APMEN NovDec10

Visit APMEN at Metalex 2010 November-December 2010

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

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

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

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

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

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

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

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Expect more.

Engineer what you envision.

Experience the new Walter.

Win With Widia Ask us about our world-class Erickson ÂŽ products: toolholders, steep-taper, HSK, collets, and sleeves!

Š2010 Kennametal Inc. l All rights reserved. l A-09-02185

Victory Top Drill M1™ Our new WIDIA Victory Top Drill M1™ delivers the overall advantages of a replaceable-tip system — with the SAME high performance and hole quality as costly solid-carbide styles!

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ENQUIRY NO 157

Contents

November-December 2010

26

FIRST CUT 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.

Emergence Of Multitasking Machining Systems: Applications & Best Selection Practices

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

Multitasking machining systems have become increasingly sophisticated and expensive, making the selection of a system for the right application an important decision.

By Manocher Djassemi, California Polytechnic State University

IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE.

34

THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS

Implementing The Success Factors Of Production

Complex components can be produced economically in large quantities, with many variations and order-specific configurations. By Gerd Trommer, for DST

36

TECHNOLOGY UPDATE Sawing With The Times

Band saw blades change as industries evolve.

By Gerry Overstreet, product manager, Lenox

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

SPETA

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

40

SOFTWARE & MEASUREMENT

Automating Welding Machinery Improves Customer Yield And Product Quality

Scalable automation control platform allows welding OEM to build better machines. Contributed

by Carolyn Leong, Rockwell Automation Southeast Asia

42

Advanced 3D Visualisation For Manufacturing & Facility Controls

Today’s manufacturing and building operations are faced with the need to reduce cost and be more competitive with the fewest of resources. As a result, providing compelling 3D graphics applications and having access to plant data is the key to having a competitive advantage. By Russ Agrusa, IEEE, Valeria G Mazza, Roberto Penso, Iconics.

4

metalworking equipment news Nov-Dec 2010

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)

the all-new 2010 2010

St-30 turning Center turning Center

The all-new, 2010 ST-30 turning center is the culmination The all-new, 2010 ST-30 turning center is the culmination ofof15 years of continuous development, and it offers the most 15 years of continuous development, and it offers the most performance value –– of of any any turning turning performance for for the the money money –– the the best best value center centeron onthe the market market today. today.

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Haas Factory Outlet Haas Factory Outlet

Singapore Singapore DKSH Technology

DKSH Technology Harbour Front Phone: +65 6471 9248 Harbour Front Phone: +65 6471 9248

Malaysia Malaysia A Division of SPC Machinery Sdn Bhd

Lumpur 03-5569-5901Sdn Bhd A Kuala Division of SPC| Machinery Penang | 604 |3801581 Kuala Lumpur 03-5569-5901 Penang | 604 3801581

ENQUIRY NO 153

Thailand Thailand A Division of Machine Tech Co., Ltd.

ABangkok Division |of 02 Machine Tech Co., Ltd. 726-7191-5 Bangkok Chonburi || 02 66 726-7191-5 3811-2700 Chonburi | 66 3811-2700

Philippines Philippines A Division of Gaylan Technologies

| of 011 63 2 915 8725 AManila Division Gaylan Technologies

Manila

| 011 63 2 915 8725

Vietnam

Vietnam Bao Son Technology Production Bao Son Technology & Trading Co. Ltd. Production Chi Minh City | +84 8 388 44 92 Ho MinhCo. CityLtd. | +84 38 71 4471 & Trading

8 388 44 92 Ho Chi Minh MinhCity City | +84 | +84 38 71 4471 Indonesia Indonesia Pt Balindo Inti Machinery Utara Inti Jakarta Uatra | +6221 56982718 Pt Balindo Machinery Utara | +6221 56982718 Jakarta Uatra

Contents Regulars • 12 Business News • 75 Product Finder • 79 Exhibition Programmes • 80A Product Enquiry Card

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56

Integration & Automation: Educating Robots

FEATURES

Teaching robots to weld with the skill of a human worker is easier said than done, but software programs allow operators to perfect the welding procedure from their desks, without tying up the robot or wasting resources through real-life trial and error.

By Partic Hed, ABB.

50

FAB & FORM SolidWorks 2011

With the launch of the 2011 version of SolidWorks, Sharon Toh, GM, South Asia, Dassault Systèmes SolidWorks Corp speaks to APMEN as she explains the theme behind the new product and the company's marketing strategies.

By Joson Ng & Michael Tham

Engineering FiveAxis Abrasive Waterjet Cutting

In the past, multi-dimensional waterjetting was lacking in accuracy. This is no longer the case as advancements covering various aspects of waterjet cutting were made. By Richard Ward, Ben Adams, WardJet

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64

EVENTS & EXHIBITION

INDUSTRY SPOTLIGHT

Roughing Up Large-Scale Work

Machining large parts need not be as heavy going as before, thanks to the steady transfer of tooling advances from mid-size machining into the large-part arena. By Dr Moshe Goldberg, Iscar

Event Review: Asiamold 2010 Event Review: Metalex Vietnam 2010 Event Preview: Medtec Southeast Asia Refer to Advertising Index

Pg 80

for Advertisers' Enquiry numbers

ENQUIRY NO 090

editor’s note

The

Published by:

Eastern Trade Media Pte Ltd

Automation Age

(a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

managing director Kenneth Tan editor Joson Ng

feels automation could well prove its worth in the long run. The keywords here however, are ‘go slow’. Gradual implementation of automation is recommended, if not, a must. For Mr To, taking the holistic approach to increase production capacity is the prudent way. For example, introducing an ERP system can go a long way in fulfilling the step to full automation in a manufacturing facility.

As the year winds down slowly to a close, it is time for us to reflect on the year gone by. The optimists say this is the year the economy recovers; the pessimists may think the economy is treading water. Deciding who is right will require further debates but one thing is for sure – as the holiday season approaches, it is time to put up the Christmas lights and hope for a better year ahead. On behalf of Asia Pacific Metalworking Equipment News, we wish you a Merry Christmas and Happy New Year.

randyteo@epl.com.sg

advertising sales manager Yessica

Picture this: robot arms picking up parts from designated racks and transferring them into machining ce nt re s. A f te r t he m ac h i n i n g process, the arm puts the finished parts onto a holding rack where it waits its turn in the CMM – this is not a scene from the latest Hollywood sci-fi blockbuster. This is what is happening now in China.

In the recently concluded Asiamold in Guangzhou, China, visitors were treated to an interesting concept, ie: iMoldshop – it showcased a fully automated mould and die making capability where parts are being made with minimum human supervision.

T h e i s s u e o f a u to m a t i o n , particularly in labour-centric China, is potentially a thorny subject. Couple that with the initial financial outlay of automating a manufacturing facility, it does not look too enticing a prospect.

Despite all the roadblocks, automation is slowly gaining acceptance in the middle kingdom. This view is echoed

by To Wai Hung, chairman of the Hong Kong Mould & Die Council who

josonng@epl.com.sg

business development manager Randy Teo

yessica@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg senior art director / studio manager Lawrence Lee lawrencelee@epl.com.sg graphic designers Jef Pimentel jeffreypimentel@epl.com.sg Zhang Yue

zhangyue@epl.com.sg

circulation executive Irene Tow

irenetow@epl.com.sg

contributors Manocher Djassemi, Gerd Trommer Gerry Overstreet, Carolyn Leong Russ Agrusa, Valeria G Mazza Roberto Penso, Partic Hed Richard Ward, Ben Adams Dr Moshe Goldberg Michael Tham board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR

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

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

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

Joson Ng Editor

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

8

metalworking equipment news Nov-Dec 2010

Best choice.

User-friendly performance.

Laser | Bending | Waterjet bystronic.com

ENQUIRY NO 172

More than just the right tool — the ultimate solution. That’s Beyond Blast.

TM

©2010 Kennametal Inc. l All rights reserved. l A-10-02451

Beyond Blast technology uses low-pressure conditions to offer high-pressure performance TM

Through-channel coolant, delivered at the cutting edge, results in twice the tool life of standard inserts

Delivers superior performance on Titanium and high-temperature alloys, using either high- or low-pressure coolant systems

Effective thermal management results in reduced cutting temperatures, improved lubricity, superior chip control, and longer tool life

That’s Different Thinking.

At Kennametal, innovation follows vision. Our revolutionary products are inspired by asking “what if?”

The solutions that follow — like our Beyond Blast through-coolant inserts — deliver remarkable results in the world’s most demanding machining environments.

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A cutting-edge insert that delivers coolant precisely at the cutting edge. Now that’s Different Thinking.

That’s Kennametal.

To learn more about your productivity gains using Beyond Blast technology, call 65.6265.9222 or visit www.kennametal.com.

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• Australia 1800.666.667 • India 9180.2839.4321 • Japan 813.3820.2855 • Malaysia 603.5569.9080 • Singapore 65.6265.9222 • China 8621.3860.8288 • Vietnam 84.8.38447917.21 • Korea 822.2109.6100 • Taiwan 886.4.23501920 • Thailand 662.642.3455

ENQUIRY NO 137

Businessnews

www.equipment-news.com

Singapore: The Civil Aviation Authority of Singapore (CAAS) has awarded grants to the first two projects under the S$100 million (US$75.8 million) Aviation Development Fund (ADF), which was launched on 1 April 2010 to promote and develop the aviation sector in Singapore.

CAAS has awarded the first grant under the S$25 million Aviation Innovation Programme to Singapore JAMCO (SJAMCO) for the setting up of a flammability test laboratory in Singapore. The co-funding will cover the purchase of equipment, materials and software, and the salaries and training of staff engaged in the project.

The flammability test laboratory will add a new capability in the Singapore aviation industry.

The laboratory will be used for the testing and certification of materials used in aircraft cabin components, such as wall / light / ceiling panels, door linings, seat belts, seat cushions and signages, prior to being fitted in aircraft. By being able to carry out flammability tests in Singapore, Maintenance, Repair and Overhaul (MRO) companies and airlines can enjoy savings from logistical costs and shorter turnaround times, as well as have greater visibility in the progress of their jobs.

More importantly, these benefits will see niches of excellence such as manufacturing, cabin interior design and modification as well as aircraft conversion being further built up in Singapore.

Aerospace Standards To Enhance Competitiveness Under the S$25 million Aviation Partnership Programme, CAAS, together with the Association of Aerospace Industries (AAIS), will be launching the Aerospace Standards (AS) Adoption Programme on 1 October 2010. This programme aims to promote the adoption of Aerospace Standards, more commonly known as AS9100, throughout the aerospace cluster in Singapore.

Martin Boose, Germany

CAAS Awards Grants To Two Projects To Enhance The Aviation Industry

The AS Adoption Programme complements the existing SPRING-AAIS initiative to drive the adoption of the AS9100 by Small and Medium Enterprises (SMEs).

Under the AS Adoption Programme, companies adopting the AS will receive co-funding for their total consultancy and certification costs.

AS9100 aims to bring the global aerospace community to a single Quality Management Standard (QMS) standard. Major companies rely on the AS9100 certification to ascertain the effectiveness and quality of their suppliers’ processes and QMS, and hence have listed AS9100 certification as a key supplier pre-requisite.

The adoption of AS9100 will bring significant benefits to aerospace companies in Singapore, as it offers a well-structured system that effectively addresses quality concerns and improves productivity, and allows the companies to penetrate new markets and engage in global collaboration. The wider adoption of AS9100 by aerospace companies in Singapore will raise the productivity and competitiveness of the Singapore aerospace cluster.

Walter Tool Scout Enables Viewing Tool Data On The iPhone Tübingen, Germany: Walter AG is presenting its iPhone application Walter Tool Scout at AMB in Stuttgart for the first time. The application will offer users mobile access to the Walter tool data in future. The application is part of a service range that the precision tool manufacturer is placing on a new footing with its brand Walter Multiply. iPhone’s have become an integral part in everyday business. Additional programs referred to 12

metalworking equipment news Nov-Dec 2010

as apps play a major role in generating high growth rates in the mobile terminals sector. These apps enable users to upgrade their iPhone’s individually with new features. In future, Walter AG will also provide mobile access to its tool data administration with Walter Tool Scout. This means that users can log on to the tool management database from any location they wish, gaining access for example to 2D and 3D tool models.

(6221) 8911 4611, (6221) 8911 5045 (6221) 8911 4769

ENQUIRY NO 154

2445 Pedro Gil Street, Santa Ana, Manila, Philippines 1009 Tel: (632) 564 2984, (632) 564 1991 Fax: (632) 563 4293

ASIA PACIFIC 205x275mm

O2_1153 ND917

12.02.10

C78/A13

150

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45˚

C 45˚

businessnews

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Husky Announces Strategic Supply Agreement With Toyo Machinery And Metal Ontario, Canada: Husky Injection Molding Systems has formed a strategic supply agreement with Toyo Machinery and Metal (Toyo). Under the terms of the agreement, Toyo will provide Husky with components and assemblies to be integrated into the H-PET AE and H-MED AE systems.

These systems will offer a level of quality and performance, but in a smaller size. As with all Husky systems, all functions within the workcell will be managed by Polaris Control, the company’s PC-based controls.

Faro & Carl Zeiss Industrial Metrology Form Solutions Network Chica go, USA: Fa ro Technologies a nd Ca rl Zeiss Industrial Metrology have launched the Innovative Solutions Network, a marketing, sales and support collaboration in North America.

Through the network, these two leaders in met rolog y w ill prov ide a broader product solutions offering, including both traditional and portable CMMs. From the simple st to the most complex metrology measurements, the network will offer customers access to more patented technologies, focused applications, and customer support programs and resources.

“The creation of the Innovative Solutions Net work w ill a llow us to better ser ve ou r customers by prov iding t hem w it h a tota l metrology solution. The technologies offered by both companies are among the most advanced equipment available today, and I am excited to see two world class companies like Faro and Carl Zeiss create such a comprehensive metrology solution,” said David Morse, SVP and MD of the Americas for Faro.

“We are pleased to work with Faro in the launch of the Innovative Solutions Network.

Like us, their strength is in developing the key technologies needed to give customers the best solution. We believe it to be a great benefit to our existing customer base as well as for those who are considering a full metrology solution,” said Greg Lee, president of Carl Zeiss Industrial Metrology.

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metalworking equipment news Nov-Dec 2010

APPOINTMENTS

Renishaw Shanghai (Trading) Gets A New MD

Paul Gallagher

Renishaw has appointed Paul Gallagher as MD of Renishaw Shanghai (Trading), which oversees the company’s business activities in China. Prior to the new appointment, Mr Gallagher ran the company’s operation in Singapore and was also sales director of Renishaw Shanghai.

The company now has six offices across the country, with operations in Beijing, Guangzhou, Chengdu, Shenyang and Qingdao complementing the subsidiary office in Shanghai.

SAM-DJSI: Posco Ranks Top In The Steel Sector Seoul, South Korea: Posco was selected as an excellent global company for six consecutive years since 2005 on the SAM-DJSI (Dow Jones Sustainability Indexes), which evaluates global sustainability, marking its position as a leading compa ny of susta inable ma na gement. T he company also was selected as the steel sector leader for fourth consecutive year since 2007.

SA M - DJSI is an international sustainable index developed between the Swiss sustainable investment institution, SAM, and Dow Jones of the US and has been releasing evaluation results each year since 1999.

Ba sed on a nnua l sa le s, susta inability is evaluated on the top 2,500 companies selected by Dow Jones, while the top 10 percent are selected as excellent global companies. Evaluation criteria includes economical profitability, environmental soundness, and social responsibility and is ca rried out through media monitoring a nd surveys while the results are utilised widely in fund investments and financial products of international financial institutions.

Posco marked the highest in the steel sector with 75 points a nd especially received the highest score in the overall social sector score.

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Consistent good performance in all materials means you can reduce and standardise tool inventory.

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• Differential tooth pitch for chatter Answering a call from the aerospace industry to improve the free machining machining of difficult to machine alloys, Seco developed Jetstream Tooling – a revolutionary new solution to the age old problem offor better • Polished Siron-A allows delivering coolant precisely to the cutting zone. chip flow and superior tool life 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 theSingapore chip away Tel from the68412802 rake + 65 face, improving chip control and tool life enabling increased cutting Malaysia Tel + 60 3 90591833 data to be applied – not just in aerospace materials. Jetstream Tooling Thailand Tel + 66 2 7467 801 has been proven to work in nearly all material groups and with a wide Vietnam Tel + 84 8 9144393 choice of coolant pressures..

