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Nov-Dec 2011
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ENQUIRY NO 200
www.iscar.com www.iscar.com ISCAR ISCAR JAPAN JAPAN 1-5-3 1-5-3 Shinsenri-Higashimachi Shinsenri-Higashimachi Toyonaka-shi, Toyonaka-shi, Osaka Osaka 560-0082 560-0082 Tel Tel + 81+ 681 835 6 835 54715471 Fax Fax + 81+ 681 835 6 835 54725472 iscar@iscar.co.jp iscar@iscar.co.jp
ISCAR ISCAR TAIWAN TAIWAN 395,395, Da Duen Da Duen South South Rd. Rd. Taichung Taichung 408 408 Tel Tel +886+886 (0)4 (0)4 247 247 31573 31573 Fax Fax +886+886 (0)4 (0)4 247 247 31530 31530 iscar.taiwan@msa.hinet.net iscar.taiwan@msa.hinet.net
ISCAR ISCAR THAILAND THAILAND 57, 59, 57, 61, 59, 63 61,Soi 63 Soi Samanchan-Babos Samanchan-Babos Sukhumvit Sukhumvit Rd. Rd. PhraPhra Khanong, Khanong, Khlong Khlong ToeyToey Bangkok Bangkok 10110 10110 Tel Tel+ 66+ (2) 667136633 (2) 7136633 Fax Fax + 66+ (2) 667136632 (2) 7136632 iscar@iscarthailand.com iscar@iscarthailand.com
ISCAR ISCAR VIETNAM VIETNAM (Representative (Representative Office) Office) Room Room D 2.8, D 2.8, Etown Etown Building, Building, 364 364 Cong Cong Hoa,Hoa, Tan Tan BinhBinh Dist., Dist., Ho Chi Ho Chi MinhMinh City,City, Tel Tel+ 84+ 884 8123 8 8123 519/20 519/20 Fax Fax + 84+ 884 8123 8 8123 521 521 iscarvn@hcm.fpt.vn iscarvn@hcm.fpt.vn
CV MULTI CV MULTI TEKNIK TEKNIK Ruko Ruko GSAGSA Block Block B B No.08 No.08 BN-BP, BN-BP, Podomoro Podomoro CityCity Jl. Letjen Jl. Letjen S.Parman S.Parman Kav.28 Kav.28 Jakarta Jakarta Barat Barat 11470 11470 - Indonesia - Indonesia Tel Tel+62 +62 21 29206242/44/45 21 29206242/44/45 Fax Fax +62 +62 21 29206243 21 29206243 contact@multi-teknik.co.id contact@multi-teknik.co.id
SINO SINO TOOLING TOOLING SYSTEM SYSTEM Blk Blk 502,502, Jurong Jurong WestWest Ave Ave 1 #03-813 1 #03-813 Singapore Singapore 640502 640502 Tel Tel+ 65+ 6566 65 6566 76687668 Fax Fax + 65+ 6567 65 6567 73367336 sinotool@singnet.com.sg sinotool@singnet.com.sg
MESCO MESCO Reliance Reliance Corner Corner Brixton Brixton St. Pasig St. Pasig CityCity Metro-Manila Metro-Manila Philippines Philippines Tel Tel + 63+ 2631 63 2631 17751775 Fax Fax + 63+ 2635 63 2635 02760276 mesco@mesco.com.ph mesco@mesco.com.ph
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ENQUIRY NO 001
Contents
First Cut
26 The Search For A Better Ecological Solution
Strict regulations and economic reasons have resulted in the rise of the concept of machining without metalworking fluids. By Dr Moshe Goldberg, Iscar
28 Wet & Dry Machining
Augustine Quek explores the different issues involving wet and dry machining
Technology Insights
32 Green Shipbuilding: Benefiting The Builders & The Environment
The green measures imposed on shipbuilders not only help in reducing harmful emissions but also act as a sustainable building measure, which results in the production of more reliable ships. By Amreet Singh
34 Transforming Business Through Digital Manufacturing
From automotive and aerospace, to fabrication and assembly, even shipbuilding, companies require the right digital infrastructure to define, plan, create, monitor and control all processes. By Samson Khaou, Dassault Systèmes (ASEAN)
Software & 36 Metrology
Using Modern Tools For Sheet Metal Reverse Engineering & Inspection Three-dimension self-positioning laser scanners can provide full, accurate and fast assessment of the sheet metal, which guarantees the quality control of vehicle parts and assembly of full-sized vehicles. By Robert Wang, Creaform Shanghai
Fab & Form
38 Hold It Right There!
Circular vacuum chuck allows tension-free clamping for turning. By Wolfgang Klingauf, Klingauf PR and Maren Röding, Witte
40 Hold On Tight The ‘seat belt’ for cutting tools allows heavy metal removal. By Wolfgang Klingauf, k+k-PR, for Haimer
2
metalworking equipment news Nov-Dec 2011
Damian Searles, Brisbane, Qld, Australia
November-December 2011
Best choice. We support you. Laser | Bending | Waterjet bystronic.com ENQUIRY NO 195
Contents
November-December 2011
Industry Focus
42 Automation: Cutting Away Constraints
It is now possible to process G-code directly with the integrated CNC kernel on the robot controller. By Alexander Bay, Kuka Roboter
ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806. SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/ Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: irenetow@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS
46 Sensible Use Of Sensors In Industries Shahnawaz Abdul Hamid investigates the use of sensors that improve safety in the metalworking industry.
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INDUSTRY Endorsements
Features Walter In Asia
The CEO of Walter Asia Pacific talks to Asia Pacific Metalworking Equipment News in this exclusive interview to dissect the company’s performance in the past year. By Joson Ng
SPETA
Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA)
52 Newline And Makino Technology Center Grand Opening
Federation of Malaysian Foundry & Engineering Industry Associations
Five years in the making, the technology centre in Malaysia opened to much fanfare and optimism. By Joson Ng
54 Moving Forward
Kennametal recently moved its office in Singapore, and Asia Pacific Metalworking Equipment News spoke to John Chang, the company’s VP and MD of Asia in an exclusive interview to find out more about the move and also the company’s plans for Asia. By Tjut Rostina and Joson Ng
Indian Machine Tool Manufacturing Association (IMTMA)
58 Events & Exhibition
China Machine Tool & Tool Builders' Association (CMTBA)
• Special Report: From The World Of Metalworking • CAD/CAM Partnership Continues To Blossom With Product Launch SeaCAD and Dassault Systèmes SolidWorks
Machine Tool Club (MTC)
release the 2012 version of the design software. By Shahnawaz Abdul Hamid
• Event Review: Vietnam Manufacturing Expo 2011 • Event Review: Wire/Tube Southeast Asia 2011
Regulars 08 74
4
Business News Product Finder
metalworking equipment news Nov-Dec 2011
79 Exhibition Programmes 80A Product Enquiry Card
Taiwan Association of Machinery Industry (TAMI)
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Refer to Advertising Index
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For Advertiser's Enquiry Numbers
ENQUIRY NO 111
editor’s note
Published by:
Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)
Reg No: 199908196C
managing director Kenneth Tan
Let’s
editor Joson Ng
Bank On
Metalworking
A quick flip through the financial section of any major newspapers today and what you are likely to find is probably news that make you cringe in your seat. From the impending bankruptcy of an entire nation to the imminent reduction in credit ratings in several others, the world economy seems to be heading towards more uncertainties. Instead of threading carefully with a tinge of trepidation, the people in the metalworking industry are predicting great things in the coming year. Even the more conservative ones feel the current positive climate should continue well into 2012. The general consensus among those in the metalworking industry is that the financial cycle runs differently from the business cycle. Despite some European countries operating dangerously in the red, the mood at EMO Hannover was entirely different. Good crowds and solid results defied the financial wet blanket draped across the Euro Zone. E mpha si si n g t he p oi nt , D r
josonng@epl.com.sg
business development manager Randy Teo
Wilfried Schäfer, executive director of the German Machine Tool Builders’ Association said: “The machine tool industry continues in full swing. In the course of the past six days (at EMO), the order volume reached a minimum of €4.5 billion (US$6.0 billion).” Though the financial and business cycles are not entirely independent of each other, there is no reason to panic as of now. This overall positive mood is summed up nicely by Klaus Ludwig, VP of Hwacheon Machine Tool. He pointed to the orders currently available in the market and there are no pertinent signs or talk that indicate an impending downturn. Even if there were to be one, he feels it is important to remain positive but till then, there is no reason to hold back on developments or investments because businesses go on, even in the worst of times. Finally, as the year slowly winds down to a close, we at Asia Pacific Metalworking Equipment News would like to wish you happy holidays and a fantastic year ahead.
randyteo@epl.com.sg
editorial assistant Sharifah Zainon sharifah@epl.com.sg graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow
irenetow@epl.com.sg
contributors Dr Moshe Goldberg Augustine Quek Amreet Singh Samson Khaou Robert Wang Wolfgang Klingauf Maren Röding Alexander Bay Shahnawaz Abdul Hamid Tjut Rostina board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR
All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 053/06/2011 PPS 840/09/2012 (022818) ISSN 0129/5519
Eastern HOLDINGS Ltd Executive Board
chairman Stephen Tay group executive director Kenneth Tan financial controller Robbin Lim
etm Joson Ng Editor
6
metalworking equipment news Nov-Dec 2011
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Trade Media Pte Ltd an Eastern Holdings Ltd company
Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806
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Walter AG Singapore 20 Science Park Road, #01-04A / 05, Teletech Park Singapore Science Park II, Singapore 117674 www.walter-tools.com www.youtube.com/waltertools www.facebook.com/waltertools
ENQUIRY NO 170
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Businessnews
Bystronic Celebrates 25 Years Niederönz, Switzerland: The supplier of complete solutions for the processing of sheet metal is this year celebrating its 25th anniversary. It was in the light of this that during a three-week period in September, the Bystronic Competence Days were held at its headquarters in Niederönz. During the total of 11 individual events, some 1,000 guests from almost 50 countries participated. T h e p r o g r a m co n si s te d of technical presentations and
discussions about the current issues in the field of sheet metal processing, of live presentations, and a tour of the production plant. At the va rious events, Bystronic’s CEO Ferdi Töngi expressed his opinion that the company will continue to maintain its track record, but at the same time pointed out that challenges will not decrease in the future. “In a changing environment, our task will continue to be the satisfaction of the requirements of a discerning
group of customers,” said Mr Töngi. In Niederönz the prime output is laser and waterjet cutting systems for the worldwide market. Other development and production centres are based in Gotha (Germany), Tianjin (China) and Brasov (Romania). Gotha and Tianjin share the responsibility for the production of pressbrakes. Tianjin is additionally responsible for the manufacture of laser cutting systems for the Chinese market. In Brasov, on the other hand, secondhand machines are refurbished for sale on the secondhand market. Additionally, the company has sales and service subsidiaries in 25 countries.
