APMEN Nov-Dec 2016 by Eastern Trade Media

IS THE FUTURE NOW? Age Of New Materials p30

DIGITALISATION In Practise

MEDICAL INNOVATIONS

p66

Smaller, Better, Stronger p65

November - December 2016

www.equipment-news.com

Right Coolant Becomes A

LIQUID TOOL

Bearing Industry

GATHERS PACE

Choosing

THE RIGHT

SLIDEWAY OIL

Superior Innovative Face Milling PER I W

CUTTING ED

GE S!

8 1

The new IQ845 family with square double-sided inserts with 8 cutting edges. The milling cutters feature a very soft cut due to a high positive cutting edge inclination, which results in a very good surface finish in roughing applications. ISCAR JAPAN 1-5-3 Shinsenri-Higashimachi Toyonaka-shi, Osaka 560-0082 Tel + 81 6 835 5471 Fax + 81 6 835 5472 iscar@iscar.co.jp

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

ENQUIRY NO 139

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 38123 519/20 Fax + 84 8 38123 521 iscarvn@hcm.fpt.vn

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

www.iscar.com CV MULTI TEKNIK Ruko Gsa Blcok B No. 8 BN-BP, Podomoro City JL.Letjen S.parman Kav.28 Jakarta Barat 11470 Indonesia Tel + 62 21 29206242/44/45/59 Fax + 62 21 29206243 multi@centrin.net.id

High pressure coolant improves chip control and prolongs insert's tool life PT. Tungaloy Indonesia Ruko Celebration Boulevard Grand wisata., Blok AA.10 No.3-5, Tambun selatan â&#x20AC;&#x201C; Bekasi 17520, Indonesia Tel: (021)8261 5808 Fax: (021)8261 5809 www.tungaloy.co.jp/id

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

Tungaloy Malaysia Sdn Bhd 50 K-2, Kelana Mall, Jalan SS6/14, Kelana Jaya, 47301, Petaling Jaya, Selangor Darul Ehsan, Malaysia Tel: +603-7805-3222 Fax: +603-7804-8563 www.tungaloy.co.jp/my

www.tungaloy.com ENQUIRY NO 155

CONTENTS

Asia Pacific Metalworking Equipment News • November - December 2016

METAL CUTTING

Bearing Industry Mass Production Gathers Pace

Soaring demand for specialized bearings is driving fast-paced changes in mass production techniques aimed at quality and price. By Robi Nudelman, Bearing Industry Manager, and Yair Feraro, Application Engineer at Iscar.

The Age Of New Materials:

Is The Future Now?

Throughout history, materials and advances in material technology have influenced humankind. Now we just might be on the verge of the next shift in this type of technology, enabling products and functions we never believed possible. By Sandvik Coromant

Press Blanking Line To Cut Steel

A smaller, but higher capacity press blanking machine at Volkswagen’s main production facility at Wolfsburg in Germany has changed the steel cutting workflow for the automaker. By Simon Scherrenbacher, specialist press officer for Schuler.

Aluminium Tubes, Sheets, Ingots Needs Specialised Cutting Tools

Cutting aluminium requires a range of machinery depending on the end-use application that vary from aircraft to window blinds with techniques that rely on higher speeds and lower cutting forces compared to metals like steel to ensure optimum cutting geometry. By Stephanie Riegel-Stolzer, Member of the Kasto Management Board.

Additive Manufacturing Lifts Space Satellite Antenna

Getting a sensitive space satellite antenna bracket to operate optimally means calling additive manufacturing to the rescue. By Terence Oh, Vice President (Asia Pacific), EOS Singapore.

GREAT GEAR & SYSTEM

The Right Coolant Becomes A Liquid Tool

If you want to be successful as a contract manufacturer and as a supplier to businesses, working on reliability, flexibility and precision count most. By Blaser

Choosing The Right Slideway Oil For Your Coolants

Slideway oil affects both the machining precision and service life of metalworking fluid. By Imtiaz Ahmed, Asia Pacific Mobil SHC brand manager, ExxonMobil Lubricants.

INDESIGN

Multi-Sensor CMM For Turbine Blades

How multi-sensor CMMs can help increase productivity and support expansion of a company’s product portfolio. By Ashley Machin, Nikon Metrology Europe.

Smaller, Better Challenges Mobile Device Makers

Mobile phone manufacturers are grappling with the need to track smaller, and better, components, presenting challenges and opportunities for designs. By Panasonic

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

ENQUIRY NO 140

VERO-S NSA plus Clamping station

Clamping pallet with clamping force blocks

Clamping pallet with magnetic clamping technology

Clamping pallet with chuck

Clamping pallet double with angle tombstone

SCHUNK Intec Pte. Ltd. 25 International Business Park, #03-51/52 German Centre, Singapore 609916 Phone: +65 6240 6851 | Fax: +65 6240 6852 | Email : info@sg.schunk.com

CONTENTS

Asia Pacific Metalworking Equipment News • November - December 2016

Augmented Reality Enhances Device Performance

Technology that enhances device performance is sweeping the world from smartphones to scanners used in major logistics work. By Jayajyoti Sengupta, APAC head, Cognizant.

FEATURES

Additive Manufacturing:

Bespoke Medical Implants Sterile and unique implants for reconstructive surgery that use high end metals for mesh are increasingly coming from 3D printed design casts that can be used across the globe. By Ed Littlewood, Marketing Manager in the Medical Dental Products Division.

Medical Innovations Are Smaller, Better, Stronger

A Secret Weapon For Aerospace, Automotive Quality Control Managers

Handling responsibility for quality control means closing the loop on coordinate measuring machine operations. By Daniel Brown, B Eng , senior product manager at Creaform

FAST FAB

Punching Machine Adaptability:

Room to Grow

An entry-level segment punching machine that can gradually be expanded into a fully-fledged combination machine has caught industry attention with a host of innovative features from punching holes to bends flanges and forms threads. By Trumpf

Digitalisation In Practice

Digital platforms are being developed on the basis of which users can apply their tools more efficiently, cut back on waste, and minimise tasks that were previously carried out manually. By Walter

BY THE HAND

Reciprocating Grinding:

In the automotive sector, reciprocating grinding is the way to go for manufacturing ball nuts in steering sytems. By Markus Isgro, marketing communications, Emag.

ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 12 Hoy Fatt Road #03-01 Bryton House Singapore 159506 Tel: (65) 6379 2888 • Fax: (65) 6379 2886 SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/ Europe/Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2886 Singapore E-mail: nurulhuda@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

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

A higher level of technology allows radius grinding machines to have more powerful software, grinding of larger workpieces, while having easier maintenance. By Studer

Machine design, tooling and programming software combine to make today’s punch press capable of complex forms. By Dan Caprio, punching product sales manager at LVD Strippit

For Advertiser’s Enquiry Numbers, Refer to Advertising Index in page

Cycle Times Cut

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Technical expertise and demand for smaller products are driving innovations in the medical sector. By SG Transmission

In With The New Radius Grinding Machines

Beyond Punching

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Preview:

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Born to bend. More in it for you: press brakes from TRUMPF.

TruBend press brakes spark a passion for bending technology. From the smallest electronic components to thick, large- format metal sheets, they allow you to tackle an unparalleled range of parts with maximum productivity. With their exceptional precision and user-friendly operation, they cover all the bases. TruBend machines have been carefully designed to create an ergonomic workplace â&#x20AC;&#x201C; and operators love working with them! That makes TruBend press brakes the perfect foundation for your success. Isnâ&#x20AC;&#x2122;t it time to choose TRUMPF? www.sg.trumpf.com

The TruBend 5130 has received the following awards:

ENQUIRY NO 141

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

GOOD SIGNS

IN CHINA?

Head Office & Mailing Address: Eastern Trade Media Pte Ltd 12 Hoy Fatt Road #03-01 Bryton House Singapore 159506 Tel: (65) 6379 2888 Fax: (65) 6379 2886 Email: apmen@epl.com.sg Web: www.equipment-news.com

managing director

Kenneth Tan

Powerhouse China captures a lion’s share of attention on the outlook for manufacturing. The reasons are clear, sales of parts, equipment tools and machinery in the world’s second largest economy likely forecasts the nature of demand for products from automobiles to airplanes down the road. So what do the latest data sets from China tells us? First off, China’s economy chugged along as expected in the third quarter, according to data released in October by the National Bureau of Statistics (NBS), showing a quarter-on-quarter gain of 1.8 percent and a year-on-year pace of 6.7 percent. For long-time China watchers those numbers seem a pale comparison to the boom that followed stimulus efforts in the wake of the 2008 financial crisis. But by meeting expectations, China’s policymakers can draw some solace from the growth rate as proof their plans are on track to swing away from a hard reliance on export-led growth to one that spurs domestic demand. Indeed, accompanying data showed retail sales up 10.7 percent, industrial output gain 6.4 percent and fixed asset investment increase 8.2 percent, with all clipping along largely as expected too. The figures come on top of purchasing manager indexes (PMIs) released at the start of November that showed China’s services sector rose at the fastest pace in two years in October as new business picked up, according to the Caixin/Markit services PMI that came in at 52.4, well north of the 50 point and above cut-off for expansion versus contraction. And Caixin’s PMI for manufacturing for October came in at 51.2, the level same for the semiofficial PMI from the China Federation of Logistics and Purchasing and the NBS, placing both firmly in expansion. Does the data point to blue skies for metalworking equipment in Asia and beyond? The answer is a qualified yes. That’s because as China moves to rebalance its economy from one model, newer ways of business are popping up that are challenging companies to rethink sales and related practices to catch the next wave. For metalworking equipment vendors and users, that means dedicating more time to study the fickle consumer yearnings of the Middle Kingdom’s billion-plus population.

IS THE FUTURE NOW? ASIA PACIFIC METALWORKING EQUIPMENT NEWS

Age Of New Materials p30

DIGITALISATION In Practise

Edward Lane LaneEdward@epl.com.sg

writer

Jonathan Chou Hao En Jonathanchou@epl.com.sg

business development manager

Randy Teo

randyteo@epl.com.sg

editorial assistant

Sharifah Zainon sharifah@epl.com.sg

graphic designer

Jef Pimentel

jeffreypimentel@epl.com.sg

circulation executive

Chang Pei Yu

peiyu@epl.com.sg

contributors

Robi Nudelman Yair Feraro Simon Scherrenbacher Stephanie Riegel-Stolzer Terence Oh Imtiaz Ahmed Ashley Machin Jayajyoti Sengupta Daniel Brown Dan Caprio Ed Littlewood Markus Isgro

MEDICAL INNOVATIONS:

p66

Smaller, Better, Stronger p65

November - December 2016

www.equipment-news.com

Right Coolant Becomes A

VOL. 30 NO. 8 NOVEMBER - DECEMBER 2016

LIQUID TOOL

Edward Joseph Horgan Lane Editor

Bearing Industry

GATHERS PACE

MCI (P) No. 031/06/2016 • PPS 840/09/2012 (022818) • ISSN 0129 5519

SLIDEWAY OIL

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 Ho Printing Singapore Pte Ltd

Choosing

THE RIGHT

editor

Cover credit: Exxon Mobil

MCI (P) No. 031/06/2016 PPS 840/09/2012 (022818) ISSN 0129/5519

Tiger·tec Gold Go for better, go for Gold. ®

For those who won’t settle for anything but the best: Tiger·tec® Gold If you had to make a choice right now – between maximum tool life, uncompromising process reliability and optimum productivity – which one would you pick? Why not choose the freedom to never have to choose again. Stay true to your own high standards in every way. Choose Tiger·tec® Gold.

Walter AG Singapore Pte. Ltd. Tel.:+65 6773 6180 ENQUIRY NO 117 walter-tools.com

BUSINESS NEWS

COVERING DEVELOPMENTS IN ASIA AND BEYOND

Asia Pacific Metalworking Equipment News • November - December 2016

Bosch To Invest €80 Million In Southeast Asia Southeast Asia: In the first half of 2016, Bosch opened new offices in the Philippines and Indonesia with the aim of being closer to its customers. The company is also strengthening its manufacturing capacity in the region and plans to expand it s mobilit y solutions plant s in Malaysia und Vietnam. Additionally, a new plant in Thailand is planned. In the past ten years, Bosch has invested almost €500 million in the expansion of its manuf ac turing and development locations in Southeast Asia. ”Southeast Asia is an important

region for the Bosch Group”, said Peter Tyroller, the member of the Bosch board of management responsible for Asia Pacific. “To support growth in the region, we are planning to invest around €80 million (US$89.6 million) in Southeast Asia this year.” In 2015, Bosch achieved sales growth of 12 percent in Southeast Asia, generating sales of more than € 78 0 million . T he company al s o expects positive development in the current year, despite partially volatile economic development in some of the ASEAN markets.

Siemens: Simatic IT eBR Software Singapore: Siemens has launched Ver sion 6 .1 of it s Simat ic IT eBR sof tware, which is the core o f i t s M a n u f a c t ur in g O p e r a t i o n Management for the life sciences industries. With a new Master Batch Record mo dule and a “ Proje c t St ar t up” package, it provides a list of outof-the-box deliverables to speed up projec t execut ion t ime. Fully integrated communication is established between the automation level and manuf ac turing IT. This enables complete electronic recording and documentation of quality-related

production data, while eliminating time-consuming manual procedures and paper-based batch reports. Adnan Abdul Rahman, head of au t o m a t i o n a n d e n g in e e r in g a t Siemens Singapore, said, “Manual recording methods that involve large amounts of data and batch protocols put a strain on both the user and the business as a whole. Therefore, it is imperative that companies leverage on paperless manufacturing solutions such as the SIMATIC IT eBR to increase the ef f icienc y of pharmaceutical manufacturing processes and to gain a competitive advantage.”

The company has manufactured locally for more than 20 years and currently has seven plant s in the region. In Malaysia, for example, Bosch manufac tures power tools, produc t s for t he C ar Mult imedia division, and steering systems. The Bosch plant in Vietnam produces v ar iable t r ansmis sions belt s for automatic drive systems. In Thailand, Bosch manufac tures washing mac hin e s , w ip e r s , an d g a s o l in e s y s tem s . S ou t hea s t A sia is al s o becoming increa singly impor t ant for the Bosch Group’s global R&D n e t w o r k . T h e co m p a n y h a s h a d development activities in Singapore, Vietnam, Thailand, and Malaysia for several years. Besides expanding its regional presence, Bosch is also strengthening its brand communication in Southeast Asia. As part of the integrated branding campaign, Bosch actively engages with partners and resellers, educating them on their various product of ferings such as sensors deployed for milling, human-robot collaboration to drive the automotive industry, digitalisation of the manufac turing sec tor and automotive parts and components. The aim of the campaign wa s to showcase the industrial work that Bosch does but in a more consumer centric fashion. This drives greater brand recall, which in turn creates a ripple effect that helps people in the industry to recognise Bosch’s branding when they see it.

The new version will of fer two main features aimed at facilitating paper le s s manu f ac tur ing : A new web -ba s ed MBR (Ma s ter B atch Record) module which facilit ates t he managemen t of key proce s s parameters, native integration with the Siemens automation layer (SIMATIC PCS 7 process control system and HMI systems), and new access to electronic work instruction lists embedded in SCADA/HMI clients. Adnan added, “Here in Southeast Asia, especially in countries such as Singapore, Malaysia and Thailand, we are seeing increasing interests in paperless manufacturing solutions from the pharmaceutical sector.”

OGP SmartScope Flash CNC300 IS your parts demand high quality measurement control? OGP SmartScope has its unique Multisensor Technology capability – cooperating Vision, Laser, Touch-probe and Micro-probe in a single setup. All the sensors are calibrated to a single XYZ reference and its enhance GD&T accuracy. With powerful MeasureMind 3D MultiSensor software, the graphic and numeric analysis data are done in seconds. SmartScope Flash CNC300 features a compact 300x300x250mm XYZ axis multisensor capability and a high quality 12:1 AccuCentric® zoom lens:- an excellent optical performance with automatic calibration on each magnification changes.

ViciVision Optical Measuring Machine MTL 1 DO you use traditional method to measure turned parts? MTL1, a high precision optical measuring machine for all kind of turned parts:- such as transmission-drive/cam/electric-motor shafts, hydraulic/pneumatic/engine valves, CV joints, turbine wheels, fasteners/screws, etc. • Quick measurement:- collects hundred measurement in 10~30 seconds, compare to 30~60 minutes on traditional method • Efficient:- features with on-board step-master, this allows MTL 1 effectively used in the shop floor • Less human error:- non-contact type allows consistent and accuracy measurement (2um on diameter and 5um for length)

New from QVI: ZONE3® The World’s Most Comprehensive Metrology Software ZONE3 Metrology Software represents a totally new way of working with multisensor measurement systems. Its built-in 3D animations clearly display relationships between parts, sensors, datum alignments, and machine tooling. ZONE3 uses CAD models and other innovative features to automatically and effortlessly generate measurement routines. Truly 3D CAD enabled, ZONE3 is easy to use and can be learned with a minimum of training. Features Include:

Visit us at the following exhibitions

THAI METALEX

at BITEC Bangkok on 23rd to 26th Nov 2016

• Full 3D CAD programming.

• Interactive reporting with live data and graphs.

• ASME Y14.5 compliant GD&T functionality.

• Multisensor auto-path creation.

DMP 2016

at Donngguan Intl Exhibition Center on 29th Nov to 2nd Dec 2016

• Live kinematic model simulation of machine with DRF and GD&T Animation.

MANUFACTURING INDONESIA 2016

at JL Expo on 30th Nov to 3rd Dec 2016

Optical Gaging (S) Pte Ltd Multisensor Metrology

www.smartscope.com.sg

21 Tannery Road, Singapore 347733 Tel: 65 6741 8880 • Fax: 65 6741 8998 • E-mail: marketing@smartscope.com.sg Singapore • Malaysia • Indonesia • Hong Kong • South China Thailand • Myanmar • Philippines • Vietnam • Taiwan • Australia New Zealand • Middle East • Myanmar

ENQUIRY NO 145

BUSINESS NEWS • ASIA PACIFIC Asia Pacific Metalworking Equipment News • November - December 2016

Check On Shanghai Auto Dealers Lifts Sales Views

S h a n g h a i , C h i n a : A nal y s t s f r om Macquarie Research said October visits to dealer showrooms in Shanghai lifted views of a sales rebound in domestic SUV brands. “ We did a channel check in Shang hai la s t Friday and visited s ome au to de aler s w i t h a small group of investors,” analysts Zhixuan Lin, Allen Yuan and Janet Lewis of Macquarie Research said in an Oct. 17 note. “The overall impression is that demand for domestic brand SUVs turned very strong in 3-4Q, following some softness in the summer.” The analy s t s s aid dealer s for G r e a t W a l l M o t o r (G W M) n o t e d improved demand while of fering f e w e r di s co un t s , le a din g t o r e stocking efforts at car lost ahead of the seasonal peak buying season in the fourth quarter. “GWM recently launched some facelif ts of existing products (like the H2 Blue, H6 Blue, H6 Sport 2017 ver sion), w hich is supp or t i ve to demand and retail pricing as both the MSRP and retail discounts are lower now,” the analysts said. “The H7 is a successful model and t he de sig n and in ter ior are comparable to international brands. There is a waiting list now, mainly because of limited supply from the OEM (original equipment manufacturer).” A s w ell , demand for t he G AC Trumpchi GS4 has seen a waiting list in Shanghai with discounts not on offer unless buyers are willing to wait two months. At the same time, the Geely Boyue has seen a waiting list of up to 5 months, the analysts said, noting dealers are hesitant to guarantee delivery earlier.

A P P O I N TM E N TS

Indonesia Names Ignasius Jonan As Energy and Mineral Resources Minister Jakarta, Indonesia: Indonesian President Joko Widodo has named Ignasius Jonan as Energ y and Mineral Resources Minis ter of the commodit y-rich nation, ending a vacancy in the post caused by a previous appointee holding dual citizenship. Jonan, a former Transportation Minister, is tasked Ignasius Jonan with shoring up a key industrial sector of the economy hit by weaker global prices and demand in the past two years after a patchy record overseeing major infrastructure projects, including the US$560 million terminal Ultimate at Soekarno-Hatta Airport that was delayed in June 2016 and then hit by power and flooding problems after it opened in August. Jonan’s views are unknown on a full mineral ore export ban pending that was put in place by a 2009 Mining Law. Indonesia lacks the smelting capacity to handle potential output of ore minerals even as demand for finished metal products is expected to grow domestically.