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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 033

businessnews

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Shell Ranked No 1 Lubricants Supplier Globally For Fourth Consecutive Year

16

The Netherlands: Shell has been named the No 1 global lubricants supplier for the fourth consecutive year in an annual research study carried out by Kline & Company (Kline).

D e sp ite o ne o f t he tou g he st op e rat i n g environments since the great depression, Shell Lubricants trumped a tumultuous 2009, growing its global market share to 13.4 percent from 12.7 percent in 2008. It also widened its lead over its nearest competitor to 2.5 percent, up from 1.6 percent the year before. These figures are especially significant, given that 2009 worldwide lubricant demand declined 8.4 percent over 2008 to 35 million tonnes.

“Kline’s research shows that despite very challenging market conditions, Shell has continued to outperform the lubricants market as a whole and maintain our global leadership position,”

said Chong-Meng Tan, executive VP for Shell B2B and Shell Lubricants. “I believe this is the result of a consistent strategy that focuses squarely on customers, as well as technologies delivering products and services that add value for clients.”

According to Kline, the impact of the global recession had been less severe in the Asia-Pacific region, which continued to show the most robust volume growth. The company achieved strong growth in China to garner an 11 percent market share, extending its lead as the top international supplier; in growth markets like Indonesia, it is a significant player among international oil companies. Kline also noted that the USA – the largest lubricants consuming market – was among those that were most impacted by the economic downturn. Nevertheless, Shell continued to maintain its leadership position with an 11.6 percent share.

Kennametal Interactive Catalog App Now Available On iTunes

Lenox Unveils Service Vehicle Customised For Band Saw Customer Service

Latrobe, USA: While economic cycles may move slowly, the pace of social media access to valuable industrial and high-tech resources is quickening.

Kennametal has debuted a catalog app for the iPad platform. Users can download any and all of the company’s product catalogs and review products and specifications, request quotes, view engineering drawings or videos, or contact technical support for more information. Now this app is available for download through iTunes at no cost.

East Longmeadow, USA: Lenox, a manufacturer of power tool accessories, hand tools, torches, solder and band saw blades has unveiled a Tech Rep Vehicle. The vehicle will be used for service and maintenance calls to prospective and current customers throughout the US and Canada as well as at distributor events, trade shows and training events.

metalworking equipment news Nov-Dec 2010

ENQUIRY NO 130

businessnews

www.equipment-news.com

APEC Ministers Target Growth Of SMEs green, medical and healthcare industries.

Ministers said that efforts could include the following and agreed to call the first three efforts the ‘Gifu Initiative’: · Supporting SMEs to take advantage of each locality’s domestic and regional resources to develop high value-added products, and to sell to the global marketplace · Promoting exhibitions and trade shows in the region that are open to the Asia-Pacific region’s SMEs · Supporting SMEs to expand and strengthen networking by launching international internship and exchange programmes

Robert Scoble , USA

· Strengthening assistance for human resources development, innovation, business change, productivity improvement, and entrepreneurship

Gifu, Japan: In a joint statement, APEC Ministers responsible for Small and Medium Sized Enterprises (SMEs) target the challenges of fostering long-term growth following the global economic crisis.

Following two-days of discussions, the ministers released the statement containing recommendations for leaders to guide the development of policy for SMEs in their respective economies.

Ministers considered the impact of the global financial crisis on SMEs and the emergency stimulus responses by APEC member economies, concluding that “overall, economic growth of SMEs in the APEC region is back on track.”

The statement discussed development of SMEs over the next few years and noted that looking forward to 2020, efforts to enhance development should focus on improving their access to global markets and increasing their participation in high-growth sectors, such as in the

· Developing a coordinated approach between SMEand related agencies to implement measures aimed at improving access to finance, capability building and the legal system The statement is a result of the 17th APEC Small and Medium Enterprises Ministerial Meeting in Gifu, Japan which was held under the theme ‘Strategy for Reinvigorating Economic Growth with Dual Engine: SME and Asia-Pacific Economy’.

Ministers recognised that continuing to support the development of SMEs was an important component of APEC’s new growth strategy, which will be formulated by Leaders in Yokohama in November.

The strategy supports ‘high quality growth’ including the attribute of inclusiveness, which aims to spread the benefits to wider sections of the community, and innovation. Enhancing SMEs is therefore crucial for APEC, given that they account for around 90 percent of all businesses in the AsiaPacific region and employ as much as 60 percent of its work force.

Sandvik Coromant Releases Free Machining Calculator App Sweden: Sandvik Coromant has released a free app designed to provide engineers and machinists with a convenient resource for calculating cutting data. Once downloaded and installed, the app helps users optimise performance of their turning, milling and drilling 18

metalworking equipment news Nov-Dec 2010

applications by calculating optimal setting based on a job’s unique parameters.

The machining calculator app features a help button that provides additional information on the calculation being executed and the input needed to generate results.

The company’s app also contains a process cost comparison that determines how tool optimisation can provide cost and time savings.

The app works with both metric and inch measurements and is available for both iPhone and Android phones.

businessnews

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IDC Energy Insights Forecasts Electric Vehicle Market to Reach 2.7 Million Cars By 2015 the luxury of taking a wait-and-see approach to PEVs: it must begin to prepare for their arrival now.”

These cars, or ‘mobile appliances’ as the industry should think of them, also represent a significant new source of revenue and, if handled correctly, profit, as well as the chance to run the night-time generation queue more efficiently. “ PE Vs r e p r e s e n t a si g n i f i c a n t r e v e nu e opportunity for electric utilities,” continues Mr Jaffe. “But they also bring challenges such as the potential of transformer overload due to PEV clustering and excessive energy borrowing when cars roam outside of their utility region. It is best for utilities to prepare for these potential pitfalls today, instead of waiting for when the trickle of PEVs becomes a flood. We believe the utilities that prepare for this new reality will be the ones that win in the long term.”

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Framingham, USA: According to research, IDC Energy Insights forecasts that Plug-in Electric Vehicle s ( PEVs) w ill become commercia lly available in 2011, and by 2015 there will be more than 2.7 million PEVs plugged into the global grid, with 885,000 PEVs in North America and more than 780,000 PEVs in Europe.

Unfor tunately, these vehicles will cause havoc on the distribution grid if they start appearing without any preparation by grid managers. The utilities that prepare today for this new reality will be the ones that will win in the long term.

“PEVs are coming,” says IDC Energy Insights Research manager Sam Jaffe. “Despite many doubters, this oft-promised technology is finally on the verge of becoming a reality, with more than 540,000 vehicles to be sold globally by 2012.

The electric utilities industry does not have

Nov-Dec 2010 metalworking equipment news

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Noida, India: The semiconductor market is mainly considered as a sophisticated and capital-intensive enterprise, incorporating a wide range of highly advanced technologies that stimulate growth in other industries through the use of electronics. According to a research report ‘Semiconductor Industry Forecast to 2012’, global semiconductor market will grow at a CAGR of around 11 percent during 2011-2013 fuelled by demand from emerging Asian economies. Countries such as India and China will fuel the demand for semiconductors in the Asia-Pacific region in coming years.

Integrated circuits or ICs remains the most dominant segment of the semiconductor industry, accounting for around 84 percent of the total revenue in 2009 followed by optoelectronics, discrete and sensors.

Research projects that future growth will be driven by the sensors segment followed by the optoelectronics, discrete and ICs semiconductors. Increasing usage of motion-control user interfaces on consumer electronics and drop-detection/protection features in portable systems will fuel growth in this segment.

Dima V, Israel

RNCOS: Global Semiconductor Industry To Grow At A CAGR Of 11 Percent

China’s semiconductor market will witness a significant growth in the coming years. The country has emerged as one of the fastest growing markets for semiconductor consumption on the global map.

One of the major reasons for this transformation has been the continuing transfer of global electronic equipment production facilities to China owing to the country’s low cost manufacturing facilities.

Expert say that Chinese semiconductor market will grow as exports of electronic products recover from the global economic crisis.

Mag & Samp Join Forces

Bentivoglio, Italy: Mag and Samputensili, two manufacturing technology companies, are joining forces to provide integrated gear manufacturing solutions, covering a variety of geared workpieces in different industrial sectors. Mag acquires the machine building operations of Samputensili in Chemnitz – subject to approval by the antitrust authorities – in order to integrate gear-cutting technology into its product portfolio. The entity is to be renamed ‘Mag Modul Verzahntechnik’.

The agreement is accompanied by a product development plan for the joint development of new generation machining centres to combine sof t a nd ha rd ma nufactur ing proce sse s in 20

metalworking equipment news Nov-Dec 2010

integrated machine tool solutions.

Markus Grob, president Mag Europe, explains this move with the trend towards integrated solutions: “Both partners will benefit from the partnership by expanding their range of offerings, allowing them to jointly open up new growth opportunities. This alliance represents an important step forward for the company in promoting its strategy of increasing core business activities by enlarging the portfolio and integrating complementary technology into its existing machine concept. On a joint basis, the partners will be able to process turning and hobbing operations in a single machine, thereby saving cycle time, setup and auxiliary times.”

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AEROSPACE

Boeing

Boeing & Cathay Pacific Airways Finalise Contract For Six 777-300ERs

Seattle, USA: Cathay Pacific Airways has purchased six additional Boeing 777-300ERs. The six new airplanes, with an estimated value of US$1.6 billion at Boeing list prices, will increase Cathay Pacific’s 777-300ER future fleet from 30 to 36.

Cathay Pacific, one of the world’s largest operators of the popular jetliner, also operates 12 Boeing 777-300s and five 777-200s.

“Cathay Pacific is a valued long-time Boeing customer. The global reach of Cathay Pacific’s 777 fleet showcases the airplane’s performance features and its passenger appeal around the world,” said Marlin Dailey, VP of sales for Boeing Commercial

Airplanes. “This additional commitment from Cathay Pacific is a testament to the greater efficiency, economics and reliability of the 777300ER.” Boeing incorporated several performance enhancements for the 777-300ER, extending its range and payload capabilities. Performance during flight testing, combined with engine efficiency improvements and design changes that reduce drag a nd airpla ne weight, contributed to the increased capability. Some 61 customers around the world have ordered more than 1,100 777s.

Malaysia Airlines Orders Two More A330-200F Freighters KL, Malaysia: Malaysia Airlines has placed a firm order with Airbus for two more A330-200F freighters, following the conversion of two existing options. The latest contract increases the airline’s firm orders for the type to four, all of which will be operated by the carrier’s subsidiary MASkargo.

“We are confident that the A330-200F is set to become a game changer in the mid-size freighter market,” said MASkargo MD, Shahari Sulaiman.

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metalworking equipment news Nov-Dec 2010

“The aircraft will enable MASkargo to efficiently match capacity closely to demand on many medium lift sectors across our cargo network, and especially those operating via intra Asia.”

The A330-200F is the latest addition to the A330 Family. Offering the lowest operating costs in its size category, it is the only modern mid-size, long haul, all-cargo aircraft capable of carrying 65 tonnes over 4,000nm/7,400km or 70 tonnes over 3,200nm/5,900km.

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AUTOMOTIVE

Nissan Increases Production Capacity In China

Hyundai Clocks High Domestic Sales In India

Yokohama, Japan: Zhengzhou Nissan (ZNA), Nissan’s local partner in China, hosted the inauguration ceremony for its second plant in Zhengzhou, Henan Province, China.

Annual production capacity of the two ZNA plants will increase to 200,000 units from the current capacity of 60,000 units. With the additional investment and plant expansion, FY 2012 production is planned to reach 240,000 units. As a result, Nissan’s annual production capacity in China expands from the current 670,000 units to 1.2 million units in FY 2012, once production from other facility expansion projects is added, including a second facility in Dongfeng Nissan’s Huadu plant.

Total investment in the construction of the second ZNA plant is approximately RMB 1 billion (US149 million). Additional investment and expansion are under discussion. With the start of operations, approximately 1,400 jobs will be created which will contribute to the economic development in Henan Province and Zhengzhou City.

New Delhi, India: Hyundai Motor India, the country’s second largest car manufacturer and the largest passenger car exporter continued to be on a growth trajectory with the domestic sales growing by 14.2 percent over the same month last year.

The company’s total sales for September 2010 stood at 51,441 units as against 53,802 units in September 2009 registering a decline of 4.4 percent. The domestic sales accounted for 31,751 units as against 27,803 units in September 2009 while the exports dipped by 24.3 percent from 25,999 units in September 2009 to 19,690 units in September 2010.

Commenting on the company’s sales performance Arvind Saxena, director – marketing and sales, HMIL said: “It is heartening to see the market on a growth trajectory and this has reflected in our sales as we achieved the highest ever domestic sales since inception in 1998.

Hopefully the festive season will further consolidate the growth. The launch of the new ‘next gen’ i10 should further strengthen our position in the compact car segment as it has been received very well by the market.”

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Erik Charlton, USA

JETRO Survey: Japanese Manufacturers In Europe & The US

Tokyo, Japan: The Japan External Trade Organization (JETRO) released the results of its surveys on Japanese manufacturers in Europe and Turkey (hereafter ‘Europe’) and Japanese manufacturers in the US. Against the backdrop of uncertainties in the US and European economies due to the euro crisis driven by Greece’s debt woes and the risk of a double-dip recession, about 70 percent of Japanese manufacturers in both the US and Europe expect to post an operating profit in 2010, largely on the back of increased sales.

Comparing operating profits for this year with a year earlier, the difference between ratios of firms citing “improved” and “declined” (by both firms in the US and Europe) was the largest in a decade. Looking ahead to 2011, more than 90 percent of firms in both regions expect profits to “improve” or “remain the same,” revealing a positive outlook for the economic situation rather than concerns over a possible doubledip recession.

Meanwhile, Japanese manufacturers and their counterparts in both the US and Europe are facing intensifying price competition. And while respondents have a more positive outlook for 2010, mainly due to increased sales, they still are planning retrenchments in personnel and management/utility costs.

Biggest Challenges For Firms In Europe More than 60 percent of Japanese manufacturers in Europe forecast improved business in 2010 (compared to a year earlier), showing a recovery in business confidence. Reflecting this, nearly 70 percent of respondents expect operating profit for 2010 (the third highest in the past decade), compared 24

metalworking equipment news Nov-Dec 2010

to 50 percent for 2009, showing that firms managed to prosper (ie: increase sales), despite uncertain economic conditions. The majority of respondents have plans to increase local production in the next one to two years and also expand sales in neighbouring emerging countries, including Russia, which is on its way to an economic recovery.

Ranking at the top of firms’ management problems/ issues were “exchange rate fluctuations” and “price competition with Korean or Chinese counterparts.”

To counter these challenges, more than 40 percent of respondent firms plan to “expand local production,” and an increasing number are eyeing to “diversify or shift procurement source to China or other locations.”

To reduce costs, a notable number of respondents said they would “hire executive-level personnel locally.”

According to the survey, growth in capital investment and employment among Japanese manufactures in the US seems to be leveling off, suggesting that firms are still waiting to make their next moves, as the economic recovery gains speed.

However, they feel the worst is over.

Management problems/issues cited most by firms included “lower sales due to price competition” and “cost increases due to yen rise and spike in raw material costs.” Firms expressed concerns over possible rising health care costs under the health care reform bill passed by Congress in March.

Firms seem mostly positive about the booming environment market, seeing opportunities in solar and environmentally-friendly vehicles, while others anticipate increased orders from local firms on the back of the Obama Administration’s export growth strategy.

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Geneva, Switzerland: Following faster than expected recovery in global trade flows so far in 2010, WTO economists have revised their projection for world trade growth in 2010 upwards to 13.5 percent.

Director-general Pascal Lamy said: “This surge in trade flows provides the means to climb out of this painful economic recession and can help put people back to work. It underscores, as well, the wisdom governments have shown in rejecting protectionism.”

Following faster than expected recovery in global trade flows so far in 2010, WTO economists have revised their projection for world trade growth in 2010 upwards to 13.5 percent. The WTO’s March forecast was a 10 percent expansion in trade volumes.