Get news on technologies and products. Post your comment and be heard. It's a 2-way street now.
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metalworking equipment news Nov-Dec 2011
German Quality from Europe s No.1! ■ 50.000 quality tools ■ More than 500 leading brands ■ The System Partner – always by your side ■ Exclusive premium brand GARANT
Represented by: Sutton Tools Singapore Pte Ltd No. 1, Ubi View #03-18 Focus One Singapore 408555 Tel: +65 6745-6388 • Fax: +65 6745-5080 E mail: suttontools.sg@sutton.com.au
Engineering Innovation Co.,Ltd. 3/279 Moo 9 Suvintawong Rd. Lumpakchee Nongchok Bangkok 10530, Thailand Tel: 662-9984045; 662-5435734 • Fax: 662-9984047 E mail: enginno@truemail.co.th enginno.service@gmail.com
CBN Engineering Sdn. Bhd. No, 20 Jalan 51/205 Highway Centre, 46050, Petaling Jaya Selangor Darul Ehsan, Malaysia Tel: 60-3-77852333 • Fax: 60-3-77883318 E mail: engineering@cbn.com.my
PT. Rukun Sejahtera Teknik Komplek Ruko Glodok Jaya No. 80-81 Jl. Hayam Wuruk Jakarta 11180, Indonesia Tel: 021-628 1615 (Hunting) • Fax: 021-626 5559 E mail: marketing@abrasive-tools.com www.rsttools.com
www.hoffmann-group.com
Bon Industrial Sales 35 Macopa St., Quezon City, Philippines Tel: 781-2740; 749-3672; 740-0458 • Fax: 712-4771 E mail: bonind@skyinet.net Manila Branch: 554 Rizal Ave., Cor. Raon St. Sta. Cruz, Manila, Philippines Tel: 734-2740; 733-1532 • Fax: 733-1534; 733-1569
ENQUIRY NO 122
businessnews
www.equipment-news.com
EMO Hannover Stimulates Business In The Machine Tool Industry
Hannover, Germany: Staged under the motto of ‘Machine Tools & More’, the six-day event in Hannover featured the latest machinery, solutions and services for every aspect of metalworking. Some 2,037 exhibitors from 41 different nations took part in the event. “The machine tool industry continues in full swing. In the course of the past six days, the order volume reached a minimum of €4.5 billion (US$6.1 billion),” said Dr Wilfried Schäfer, executive director of the German Machine Tool Builders’ Association (VDW), the organiser of the event. “Against the backdrop of an upswing in orders over the past few months, EMO’s positive outcome means an even stronger market footing for exhibitors,” said Dr Schäfer. With nearly 40 percent of all attendees coming from abroad, exhibitors were delighted with the event’s international turnout. “ T h e s t r o n g i n te r n a t i o n a l
appeal makes the show unique throughout the industry, and is a key factor in its success,” said Dr Schäfer, adding that he saw the show as a reflection of ongoing globalisation. This accounted for a shift in foreign attendance, with an increase of more than 6.5 percent in the ratio of foreign visitors from outside Europe, particularly Asia and South America, which in turn led to record-breaking figures for the duration of stay per visitor: “One out of every four attendees spent more than three days at EMO 2011,” Dr Schäfer emphasised. Among foreign visitors, this figure even reached 75 percent. Around half of all attendees said their investments were targeted at expanded capacities, while 20 percent were planning to make first-time purchases of machine tools. The show attracted some 140,000 visitors from more than 100 countries over six days.
Vero Software & Planit Holdings Merge
G louce s ter s h i r e , U K : Ve ro Software, a provider of CAD/ CA M /CA E solut ion s for t he tooling industry, has merged with Planit Holdings, a developer of CAD/CAM software for the production engineering, sheet metal, metal fabrication and woodworking sector. The combination of Vero and Planit creates the third la rgest CA D/CA M vendor — only behind Dassault Systèmes and Siemens PLM*. The merger of the two orga nisations will provide the platform to build even stronger products through enhanced development capabilities and further extend a g row ing in f luence on t he global market. * Source : CIMData
Ford India Breaks Ground For Second Plant India: Ford India has opened its 76,000 square feet (7,060 sq m) Parts Distribution Centre near Gurgaon in Haryana to support its growing sales. Despite challenging market conditions, the company’s sa les have increa sed by 35 percent so far this year. Earlier, the company broke ground for its new plant in Sanand, Gujarat. 10
metalworking equipment news Nov-Dec 2011
The company sold 90,612 wholesale and export vehicles from Ja nua r y to September 2011, compared to 67,253 units sold during the same period last year – a 35 percent increase year-over-year. In September 2011, the company had combined wholesales and exports of 10,270 units.
The compa ny ha s a lso inaugurated a warehouse for spare parts in northern India near Gurgaon in Haryana state. To support its growing sales, the company is set to expand its sales and service network to more than 200 outlets in 120 and beyond cities by the end of this year.
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ENQUIRY NO 189
businessnews
SolidWorks 2012 Released Singapore: DS SolidWorks has unveiled the SolidWorks 2012, a 3D design solution that enables users to work more efficiently and have the data they need to make better design decisions throughout the product development process. The 20th release of the CA D software provides more than 200 new functions to users. Benefits take shape throughout the software with a variety of improvements in areas such as assembly and drawing capabilities, built-in simu lat ion, de sig n cost ing, routing, image and animation c re at ion a nd pro duc t dat a management that will positively impact design teams each and every day. “SolidWorks 2012 focuses on the a re a s that w ill help our customers drive t he i r bu si ne s se s to h i g he r productivity and profitability,� said Sharon Toh, GM, South Asia for SolidWorks.
www.equipment-news.com
Gildemeister Sold 847 Machines At EMO
Bielefeld, Germany: With order intake of â‚Ź207.6 million (US$282.7 million) and 847 machines sold, Gildemeister takes positive stock of the EMO 2011. This trade fair was the most successful EMO of all time for the company with the highest order intake at a trade fair in its history. Moreover 5,746 follow-up offers could be triggered, building the basis for a successful order intake within the next few months. The company also exhibited energy solutions and presented live how companies can generate and even store a part of their energy needs themselves by solar and wind technology.
Nissan Sets Global Benchmark Yokohama, Japan: Nissan Motor announced the world's first* ultra high tensile strength steel rated at 1.2 gigapascals (GPa) which is highly formable, to the extent that it can be used for cold pressing structural body parts. To be deployed globally in models across the company's lineup from 2013, it will reduce vehicle body weight by up to 15 kg, representing a step in improving environmental impact as well as driving performance. Developed in collaboration with Nippon Steel Corp and Kobe Steel, the ultra high tensile strength steel will be used for centre pillar reinforcements, front and side roof rails and other key structural components. By exceeding the 12
metalworking equipment news Nov-Dec 2011
structural body performance of previous materials with less thickness, the steel will contribute to increased dynamic performance and fuel economy. T he mater ia l w ill a lso contribute to lower total costs including that of manufacturing, as superior cold-pressing formability supports mass production. This breakthrough overcomes significant obstacles. Until now, high tensile strength steel involved a critical trade-off: increased strength came with increased rigidity and a consequent reduction in press formability. Traditionally, only high tensile steel rated up to 980 MPa can be used in cold pressing structural body parts, requiring complex press work.