China Subsidiaries Win $1.2Bn Deal For Boten-Vientiane Highway In Laos Vientiane, Laos: Contrac t s have been awarded to China Railway Group subsidiaries for civil work s on the f irs t three sec tions of the BotenVientiane railway. At present, a short metre-gauge branch of the Thai network which crosses the River Mekong from Nong Khai to reach a railhead at Tha Na Laeng is the only railway in Laos. The three contracts were awarded by Laos-China Railway Co Ltd to China Railway No 5 Engineering Group, China Railway International Group and China Railway No 8 Engineering Group, with a total value of 8.13 billion yuan. This means that China Railway Group has won a total of four of six lots for the project, as yet another subsidiary China Railway No 2 Engineering Group was previously awarded a 2.28 billion yuan contract covering Section Four of the project. Once completed, the 414 km standard gauge Boten-Vientiane Highway will start at Mohan on the China-Laos border and run south to the capital Vientiane and the Thai border town of Nong Khai. There will be 31 stations in total, including the cities of Luang Prabang and Vang Vieng. Additionally, the line will connect with China’s Yuxi – Mohan railway, as well as Thailand’s metre-gauge line leading to Bangkok. The highway’s single track electrified mixed traffic line will be built to China’s GB Grade 1 standards, with suitable alignment for 160 km/h passenger and 120 km/h freight services. Due to mountainous terrain, a total of 258.5 km of bridges and tunnels will be needed. The total cost of the highway is estimated at 37.4 billion yuan.

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ENQUIRY NO 147

BUSINESS NEWS • EUROPE & MIDDLE EAST Asia Pacific Metalworking Equipment News • November - December 2016

British Manufacturing Imports Hit By Weaker Pound UK: Many British manufacturers are facing higher cos t s for impor ted raw materials with the pound down around 17 percent against the dollar since the Brexit referendum on June 23, hitting investment plans for new machinery and throwing up the need for contingency planning on market access for firms from autos to food. Already, global automakers Nissan and Toyota that run factories in Britain have sought assurances on access to European Union markets that may be at risk if Britain fails in efforts to keep trade links in place as it exits the European Union over a two-year period that may begin March next year. Both f irms have said they may scrap new investment in car plants that are linked to the jobs of more

than 800,000 in Britain and are mainly foreign owned, according to the Society of Motor Manufacturers and Traders industry body. “Companies which operate in the United Kingdom will need to quickly re-assess their Brexit contingency planning in order to identify core areas of interest for the exit negotiations and understand how and where to engage to influence those discussions towards their commercial objectives,” according to global law firm DLP Piper. “Many UK companies will now be seeking to support and influence the UK Government in these vitally important negotiations.” Nissan, for example, builds around a third of Britain’s car output at Sunderland in northeast England and

has publicly said it is looking for a site to build its next Qashqai sport utility vehicle with a decision due in 2017 and suggested that Brexit would make Britain a more difficult choice. In addition to the uncertainty over market access, there is growing worry over a weaker pound since the vote, which has made metals more expensive to import along with machines and the raw materials to feed them in food manufacturing, raising concerns of food prices inflation. To be sure, export firms in areas such as pharmaceuticals that do not rely overwhelmingly on imports are benefitting from the weaker pound. But on the machine and equipment sales side new equipment is likely to be more expensive that before the sharp drop in the pound.

Lantek, Bystronic Launch Sheet Metal Production Partnership

Starrag Group: New Orders From USA’s Orizon Bolsters Business Switzerland: New multi-million dollar orders from aerospace supplier Orizon Aerostructures for Switzerland’s Starrag Group’s Ecospeed F2060 high-speed machining centres and an automated pallet shuttle system have deepened a relationship that began at the start of the year. They will be connected to form a flexible manufacturing system and allow the customer to manufacture aluminum aircraft structures at a lower cost than is possible using conventional fabrication methods. The system will feature integrated production system software, which will ensure connectivity between all components of the manufacturing system and facilitate preventive maintenance. Orizon bought its first Ecospeed F2060 in January 2016, and the added six machining centres and rail guided pallet shuttle system will aid the Oklahomabased firm to make a range of aluminium structural components at increased efficiency and productivity. Installation of the new system will begin in early 2017 and is scheduled to be completed by the end of the same year.

Switzerland: Leading sheet met al systems processing f irm Bystronic ha s joined hands with L antek to bring sof t ware solutions to bear on optimized produc tion of sheet metal, tube and prof ile par ts. The t wo companies, according to a press relea se, have entered into a long term technolog y par tnership and a strategic global alliance whereby Lantek will provide Bys tronic with manufac turing management sof tware systems and consultancy exper tise. “Bystronic want s to satisf y it s customers’ needs with a reliable and robust manufacturing management sys tem which has been widely te s ted wor ldwide to suppor t i t s excellence in machines and it s global sales network,” according to the release. “Lantek brings it s global presence, its sof tware engineering expertise, and its unique and power ful manufac turing management system, providing an ideal match for the manufacturer. Together, Lantek and Bystronic will

ENQUIRY NO 146

BUSINESS NEWS • EUROPE & MIDDLE EAST Asia Pacific Metalworking Equipment News • November - December 2016

be able to accelerate the pace of key developments.” Under the pact, the companies will develop an ME S s ys tem that can be seamlessly integrated with Bys tronic‘s machine sys tems and software, aiming for the realization of the digital factory for both Lantek and Bystronic customers.

Pemamek Signs Panel Line To MV Werften Rostock Shipyard Rostock, Germany: Pemamek signs a landmark deal with MV Werften to deliver Europe’s most advanced thin panel laser-hybrid welding line to MV Werften’s Rostock shipyard. The Rostock shipyard, located in the north of Germany, is one of the three largest shipyards in the German state of Mecklenburg-Vorpommern (MV). The a s sig ned deliver y is a par t of an investment programme of MV Werften. The contract covers designing, delivery, site training and assistance. “ W i t h t h e in v e s t m e n t in o ur Rostock yard and especially in this ne w and mo s t e f f icien t w elding method, we will further increase our steel prefabrication capacit y and thus improve our productivity,” says Jarmo Laakso, managing director of MV Werften. The complete solution of PEMA thin panel laser-hybrid welding line consists of most modern solutions available in the market s, such as integrated one sided welding and milling station, integrated prof ile assembling and welding station and robotised welding of T-beams to the deck panels, and more. T h e t h i n p a n e l l a s e r- h y b r i d panel line does not only contain welding processes, but the complete pr o duc t ion c hain f r om ma t er ial handling to milling providing highquality end products. It will enable MV Werften to improve manufacturing ef f icienc y and improve capacit y. Through the investment in advanced welding methods, the shipyard will acquire one of the most modern panel lines in whole Europe.

Fluke Acquires eMaint Enterprises Dublin, Ireland: Electronic tes t tool s and sof t ware provider Fluke has acquired eMaint Enterprises, LLC, a computerised maintenance management sof t ware developer. eMaint ’s sof t ware platform is used by more than 50,000 maintenance professionals in 55 countries providing asset management solutions in multiple markets including food processing, healthcare, facilities, fleet, services, and manufacturing. Fluke’s line of handheld test tools and portable sensors are commonly used by service and maintenance technicians, electricians and plant engineers around the world. eMaint’s web-based, Software as a Service solution can be accessed on PCs, smartphones, tablets, and other browser-based devices. Fluke tools, software and data expertise together with eMaint’s SaaS offering represents a convergence of maintenance solutions to ensure uptime and maximise return on assets for maintenance and operations managers. “eMaint brings not only world-class software development but the sales and customer support to help maintenance professionals succeed,” said Fluke President Wes Pringle. “Their leadership in maintenance management software combined with Fluke’s brand strength and expertise will drive new generations of connected technologies with groundbreaking levels of support for our customers.” The synergy between both companies will allow customers to utilitise both eMaint’s cloud-based CMMS with Fluke’s test tools and sensors, resulting in improvements in maintenance and reliability.

Carbon Announces US$81 Million In Funding And International Expansion California, USA: Carbon announced funding of US$81 million from new investors GE Ventures, BMW, Nikon and JSR, as well as existing investors, bringing Carbon’s funding total to US$222 million. Supported from new investors GE Ventures, BMW, Nikon and JSR, as well as existing investors, the company also plans to offer its proprietary CLIP technology internationally and is accelerating production to meet worldwide demand for its M1 printer. The company plans expand to Europe, Japan and other Asian markets. “In today’s digital world, additive manufacturing is changing how products are designed, made and serviced at GE,” said Steve Taub, Senior Director of Advanced Manufacturing, GE Ventures. “We are excited to work with Carbon as part of our vision in deploying additive manufacturing applications across GE.” Series C participants Nikon Corporation and JSR Corporation are exploring synergies making Carbon’s technology available in Japan as well as entry into other Asian markets. Nikon will bring their expertise in metrology and 3D data profile, including 3D measurement and X-ray CT. JSR, an important producer of fine chemicals associated with the manufacture of microelectronics, will enhance exploration of new materials and extension of Carbon’s supply chain. Carbon collaborates with manufacturing companies and service bureaus to deliver parts for customers in industries such as automotive, medical, apparel, and consumer electronics.

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BUSINESS NEWS • EUROPE & MIDDLE EAST Asia Pacific Metalworking Equipment News • November - December 2016

Renishaw Facility In Wales Hosts Training Theatre, Manufacture Ops Miskin, UK: Precision engineering firm Renishaw has officially opened a Healthcare Centre of Excellence in South Wales that mock non-sterile operating theatre for prac tice in delicate neurosurger y techniques and related training facilities a s well as a facility for the manufacture of class 3 custom medical devices produced on Renishaw

metal additive manufac turing (3D printing) machines. The site in Miskin, close to the Wel sh town of Cardif f, mark s the lates t push by the company in manufac turing for the healthcare s ec tor, including pat ientspecif ic impl ant s , dent is t r y and neurosur ger y, according to a press release.

The training centre in particular is part of an overall effort to allow neurosurgeons the oppor tunity to practise in situations that mimic a reallife hospital setting, but without the complication of a sterile environment. “In the s tate-of-the-ar t suite, which is lead-lined to enable X-ray use, sur geons c an be t r ained to perform highly complex stereotactic neurosurgery procedures using the Renishaw r ang e o f neurolo g ic al product s,” according to Renishaw, adding that related video and audio live feeds allow colleague to watch in an adjacent lecture theatre or to be streamed online to anywhere in the world. At the same site, the company makes cus tom medical devices under an ISO13485 quality management system and using its latest metal additive manufacturing machines to enable the precision produc tion of dental frameworks, craniomaxillofacial patient specific implants, jigs and guides.

GMTA Celebrates 25 Year Anniversary

Flexicon Opens German Office A schaf fenburg, Germany: Flex icon (Europe) ha s opened an of f ice in Aschaffenburg, Germany to provide factory-direct engineering services and technical sales support to customers throughout Germany. Keith Bourton, MD of the company said: “The Aschaffenburg location will fuel Flexicon’s rapid growth in the region by providing a dedicated Germanlanguage staff with full access to corporate resources.” Aschaf fenburg of f ice is headed by regional sales manager, Christian Löchler. He will be responsible for building relationships with plant engineers, managers and other equipment specifiers in facilities that handle bulk solid materials across the food, pharmaceutical, mineral, plastics and general chemical industries. The office will have full access to the company’s engineering resources, including details on more than 20,000 installations of Flexicon bulk handling equipment and engineered systems worldwide. Flexicon is widely recognised for their bulk handling equipment including flexible screw conveyors, tubular cable conveyors, pneumatic conveying systems, etc.

Chicago, USA: The German Machine Tools of America (GMTA) held a celebration in Chicago during the International Manufacturing & Technolog y Show (IMTS), commemorating the company’s 25th anniversary. The evening was hosted by Walter Friederich, president of GMTA, Scott Knoy, vice president sales, and Claudia Hambleton, chief financial officer. Mr Friederich welcomed guests with a speech thanking them for their support over the last 25 years, as well as mentioning the recent opening of their newest office in Queretaro, Mexico. The guests took part in a dinner buffet, open bar and the live band music while cruising Lake Michigan on a private yacht charter.

ENQUIRY NO 154

BUSINESS NEWS • THE AMERICAS Asia Pacific Metalworking Equipment News • November - December 2016

World Economic Forum Explores Fourth Industrial Revolution

San Francisco, USA: Global executive conclave organiser the World Economic Forum has opened a centre in San Francisco intended as a platform for exploring the frontiers of what is termed the Four th Indus trial Revolution, covering issues from technologies to ethics among scientists, company executives, academia and civil groups. The focus , according to the World Economic Forum, is to better understand the impact of the scientific and technological changes impacting the way we live, work and relate to one another. It is the first permanent, globally active office of an international organization in the Bay Area. “Given the accelerating change brought on by innovation, continuous public-private cooperation on a global level is needed more than ever,” said Klaus Schwab, Founder and Executive Chairman of the World Economic Forum, ahead of the opening in San Francisco. “This is the purpose of our Centre for the Fourth Industrial Revolution in San Francisco, which will serve as a global platform for dialogue and collaborative ac tion on the mos t important questions related to the impact of emerging technologies.” One key focus of the centre is to unders tand how disruptive technologies and scientific advances affect the economy and society, and facilitate the development of policy frameworks and norms to govern them, building off the proximity to nearby Silicon Valley where new business models such as artificial intelligence and robotics, precision medicine, block chain, drones and their civilian use, autonomous vehicles and 3D printing are all part of the mix.

Mitsui Seiki Blue Arc Billed As New Standard To Cut Tough Alloys New Jersey, USA: Japan’s Mitsui Seiki said the Blue Arc machining process has set a new standard in speed and the ability to cut tough alloys such as titanium and that its partner in developing the product, General Electric (GE), has a prototype ready and waiting for prospective customers to test. Scott Walker, president of Mitsui Seiki USA, told reporters on the sidelines of the Trends in Advanced Machining, Manufacturing & Materials (TRAM) conference held in Chicago in September, that he agreed with a GE assessment that the Blue Arc machining process “cuts through titanium like a hot knife through butter.” GE and Mitsui Seiki worked together to design and build a five-axis, horizontal machining centre with a Blue Arc head attached. The unit was built at Mitsui’s headquarters in Japan just outside of Tokyo. For its part, GE has the prototype machine in its global research facility in Van Buren Township in New Jersey in the USA and, according to a press release, it is ready for testing by interested companies. The crowning Blue Arc head is an electro-erosion metal removal method and represents the fastest way to rough cut extremely tough alloys such as aerospacegrade titanium and nickel alloys. “Using high amperage, low voltage electrical energy, sparks and heat are created between the electrode tool and the workpiece. During the sparking, electrical arcing activity, portions of the workpiece are melted and the molten material is quickly flushed away with a high-pressure system.” according to a press release. And the companies said that very low force is used during the process, allowing higher feeds and speeds that make Blue Arc about four to five times faster than conventional machining of these super tough materials. “Because of Blue Arc’s low forces, the process can eliminate a high-powered, high torque machine tool and highly engineered cutting tools and replace them with a smaller, less rigid machine and a simple electrode tool,” according to the release. “The process is ideal for difficult to reach, deep cuts and very thin cuts for applications in aerospace, power generation and automotive.” The prototype Mitsui Seiki Blue Arc machine available for companies to test is a hybrid that can handle Blue Arc and conventional machining on a single platform. In operation, the Blue Arc process conducts roughing operations and then the head is removed using a dedicated robot for the job. A conventional multiple-point cutting tool is then put in place to perform finishing operations.

BUSINESS NEWS • THE AMERICAS Asia Pacific Metalworking Equipment News • November - December 2016

Keep An Eye On Electric Cars For New Metal Demand Global: Elec tric car s are opening a wider window for metalworking firms looking to tap into automotive industry work as the need for more exotic metals and related components sweeps through the manufacturing c ycle and the number of elec tric and hybrid vehicles on t he road worldwide surpassed 1 million last year, according to the International Energy Agency. For the metalworking industr y materials that are used in electric vehicles are bringing once tangential comp anie s to t he au to indus t r y into focus such as New York-listed Albemarle and Australia’s Orocobre that produce lithium for electric car batteries. Most electric car batteries use lithium nickel manganese cobalt oxide cathodes and graphite anodes. At the same time, metals such as nickel, cobalt and manganese may see less demand and newer technologies aiming to use fuel such as hydrogen to power vehicles may revolutionize the industry. D e spi te t he po ten t ial f lu x in demand , machining and rel a t e d sectors of metal working are keen for growth in market that in some cases gets subsidies as part of pollutionfighting efforts and has a champion in high-flying entrepreneur Elon Musk’s Tesla Motors based in the U.S. But automakers around the world are also in the game and with varied s trategies , making it dif f icult to estimate what exact kinds of metals will be key as technology advances no t onl y for b a t t er ie s , bu t al s o other aspects such as replacement an d e n g in e p ar t s . F o r e x amp le , rare ear t hs such a s dy sprosium, neodymium and terbium from companies such as China’s Xiamen Tungsten and China Minmetals Rare Ear th are used in the elec tronic components of electric motors. At le a s t one fore c a s t by IHS Automotive said elec tric-powered vehicles will make up 4 percent of all light vehicles worldwide by 2020, or about 4 million units.

Airbus Group Extends Contracts With Hexcel Connecticut, USA: Hexcel Corporation’s two key contracts with Airbus Group have been amended and extended, and are expected to generate US$15 billion in sales. The existing contract relating to Hexcel supplying composite materials such as fabrics, resins, prepregs and adhesives for commercial aircraft, helicopters, space and military programs has been amended. Specific commercial programs covered include the A350XWB secondary structures, A380, the A320 and A330 family, and ATR commercial aircraft. The NH90, Tiger and EC135 helicopter programs are also included, as are the A400M military transporter and Ariane launch vehicle. A second contract to supply HexPly M21E/IMA carbon fibre prepreg for the primary structures of the entire Airbus A350XWB aircraft family (including the A350-1000) has been extended through 2030. Hexcel chairman, chief executive officer and president Nick Stanage said, “We look forward to our continued partnership with Airbus Group to develop innovative solutions to maintain their competitive objectives.”

Light Vehicle Sales Rise For Sixth Consecutive Year Global: A 1.7 percent increase in light vehicle sales saw a total of 86.8 million units sold across the world in 2015, according to Euromonitor. However, this was the lowest annual growth rate since 2010, and revised estimations point to a slower compound annual growth rate (CAGR) of 2.7 percent between 2015 and 2031. This is compared to a CAGR of 3.4 percent between 2000 and 2015. Sales of sports-utility vehicles (SUVs) have been pulling ahead in recent years, with global sales almost quadrupling between 2000 and 2015. As previously predicted, SUVs have now actually overtaken the lower medium cars (vehicles such as the VW Golf and Toyota Corolla) to become the largest single vehicle segment in 2015, with 22.9 percent of light vehicle sales globally. As such, the global CAGR for SUVs is predicted to be at a robust 4.8 percent. The small car segment is also forecast for healthy growth, due to key social changes such as urbanisation, increased female employment, smaller households and an ageing population, in conjunction with increasing emissions regulations. Small cars will enjoy an estimated global CAGR of 2.9 percent between 2015 and 2031. Rising incomes allow an ever increasing number of consumers to get off a bike and into owning a car for the first time. Additionally, there is significant growth potential for entry-level cars in markets such as India, ASEAN, and the Middle Eastern and African regions. China remains the largest light vehicle market since 2009, with 23.6 million vehicles sold in 2015 and accounting for more than 1 in 4 sales globally.

BUSINESS NEWS • THE AMERICAS Asia Pacific Metalworking Equipment News • November - December 2016

Do MSC Industrial Direct Earnings Point To Metalworking Slowdown? New York, USA: Third quarter results by US-based MSC indus trial have prompted investment research and management company Morningstar to downgrade it s outlook for the f i r m t h a t d o m in a t e s t h e U S $ 1 0 billion metalworking dis tribution segments of maintenance, repair, and operations. Morningstar senior equity analyst Kwame Webb said in a ratings update published on Oct. 18 that the fair value estimate for the U.S-listed firm dipped to $80 a share from $82 after third quarter earnings that showed a sales decline of 2% year-on-year to US$728

million, even as operating income rose 1% to US$106 million. Discussing the operating e n v ir o nm e n t , m an a g e m e n t s aid customers are becoming incrementally cautious, announcing plant shutdowns, initiating furloughs, and reducing their order activity,” Webb said. “The softer environment spurred management to predict fourth quarter average daily sales will decline 5% year over year relative to the third quarter’s 4% decline. Given these headwinds, we have reduced our sales growth rates for the remainder of fiscal 2016 and 2017.”

Schuler Press Assists With Overseas Expansion Mississippi, USA: Automotive supplier Feinwerktechnik hago GmbH recently opened a new site, hago Automotive Corp, in the southern USA. The key production system at the plant in Iuka, Mississippi is a 630 ton servo press from Schuler. “As an SME with little experience in internationalisation, it was extremely important to eliminate as many risks as possible”, explains Marcel Wegmann, authorised representative at Feinwerktechnik hago GmbH. The system can be used in a wide range of applications and is highly productive. As of 2017 it will be used to produce sheet metal parts for body shells, gear boxes and exhaust gas systems for a new off-road vehicle from a premium German manufacturer. “We see the Schuler press as a type of all-purpose weapon, which covers a very large part of our product portfolio”, says Marcel Wegmann. “It enables us to economically produce large parts in transfer operation as well as smaller parts using progressive dies with maximal stroke rate and accuracy.” An identical system located at hago’s headquarters in Küssaberg, Germany will also have an added advantage: “This means that we can also fully break-in and optimise complex dies that we have developed and constructed in Germany at the site in Küssaberg”, explains Marcel Wegmann. As a result, there is no need to run them in at the site in the USA.