Me rc ha nd i se e x p or t s of developed economie s a re predicted to expand by 11.5 percent in volume terms while the rest of the world (including developing economies and the Commonwealth of Independent States) is expected to see an increase of 16.5 percent for the year.

This would be the fastest yearon-year expansion of trade ever recorded in a data series going back to 1950. But such a large growth rate should be understood in the context of a severely depressed level of trade in 2009, when world exports plunged by 12.2 percent. The next fastest year-on-year growth was 11.8 percent in 1976, one year after the

then unprecedented decline of 7.3 percent in 1975.

“The strong recovery of trade signals improved economic activity worldwide,” said Mr Lamy. “This surge in trade flows provides the means to climb out of this painful economic recession and can help put people back to work. It underscores, as well, the wisdom governments have shown in rejecting protectionism.”

World merchandise trade rose sharply in the first two quarters of 2010, driven by the recovery of GDP in both developed and developing economies. Most economists expect output growth to slow in the second half as fiscal stimulus measures expire and the inventory cycle winds down. This is likely to restrain the growth of trade in the second half of 2010 compared to the first half.

The globa l trade grow th projection is consistent with the WTO Secretariat’s time-series model for import demand in a range of advanced economies, and assumes a reduced rate of GDP growth for developed countries in the second half of 2010 rather than an absolute decline.

Risks to the forecast are mostly on the downside, particularly if an unforeseen financial or macroeconomic shock triggers another economic downturn.

However, some upside potential exists as well if growth is better than expected in the second half of the year.

ENQUIRY NO 181

JayLopez, Philippines

WTO: Trade Likely To Grow By 13.5 Percent In 2010

Nov-Dec 2010 metalworking equipment news

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cut

Emergence Of Multitasking Machining Systems:

Applications&

Best Selection Practices Multitasking machining systems have become increasingly sophisticated and expensive, making the selection of a system for the right application an important decision. By Manocher Djassemi, Industrial Technology Area of Orfalea College of Business, California Polytechnic State University

A

cross a ll industria l markets and sectors the production challenges facing manufacturers revolve a rou nd cut t i n g le ad t i me s, i nc re a si n g t h rou g hput a nd gett ing product s to ma rket quicker. Other issues facing mass production shops include shorter runs, higher product mix, tighter tolerances, more 26

metalworking equipment news Nov-Dec 2010

complex geometries in tougher materia ls, a nd complete machining in a single handling.

T he introduction of new technologies and innovations ha s made a new generation of machine tools k now n a s Multitasking Machining (MTM) systems more responsive to these challenges. MTM systems a re Computer Nu mer ica l Control (CNC) systems capable

of p er for m i n g a v a r ie t y of operations with multiple tools and/or spindles in single setup.

The tangible benefits of M T Ms have draw n t he attention of a large sector of the ma nufacturing industr y including automobile, mould a nd die ma nufacturers, a nd aerospace companies as a means to gain substantial productivity, quality improvement and profit.

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LabVIEW, Nationalni.com, Instruments, andare NI trademarks TestStand are trademarks of National Instruments. Š2010 NationalŠ2010 Instruments. rights reserved.

LabVIEW, National Instruments, and NI ni.com, TestStand of National Instruments.

Other productnames and company names listed are trademarks of their respective companies. 2036 Other product and company listed are trademarks or trade namesoroftrade their names respective companies.

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Figure 1: The framework of factors for selecting a multitasking machining system

Framework Of Selection Process Figure 1 shows a framework o f fa c to r s i n v o l v e d i n t h e decision-making process for a selection of a MTM system.

Determination of production goa ls a nd ava ilable budget represent the starting point for MTM-selection process.

Next, a decision is made to consider a basic two-five-axis machine or a more complex one with a higher number of axes, spindles and/or tool systems. At this stage a detailed analysis of needs and constraints determine the number of a xes, spindle and type of tool systems that match the production goals.

In final stage, general machine characteristics are determined to compliment t he M T M selection process. These factors are discussed in the following sections along with application recommendations.

Production Goals Before adopting a multitasking system a decision maker must have a clear understanding of the production goals for using such complex technology and major capital investment: (1) Production flexibility – A key feature in MTM systems is flexibility, which takes 28

metalworking equipment news Nov-Dec 2010

various forms from machines that can do more because of multi-axis, multi-tool, and multi-spindle capabilities to those that can adapt to cha nge s in pro duc t a nd market demand.

(2) Cycle time reduction – Most MTM systems are capable of proce ssing multiple parts simultaneously using multiple spindle s a nd/or a xe s of motion. Because of these attributes, once material is loaded on the machine , a completely finished workpiece is output, allowing substantial reductions of in - proce ss time.

(3) Lean manufacturing – Multitasking can contribute to a lea ner operation by reducing non-value added times such as setup time as well as process simplification and streamlining.

(4) Quality control – MTM systems have the potential to improve part accuracy by not hav ing to ha ndle parts between operations, which eliminates the risk of stacked tolerances, reduces scrap rates and eliminates re-fixturing.

General Attributes The determination of general att r ibute s of M T M systems includes the machine’s body, way system a nd spindle drive system, among others.

It is not much different from conventional machine tools.

A br ie f re com me ndat ion is provided for each feature: · Machine’s body – For the most part, machine tools utilise castings in their body because they exhibit good overall strength and vibration damping characteristics at a low cost. It is necessary for castings to have uniformly thick walls as variation in wall thickness can cause cooling and distortion problems. · Way system – The way system of a machine tool is one of the most important factors a f fe c t i n g cha rac ter ist ic s such as part surface finish and overall accuracy. The way system has two main functions. The first function is to suppor t the spindle and table, and the second is to guide the movement of the machine components.

There are two primary types of way systems: box ways and linear guides. Of the two primary types linear guides

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provide faster positioning.

This speed comes at a price as linear guides offer less vibration damping, less ability to withstand side thrust, and less ability to resist damage from crashes.

torque, spindle run-out, lowheat generation, and thermal stability. Machining different materials will affect these areas differently so there are many types of spindles, each for specific applications.

· Controls – The control of any machine is the brain, which translates all the written code into precise movements and actions. The control interprets progra mmed code, sends commands to the machine to move its various components, monitors machine response, processes part programs and offers the ability to edit and fine tune existing programs.

· Ergonomics – Ergonomics may seem like a low priority and is easy to ignore but the operator must have ready access to various areas of the machine to work effectively.

For instance, the machine table should be within the reach of the control and located at an accessible height.

· Spindle drive system – The spindle is considered the heart of a MTM system. For con si ste nt p a r t s qua l it y the spindle must maintain prop e r st i f f ne s s, rol l i n g

· H i g h - sp e e d m ac h i n i n g – The decision for adopting a high-speed MTM system is influenced by two major factors. First, the reduction of cycle time when cutting time accounts for a significant portion of overall machining

t i me . S e cond, t he fa ster dissipation of cutting heat through faster chip removal, which results in less thermal expansion and highdimensional tolerances. · Materials of workpiece – One of the basic requirements evaluated when determining performance needs is the type of materials to be machined.

This will determine the levels of critical features such as spindle RPM, torque, and highspeed horsepower.

Multitasking Attributes Most MTM systems contain five or more axes of motion, capable of utilising any combination of x, y, z, a, b, and/or c-axes. This group of machines is commonly equipped with two or more tool systems and spindles and can operate in synchronous or asynchronous machining modes.

Figure 2: Taxonomy of MTM systems

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metalworking equipment news Nov-Dec 2010

ENQUIRY NO 169

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Multi-Axis Impact The number of axes of motion influences the performance of a MTM system in a number of ways.

For instance, a five-axis machine can often equal the output of two three-axis machines and generate additional savings in inventory, floor space, and energy consumption. · Part geometry – One of the major factors that influence the number of axes is the complexity of part geometry.

Typically a multisided part or multisurface part requiring multiple setups is a good candidate for MTM. · A c c u r a c y – F o r s o m e applications the selection of a MTM system depends on how much movement or re32

metalworking equipment news Nov-Dec 2010

Ozgur Ari, Turkey

With the non-stop development of new machining methods and options, users must determine what type and configuration of MTM will best match their needs. Figure 2 shows a taxonomy of MTM systems that is constructed based on major structural and functional features including spindle orientation; number of axes, spindles and tool systems.

While most MTMs can be identified as milling or turning type machines a hybrid MTM may comprised of a wide range of functions such as turning, milling, contouring with the c-axis, off-centre machining with the y-a xis, milling of angled surfaces with the b-axis, heat treatment by laser, and grinding.

MTMs can be also subdivided into machines with vertical and horizontal spindle orientations.

This structural feature which is inherited from conventional milling machines affects other machine features such as rigidity, chip excavation, machine size and fixturing capability.

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When the number of axes in a MTM system goes beyond a common five-axis machine, the ability to streamline the process by combining several operations can be enhanced significantly

fixturing of the part can be eliminated rather than just looking at complex geometry.

This is because every time a part is moved, there is a potential for error.

systems. One of the recent developments in design of multitasking systems is the addition of y-axis spindle and its associated rotary b-axis.

· H i g h - s p e e d a d v a n t a g e – Conventional three -a xis high-speed machining has lim itat ion s whe n m il ling deeper cores or cavities. The length of the cutters that have to be used with a three-axis system can result in chatter and poor surface quality.

Five-axis machining enables shorter cutters to be used since the head can be lowered toward the job and the cutteroriented toward the surface.

As a result, higher cutting speeds can be achieved with no loss in accuracy.

Further Research M T M s y s te m s prov ide t he capability for manufacturing a wide range of products at a cost, which will be insignificant over the life of the system. While these systems are capable of meeting several production goals such as cycle time reduction, minimising non -va lue added time s a nd concurrent processing of multiple parts, they possess inherent programming and reliability challenges due to their complex configuration and simultaneous machining functions.

Closely related issues are the tooling and fixturing aspects of MTM systems, which were not included in this study. Although, it typically represents a very small percentage of total system cost, tooling can have a disproportionate impact on throughput and total parts cost. In recent years, machine tool builders and cutting tool suppliers have paid more attention to new tool designs that can take better advantage of the MTM unique capabilities. MEN

· Many-axis advantage – When t he nu mb er of a xe s i n a MTM system goes beyond a common five-axis machine t he abilit y to st re a m line the process by combining several operations can be e n h a n c e d s i g n i f i c a n t l y.

Turning, milling, contouring w it h t he c - a x is, a nd of f centre machining with the y - a x i s, a re a m o n g m a ny capabilities offered by such advanced hybrid MTM

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F

ocusing on a demanding f i e l d o f te c h n o l o g y provides the opportunity to gain high levels of expertise. In light of this, Leser of Hohenwestedt, Schleswig-Holstein have invested in a production system for valve bodies and their spring caps, manufactured in sizes ranging from DN15 to 200.

The company set about futureproofing the company by starting an initiative, which included investment in a project to update its production machinery and machine tools. The head of production drew up the principal requirements for the machinery they were seeking.

It had to be possible to carry out the entire production process on a single machine. At the same time, it was necessary to ensure that there would be a consistent first-class service. This means a secure supply of spare parts that high precision and productivity levels would be assured, along with a high availability rate, and a low life cycle cost.

A mong other things, the process required a burr-free back turning process, and a maximum of two workpiece clampings to produce the finished component.

The new machining centre had to be equipped with a horizontal working spindle and be able to machine the fixed workpiece in full in a maximum of two clampings.

The Right Match In order to achieve their aim, the company decided to invest in new machines. Using a systematic and differentiated selection procedure, they formulated a criterion, ie: the capacity of the new machine to carry out the entire machining process in a single clamping. This contributes greatly to the level of productivity and the performance of the entire machining system.

Two Scha rma n DBF 630s machining centre s met the qualifications set by the company.

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metalworking equipment news Nov-Dec 2010

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Implementing The

Success Factors

Of Production

Complex components can be produced economically in large quantities, with many variations and orderspecific configurations.

By Gerd Trommer, for DST Where in the past the individual components were machined on different machines, the production engineers at Leser now prefer a production flow on the machining centres for each of the three ranges of valve.

Operators at two load/ unload stations place the valve body castings and the spring caps onto separate pallets. It is always crucial that as little non-productive time as possible should be lost during the machining process. The fixtures and jigs are arranged in the correct order. For example on one pallet, the support fixtures can accept up to 16 workpieces on four sides.

Timesaving In Clamping Clamping is hydraulic, and is effected either by jaws or chains.

It takes approximately 10 minutes to set up the first part for a series; thereafter it takes only another minute to clamp and unclamp each part. The turning-drilling-milling head is what enables the machining centre to fully machine most of the parts in a single clamping.

Whereas the conventional machining on lathes involved seven clampings, and depending on the size, took between 200 and 300 minutes to complete, the throughput time on the DBF 630 is 40 to 45 minutes. This means a time saving of 75 to 84 percent.

Employees at Leser feel every investment becomes relative when the machine’s productivity is calculated. The timesaving and profitable solution provided by their machines come from turning, drilling and milling on a single machine in a single clamping.

It allows complete machining w it h co nce nt r ic a n d a x ia l accuracies calculated in Âľm. This accuracy is crucial in the case of sealing surfaces in pumps and valve casings. With regard to the different workpiece and machining operations, flexibility is high, and therefore also economical for batch size of one. MEN Enquiry No. 8002

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NIKON CORPORATION NIKON NIKON CORPORATION CORPORATION Shin-Yurakucho Bldg., 12-1, Shin-Yurakucho Shin-Yurakucho Bldg., 12-1, Bldg., 12-1, Yurakucho 1-chome Yurakucho Yurakucho 1-chome 1-chome Chiyoda-ku, Tokyo 100-8331 Japan Chiyoda-ku, Tokyo Japan Japan Tel: Chiyoda-ku, +81 Tokyo 3 3216100-8331 2371 100-8331 Tel: Fax: +81Tel: 3 3216 +81 32371 3216 2371 +81 3 3216 2388 Fax: +81Fax: 3 3216 +81 32388 3216 2388

NIKON SINGAPORE PTE. LTD. NIKON SINGAPORE NIKON SINGAPORE PTE. LTD.PTE. LTD. 80 Anson Road, #10-01/02 80 Anson 80 Road, Anson #10-01/02 Road, #10-01/02 Fuji Xerox Towers Fuji Xerox Fuji Towers Xerox Towers Singapore 079907 Singapore Singapore 079907 Tel : +65 6559 079907 3618 Tel : Fax +65:Tel 6559 : +65 3618 6559 +65 6559 36683618 Fax : +65Fax 6559 : +65 3668 6559 3668

NIKON MALAYSIA SDN. BHD. Tel :MALAYSIA +603 3609 BHD. NIKON NIKON7809 MALAYSIA SDN. SDN. BHD. Tel : NIKON +603Tel7809 :INDIA +603 3609 7809 3609 PVT. LTD. Tel: INDIA +91 124 4688500 NIKON NIKON PVT. INDIA LTD.PVT. LTD. Tel: +91 124 Tel: +91 4688500 124 4688500

For more information visit: For more For more information information visit:visit: www.nikon-instruments.jp/eng/ www.nikon-instruments.jp/eng/ www.nikon-instruments.jp/eng/

NIKON INSTRUMENTS (SHANGHAI) CO., LTD. NIKON INSTRUMENTS NIKON INSTRUMENTS (SHANGHAI) (SHANGHAI) CO., LTD. CO., LTD. Tel : +86 21 5836 0050 Tel : Tel +86: Tel 21 :5836 +86 21 0050 5836 +86 10 5869 22550050 (Beijing office) Tel : Tel +86: Tel 10 :5869 +86 10 2255 5869 (Beijing 2255 offi (Beijing ce) offi +86 20 3882 0550 (Guangzhou office) ce) Tel : NIKON +86Tel 20 INSTRUMENTS :3882 +86 20 0550 3882 (Guangzhou 0550 (Guangzhou offi ce)LTD.office) KOREA CO., Tel :INSTRUMENTS +82 2 2186 8400 NIKON NIKON INSTRUMENTS KOREA CO., KOREA LTD.CO., LTD. Tel : +82 Tel 2 2186 : +828400 2 2186 8400

ENQUIRY NO 142

technology

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update

S

teel is all around us. It is in the cars we drive, the bridges we cross, and the buildings we live and work in. The strength properties and overall versatility of steel have made it the material of choice since it was adopted by the construction and fabrication industries nearly 150 years ago.