The 1.2 GPa steel, combined with Nissan-developed advances in welding methodology, overcomes both obstacles. Development of the material was realised by a breakthrough in the ability to control its structural formation at the submicron level in combining hard and soft layers to achieve both strength and formability. O n c e t h e m a te r i a l w a s developed, extensive experimentation was required to develop an optimal spot-welding methodology. This has been achieved with a proprietary process that involves optimisation of welding pressure, current volume and power distribution. * For use as structural body parts in cold pressing
ENQUIRY NO 202
businessnews
www.equipment-news.com
Fraunhofer: Laser Polishes Components To A HighGloss Finish Germany: Fraunhofer researchers will be presenting a machine tool that uses laser polishing to give even complex 3D surfaces a high-gloss finish. In collaboration with the companies Maschinenfabrik Arnold and S&F Systemtechnik, researchers at the Fraunhofer Institute for Laser Technology ILT have developed a type of machine tool, which can polish both simple and complex surfaces using laser beams. “Conventional methods remove material from the surface to even it out. Our method is different: It uses a laser to melt a thin surface layer roughly 20 to 100 µm deep,” says Dr-Ing Edgar Willenborg, section head at the ILT. “Surface tension — a property that applies to all liquids — ensures that the layer of liquid metal solidifies evenly.” Depending on the material, the project team can already produce surfaces with an average roughness (Ra) of between 0.1 and 0.4 µm. “Hand polishing can still get better results than that,” Dr Willenborg admits, “but the point is that in many applications — for example moulds for glass-making, forming and forging tools — a medium-quality surface is all that is needed.” The machine has the potential to save considerable amounts of time and money in these areas: The machine polishes surfaces up to 10 times faster than a hand polisher and is an option for serial production and for polishing small batches.
APPOINTMENTS
Klas Forsström Is The New President Of Sandvik Coromant
Klas Forsström
Klas Forsström has taken over the position of president of Sandvik Coromant. Mr Forsström has been with the Sandvik Group for about 17 years, mostly at Sandvik Coromant. His work has included leading positions in R&D, product development, marketing, business development and sales. Most recently he held the position as president of Sandvik Hard Materials.
Berry Metal Names John Mroz As VP Of Sales & Marketing
John J Mroz
How it Works
• Laser melts thin surface layers • Surface tension ensures the layers of liquid metal solidifies evenly
Berr y Metal Company has announced the addition of John J Mroz as VP of Sales and Marketing. Mr Mroz will be responsible for providing customers with technical support and service in the use of injection lances for steelmaking. Prior to joining the company, he was employed by Heraeus Electro-Nite Company as sales manager, steel products and by LTV Steel Corp as part of their Steel Producing Operations Management team.
NX 8 Enhanced Singapore: Siemens PLM Software has announced the release of NX software, the company’s integrated computer-aided design, manufacturing and engineering a na ly si s (CA D/CA M /CA E ) solution. The software includes enhancements to its CAE offering — including its NX Nastran software for solving simulation problems. NX 8 for simulation offers solutions for optimisation and multi-physics analysis, along with 14
metalworking equipment news Nov-Dec 2011
Siemens PLM
methods for analysing complex assemblies. Enhancements to NX Nastran include improvements in nonlinear and dynamic analysis, as well as increases in computational performance and modeling ease-
of-use. The new and existing functionality in NX CAE helps reduce the time spent preparing and solving analysis models by up to 70 percent when compared to traditional CAE tools.
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Flow Asia Opens New Office
Manufacturing Technology Orders Up 101 Percent From 2010
Hsinchu, Taiwan: Flow Asia Corp has invested some US$500,000 (remodeling work) in an office at Hsinchu Science Based Industrial Park in Taiwan. The company is the subsidiary of Flow International Corp, which develops and manufactures ultrahigh pressure waterjet technology and also a provider of robotics equipment headquartered in Kent, Washington. With this 1,200 sq m facility, the company has added a demonstration laboratory centre providing equipment demonstrations, application R&D and a higher standard of technical training program to continue support to associates based in Taiwan, India, South Korea, New Zealand, Australia and South East Asia. Over the last two years, the company has established its marketing alliance relationship with local agents and distributors to expand its business in SE Asia, India, South Korea, and Australia.
Ivan Prole, Belgrade, Serbia
SKF Committed To Sustainability
USA: SKF announced that the company has been selected to be a member in both the Dow Jones Sustainability World Index (DJSI) and the pan-European 16
metalworking equipment news Nov-Dec 2011
sustainability benchmark for the Industrial Engineering sector. The DJSI represents the leading global companies from 57 sectors in the area of sustainability.
USA: August US manufacturing technology orders totaled $460.61 million according to AMT — The Association For Manufacturing Te c h n o l o g y a n d A M T D A , the A merican Machine Tool Distributors’ Association. This total, as reported by companies participating in the USMTO program, was down 9.4 percent from July but up 88.5 percent when compared with the total of $244.35 million reported for August 2010. With a year-to-date total of $3,439.21 million, 2011 is up 101.0 percent compared with 2010. “Despite news reports that wider economic growth may be stagnating, the manufacturing technology industry is sustaining its momentum,” said Douglas Woods, AMT president. “With orders still up substantially over last year, there is clearly optimism within the industry as firms are seeing future growth opportunities that merit new capital investment.” “Susta inability is a longterm commitment for SKF and I am very proud that we have been recognised for our efforts, particularly in the areas of promoting sustainable products,” says Tom Johnstone, president and CEO. The company defines sustainability as SKF Care, which encompasses Business Care, Environmental Care, Employee Care and Community Care. It has a strategy called Beyond Zero, which focuses on both reducing the env ironmental impact of its own operations and on helping its customers reduce the environmental impact in their operations and in the use of their products.
ENQUIRY NO 197
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GE To Provide Power Boost For Indonesia
Jakarta, Indonesia: GE’s aeroderivative gas turbine technology has been selected for an Independent Power Plant (IPP) that will help meet an urgent need for more electricity in the rapidly growing East Kalimantan region of Indonesia. The project also supports the Indonesian government’s initiative to increase the overall supply of reliable power for the country, where approximately one-third of the population has no access to electricity. The company will supply two 41-megawatt LM6000-PG aeroderivative units to PT Kartanegara Energi Perkasa (KEP), owner of the Senipah Power Plant, located 70 km from Balikpapan, East Kalimantan. This will be the first installation of the technology in Asia and the second in the world, following a project at Turlock, California, which recently was commissioned. “In East Kalimantan, which is experiencing rapid growth, the availability of a reliable electricity supply can be a catalyst for the development of new industries, housing and other commercial enterprises. The availability of gas in the Senipah region makes electricity production very cost-competitive. In addition, the project aligns with one of the power plan targets set by the government, which is to have all of the new IPP plants in Indonesia based on non-oil fuels, such as coal, natural gas, geothermal, hydro and solar,” said general (Ret) Luhut B Pandjaitan, majority owner of PT KEP. In simple-cycle operation, the Senipah facility will generate 82 megawatts of power, with a plant availability of 85 percent. The company plans to upgrade the Senipah plant from simple cycle to a combined-cycle operation in the next phase of development, scheduled for 2013, which will enable the facility to deliver even higher power output and efficiency.
Objet Makes Materials Available In More Territories & 3D Printers
Rehovot, Is r ael: Objet ha s announced that the 3D printing materials it released in the first half of 2011 are now available on additional 3D printing platforms and in more territories. Objet VeroWhitePlus, a rigid white material with enhanced dimensional stability is now available worldwide for all Objet 3D printers. Objet VeroClear, a water-clear transparent material is now available for all Objet Eden and Connex 3D printers. Finally, Objet ABS-like Digital Material ( RGD5160 - DM ), a composite material for simulating ABS grade engineering plastics is now available for all Objet Connex 3D printers, including the multimaterial Objet260 Connex. Commenting on the new material availability, Zehavit Reisin, head of Consumables Line of Business at Objet said: “By widening our material availability to additional platforms and regions we are constantly enhancing the prototyping capabilities for all our customers on all our platforms, both new and old.”
Posco In Agreement With Shell S out h Kor ea : Posco sig ned a long- term Enterprise Fra mework A g reement w ith multi-national oil major company Shell on the thick steel plate supply for offshore plant. Accordingly, the company will 18
metalworking equipment news Nov-Dec 2011
be the sole steel plate supplier for various structures on all the offshore plant projects ordered by Shell until 2016, with a n o p p o r t u n i t y to r e n e w t h e contract for another five years depending on performance.
Through this agreement, Posco plans to secure global leadership in the steel market for offshore structure s a nd become a global steel major company by developing high value-added steel for energy.
MACHINE TOOL INDONESIA 2011 Stand No: 3417 Nov 30 - Dec 3, 2011 Jakarta, Indonesia
Singapore
Thailand
Malaysia
Vietnam
Hexagon Metrology Asia Pacific Pte. Ltd. 2 Woodlands Sector 1 #01-10 Woodlands Spectrum 1 Singapore 738068 Tel : +65 6463 6242 Fax : +65 6463 8030 contact@hexagon-metrology.com.sg
Hexagon Metrology (Thailand) Ltd. 3 Soi, Bangna-Trad 34, Bangna-Trad Rd. Bangna, Bangna, Bangkok 10260 Tel : +66 2361 3695 to 9 Fax : +66 2746 9607 hexagon.thailand@hexagonmetrology.com
Hexagon Measurement Technologies Sdn.Bhd 11 Jalan PJS 7/21 (758921-A) Bandar Sunway 46150 Petaling Jaya, Selangor, Malaysia Tel : +603 5632 8900 Fax : +603 5632 8955 contact.my@hexagonmetrology.com
Hanoi Representative Office 5th Floor, Regus Hanoi Press Club, 59A Ly Thai To Street, Hoan Kiem District, Hanoi, S.R. of Vietnam Tel: +84 4 3936 7935 Fax: +84 4 3936 8069 hexagon.thailand@hexagonmetrology.com
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Delcam Summit Celebrates 15 Years & 2,000 Customers For China Subsidiary Z hu h a i , C h i n a : Delca m held its annual Asian Technical Summit in Zhuhai, China, from September 6 – 8, 2011 as part of the celebrations of the 15th anniversar y of t he fou nding of its Delcam China subsidiary. The summit is held each year to present the latest developments from the company to its customers, academicians and the technical media in the region. This year’s meeting, which was sponsored by HP, was the 11th in the series and the second to be held in China. Close to 200 delegates attended, mainly from China but also from 10 other countries. The summit featured presentations on the latest versions of the company's range of CAM systems before their official launch at the EMO exhibition. Updates were also included on the other software in the company's portfolio, including the company’s design and inspection programs, plus the dedicated software for the footwear, orthotics and dental industries. The summit comes at a time when the company is setting new records for its business in China. Sales of software have increased by more than 50 percent in the first half of this year compared to the first six months of 2010.