MSC aids selling for nearly 3,000 suppliers covering 325,000 customers, according to Mornings tar and “differentiates itself by competing on deep metalworking expertise, quick produc t deliver y, and automated inventor y s tock ing and ordering solutions for customers.” Webb added that “these solutions make the purchasing process completely automated, so customers was te lit tle time ref illing orders. This emphasis on IT investment has raised website and electronic portal sales to greater than 50% of overall corporate sales.” But Webb cautioned there may be a distant threat to the model as suppliers consolidate in the face of headwinds and competition grows from a small, but growing, trend of buying groups. “If suppliers consolidate, that would increase disintermediation risk,” Webb said. “A related phenomenon is the buying consortiums that some private equity firms have assembled among their portfolio companies. We believe these buying consortiums are relatively rare and we would note that because the companies ultimately have to leave their PE sponsor’s portfolio, they have to return to independent distributors. There is an ongoing consolidation trend among customers and suppliers, but we do not view it as rapid enough to create a negative moat trend.”

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BUSINESS NEWS • THE AMERICAS Asia Pacific Metalworking Equipment News • November - December 2016

Hitachi Machine Room-Less Elevator For Asia And The Middle East

Tokyo, Japan: Hitachi Ltd and Hitachi Building Systems Co Ltd announced that they will launch a new machine roomless elevator for Asia and the Middle East. This elevator will be gradually released over time across countries in both regions. In recent years, there has been a growing demand for machine roomfewer elevators in the Asian and the Middle Eas tern market s. Machine room-less elevators are designed to have no machine room where a traction machine, a control board, and other lifting components are normally installed. Instead, these components are housed inside the hoist way. The new elevator model, which was developed in Japan, has basic specifications that meet the different standards of each country. The latest design and functions ensure a high level of safety based on the electronic safety technology. It also uses a regenerative operation system and LEDs to save on energy, while a deodorising ion generator helps to create a clean and comfortable environment in the car. While conventional models use me chanic al s afe t y dev ice s such

Tokyo Institute Of Technology Thinfilm Ferroelectric Material Eyed In Next-Gen Sensors

Tokyo, Japan: Researchers at the Tokyo Institute of Technology led by Hiroshi Funakubo and co-workers have demonstrated the potential of a new, thin-film ferroelectric material that could improve the performance of next-generation sensors and semi-conductors. The work centres on ‘ferroelectric’ materials that can switch between different states of electrical polarization in response to an external electric field. This f lexibility means they show promise for many applications, for example in electronic devices and computer memory. Current ferroelectric materials are highly valued for their thermal and chemical stability and rapid electro-mechanical responses, but creating a material that is scalable down to the tiny sizes needed for technologies like silicon-based semiconductors (Si-based CMOS) has proven challenging. Experiments to determine the ferroelectric properties of an inorganic compound called hafnium oxide (HfO2) were conducted for the first time. Crucially, the crystal structure of HfO2 allows it to be deposited in ultra-thin films, meaning it may prove invaluable for next-generation technologies. Ferroelectric properties stem from the shape and structure of the crystal used. The team knew that an ‘orthorhombic’ crystal of HfO2 would likely exhibit ferroelectricity. Funakubo’s team wanted to pinpoint the material’s spontaneous polarization and the Curie temperature (the point above which a material stops being ferroelectric due crystal re-structuring). To do this, they needed to grow a carefully-ordered crystal on a substrate, a process known as epitaxy, which would give them well-defined data on an atomic scale. The researchers found that one particular epitaxial film, labelled YHO-7, exhibited ferroelectricity with a spontaneous polarization of 45µC/cm and a Curie temperature of 450 °C (see image). The experimental results confirm earlier predictions using first principle calculations. From a scientific and industrial point of view, a Curie temperature of 450°C is of great interest, because it means the material could fulfil functions for future technologies. In contrast to many existing ferroelectric materials, the new thin-film exhibits compatibility with Si-based CMOS and is robust in miniature forms.

as switches and sensors, the new elev ator employ s hig h-precision electronic safety technology with a new microcomputer control system, resulting in an even higher level of safety. This is a new technology that is used to control -high-speed elevators that run at 1,200 m/min. An infrared sensor at the doors prevents boarding and departing passengers from getting caught between the doors. This sensor also flashes red to let users know that the doors are closing. The new elevator model uses LED

lights in the car, helping to reduce the lighting power to levels lower than conventional models with fluorescent lig h t s . In addi t ion , t he t r ac t ion mechanism acts as a power generator to transmit power back to the electrical network in the building. Hitachi will begin sales of this new elevator model in the Middle East and countries across Asia, including Thailand, Philippines , and India . Through these activities, it aims to receive orders of approximately 5,000 units in the regions.

METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ November - December 2016

Bearing Industry Mass Production

GATHERS PACE

Soaring demand for specialised bearings is driving fastpaced changes in mass production techniques aimed at quality and price. By Robi Nudelman, Bearing Industry Manager, and Yair Feraro, Application Engineer at Iscar.

Editorial

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earings are necessary for almost any mechanical system and many other element s that require rot ational motion. If something, turns, twists or moves, it most likely has a bearing in it. Today, the most popular bearing type in the market is the ball bearing, but roller bearings, needle, tapered, spherical and thrust bearings are also quite common. The sizes of bearings variously range from very small diameters such as 2 mm for electronic systems up to diameters of 6000 mm mostly for wind power turbines. Linear

bearings and bearing housings are also part of the industry, but with different geometrical characteristics. Key For Automotive Industry When talking about bearings, one of the most demanding industries today is the automotive industry. Every car has an average of 100-150 bearings, while motorcycles have between 2530. With an annual production rate of over 93 million cars and 140 million motorcycles a year, the demand for bearings is higher than ever and continues to rise. The need for bearings is also increasing in other industrial sectors such as machine production, electrical appliances, construction and infrastructure machinery, and aviation, power generation. Along with the remarkable increase in bearing produc tion, there is pressure on bearing producers to reduce costs. Because of the demands for lower prices, several leading companies are building new production plants in countries such as China, India and in Eastern Europe where manufacturing costs are less. Faster Machining Cycles In addition, many of bearing manufacturers are looking for faster machining cycles and more efficient processes to enable them to fulfill market requirements. They are also trying to find options to minimise raw material loss by optimising their machining methods and replacing old tech tools that can no longer withstand the high machining conditions and long tool life requirements. In the world of bearing production, it is very important to stay well prepared with the most innovative tools as competition is aggressive and non-efficient machining processes may cause a loss of business. Iscarâ&#x20AC;&#x2122;s experienced engineers are capable of supporting any bearing design with advanced machining solutions that can ensure maximum performance, efficiency and preciseness. Most of the small to medium size bearing diameters are mass produced on multi-spindle machines or on simple single-task machines that are only able to per form one or two operations on the machined rings, and a few machines of this type are needed to complete an entire part. Knowledge And Experience Knowledge and experience are needed to provide comprehensive solutions for a variety of these applications with very efficient tools for Parting, Trepanning, Grooving, Profiling and Turning operations.

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

The need for bearings is also increasing in other industrial sectors such as machine production, electrical appliances, construction and infrastructure machinery, and aviation, power generation. Many I s c ar in s er t s ar e de s ig n e d a s multi-corner inserts such as the Penta, and feature economic advantages due to their five cutting edges. These inserts are mostly used for parting-off operations; seal groove machining, and raceway grooving, among other areas. The unique structure of the Penta inserts e n ab le g r in din g unl imi t e d numb e r s o f different shapes and geometries with a very attractive cost per edge; thus assisting Iscar customers reduce production costs enabling them to easily compete with their products. P en t a in s er t s c an al s o b e u s e d f or Trepanning which is an axial operation for the separation of one thick forged ring to two separate outer and inner rings. For such operations, Iscar also offers other types of inserts such as BGR and BGMR for wider rings that dictate deep separation operations. Multi-Parting Systems Developed multi-par ting s ys tems for customers that feature an assembled set of parting blades or adapters designed for parting a few rings at a time are now offered. Such sets are provided with the very popular Tang-Grip and Do-Grip insert, and also with the Penta inser t s. Such par ting sys tems dramatically shorten one of the most common operations in bearings production. Iscar’s unique parting-off products are provided in very narrow sizes that enable manufacturers to signif icantly reduce the width of inserts, down to 0.7 and 1.0mm, and therefore save on raw materials. Such savings help produce up to 15 percent more rings out of existing steel tubes. Iscar’s Turning division provides a large variety of latest geometries and carbide grades as well as Ceramic and CBN inserts for f inish turning operat ions of harden bearing rings up to 64 HRc. CBN inserts with chipformers are Iscar’s solution for such

operations and can easily replace expensive grinding processes. For wide profiling operations on multispindle machines, Iscar has the V-Lock and FTB inserts that can provide a solution for wide profiles of 10 up to 51mm width. For large bearing rings, Iscar has developed unique drills based on the popular Sumo-Cham drills and the unique FCP inserts that provide outstanding performance and superior surface quality in such heavy duty drilling operations. Most bearing manufacturers (excluding spe cial s) re quire ma s s produc t ion and exact preciseness when meeting deadlines and quality. Iscar has the knowledge and experience to provide comprehensive solutions for a variety of applications in parting, grooving and profiling, turning, drilling and milling.

Top: Profile turning with Iscar’s YNMG 25 degree insert. Above: Parting with Tang-Grip.

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

Sandvik

The Age Of New Materials:

IS THE FUTURE NOW?

Editorial

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8002 Turn to page 80a to enquire or log on to: www.equipment-news.com

emands from industry are requiring that materials be lighter, tougher, thinner, denser and more flexible or rigid, as well as to be heat- and wearresistant. At the same time, researchers are pushing the boundaries of what we imagine is possible, seeking to improve and enhance existing materials and at the same time come up with completely new materials that, while years away from day-to-day use, take us down entirely new technological pathways.

Graphene is a single atom thick (1 million times thinner than a human hair) but 200 times stronger than steel by weight, extremely flexible, super light and almost transparent with great heat and electricity conductivity. It’s the stuff legends are made of. In fact, researchers at Nankai University in Tianjin, China, recently found that a graphene sponge can turn light into energy, thus taking humankind one step closer to a fuel-free spacecraft, one that runs by the light of the sun.

Sky’s The Limit Based on the research we’re seeing today, the field of applied material science is set to move in new, almost science-fiction-like direc tions. Looming resource scarcit y is demanding innovations and out-of-the-box thinking. On the materials front, composites with such desirable attributes as low weight, high strength and high durability look likely to take a larger market share, and more of these materials will likely be based on renewable resources, as the need for this becomes greater. The most promising jewel in this arena is graphene.

Heading For The Graphene Revolution Graphene was discovered almost accidentally when professors Andre Geim and Kost ya Novoselov at the University of Manchester in England experimented with pencils and sticky tape in 2004. In 2010, Geim and Novoselov won the Nobel Prize in physics for their graphene research, and the European Union subsequently committed 1 billion euros to fund the Graphene Flagship, a research initiative aimed at speeding up the development of commercial applications. Potential area s of application range from water purification and energy storage to household goods, computers and other

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

Death Of Metals? Metals have dominated industry, defining entire periods of human history. Such long-term use has created a wealth of information and expertise, but scientists and researchers continue to work to extend the boundaries of these materials. Nanomaterials f igure prominently in this research, enhancing metals and opening up new application areas. Developments in metal matrix nanocomposites – composites that partially consist of carbon nanotubes or nanoparticles – could usher in a new era of weight reduction in the aerospace industries, with added strength and stiffness. Self-Healing Properties Nanocomposite research is opening up the possibility of materials that fix themselves, much the way the human body heals itself. Researcher s at the Beckman Ins titute’s Autonomous Materials Systems Group at the University of Illinois in the United States are working on fibre-composite materials with selfhealing properties that involve the integration of healing agents that are released to mix and polymerise when a defect is detected. “Materials that heal themselves are coming,” says material scientist Mark Miodownik. For now, what’s technically possible isn’t close to being reasonable economically, but the possibility of fixing anything on the fly, from airplane wings to bike frames to car parts crucial to the safety of vehicle and passengers, is on the horizon. And it will have massive impact on product development, life cycle and sustainability. Researchers are even working on materials that will allow a roadway to repair itself instead of waiting for an overworked, understaffed maintenance crew.

Sandvik

electronics. Meanwhile, although graphenerelated patents are increasing by the thousands, widespread industrial adoption of graphene is limited by the expense of producing it – but that may be about to change. Researchers at the University of Glasgow have found a way to produce large sheets of graphene at a cost some 100 times cheaper than the previous production method. Synthetic skin, capable of providing sensory feedback to people with limb prostheses, is one of the many possibilities that could grow out of this development. “Graphene could help provide an ultraflexible, conductive surface that could provide people with prosthetics capable of providing sensation in a way that is impossible for even the most advanced prosthetics today,” says Dr. Ravinder Dahiya, who led the research team at the University of Glasgow. Outperforming Nature For thousands of years, material science moved forward through a series of accidental discoveries of materials that existed in nature. Today researchers are looking beyond what’s in the natural world, combining multiple conventional materials or parts of materials and focusing on the inherent structure or pattern, to create properties that do not exist in nature – or at least haven’t been discovered thus far. One such development is an arrangement of ridges formulated to resemble a shark’s skin. The micropattern, named Sharklet, protects against the harboring and transmission of bacteria and is being developed for use in hospital and health-care settings. Another materials development involves invisibility. Physicists in several countries are working on metamaterials that hold the promise of rendering objects invisible by cloaking them with a material that can bend the electromagnetic radiation, such as light, around an object, creating the illusion that it isn’t really there. Key Driver: Sustainability Material science and the development of new materials, as well as improvement of existing ones, look likely to play a crucial role in such areas as resource scarcity and sustainability. New materials – for example, light-absorbing building material s – could help counter global warming. We seem to be on the verge of a new age, one that is characterised not only by digitalisation and the Internet of Things but also, importantly, by new materials – materials that can make our future easier, safer and more sustainable. The sky really is the limit.

Molecular representation of graphene.

METAL CUTTING

PRESS BLANKING LINE To Cut Steel

Asia Pacific Metalworking Equipment News • November - December 2016

straightener prepares the material before the highly dynamic roll feed guides it with a maximum speed of over 200 metres a minute into the blanking press. The sensitive blanks are then de-stacked using the “Stop2Drop” process. The state of the entire line can be permanently monitored during this time by means of Condition Monitoring.

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olk s wagen’s ma s sive Wolf sbur g manufacturing plant in Germany has installed a TwinServo Technolog y press blanking line from Schuler with a production capacity of 33,000 blanks a day, replacing three older machines The automobile manufacturer uses it to cut sheets of steel for its entire plant, which are later formed into engine hoods, doors or roofs. The line has replaced three older machines. The new “Route 20”, as it is known internally, produces around 33,000 blanks a day. This represents an increase in production capacity of 25 percent. In a performance test at the start of August, the system actually produced 52,000 blanks within 24 hours – and there were ten setups during this time. Thanks to the high availability of the press blanking line, the setup can be performed in less than ten minutes (“Single Minute Exchange of Die”, SMED). The compact design of the 800 ton TwinServo press at the heart of the line reduces the footprint by around 30 percent, and the moving bolsters and dies are easier for operators to access. With fully automatic coil loading, including cutting and moving in, the strip can also be replaced in no time at all. The high-precision

Other Automotive Users The TwinServo Technology (TST) was unveiled in 2012. In the meantime, several companies have decided for the further development of Schuler’s ServoDirect Technology (SDT), which has established itself on the market – like automotive supplier Fischer & Kaufmann (Fiuka), who improves both product quality and die life with a TwinServo press. “We already have a number of presses from Schuler and Müller Weingarten in operation,” said Site Manager Tobias Heutger. “The quality and performance are always exactly right for us.” With the new TwinSer vo press, Fiuka now has the most modern line available on the market. “We are generally open for new technologies,” says Heutger. “Ultimately though it was the price-performance ratio which wa s decisive. Compared to our conventional presses, we can more than double the number of strokes per minute from a maximum of 16 to 34 now.” Opposites Combined TwinServo Technology features two decentralized servo motors in the press bed. This new design makes it possible to combine properties and characteristics which used to be regarded as contradictory. The result: benefits for the user which cannot be achieved with conventional press designs. In a traditional press, the slide is pushed downward – thus closing the die and generating the press force. The resulting reaction force has to be absorbed by the press frame. Due to restric tions caused by par t transpor t considerations, presses are often designed in two parts clamped together by tie rods. The

METAL CUTTING

force is then distributed over the entire press frame and the pre-tensioned tie rods. In the TST design, the slide is no longer pushed downward but pulled downward. This makes the force flow much more direct and thus reduces deflection by around 30 percent. Favourable leverage effects with force application points toward the outer edges result in geometrically enhanced conditions and offcentre force applications. This improves tilting resistance by up to 400 percent compared to conventional machines. A further decisive benefit: as the force application points on the slide are located further toward the edge, the entire clamping surface can now be used: This means one can achieve both greater eccentricities as well as greater eccentric loads in absolute terms â&#x20AC;&#x201D; which are particularly important for multistation presses. In addition to the rigid construction of the press, slide tilting can also be actively influenced during strong eccentric loads by regulating the two electronically linked drives of the TwinServo press. This also results in shorter try-out times and reduced die wear.

Admissible press force [kN]

Asia Pacific Metalworking Equipment News â&#x20AC;˘ November - December 2016

Additional usability of TST TST 10.000 kN Conventional 10.000 kN

Eccentricity [mm]

With the same useful space as a conventional machine, the external dimensions are much more compact. As a consequence, the press has a smaller footprint and also fits in halls with lower ceilings. Although the drive has been integrated into the press bed, the foundation dimensions and underfloor space requirements have not increased, and accessibility for service and maintenance remains good.

As the force application points of the slide are located further toward the edge, this opens up new possibilities for part production.

ENQUIRY NO 132

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

Schuler’s Tianjin Demonstration Centre Launched

Since the oil-lubricated drive parts are separated by seals, the press work area is largely oil-free.

The automobile manufacturer uses it to cut sheets of steel for its entire plant, which are later formed into engine hoods, doors or roofs. The line has replaced three older machines.

Drive Parts Separated The oil-lubricated drive parts in the press bed are separated by seals from the press work area. As a result, the work area can be said to be largely oil-free. This also prevents the formation of the dreaded oil mist – which sooner or later precipitates as an oil drop in the work area. The compact design of the TST means it can be completely enclosed by sound insulation. As this sound enclosure stands freely and is not connected to any machine parts, there is no transmission of structure-borne sound. Compared to conventional presses, noise emissions are reduced by around 15 decibels – corresponding to a halving of noise pollution for employees. The stated benefits are further enhanced by the possibilities offered by modern servo drive technology. Such drives enable the user to actively influence the speed of the forming process. In combination with various operating modes, such as full stroke or pendular stroke, users can achieve significant output gains over presses operated with flywheels.

German metal forming technolog y f irm Schuler launched the first technology centre for forming technology systems in China’s industrial metropolis of Tianjin, aiming at automotive manufacturers, suppliers and other companies from the sheet metalprocessing sector. The facility allows potential customers to try out a servo press from the latest generation with the Servo TechCenter Tianjin marking the company’s first demonstration centre in Asia and located in the largest press market in the world. “We support our customers in optimising

In China In September, Schuler launched a technology centre for forming technology systems featuring a TwinServo press with an innovation day. The demonstration and reference centre in the Northern China industrial metropolis of Tianjin offers automotive manufacturers, suppliers and other companies from the sheet metal-processing sector the opportunity to try out a servo press from the latest generation for themselves. The Servo TechCenter Tianjin is Schuler ’s f ir s t demons t rat ion cent re across all of Asia and forms a key part of the company’s strategy, to be ranked among the leading providers in China, as the largest press market in the world, in all the key price-performance sectors.

their productivity and therefore becoming even more successful”, Chief Operating Officer, Dr. Peter Jost said at the launch. “Our first TechCenter in China has not only put our technological leading position to the test, but also underlines the significance of the Chinese market for Schuler’s future growth.” Schuler has operated in China since the early 1990’s and recently bought Chinese press manufacturer, Yadon, in the middle price-performance segment. In addition to Tianjin, Schuler al so offers customer-specific consulting services at the German sites in Göppingen, Erfurt, Gemmingen and Heßdorf as well as at the US TechCenter.

ENQUIRY NO 142

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

met al , of fer s a comprehensive range of machinery specially designed for aluminium and other light metals. The K a s to por t folio includes a wide selec tion of machines in all sizes, from semi-automatic floor-standing circular saws for workshops to gantry-type band sawing machines for aluminium mills. Kasto, based in Achern, Black Forest , Germany, of fers dependable and efficient solutions for sawing tubes, profiles and solid materials as well as sheets, plates, ingots and castings. The range includes versatile multipurpose saws for various materials, plus saws that are optimised for machining aluminium.