As a key component of our transportation infrastructure, steel has been, and continues to be, an important player in increasing globalisation for many industries.

This globalisation, although helping to sustain the steel industry, has changed it as well. Manufacturers now are required to make advancements every day to keep up with this changing marketplace.

Changing Steel Advancements in the steel industry are vital to both economic competitiveness and growth.

According to the American Iron and Steel Institute (AISI), many of the steels made today did not exist as recently as 20 years ago.

Most grades of steel in use today are lighter, stronger, thinner, and easier to shape. Advancements in galvanising and coating steel – particularly high-strength steels – have led to a greater ability to resist decay and corrosion more than any other material.

But these steel advancements have brought with them new challenges for band saw blade manufacturers. The special treatments, added elements, and different melt source processing techniques tend to alter the properties of steel and make it more challenging to machine. For example, the elements added to make steel corrosion-resistant can work-harden when they are sawn and cause premature blade wear and band breakage due to fatigue.

In addition, globalisation means that standard items ordered from traditional local steel service centres can come from a variety of 36

metalworking equipment news Nov-Dec 2010

Sawing With The Times

Band saw blades change as industries evolve.

By Gerry Overstreet, product manager, Lenox sources, both domestic and foreign.

A variety of sources typically leads to variability in the steel’s machinability, which directly affect tool life and, therefore, profits for manufacturers.

Increasing costs are forcing manufacturers and machine operators to seek more economical ways to cut steel.

Modern, advanced metals have pushed equipment-makers to generate new saw machine designs and improve saw blades to help keep manufacturing costs under control. Over the years a number of band saw blade advancements have helped fabricators sustain profitability and remain competitive in the global economy.

Improvements include more durable cutting edge and backing materials for bimetal blades, improved carbide-tipped products, coatings, heat-treating techniques, and new tooth forms

designed with advanced computer modeling techniques. Many manufacturers are working to blend these technologies together.

Better Teeth, Better Carbide I n c re a s i n g l y s o p h i s t i c a t e d techniques for modeling tooth forms, in combination with improved band saw design, have led to improvements in carbidetipped blades for a wider range of sawing applications. A hollow section such as a tube or pipe is a cutting challenge because it is an interrupted cut – the blade cuts the two walls, but the cut is interrupted in the empty space between the walls – which can create substantial vibration.

For such applications, blades are typically bi-metal, have zero rake angle (or a negative rake angle), and have a low back clearance angle. New tooth form designs are now also allowing carbide-tipped blades to be used

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Telephone Telephone +49-2166-454-0 +49-2166-454-0 Telefax Telefax+49-2166-454-477 +49-2166-454-477 E-MailE-Mailinformation@ds-technologie.de information@ds-technologie.de

technologyupdate

for this application; one which was previously not an option.

These elements provide a durable tooth tip to withstand both the stresses of making interrupted cuts and vibration.

In addition, as carbide blade technology has become more widespread, manufacturers have developed new carbide grades to optimise its effectiveness. Producing blades with the toughness and durability necessary for band sawing used to mean using grades of carbide that could not withstand abrasive cutting. New chemical content and grain size distributions allow manufacturers to produce band saw blades without such compromises.

As tooth forms and edge materials improve, the limitation in blade life is often now the durability of the backing steel that supports the tooth structure.

Blade Surface Preparation B l a d e s u r f a c e p re p a r a t i o n techniques can reduce the occurrence of band breakage caused by metal fatigue. Such breakage can be the result of many factors, or combination of factors, including improper band tension; band guides in poor condition or improperly adjusted; improper tracking of the band on the wheels; and conditions in which bands are required to twist severely between the wheel and guides.

In all these cases, the stresses on a blade usually begin at points that metallurgically are susceptible to cracking.

• Coatings To help minimise the effects of these new materials on overall blade life, many manufacturers suggest using a Physical Vapour Deposition (PVD) coating to stand up better to new material challenges.

PVD coatings commonly used for cutting tools are titanium 38

metalworking equipment news Nov-Dec 2010

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nitride (TiN) and aluminium titanium nitride (AlTiN). TiN can provide a Vickers hardness of approximately 2,500 Hv; AlTiN provides approximately 4,100 Hv. • Surface Compression Blade surface preparation, which takes place after heat treatment and tempering, can significantly re d u c e t h e l i k e l i h o o d o f cracking under stress. The blade preparation process places a very thin external layer of the blade material under extreme compression, which makes it less likely to crack.

This altered backing steel increases fatigue resistance and fracture toughness and decreases notch sensitivity.

• Peening Peening is one blade surface preparation technique increasingly used to combat stress fractures.

Peening or shot peening is a process of stressing the surface layer of a material by bombarding

it with a selected medium (usually round steel shot) under controlled conditions. In addition to steel shot, several other media can be used, such as glass and ceramic bead and cut wire.

Each media is selected based on the material being peened and desired outcome.

Cutting A Path The industrial and global forces that have created newer, harder, and tougher materials and made cutting more competitive are not going away any time soon.

To d a y ’s d i f f i c u l t - t o - c u t materials, such as high-strength s t e e l ( H S S ) ; h i g h - s t re n g t h , low-alloy (HSLA) steel; and ultrahigh-strength steel (UHSS) might be commonplace tomorrow, and other, more challenging alloys are likely to appear. Where such alloys lead, blade, sawing machine, and coating manufacturers are sure to follow.

Enquiry No. 8101

Lenox: Multi-Purpose Bi-Metal Blade

Lenox has developed the Q88, a bi-metal band saw blade designed for demanding sawing applications. The blade is optimised for cutting carbon steels, alloys, tool and mould steels, as well as stainless. The Q surface preparation technique strengthens the blade’s backing steel to increase fatigue life and eliminate the likelihood of blade failure due to breaks.

The tooth geometry of the blade allows the teeth to easily penetrate the cutting surface on saws that have limited feed force – a cutting condition common in Asia.

The tooth profile is combined with a set pattern that reduces noise and vibration, which results in smooth, straight cuts. MEN

Enquiry No. 8102

S 33 NEW S 33 NEW S 33 NEW STheThe SThe 33 NEW NEW reasonably priced Thereasonably reasonablypriced priced reasonably priced

The The reasonably reasonablypriced priced for unrestricted grinding length & simplest programming. for for unrestricted unrestricted grinding grinding length length & & simplest simplest programming. programming. for unrestricted grinding length & simplest programming. forforunrestricted unrestrictedgrinding grindinglength length & &simplest simplestprogramming. programming.

Worldwide unique Worldwide Worldwide unique unique Worldwide Worldwide Worldwide unique unique Even theunique most complex work pieces can now be ground in one clamping. A new wheelhead Worldwide Worldwide unique unique Even Even the most the most complex complex work work pieces pieces can now can be now ground be ground in one in one clamping.

A A wheelhead new wheelhead Even Even Even the the most the most most complex complex work work work pieces pieces cancan now can now be now be ground be ground in Internal one in one inclamping. clamping. one clamping. clamping.

A new new A new A make wheelhead new wheelhead wheelhead with two motorcomplex spindles forpieces external grinding andground an grinding unit this possible.

Even Even the most the most complex complex work work pieces pieces can now can be now ground be ground in one in clamping. one clamping.

A new A wheelhead new wheelhead with two with motor two motor spindles spindles for external for external grinding grinding and an and Internal an Internal grinding grinding unit make unit make this possible. this possible. with with two with two motor two motor motor spindles spindles spindles for for external for external external grinding grinding grinding and and an and an Internal an Internal Internal grinding grinding grinding unit unit make unit make make this this possible. this possible. possible.

Now three wheels can be used to grind a workpiece to your individual requirements and with two with motor two motor spindles spindles for external for external grinding grinding and an and Internal an Internal grinding grinding unit make unit make this possible. this possible.

Now Now three three wheels wheels can be can used be used to grind to grind a workpiece a workpiece to your to individual your individual requirements requirements and and Now Now Now three three three wheels wheels wheels can can be can be used be used used to to grind grind to grind a workpiece a workpiece a workpiece to to your your to individual your individual individual requirements requirements requirements and and and even faster than before – a complete machining in the extra class.

Now Now three three wheels wheels can be can used be used to grind to grind a workpiece a workpiece to your to individual your individual requirements requirements and and even even faster faster than before than before – a complete – a complete machining machining in the in extra the extra class. class. even even even faster faster faster than than before than before before – a–complete a–complete a complete machining machining machining in the in the inextra the extra extra class. class. class. even even fasterfaster than before than before – a complete – a complete machining machining in theinextra the extra class.class.

Munger Machine Tool Pte Ltd. Munger Munger Machine Machine Tool Pte Tool Ltd. Tel. +65 6764 63Pte 88Pte Munger Munger Munger Machine Machine Machine Tool Tool Pte Tool Ltd. Pte Ltd.Ltd. Ltd. Tel. +65 6764 +65 63 6764 88 63 88 E-mail mungermachine@pacific.net.sg Tel.Tel.Tel. Tel. +65 +65 6764 +65 6764 63 6764 88 63Pte 88 63Ltd. 88Pte Ltd. Munger Munger Machine Machine Tool Tool E-mail E-mail mungermachine@pacific.net.sg mungermachine@pacific.net.sg MMT Thailand, E-mail E-mail E-mail mungermachine@pacific.net.sg mungermachine@pacific.net.sg mungermachine@pacific.net.sg Tel. Tel. +65 6764 +65 63 6764 88Tel. 63+66 88 2 391 9953 MMT Thailand, MMT Thailand, Tel. +66 Tel. 22 391 +66 9953 2212391 Malaysia, Tel. +60 3269953 6309 MMT MMT Thailand, MMT Thailand, Thailand, Tel.Tel. +66 Tel. +66 391 +66 2 391 9953 391 9953 9953 E-mail E-mail mungermachine@pacific.net.sg mungermachine@pacific.net.sg MMT Malaysia, MMT Malaysia, Tel. +60 Tel. 12 +60 326 12 6309 326 6309 MMT Malaysia, Malaysia, Malaysia, Tel.Tel. +60 Tel. +60 +60 326 129953 12 6309 326 6309 6309 MMT Thailand, MMT Thailand, Tel. +66 Tel. 212391 +66 2326 391 9953 Integrated Machine MMT Malaysia, MMT Malaysia, Tel. +60 Tel. 12Tool +60 326Sales, 12 6309 326Inc. 6309 Integrated Integrated Machine Machine Tool Sales, Tool Sales, Inc. Inc. Bacoor, Cavite, Philippines Integrated Integrated Integrated Machine Machine Machine Tool Tool Sales, Tool Sales, Sales, Inc.Inc.Inc. Bacoor, Bacoor, Cavite, Cavite, Philippines Philippines Tel. +63 46Tool 417Sales, 1359 / 417 0134 Bacoor, Bacoor, Bacoor, Cavite, Cavite, Cavite, Philippines Philippines Philippines Integrated Integrated Machine Machine Tool Sales, Inc. Inc. Tel. +63 46 +63 417 46 1359 417 // 417 1359 0134 // 417 0134 E-mail imtsph@pldtdsl.net Tel.Tel.Tel. Tel. +63+63 46Cavite, +63 417 46 417 46 1359 417 1359 417 1359 / 417 0134 417 0134 0134 Bacoor, Bacoor, Cavite, Philippines Philippines E-mail E-mail imtsph@pldtdsl.net imtsph@pldtdsl.net E-mail E-mail E-mail imtsph@pldtdsl.net imtsph@pldtdsl.net imtsph@pldtdsl.net Tel. Tel. +63 46+63 41746 1359 417/ 417 13590134 / 417 0134 E-mail E-mail imtsph@pldtdsl.net imtsph@pldtdsl.net

Fritz Studer AG Fritz Studer Fritz Studer AG AG FritzFritz Studer Fritz Studer Studer AGAG AG CH-3602 Thun CH-3602 CH-3602 Thun FritzCH-3602 Studer FritzThun Studer AG AG 11 11 · Fax +41-33-439 1112 CH-3602 CH-3602 Thun Thun Thun Tel. +41-33-439 Tel. +41-33-439 Tel. +41-33-439 11 ··11Fax 11 +41-33-439 ·· Fax +41-33-439 1112 1112 CH-3602 CH-3602 Thun Thun Tel.Tel. +41-33-439 Tel. +41-33-439 +41-33-439 11 11 11 11 Fax 11 · Fax +41-33-439 Fax +41-33-439 +41-33-439 1112 1112 1112 www.studer.com www.studer.com www.studer.com Tel. +41-33-439 Tel. +41-33-439 11 11 ·11Fax 11+41-33-439 · Fax +41-33-439 1112 1112 www.studer.com www.studer.com www.studer.com www.studer.com www.studer.com

ENQUIRY NO 036

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Automating

Welding Machinery Improves Customer Yield And Product Quality M

anual welding can be a slow and cumbersome task. The process often require s employee s to precisely position the object on the welding table, lower the cylinders that weld the object together, and move the completed product to the next stage of the manufacturing process.

The welded object is frequently heavy, and the repetitive lifting motions pose numerous ergonomic risk s to employee s. Ma ny manufacturers in the aerospace, government, automotive, furniture and sheet-metal industries are switching to an automated welding solution to help mitigate these ergonomic and quality issues.

Anticipating this move, engineers at Janda Company, a standard and Scalable automation control platform allows welding OEM special resistance welding equipment to build better machines. Contributed by Carolyn Leong, manufacturer in the US, upgraded the Rockwell Automation Southeast Asia control system on their resistance welding machinery. This move is helping the company’s and required large, unwieldy control panels. customers eliminate the physical risks associated with “This type of control system was sufficient when manual welding while producing higher quality parts customers needed tolerances of one-eighth inch,” and products in less time, with fewer people and a said Mr White. “But now, customers are demanding reduced amount of scrap. tolerances as small as one-ten thousandth inch.”

As the company ships machines all over the world, they Overcoming Challenges Of Today needed a control platform that could be monitored and “Our customers are facing the same economic repaired from anywhere. challenges that are affecting most manufacturing “If our customers in Russia needs to wait for a operations today,” said Bob White Jr, president, Janda. replacement part to arrive from the US in order to get “For example, by automating the welding process, our its machine back up and running, the downtime could customers can reduce the number of personnel needed cost that company a significant amount of money,” said to operate the machine from five people to just one, and Mr White. improve their yield on that machine from four parts “Similarly, if we need to fix a programming glitch per hour to 12.” in their system, they can’t wait for us to fly over The company’s engineers helped manufacturers from California. We needed to update our welding machinery with automation equipment that is take advantage of these benefits by updating the available – and remotely accessible – globally.” control system on their welding machines. Previously, the company’s machinery was based on relay logic and Integrating Automation cam timers, which were challenging to maintain, not To update their welding machinery, Janda engineers very adaptable for new manufacturing requirements, 40

metalworking equipment news Nov-Dec 2010

turned to Rockwell Automation to provide the automation technology. Depending on the size of the welding machine, the engineers install different controllers.

“With the scalable control platform, we’re able to match the control requirements of each customer and automate the entire welding process,” said Mr White.

“Because the controllers are equipped with EtherNet/IP for connectivity, we’re able to repair any programming glitches on installed machines from anywhere in the world.”

For example, engineers at Janda’s California facility monitored a Programmable Logic Controller (PLC) on a welding machine in South Korea that was experiencing a programming issue. They identified and fixed the problem, all without leaving the US. “A control platform that we can access from anywhere allows us to provide better customer service,” said Mr White. “It also means we can compete globally, which is a necessity in this economy.”

To address their customers’ tight tolerance requirements, the engineers also installed servo drive with interface motion module allowing seamless integration between the controller and servo drives for precise positioning and control.

“With positioning of either the welding table or the weld guns controlled by the drive through the controller, our customers can reduce the scrap that was being produced due to inaccurate welds. Their final product will be of much higher quality,” said Mr White.

In addition, the Kinetix servo motors used in this case possess smart motor technology to provide automatic identification of correct motor-to-drive connectivity, reducing commissioning time for Janda’s engineers.