LiuGong Opens APAC HQ In Singapore
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Toyota To Start Vehicle Exports From India Toyota City, Japan: Toyota Motor Corp (TMC) announces that its production and sales subsidiary in India, Toyota Kirloskar Motor ( T K M ), is to b eg in e x p or t of the ‘Etios’ series sedan and hatchback to South Africa in March 2012. Although TKM has been manufacturing vehicles for sale in India since 1999, exports of the Etios will mark Toyota’s first vehicle exports from India. In line with its Global Vision released in March of this year, TMC is positioning emerging markets as a priority and is aiming to increase sales in those markets. To match the growth of India’s automobile market, TKM’s annual production capacity is scheduled to increase from its current 160,000 vehicles to 310,000 vehicles in 2013. The start of vehicle exports from India represents an expansion beyond India’s domestic market for TKM and a commitment by TMC to developing India into a global production and supply base for vehicles and transmissions. Singapore: LiuGong, a wheel loader manufacturer, has opened its Asia Pacific headquarters in Singapore. The 45,000 square feet (4,180 sq m) facility will support corporate functions and serve as the company’s sales hub, technical support and trading hub for Asia Pacific, excluding China. The facility is also the first spare parts distribution centre for Southeast Asia and the Pacific islands. The company expects its Asia Pacific headquarters in Singapore to generate more than US$50 million in revenues in the first year of operations, with expected annual growth rates of 30 percent. The office will serve Southeast Asia, New Zealand, Papua New Guinea and other islands in Pacific.
SETTING SETTINGTHE THESTANDARD STANDARD www.bilz.de www.bilz.de www.bilz.de LMT Asia Pte Ltd 1 Clementi Loop #04-01, Clementi West Distripark 129808 Singapore Tel: (65) 6462 4214 Fax: (65) 6462 4215 Email: sales@lmta.com.sg
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Steel Industry Calls For Shift In Vehicle Regulations Paris, France: WorldAutoSteel, the automotive group of the World Steel Association, pressed the need to shift the basis of vehicle emissions regulations from tailpipe emissions to a total Life Cycle A ssessment (LCA). LCA considers emissions from all aspects of a vehicle’s life, from material production to end- of-life -recycling, and should play a n impor ta nt role in current regulations in discussion around the world. “W hen vehicle emissions assessment is focused solely on emissions produced during the driving phase (tailpipe), t his encou ra ge s t he u se of g re en hou se ga s - inten sive
mater ia ls in a n e f for t to reduce vehicle weight and fuel consumption,” said Cees ten Broek, WorldAutoSteel director. “However, this may have the unintended consequence of i nc re a si n g g re e n hou se ga s emissions during the vehicle’s total life cycle.” Alternative materials, such as aluminium, magnesium and carbon fibre, produce emissions during their manufacture that are five to 20 times greater than steel. The US is currently examining further fuel economy and emissions requirements for 2017-2025. And while the midterm review of EU legislation on
emission standards for new cars is expected for next year, in many Asia Pacific countries vehicle efficiency standards also are being assessed. In light of these developments, the industry is calling for a shift from tailpipe emissions regulations to a life cycle a sse ssment approach that effectively measures the carbon footprint of today’s and future cars. “Legislation that focuses only on one part of the vehicle’s life cycle will become immediately out of date as the electric vehicle becomes more prominent on the road,” said Mr ten Broek. “We are only shifting the problem to other vehicle life cycle phases.”
Aerospace
Airbus: More Aircraft Needed In Russia Tou lou s e, F r a nce: Russia n carriers will need more than 1,000 passenger aircraft over the next 20 years in response to the strong traffic growth, according to the latest Airbus Global Market Forecast (GMF). The forecast ranks Russia sixth in the top 10 countries for passenger aircraft demand after US, China, India, Germany and UK. The Russian passenger aircraft fleet of 100 seats or more is expected to grow strongly from 519 aircraft in service in 2010 to 1,058 by 2030. This means that over the next 20 years Russian airlines will need 1,006 aircraft, valued at US$95 billion to meet fleet growth as well
Passenger traffic in Russia is expected to increase at a rate of 5.6 percent per year on average over the next 20 years. as aircraft replacement. These additional aircraft will include some 839 single-aisle aircraft which are currently prominent in the region’s fleet, 145 wide-bodies and some 22 Very Large Aircraft (VLA) to satisfy strong international travel growth. The growing demand for aircraft is the consequence of the increase of passenger traffic in Russia driven by consistent economic growth and
the ongoing airline consolidation. According to Airbus forecast, passenger traffic in Russia is expected to increase at a rate of 5.6 percent per year on average over the next 20 years, which is much faster than the world average of 4.8 percent. The biggest traffic growth is expected to be on international destinations from Russia to Asia-Pacific (+7 percent) and CIS regions (6.7 percent).
Indonesia All New, In Bahasa Indonesia 22
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INNOVATIVE BAND SAW BLADES FOR YOUR REQUIREMENTS OF TODAY AND TOMORROW Customised band saw blades and support for higher efficiency With more than 50 years of experience in the development and production of high-performance tools, WIKUS is Europe‘s largest manufacturer of band saw blades and global technology leader in metal sawing. Precision band saw blades from WIKUS represent innovation and productivity with the objective of higher efficiency for the customer. WIKUS is offering you: · Innovative band saw blades, optimised for all kinds of sawing tasks · Competent and individual customer service in the entire sawing process · Cutting tests directly on location of the customer
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WIKUS-Sägenfabrik Wilhelm H. Kullmann GmbH & Co. KG Melsunger Str. 30 34286 Spangenberg Germany Tel.: + 49 5663 500 – 0 eMail: info@wikus.com
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AAIS Launches Its Aerospace Productivity Drive
Boeing Opens China Service Centre In Beijing
Cylonka bsg, Poland
Singapore: The Association of Aerospace Industries (Singapore) (AAIS) launched its aerospace productivity drive at the Singapore AeroIndustry Annual Meeting, held at the Singapore Aviation Academy. Themed ‘AeroProductivity — it’s everyone’s business’, AIAM 2011 provided the ignition for the association’s drive for higher productivity this coming work year. The event included a conference focusing on productivity in the areas of human capital, technology adoption, processes and capabilities upgrading, as well as an AeroProductivity showcase. From initiatives which were undertaken to understand the manpower gaps and needs of the industry in the Association’s 2010 work year, the AAIS affirmed the need for companies to focus on enhancing manpower capabilities to increase productivity in order to maintain Singapore’s sustainability as an aerospace hub. In the Singapore Aerospace Manpower Study commissioned by the association in 2010, it was found that the industry’s average revenue per employee in 2009 was about S$439,000. The study revealed that this is expected to grow by about 13 percent, to S$496,000, by 2015. Productivity growth rates differ by subsectors, with avionics and manufacturing leading the pack at an increase of S$425,000 and S$252,000 per employee respectively. At AIAM 2011, three memorandums of understanding were also signed. These would seal partnerships that will lead to the implementation of initiatives that aim to enhance workforce, organisation, and industry capabilities. The event was graced by Guest-of-Honour, minister for Transport, Mr Lui Tuck Yew.
Beijing, China: Boeing opened a service centre in Beijing to provide enhanced product support to China’s growing commercial aviation industry. “We are bringing Boeing’s world-class airplane services and support closer to our China customers, providing them a competitive edge in their markets,” said Lou Mancini, senior VP of Commercial Aviation Services. The service centre comprises qualified pilots and experts in flight operations, spare parts and maintenance engineering who are serving in airlines in China. With Beijing-based experts who are fluent in Chinese and knowledgeable about customers’ concerns and issues, the team will enhance the company’s day-to-day support of more than 800 Boeing airplanes currently in service in China. The service centre also will work closely with the company's engineering teams in Seattle and Long Beach, on unique customer requirements and to develop products and services to further the reliability, efficiency and safety of the Chinese commercial airline fleet. The company projects that China’s demand for air travel will grow at an annual rate of 7.6 percent during the next 20 years, creating the need for more than 5,000 new airplanes by 2030.
ST Aerospace Unveils Engine Facility In Xiamen Singapore: ST Aerospace and Xiamen Aviation Industry Co (XAICO) announced that their joint venture company ST Aerospace Technologies (Xiamen) Company (STATCO) has unveiled its engine Maintenance, Repair and Overhaul (MRO) facility in Xiamen, China. 24
metalworking equipment news Nov-Dec 2011
The US$78 million facility has a capacity to support up to 300 engines annually. It will initially provide MRO and total support for the CFM56-7B and CFM56-5B series of engines that power narrow-body aircraft such as Boeing 737 next generation aircraft and the Airbus
A320 family of aircraft. The facility is located on a 38,620 sq m plot of land, near Xiamen Gaoqi International Airport in Xiamen. With a build-up area of 29,860 sq m, it houses an engine shop designed to operate with a streamlined production flow system.