Aluminium Tubes, Sheets, Ingots Needs

SPECIALISED

CUTTING TOOLS Cutting aluminium requires a range of machinery depending on the end-use application that vary from aircraft to window blinds with techniques that rely on higher speeds and lower cutting forces compared to metals like steel to ensure optimum cutting geometry. By Stephanie Riegel-Stolzer, member of the Kasto management board.

Editorial

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luminium is used for a wide range of purposes in construction, including facades, blinds and window elements. But it has applications in many other areas of manufacturing as well: ships, aircraft, motor vehicles, machines and household goods. When it comes to machining of aluminium, numerous companies rely on the sawing technolog y of Kasto Maschinenbau GmbH & Co. KG. The company, which is a leader in sawing and storage of bar stock and sheet

Special Characteristics Owing to aluminium’s special characteristics, the rules for sawing it dif fer from those for other materials such as steel. Cutting speeds must be higher and cutting forces lower. To ensure clean, exac t cut s, it is especially impor tant to have an optimum cutting geometry along with good lubrication and cooling. Chips can readily cause problems owing to the high speeds and must be removed in an effective manner. Users who saw aluminium on a regular basis are therefore advised to purchase a machine that is specially designed for this purpose. The Kastoalu range comprises a number of floor-standing circular saws for use in workshops. They are especially suitable for aluminium, other light metals and plastics. High-Performance Carbide Their high-performance carbide saw blades have trapezoidal flat teeth with a positive cutting angle, ensuring perfect results even at low cutting pressures. Users have a choice of saw blades with different numbers of teeth depending on the panel and plate thickness. This allows the creation of reproducibly precise, burr-free cut parts. Less work is required for reworking, and the parts can be further processed or installed right away. The Kastoalu range includes the semiautomatic models E 12 / U 12, U 14 and U 20, which cover a cutting range from 100 to 200 mm (for tubes and profiles), as well as the fully automatic, numerically controlled Kastoalu A 13 with a cutting range of 100 mm (likewise for tubes and profiles). The semi-automatic saws are capable of straight and mitre cuts, with an increment-free mitre angle between ±45° and ±90° depending on the machine. The Kastoalu A 13, in contrast, is suitable only for straight cuts. All the models have a

METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ November - December 2016

hydro pneumatic, infinitely adjustable saw feed plus pneumatic horizontal and vertical clamping elements. An efficient micro-spray lubrication system and an integrated air gun come as standard, and a connecting sleeve for installing a chip suction unit is standard as well. Various roller tracks and measuring systems are available as optional accessories. Kasto developed its Kastospeed M line for low-cost, high-volume cutting of aluminium, copper and brass. This circular saw is available in two versions, with a cutting range of up to 90 mm or up to 152 mm (round stock). The robust machine construction with an obliquely meshing spur gear mechanism, combined with a hydraulically damped measuring stop and a bar pusher that can be moved rapidly into position, ensures precision cutting and very high output. Saw Blades Depending on the application, high-speed steel, carbide tipped or PCD saw blades are used. Material feeding and sorting can be adapted to the customerâ&#x20AC;&#x2122;s requirements by means of a well-designed modular system. The band saws of the Kastotec M series provide a quick, economical solution for all common aluminium materials up to a diameter of 830 mm (round). A spindle-driven material advance slide exactly positions the material to be sawn. Precision-balanced drive elements permit very high cutting speeds in combination with smooth running that is kind to the tools. Specially designed blade guides support the tool and form short chips that are easy to dispose of. The Kastotec M also has a selfexplanatory control system with a clearly structured interface that makes operation much easier and reduces set-up times. The Kastovertical M is the ideal machine for efficient sawing of small aluminium ingots, plates, castings and test strips with a maximum height of 600 mm and a length of up to 1,250 mm. A moveable material support table ensures quick, safe handling of stock.

makes operation easy. For material wit h l ar ge dimensions , Kastomaxcut is the product of choice. This gantry-type band sawing machine is suitable for fully automatic sawing of aluminium plates with a thickness of six to 2,000 mm. Depending on the version, the Kastomaxcut can handle ingots with cross-sections of up to 2,200 x 850 mm and lengths of up to 4,100 mm. Its heavy-duty design makes it suitable for medium-scale to very-large-scale production. The cutting speed is continuously variable from 300 to 3,000 m per minute. Nevertheless, the saw runs very quietly and without vibration. The Kastomaxcut can be operated with both bimetallic and carbide blades. Aluminium Plates, Ingots This heavy-duty machine is used in aluminium mills and other facilities. For example, Gleich Aluminiumwerke in Kaltenkirchen, Germany, uses the saw to manufac ture aluminium plates from ingots measuring 2,000 x 4,000 x 800 mm. The company supplies customers in the mechanical engineering, tool-making, aerospace, automotive and cons truc tion industries. The machine has significantly increased saw blade lives and reduced downtimes, at the same time offering a high cutting precision. Moreover, thanks to fully automatic operation the company was able to increase its production while maintaining consistently high quality. The Kastomaxcut is equipped with strong roller tracks and transverse conveyors plus a vacuum transfer unit to handle the ingots, which can weigh up to 15 tonnes.

Depending on the application, high-speed steel, carbide tipped or PCD saw blades are used. Material feeding and sorting can be adapted to the customerâ&#x20AC;&#x2122;s requirements by means of a welldesigned modular system.

Kastowin pro AC 5.6 Metal sawing and storage specialist Kasto has brought out a new highperformance band saw, the Kastowin pro AC 5.6, highlighting short cutting times, long tool life and intuitive operation in the fully automatic

Cutting Speeds Precision-balanced drive elements and specially designed blade guides permit cutting speeds of up to 100 m per minute and high cutting performance while ensuring a smooth sawing process with minimal tool wear and an optimal operational lifetime. The band wheel housing is designed to optimise the path of flying chips to a suction device. The cut ting speed and feed rate are continuously adjustable, and the Kasto BasicControl system with colour-touch screen

machine optimised for bimetallic and carbide blades. The equipment can be applied across steel production, forging mills, machine manufacturing and the automotive industry. The Kastowin pro AC 5.6 boasts an innovative feed system controlled by means of two ball screw spindles, each with a servo drive for precise, infinitely variable control. The Kastowin pro also has a retraction unit on each side for lifting the band from the surface when the saw head moves back. This makes for particularly efficient, exact sawing with minimal tool wear. In addition a powerful coolant pump and a large coolant reservoir aid in handling difficult-to-machine materials with minimal tool wear.

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

ADDITIVE MANUFACTURING Lifts Space Satellite Antenna Getting a sensitive space satellite antenna bracket to operating optimally means calling additive manufacturing to the rescue. By Terence Oh, Vice President (Asia Pacific), EOS Singapore.

Editorial

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or many people, talking of the infinite vastness of the universe conjures up stories of science fiction, usually told by a Hollywood film studio. However, in real life, more than in any other area, it is arguably in space travel that a strong will and clear vision are vital for creating the necessary technology and readying it for deployment in the cosmos. This was the challenge faced by one of our customers, RUAG – a Swiss technology group with global operations, active in the fields of aerospace, defense and security – in the construction of its Sentinel satellite, designed for observing our planet from on high. Even here, beyond the Earth’s atmosphere, additive manufacturing is playing a key role. Weight Counts According to reports by the German Centre for Aerospace (DLR) from 2016, the mission costs of space exploration per kilogram of transported payload are upwards of €20,000 (US$22,118). Ever y single gram saved reduces total launch costs, as the system requires less fuel for the ascent. As a result, aerospace engineers need to shave every possible gram from every component – as excess weight accumulates

rapidly. In this case, the Swiss RUAG group was in need of an optimally designed antenna bracket. Yet weight optimisation alone is not enough. During a rocket launch, the payload gets well and truly shaken up and the level of vibration is considerable. Also, the enormous speeds of several thousand kilometres per hour, not to mention the high G-forces, mean that the flight will not be as smooth as you would expect on a passenger jet. Stability and rigidity form a second essential on any specification sheet. Unfortunately, this requirement is usually diame t r ic ally opp o s ed to t he ne ed for lightweight design. Engineers To The Rescue Engineers employ complex structures to identify a workable level compromise between form and weight. The RUAG team sought the optimum combination of strength and weight for the structure of its antenna bracket, as conventional manufacturing methods had been exhausted. Thankfully, additive manufacturing provided the perfect possibility of achieving the necessary freedom of design, minimising weight and integrating functions.

METAL CUTTING Asia Pacific Metalworking Equipment News • November - December 2016

Antenna bracket changes for Sentinel satellites (EOS GmbH)

Original design

Optimised topology

Component tes ting represented a particular challenge, not least because of the aforementioned vibration. In outer space, reliability counts, as repairs are generally not possible. This also explains why the authorisation of such components is such a protracted and complex process. Every certification represents an accolade for the engineers who have achieved it. In such cases, the complete production chain plays an important role, particularly in the aerospace sector. Fundamental suitability and rigidity testing formed the star ting point of the antenna bracket’s design. The next step comprised the selection of material, definition of processes and initial basic tests in respect of the material characteristics. Theoretically Perfect Form The initial test structures then constructed, to serve as the starting point for the topological optimisation of the component. RUAG was eventually able to achieve the theoretically perfect form for the antenna bracket, through a combination of intensive work with a CAD and FEM system from Altair and guidance from EOS on design and construction using additive manufacturing. The approximately 40cm long antenna bracket was produced by citim GmbH from Barleben in Germany using the EOS M 400. With a construction volume of 400 x 400 x 400mm, it was possible to produce two antennas, 30 tensile test pieces and various test items in a single construction order. The construction time was approximately 80 hours. The parameter set used was for a layer thickness of 60 µm, optimised for surface quality and productivity. The aluminium alloy used, EOS Aluminium AlSi10Mg, is characterised by high strength and strong resistance to dynamic stress, making the material perfectly suited for use with high-stress components. Comprehensive tests were carried out to demonstrate the required characteristics — in the aerospace sector, these comprise up to 80 percent of the total scope of

Redesigned anetnna braket

a project. Specially manufactured structures were used for testing. Among other things, engineers examined the brackets in computer tomography. Various mechanical and physical procedures were also performed. At times, the stresses brought to bear on the component deliberately exceeded the load limit s, ultimately leading to the destruction of the test pieces. Exceeding Expectations The result of these efforts was that the new antenna bracket for the Sentinel satellites exceeded all expectations. The component was awarded certification and with that, the approval for its utilisation in outer space. The achievement is all the more remarkable considering that the use of additive manufacturing in space is still in its infancy. For example, the component’s minimum rigidity requirements were exceeded by more than 30 percent — a margin that is easily sufficient to ensure that, even after a turbulent flight, an ideal antenna position could be attained — and radio communication with Earth guaranteed. The required level of stability was achieved, in part because of the highly uniform stress distribution. Moreover, the use of additive manufacturing led to a significant reduction in the weight of the final component: down to 940g from 1.6kg, representing a saving of over 40 percent. In this instance, the use of innovative technology succeeded in achieving an unlikely combination: improved component characteristics and lower system costs. W i t h addi t i ve manu f ac t ur ing , w e’ ve enabled our cus tomer to not only enter unchartered territory on the process side, but also be rewarded with a stable, lightweight component. Clearly, it has shown that it can fulfil the fundamental procedural demands of space travel. So, while Hollywood tells exciting stories, innovative technology continues to live them every day, extending the frontiers of design and construction.

Fundamental suitability and rigidity testing formed the starting point of the antenna bracket’s design.

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • November - December 2016

Worker at Otto Ackermann

Cubic milling part

The Right Coolant Becomes

A LIQUID TOOL

If you want to be successful as a contract manufacturer and as a supplier to businesses, working on reliability, flexibility and precision count most. By Blaser

Editorial

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8101

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t to Ackermann AG from Lachen specialises in machining manufacturing of ultraprecise parts. As an important partner of renowned industrial companies, the Swiss company has in the past 48 years made its name in the field of CNC machining of aluminium, non-ferrous metals and plastic, and this name stands for the highest quality and precision. “However, we primarily specialise in aluminium machining”, says Otto Ackermann, Chairman of the Board and Founder of Otto Ackermann AG.

Tool Life Twice As Long The heads of production at Otto Ackermann realised there were quality fluctuations in the coolant used up to that time, which led to problems — especially in the case of thread cutting. In order to improve the quality of the manufactured precision parts, the safety and the stability, attempts were made to find a perfectly suitable coolant for the needs of Otto Ackermann. “In the case of aluminium processing, it is also important to make sure that the workpiece does not become wet, as it has to remain clean and stainless for fur ther processing. We were only able to achieve all of this by using Blaser Swisslube’s coolant solution,” says Otto Ackermann. Simplified Monitoring And Performance The installation of a 17 cubic metre central system simplif ies coolant monitoring and maintenance. “Our production is spread over several buildings and various levels. By means of the central system, we can achieve the same temperature on all machines, which also helps to strongly improve the precision of the parts. Furthermore, this significantly simplifies the maintenance, as everything can be found in the same place,” Otto Ackermann adds. The result of the coolant changeover is rather impressive: Blasocut 2000 Universal, the coolant recommended and used by the Blaser specialists, was able to double the tool life.

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • November - December 2016

Apart from that, employees rarely had to cease their work due to allergic skin reactions. “I care very much about the health of my staff. This is why it was so important to me to find not only the best coolant for the machines, but also a skin-friendly solution for our employees, because let’s be honest - the greatest potential of any company are the people working there, and you have to take care of them,” Ackermann says. Customised Maintenance, Servicing Concept Furthermore, in cooperation with Blaser, a simple maintenance and servicing concept for the production facility was developed and implemented, and systematic and regular monitoring of the coolant was introduced. “An employee checks the concentration of the emulsion on a weekly basis using a refractometer measures the pHvalue and checks the entire central system. Once a month we send a sample of the coolant to Blaser Swisslube’s customer service laboratory, after which we receive an e-mail containing an evaluation of the laboratory examinations. This is an important point for us, as in this way we are always on the safe side and - if necessary - receive recommendations from specialists”, Otto Ackermann explains. “A coolant which is ideally suitable for the customer’s requirements must be regularly monitored and maintained, as this is the only way it can become a Liquid Tool and can let machines and tools develop their full potential,” says Blaser Swisslube’s application engineer in charge. Continuing Optimisation Together “Thanks to our company-owned technology centre, we have the ideal prerequisites for simulating and testing the most diverse machining operations of our customers. After we achieved very good results in aluminium processing using our B-Cool 755 coolant, I recommended this product to Otto Ackermann last year. I was certain that we would achieve even better results using B-Cool 755,” Blaser’s application engineer explains. Otto Ackermann adds: “We changed over to B-Cool 755, and the results were convincing. The consumption was reduced yet again thanks to the lower top-up rate, the machines have become even cleaner, and the tool life has increased, too. Ultimately, I can only say that the cooperation with Blaser is going brilliantly. We have never regretted this step. It was a close cooperation from the very beginning, and Blaser constantly supports us, so that in the future we can be even more productive and economical.” The Liquid Tool Blaser Swisslube’s goal is to optimise its customers’ manufacturing processes with the Liquid Tool and to improve their economic efficiency, productivity as well as the machining quality. In close cooperation with the customers and based on a holistic view of the manufacturing process, Blaser Swisslube presents the possibilities to fully exploit the potential of machines and tools by using the right metalworking fluid which becomes a Liquid Tool. This promise is backed by excellent products, customised services, competent experts and its long experience in the metalworking industry.

ENQUIRY NO 150

THE BRILLIAN T TOUCH

ULTRA PRECISION PROBING Marposs Diamond systems redefine the rules of on-machine part measurement, where precision requirements are pushed to the limits daily. WRP60p Diamond probe allows precise part inspection on large, 5-axis milling machines and machining centers, guaranteeing high part precision and less scrap.

Y O U R G L O B A L M E T R O L O G Y PA R T N E R

www.marposs.com

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GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • November - December 2016

Pacific, excluding Japan, will grow at a compound annual growth rate (CAGR) of 4.8 percent for the 2015-2019 period. Manufacturers are moving towards automation and digitalisation to ensure that their factories are operationally efficient. The rise in intelligent manufacturing calls for more complex machine tools and machining processes, creating a demand in the metalworking industry. Consequently, the expansion in metalworking has resulted in a demand for metalworking lubricants. The global metalworking fluids market was estimated to be worth US$8.3 billion in 2014 and is expected to reach US$9.74 billion by 2020 based on a CAGR of 3.2 percent from 2015-2020. This growth is in part driven by the use of removal f luid as a coolant across the manufacturing industry to maintain optimum temperature and to remove unwanted metal chips during the grinding, drilling, and other processes.

CHOOSING THE

RIGHT

SLIDEWAY OIL

FOR YOUR COOLANTS

Slideway oil affects both the machining precision and service life of metalworking fluid. By Imtiaz Ahmed, Asia Pacific Mobil SHC brand manager, ExxonMobil Lubricants

Editorial

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8102

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he metalworking industry in Asia Pacific is booming due to a rise in urbanisation, cheaper manufacturing cost s and increasing automation in the region. This has in part been driven by strong growth and an optimistic outlook in the Asia Pacific region as it remains an attractive manufacturing hub for regional and global exports. According to the IDC Manufacturing Insights Spending Guide, manufacturing spending in Asia

Major Technology Trends A lot of friction and heat is produced, whether from the simple production of nuts and bolts to more complex, tougher metalworking processes. In addition, these heavy duty processes require machines to be both precise and efficient in their working, which is why lubricants and coolants play a vital role in the machine’s performance and maintenance. In addition, companies are looking for ways to reduce costs while increasing profitability, and many players in the metalworking industry are adopting green practices, including using vegetable-based coolants, and finding ways to reduce wastage such as implementing recycling programs or reusing coolants instead of disposing them. However, not all cutting fluids can be reused as they do not meet the lubrication, cooling and protection requirements of each application for every machine. This is why choosing the right combination of high quality lubricants – slideway oils, water soluble cutting fluids and neat cutting oils – ensures machine tools run smoothly for a longer time, and helps to cut costs and reduce wastage, ultimately enabling the machines to be more operationally efficient. Stick-Slip Effect Slideway operations in particular require special attention to friction to ensure it runs smoothly and with precision. When moment frictional control is lost, this can cause inaccuracies, ultimately resulting in lost productivity. Slideways move in a linear motion, therefore the slides would have to stop when they reach the end and move again in the opposite direction.

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • November - December 2016

Their stepwise manner of operations would mean that they need to use mixed lubrication to operate efficiently. Consequently, a mixed lubrication setting would make slideways more susceptible to the stick-slip phenomenon. Stick-slip occurs when there is more static friction than dynamic friction. This causes jerky movements to the slide and the attached work tool. Uncontrolled motion such as this can result in inaccuracies in operations, poor quality and loss in production. To have better friction control, friction modifiers such as special additives are being added to the lubricant.

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High volumes of tramp oil in aqueous coolants can also change coolant concentrations and cause coolant foaming, which makes monitoring more difficult.

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Lubricity in the machine may be reduced, which leads to tool wear and poor precision finish.

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Coolant pH levels can also be reduced, which causes corrosion.

•

There is also a risk of increased bacterial growth and the formation of undesirable odours in the machine shop. These complications reduce the life of coolants and causes health problems for employees.

Tramp oil can also enter the metalworking fluid in more than one way, including leaks from way, gear, spindle, and hydraulic oils, or oil on parts from previous operations. The more oil is used, the more tramp oil will need to be removed, resulting in an increase in operational and maintenance costs, as well as reduced productivity in the long-run.

Manufacturing spending in Asia Pacific (excluding Japan) is predicted to grow at a CAGR of 4.8 percent until 2019.

Jerky Operation

Friction

Slideway Oil Choosing the right slideway oils enhances the productivity of modern machine shops as they affect both the machining precision and service life of the metalworking fluid. Slideway oils must provide outstanding friction control and excellent separability from aqueous coolants that are commonly used in metalworking operations. Such lubrication usually happens in an open machine system, which increases the chances of contamination in the coolant circulation system. The contamination between slideway oil s and aqueous coolant s will eventually form tramp oil. Tramp oil is a primary contaminant in these systems and causes a lot of problems that affect the working life of the equipment:

Smooth Operation

Speed

Elasticity Driving Force

Slide Slideway

What To Look For: Coolant Separability Knowing what properties to look out for when choosing slideway lubricants is vital to prevent the formation and contamination of tramp oil. A key factor is the ability of slideway oils to separate from water-soluble coolants quickly and completely. If the separation between the oil and the coolant is not complete, the per formance of the aqueous coolant can be severely affected, which results in high operational cos t s and unscheduled machine downtime. A slideway oil with good coolant separabilit y proper ties will also allow machine tools to operate with optimal precision. This will help enhance the life and per formance of the aqueous coolant and improve metalworking processes. Proper Maintenance of Machining Processes While slideway oils are the most common source of oil contamination in aqueous coolants, other lubricants such as hydraulic oil, gear

Slick-slip effect causes uncontrolled jerky movements to the slide and the attached work tool. To have better friction control, friction modifiers are added to the lubricant.