The engineering team also equips each welding machine with a touch-screen Allen Bradley PanelView Plus Human-Machine Interface (HMI). From the HMI, the engineers can view the machine’s schedule or reset the machine remotely if needed.

Improving Quality While Saving Money “Because we only need to learn one programming environment, we have been able to reduce our electrical design time by 25 percent,” said Mr White. “And once the machine is complete, we’re able to assemble machines 30 percent faster upon installation.”

Switching from a relay to a single controllerbased system also reduced the cost of building their machines. Instead of buying 25 to 50 relays per machine, which took up to eight hours to install, the company purchases a single controller, which takes just 20 minutes to program.

“The controller is cheaper than buying and wiring all those relays, and the money we save in reduced programming time is significant,” explained Mr White.

software&measurement

“The size of our control panels has also been reduced by about half, from 60 inches by 60 inches to 30 inches by 48 inches.”

Where the relay logic used to make maintenance and machine upgrades challenging, the use of a controller or a PAC has simplified things significantly.

If a part needs replacing or a component needs to be added, it previously required pulling the entire control panel apart.

By using one controller instead, adding a timer takes just one minute, and the company’s customers do not have to worry about the contacts on their relays wearing out. The weld equipment maker is also able to provide customers with a more consistent and robust electrical system that experiences less downtime.

By using the servo drives for positioning control, Janda machines now operate faster with much tighter tolerances, which means customers are able to produce higher quality parts more quickly. Because the entire machine is controlled on a single platform, it can be operated by just one person.

“One of our customers went from producing 30 parts per hour to producing 200 higher-quality parts per hour – with four less personnel,” said Mr White.

“They’re saving money and improving their yield, all while maintaining – or even improving – the quality of their product.” MEN Enquiry No. 8201

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Advanced Visualisation Jer Thorp, Canada

For Manufacturing & Facility Controls

M

anufacturing systems are comprised of products, equipment, people, information systems, control and support functions for the competitive development, production, delivery and total life cycle of products. The goal consists of satisfying market as well as social needs.

Industrial and automotive ma nufacturers a re facing numerous challenges across a l l p h a s e s o f t h e p ro du c t development process – shorten development times, managing global supply chains, fierce competition, and increasingly complex products. They are in need of solutions that can help them get to market faster, c h e a p e r a n d w i t h g r e a te r functionality and capability.

The best strategy is to adopt, open industrial standards for providing complete integration of 42

metalworking equipment news Nov-Dec 2010

Today’s manufacturing and building operations are faced with the need to reduce cost and be more competitive with the fewest of resources. As a result, providing compelling 3D graphics applications and having access to plant data is the key to having a competitive advantage. By Russ Agrusa, Member, IEEE, Valeria G Mazza, Roberto Penso, Iconics.

multiple systems at the hardware level as well as to choose the latest available software tools that can have long term usefulness and can be current for at least five to ten years. In past systems 2D graphics for automation were and still are for the most part the dominant approach.

Now the landscape is about to change and a new 3D approach is more than just hype. It is not ‘just a passing fad’; it is now a reality.

Modern visualisation applications are leading the way to incorporating 3D graphics technology into a vast array of industrial solutions that can meet real customer needs in multiple industries, including: automotive, building automation, oil, gas & petrochemical among many others.

3D Enhances Real-Time Visualisation 3D visualisation can benefit Human Machine-Interface (HMI)

applications by providing true to life shapes, forms, processes and other details that otherwise are lost when viewed in a traditional 2D manner. Having a 3D model, set of images or animation allows better interactivity with the idea, process or product. When an idea needs to be presented to the potential client, most times the idea is best received in a 3D form.

We live in a 3D world; our eyes and brains are used to seeing and perceiving depth, perspective and form.

Products come alive when they can be delivered in a 3D format.

Process and technologies can be improved, both in function and visualisation, by showing them in a 3D environment, especially when the environment can be made to resemble the actual working conditions of the process – rather than a simplified 2D drawing.

Technically, a 3D image is the best way to handle visualisation

software&measurement

of a large number data and to keep a global vision on a system.

It is indeed the most natural way to represent a large number of heterogeneous information.

Using 3D displays greatly improves design quality because it is a more complete process than 2D design. As a result, many human errors that can occur w ith traditiona l 2D design methods are avoided.

This makes 3D HMI solutions a powerful business tool: it can communicate complex subject quickly, reduce costs and errors rate, and make collaboration more efficient and flexible.

Bridging The Gaps In Your Design & Manufacturing Workflow Compared to several years ago, the automotive industry has been very rapidly changing. New

business workflows, processes, procedures and manufacturing te ch n ique s mu st supp or t environments that inevitably r e d u ce t h e m a nu f a c t u r i n g design and preparation time in developing a new automobile. This requires engineering systems that improve collaboration, driven by the asset utilisation of factory resources and substantial reduction in costs.

By using this new approach and system, savings in time and cost of process and material planning are possible, and the reliability of the plan result is greatly improved. As customer dema nds diversif y, product lifecycle is shortened and global competition among companies becomes fiercer, automotive companies strive to discover new pa radigm shifts a nd technologies for rapid and cost

effective ways of developing new products.

As a result, the goal consists of adopting several specialised standards under one umbrella to supports as many aspects of the engineering chain as possible.

This is the innovation brought

by AutomationML (Automation Markup Language) to achieve r e l i a b i l i t y, a v a i l a b i l i t y o f knowledge, independence and cost effectiveness, by combining well accepted sta nda rdised formats already deeply used in the market.

The Glue For Seamless Automation Engineering The engineering cost of a n automation project is typically 60 percent of the total project cost.

In the past optimisation strategies have addressed the bought-in parts well; a wide area to increase

ENQUIRY NO 179

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Robotic arm is only a small facet of automation, software programs make up the main bulk of it

efficiency is still in engineering, for example: · Factory plans are manually redrawn in other tools for production line planning · C o m p a n i e s s u f f e r f r o m heterogeneous CAD (Computer-Aided Design) tool where CAD systems do not collaborate · Conveyor Sequence s a re developed with office tools and are not reusable with PLC programming.

AutomationML, as an open intermediate format, improves automation eng ineering, reducing costs associated with that. AutomationML is a neutral data format based on XML for the storage and exchange of plant engineering information.

The goal is to interconnect the heterogeneous automation CAD tools of modern engineering production planning of the different disciplines, eg: mechanical plant engineering, electrical design, visualisation development, PLC and robot control.

The data format describes real plant components as objects encapsulating the different aspects of the plant operation.

44

metalworking equipment news Nov-Dec 2010

An object can consist out of other sub-objects, and can itself be part of a bigger composition. It can describe a screw, a claw, a robot or a complete manufacturing cell in different levels of detail.

Ty pica l obje c t s in pla nt automation comprise information ab out top olo g y, ge ome t r y, kinematics and logic, where logic comprises sequencing, behaviour and control.

Digital Prototyping: Beyond 3D Design Over the past couple of decades, there have been several dedicated software applications available to eng ineers to create HMI applications. Major drawbacks of such dedicated software include the advanced knowledge required although their lack of integration with 3D Computer-Aided-Design (CAD) software. Consequently, designers and engineers have been working in isolation from one another resulting in duplication of work, increasing design change time and cost, and longer time to market.

In today’s global market, as manufacturers work to reduce design cycle and cost margins, industry experts are championing digital prototyping as a way to cost effectively validate design ideas and accelerate the development

of competitive products.

Digital prototy ping gives manufacturers the ability to virtually explore a complete product before it is built and put into production. This is done so they can create, validate, optimise, and manage designs from the conceptual design phase through the manufacturing phase of product development.

By using a digital prototyping, manufacturers can boost design efficiency and innovation by visualising and simulating the real-world performance and characteristic of a specific design, and save time and money by reducing the number of physical prototypes that are built.

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FARO Singapore Pte Ltd, 3 Changi South Street 2 #01-01, Xilin Districentre Building B, Singapore 486548 Tel: (65) 6511.1350 | Fax: (65) 6543.0111 | Email: salesap@faro.com| www.faroasia.com

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FARO Offices FARO Thailand Tel : (662) 744.1275 Fax: (662) 744.3178 | FARO Vietnam Tel: (84) 3.84.8108 Fax: (84) 3.845.8018 FARO Malaysia Tel: (603) 8064.4224 Fax: (603) 8064.4334

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Fig 1: HMI visualisation applications are possible with the proliferation of modern technology

Leveraging 3D In HMI Applications Many industrial and manufacturing systems have a need to create HMI visualisation applications using numerous 3D file formats, usually provided by third-party companies. This has been a hurdle and challenge in the past, since it required several software tools installed i n t h e s a m e p l a t fo r m a n d necessitated a deep knowledge of miscellaneous 3D applications.

Consequently, time and money were lost and productivity was compromised.

Providing a world-wide industry standard and universal cross conversion of 3D file formats that allows high fidelity translation, optimisation and viewing is the solution for numerous companies in the 3D industry.

Low-Poly 3D Models For Industrial & Manufacturing Systems 3D HMI applications are often confronted with either very dense and over-sampled surfaces or models, which are far too complex for the limited hardware resources of modern personal computers.

A s ma ny appl ic at ion s i n computer graphics and related fields, HMI applications ca n benefit from automatic simplification of complex p o l y g o n a l su r fa ce m o d e l s , usually coming from 3D CAD d r a w i n g s . R e c e n t l y, m u c h research has gone into this subject in order to develop the most effective polygons reduction algorithm. The goal 46

metalworking equipment news Nov-Dec 2010

Fig 2: An example of HMI visualisation

simply, consists of retaining the quality, fidelity and the appearance of the original 3D drawings while reducing the overall number of polygons.

The core of the polygon reduction algorithm is based on the ‘Edges Contraction’ technique.

Edge contraction simply means that the two end vertices of a model edge are replaced by a single new vertex. This target vertex is usually somewhere in between the other two, in a place where it best approximates the original model. This edge contraction step removes a vertex and one, two, or more faces from the model, depending on the mesh neighbourhood. When this step is repeated several times, it results in a simpler model, which is an approximation to the original.

Since data is removed from the original model the resulting model will only be a very close approximation; each of these steps is associated with a given increase in error (cost of contraction) that is recalculated at each step.

Then the lowest cost contraction is performed again until the desired target face count is reached.

Simplification can also be stopped when the lowest error contraction is above a certain error threshold.

Elevate HMIs To New Levels The goal of the next generation in industrial automation software consists of giving the user the

power to quickly and efficiently create HMI integrating graphics, real-time manufacturing data and business information.

F i g u re 1 a nd 2 a re fe w examples of real HMI visualisation applications that users are able to create with the powerful tools and the innovative technologies available today.

Manufacturing and facility control operators, who want to extend and branch out of the traditional 2D graphics, and provide a real-time 3D visualisation, may need some guidance, training and orientation to learn these new powerful standards based technolog ie s. Through this process, the gap between design and manufacturing workflow will be ultimately reduced.

Built on the foundation of highperformance graphics hardware subsystems, HMI systems in the future will require a higher level of sophistication with respect to configuration and overall operation.

The promise of 3D graphics brings HMI visualisation applications to a new level of awareness for today’s manufacturing and facility controls designers.

W hat is ne e de d now a re automated software tools that make designing, prototyping and automated generation of HMI visualisations systems an easier process. MEN Enquiry No. 8202

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Techno Machinery (S) Pte Ltd No. 23 Kaki Bukit Industrial Terrace Singapore 416103 Tel: +65 6417 9973 Fax: +65 6745 9166 Email : sales@techno.com.sg

BME Industries (M) Sdn. Bhd. D-G-2 & D-1-2, Persiaran Relau Sungai Ara, 11900 Bayan Lepas Penang, Malaysia Tel: +604 640 8686 Fax: +604 640 8688 Email : bme@henko.com

HSM Machinery Co., Ltd. 6/155 M.7 Srinakarin Rd T. Bangmuang, A. Muang Samutprakam 10270, Thailand Tel: +66 2759 9445 Fax: +66 2759 9446 Email : info@hsm.co.th ENQUIRY NO 163

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Integration & Automation:

Educating

P

recise, clean, mass-produced welds are taken for granted by consumers of manufactured products, but they are not so easily achieved.

Human welders draw on their experience, intuition and trial-and-error to establish the right parameters for the job. Transferring this kind of skill to a robot is easier said than done, but it is achieved with the introduction of a robot welding simulation software.

Robots have often been introduced into manufacturing plants to improve productivity and relieve workers of hazardous, strenuous or tediously repetitive tasks. The benefits have been many-fold, from improved health and safety to lower energy bills for operators.

An additional contribution comes from robots’ unerring accuracy. Their ability to repeat tasks over and over, each time achieving the quality standards expected by customers, and ensuring that goods are finished correctly first time, with no costly repairs or wasted materials.

But robots can only get it right if they have been programmed correctly and that can be a timeconsuming process. ‘Teaching’ a robot to perform a arc-weld, for example, means providing it with the knowledge that comes from many years of human experience and the intuition that enables it to choose the appropriate process for a new task.

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Teaching robots to weld with the skill of a human worker is easier said than done, but software programs allow operators to perfect the welding procedure from their desks, without tying up the robot or wasting resources through real-life trial and error. By Partic Hed, product manager for arc welding, robotics business unit, ABB. A Wasteful Approach This in-depth understanding of the welding process can be acquired by trial and error. Indeed, most new welding parameters are established by experienced welders performing a series of test welds and adjusting parameters to hone the result, but this is a wasteful approach. The test welds use up materials, manpower and energy. They also tie up a robot that could be in productive use elsewhere.

To reduce the need for such wasteful tests, programs such as ABB’s VirtualArc software can be used. The program provides the ability to define the exact weld parameters required for an application and then test them, without any welds actually being carried out.

Many companies provide post-weld analysis software that allows operators to speed up the trial-and-

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error approach to establishing weld parameters. The software uses a simulator that incorporates information on the equipment available, such as the welding device, and the power supply. In addition, it also includes application data, such as the materials to be used, the plate thickness and the required joint configuration.

Saving Time Using this information, the program can deliver a full set of weld parameters, along with a profile of the resulting weld. This enables the operator to assess the quality of the weld produced under a particular set of conditions in the space of a few minutes, a fraction of the time needed to perform a ‘real’ test.

Depending on the results of the virtual test, the operator can adjust parameters such as weld speed, torch angle and optimise for maximum productivity and minimum energy use, while maintaining the required quality of the weld and allowing the plant’s robots to continue with their work on other applications.

As a result of preweld analysis, operators can save materials and energy, and reduce the production of welding fumes. MEN

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ABB: Weld Joint Seam Tracking System

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Enquiry No.8204

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ENQUIRY NO 162

WeldGuide III is an adaptive sensing system that performs weld joint seam tracking during the robot arc welding process. The system identifies variations in the weld joints and dynamically corrects the robotic torch path whilst in motion.

Utilising voltage and current sensors, the system takes real-time measurements through the welding arc to make any adjustments necessary to keep the robotic welding torch on the joint path; regardless of the path programming.

A combination of hardware and software, designed for ABB’s IRC5 robot controller, the system requires less initial programming than traditional robotic seam tracking systems and is suitable for applications on heavy weldments.

Nov-Dec 2010 metalworking equipment news

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Fab&

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Form

Engineering Five-Axis

Abrasive Waterjet Cutting

T

h e re i s n o i g n o r i n g waterjet cutting is forging its place into every area of manufacturing and engineering. New materials often demand waterjet cutting. With single and multiple head five-axis waterjet cutting available on a single machine, the technology is becoming more and more accessible, and the lack of that capability is becoming a competitive disadvantage.

Waterjet is opening doors – forgings are being replaced with parts nested into sheet material cut into the most complex of shape s. Ca stings a re being scanned and flashing trimmed, eliminating multiple tedious steps and labour. Near net shape cutting of ever y thing from complex blades to helical rack and pinion to accurate cutting of composites, laminates of high nickel alloys, glass and phenolics, plastics, ceramics, armor plating of most make and composition are easy.

The process is no longer limited to flat, plane cutting. If you can imagine it, waterjet can probably be used to cut it. The principles of waterjet cutting are fairly simple.

In a nutshell, water at pressure of 60,000 psi or more is channeled to

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a cutting head through sheathed, 0.25” diameter autofrataged stainless steel tubing that in short lengths is not flexible.