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UCIMU: Orders Grew By 58.2 Percent In The Third Quarter Giancarlo Losma, UCIMU president, says: “Despite the particularly uncertain context, the Italian industry of the sector has recovered a good share of the ground lost during the 2009 crisis, by strongly increasing its activity in foreign markets.� During the first six months of the year machine tools exports increased by 27.8 percent compared to the same period of 2010. Deliveries grew in Germany (+67.3 percent), which regains its position as main outlet market for the Italian products of this sector. Sales in China slightly decreased (-1.3 percent) Positive results for deliveries to United States (+100.9 percent), France (+6.3), Brazil (+63.4 percent), India (+40 percent), Russia (+8.7 percent) and Turkey (+113.1 percent).
ENQUIRY NO 199
Italy: The machine tools index of orders has grown significantly with an increase of 58.2 percent in the third quarter 2011 compared to the period of JulySeptember 2010, for an absolute index value of 73.9 (base 2005=100). This emerges from the survey drawn up by the Studies Department of UCIMU-Sistemi Per Produrre, the association of Italian machine tools, robots and automation manufacturers. The positive trend, which started at the beginning of 2010, consolidates the recovery of the Italian industry in this sector that, as emerges from the survey, has obtained positive feedback both from the domestic and the foreign markets. For the first time, after four consecutive quarters of decrease, the index of orders for the domestic market sets off again marking an increase of 96.8 percent. Nonetheless the absolute value is still low reaching a quota of 30.3. The performance of the orders placed in foreign markets was excellent, marking an increase of 32.3 percent compared to the same period of the previous year, for an absolute vale of 114.3.
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The
Search For A Better Ecological Solution
Strict regulations and economic reasons have resulted in the rise of the concept of machining without metalworking fluids. By Dr Moshe Goldberg, marketing technical advisor, Iscar
I
n the current, competitive manufacturing environment, end users of metalworking fluids are looking to reduce costs and improve productivity. The costs of ma inta ining and eventually disposing of metalworking fluids, combined with health and safety concerns, have led to a heightened interest in either eliminating metalworking fluid altogether or limiting the amount of metalworking fluid applied. The former process is known as dry machining while the latter is referred to as near-dry machining or minimum quantity lubrication. During machining, 70 percent of the generated heat originates from pla stic deformation of the workpiece. The remaining 26
metalworking equipment news Nov-Dec 2011
30 percent of the heat arises from friction at the chip/tool and tool/workpiece interfaces.
Without metalworking fluid, excessive tool wear and inferior surface finish may occur during machining because the use of fluids during machining can result in effective lubrication and cooling at the tool/workpiece interface, as well as effective flushing of the chips. Ta k i n g e c o n o m i c a l considerations into account, manufacturers are turning to dry or nearly dry machining solutions, with the intention to benefit from coolant cost savings or improved tool life. Dry Machining Supported By Substrate & Coatings The method of dry/near- dry machining is backed up by some of the technology available in cutting tool materials, such as advanced coated carbide, ceramics, cermets, cubic boron nitride, and polycrystalline diamond. For coating, the technologies comprise coatings based on Titanium Nitride (TiN), Titanium Ca rbon Nitride ( TiCN ) a nd Titanium A luminium Nitride (TiAlN), which were developed to withstand more severe operating conditions. The Ti A lN, in pa rticula r, has emerged as a coating that exhibits thermal stability up
Regulating Metalworking Machining Fluids Metalworking machining fluids have undergone intense regulatory scrutiny throughout the last two decades, led by the United Auto Workers in USA who petitioned the Occupational Safety and Health Administration (OSHA). Their aim is to lower the permissible exposure limit for metalworking fluids from 5.0 mg/m3 to 0.5 mg/m3. Consequently, OSHA established the Metalworking Fluid Standards Advisory Committee (MWFSAC) in 1997, which developed specific standards and guidelines related to metalworking fluids. In its final report in 1999, MWFSAC recommended that the exposure limit be 0.5 mg/m3 and that medical surveillance, exposure monitoring, system management, workplace monitoring and employee training are necessary to monitor worker exposure to metalworking fluids.
Enquiry No. 8001 Turn to page 80a or log on to www.equipment-news.com to enquire
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Dry Machining Limitations While the technology to carry out dry machining has improved, metalworking fluids are still needed to ensure that higher speeds and feeds can be used and to ensure that the surface finish of work piece s meets expectations. Certain dry machining trials have indicated that new tool coatings have been helpful. However, the absence of cutting fluids cannot solve the problem of dry machining at a rate needed to achieve high productivity. Industry has not seen any increase in dry machining beyond its current use for cast iron. Dry machining, presumably, cannot overcome the positive benefits of using metalworking fluids. The tradeoff in using metalworking fluids is normally a compromise between fluids disposal costs and productivity. Near-Dry Machining Near-dry machining incorporates the application of small amounts of lubricant to the tool/workpiece interface. The key to the process is atomising the lubricant, with air as the carrier, into a fine aerosol. The lubrica nts used a re vegetable oil-based products, which are priced relatively lower than conventional cutting fluids (synthetic oils). While the price is higher than most coolants used in conventional applications, the consumption rate is minimal. I n n e a r- d r y m a c h i n i n g , though the lubricant is applied directly through a nozzle pierced through the cutting tool, the coolant applied by the flooding method cannot be used in neardry machining. That brought about the development of the
minimum quantity lubrication technology, a system, which de l i ve r s a i r a nd oi l m i xe d together as closely as possible to the cutting tool. Tr ia ls u sing t his system have indicated that near- dry machining demonstrates most effective performance on cast a luminium a lloys a nd steel alloys in various metalworking
operations such as turning, milling and hole making. W h i le d r y a nd ne a r- d r y machining will not, in the near future, replace wet machining, these two techniques will provide cost- effective alternatives in niche applications. MEN Enquiry No. 8002 Turn to page 80a or log on to www.equipment-news.com to enquire
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Welding, Cutting, Stamping, Bending, drilling, joining, milling, handling, monitoring, measuring, folding, polishing pot lids, sharpening knives. No matter what processes are to be mastered, KUKA has a solution for the metal industry. The versatility of KUKA robots makes them interesting for any type of metalworking application. KUKA ROBOT AUTOMATION (M) SDN BHD No. 5, Jalan BP 4/9, Bandar Bukit Puchong, 47120 Puchong, Selangor, Malaysia Tel : +60(0)3 8063 1792, Fax : +60(0)3 8060 0631, Email: info@kuka.com.my, Website: www.kuka.com.my THAILAND OFFICE 111/1, Moo 12, Rachatheva, Bangplee Samutprakarn,10504, Thailand Tel : +66(0) 2312 4954, Fax : +66(0) 2750 4399, Email: info@kuka.com.my, Website: www.kuka.com.my
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to a temperature of 900 deg C. The coating displays a very low friction coefficient, enabling its use under almost all dry machining conditions.
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Wet&Dry
Machining
Augustine Quek explores the different issues involving wet and dry machining.
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etalworking processes such a s cutting, grinding and milling, involve s mater ia l removal primarily through plastic deformation and/or friction. Most of the energy used in the processes is dissipated as heat. Therefore, a common practice in metal machining is to use a range of oils and liquids known as metalworking fluids to reduce the amount of heat in the cutting zone, reduce tool temperature and increase tool life. In addition to cooling, metal cutting f luids a lso prov ide lubrication at the interface between the tool and workpiece, and facilitate chip removal. Faster fluid flow helps improve the quality of the workpiece by continuously removing the fines, chips, and swarfs from the tool being used and the surface of the workpiece. Dry Machining Dry machining avoids the use of these fluids during metalworking operations. This is based on the fact that some machining operations are more amenable to dry machining. The heat generated from openfaced operations such as milling and boring can be easily managed and the resulting chips can be easily moved away from the toolworkpiece interface, reducing the need for lubrication. There are other advantages of dry machining, including the elimination of coolant and its disposal costs, thermal shocks created by flood coolant, and no danger in igniting oil coolants from hot chips. 28
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Damian Searles, Brisbane, Qld, Australia
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Coatings applied to cutting tools have also improved to the extent that made dry machining possible. Instead of aluminium oxide, Titanium Nitride (TiN), Titanium Carbon Nitride (TiCN) and Titanium Aluminium Nitride (TiAlN) have been developed to withstand more severe operating conditions. The use of TiAlN has been particularly attractive for dry machining due to its thermal stability up to a temperature of 900 deg C, and its very low friction coefficient. Coated cutting tools can be used without metalworking fluid in hard turning. This finishing process is used on steels with hardness ratings above 60 HRC at cutting speeds two to four times higher than those used for conventional cutting tools. Milling is another operation that can be run dry, because tool life can be superior under dry as opposed to wet conditions. Coolant use in milling leads to higher fluctuations in the temperature of the cutting edge as the tool goes in and out of the cut. This effect can cause thermal cracking, leading to premature tool failure by edge microfracture. To ol l i fe a l so i nc re a se s because coated carbide, ceramics, cermets, Cubic Boron Nitride (CBN ), a nd Polycr ysta lline Diamond (PCD) are all brittle, they are susceptible to the chipping and breaking caused by thermal stresses. This is especially so during face-turning and milling operations, and can be aggravated by the introduction of coolant. For continuous cuts, the high
tool tip temperatures that occur in dry turning serve to anneal (soften) the pre-cut area, which lowers the hardness value and makes the material easier to shear. As such, dry machining can be feasible and environmentally friendly in certain metalworking processes. If dry machining processes are integrate correctly, manufacturing can realise improve work piece accuracy, reduced manufacturing cost, and other related benefits associated with high speed dry machining. Recent research reveals that trend in manufacturing is to minimise or eliminate the use of metal working fluids in manufacturing processes. Dry machining has the potential to reduce environmental pollution, health hazards, and costs associated with the use of metal working fluids. Dry Vs Wet Machining Dry machining has certain limitations, which must be compensated for. Many stages of machining still cannot be done dry at the rate needed to achieve the productivity found with using metalworking fluids. Another reason is that the lubricious coatings on cutting tools do not last long enough to deliver the productivity needed in today’s manufacturing environment. Removal of metal working fluids in manufacturing processes can give rise to a variety of machining problems related to heat, tool life, and chip removal. In dry machining, the functions of metal working fluids must be assumed by alternative methods. The challenge of heat dissipation without coolant requires a completely different approach to manufacturing. Different types of material being worked also influences wet to dry machining. Eliminating coolant from steel and cast iron machining operations typically can be accomplished with little problem. Stainless steel machining can be done dry, but special attention must be given to surface finish.