The global metalworking fluids market is expected to reach US$9.74 billion by 2020.

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • November - December 2016

centrifuges can also be used is larger systems to remove cont aminant s . Alternat ively, contaminants can also be removed manually by using specialised equipment such as an industrial vacuum cleaner. On top of choosing the right slideway oil and coolant for your metalworking needs, using a single supplier for both metalworking fluids can help limit compatibility and contamination issues. This, combined with proper maintenance and regular testing, play a part in ensuring precise and efficient operations.

Metalworking fluids are considered as liquid tools and can have a direct impact on productivity and profitability.

oil and grease can interfere with the life of the coolant. Metalworking operators need to adopt maintenance practices to prevent contamination from interfering with a machine shop’s operational efficiency. Op er a tor s ne e d to moni tor co ol an t concentration on a regular basis to maximise coolant life. This is to ensure that there is no build-up of tramp oil as a result of slideway oil emulsification. Tramp oil can be detected in the system by using lubricant analysis. Operators can test for coolant concentration by measuring by titration and then compare the results with new, unused coolant to determine the levels of emulsified tramp oil. Removal of tramp oil is done by automatic skimmers that can be found in many modern machine tools available today. Filter and

Driving Efficiency And Advancing Productivity Metalworking fluids such as slideway oil and coolants were once considered as a basic necessity to keep machine tools operating. Today, they have become important factors to enable machine shop operators to improve operational efficiency so as to reduce costs and increase profit margins. Metalworking fluids are now considered as liquid tools and they should be treated with the same degree of importance as machines tools since they have a direct impact on productivity and profitability. While the selection process of slideway oils and coolants is dependent on the variety of applications in machine shop, choosing good quality metalworking fluids will work for most applications such as turning, drilling, milling, forming and stamping. The metalworking industry needs to ensure operational excellence with the right lubrication solutions and proper maintenance allowing them to focus on innovation to capitalise on future growth opportunities.

Mobil Vactra Oil Numbered Series A slideway oil with good coolant separability properties will also allow machine tools to operate with optimal precision.

Modern slideway lubricants must have a balanced combination of base oils and additives to ensure easy start-up, continuous transition and smooth movement even under heavy loads. The Mobil Vactra Oil Numbered Series are specially formulated and designed to meet the strict requirements of slideway operations. The lubricants’ high lubricity, load-carr ying performance and coolant separability enhances performance and product quality. Slideway oils and coolants need work in tandem so that both metalworking fluids have prolonged service life and achieve peak performance in machines. Mobil Vactras separability from aqueous coolants, combined with the Mobilcut series of water miscible coolants, further facilitates high performance in slideway operations while reducing the chances of cross contamination. Mobilcut’s non-chlorinated coolants are developed with base oils, additives, and emulsifiers. They are also designed with low foam potential and long-term corrosion protection. These concentrated coolants offer low maintenance and high stability to further improve your slideway’s service life and productivity.

by the best in the business

Machine Tools

Sheet Metalworking

Cutting Tools

EDM, Grinding, Turning, Machining and many more are the focus of this section, the mainstay of metalworking.

Productivity in machining is very much on the back on every job shop owner’s mind and we intend to help you achieve that.

Metrology & Design

This section will explore the ways and means available today to make that ‘perfect’ part with what the metrology & design world has to offer.

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IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

Multi-Sensor CMM The moving blades and guide blades which occupy a large percentage of Fine Forge’s produc tion are essential for the optimal functioning of steam turbines. The company is re sponsible for manuf ac turing up to 95 types of moving blades and 24 types of guide blades, all of which have dif fering, complex geometry. They required a system that could make 3D scanning easy for the wide range of varying shapes and sizes. The blades, which are made from X20, X10 and X22 compositions of stainless steel, are developed and supplied to different customers for applications in the power and industrial sectors. The company previously used manual and destructive measurement methods which were counter-productive, with data collection methods par ticularly time-consuming as well as the waste of expensive materials and parts. Fine Forge wanted to replace its manual methods and find a method that could introduce reverse engineering capabilities to help slash CAD design turnaround times. These point s were the criteria before consulting an array of CMM suppliers. A fast and accurate multi-sensor system that could facilitate QA and reverse engineering was required.

Multi-Sensor CMM For

TURBINE BLADES

How multi-sensor CMMs can help increase productivity and support expansion of a company’s product portfolio. By Ashley Machin, Nikon Metrology Europe Editorial

Got a Question? Make An Enquiry.

ENQUIRY NUMBER

8201

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

ith Indian authorities pushing for more locally sourced and manu f ac t ur e d co mp o n e n t s , Fine Forge was founded with the aim to replace the need for imported turbine blades with locally manufactured component s. The company based in Hyderabad specialises in the manufacture of turbine blades.

Better Insight After consulting other suppliers and searching the market, it was discovered that Nikon Metrology could provide the most full and comprehensive solution. T h e c o m p a n y ’s m u l t i - s e n s o r A l t e r a CMM with Camio software combines touch probing , SP 2 5 cont inuous sc anning and laser scanning, providing Fine Forge with a complete inspection toolbox. Regarding accurac y, the Nikon LC15Dx is closing the gap with tactile inspection systems, delivering the most accurate results possible for a laser scanner. Thanks to the optical chain design using a Nikon focusing lens, the scanner is able to obtain a probing error of just 1.9 µm. Not only does the scanner f acili t ate t he mea surement of comple x shapes, it also helps speed up inspection and reverse engineering requirements. For difficult-to-access elements such as internal features and diameters or in the case of only a few sections to measure, the laser scanner can switched with the tactile SP25. The Camio sof tware is also able to switch laser scanner and tac tile probes conveniently a s well . The sof t ware al so allows for inspection task reports, providing

IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

a detailed analysis in the form of instant, easy-to-interpret results. T he produc t i v i t y increa s e since t he installation has helped the team to look for new possibilities and expand into different sectors. Vinod Reddy, managing director at Fine Forge explained that with the installation of the Nikon system, they are now able to explore new possibilities in pipe fittings and heavy truck components.

Nikon: LC15Dx CMM Laser Scanner Nikon’s LC15Dx CMM laser scanner aims to approach tactile probe accuracy. In tests comparable to ISO 10360-2 MPEP and ISO 10360-5 MPEAL the LC15Dx achieved the accuracy associated with using a tactile probe on a CMM. Unlike a tactile probe, the LC15Dx uses non-contact 3D laser

New Capabilities Many of the pipe fitting manufacturers never had the drawings for their par ts, but the LC15Dx’s reverse engineering capabilities has enabled easy migration from the power industry to heavy truck components and pipe fittings, making exploring this market possible. However, turbine blade manufacture does still remain part of the business today. The introduction of the laser scanner now enables the measurement of larger complex sheet metal blades, which was not possible before. The multi-sensor CMM is equipped to deal with many more different workpieces. After the installation of the Nikon system,

triangulation to measure the surface directly and eliminate probe compensation errors. Nikon’s ESP3 technology allows for a mixture of surface materials, finishes, colours and transitions to be measured efficiently without user interaction, manual tuning and part spraying, including small and fragile parts. Unwanted reflections from very shiny surfaces are neutralised by an advanced software filter while changes in ambient light are absorbed by a high grade daylight filter.

t he team at Fine For ge have expres sed their satisfaction with the investment and the oppor tunities introduced. Since then, t he comp any ha s di v er si f ie d , and no w supplies steel forgings for power, automotive industries and more.

ENQUIRY NO 061

Efficient, versatile and easy to use Featuring a bar capacitiy of 25.4 mm diameter, the Tornos Swiss GT 26 is a Swiss-type lathe equipped with six linear axes and two C axes. Versatility, high performance in value-added operations, and ability to work with or without a guide bush make the Swiss GT 26 a comprehensive bar turning solution. Discover more : www.tornos.com

Your advanced machining solution

Swiss GT 26 We keep you turning

IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

SMALLER, BETTER CHALLENGES

Mobile Device Makers

Mobile phone manufacturers are grappling with the need to track smaller, and better, components, presenting challenges and opportunities for designs. By Panasonic.

Editorial

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ENQUIRY NUMBER

8202

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

far cry from the bulky mobile phones of the early 2000s, today, a 0.25 x 0.125mm chip resistor is one of the most widely used components in mobile phone manufacturing. It’s not news that the demand for smart phones, wearable devices and other personal electronics is increasing rapidly. In the case of mobile phones, more than 1.8 billion phones – inclusive of feature and smart phones – were manufactured in 2015, with the number projected to increase to two billion in 2020. What is news, is that in order to meet rising consumer demands - smaller, thinner, longer batter y life, higher per formance these highly complex electronic products require ever-shrinking components, requiring manufacturers to evolve and keep up with the ever-changing requirements of the industry. Mobile phones are highly complex electronic products. Feature phones require between 600-800 components, while smart phones require upwards of 1,000. As higher functionality continues to be expected by consumer s , t he number of component s ultimately increases year-on-year. But the demand for smaller and thinner devices and the need to balance longer battery life with higher performance also pose new challenges for devices manufacturers. Printed Circuit Boards Printed circuit boards eliminate the space

Equipment displays at the Panasonic Solution & Innovation Centre Thailand.

challenge of complex wirings and moving par t s t hat were commonpl ace wit h t he point-to-point wiring that preceded them - without them, f itting a large number of interconnected electronic components into an ever-shrinking space would be impossible. Today, a 0.25 x 0.125mm chip resistor is one of the most well-known components in mobile phone manufacturing. During manufacturing, chip resistors are soldered onto circuit boards, with the solder being applied as a paste and shaped into the boards through screen printing, requiring a high level of accuracy despite its small size. Surface Mount Technology Another noteworthy innovation in the field is surface mount technology, which produces electric circuits through the direct mounting of components on the surface of printed circuit boards. The new technology is also evolving to increase the mounting/insertion rate and accuracy of increasingly miniscule components. Surface mount technology has come a long way since it first emerged in the 1950s and 1960s , resulting in many advantages over their leaded predecessors in terms of manufacturability and performance. Surface mounting has also resulted in a reduction in labour cost and increasing productivity rates in the production of printed circuit boards, as process lends itself well to a high degree of mechanisation and mass production.

IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

Chip Mounter Machines O n e s u c h co mp an y le adin g t h e c har g e t o w ar d s m o r e e f f i c i e n t m anu f a c t ur in g technologies and equipment is Panasonic. The elec t ronic s g iant is s t ill commonly known for its consumer electronics, when in fact, Panasonic today is on track to attain a 40 percent share in the chip mounter machine field in South East Asia. Its newly opened Solution & Innovation Centres in Thailand, Indonesia and Vietnam therefore highlights the company’s highlyef f icient manufac turing technologies and equipment. Tapping into Panasonic’s manufacturing know-how, the Solution & Innovation Centres showcase the company’s suite of manufacturing technologies such as autoinser t ion and sur face mount machines , designed specifically for the inserting and mounting of small electronic components on high-density printed circuit boards. In addition to Panasonic’s latest chip mounter and welding machines, peripheral equipment from other par tner s, such as component tower and inspec tion

m a c h in e s , a r e a l s o f e a t ur e d , w i t h t h e s yner g y hig hlig ht ing t he impor t ance of net work compatibilit y and technological interconnectedness, and the contribution of interconnectivity to the success of Industry 4.0 and IoT-supported manufacturing. Seminar hall s and conference rooms located within the centres also ser ve to showcase Panasonic’s factor y automation t e chnolo g ie s to i t s c u s t omer s t hroug h technical seminars and events. Trial Run To e x p e r i e n c e a c t u a l m a n u f a c t u r i n g processes at the centres, such as circuit board printing and welding, customers are invited to bring their own materials and electronic components for a trial production ahead of any agreements with Panasonic. P a n a s o n i c ’s S o l u t i o n & I n n o v a t i o n Centres are al so present in Chicago, US A and Munich , G er many, w i t h g lob al expansion taking place in the near future and more centres in the pipeline, tying in with Panasonic’s expansion of its factor y automation business globally.

Mobile phones are highly complex electronic products. Feature phones require between 600-800 components, while smart phones require upwards of 1,000. ENQUIRY NO 143

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

BEHRINGER and BEHRINGER EISELE - world leading producers of high-performance band- and circular sawing systems offer a wide range for every kind of metal - including stainless and special alloys. BEHRINGER‘s mitre cutting bandsaw HBP410-723G grows in step with requirements. The models are designed to cut sectional steel and solid metal materials. An extensive range of peripheral devices, such as infeed, outfeed and measuring systems, offer versatile possibilities. Use the potential of innovative HighPerformance Band- and Circular Saws of BEHRINGER and BEHRINGER EISELE. Experience machines and solutions for high precision and profitability. True to the motto „RED HOT EFFICIENCY“.

IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

Jayajyoti Sengupta, APAC Head, Cognizant

AUGMENTED

REALITY A

Enhances Device Performance Technology that enhances device performance is sweeping the world from smartphones to scanners used in major logistics work. By Jayajyoti Sengupta, APAC head, Cognizant.

Editorial

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8203

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ugmented reality (AR) has captured the attention of everyone worldwide. This was evident yet again when Niantic launched the Pokémon Go game application. Since its release in July 2016, the app has quickly gained widespread popularity, surpassing even the number of daily active users of Twitter. In addition, with the average player spending nearly 44 minutes a day on the app, the game also received a higher usage time than WhatsApp, Instagram, Snapchat and Facebook Messenger — a testament to its success. The key to the game’s popularity perhaps lies in its ability to successfully induct players into the world of Pokémon. Using an avatar, users have to move around in the real world in order to capture creatures via the in-built camera on their device. Brings Digital World To Life More than a passing fad, AR is now becoming an important technology in the enterprise, literally bringing the digital world to life. For all their benefits, AR applications are also not complicated to deploy, and once properly in place, they require minimal effort for maintenance.

Success stories lend greater credibility t o t h e b e n e f i t s o f A R an d ce m e n t t h e technology’s position as an innovation set to take the world by storm. For example, in a pilot project, DHL found they were able to improve accuracy by minimising errors, and increase efficiency by 25 percent when they equipped warehouse workers with ARenabled smar t-glasses that guided them through item picking for order fulfilment. It is no wonder then, that many earlyadopters in retail, manufacturing, utilities, education, tourism and gaming have started conducting field trials to test the technology’s ability in improving their employee engagement, workflow and business processes. AR For Training One area where AR is gaining traction is in work force training. Many companies are increasingly applying AR tool s to create t r aining pro g r ams t hat dr i ve employee engagement . According to the American S o cie t y for Tr aining and D e velopmen t , investment in employee training has a direct impact on the bottom-line. The s tudy found that a mere US$680 increase in training expenditures per employee generated a six percent improvement in total shareholder return on average. In addition, a Louis Harris and A ssociates poll found employee retention was two-thirds higher than that in an average company when employees felt they were given adequate training. Textbook To Playground Perhaps the greatest benefit of AR-based training lies in its ability to take learning from the textbook to the playground. Rather than have employees rely on hard copy instructions or user manuals, they are equipped with a handheld device such as an iPad or a wearable such as Google Glass instead. When these devices are directed on the AR machine, a realistic, 3-D, life-sized model of the machine is rendered into the physical world with information on each part of the machine and its role, making it seem as if they are training on a real machine. Learners can then interact with the 3D model using gestures and touch. The ability to customise AR-based training for dif ferent situations is another one of AR’s key value propositions. In the medical sector, for example, AR technology is being used in training sessions on body parts and func tionalities for medical student s. The same technology can also be tailored to other industries easily.

IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ November - December 2016

AR Aids Industrial Design Today â&#x20AC;&#x2122;s rapidly evolving technolog y and business landscape also means organizations o f t en r e quir e ag il i t y and s p e e d in t he workplace for competitive advantage. AR technologies can enable custom-designed main t e nan ce s o lu t io n s w h er e co mp le x procedures can be animated direc tly on the equipment. This enhances effectiveness or accuracy for employees as animation-based instruc tions and reference materials are overlaid directly on the physical equipment. AR for inspec tion and maintenance is now being used across a wide spectrum of industries. Field service agents, for example, can use AR and wearable technology to access checklists and work manuals, interact with systems via voice and gestures, and provide remote support. AR is eliciting interest in the energy and utilities world for asset inspection, meterreading, remote monitoring of tasks, and health and safety. In healthcare, AR can help nurses and clinicians to learn about surgeries, carry out modelling of organs, and explain

medical procedures. Automotive companies can benefit from AR in diverse areas such as factory planning, product visualization, worker support and customer support. T h e t e c hn o lo g y c an h e l p in du s t r ial designers visualize and experience a productâ&#x20AC;&#x2122;s design and operation, car body structure and engine layout, to name a few. Now At Enterprise Level AR has been around for a while, but was seen more as a fun thing rather than as something useful at an enterprise level. That has changed. AR is now viewed as a potential g ame changer, because it can pro duce e x p er ience s t ha t c an ac t uall y reduce hardware and people dependencies by delivering real-time information on user movements. Given the speed at which AR is impacting existing industries and creating new ones, it could also provide a huge benefit to any company willing to make the investment. In the end, the flexibility offered by AR makes it a frontrunner in the race for enterprise adoption over the long term.

Rather than have employees rely on hard copy instructions or user manuals, they are equipped with a handheld device such as an iPad or a wearable such as Google Glass instead. ENQUIRY NO 050

IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

A SECRET WEAPON

For Aerospace, Automotive Quality Control Managers Handling responsibility for quality control means closing the loop on coordinate measuring machine operations. By Daniel Brown, B Eng, senior product manager at Creaform.

Editorial

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ENQUIRY NUMBER

8204 Turn to page 80a to enquire or log on to: www.equipment-news.com

ualit y control managers in the automotive and aerospace indus tries are responsible for ensuring that manufac tured par t s meet cus tomer s’ requirement s, specif ications, and tolerances. To do so, they rely on coordinate measuring machines (CMMs), which are the most precise metrology equipment available for quality inspection. Getting this level of precision, however, come s at a pr ice (of ten in t he for m of i n c o n v e n i e n c e) . T h e C M M m a y n o t b e

available to practice first article inspection (FAI), or, worse, it may be totally loaded because a fault has been found at the end of the production of a part. Then, lots of back and forth between the CMM and the shop floor is necessary to locate where the issue has occurred. Handcuffed In those situations, quality managers are handcuffed by the technology and limited in the execution of their work. What if they had a secret weapon to deploy when the CMM is loaded? What if they could have access to a portfolio of alternative solutions that they could rely on to improve the quality inspection? In order to make sure that you are never restric ted in the exercise of your duties, we’ve compiled the following list of different metrology tools available to QC managers, with the pros and cons of each. A Look At Options Hand measuring tools are among the ways to approach the issue of monitoring. The most common hand measuring tools include micrometres, slide callipers, indicators, and gages. These tools are mainly used for simple inspections and basic measurements such as measuring a diameter or a thickness

IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

or any other dimensions that do not justify or require a report. The pros of hand measuring tools are: simplicity of use; a basic level of technical exper tise needed; high precision; quick use for simple measurement and features. But there are reasons as well not to rely exclusively on such tools, including repetition: because the measurement depends on the operator ’s manipulations and dif f icult y selecting the most suitable tool, because each measurement requires a different tool. As well, they can be hard to use for complex parts.

Laser Trackers There is also a subcategory in laser trackers that are of ten used to measure parts of large dimensions. While fixed CMMs are limited by the table surface and portable CMMs are limited by their measuring volume, laser trackers can measure parts like aircraft wings or auto frames, as well as large toolings. Their disadvantages are that they require a rigid setup and are sensitive to instabilities in the environment. Portable CMMs That brings us to portable CMMs, an alternative solution when a par t cannot be moved from the

production floor to the measurement lab. These include the advantages of fixed CMMs, as well as portability, which enable one to move the CMM to the shop-floor, another building, or a supplier’s facility.

ENQUIRY NO 027

Live Tools for machining centers

Fixed CMMs The next option is to rely on fixed CMMs, which are definitely a better choice than hand measuring tools for complex parts. Indeed, they can measure any type of feature with a high level of precision. Because of that, they are the no.1 metrology equipment choice for quality control managers. They are so popular t hat t hey are of ten lo aded by different operations. Fixed CMMs are also flexible, allow access to automated reports and show ability to measure and inspect any types of feature as well as provide unbeatable precision. However, they also have some dr aw b ac k s , inc luding t ha t t he shape of measured parts is limited due to the size of the measuring table, high cost of utilisation and a high level of technical expertise needed for equipment f ixed to the ground and that requires a rigid setup.

Like portable CMMs, most 3D scanners can be moved around on the production floor, but they also have the capability to measure in a complex production environment.