Abrasive is fed to the cutting head where the water pressure, as it transforms from potential energy to kinetic energy, accelerates the abrasive grains to over 2,200 miles per hour in a nozzle that is 3” long.

Accuracy – Spot On I n ye a rs pa st, when mu lt i dimensional waterjetting was new, the understanding was that there would be a sacrifice in tolerances. This is no longer the case. With advances in engineering of the nozzles and orifices used, the width of the waterjet stream is now predictable to 0.0005”, allowing manufacturers to support demands for precision five-axis parts.

Key to creating an accurate five-axis mechanism is the ability to measure the results. As such, a 3D spatial laser tracker is employed to measure the actual mechanisms and correct for any ‘real world’ inaccuracies that crop up in the manufacturing proce sse s or from materia l properties.

Standard laser interferometers are incapable of measuring all of

In the past, multidimensional waterjetting was lacking in accuracy.

This is no longer the case as advancements covering various aspects of waterjet cutting were made.

By Richard Ward, president; Ben Adams, engineer, WardJet

the parts once they are assembled and operating in space. Once a final mechanism is measured, the data can be used to electronically compensate, on the fly, for any repeatable errors that occur, pushing the envelope on accuracy to new bounds.

Keeping Variables In Check Imagine your finger is the nozzle in a cutting head. Now wave it around and notice how flexible your wrist, elbow and shoulder are, not to mention the muscles as they twist and flex. So how do you get high pressure water bolted to a fixed position on the face of the Z carriage to the fixed position of the cutting head mounted on the other end of an ‘arm’ that twists, spirals and rotates?

Any additional forces generated in flexing the high-pressure tubing will typically cause variations in positional and repeatable tolerances. Coiling the highpressure tubing to reduce these forces normally shows unacceptable results in laser tracking.

By directing the high-pressure tubing through the centre of rotary actuators, it is possible to virtually eliminate varying torsion, sheer and moment loads on the

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cutting head. The combination of swivels and routing the 0.25” highpressure tubing means no coiling is necessary.

There is no wind up of the highpressure tubing often associated with five-axis waterjet cutting and lengths of the high-pressure tubing are short. All high-pressure tubing eventually fatigues and fails, releasing high-pressure water from hairline fractures. It is important to design a mechanism that fails in a safe manner and is easily repaired.

Getting Abrasive To The Cutting Head The abrasive, which is typically garnet ranging from 150 to 50 mesh, is fed into the waterjet stream 3 to 4 inches above the tip of the nozzle.

There is a way to direct the abrasive through the middle of the actuator without any wind

up of the 3/8” abrasive resistant hose. This reduces the length of the path the abrasive travels from the mini hopper to the cutting head. A swivel system allows the abrasive to be passed through the centre of the motor, collected and directed back into a flexible hose.

The result is sea mless delivery of garnet to the cutting head no matter what the cutting head position or angle of attack.

Bu l k y tubing a nd awk wa rd mechanisms subject to pinching, clogs and blockages are reduced into a simple straight path from abrasive hopper to cutting head.

Covering All Angles A ny five - a x is prog ra mming revolve s a round a common mandate that the part does not change position while cutting.

Fixturing for a five-axis mill is

often substantial to ensure the part does not move. In waterjet cutting, one has to presume materials will move through the redistribution of stresses as material is cut.

A spring assisted, self-locating crash sensor has a low voltage signal passed through the foot which when interrupted detects a crash.

The height sensor is pneumatically controlled and can take periodic samples of the location of the material or continuously ride on the material. The analog feedback allows adjustments to be registered and responded to.

What is most impressive is the height and crash sensor can be deployed to work while the head is cutting at angles approaching 50 deg ree s off the vertical. MEN Enquiry No. 8301

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TORNOS TECHNOLOGIES ASIA LTD MALAYSIA REPRESENTATIVE OFFICE No. K-7-1 Lorong Bayan Indah Dua Bay Avenue 11900 Pulau Pinang Malaysia Tel. +6 (04) 642 6562 & 6563 / Fax +6 (04) 642 6561 Email: malaysia.contact@tornos.com

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spotlight

Roughing Up Large-Scale Work T

hanks to the steady transfer of tooling advances from mid-size machining into the large-part arena, you no longer need to fall back on ‘brute force’ practices for rough milling and turning of rail-car wheels, wind-turbine hubs, machine and offroad equipment frames and other gigantic workpieces.

Such gains stem mainly from six advances in tooling that have proven out well in smaller scale applications and tool sizes. Now they have been extended to insert sizes up to 22 mm. They include tangential clamping, helical cutting edges, surface coating treatment, high positive rakes, high feed geometries and aggressive chipbreakers.

Together these adva nces enable much higher cutting rates while simultaneously reducing cutting forces, extending insert life and improving process security.

New Look For Large-Scale Tooling In tangential clamping, the insert lies flat in the cutter’s pitch circle rather than upright or radially.

This is a real departure in cutter design with several benefits.

Principally, it presents the insert’s strongest cross section to the main cutting force vector, thereby permitting much higher cutting

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Machining large parts need not be as heavy going as before, thanks to the steady transfer of tooling advances from mid-size machining into the large-part arena.

By Dr Moshe Goldberg, marketing technical advisor, Iscar loads per tooth. It also enables a given size cutter to accommodate more inserts, which reduce pertooth cutting forces.

Also, tangential clamping makes stronger cutter bodies possible because insert seat pockets can be shallower, leaving more metal in the cutter body itself. Tangential tools have been proven suitable for heavy flat roughing and moderate ramping, even under adverse conditions.

For heavy rough milling on large scale work, suitable tools feature tangential clamping, 22 mm four-cornered inserts and a 65 deg lead angle, suitable for scarfing, scaling and other punishing duty.

Cutting Edge Helical cutting edges create a gentler cutting action, much like scissors shearing paper. The cutting edge itself is not straight; rather it has a slight helical curve.

A straight edge never slams into the cut. This reduces cutting forces, protecting the tool and machine especially from the impact loads resulting from the interrupted cuts inherent in milling of any kind.

Coating In Tools Surface treatment is another important aspect. In Sumo Tec by Iscar, on a micro level, the treatment produces a smoother, slipperier surface on the insert with fewer thermal stresses and stress raisers than would be found in an untreated plain CVD or CVD coating.

This leads to cooler cutting (heat is a key enemy of machining inserts), less friction and much reduced risk of insert rupture. On average, Sumo Tec coated inserts have double throughput and extend insert life by 40 percent compared to identical but untreated inserts, according to the maker.

Getting The Angles Right High positive rakes substantially reduce cutting forces by creating more of a shearing, rather than scraping action at the cutting face.

While protecting the cutting tool and machine, this feature also reduces the power required to remove a given volume of metal.

The larger the workpiece and machine, the more important is this benefit. High-feed insert geometries in large inserts enable the same ‘feed fast/cut shallow’ machining practice that has

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High tech cutting tools can improve machining rates by two to one or more while extending edge life, reducing cutting forces on the machine and fixturing, and conserving energy as well

proven effective on smaller scale work for more than a decade.

Metal comes off faster but cutting loads are lower. To put it another way, metal comes off faster on lighter-duty machines. For largescale work, this strategy also can reduce unit energy consumption.

High feed inserts themselves are characterised by larger corner radii and shallower lead angles than are found in conventional inserts.

As long as the cut is kept shallow, this geometry takes advantage of chip thinning and creates a fundamentally more rigid, more stable cutting system. Resolved cutting forces are more axial than lateral, putting less wear and tear on the spindle and machine frame at a given metal removal rate.

Breaking The Chip A gg re ssive chipbea kers – essentially deep grooves on the insert’s top surface right behind the cutting edge – ensure more reliable chip control and evacuation, even on long-chipping stainless steels and other nickel-based alloys.

On inserts for short-chipping cast irons and steels, slightly different chip control features propel the cuttings clear of the cutting zone to reduce re-cutting and resulting extra edge wear.

In large scale work, effective chipbreaker geometries can 54

metalworking equipment news Nov-Dec 2010

substantially improve process security on long-cycle unattended and ‘lights-out’ operations.

Large Parts, Big Dividends Higher throughput aside, these six advanced tooling features

mentioned earlier bring added benefits to large-scale machining.

For one thing, their freer cutting geometries put less strain on the fixtures of cumbersome asymmetric parts that do not lend themselves to easy, rigid clamping.

For another, they enable more complete machining of heavy parts not easily shuttled to different machines for different operations.

And finally, their longer lasting edges eliminate the delays, tool marks and ‘touching off’ that follows an edge failure in mid-cut.

Most important, you can eliminate production bottlenecks on large work, and deliver sooner. This has proven especially important in the fast growing wind-turbine industry, where the main diet is huge components.

Enquiry No. 8401

Improving Machining Rates High tech cutting tools can improve machining rates by two to one or more while extending edge life, reducing cutting forces on the machine and fixturing, and conserving energy as well. Gains are possible in carbon or alloy steel, stainless steel, cast iron or cast steel.

Here are some examples from Iscar of improved productivity: • A German manufacturer of power generation equipment is now shoulder milling a heavy GGG70 cast iron hub at 0.35 - 0.42 mm/min feed rate per tooth, with insert edges lasting 40 minutes – enough to complete several parts per edge.

Table feed is 557 - 668 mm/min at a width of cut of 0.7 x tool diameter and an 11 - 15 mm Depth Of Cut (DOC).

Also contributing to productivity is the fact that chip control is no longer an issue. Chip evacuation is effective, preventing re-cutting and thereby extending tool life. These results are at least 30 percent better than the norm for this type of work.

• Another European manufacturer of heavy equipment reports similar gains when rough milling shoulders on large stainless steel bars. Feed per tooth is 0.37 mm with machine parameters set at 482 mm/min feed and 9 - 11 mm DOC, with much less flank wear than before. Even at this elevated machining rate, insert edges last nearly an hour. The overall margin of improvement over conventional practice for this type of work is over 20 percent. Aggressive chipbreaker geometries on the inserts produce short curly chips on this long-chipping CrMnS13V material. MEN

Enquiry No. 8402

ENQUIRY NO 175

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SolidWorks

2011

With the launch of the 2011 version of SolidWorks, Sharon Toh, GM, South Asia, Dassault Systèmes SolidWorks Corp speaks to APMEN as she explains the theme behind the new product and the company’s marketing strategies.

By Joson Ng & Michael Tham.

S

usta inability equa ls innovation – this is the theme for the 2011 version of SolidWorks.

The inspiration behind the theme according to Ms Toh can be drawn from daily experiences. She says: “Today, from buying a car to the detergent you use and even clothing, you cannot escape the green theme. For me, sustainability is here to stay. It is not a passing fad. Therefore from our point of view as a technology provider, it is really important to share with our customers how they can use this to further innovate their products.”

Embracing innovation is one thing an enterprise should adopt as a guiding principle. Transforming innovation into a business success however, can be hailed as a masterstroke. This process, as Ms Toh describes is a “driving force behind success in business.”

She says: “Being innovative is what the majority of our customers do everyday. It includes taking existing technology and turning it into a finished product that appeals to people. Our job is to help our customers do that easily.

By just adding this key component (sustainability), it is possible

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to reach new markets and find new customers.”

The Issue Of IP A nother major focus of the latest version is on speed and collaboration, resulting in more productivity and profitability. The issue of collaboration however,

in the design world, may be a sensitive one. On one hand, as a software developer, the company understands the need to protect design Intellectual Properties (IPs).

On the other hand, in today’s industrialised world, it is almost impossible to work alone in a design project and hence the need to share information is of critical importance. A potentially tricky issue has been solved by a function called defeature.

Say Ms Toh: “It’s true that many companies need to work together. Oftentimes we have to acquire parts from vendors.

These vendors supply you and t hey may a lso supply your competitors. With the defeature tool, t he u ser ca n sha re information and at the same time protect his or her intellectual properties. With this function, the component can be presented as it is with features critical for cooperation and removing sensitive features, which should not be shown. In addition, this function helps reduce file size as not all information are displayed.”

Dassault Systèmes: 2D CAD Product

DraftSight is a professional-grade, open 2D CAD product for users who want a better way to create, edit and view DWG files. DraftSight is easy to use and is available for professional CAD users, students and educators to download and activate for free at its website.

Based on an advanced architecture, the software program has a small footprint, should take less than a few minutes to download, and runs on multiple operating systems including Microsoft Windows XP, Windows Vista, Windows 7 and the Mac (Linux support will be available later this year).

Enquiry No. 8501

features

Cloud Computing – Aiding SMEs Sustainability is usually associated with Product Life Cycle Management (PLM). Full scale PLM involves a product’s inception to disposal according to Ms Toh and only the bigger companies have the resources to carry it out effectively as PLM includes consumers’ research data and trending as well.

In order to assist SMEs which may not be able to invest as much into PLM but are still in need of it nonetheless, the 2011 version features Product Data Management (PDM), which allows cloud computing.

“With cloud computing, the users do not have to maintain a large database on their own. This is good for companies with less than 20 people,” she says.

Marketing Strategy & Hot Spots With the company dominating the aerospace and automotive industries, Ms Toh views alternative energy as an interesting industry.

“From wind to solar energy, we are represented, particularly in South Korea,” she says.

Mov i n g c lo se r to home , Vietnam is one country that Ms Toh has her sights on. Giving us a clearer picture, she says: “We feel Vietnam is a developing country and one of the fastest growing market. Looking at their demographics, you can tell they have a lot of young people who are well-trained and speak good English. This is a key component for growth for a country.”

According to a report, majority of designers in the country still use 2D software programs. As such, the company feels education is

the top priority. “We are working with institutes and companies to stress the importance of IPs and the benefits of 3D design suites.

Concurrently, we launched a free 2D design suite in August 2010 called DraftSight. As many of them are still paying for 2D software programs, we hope by providing this free software, we can in a way encourage designers from the developing countries to make the transition into 3D programs and also pay more attention to IP,” she says.

Ms Toh reveals no marketing e f fo r t s we re m a d e fo r t he launch of DraftSight. Despite adopting a low-key stance on this software, there were about 250,000 downloads within the first month of launch.

Enquiry No. 8502

ENQUIRY NO 072

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Features

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SolidWorks Innovation Day 2010 SeaCAD: The Race To Innovate

ATE: Innovation & Sustainability

With a racecar fronting its poster for this year’s launch, ‘staying ahead’ seems to be the buzzword for SeaCAD, which was presenting the 2011 version of SolidWorks. In his welcome speech, Conrad A Montgomery, CEO and founder, SeaCAD Technologies stressed the importance of making innovation a top piority and how by using the best in class tool and technology are ways to stay ahead of the competition.

The event saw a general session where attende e s were int roduce d to product enhancements in the 2011 version and also two breakout series that featured topics like Easy Transition to SolidWorks, Optimise and Design Sustainable Products and Creating Realistic Design Motion among others.

In the general session, some of the new features of SolidWorks 2011 include ‘revolve up to surface’ which according to the presenter, allows more flexibility in design. When it comes to sheet metal, the software has improved flattening ability for complex shape.

The event ended with a plaque presentation and a lucky draw where some participants walked away with some attractive prizes.

The SolidWorks Innovation Day 2010 which was organised by Advanced Technology Enterprise (ATE), was held in Singapore on October 14.

Isaac Chong, MD, ATE kicked off the event with an opening address. He explained that innovation is not a mere concept, just a product or technology. Rather, it is a continuous process of asking, ‘what if.’ Mr Chong cited examples of innovative ideas that came about because someone asked the ‘what if’ question.

Such ideas include mobile applications that can be used to monitor heartbeat and blood glucose levels. He also gave an example of a device that can read brain waves and translates them into commands – allowing human users to interact with machines via thought processes.

Keynote speaker Sharon Toh, GM of South Asia for Dassault Systèmes SolidWorks emphasised on the importance of sustainability.

“In the 198 0s, achiev ing competitive advantage often meant lowering costs and increasing efficiency.” However, the focus today has shifted. Ms Toh believes that the next wave of consumers will increasingly demand Green products. MEN

Concorde Hotel Singapore Oct 8, 2010

Mandarin Orchard Singapore Oct 14, 2010 Enquiry No. 8503

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metalworking equipment news Nov-Dec 2010

Enquiry No. 8504

THE COMPLETE SOLUTION FOR STEEL TURNING

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ENQUIRY NO 182

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Providing for

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

Years in the Making

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

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

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

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

Setting Solid Edge apart from other

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metalworking equipment news Jan-Feb 2010

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

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

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

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

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

In Solid Edge ST3, both synchronous and

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

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

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

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

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

Three weeks of design… all done in a day?