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removal other than fluid flow. Cut t i n g f lu ids a re of te n necessary while drilling because they provide lubrication at the drill tip and flush chips from the hole. Without fluids, chips can bind in the hole, and the inner surface roughness can average twice as high as when machining wet. Cutting fluids also can reduce the required machine torque by
lubricating the point at which the drill touches the hole’s wall. Dry But Not Quite Another practice in the use of metalworking fluids is near-dry machining. Near-dry machining involves the application of small amounts of lubricant to the toolworkpiece interface. The key to the process is atomising the
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Mould steels such as 4140 and 4340 can be milled and shaped with coated tooling. These alloys typically have Rockwell hardness ratings (HRC) ranging from 52 to 58 HRC. But there are limitations because metals such as titanium and stainless steel are not amenable to dry machining. Titanium has a very low thermal conductivity rating, which means that heat cannot be effectively carried away from the workpiece during the process. Stainless steel machining typically produces long chips that extend the contact length between the chip and the tool and, as a consequence, increases the amount of heat in the cutting zone. However, dry machining of superalloys (cobalt-, nickel-, chromium-, molybdenum-, or tungsten-based alloys that are able to withstand high stress at high temperatures) may not be possible due to the extremely high amount of heat generated during metal removal operations. As mentioned, certain types of operation are more easily done dry without the use of coolant, such as turning and milling. Most of today’s tools, such as coated carbide grades, ceramics, cermets, polycrystalline cubic boron nitride, and polycrystalline diamond, are brittle. They chip, fracture, and crack, especially in facing and milling operations where rapid repetitive thermal fluctuations lead to expansion and contraction of the cutting tool edge. Keeping the tool hot is beneficial, because a hot tool is often a tougher, more reliable tool. In this case, the presence of coolant may actually exacerbate the tool cracking problem. Certain processes, especially closed-face machining operations such as drilling and tapping cannot be efficiently run dry because the metal chip remains in close proximity to the tool-workpiece interface. Such proximity increases the prospects of chips damaging the tool and the workpiece surface because there is no other mechanism in place for chip
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lubricant, with air as the carrier, into a fine aerosol. A recent development in near-dry machining is the application of the lubricant directly through a hole in the cutting tool, much like delivering the metalworking fluid through the spindle in wet machining. In contrast to dry machining, the lubricant is available to facilitate machining operations. Suitable applications for near dry machining are operations such as drilling and sawing. Heavy lubricants such as oil work best in difficult operations (drilling, grooving, parting-off) and on difficult materials such as stainless steels and hightemperature alloys. Cutting speeds and feeds are usually low and do not generate high cutting temperatures. The oil is used to lubricate (not cool) and resist metal buildup. Under these conditions, it may be possible to remove the lubricant. Increasing the sharpness of the cutting edge, increasing rake angle, and adjusting the lead angles may result in lower friction, eliminating the need for added oil. Under conditions where lubrication is needed, minimum quantity lubrication, which consists of drops or droplets of oil suspended in compressed air, may be all that is needed. Near-dry machining is most effective on cast aluminium alloys and steel alloys in operations such as gun drilling and deep hole drilling. Japanese machine maker Horkos Corp for example, has a near-dry machine that uses a combination of gravity drop and vacuum remove fines and chips. However, there are several limitations for near-dry machining. Coolant applied by the flooded method cannot be used in neardry machining, as is high-volume machining. If multiple operations are done in a short period of time, then more nozzles must be employed to direct sufficient metalworking fluid to the working interface of each operation. The cost of near-dry machining 30
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is also higher than conventional machining because the lubricant is used neat and is utilised in one pass instead of recirculated. In addition, near-dry machining may not offer better protection for the health of the worker. A recent study on near-dry machining indicated that the mist generated by this technique was higher than that with wet machining. Versatility The Answer? Given the limitations and constraints faced by both dry and wet machining, multi-purpose, or all-in one machines have become popular, All-in-one machines such as Makino’s S56 vertical machining centre with graphite package have wet and dry hardmilling capabilities but can also be configured for graphite milling. Mounting pressure to minimise costs while improving machine and spindle utilisation has forced many shops to consider replacing their dedicated machines with all-in one machines. Using these machines, die and mould shops can lower costs by reducing downtime, training and maintenance spend. In
addition, shops can decrease leadtimes and improve machine and spindle usage. W hile dr y a nd ne a r- dr y machining will not, in the near future, replace wet machining, these two techniques will provide cost-effective alternatives in niche applications. The function of the metalworking fluid when used with coated tooling may also change. While the need for dry machining may be apparent, most manufacturers are still concerned with issues such as the perceived inability to transfer heat while cutting dry, change over cost and finishing quality. Special tooling utilising high performa nce coatings, heat resistant materials and through spindle air are now tilting the balance in favour of dry machining. By examining the manufacturing processes capable of dry machining, it becomes apparent that the key is a balance between advanced metal cutting strategies, special tooling and the machine tool specifications. Enquiry No. 8003 Turn to page 80a or log on to www.equipment-news.com to enquire
Metalworking Fluids: What’s In Them? Although metalworking fluids will generally vary in composition, formulations have traditionally been based on a petroleum feedstock, raising concerns about environmental degradation and toxic substances release to the environment throughout the life cycle. They may also contain up to eight additives that are harmful to human health and are toxic to the terrestrial and aquatic ecosystems. The table below lists these possible additives. MEN Additive
Examples
Biocides
triazine compounds, oxazolidine compounds
Sulphurised or chlorinated compounds, extreme pressure additives
sulfurised fatty materials, chlorinated paraffins, phosphorus derivatives
Corrosion inhibitors
calcium sulfonate, sodium sulfonates, fatty acid soaps, amines, boric acid
Emulsifiers
triethanolamine, sodium petroleum sulphonates, salts of fatty acids and nonionic surfactants
Anti-mist agents
polyisobutylene polymer
Alkanolamines, stabilisers, and dispersants
N/A
Enquiry No. 8004 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 173
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Robert Proksa, Jaworzno, Slaskie, Poland
Insights
Green Shipbuilding:
Benefiting The Builders &
The Environment
The green measures imposed on shipbuilders not only help in reducing harmful emissions but also act as a sustainable building measure, which results in the production of more reliable ships. By Amreet Singh
T
he shipbuilding industry remains highly dynamic and competitive coming out of the recent financial crisis. Both the European and Asian Shipbuilding powerhouses are constantly seeing an increase in demand in the number of ship orders and stakes are only getting higher. With improvements in technology and increase in ship demands, the industry looks set to bolster ahead amidst current fears of the global financial industry dipping into yet another recession. Shipyards continue to remain an important and strategic asset in many shipbuilding countries and play a great role in their industrial infrastructures. Complex vessels such as ferries, cruise ships, dredgers as well as oil tankers continue to dominate alongside vessels such as those required for naval purposes. Also, alongside the main 32
metalworking equipment news Nov-Dec 2011
chassis building of ships, internal equipment requirements as such propulsion systems, diesel engines as well as systems to operate electronics and cargo handling push the demand for such shipyards. Annual turnovers run into the billions and this industry plays important roles in the countries they operate in by providing hundreds of thousands of jobs. Emission Sanctions Being Introduced The future of the industry remains bright in Asia as there are forwardlooking plans being announced to develop the shipbuilding arena. For example, the South Korean government is investing heavily in green technology due to sanctions on greenhouse gas emission values by the International Maritime Organization (IMO). A report by the IMO stated
that global shipping industries carbon dioxide emission values have surpasses one billion tonnes, making it a contributor of 3.3 percent of total global emissions. IMO amended the MARPOL Annex VI Regulations, which prevents air pollution from ships and also added a new chapter to its regulation on ship energy efficiencies. This has made it mandatory to implement Energy Efficiency Design Index (EEDI), for new ships, and the Ship Energy Efficiency Management Plan (SEEMP) for all ships. These systems are being put in place so that SOx emissions can be reduced by 95 percent and NOx emissions by 85 percent. The South Korean government has responded by investing more than US$267 million over the next 10 years to ensure these measures are put into place. Building A Sustainable Ship The green measures not only help in reducing the emissions they produce but also act as a sustainable building measure which pushes for a more reliable ship as well. According to the Guangzhou Shipyard International Company, green ship building technology does more than reduce end product emissions. Emissions during the design, manufacturing and service processes also add to the overall level of harmful emissions. The idea of green shipbuilding is extended to having a green shipyard as well. By doing so, air, water and soil pollution is reduced and as a result,
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resources can be saved alongside improvements in economic and social benefits. The idea of the green shipyard focuses of reducing consumption of materials and energy and environmental pollution in the ship manufacturing and service processes and also on the recycling of parts and accessories in ship maintenance, as well as the reusing of materials in the building process. Selection of marine equipment now holds a focus on low energy consumption, low pollution and high efficiency as to achieve the guidelines laid out above. For example, there is a strong emphasis on the rationality of load factor of the main engine as well as the generator and air condition systems among others. These equipment selections also are driven based on the amount of vibration and noise that is produced as these are contributing factors to noise pollution and efficiency. Technologies Introduced Electric propulsion systems as opposed to conventional ones are also being introduced. These technologies bring about better manoeuvring, lower vibration and noise levels as mentioned above as well as produce a higher reliability rate. Their small volume and lightweight arrangement also