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IN DESIGN Asia Pacific Metalworking Equipment News • November - December 2016

Portable CMM on the shop floor

Because each solution has its pros and cons, being able to rely on different tools is the key to performing excellent quality controls.

On the plus side, they show portability: the measurement tool goes to the measured part (rather than the opposite, simplicity of use and the ability to measure directly on the production floor. H o w e v e r, t h e y m a y b e s e n s i t i v e t o vibrations and not adapted to uns t able shop-f loor mea surement s a s well a s requiring a rigid setup, and noting that operator experience and skills can affect the measurement accuracy. Optical There is also a subcategory here in optical portable CMMs. This subcategor y of fers the same advantages of portable CMMs, with an extra: a rigid setup is no longer required. This means that everything (i.e., the tracker, the measuring tool, and the measured part) can move during the measurement. Therefore, it reduces the pressure placed on operators. In addition, their level of exper tise does not need to be so high because fewer errors w ill b e c aus e d by e x t r a manipul a t ion s and alignments. In short, optical portable CMMs are perfectly adapted to shop-floor measurements. 3D Scanners Finally, there are metrology-grade 3D scanners complete our portfolio of alternative solutions to rely on to improve quality inspection. Like portable CMMs, most 3D scanners can be moved around on the production floor, but they also have the capability to measure in

a complex production environment—just like optical portable CMMs—that is often influenced by temperature variations, vibrations and inexperienced operators. However, it is through the information density they can acquire and analyse that 3D scanners distinguish themselves from other measuring equipment. Because of that, they are the preferred solution for FAI, where each dimension measurement is critical. The complete part (dimensions and aesthetics) must be inspected and approved during the FAI. Therefore, it is risky to omit defaults with a probing unit that only measures a restricted number of points (or samples of points). This occurs through speed of acquisition and density of information analysed, the short time required to characterise a complete part and via efficiently digitising complex shapes with a ver y large number of point s and without contact. However, there are some drawbacks too such as the need for the measured part to be in the line of sight of the scanner and as an overkill solution to inspec t simple geometrical features like pins and holes. The Answer So the secret weapon for quality control teams, therefore, is to have different measurement options to inspec t par t s . Because each solution has its pros and cons, being able to rely on different tools according to the type of inspection being performed or the shape of the piece being measured is the key to performing excellent quality controls.

For Forfurther furtherinformation informationplease pleasecontact contactthe theoffice officeclosest closesttotoyou: you: Maysia Maysia Stephanie Stephanie PTPT Pamerindo Pamerindo Indonesia Indonesia Jakarta Jakarta T: +62 T: +62 2121 2525 2525 320 320 F: +62 F: +62 2121 2525 2525 482 482 / 522 / 522 9268 9268 E: maysia@pamerindo.com E: maysia@pamerindo.com W:W: www.pamerindo.com www.pamerindo.com

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FAST FAB Asia Pacific Metalworking Equipment News • November - December 2016

Trumpf

Punching Machine Adaptability:

ROOM TO GROW

An entrylevel segment punching machine that can gradually be expanded into a fully-fledged combination machine has caught industry attention with a host of innovative features from punching holes to bends flanges and forms threads. By Trumpf

Editorial

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ENQUIRY NUMBER

8301

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

he search for an economical, compact and automation-friendly punching machine that is specifically designed to grow with their business will be unveiled by Trumpf at this year’s Euroblech. The TruPunch 1000 can be expanded into an equally space-saving TruMatic 1000 fibre punch laser machine, allowing sheet metal processors to upgrade their machine to keep pace with their growing business. Solid-State Laser With its expandable functionality, the TruPunch 1000 provides the perfect entry point into the world of professional punching. It can handle sheets up to 6.4 mm thick at rates of up to 600 strokes a minute, yet is remarkably compact. With a footprint of just 6.5 x 4.9 metres, the TruPunch 1000 stand-alone machine is around 15 percent smaller than its predecessor. “The space we have here is limited, but the compact TruPunch 1000 slotted into the same space previously occupied by a Trumatic 200,” said Thomas Herberger, managing director of Herberger Metallwaren, a company that participates in the product testing program. “Now we can process medium-format sheets without having to reposition them and that really speeds up our production process.” As their business evolves, sheet metal processors sometimes yearn for the greater variety of parts that can be manufactured by a combination system – and with the TruPunch 1000 there’s no need to buy a second machine. Thank s to it s novel modular design, the

TruPunch1000 can be retrofitted with a laser cutting system, a laser evacuation unit and a beam guard system. A 3 kilowatt TruDisk solid-state laser can be connected up to convert the TruPunch 1000 punching machine into a punch laser machine. This configuration precisely matches the other recent addition to the product range of Trumpf: the TruMatic 1000 fibre. A First This is the first time that Trumpf has offered a combination machine in the entr y-level segment, a move that makes it easier for customers to make the switch from purely 2D laser processing to punch laser technology. Customers who already have a TruDisk solid-state laser can also use this to operate the TruMatic 1000 fibre via the Trumpf laser net work . The price of the new machine is undoubtedly appealing, and – with the TruMatic 1000 fibre’s specifications matching those of the previous TruMatic 3000 fibre model – customers don’t need to sacrifice anything in the way of performance. Both the new models in the 1000 range offer completely redesigned drive technology, which is crucial to the success of the modular concept. T he paten ted “D elt a Dr i ve” li ter ally mark s a new movement in the world of industrial punching technology. The advanced engineering team of Trumpf came up with the new drive to facilitate the construction of smaller machines and open up new methods of material handling.

FAST FAB

The secret of the Delta Drive is that it eliminates the need to move the sheet and work table in the y-axis – normally an integral requirement of sheet metal processing. It achieves this by making the punching head quickly manoeuvre in that direction. This new approach involves a drive system that is powered by two servomotors. When the servomotors move in the same direction, they allow the punching head to move back and forth in the y-axis. And when the ball screws rotate in opposite directions, this activates the punching stroke. The y-axis can be accelerated far faster in this arrangement, because the punch drive is also used for travel motion, eliminating the need to move the sheet or work table. As a result, the punching process is more dynamic and the machine is more productive. Furthermore, the lower relative movement between the machine table and the metal sheet reduces the risk of jamming and collisions, making the process more reliable overall. Finally, the stationary machine table significantly reduces the size of the machine’s footprint. Automatic Sorting Both the TruPunch 1000 and the TruMatic 1000 fibre can automatically sort finished parts measuring up to 180 mm × 180 mm. All processed parts are sent down a chute into a sorting unit which moves in a linear direction. From there they can be sorted into a series of boxes (up to 4 different 400 mm × 300 mm boxes). The boxes are positioned below the machine, which provides for easy removal by the operator. Due to the innovative movement of the punching head, the machine also offers an alternative way to remove the parts. This second method comprises an additional big flexible parts flap, which is available as an optional extra for the TruPunch 1000 and fitted as standard in the TruMatic 1000 fibre. The flap can be equipped with a sensor that detects whether all the parts have been properly ejected from the machine’s working area. Designed with relatively generous proportions, this parts flap can also be used to eject long and wide parts into containers or onto conveyors or pallets during both punching and laser operations. “Often we fill sheets with just four to six parts, and in the past we had to remove and sort them manually,” Trumpf testing partner Herberger of explained. “But with the TruPunch 1000 nobody has to keep watch over the process because the machine simply ejects the parts through the generously sized flap and places them straight in the crate for us.”

Trumpf

Asia Pacific Metalworking Equipment News • November - December 2016

Right Fit Trumpf was also determined to make the TruMatic 1000 fibre as compact as possible. One way the company achieved this was by developing a special space-saving beam guard system that is compatible with the machine’s modular concept. This protective housing is gathered closely around the machine table in a skirting manner. In punching mode it moves downwards, giving the operator a direct and unobstructed view of the process. But as soon as the program switches to laser processing, the protective skirt rises and a hood is lowered over the Delta Drive, to which the laser processing unit is attached. This protec tive screen ef fec tively intercepts the small amount of scattered that could potentially escape at a shallow angle below the work table brushes during production. There are also two laser safety screens that allow visual monitoring of the ongoing process. Even in their automated versions, these two machines from the 1000 product series are more compact than any other comparable machines on the market. Both of them can also be connected to the new SheetMaster Compact. This automat ion s y s tem loads small and medium-for mat shee t s and bl ank s and unloads micro joint sheets and scrap skeletons. Thanks to its optimised loading cycles, it can reliably complete most of these tasks while the machine is in operation. Both machines are equipped with an intuitive touchscreen to make life easier for operators. The MobileControl app can also be used to operate the machines from a tablet. The TruTops Boos t Punch sof t ware is required for programming, and both the license and maintenance agreement already come with the machines as standard.

Delta-Drive eliminates the need to move the metal sheet and machine table in the y-axis by moving the punching head in this axis instead.

As their business evolves, sheet metal processors sometimes yearn for the greater variety of parts that can be manufactured by a combination system.

FAST FAB Asia Pacific Metalworking Equipment News • November - December 2016

Fast forward to the twenty-first century: the modern punch press is more capable than ever when it comes to forming, including the processing of complex, 3D parts. Today’s punch press can create bends in sheet metal that until recently only a press brake could produce. Being able to form a part on a punch press can help signif icantly reduce par ts costs. Bending is one of the most common bottlenecks in the fab shop, which is why shortening or eliminating the bending operation makes so much sense.

BEYOND PUNCHING

Machine design, tooling and programming software combine to make today’s punch press capable of complex forms. By Dan Caprio, punching product sales manager at LVD Strippit

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he introduc tion of the hydraulic press drive decades ago brought new versatility to the punch press – allowing the punch stroke to start and stop at any point along the ram path. The flexibility of the ram control coupled with automatic tool rotation technology opened the door to a broader range of punching and forming capabilities. The control and programming system’s ability to integrate special functions allowed users to take full advantage of the latest tooling designs, such as a wheel, hinge or bend tools.

Not Your Conventional Punch Press To form on a conventional turret punch press, you might have a feed clearance of only .984 inch or less. Part of that space is taken up by the form die, which raises the material slightly, and then you have the material thickness. Some tools allow you to use a significant portion of that clearance, but as a rule, you can form reliably in a space that’s only 50 percent of the total feed clearance minus the material thickness. That’s not much. New punch press designs, however, have clearances that take forming into account. Some systems make room for up to three inches of forming space from the lower dies to the upper punch. This allows for significant forming and bending, including the forming of flanges up to three inches high. These punch pres ses don’t have the traditional turret setup, but instead use what is known as a tool-changer design. In the toolchanger-style punching machine, the lower carousel is underneath the brush table, and dies emerge and retract through a die to move down and out of the way between hits. Bending Tools This punch press design opens the door for more forming possibilities, and not just for ribs, louvers and other short forms, but also the kind of tall flanges that would normally be formed on a press brake. The bending punch and die in a punch press are a hybrid between a panel bender and a press brake, with some unique attributes. The punch looks like a miniature hold-down tool on a panel bender, while the die has a V geometry similar to what’s found on a press brake die. The die body actually rotates during the bend. This rotation folds the workpiece against a stationary upper punch, and the die’s degree of rotation determines the bend angle. The radii you can achieve depends on the V-die design, which can be determined when ordering the tool from the manufacturer. Or, if you need to achieve a certain radius, such as for a profound-radius

FAST FAB Asia Pacific Metalworking Equipment News • November - December 2016

bend, the die rotates at certain degrees to bump the metal as the piece progressively moves forward. It’s bump bending, punch press-style. Accounting For Thickness Tolerances are extremely tight, both in the positioning accuracy of the machine and the machining accuracy of the tool, similar to the tolerances available on a modern press brake with precision tooling. Press operators also can input changes in thickness. Say one batch of material is on the lower end of the thickness tolerance window, while the next batch is at the high end, such as 0.055 inch for one batch and 0.061 inch for another batch. This can make a difference in the bend angle, but as long as the operator checks the sheet thickness and makes the parameter change in the program, the machine can account for it. A change in the program code is made that tells the ram how far to come down before it performs its operations. Besides the 3 inch height limitation, there are other constraints to consider. Unlike a press brake operator, a punch press can’t flip a part over, so a part with both positive and

negative bends can create problems. Also, the angle of bend is usually limited to 90 degrees or less; acute bends greater than 90 degrees complementary aren’t practical, for the most part (depending on the tooling you have). And because of tonnage limitations, the material can be only so thick. This varies, depending on your punch press and tooling, but typically it is up to about 0.118 inches.

Tolerances are extremely tight, but operators can change parameters to suit different thicknesses.

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FAST FAB Asia Pacific Metalworking Equipment News • November - December 2016

reduce the cycle time, but works only if there is no danger of interference between the flanges and the tooling. Consideration Of Tabs Tabs keep the part stable during bending, but where exactly you put those tabs, their width, how many, and how they’re cut depend on the flange geometries. Some pieces may call for only a few or even just one tab at a flat section of the part. Other times the bending operation itself can break the tabs. This can be useful when bump bending. During such a sequence, the microtabs holding the part in place break, and after the last bump, the part breaks free and slides down the chute. Programming also needs to take into account how exactly these parts slide down the chute. For example, if a large, heavy part with a high flange slides down the chute incorrectly, its landing may be rough enough to change its bend angles slightly or it may land on other formed parts with enough force to change their bend angles. You can overcome these problems by making changes to the program.

When programming a punch press, taking into account how exactly the parts slide down the chute is important. A large, heavy part with a high flange may be rough enough to change its bend angles slightly.

Programming Strategies When you bend on a punch pres s, your programming options abound. Traditionally, you program the forming sequence at a point whether it won’t interfere with any other part. This usually means you’re forming near the end of a nest’s punching sequence, after most or all of the flat-part punching is completed. At this point you may decide to bend all the flanges in a part at once. You cut the profile, leaving tabs connected to the nest to ensure part stability’ bend the flange, then perform the final punching to cut the tabs and release the part so it can slide down the chute. This strategy can work well if you want to evacuate the formed part from the nest as soon as possible to avoid collisions with the tools. Alternatively, you can punch the profiles (minus the material for the tabs) on multiple parts – say, all the parts in one row – form the bends, then send them all down the chute with the final punches that cut the tabs. This strategy reduces the number of tool changes and so can

Software Makes A Difference It ’s possible to program these variables manually, but it can be complicated and time-consuming. There are plenty of details to consider, including which way to rotate the bend tool (the tool set rotates 360 degrees to align with the programmed bend lines); how to position and sequence everything to avoid interference; and which width of bending tool to use, depending on which tool you have in your library and the bend length you need. In more challenging cases, manually programming may not be very efficient, and it actually may take you less time to form the flanges on the press brake, especially if those parts are heading to the brake anyway for a few remaining bends. Determining Sequences This is where the final piece of the puzzle comes into play: software that can automate the task of determining the punch and bend sequences. With such software, you can feed the 3-D model of the part you want to bend on the punch press to the software, and it will unfold the part and suggest strategies to punch and bend it, based on the tools available on the machine. The offline program works similarly to offline bend programming for press brakes. It sees the interference points, knows just how the tool needs to rotate, and sequences it in an efficient way. As a programmer, you can either accept the software’s recommendation or tweak it manually to suit your needs.

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Additive Manufacturing:

BESPOKE MEDICAL IMPLANTS

Sterile and unique implants for reconstructive surgery that use high end metals for mesh are increasingly coming from 3D printed design casts that can be used across the globe. By Ed Littlewood, marketing manager in the medical dental products division

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rom complex recons truc tive facial surger y to or thopaedic and trauma sur ger y, adv ances in addit ive manufacturing have inspired a growing number of progressive surgeons to commission metal 3D printed patient specific implants (PSIs) and cutting guides for both complex and straightforward procedures. Ed Lit tlewood, Marketing Manager in the Medical Dental Produc t s Division of g lob al eng ine er ing comp any Renishaw, di s c u s s e s ho w addi t i ve manu f ac t ur ing contributed to the success of a craniotomy and cranioplasty procedure and how future additive manufacturing developments can improve implant production.

Increasing Efficiency and Safety Case studies are emerging which provide compelling ev idence t hat t he sur geons embracing additive manufacturing technology over s t andard implant s or traditionally manufac tured implant s are consis tently delivering bet ter and more predic t able outcomes, in terms of patient safety and satisfaction, and hospital efficiencies and economies. In t he que s t for b e t t er qual i t y and ef f icienc y, UK NHS hospit al s have used 3D-printed anatomical models, guides and implant s to improve t he predic t abilit y, accuracy, safety and speed of operations. A hospit al in Spain ha s proved t hat the technolog y can al so be used across international borders in a classic example of global technology transfer with UK experts. The success of this project is a strong indication that additive manufacturing is ready to play a more prominent part in the production of bespoke medical implants. Case Presentation Neurosurgeon Bar tolomĂŠ Oliver, MD, PhD, prac tises at the Teknon Medical Center in Barcelona, Spain and has trained internationally including in Canada, USA and Sweden. A 68-year-old female patient presented to his depar tment with a benign grow th from the left side of her cranium, caused by a meningioma, a tumour that arises from the meninges â&#x20AC;&#x201C; the membranes surrounding brain and spinal cord. The computerised tomography (CT) scan revealed the growth was expanding outwards into the skull-bone. The patient required a craniotomy to remove the growth and a cranioplasty to rebuild her skull. Dr Oliver pl anned for t he combined cr aniotomy and cr aniopla s t y oper at ion allowing the patient to be treated in a single procedure. He knew the operation should not present any challenging problems, but his priority was to ensure it gave the best results to both patient and hospital. He chose to partner with UK experts in 3D design and printing who had shown repeated evidence of supporting predictable outcomes in complex facial reconstructive surgery. Brainstorming And Design Dr Oliver briefed PDR, a design consultancy and applied research centre, based in Cardiff, UK, to design both a PSI cranial plate for the cranioplasty and a custom surgical cutting guide for the craniotomy. The 3D metal printing

FEATURES Asia Pacific Metalworking Equipment News • November - December 2016

Models, guides and implants for cranial surgery.

partner was Renishaw plc, which had expertise in precision measurement and healthcare. The hospital’s CT scans were transferred from Spain to the UK, imported into MIMICS software program at PDR’s offices, and then converted into an STL file for modelling by PDR. PDR created a 3D vir tual model of the cranial plate by mirroring the healthy side of the cranium using Geomagic Freeform Plus software to deliver a good aesthetic design. PDR also modelled the cutting guide which would be placed on the cranium to help mark the perimeter or limit of the craniotomy and act as an aid in freehand work during surgery. The initial designs were sent back to Dr Oliver for first review. It then only took a 40 minute Skype session with Dr Oliver, PDR and Renishaw’s Spanish representative, for the surgeon to share his design modifications. Design Freedom And Flexibility Renishaw received the files of the approved designs for both the implant and cutting guide and 3D printed them at its central manufacturing unit in Stonehouse, UK , despatching the components to Barcelona within two weeks of receiving the files. T h e p ar t s w er e manu f ac t ur e d on a Renishaw AM250 metal 3D printing machine in titanium with a satin finish as per Dr Oliver’s specification. The material used was Ti MG1 tested to ISO 10993 part 1, which was then treated with Renishaw’s X-flex technology. This ensures high ductility, which is important to prevent the risk of breakages in surgery should the implant need to be adjusted, for example due to unexpected hard tissue changes. Ensuring an excellent aesthetic outcome meant that the contoured cranial plate n e e de d t o ma t c h t h e p a t ien t ’s c r anial contours accurately. While t he vir tual modelling enabled precision design, the plate needed to be thin

enough to maintain aesthetics, but resilient enough to handle all of the other necessary requirements: additional screw holes to give Dr Oliver flexibility to fix the implant and perforations to allow fluid transfer and tissue to grow through it. The implant ex tended 8 mm past the cut margin – giving an 8 mm offset allowed for cutting tool radius and standard screw diameter - and was designed for 1.55 mm diameter screws. This design freedom enabled by the additive manufacturing process meant that the material was thicker around the screw holes but 0.5 mm overall, to fit Dr Oliver’s precise specification. Additional Safety Factor Dr Oliver had specified that a “pan-handle” be designed into the cutting guide to help position it during the craniotomy, aiding stability and improving the ergonomic performance of the device. An arrow was added onto the guide to indicate the orientation. The decision was taken to use the cutting guide to mark the perimeter of the craniotomy. Dr Oli ver e xecu ted a f reehand incision following the markings, after the guide was removed. This approach enabled an easier way to handle the complex skull geometry around the temporal area which curved to a tight radius. With additional redundant screw holes, Dr Oliver was able to operate with maximum discretion, due to his design. He had specified more fixation options in the event that he needed to adapt at short notice. The operating theatre is a characteristically changeable environment and it pays to guard against possible mishaps. The implant gave him that additional safety factor. The operation was successful and incidentfree with the cranial plate being fitted safely and accurately.

The success of this project is a strong indication that additive manufacturing is ready to play a more prominent part in the production of bespoke medical implants.

FEATURES Asia Pacific Metalworking Equipment News • November - December 2016

Implant with pre- and post-cranioplasty comparison.