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

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

Experience in person how Solid Edge has fulfilled the vision of synchronous technology with the release of ST3. Current and future Solid Edge users are welcome. Join a Solid Edge ST 3 event near you: 10th November to 22 December 2010. Call ECSS at Phone No: +65 6295 3566 or email: sales@ecss.com.sg

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

ENQUIRY NO 177

33 3

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exhibitions

Event Review:

Asiamold 2010

O

ver 12,500 visitors from 42 countries and regions attended Asiamold held at the Poly World Trade Centre Expo from September 15 – 17, 2010. This was a 20 percent increase in the visitor numbers from 2009.

The top 10 countries and regions by visitor volume were China, Hong Kong, Taiwan, the United States, Germany, Malaysia, Thailand, Singapore, Japan and South Korea.

The fourth edition of the fair – sister event to EuroMold – received 11,199 domestic visitors and 1,302 international visitors, reflecting a year-on-year growth of 21 percent and six percent respectively.

Showing at the fair were 310 suppliers from 15 countries and regions, covering two halls in a total exhibition area of 20,000 sq m. The exhibitor number was up 10 percent on last year. i-Moldshop & Hong Kong Gallery The i-Moldshop was a popular draw for visitors who wanted to know how the latest range of CAD/CAM systems, automation software, robots, digital CNC,

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metalworking equipment news Nov-Dec 2010

EDM, CMM & pallet together with related production equipment that could help facilitate and upgrade the mould and die manufacturing process. Over the fair period, experts led a series of live demonstrations of automated mould-making processes, which attracted large crowds.

Visitors were also seen heading to the Hong Kong Gallery, a new initiative by the Hong Kong Mould & Die Council. With the theme ‘World Brands Made by Hong Kong’, exhibits on display included packaging products, toys, automotive, precision components, optical products

as well as home appliances along with the relevant moulds involved in the manufacturing processes.

The informative seminars held on mould & die technology and development were also well attended by visitors. The next edition of Asiamould will take place at the Poly World Trade Centre Expo from 21– 23 September 2011.

Poly World Trade Centre Expo Guangzhou, China September 15 – 17, 2010 Enquiry No. 8601

ENQUIRY NO 158

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Automating Success Meticulous planning, adopting automation and paying attention to the needs of exhibitors – these are things that make them tick, according to the organisers of Asiamold. APMEN finds out more from Dr -Ing Eberhard Doring, CEO of Demat and Louis Leung, deputy GM of Messe Frankfurt. By Joson Ng Q: Tells us more about the concept of the show: ‘From design to prototyping to series production’, and the inspiration behind it.

LL: This successful concept has been in used for the last 16 years in Euromold and as the organiser of its sister event, Asiamold, we decided to use this concept as well. From the beginning of Asiamold, we feel this concept is ideal for the Chinese market. With its emphasis on design, which the Chinese mould and die makers are not too well-known for, we hope they can shed the tag of sub-contracting manufacturing.

We have also seen factories upgrade their facilities to include simulations and prototyping.

Q: According to the event’s website, some 80 percent of exhibitors are repeat exhibitors from last year. Why do you think this figure is so high?

LL: The most important reason is that the show remains professionally run and specialised. There are other events in China related to mould and die but they have elements of machine tools and packaging. For us, we are focussed and devoted to the mould making industry.

Q: What would the organiser be looking to do in order to ensure this figure is maintained or even surpassed next year?

ED: It is very important to attracted visitors. This year’s show features the iMoldshop, an automotive workshop and also a Hong Kong gallery.

LL: It is essential the concept of the show uses the German standards. In addition, it is vital to provide services to exhibitors and visitors alike. For example, this year we setup a beer garden. It may be a small

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metalworking equipment news Nov-Dec 2010

thing but we believe it goes a long way. If the food at the show is not good, they may go outside for lunch and may not return afterwards. Also, in an effort to keep them at the show, we provide WIFI service to all.

Q: iMoldshop generated a lot of interest this year. With automation as its central theme, it is a break from the traditional labour-centric mould and die industry of China. Do you think China is ready for automation, taking into account the cost of implementation and the mindset of its people?

E D : T he tr adi tio n a l way of m oul d making is normally one piece at a time.

Automation can bring 1,000 pieces with high level of repeatability. The process of evolution from artist to engineer has begun and so must the paradigm shift in the whole mindset towards quality and maintenance. For example, the Chinese mould manufacturers used to receive CAD files from Europe. Now they can reiterate the whole manufacturing process using the data they have now.

LL: China cannot maintain its image of a sub-contracting manufacturing hub. The first step is to manufacture high quality

products. This is where automation is key.

It is not introduced to replace workers.

The work force should concentrate on designing and making very high precision mould. If a factory adopts automation, they will also have more technical knowledge and as a result, making it easier to make the product people want.

Q: What is the outlook for China’s mould and die industry in 2011?

LL: I understand from the officials of Guangzhou die and mould industry that we still have shortage of moulds in China.

The country currently imports from other places. These are rather surprising figures from the custom. China imports more moulds than it exports. One of the key reasons being the imported moulds are usually the very precise ones that cannot be manufactured in China. The technological standard is still behind Germany, Japan and the US but the situation however, will be changed.

Maybe for next 10 to 12 years, importing or using European mould and die will reduce as local manufacturers learn how to manage mould productions in shorter lead time.

Enquiry No. 8602

ENQUIRY NO 171

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Hong Kong Mould & Die Council Looks Closer To Home

In addition to quality, he also feels the stre ngth of Hong Kong mould and die companies lies in after sales services, product developments and communications. As such they are able to provide “solutions” rather than a madefrom-print product.

Strategic Shift & Adopting A Forward Thinking Approach

APMEN speaks to the chairman of Hong Kong Mould & Die Council (MDC) in this exclusive interview where the need to focus on the latest technologies and businesses closer to home is on top of the council’s agenda. By Joson Ng “For the last 10 years, China’s mould and die industry has been getting stronger gradually,” says To Wai Hung, chairman of MDC who graced the opening of Asiamold 2010.

Continuing his bullish assessment of the industry, he says: “The mould and die industry in southern China generally serves four major automobile makers so there are many tier one and two suppliers here.”

Elaborating, he says companies like Honda, Toyota, Nissan and Volkwagen are major driving forces behind the automotive industry in China, as such they play an important role in the mould and die industry too.

In addition, the mould and die industry is also supplemented by the demand to manufacture mobile phones and computer casing. He also mentions these are “very busy times” for the suppliers for mobile phone casing.

Mr To star ted his manufacturing career when he founded a metal

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stamping company in Hong Kong back in 1975. Catching the electronic boom in the 1980s and early 1990s, he ventured into Dong Guan, China in 1992 and started supplying major international laser printer brands like Nikon, Canon, Minolta, Espon and Brother. He became the chairman of Hong Kong Mould and Die Council in 2003.

The HK Contingent In Asiamold A feature of this year’s Asiamold is the Hong Kong Gallery organised by the MDC. With the tagline ‘World-class product by Hong Kong’, it has garnered plenty of attention. According to Mr To, it is imperative to distinguish Hong Kong enterprises from the rest.

Says Mr To: “The gallery aims to demonstrate the quality of our products and also to highlight our capacity and know-how. Quality is the way to go and this is the message we are trying to put across.”

Over the years, with the decline of US and European economies, Mr To reveals the council and its members have been slowly but surely shifting their focus from the US and Europe back to their familiar neighbourhood, ie: China. With China overtaking Japan as the second largest economy in the world behind the US, the move has paid dividends.

The economic prowess shown by the middle kingdom has translated into much optimism, especially in the mould and die industry according to Mr To. He feels the younger generations in China are more keen to join the industry compared to their US, European or Japanese counterparts. In order to catch this wave, the council has plans to do more in 2011 by attending events, organising seminars and factory visits.

Casting his eyes to the future, he has a certain penchant for the word ‘automation’.

He predicts automation will play a big part in mould and die manufacturing, even in labour-intensive China. Visitors to Asiamold were treated to a preview in a form of iMoldshop, a concept mould making workshop.

Automation could well prove its worth in the long run but the route may not be all smooth sailing. Taking the small steps in this case is important as he concludes: “Many are talking about automation.

Thanks to iMoldshop, many members are asking me how to incorporate automation in their jobshop in order to increase their capacity. I believe taking the holistic approach to increase their capacity is a prudent way. For example, introducing an ERP system can go a long way in fulfilling the step to full automation in a manufacturing facility.”

Enquiry No. 8603

ENQUIRY NO 173

EVENTs&exhibitions

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Event Review:

Metalex Vietnam 2010

1-On-1 With Duangdej Yuaikwamdee In this exclusi ve inter v ie w, Duangdej Yuaikwamdee, deputy MD, (commercial), Reed Tradex, fresh from the conclusion of Metalex Vietnam, speaks to APMEN on his thoughts on the show and metalworking in Vietnam.

I

n the recently concluded Metalex Vietnam, some 11,410 industry leaders nationwide visited the show organised by Reed Tradex.

Visitors got first-hand experience to see a wide array of the latest innovations and technologies from the world’s famous brands, while enjoying a rare opportunity to nourish themselves with industrial trends and strategies for their business developments.

Simultaneously, exhibitors got direct contacts with many prospective buyers, while furthering their networks with possible partners and agents. As a result, exhibitors have made their confirmation to participate in the forth-coming shows, and visitors have shown interest in attending the next series.

Together, a number of authorities and influential figures in manufacturing and metalworking industries both in Vietnam and overseas has further strengthened the image of the event, and has reflected its essentiality to the fast-growing developments of the related industries and businesses in Vietnam.

Also, this event includes top-level representatives from the following institutes: • • • • • • • • • • •

Vietnam Automation Association (VAA) Vietnamese Society of Automotive Engineers (VSAE) Vietnamese Association of Mechanical Industry (VAMI) Vietnam Steel Association (VSA) Vietnam Electro – Technical Industry Association (VELINA) Association of Electronics Industries in Singapore (AEIS) Singapore Manufacturers’ Federation (SMa) Taiwan Association of Machinery Industry (TAMI) China Council for the Promotion of International Trade (CCPIT) BOI Unit for Industrial Linkage Development (BUILD) Department of Export Promotion (DEP)

Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam October 7 – 9, 2010 Enquiry No. 8604 70

metalworking equipment news Nov-Dec 2010

In your opinion, what is/are the special feature(s) Metalex Vietnam has over other major shows in the country? Are there any specific amenities offered by the organiser this year to make the visitors’ stay in the show more rewarding?

What are your thoughts on the show this year in terms of visitor turnout and exhibitors’ feedback?

DY: There are three major factors that distinguish Metalex Vietnam from other exhibitions. The event showcases the right technologies for SME industry, and is also a solution-providing platform where v i s i to r s c a n ex p e r i e n c e l i ve demonstrations of machiner y before making decisions. The show also opens many opportunities for Vietnamese industrialists and industrial par ts manufacturers to connect with Japanese OEM outsourcing companies in Vietnam, who are looking for potential local manufacturers to reduce costs of imports.

Finally, the event is also an industrial stage for foreign-owned factories in Vietnam who are looking for industrial par ts from local manufacturer, or who want to expand their business locally, to come and visit the show to acquire technologies and find the right partners.

For spe cial a me nitie s, we have organised a special zone c a lle d ‘Hi -Te c h Zone’, whic h

ENQUIRY NO 178

EVENTs&exhibitions

Mr Duangdej feels JETRO has a big role to play in the development of Vietnam’s industries

demonstrated the real application of productivity-enhancing automated manufacturing. Vietnam at present is on a self-preparing stage to embrace new opportunities, and develop new potential manufacturing process. Automated manufacturing process will be a key factor in the development of the Vietnamese industry. Since automation will be practiced more in Vietnamese industries, local mechanics will develop into robot engineers.

There is a strong Japanese presence in this year’s Metalex Vietnam. The seminars organised by JETRO are very good examples. How important is Japanese participation in Metalex Vietnam and more importantly, how significant is Japanese investment in Vietnam’s metalworking or manufacturing industry?

DY: JE TRO’s par ticipation in Metalex Vietnam is an important driving force to develop industrial sectors in Vietnam. Vietnamese industrialists have realised that quality manufacturing process of industrial parts will upgrade both skills development and product’s quality.

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Nowadays, Japan is interested in investing a great amount in Vietnam, as seen in a case where Toshiba opened a motor assembly factory that is energy-saving and capable of high-speed producing. It has only established this type of factory in three countries: USA, China, and Vietnam.

The event will be the platform to connect and inspire Vietnamese industrialists with the importance of te c h n o l o g y u tili s a ti o n fo r better production quality, higher development of Vietnam industries, and greater market expansion to overseas making the show a key factor to elevate overseas investments to grow along with local investments.

This year’s edition is the fourth.

In your own words, how has the show evolved from the inaugural event right up to the current event?

DY: Since its previous editions, the event has been a trade show focusing on machine tools and metalworking technologies, providing manufacturing solutions to Vietnamese industries. In this edition, we have extended business opportunities by co-locating with JETRO’s 4th Exhibition on Supporting Industries in Ho Chi Minh City, and have created a Reverse Exhibition, where Japanese purchasers showcase industrial parts they want to buy from local manufacturers visiting the show, while Vietnamese companies exhibit products which they can manufacture and supply.

The combination of these two types of exhibitions will help enhance production and expand Vietnam market to global competition.

Next year, we will offer even more business opportunities in order to serve Vietnamese industrialists’ d e m a n d s by c o - l o c a ti n g t h e show with an electronics parts manufacturing and electronics assembly line technologies show called Nepcon Vietnam.

What is the overall theme of the show this year? How do you plan to attract more exhibitors and visitors to the show next year?

DY: Our plan consists of three factors, which includes increasing industrial profile by organising a n ex h i b i t i o n f o r t h e r e l a te d electronics parts manufacturing i n d u s t r y. W e w i l l c o n d u c t c u s to m e r ’s i n s i g h t s u r ve y through factory visits to ask their technology demands, and utilise t h e i n fo r m a ti o n to s h owc a s e the right technologies for their needs. Finally we will expand our international pavilions; by next year, Czech Republic, Italy, Turkey and Germany will join the event as international pavilions.

Is Vietnam ready for more advanced machine tools/ metrology equipment or do you see the main bulk of demand to be for entry-level products?

DY: Currently, Vietnam is on the developing stage to utilise more advanced technologies, and local manufacturing industrialists have the potential for global competition.

It is not very important as per whether or not Vietnam is ready for advanced machine tools or metrology equipment; but it should be taken in consideration towards how Vietnam can attract overseas organisations to invest in the country. If more investors expand their business to Vietnam, it will stimulate Vietnamese industrialists to b e m o re c o m p e ti tive, a n d they will eventually upgrade their production process with advanced te c hnolo gie s a n d m ac hine r y; for example, they could elevate t h e m s e l ve s f r o m m o to r c yc l e a s s e m b l y l i n e to a u to m o t i ve assembly line in the future. MEN Enquiry No. 8605

Held Inconjunction with :

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

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

ENQUIRY NO 159

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

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

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Event Preview:

Medtec Southeast Asia

M

edtec Southeast Asia comes to the ASEAN region for the first time this December, highlighting the status of Singapore as a hub for medical device design and manufacture and the emergence of the ASEAN region in its entirety as a key location for medical device design and production.

The event is the international sourcing event for medical device design and production professionals in Southeast Asia. It joins similar successful events already held regularly in China and Japan, as well as Europe and the US. Recognising the growing influence of Singapore and its neighbours in the medical equipment and device segment, the organiser adjudged that it was timely to bring its Medtec event to the island state.

Attractions On Show Medtec Southeast Asia is set to showcase the latest in technologies, components, solutions and other inputs for medical device design and manufacture. On this account, it will be an event for leading device companies with R&D and manufacturing operations in the region.