means that these ships can be equipped with middle-high speed diesel generators with gear boxes and shafts that are of small volumes, which in turn makes it easier to increase loading capacities. Efficiencies within the shipping industry are not capped at the shipyard itself. Other factors such as fuel choice are also shaping the current shipping climate. Examples include the choosing of vapourised natural gas instead. This can bring about a savings of up to 35 percent. These savings goes to the price of fuel as well as the reduction of emissions. Benefits For Builders Green shipbuilding is a viable option today for any shipbuilder and goes beyond fulfilling mandatory requirements set by the IMO. In reality, by embracing the new technologies presented, shipyards as well as clients can find themselves with a less costly and more reliable product in the long run. Furthermore, with the ship’s more reliable nature, maintenance costs will also be reduced alongside costs factored in for downtime. All in all, the direction in which the shipbuilding climate is entering is one that is beneficial to all parties involved. Enquiry No. 8101 Turn to page 80a or log on to www.equipment-news.com to enquire
The marine industry in Singapore is following the same upward trend that the global shipping industry is heading towards. Sembcorp Marine for example has recently posted a first half profit of S$300.5 million (US$249.2 million) for the year 2011. The profit is attributed to new rig building projects which were secured in the fourth quarter of the previous year. Similarly, Sembawang Shipyard, a subsidiary of Sembcorp Marine, has seen positive growth in the current year with S$215 million worth of contracts being secured through newbuilding and upgrading contracts. The contracts come from companies such as Teekay Shipping (Australia) for the engineering, procurement and construction and commissioning of a blue water research vessel. MEN
Enquiry No. 8102 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 126
Marine Industry On The Ascendancy
Nov-Dec 2011 metalworking equipment news
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Transforming Business Through
Digital Manufacturing
From automotive and aerospace, to fabrication and assembly, even shipbuilding, companies require the right digital infrastructure to define, plan, create, monitor and control all processes. By Samson Khaou, GM, Dassault Systèmes (ASEAN)
D
igital manufacturing runs from initial process planning and assembly simulation to modeling welding lines, robot and cell programming, to a complete definition of the production facility and equipment. It enables customers to achieve exemplary levels of innovation, quality, cost control and time-tomarket that are revolutionising the way they do business, whether they manufacture jumbo jets or mobile phones. A global environment for authoring and managing digital knowledge translates into control over the definition of products, the virtual manufacturing processes and the simulation of production factories. PLM, A Prelude To Automation Every detail can be worked out before the implementation stage by using 3D visualisation and the manipulation of digital content. As a result, all departments — from design through marketing to maintenance — can seamlessly share, reuse and enhance product information in the pursuit of an
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optimal strategy. Enterprises large and small can now work with a digital representation of their intellectual property. It is a key manufacturing asset and is becoming the natural vehicle to drive success. To truly achieve business transformation with digital manufacturing, it is vital that Product Lifecycle Management (PLM) is practised extensively to make it a reality. The next natural progressive step to extend beyond a PLM strategy is automation. It allows you to simulate total production systems in a completely virtual environment and to explore as well as optimise processes for effective manufacturing operations. Automation In Manufacturing As PLM amalgamates design, simulation and execution in the production processes, automation becomes a collaborative programming solution to digitally define, control, and monitor automated systems. Control engineers can design automation systems and describe the PLC program in a logic
modeler language, then validate the logic against the 3D model of the cell, machine, or an entire line. Automation also provides a synergistic workspace for control and mechanical engineers to share knowledge, react to changes and communicate within the same digital environment. For manufacturers to survive and be competitive, it is becoming increasingly important to ensure that the organisation follows the best standards and employs the best methodologies across the entire network to meet the needs of their industry. As manufacturers are working in a much more diverse and complex environment, typically including global sites and their suppliers, demand for faster responses and higher levels of integration are applying increased pressure on the industry today. Programming Robots In order for manufacturers to confidently meet the needs and challenges of OEM suppliers, a comprehensive and role-based robotic programmer solution that offers advanced simulation capability with dedicated offline programming tools is required to mirror accurate real world processes. Ideally, this solution will provide detailed forecasting, calibration, and post processing tools to allow users to accurately program robotic systems offline for specific welding applications. Companies will be able to significantly reduce production ramp-up time and costs due to the manual programming of robots tasks and motions by validating the complete process and ‘what-if’ scenarios in a 3D digital environment before any actual physical deployment. By utilising systems simulation in a 3D virtual environment, an advantage will be gained as the 3D direct manipulation shortens the user’s learning curve and improves
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the user’s efficiency in designing and programming. Service organisations and tooling supplier play a vital role in today’s marketplace, providing automated manufacturing systems, designing flexible workcells and robot programming for OEMs. As such, these contenders in the industry can likewise, capitalise on this technology in their daily operations. Ensuring Manufacturability The goal of any manufacturing company is to develop a product that meets market demand with exceptional quality and with a profitable return on investment. Even the most innovative product will fail if it is not ‘manufacturing ready’ and produced both effectively and efficiently. Improved quality and shorter time-to-market for new programs is increasingly important for many modern manufacturers, with the ultimate goal that designs are ‘100 percent manufacturing ready’ as a standard design and engineering deliverable. Ensuring this level of product manufacturability and profitability is, however, extremely difficult in a mainstream environment. Digital manufacturing strategies can offer radical solutions to meet these challenges and goals. The technology will help to ensure a solid business model for any enterprise and revolutionise the product lifecycle by creating new value and innovation at each stage of the process. Through the sheer nature of technology, simulation is the conduit for unleashing ideas in an already capable workforce. Not only is it an effective way to visually plan, define, validate and optimise, it allows employees to take it a step further: to explore forward-thinking ideas and experiment without physical constraints. Enquiry No. 8103
Digital manufacturing enables customers to achieve exemplary levels of innovation, quality, cost control and time-to-market from the manufacture of jumbo jets to mobile phones
Gavin Spencer, Lancing, West Sussex, United Kingdom
Digital Manufacturing: Continuous R&D Leads To Growth With 21 shipyards around the world, South Korea’s STX Shipbuilding has played a key role in the development of the shipbuilding industry since its inception. Wanting to improve design-to-manufacturing productivity and enabling real-time product data visibility, STX Shipbuilding embarked on a Process Innovation (PI) project, which is a company-wide management innovation system that the shipbuilder adopted to organise its efforts to develop new engineering methods, ensure that change requests can be easily incorporated into the final data, and improve its production processes. “Shipbuilding takes a long time and accordingly, continuity is the key to successful production,” said Hyo-Gwan Leem, senior VP of STX Shipbuilding. Streamlining Operations Central and Engineering Central products, enables the company to create a Master bill of materials (BOM) for each ship under construction. The Master BOM is then broken into ‘Project BOMs’ that detail all the parts for that particular project. “In particular, we used a Master BOM to better integrate disparate data between the 120,000 to 150,000 parts per ship building project and to share this data among engineers. The fully integrated product lifecycle management platform is mission critical for improving organisational collaboration and best practices,” he said. As such, the company streamlined its business process by eliminating inefficient tasks and currently expects to reduce costs by KRW 100 billion (US$70 million) in five years. MEN
Enquiry No. 8104 Turn to page 80a or log on to www.equipment-news.com to enquire
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Nov-Dec 2011 metalworking equipment news
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Metrology
N
owadays, the intense competition prompts automobile manufacturers to expedite the development of new car models to compete for market shares and profits. As the design and manufacture technologies on engine and chassis mature, the new car model focuses mainly on the development of vehicle body styling and electronic devices. During its development, the sheet metal of the vehicle body has multiple characteristics including complex shape, large-size structure, high accuracy and high quality surface. Statistics show that 40 percent of designers and engineers are undertaking sheet metalrelated work in new car model development. The quality of the sheet metal is crucial to the success of new car model development, which raises new challenges for the inspection of sheet metal. However, the traditional gauge and 3D CMM cannot provide full assessment to the spatial surface shape of the sheet metal due to its own limitations. Their efficiency is low and cannot totally meet the inspection requirement for largescale automobile production. How to provide quick, precise and c onve nient insp ectio n of sheet metal has become a key issue for the automobile manufacturers to address. Adding Mobility To Inspection Three-dimensional laser scanning technology can be a solution to that issue, as it allows free movement of the parts while scanning, and enables data acquisition from hard-to-reach areas. One of those products, the Handyscan, can generate a data accuracy of up to 0.04 mm, acquire point clouds fast and allows easy operation and no limits in terms of size according to the manufacturer. It can be used for new car model development, parts quality control as well as for
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metalworking equipment news Nov-Dec 2011
Using Modern Tools
For Sheet Metal Reverse Engineering & Inspection
Three-dimension selfpositioning laser scanners can provide full, accurate and fast assessment of the sheet metal, which guarantees the quality control of vehicle parts and assembly of fullsized vehicles. By Robert Wang, applications engineer, Creaform Shanghai full-sized vehicle assembly. The main applications of 3D laser scanners in automotive industry include inspection of the surface, boundary and holes of the vehicle parts, and reverse engineering of the vehicle parts and full-sized vehicles. Using the 3D laser scanner and the accompanying software in sheet metal inspection can help in measuring the actual spatial error of
the parts quantitatively and present the results visually. It performs well in the quality control management, and avoids the limitation of traditional gauge and 3D CMM that can only inspect limited cross sections. It helps to reduce the cost of new car model development, shorten the development cycle and smoothly assemble full-sized vehicle. Enquiry No. 8201 Turn to page 80a or log on to www.equipment-news.com to enquire
Case Study Using a left-side inner panel welded assembly of a developing electric motor car as research object, the following illustrates the complete process of quality analysis of automobile sheet metal using noncontact technology. Scan The Sheet Metal Scan the parts with the laser scanner, including the surface, hole positions and boundaries. The scan result is shown in figure 1.