Dr Oliver executed a freehand incision following the markings, after the guide was removed. This approach enabled an easier way to handle the complex skull geometry around the temporal area which curved to a tight radius.

Post Surgery The patient was discharged after four days in hospi t al and e x amined in follow-up appointments after 15 days and at monthly intervals. She was free from complications. Post-operative CT scans showed good implant performance. Describing the main benefits for the patient, Dr Oliver mentioned “the excellent aesthetics offered by this implant” adding that “the patient is very happy with it”. Safety Is Paramount A relatively routine operation to remove a tumour has proven three main benefits of being able to make a PSI to the surgeon’s design: safety, patient satisfaction and savings in surgery time. With safety being the paramount priority, supplying a predefined cutting guide and the corresponding implant helped eliminate all the risk that might come from the freehand work of the procedure. Dr Oliver’s own verdict: “It ensured an absolutely safe operation with no risk to the patient.” Patient satisfaction was also a priority and the precision of the PSI enabled the surgeon to provide the aesthetic quality needed. As with more complex facial reconstruc tion procedures, the power of patient-specif ic d e s i g n p r o v i d e d a d d e d dim e n s i o n s o f consistency and predictability. A 30 percent saving in theatre time was the third benefit of this streamlined method. As Dr Oliver noted, “parts were delivered to us according to plan which allowed us to prepare them for the surgery. No adjustment w a s n e e de d dur in g s ur g er y. U s in g t h e 3D-printed cutting guide and implant saved us approximately 30 percent of the time required for this kind of surgery.” For his worldwide peers Dr Oliver believes his approach offers a good model. He comments, “working with precise products and good planning is very positive and recommendable.”

The 30 percent time saving has huge significance for hospital management and health economist s where theatre time is costed by the minute. Therefore every minute saved can offer substantial cost savings for healthcare providers. Additionally, shorter surgery times can help reduce infection risk, accelerate the patient ’s recover y and allow for higher theatre throughput. The digitised workflow connecting design experts, surgeons and manufacturing illustrates the power of global technology transfer and international co-operation. It has the potential to democratise technolog y by giving any hospital, in any corner of the world, access to precision technology, products and materials. Future Outlook As a result of the benefits additive manufacturing offers within the healthcare sector, projects are underway to enable the widespread use of 3D printing to produce bespoke implants through design and laser melting. One example is the award winning project, Additive-manufacture for Design-led Efficient Patient Treatment (ADEPT). Four UK partners have collaborated on the project; engineering company Renishaw, industry partner LPW Technology Ltd, with exper tise application of computer-aided technologies (CAT) in maxillofacial surgery, the Abertawe Bro Morgannwg University Health Board and academic partner PDR, which led the project research. Producing Bespoke Impants The three-year project focuses on advancing design and 3D printing in cranio-maxillofacial surgery in order to produce bespoke implants. The project aims to create new software to produce commercially viable implants using a method that is significantly more efficient than other existing technology. The prototype ADEPT software automates a large amount of implant design, which makes it easier to order patient-specific implants. The work is now in the latest stage of user trials. To complement these initiatives, Renishaw is setting up a global network of solutions centres, which provide a secure development environment for companies that want to build their knowledge and confidence using additive manufacturing technology. Renishaw’s additive manufacturing facilities in Pune, India and Shanghai, China, are cornerstones in Renishaw’s ambition to be a major contributor to the adoption of additive manufacturing in the established and fast growing high technology manufacturing sector in Asia and the Pacific.

FEATURES Asia Pacific Metalworking Equipment News • November - December 2016

Medical Innovation:

SMALLER, STRONGER

Technical expertise and demand for smaller products are driving innovations in the medical sector. By SG Transmission

or metalworking companies focusing o n t h e m e d i c a l s e c t o r, h a v i n g t he te chnolo g ic al k now -how and produc t ion c apabilit ies to create metal components or devices with pin-point precision and repeatability is important. A s teady s tream of innovations is rising in the sec tor, where smaller, more intricate products are also a rising demand for customers. Doing Without The Brakes For example, clutches and brakes are used in a variety of applications in the medical sector, such as surgical robot s, medical imaging equipment and medical actuators. N o w, UK s p e c ial t y manu f ac t ur er S G Transmis sion ha s designed and made a permanent magnetic clutch for medical devices, replacing the need for both a brake and a clutch, saving money and weight. The fail-safe clutch utilises rare earth permanent magnet s to generate the magnetic f ield, which keeps the clutch engaged should the power fail. T he innov at i ve clu tch w a s de sig ned to replace an exis ting clutch in a drive mechanism, which needed power to engage the clutch. The permanent magnetic clutch has the potential to replace both components and not only save space, weight and part count, but also save on cost. Paul Shor t , technical manager at SG Transmission, said: “If the drive system uses a gearbox where the output shaft cannot be ‘back driven’ then, in some applications, by employing a permanent magnetic clutch this mechanical advantage can be used to provide

a p o s i t i v e s t o p/h o ld action in the event of a power failure. Therefore, the permanent magnetic clu tch is sui t able for many sectors including medical and military, where a permanently engaged clutch would be advantageous.” Ultra-Slim Magnetic Brakes Another development was the design of an ultraslim permanent magnetic brake with a brake field depth of less than 13 mm. The design engineers were challenged with designing an efficient magnetic circuit for a robotics manufacturer, where length was restricted and footprint size limited, which also incorporated the coil to de-energise the brake. The ultra-slim brake has been developed by using extremely high energy permanent magnets to obtain its high torque in a small space. The brake has a small outside diameter and a brake field of less than 13 mm, with a comparatively large bore through the centre for the application’s drive shaft. Creating Bespoke Solutions Andy Collinson, chief executive officer of SG Transmission, said that both products were due to their manufacturing facility’s ability to create bespoke solutions, where envelope size is highly tolerant or weight restrictions are present “We are approached by a lot of customers who have previously been told by other manufacturers that their requirements simply cannot be met. It is our job to work alongside the customer to develop an innovative solution, to meet their specification,” he concluded.

The failsafe clutch utilises rare earth permanent magnets to generate the magnetic field, which keeps the clutch engaged should the power fail.

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FEATURES Asia Pacific Metalworking Equipment News • November - December 2016

To thoroughly test them and develop them further to ensure they are fit for everyday use, Walter set up two test segments: In Walter’s manufacturing environment, practical tests are running on ten machines, while a further five machines in the Technology Centre have been equipped with the new digital applications.

DIGITALISATION IN PRACTICE

Digital platforms are being developed on the basis of which users can apply their tools more efficiently, cut back on waste, and minimise tasks that were previously carried out manually. By Walter

he digitalisation of the manufacturing industry is beginning to take shape. T he main objec t i ve ha s alread y been def ined: The continuous digitalisation and networking of all production processes, or “digital manufac turing” for short. In recent months, experts at Walter have come significantly closer to achieving this objective.

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Potential for Optimisation “Of course, digital manufacturing is not an end in itself,” explained Holger Langhans, director of Walter Multiply. “In the discussions that we held with our customers, it always came down to the question of how digitalisation can help them to optimise manufacturing processes (and the processes associated with those), increase productivity and reduce costs.” Since then, Mr Langhans and his team have implemented some of these opportunities in the form of software modules or applications.

Sorting It Out Florian Böpple, expert in digital manufacturing at Walter: “As things stand today, we have more than a dozen apps undergoing continuous testing. Previous results have shown that we are on the right path here: In a very practical way, they are helping to detect and unlock the potential for optimisation in the process chain, to make the processes significantly more transparent, and to visualise the potential.” The solutions involved here address topics that, in practice, affect the everyday work of every manufacturing operation: “We are working on reducing waste when it comes to materials and tools. We are optimising interfaces in the process chain, minimising the manual tasks, and improving the interaction between machines — the machine-to-machine connection.” Optimising Loading One of these applications, which is already running, is used to optimise loading. The principle is simple: The user first selects the program that they want to run next on the machine. The “Loading Optimisation” app automatically compares the tools that are called up in the manufacturing program with those that are already available on the machine. The benefits are obvious: The user can see, at a glance, which tools they should set up and which they shouldn’t; this reduces their average manual effort. And, if there is sufficient space on the machine, they can set up all of the tools that are required for the planned orders. Reducing Costs The “Tool Cost Drivers” app should interest produc tion managers and controllers in particular. They are informed, at a glance, about what tools create which tool costs. This is made possible by the link between real tool usage data from the machine and the purchase prices for the tools. The data can then be used to determine which tool has created the highest costs based on its actual usage, and therefore should be top of the priority list when it comes to optimisation. “So, in a very simple way, we are helping to ensure that the average costs per tool are kept transparent,” Mr Böpple said. Another app called the “Batch-By-Batch

FEATURES Asia Pacific Metalworking Equipment News • November - December 2016

Data can be used to determine which tool has created the highest costs based on its actual usage, and therefore should be top of the priority list when it comes to optimisation. Optimisation” has also been in use at Walter for some time now. It analyses the tool that is currently being used and defines any potential for optimisation by using a sophisticated algorithm. As a result, the application displays a table with the areas that have potential for optimisation, which are possible depending on the batch and the tool. In addition, the entire potential for savings is displayed as a percentage. This information means that users are well-placed to specifically intervene and to unlock the potential for optimisation. Many Fields Of Application More than a dozen of these apps have been developed and used by Walter’s experts since the start of the project (at least a year ago). They are all currently being used in the pilot phase in Walter’s manufacturing. “Our objective is to establish an application platform that covers the most important topics in the manufacturing environment,” added Mr Langhans. “We are already well on our way to achieving this objective”. The software modules are so basic in their design that their universal benefits can be delivered to many sectors – far beyond metal cutting. According to Mr Langhans, “Manufacturing companies often have similar areas where “the screws can be tightened”, which they can use to optimise their processes and structures. Our project is therefore generating a lot of interest from many business partners.” In the near future, several pilot customers will begin using the applications and testing them in practice. Their experiences should help the experts at Walter to further develop the software modules based on the customer-specific requirements. And, in the end, this should deliver the required results under as wide a range of conditions as possible. Open, Modular Approach The application platform follows an open and modular approach and, as a result, can be flexibly adapted to meet forthcoming requirements. In future, users themselves should be able to add their own applications to the platform. Not insignificant: The data that is collected and generated from this sits on the customer’s servers and not in the cloud. “The company stays in control and decides for themselves who

receives what data,” added Mr Böpple. “Generally speaking , we give our cus tomer s an extremely powerful instrument — one which is extremely easy to install and which is simple to operate via the webbased interface.” All applications are based on real-time data, which means that the source of errors, along with optimisation potential, can be very quickly identified. “Our knowledge has been incomparable when it comes to other solutions on the market.” Walter’s new technology centre in Tübingen, Germany is where the application platform is being operated continuously, thoroughly tested and subsequently enhanced. Customers can also try out all of the applications and the platform for themselves.

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Reciprocating Grinding:

CYCLE TIMES CUT F In the automotive sector, reciprocating grinding is the way to go for manufacturing ball nuts in steering sytems. By Markus Isgro, marketing communications, Emag

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ew areas of car design are currently at trac ting more at tention from developers than the steering system. There are several reasons for this: Firstly, complex assistance systems to support the driver are a huge trend in automotive manufacturing. Secondly, customers are increasingly demanding highly precise steering. Both these requirements ultimately give rise to new technological solutions. Purely electrical steering systems, in particular, are becoming more important. They are easier to adapt to different types of vehicles, require less energy (and therefore less fuel) than hydraulic systems, and generally enhance driver comfort. Refining Production Technology These developments, however, are also focusing the attention of the designers on the production of the required components. It often needs to become more precise, and needs to do that with maximum efficiency as well. These conditions are leading to changes in production technology, and a novel approach called reciprocating grinding is able to machine the ball nut of the steering system very finely and reliably.

Emag recently developed a vertical grinding machine utilising reciprocal grinding. Called the VLC 250 PDS, processing time required was reduced by around 30 percent compared to alternative techniques. This approach shows a lot of promise, and other automotive components could benefit from such reciprocating grinding in future. Extreme Precision And Resilience Ball screws are one of the most demanding produc tion t a sk s in the world of met al machining, requiring extreme precision. Only then can the circulating ball bearings roll with minimal friction between the screw shaft and the ball nut, ensuring motion with high efficiency and low driving torque. At the same time, if the assembly is used in a steering system, for example, it must be able to safely withstand the stresses of several thousand hours of driving. Hardening of the part is first followed by external grinding. Then begins the demanding process of grinding the ball track to generate the profile with the quality parameters required. However, this process is relatively time-consuming, especially for ball nuts, because various preparatory steps are needed. Before starting the grinding process

BY THE HAND Asia Pacific Metalworking Equipment News • November - December 2016

“The innovative synchronisation with two pick-up spindles always results in exceptionally low non-productive times and a drop in per unit costs.” – Marina Manger itself, the pre-machined inner profile of the part has to be aligned precisely in the machine so that the grinding spindle can be applied to the runout of the thread. This increases the machine’s non-productive time and drags out the cycle time per part. “It was exactly this situation that led us to collaborate with a German automotive supplier about three years ago to develop a new production solution for the grinding of ball nuts, in the form of the VLC 250 PDS vertical grinding machine,” said Marina Manger from technical sales at Emag. “Our design is ba sed around a fully automated process with two pick-up spindles and two feeding devices. They make it possible for two parts to be active in parallel, but with each of them going through a different step of the process. That saves a great deal of time,” Ms Manger explained. Positioning And Grinding In Parallel The design engineers call this approach reciprocating grinding. Specifically, their design uses the following arrangement: The two pick-up spindles move alongside each other on the same X-axis, but take parts from two different feeders, each of which is located at one end of that axis. This allows, for example, pick-up spindle A to take a par t from the feeding device assigned to it on one side and transport it to the corresponding measuring probe on the machine for positioning, while pick-up spindle B is already in the machining area, transporting a part either to the first grinding spindle for preliminary grinding or to the second grinding spindle for finish grinding. In addition, both the grinding spindles are installed on a rocker that allows the contact angle of the tool to be adjusted according to the lead angle of the ball track. When the twostage grinding procedure is completed, the part is conveyed out of the machine via the feeder. Directly after that, pick-up spindle A transports it s previously aligned workpiece into the machining area from the other side. Perfectly Synchronised The whole process is then performed again

in the reverse direction, forming a perfectly synchronised system in which the positioning of one part and the machining of another part always take place in parallel. Non-productive idle time arising from the alignment process is thus minimised. In practical terms, this means that the cycle time for grinding a ball screw falls by about 30 percent compared with the production processes used previously. Additional speed and high productivity are also contributed by the machine components used: The pick-up spindles are arranged on very rigid compound slide rests and their axis motion is perfectly matched to the specific work task. The powerful linear motor in the X-axis ensures high acceleration. At the same time, the typical Emag approach of using just one clamping operation for the machining process safeguards workpiece quality and process reliability, as it minimises the risk of clamping errors. Operator comfort and ease of access were important priorities for the developers, so large doors allow easy access to the machining area. Tools, clamping equipment, and measuring probes can always be changed quickly. New Market Potential German grinding specialist Emag has seen multiple sales of this machine design since its introduction in 2013. So far it has been used exclusively for machining ball nuts of various sizes at several of the customer’s sites. But the future beckons with new areas of application, according to those in charge of the project at EMAG. Ms Manger is optimistic, saying, “This approach could be used successfully for many two-stage grinding processes. The innovative synchronisation with two pick-up spindles always results in exceptionally low non-productive times and a drop in per unit costs. We want to introduce these benefits more extensively in new areas of application in the years to come.”

Ball screws are one of the most demanding production tasks in the world of metal machining, requiring extreme precision. Reciprocal grinding is a promising approach that saves time.

The cycle time for grinding a ball screw falls by about 30 percent compared with the production processes used previously.

BY THE HAND Asia Pacific Metalworking Equipment News • November - December 2016

RADIUS GRINDING MACHINES

In With The New

A higher level of technology allows radius grinding machines to have more powerful software, grinding of larger workpieces, while having easier maintenance. By Studer

Editorial

Got a Question? Make An Enquiry.

ENQUIRY NUMBER

8502

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rinding machine specialist Studer is bringing three new radius internal c ylindrical grinding machines to market. These are intended to replace theCT700 and CT900 models. The main f ields of application of the company’s new S121, S131 and S141 radius grinding machines are the manufacture of dies, especially in the packaging industry, where tungsten carbide and ceramic are primarily processed, and the production of hydraulic components such as axial pump pistons, guide

plates and housings made of hardened steel, cast iron and copper. Other fields are the production of complex workpieces with several tapers greater than 20 deg to 90 deg in a single clamping, where the main applications are in the watch and medical technology with extra-hard materials such as industrial ceramic, sapphire and tungsten carbide, as well as the manufacture of human implants for shoulders, knees and hips from ceramic and titanium. Out With The Old In the past, this range of parts was covered by the company’s universal internal cylindrical grinding machines CT750 and CT960. With its market entry, the new S121 radius grinding machine will now take over the range of applications of the CT750, while the S131 has been designed for the previous component range of the CT960. New with the S141 radius grinding machine is that the machining of larger workpieces is also now possible: •

The swing diameter above table is 250 mm for the S121, 300 mm for the S131 and 400 mm for the S141.

•

External diameters up to 160 mm can now be machined with an external grinding wheel 250 mm in diameter.

BY THE HAND Asia Pacific Metalworking Equipment News • November - December 2016

• The maximum length of parts including clamping device is 300 mm for all three radius grinding machines • The maximum workpiece weight including clamping device is 100 kg. There are good reasons why Studer is replacing the successful CT models, which translate into increased customer benefit. Firs t and foremos t , a higher level of technology has been achieved with the new radius grinding machines. This is evident in the machine bed, which now comprises of Granitan and thus of fers higher dampening levels, thermal stability and guidance accuracy. It is also reflected in the StuderGuide guideway and drive system with linear motors, which features high wear resistance, a long working life and high dynamics (interpolation possibility). The main benefit which customers can derive from the new machines is the extended range of parts possible due to the larger size of the machine, and the new dressing concept which, thanks to the new arrangement on the B-axis (simultaneously swivelling workpiece table) is

not only simpler, but also offers greater thermal stability and mechanical rigidity. The fact that the new S121, S131 and S141 are now also manufactured according to the Thun modular principle also means non-variable parts in maintenance and service and consequently a higher availability of service technicians. It also means harmonisation of the components and, with the new design and improved ergonomics, an increase in the machine’s value. Powerful Software Special mention should be made of the StuderSIM software in regard to the new radius grinding machines. This software acts as an assistant, with which workpieces derived from a drawing can be completely defined, all necessary geometric data for the grinding cycles can be generated and with which the grinding process can be checked and visualised by means of simulation on a PC or on the machine. It is complemented by hardware which features the previously mentioned Granitan machine bed and the StuderGuide guideway and drive system with linear motors. It also includes X and Z-axes in a cross-slide arrangement as well

The StuderSim software assistant can generate all necessary geometric data for the grinding cycles, and the grinding process can be checked and visualised.

ENQUIRY NO 043

BY THE HAND Asia Pacific Metalworking Equipment News â&#x20AC;˘ November - December 2016

4-position spindle turret (high-precision) with direct drive.

Grinding internal tapers and radii on a die.

The radius grinder machine beds now comprise of Granitan and thus offer higher dampening levels, thermal stability and guidance accuracy.

while the universal cylindrical grinding machines have a swivelling table, which can be positioned from -10 deg to +20 deg. In addition, the spindles on the radius grinding machines are arranged at the rear of the turret, while this is the other way round on the cylindrical grinding machines: they are at the front. There are also differences in the dressing concept. The radius grinding machines have the dresser on the B-axis, while the cylindrical grinding machines are equipped with two swivelling dressers. Last but not least, the S121 to S151 cylindrical grinding machines use the Studer operating system StuderWIN, while the new radius grinding machines use the StuderSIM operating system.

as a cross slide, which in the case of the S121 can either take one spindle, two spindles in parallel or two spindles on a hydraulic turret, and in the case of the S131 and S141 comes with a 4-position turret with direct drive. The machines are also equipped with a workhead on a simultaneously swivelling B-axis, a dressing spindle or a fixed dresser on the B-axis and a measuring probe on the grinding head. Other new features are, finally, the enclosure and the control console in the STUDER design. The S121, S131 and S141 radius grinding machines differ from the universal cylindrical grinding machines of the same name in a number of technical details. The B-axes of the radius grinding machines are set up simultaneously and offer interpolation (from -60 deg to +90 deg),

Market Segments In addition to the S121, S131 and S141 new radius grinding machines, Studerâ&#x20AC;&#x2122;s platform of internal cylindrical grinding machines includes the simple S110 and S120 machines, the S121 to S151 universal internal grinding machines and the S122 production internal grinding machine. Five machines have been replaced (S120, S145, S151, CT700, CT900), enabling four new market segments to be opened up. The S121 universal internal grinding machines are small machines for a large application range, the S122 production internal grinding machine is a machine for large component output and high availability, and the S141 and S151 universal internal grinding machines (700 and 1300 mm) are machines for long workpieces. Finally, a fourth market segment is opened up with the new S141 radius grinding machine for parts up to 400 mm in diameter.