Coinciding with the debut of the event in Singapore will be a two-day international conference and workshop focusing on topics of particular relevance to the region’s medical device sector. Sessions include Investing in the Medical Device Industry in Southeast Asia, Managing Supply Chain: Challenges & Strategies, Innovation in Materials: New Materials, New 74

metalworking equipment news Nov-Dec 2010

Functionality & Packaging Solutions, and Process Innovation for Medical Manufacturing. The workshop component will cover Biological Safety Programs that Comply with Global Requirements.

Highlights include a presentation, entitled Thailand – ASEAN’s Medical Device Manufacturing Hub, a lecture

on regulatory due diligence in establishing supply-chain relationships within the medical devices industry covering supplier selection and qualification, and a paper entitled Strategic Innovation: A Business Imperative for Accelerated Growth.

Enquiry No. 8606

Why Singapore?

In 2009, Singapore’s medical technology sector’s output was valued at about S$3 billion (US$2.2 billion). This represents a doubling in revenue compared to 2000. The target for 2015 is S$5 billion in output, representing 11 percent per annum growth.

Singapore is home to 35 manufacturing plants of global medical technology companies; 26 operate R&D centres and 29 have their regional headquarter functions based in the country.

The country is one of the world’s leading manufacturing sites for research tools and diagnostics instruments, supplying more than half of the world’s micro-arrays and 50 percent of the global demand for thermal cyclers.

The supporting industry for medical devices in Singapore is proactively moving to win more business through establishing the MedTech Manufacturing Consortium, which aims to overcome entry barriers so that local firms can tap the worldwide medical technology sector and the proper supply chain can be put in place at the local level. Many local companies in both Malaysia and Singapore are also leveraging their expertise in the electronics sector to successfully diversify into medical device component manufacture.

The medical device and equipment industry in ASEAN also enjoys strong government support. Southeast Asia spends an estimated $2 billion annually on medical devices and equipment and countries such as Singapore and Malaysia have made in their priority to boost local production, reduce reliance on imports, and indeed play significant roles in global exports markets moving forward.

Suntec Singapore Singapore December 1 – 2, 2010 Enquiry No. 8607

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ProductFinder

Faro: Small & Light 3D Laser Scanner

Hwacheon: Machining Solutions Across Industries

Focus3D is a high performance 3D laser scanner for detailed measurement and docu mentat ion w it h intuitive touch screen control. It is four times lighter and five times smaller than its predecessor and is the smallest and lightest laser scanner ever built, according to its maker, Faro.

Using laser technology to produce detailed 3D images of complex environments and geometries in only a few minutes, the resulting image is an assembly of millions of 3D measurement points in colour, which provides an exact digital reproduction of existing conditions.

The laser scanner is suitable for documentation of large environments, quality control of components and reverse engineering.

Hwacheon has developed the Vesta series to cater to various applications in many industries. For example, the Vesta 660 and Vesta 1000 cater to parts manufacturers looking to machine parts made from aluminium or steel.

Those looking to cut tougher materials like forged steel material or materials used in aircraft industry, the Vesta 850B and Vesta 1050B, with a rigid box guide way system are the answer.

Also, the company has developed a swing pallet VMC – Vesta 610D. Focus has been on the compatibility and machining performance with a maximum rapid feed rate of 40 m/min, a maximum spindle speed of 10,000 rpm and a tool changing time (tool to tool) of 1.5 s.

Enquiry No. 8701

Enquiry No. 8702

AMAZING ADVANCED TECHNOLOGIES

Metalex Thailand 2010 24-27 Nov 2010 • Booth: 6P05

Manufacturing Indonesia 2010 1-4 Dec 2010 • Booth: 322 Hall A

5 Axis Waterjet Cutter With Elect Servo Pump 5 AXIS Cutting Sample

Smart Hybrid Finishing

New OptiRough Toolpath

New Dynamic Milling Techniques

Easier Multiaxis Machining

ENQUIRY NO 170

• Precision Angle Cutting • +/- 60 deg.

• Control Taper Cutting

ELECTRIC SERVO PUMP

• No Hydraulic Oil Leakage Problem • Small Szie & Compact, Save Space • Low Noise, 68db, Normal Pump 80db • Extreme Low Electric & Water Consumption • Precisely Control Working Pressure & Flow Rate • Prolong Spare Parts Life Of Span • Less Maintenance • Change Parts Within 5 min.

Servo Pump Retrofit To Your Existing Waterjet Visit Us at Manufacturing Indonesia Hall A, Booth no. 3206

PLEASE CONTACT

Creative Machinery Enterprise

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

New Plunge Turn Toolpath

Mastercam Machine Simulation

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

Techtown Pte Ltd

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

ENQUIRY NO 166

5 AXIS ROTATING HEAD PAC-60

Nov-Dec 2010 metalworking equipment news

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Hypertherm: Metal Cutting Systems

Mori Seiki: Horizontal Machining Centres

The Powermax65 and Powermax85: two systems by Hypertherm that come with more torch options and a more rugged torch design for greater durability in harsh cutting environments.

Four torch options – an ergonomic 75-degree hand torch, a 15-degree hand torch for gouging and cutting in tight locations, a 15 inch full-length machine torch, and a 6 inch short barreled machine torch for robotic and pipe-cutting applications – provide greater versatility.

Operators can now easily cut metal that may have been hard to access in the past. In addition, the torches are up to five times more rugged and durable than before.

Mori Seiki has developed the X-class version of HMC – the NHX4000 and NHX5000/40 horizontal machining centres.

The HMCs have rapid traverse rate of 60 m/min.

The NHX4000’s pallet indexing time is 1.0 second (1 deg indexing specifications), and the NHX5000’s is 1.49 seconds (90 deg indexing specifications). Both models offer increased productivity by reducing noncutting time.

In addition, they provide high-rigidity and stable machining by using a thick, high-rigidity bed with the X- and Z-axis linear guides placed in a high position, spindle with a large-diameter bearing, and a table and pallets with a powerful clamping force.

Enquiry No. 8703

Enquiry No. 8705

Mazak: Multi-Tasking Innovation

76

Rockwell Automation: Compact PACs

Manufacturers every where are aware of the benefits of multi–tasking machining. However, for a variety of reasons not all manufacturers have installed machine tools that can perform ‘donein-one’ operation.

These reasons include concerns about difficult operation and programming, difficulties in machine setups and high purchase cost. The Integrex j-200 has been developed by Mazak to eliminate these concerns. These multi-tasking machines are designed to deliver high-speed, high-accuracy and ease of operation.

Ro ck wel l Automat ion ha s i nt ro duce d t wo controllers to provide machine builders and manufacturers with integrated safety, motion, discrete and drive control capabilities in a single controller for midrange applications.

The Allen-Bradley L43S and L45S Compact Gua rdL og i x Prog ra mmable Automat ion Controllers (PACs) extend capabilities previously available only in the larger ControlLogix platform.

These include diagnostics a nd information capabilities that help reduce nuisance shutdowns and prolonged restarts, as well as a single programming environment for enhanced design and development productivity.

Enquiry No. 8704

Enquiry No. 8706

metalworking equipment news Nov-Dec 2010

productfinder

www.equipment-news.com

Techni: Waterjet Cutting Machine

Tornos: Productive & Cost Effective Drilling Machine

Enquiry No. 8707

Enquiry No. 8708

ENQUIRY NO 060

TechJet X2-6000, part of the Techjet-X2 series has been designed by Techni to create a precise, easy-tooperate, safe and reliable waterjet cutting machine.

It incorporates linear scale feedback to ensure the accuracy of motion. By mapping the entire cutting area with a laser-calibrated digital encoder, the motion system can deliver positional accuracy of 0.01mm.

According to the manufacturer, other features include but not limited to fully enclosed bellows to completely protect the linear bearings and drive system, stainless steel apron to protect the machine when loading/unloading and power ‘Z’ axis.

The PB 700 by Tornos is a horizontal bar and profile drilling machine. Working on three or four axes, it can machine simple parts to precise specifications on a continuous basis.

Designed on a modular basis, it supports various spindle head configurations (horizontal, vertical or lateral). The addition of an optional NC dividing head offers a wider range of machining operations for more complicated parts.

An offspring of the 1005 family, the machine offers all the possibilities of a simplified drilling machine, while providing rigidity. Designed to machine parts (boring, milling, cutting-off) from bar stock or profiles.

The machine is applicable in fields such as optical instruments, dental (brackets), watch making, and other high precision sectors.

Nov-Dec 2010 metalworking equipment news

77

productfinder

78

www.equipment-news.com

Vision Engineering: Video Measuring Machine & Stereo Inspection Solutions

Widia: Inserts For Economical Milling

Vision Engineering’s Falcon video measuring solut io n w it h C N C is a power ful yet compact machine, suitable for a range of medical device measuring applications including three-axis measurement of precision machined component parts, with its CAD import and export facility, and advanced data analysis including PC software integration.

Also, the Mantis Elite- Cam with onscreen measurement, a stereo inspection system, has also been developed. It is suitable for high-resolution inspection of medical devices. With it, components can be inspected, reworked, digitally captured, and now measured on screen within minutes.

Inserts for Widia’s Victory M1200 face mill series are designed to provide results in aluminium when machining the common milling operations.

Their combination of toughness and wear resistance allow faster feed rates, and the 12 cutting edges per insert, as well as the reduced power consumption resulting from the free-cutting geometry, make them economical to use.

The LDJ geometry featuring optimised rake angles is designed to be free cutting. The insert is available in two grades, THMU and a TiB2-coated TN6501. Both inserts are peripherally ground and feature polished rake surfaces.

Enquiry No. 8709

Enquiry No. 8711

Walter: Monoblock Toolholders

Witte: Hybrid Clamping Chuck

Walter is expanding the clamping options for the ConeFit modular milling system by introducing monoblock toolholders. With these monoblock toolholders, the company is now offering users of its modular milling system an option with as few joins as possible.

The toolholders that have the ConeFit thread fit directly into the machine spindle and this means that there is no need for the usual cut-off area between the modular tool shank and the collet. At 2xD, the clamping length of the mill is short. The entire tool/ clamping system therefore maintains a level of stability. During machining, high cutting data can be achieved and the performance of the tool can be used to its full extent.

Magnetic and vacuum clamping chucks are commonly used to hold different materials for machining.

Whilst magnetic chucks are limited to magnetisable materials, vacuum clamping technology is suitable for a substantially larger range of materials.

However such work pieces must fulfill certain criteria like large surface area and flatness.

In order to use the advantages of both systems and achieve a synergy, the specific characteristics from magnetic and vacuum clamping technology have been united in one product. In MagVac by Witte, magnetic and non-magnetic work pieces can both be clamped using one system.

Enquiry No. 8710

Enquiry No. 8712

metalworking equipment news Nov-Dec 2010

Exhibition 2010/2011 Programmes November

March

May

ShuiNan Economic & Trade Park Taichung, Taiwan Taiwan Machine Tool & Accessory Builders' Association ricky@tmba.org.tw www.tmts.tw

TWTC, TWTC Nangang Taiwan TAITRA timtos@taitra.org.tw www.timtos.com.tw

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

3–7 TMTS 2010

9 – 13 CIIF

Shanghai New International Expo Centre Shanghai, China National Development and Reform Commission ciif@shanghaiexpogroup.com www.ciif-expo.com

24 – 27 Metalex Thailand 2010 BITEC Bangkok, Thailand Reed Tradex Channipar.Vala@reedtradex.co.th www.metalex.co.th

December

1-4 Machine Tool Indonesia 2010 Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo info@pamerindo.com www.machinetoolindonesia.com

2011 January 20 - 26 IMTEX 2011

Bangalore International Exhibition Centre Bangalore, India Indian Machine Tool Manufacturers’ Association imtma@imtma.in www.imtex.in

1–6 TIMTOS

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

23 – 26 MTA 2011

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

23 – 26 INAPA 2011

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

April

4–8 Hannover Messe 2011

4–8 Metaltech 2011

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

12 – 15 Intermach 2011

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

25 – 28 MTT Expo 2011

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

June

8 – 11 Manufacturing Surabaya 2011

Exhibition Grounds Hannover, Germany Deutsche Messe www.hannovermesse.de

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

27 – 29 ASX 2011

July

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

www.equipment-news.com

5–8 MTA Vietnam 2011

Saigon Exhibition & Conference Center (SECC) Ho Chi Minh City, Vietnam Singapore Exhibition Services events@sesallworld.com www.mtavietnam.com Nov-Dec 2010 metalworking equipment news

79

advertising index

Advertiser

Enquiry No.

4T TECHNOLOGIES PTE LTD

19

112

BRUDERER PRESSES (FAR EAST) PTE LTD

53

161

BRUTSCH-RUEGGER METALS

49

162

BYSTRONIC PTE LTD

09

172

CREATIVE MACHINERY ENTERPRISE

75

170

DELCAM PLC (INTERNATIONAL DIVISION)

07

090

DMG ASIA PTE LTD

31

169

DORRIES SCHARMANN TECHNOLOGIE GMBH

37

167

ECMI SERVICES PTE LTD (MTT EXPO 2011)

73

159

EVERISING MACHINE CO

55

175

exxon mobil asia pacific

33

108

FARO SINGAPORE PTE LTD

45

180

FRITZ STUDER AG

39

036

HAAS AUTOMATION INC

05

153

HEXAGON METROLOGY ASIA PACIFIC PTE LTD

21

164

HOFFMANN GMBH

17

130

HONG CHEK CO (PTE) LIMITED

23

140

HWACHEON ASIA PACIFIC PTE LTD

47

163

IDEMITSU LUBE (SINGAPORE) PTE LTD

13

154

ISCAR LTD

IFC

176

BC/02/10

135 / 157 / 137

LICO MACHINERY CO LTD

57

072

MALAYSIAN EXHIBITION SERVICES SDN BHD (MTA Malaysia 2011)

67

171

MAWEA INDUSTRIES SDN BHD

43

179

NATIONAL INSTRUMENTS

27

156

nikon singapore pte ltd

35

142

SECO TOOLS (S.E.A) PTE LTD

15

033

60/61

177

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2011)

65

158

sumitomo electric hardmetal asia pacific pte ltd

59

182

TAIWAN TAKISAWA TECHNOLOGY CO LTD

77

060

TECHTOWN PTE LTD

75

166

TORNOS TECHNOLOGIES ASIA LTD

51

160

TRADE-LINK EXHIBITION SERVICES SDN BHD (Metaltech 2011)

69

173

TRAVERS TOOL CO., LTD

41

132

tungaloy singapore (pte) ltd

29

165

UBM Asia (Thailand) Co Ltd

71

178

WALTER AG SINGAPORE PTE LTD

01

168

WENZEL ASIA PACIFIC PTE LTD

25

181

FC / IBC

155 / 174

KENNAMETAL INC

SIEMENS PRODUCT LIFECYCLE MANAGEMENT SOFTWARE (SG) PTE lTD

YAMAZAKI MAZAK SINGAPORE PTE LTD

80

Page No.

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metalworking equipment news Nov-Dec 2010

ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing,Automation & Quality Control

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ASIA PACIFIC METALWORKING

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The Engineering Journal For Manufacturing,Automation & Quality Control

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❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

Machine features • High accuracy, high rigidity B- and C- axis with high contouring torque

• Simultaneous 5-axis controlled machining with tool tip center control

• Smooth chip disposal

Long Boring Bar Maximum length of 1,000 mm (39.37”)

Minimized Vibration

ACTIVE VIBRATION CONTROL

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

INTELLIGENT THERMAL SHIELD

Unique Mazak heat displacement compensation system Verbal Message System (Patent Pending)

MAZAK VOICE ADVISOR

Verbal support for machine setup and safe condition confirmation Machine Interference Prevention

INTELLIGENT SAFETY SHIELD

Function for safe operation during machine setup and manual operation

Tel : +65 6862 1131 Fax : +65 6861 9284 Email : marketing@mazak.com.sg Website : www.mazak.com

ENQUIRY NO 174

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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.

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.

• Australia 1300.094342 • India 9180.2839.4321 • Japan 813.3820.2855 • Malaysia 603.5569.9080 • Singapore 65.6265.9222 • China 8621.3860.8288 • Vietnam 84.8.38447917.21 • Korea 822.2109.6100 • Taiwan 886.4.23501920 • Thailand 662.642.3455 ©2010 Kennametal Inc. l All rights reserved. l A-09-02229

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