiries, please email: info@henko.com • Website: www.henko.com

ENQUIRY NO 096

ENQUIRY NO 167

To know more about New Generation Five Face Machining Center MCTH500 and to find out EXCELLENT PRODUCT RANGE in Horizontal and Vertical Machining Centers call us today.

Nov-Dec 2009 metalworking equipment news

89

productfinder

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Renishaw: Automated Check For Multi-Axis Machine Tools

Renishaw has extended its market range of machine tool testing and calibration systems, with AxiSet Check-Up, a cost-effective solution for checking the alignment and positioning performance of rotary axes.

In just a few minutes, users of five-axis machining centres and multi-tasking mill-turn machines can now identify and report on poor machine alignments and geometry that can cause extended process setting times, as well as non-conforming parts.

The product provides accurate and repeatable test results using automated probing routines to gather performance data from a reference artefact.

Walter: CVD-Coated Indexable Inserts

The SilverTiger by Walter delivers a performance increase of 50 to 100 percent. This family of CVD-coated indexable inserts for milling, turning and drilling is based on a coating combination in conjunction with a surface treatment. The result is a surface in which stresses are reduced.

Benefits include the reduction of thermal cracking and tribochemical wear on the cutting edge and the rake face respectively.

Application areas include dry and wet milling of cast iron and steel materials in a variety of industries like energy, aerospace, automotive, general mechanical engineering and railway.

Enquiry No. 8711

Enquiry No. 8709

Waldmann: LED Machine Lighting

90

Widia: Fine Boring System

The Slim LED is a lighting solution by Waldmann fo r m a c h i ne s a n d equipment w ith space-constraints a nd limited installation space. The luminous power, powered by the LED technology, allows large - scale and effective illumination of machine workplaces.

I n addit ion, t he light emission direction can be individually adjusted. Available in lengths ranging from 196 to 1,176 mm, the product is water and dust-tight according to IP 67. Lastly, the LEDs have a minimum service life of 50,000 operating hours.

The Rotaflex hole-finishing system from Widia, now features new developments. With both roughing and precision finishing heads available, it is a single system for both roughing and fine-finishing operations over a broad diameter range – 6 mm to 520 mm.

Because of the system upgrades, up to 20 percent higher feed rates are possible in rough machining applications due to less vibration. A coupling system is one major feature. It no longer requires torque flats to disassemble.

Enquiry No. 8710

Enquiry No. 8712

metalworking equipment news Nov-Dec 2009

Exhibition Programmes

/

2009 2010 November 3–7 Metalworking & CNC Machine Tool Show 2009 Shanghai New Int’l Expo Centre Shanghai, China Hannover Fairs Shanghai mwcs@hfchina.com www.metalworkingchina.com

19 – 22 Metalex 2009

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

December 1–4 Blechexpo

Stuttgart Exhibition Centre Stuttgart, Germany PE Schall frank@schall-messen.de www.blechexpo-messe.de/de/blechexpo

2-5 Manufacturing Indonesia 2009 Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo Buana Abadi info@pamerindo.com www.pamerindo.com

2–5 EuroMold

Exhibition Center, Frankfurt Main Frankfurt, Germany DEMAT info@demat.com www.demat.biz/euromold/english/index.php

January 19 – 20 SAMPE Asia 2010

Kuala Lumpur Convention Centre Kuala Lumpur, Malaysia SAMPE sampeibo@sampe.org www.sampe.org

21 – 26 IMTEX Forming 2010

Bangalore Int’l Exhibition Centre Bangalore, India Indian Machine Tool Manufacturers’ Association (IMTMA) imtma@imtma.in www.imtex.in

February 9 – 11 Composites 2010

Mandalay Bay Convention Center Mandalay Bay, Las Vegas ACMA www.acmashow.org

March 24 – 27 INAPA 2010

JIExpo Jakarta, Indonesia Global Expo Management www.inapa-exhibition.net/contact_us.php www.inapa-exhibition.net

April 13 – 18 SIMTOS

KINTEX Seoul, S Korea KOMMA kate@komma.org www.simtos.org/

www.equipment-news.com

14 – 17 Intermold 2010

Intex Osaka Osaka, Japan Japan Die and Mold Industry Association iminfo@itp.gr.jp www.itp.gr.jp/im/english/index.html

19 – 23 Hannover Messe Exhibition Grounds Hannover, Germany Deutsche Messe www.hannovermesse.de/

21 – 24 Japan Int’l Welding Show 2010 Tokyo Big Sight Tokyo, Japan Japan Welding Engineering Society info@weldingshow.jp www.weldingshow.jp/english

May

5–9 MTA Malaysia 2010 Putra World Trade Centre Kuala Lumpur, Malaysia Malaysian Exhibition Services enquiry@mesallworld.com www.mta-asia.com

5–9 Metaltech 2010

Putra World Trade Centre Kuala Lumpur, Malaysia Trade-Link Exhibition Services info@tradelink.com.my www.tradelink.com.my/metaltech

8 – 11 MT Duo

Taipei World Trade Center (TWTC) Exhibition Hall Taipei, Taiwan TAITRA & TAMI mt@taitra.org.tw www.mtduo.com.tw Nov-Dec 2009 metalworking equipment news

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ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing,Automation & Quality Control

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The Engineering Journal For Manufacturing,Automation & Quality Control

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❑ 160 ❑ 180 ❑ 200 ❑ 224 ❑ 078

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CNC Machining Milling Gear Cutting Grinding Stamping Shearing

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Dies & Moulds mfg.

Motor Vehicles Parts

❑ 123 ❑ 160 ❑ 180 ❑ 200 ❑ 224 ❑ 078

Shipbuilding Design & Consultancy Services Govt bodies, Trade Assns, Exhibitions Cos. Agent/Distributor/Trader of Machine Tools & Accessories Mechanical, Fabrication and all other metal engineering works Others (Please specify)_____________________________________

JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt

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ENQUIRY NO 136

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

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

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