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • November - December 2016

Preview:

MANUFACTURING INDONESIA 2016

Indonesia’s Industry Ministry is on target for investment in the domestic manufacturing industry to reach 270 trillion rupiah (US$21.6 billion) this year alone.

anufacturing is a key pillar of the Indonesia economy. According to the statistical report entitled “ I n t e r n a t i o n a l Ye a r b o o k o f Industrial Statistics 2016”, the manufacturing sec tor in Indonesia is repor ted to have contributed nearly a quarter of the nation’s gross domestic product (GDP). Despite the prevailing global business climate, Indonesia has continued to register positive growth in spite of market challenges. PT Pamerindo Indonesia, the leading exhibition organizer for trade and industrial exhibitions in Indonesia will organize the annual Manufacturing Indonesia 2016 series of exhibition. The 27th international edition of manufac turing machiner y, equipment , materials and services exhibition will be held on November 30 – December 3, 2016, at the Jakarta International Expo, Kemayoran Jakarta. Project Director of PT. Pamerindo Indonesia, Maysia Stephanie commented: “Ongoing developments in the manufacturing sector will carry implications on the Indonesia economy, since its growth will create higher employment oppor tunities in various indus tries thus proliferate upon the state of our economy.” “Not withs t anding the current market c ir c um s t an ce , w e r emain r e s o lu t e and confident on the staging of the Manufacturing Indonesia series of exhibitions, in fact for 27th edition this year. We are highly optimistic that the manufacturing sector will strengthen next year. As a barometer, for the current edition of the exhibition, we have already witness a signif icant grow th on local exhibitors compared to last year.” shared Maysia. “Alt houg h companie s in gener al are cautious with huge purcha ses , they are nevertheless looking into ways of increasing efficiency so that their production process runs optimally. The main focus now is on sustainability. For which, the forward looking business owners and companies are constantly vigilant on opportunities and avenues to drive their competitive advantages while waiting for more favourable market conditions.” she said. PT Pamerindo Indonesia is constantly

innovating at ever y exhibition organized. Through the Innovation Spotlight Content Theatre this year, exhibitors can utilize on this open screen presentation platform to introduce new technologies and/or products that are being launched at the exhibition. “At Manufac turing Indonesia 2016 we want to create a value added service to our exhibitors, in enabling them to engage with the potential buyers through an interactive presentation format on their latest products and/or services. This presentation facility is available at no cost and open to all exhibitors.” explained Maysia. This year, more than 2,000 companies from 32 countries/regions, will be exhibiting including the presence of 22 pavilions from countries and regions such as China, Germany, India , Japan, Korea , Sing apore, Taiw an, Thailand and Turkey. Manufacturing Indonesia 2016 is supported by Ministry of Industry, Republic of Indonesia, A ssociation of Metalwork and Machiner y (ASPEP), Indonesia Precision Tooling Industry Association (AIPPINDO), Indonesian Automotive Parts & Components Industries Association (GIAMM), Indonesian Machine Tool Industries Association (ASIMPI), Indonesian Mould & Die Industry Association (IMDIA), Indonesian Foundr y Industries Association (APLINDO) and Federation of Indonesian Metalworks & Machinery Industries Association (GAMMA).

Manufacturing Indonesia 2016 Jakarta International Expo Nov 30 – Dec 3, 2016 Editorial

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8601

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PRODUCT FINDER

KEEPING YOU INFORMED ON THE LATEST PRODUCTS

Asia Pacific Metalworking Equipment News • November - December 2016

Aicon 3D Systems: MoveInspect Version 7

The MoveInspect Version 7 has a new calibration method, more interfaces, and redesign of the user interface. The new method “reference field and object” is especially suitable for multiple camera arrays like AICON’s 3D Arena. The latest MoveInspect software version works with the new high-resolution HF4 cameras, applicable for measurements of up to 1000 Hz. Additionally, the program is now able to read the measuring results of IES tilt sensors and data recording modules of third-party suppliers and to share the information with the analysis software. Measuring results of either MI.Probe or active probe can directly be transferred to Microsoft Excel. Licensed customers with a valid software maintenance contract will automatically receive the new MoveInspect Software version 7 with the next software update.

ENQUIRY NUMBER

8701

Enerpac: Smart Electric Torque Wrench

Faro: Freestyle3D Objects Handheld 3D Laser Scanner

Faro introduces Freestyle3D Objects, a new mediumvolume, handheld 3D laser scanner for reverse engineering applications. The mid-range scanner is easier to use than narrow field-of-view scanners that have high resolution but are difficult to handle as the tracking is easily lost, yet provides more detail and precision than large volume handheld scanners. With a scan range of 0.3 to 0.8m, Faro Freestyle3D Objects is optimised for scanning mid-sized components and items in almost every industry. Once the object has been measured, the user receives the data prepared in Scene Process 6.1, offering a large scale meshing tool, or the user can export the data into many end user applications.

ENQUIRY NUMBER

8703

Fluke: TiX620 Infrared Camera

The new Electric Torque Wrench tool is operated via a touchscreen housed in an impact and flame resistant control box. Using the touchscreen, the operator is able to input the number of fasteners and the desired torque value for each fastening step, followed by the required angle of turn. This sequence may then be saved as an automatic preset for future use. For simpler jobs, torque values may be input with a digital slider on the touchscreen, or directly into the rear control panel on the wrench. Once the input torque is achieved, the tool stops, and a pass/fail indicator verifies that it is ready to move on to the next fastener. When the job is completed, the fastening record can be viewed on the touchscreen, or exported to a computer via a USB connection on the control box.

ENQUIRY NUMBER

8702

Fluke’s TiX620 Infrared Camera has a 5.6 inch LCD screen and 640 x 480 resolution, enabling thermographers to identify issues and edit images directly on camera while still in the field. The camera provides users with EverSharp multifocal recording which captures multiple images from different focal distances and combines them into one image, displaying each object from foreground to background clearly. The camera also features Fluke IR-Fusion technology with three different operating modes: Picture-in-Picture, full visible light, and Autobland. On-board analytics allow users to adjust or enhance images on the camera without additional software. The SmartView software is included, and provides a suite of advanced tools to view, optimise, annotate and analyse infrared images, and generate customisable reports.

ENQUIRY NUMBER

8704

PRODUCT FINDER Asia Pacific Metalworking Equipment News â&#x20AC;˘ November - December 2016

Heimatec: Unique Flexible Adaptor System

Fronius: Virtual Welding Platform Function Range

Austrian welding technology firm Fronius has expanded the range of functions on its Virtual Welding simulator Practise TIG, allowing practice sessions to become familiar with the welding torch without relying on consumables. Users can also learn how to handle a filler metal through a package for new Virtual Welding systems as standard and can be ordered as an upgrade kit for existing devices, consisting of a terminal with a screen and a shelf on which the user places a plastic workpiece. A faithful replica of a real welding torch is then used to draw a virtual weld seam, which is reproduced in real time as a graphic on the screen and can be examined through 3D glasses for a realistic view of the work. Current training functions cover MIG/MAG, robot and manual metal arc processes.

ENQUIRY NUMBER

8705

The unique Heimatec u-tec flexible adaptor system for all Angle Head tools is suitable for most popular brands of machine tools in the global market and allows a standard ER output live tool to accept various adaptor s for dif ferent applications. As well, quick changeover of tools on almost any lathe or mill is possible and a face mill adaptor can be quickly positioned on the standard tool holder, which reduces cost and changeover time. Heimatec has ensured that the unique polygonal drive highpower transmission guarantees great stability and no loss in performance and accuracy and that the u-tec system with its internal threading enables the cutting tool to remain closer to the bearing to increase rigidity and performance. Among other key features, Angle Head tools are available in offset and slim version, for special machining tasks where immense space constraint appears and special plunging offset output is required to maximize the usable tool length.

ENQUIRY NUMBER

8706

ENQUIRY NO 044

PRODUCT FINDER Asia Pacific Metalworking Equipment News • November - December 2016

Kennametal: KM4X63 Tool System Hexagon: Global Evo CMM

The Global Evo coordinate measuring machine (CMM) from UK-based Hexagon Manufacturing Intelligence and designed in collaboration with the internationally-renowned industrial design house Pininfarina sets its goal as speed. St ate-of-the-Ar t technolog y allows pushing the boundaries of performance along with a patent-pending Compass vibration-reduction system to combine speed and accuracy for the fastest tactile scanning performance for a CMM in its class.

ENQUIRY NUMBER

8707

Hypertherm: SilverPlus 400 Amp Electrode

Hypertherm introduces SilverPlus 400 amp electrode for its HyPerformance HPR400XD plasma cutting systems, able to deliver a consistent range 4 and 5 cut quality. By fusing the silver tip to a copper blank, SilverPlus electrodes are designed to last to a pit depth of at least 0.080 of an inch, when compared to standard electrodes that last to a pit depth of 0.040 of an inch. When used with an oxygen plasma gas on mild (carbon) steel, the electrodes can burn deeper than copper electrodes. All these act as factors designed to improve nozzle life. In addition to the 400 amp version, 130, 200 and 260 amp versions are also offered.

ENQUIRY NUMBER

8708

Kennametal’s new KM4X63 range has a 100 mm spindle connection with four ball tracks instead of two and up to 40 percent greater clamping force than comparablysized tooling. It also has a maximum bending moment of 2,100 Nm and, depending on the machine, clamping force of 36 to 58 kN. The spindle connection can reach spindle speeds of 38,000 rpm due to its inherently balanced design, nearly twice that of similar tool holders. 30 new line items, most of which will be extensions in the 80 to 200 mm range, and centreline turning tools to support mill-turn applications, will be added by end of 2016.

ENQUIRY NUMBER

8709

LVD: Flexible Automation For Punching

LVD’s Flexible Automation for Punching (FA-P) system for its Strippit-PX series of punch presses offers advanced load/ unload, part picking and a large area for stacking punched parts directly onto the allocated pallet. The system loads sheets up to 3050 x 1525 mm and material thicknesses up to 4 mm from two shuttle tables with a maximum capacity of 3000 kg. The automation system can handle punched parts from 200 x 100 mm to large sheet sizes. A large stacking area of 8 m² provides space for 8 euro pallets. A unique laser distancesensor measures the height of the pallet and the stacked parts. Following this measurement, the punched parts are directed from the table to the correct pallet piece by piece.

ENQUIRY NUMBER

8710

PRODUCT FINDER Asia Pacific Metalworking Equipment News • November - December 2016

ENQUIRY NO 144

ARNO – DECO CUT DECO-CUT is a modular system for manufacturing small, thin-walled and accurate parts. • Shank sizes from 8x8 to 20x 20 mm and cylindrical shank Ø 10 mm

Mate: Ultra QCT Quick Change Tooling

Mate Precision Tooling has introduced a quick change, toolless thick turret punching system, the Ultra QCT. Designed for faster setups, Ultra QCT features a tool-less punch retention mechanism. The setup involves flipping the latch to remove and, a snap, to place the new insert. The punch is keyed at the perimeter of the tool – not the centre – providing greater angularity control. The shoulder of the punch remains securely guided by the guide when punching. Only one punch driver is needed for rounds or shapes. Ultra QCT is a longer lasting tooling as the punch insert is made from MPM4 tool steel. Independent studies have shown M4PM to last as much as 56 percent longer than conventional high speed tool steels.

ENQUIRY NUMBER

Features • Double sided insertsa • Due to V-shaped insert pocket with 3-point location a very strong insert location is achieved with highest repeatability in insert length and height • Quick insert changes due to centrally located screw • Geometries specially developed for swiss style auto lathes • Fine grain carbide with or without high performance PVD coatings • Ground shanks on all toolholders Have a look at the Arno sliding head auto tooling. http://www.arno.de/katalog/05_1_o/

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

www.arno.com.sg

8711

CAMPRO 049

ENQUIRY NO 049 ENQUIRY NO 049

PRODUCT FINDER Asia Pacific Metalworking Equipment News • November - December 2016

Sandvik Coromant: CoroPlus Platform

The CoroPlus plat form f rom S and v ik Coroman t gives access to connected s olu t ion s t ha t incre a s e security and save time in design and planning. The platform spans from connec ted cut ting tool s to software solutions and IoT devices, such as being able to remotely adjust the cutting diameter on your fine boring tool for quick and easy set-ups with Corobore. Promos 3+, developed by Prometec, enables on-site or cloud-based solutions that give access to information from a micro to macro perspective. Other tools include the CoroPlus ToolGuide that allows retrieval of the speeds and feeds for the tool assembly via an open Application Programming Interface (API) connecting to the CAM software, and Silent Tools, a connected dashboard that expands opportunities for in-cut monitoring, process learning and optimisation.

ENQUIRY NUMBER

8712

Siko: AP05 Bus-Compatible Position Indicator

Siko’s new AP05 is attachment-compatible and has the same attachment dimensions as its predecessor. It also has an inverted, backlit LCD display. Along with the LCD directional arrow, the AP05 position indicator also offers intuitive user guidance via the right and left status LEDs, both integrated into the case and in two colors. These not only signal positional status (InPos or OutPos) but also simultaneously indicate the required rotational direction. The AP05 can be equipped with either an RS485 or a CAN interface. With a hollow shaft, it can accommodate spindle shafts of up to 20mm in diameter. It also has a connector plug with optional cable outlet and an integrated magnetic absolute value transmitter.

ENQUIRY NUMBER

8713

TC/American Crane Company: Jet Engine Monorails And Cranes Systems

TC/A mer ic an je t eng ine handling s y s tem s include specialised equipment such as lift stations, track openers and turntables meet facilit y layout and produc tion requirements. These systems keep the engine off floor carts and enable engine access below, above and all sides during assembly or disassembly. Each system star t s from a line of pre-conf igured monorails and cranes systems which are customised to building and application requirements. Engine carriers may consist of a simple set of trolleys attached to engine tooling for manual positioning. Or they may consist of a motorised carrier with hoists connected to a load beam or other unique lifting points on the engine fixture. Engine technicians operate these carriers via pushbutton pendant, radio or infrared controls for precise control with maximum safety.

ENQUIRY NUMBER

8714

ZWSoft: ZW3D 2017 Beta

ZWSoft’s ZW3D 2017 Beta brings new features and numerous enhancements to improve efficiency and minimize overheads in the process of designing and manufacturing. The new hem flange allows expanded flange creation with all necessary pre-defined hem types provided, and the brand-new jog helps users create 2 bends at one time to better suit design technology T h e C A M m o du le in Z W 3 D 2 0 1 7 b e t a h a s n e w functionalities, in a bid to improve the efficiency & reliability of CNC machining. For example, the flat finishing operation is added to automatically detect all planes and generate tool-paths accordingly in one click. The program also reduces the file sizes of various formats, like NX, Step and z3 by 30 percent compared to previous versions.

ENQUIRY NUMBER

8715

2016 - 2017 Asia Pacific Metalworking Equipment News • November - December 2016

NOVEMBER 23 – 26 Metalex Thailand 2016

Bangkok International Trade & Exhibition Centre

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

23 - 27

Taiwan International Machine Tool Show Greater Taichung International Expo Center

EXHIBITION PROGRAMMES

MARCH 7 – 12, 2017 TIMTOS 2017

Taipei World Trade Center 5, Hsin-yi Rd. Section 5 Taipei, Taiwan TAITRA (Taiwan External Trade Development Council)

APRIL 5 – 7, 2017

Vietnam Manufacturing Expo 2017

17 – 20, 2017

INTERMACH 2017 SUBCON Thailand 2017 Sheet Metal Asia 2017

Bangkok International Trade & Exhibition Centre

8 Bangna-Trad Road (Km.1), Bangna Bangkok 10260 Thailand UBM ASIA (Thailand) Co Ltd.

JUNE 21 – 24, 2017

91 Tran Hung Dao Str. Hanoi,Vietnam Reed Tradex Company

MANUFACTURING EXPO 2017 INTERMOLD 2017 NEPCON 2017

Manufacturing Indonesia 2016

4 - 7, 2017

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

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

1 Expo Drive Singapore 486150 Singapore Exhibition Services Pte Ltd

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

NOVEMBER 30 – DECEMBER 3

Jakarta International Expo

2017

JANUARY 18 – 20, 2017

NEPCON Japan 2017 Tokyo International Exhibition Center (Tokyo Big Sight) 3-21-1 Ariake, Koto-ku Tokyo 135-0063, Japan Reed Exhibitions Japan

JANUARY 26 – FEBRUARY 1, 2017

IMTEX 2017

Bangalore International Exhibition Centre

10th Mile, Tumkur Road Madavara Post, Dasanapura Hobli Bangalore 562 123, India IMTMA (Indian Machine Tool Manufacturers Association)

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

MTA 2017

Singapore Expo

MAY 11 – 14, 2017

MACHINE TOOLS THAILAND 2017

Bangkok International Trade & Exhibition Centre (BITEC)

JULY 4 – 7, 2017

MTA VIETNAM HO CHI MINH 2017 Saigon Exhibition & Convention Center - SECC

799 Nguyen Van Linh Parkway Tan Phu Ward, District 7 Ho Chi Minh City Singapore Exhibition Services Pte Ltd

Bangkok International Trade & Exhibition Centre 8 Bangna-Trad Road (Km.1) Bangna, Bangkok 10260 Thailand UBM ASIA (Thailand) Co Ltd.

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

The Editor (APMEN)

Eastern Trade Media

12 Hoy Fatt Road, #03-01 Bryton House Singapore 159506 Email: apmen@epl.com.sg Tel: (65) 6379 2888 Fax: (65) 6379 2886

ADVERTISING INDEX

Asia Pacific Metalworking Equipment News â&#x20AC;¢ November - December 2016

Page Number

Enquiry Number

AGATHON AG

153

AGMACHINE TECHNO CO LTD

044

ARNO WERKZEUGE S.E.A. PTE LTD

144

BEHRINGER GMBH

143

BENIGN ENTERPRISE CO LTD

146

COMPRO PRECISION MACHINERY CO LTD

049

CREAFORM

132

DEES HYDRAULIC INDUSTRIAL CO LTD

045

HEIMATEC GMBH

027

HEXAGON MANUFACTURING INTELLIGENCE

149

HWACHEON ASIA PACIFIC PTE LTD

152

ISCAR LTD

IFC

139

KENNAMETAL INC

122

LIEN CHIEH MACHINERY CO LTD

043

MARPOSS KABUSHIKI KAISHA (SINGAPORE BRANCH)

150

OKUMA CORPORATION

IBC

138

OPTICAL GAGING (S) PTE LTD

145

PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA 2016)

137

REED EXHIBITIONS JAPAN LTD

154

SCHUNK INTEC PTE LTD

140

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2017)

156

SUTTON TOOLS PTY LTD

151

TAIWAN TAKISAWA CO LTD

050

TORNOS TECHNOLOGIES ASIA LTD

061

TRUMPF PTE LTD

141

TUNGALOY SINGAPORE (PTE) LTD

155

UBM ASIA (THAILAND) CO LTD (INTERMACH 2017)

142

UNITED GRINDING GROUP

147

WALTER AG SINGAPORE PTE LTD

117

YIH CHUAN MACHINERY INDUSTRY CO LTD

148

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ASIA PACIFIC METALWORKING

No. 8 2016

The Engineering Journal For Manufacturing,Automation & Quality Control

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CNC Machining Milling Gear Cutting Grinding Stamping Shearing

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EDM/ECM Inspection/Measuring/Testing Design with CAD/CAM Drilling/Boring Tapping/Threading Lapping/Honing

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Forging Rolling Die Casting Welding Turning Coil Forming

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Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

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❑ No ❑ No ❑ No

YOUR METAL PROCESS USED ? (Please be specific) ❑ 300 ❑ 303 ❑ 306 ❑ 309 ❑ 315 ❑ 318

CNC Machining Milling Gear Cutting Grinding Stamping Shearing

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EDM/ECM Inspection/Measuring/Testing Design with CAD/CAM Drilling/Boring Tapping/Threading Lapping/Honing

❑ 313 ❑ 316 ❑ 319 ❑ 322 ❑ 302 ❑ 305

Forging Rolling Die Casting Welding Turning Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 OTHERS (Please specify)

YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122

Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg. Dies & Moulds mfg. Motor Vehicles Parts

❑ 123 Shipbuilding ❑ 160 Design & Consultancy Services ❑ 180 Govt bodies, Trade Assns, Exhibitions Cos. ❑ 200 Agent/Distributor/Trader of Machine Tools & Accessories ❑ 224 Mechanical, Fabrication and all other metal engineering works ❑ 078 OTHERS (Please specify)__________________________________

JOB FUNCTION (Please be specific) ❑ 021 Senior & Middle Management ❑ 023 Maintenance Engineering ❑ 025 Research & Devt

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