Figure 1: Scan data of sheet metal
software&metrology
Figure 2: Results of 3D compare
Figure 3: Results of compare features
Figure 4: Results of compare boundary
Preprocess The Scan Data First, import the scan data and CAD model into a post-processing software, and apply preprocessing such as noise reduction. Then, create features such as holes, rounded slots and rectangular holes in the CAD model, and create corresponding features in the scan data. RPS Alignment Between Scan Data & CAD Model The software provides multiple alignment methods, among which RPS alignment. The RPS alignment declares a set of reference points common for development, manufacture, inspection and batch assembly. It is a constraint-based reference point system alignment method, which can ‘lock’ the key points in the model to establish the relationship between point clouds coordinate and CAD model coordinate. This method prioritises the key additional
points during the quality control, and is suitable for inspecting automobile sheet metal with selfpositioning features such as holes and slots. Therefore, this paper uses the RPS to align the scan data with the CAD model. Error Evaluation Of Parts Figure 2 shows the colour-coded deviation spectrum between the scan model and CAD model, from which operator can quickly browse the distance and error in x/y/z axis between any corresponding points in scan model and CAD model. Figure 3 shows the error of diameter and centre point on corresponding features such as round hole and rounded slot between scan model and CAD model. Figure 4 shows the boundary error between scan model and CAD model. MEN
Enquiry No. 8202 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 177
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Nov-Dec 2011 metalworking equipment news
37
Fab&
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Form
DIFFICULTY: Clamping using three-jaw chucks is not always suitable for final machining without deforming the workpieces.
SOLUTION: The adoption of vacuum chucks.
CONCLUSION:
Hold It
Right There!
Circular vacuum chuck allows tension-free clamping for turning. By Wolfgang Klingauf, Klingauf PR and Maren Roeding, PR manager, Witte
M
adsen Machine Technology from Horsens in Denmark specialises in turning removal of deep-drawn and rolled parts in metal including stainless steel. Such parts are relatively thin-walled and exhibit enormous material tension due to their manufacturing process. Special know-how is needed to control forces arising during milling and machining finished products with tight tolerances. According to Morten Helding Madsen, co-owner of the company, they mainly export turned parts for automotive, medical and pump industries. Also responsible for the growth among other things are special orders, for instance from an automotive supplier for 100,000 dampers per year. These parts are supplied as rolled semi finished products. They weigh around 8 kg and have an outer diameter of approximately 330 mm. It is Mr Madsen’s job to not only machine the reverse flange inside and out, but also to carry
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metalworking equipment news Nov-Dec 2011
out milling of the face ends. Tight dimension and position tolerances are required. Better Clamping Required Until now clamping parts using three-jaw chucks was sufficient, but this method met its limits for dampers. Mr Madsen described the problem: “For face milling on one end we can clamp the flange inside using a three-jaw chuck. But for the other end the part is too big. Also the surface would become
The special dampers can now be machined within the required tolerances, in reasonable time.
convex because of the tension and we could not maintain the required tolerances.” So the company went in search of alternative clamping methods. Tests with magnetic chucks were carried out, but because of the pull affecting iron chips, it did not lead to the desired results. During discussions with their machine supplier the idea arose to try a vacuum chuck. Vacuum would allow an even and tension free part clamping process. Mr Madsen reports: “The first tests have showed that our skepticism regarding holding forces was unfounded. We machined these parts with approximately 2,000 RPMs and clamping was 100 percent reliable.” He emphasises a further advantage — the system is easily cleaned using compressed air or water. Compared to magnetic alternatives that is an advantage.
Better clamping was required to satisfy production needs
fab&form
When Not Having Air Is A Good Thing Vacuum systems are available in different versions depending on the application and specialities to be taken into account during clamping, whereby the principle set up is always the same: Vacuum is generated via a modular vacuum unit with integrated liquid separator, v a c u u m t a n k a n d p re s s u re controller. For applications on turning machines, circular vacuum chucks are the best option, they range from 100 - 630 mm diameter. For larger or smaller parts, special solutions are available. Circular chucks allow fixation of parts with different size inner and outer diameters. Freely adjustable stops ensure accurate positioning of work pieces.
Meanwhile the company is now using four such chucks from Witte. Two are permanently installed on Gildemeister CTX420 linear machines. These machines are used for manufacture of the previously mentioned dampers. The third system is mounted when required on a CTX400 to turn a lid insert, which is required in smaller quantities. Changing the chucks is a fast process. Mr Madsen confirmed that setting up vacuum on a machine takes no longer than one to two hours. For the 30 employees at the company, it is important to keep an eye open for innovations which will optimise quality, price and delivery time of their products. For the director the clamping systems are an important component of his modern machinery: “Without
Advantages Of Vacuum Clamping Systems • Reduce clamping time • Universal clamping system for different parts • Clamping non-magnetisable parts • Oscillation-free machining • Clamp thin parts and foils without deformation • Problem-free machining of contours and cutouts • Suitable for many types of machining and materials
this vacuum clamping system we could not machine these dampers in the required tolerances, or only by taking a lot more time.” MEN Enquiry No. 8301 Turn to page 80a or log on to www.equipment-news.com to enquire
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Nov-Dec 2011 metalworking equipment news
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Hold On Tight The ‘seat belt’ for cutting tools allows heavy metal removal. By Wolfgang Klingauf, k+k-PR, for Haimer
P
roductivity of the highest level should be delivered even when faced with challenging conditions like High Performance Cutting (HPC), in which the capability of the machine tool is exploited to its very limits. Oliver Sax, manager, Global Solid End Milling Products Portfolio at Kennametal, explains: “Many segments are being subjected to fierce competitive pressure. They are looking for manufacturing solutions that give them the highest possible metal removal rates. HPC is becoming more and more popular, in particular where the proportion of metal removal is high, as it is in the aerospace industry for example.” T h e t re n d h a s b e c o m e increasingly evident in the last few years, ever since high performance cutting tools that facilitate demanding machining operations have been on the market. The tools can withstand the high torques, feeds and forces that occur during machining without breaking. Tougher Operations Require Better Locking The danger of the milling cutters being pulled out of the tool holder at extreme forces has significantly increased, particularly during demanding HPC and High Speed Cutting (HSC) processes. This is true for tool holders that offer precision clamping with good concentricity such as shrink-fit, hydraulic expansion or power chucks, for example. The holders work with frictional locking, but their clamping force is often not sufficient for HPC. It is estimated that about 70 percent of all users are currently forced to use standard Weldon holders for heavy roughing 40
metalworking equipment news Nov-Dec 2011
operations due to security concerns, because the clamping screw of these holders creates a positive locking. This means that any desired torques can be transferred — but combined with the known disadvantages of poor cutting tool run-out, weak clamping due to the shank needing a little space in the chuck and shorter tool life of the expensive HPC cutting tools. Reliable Milling Achieved Keith Wiggins, leader, Global Tooling Systems Product Management at Kennametal, has been investigating a fail-safe/high-accuracy tool holding system to complement their high performance portfolio for a long time now and is well aware of the problems with aggressive heavy chip removal. “For years now we have been investigating a holding solution that has best possible accuracy with a fail-safe security clamping system that would gain the full potential from our cutting edge performance. With the Safe-Lock from Haimer we now have a non-slip holding solution to complement our toolholder offering.” The lock system is a pull-out protection for round shanked cutting tools of all types. The principle is simple and effective: helical grooves are ground into the shank of the tool. These together with the respective pin drivers in the chuck prevent the tool from spinning or even being pulled out of the holder altogether under extreme machining conditions, a malfunction that can be very expensive where such costly tools and workpiece materials are concerned. The trick here: The helical path of the lock system grooves means that the length of the
tools can also be adjusted. In other words the tools can be reground and pre-set as usual. The lock system adopts the shrink-fit technology and the clamping process is simple. The chuck is heated as usual and the tool inserted with a slightly twisting movement. The locking elements of the system find their own way into the grooves when the tool is turned. A spring can be used to aid in the play-free positioning of the tool. The holder cools down after a few seconds creating the press fit and positive locking. Concentric accuracy of <3 µm is achieved during shrinking. Stable tool clamping achieved in this way allows users to machine even greater cutting depths with higher feed rates. The tangible benefits at
Safe-Lock is a pull out protection in which grooves are ground into the shank of the tool. These together with the respective pin drives in the chuck, prevent the tool from being pulled out of the holder during extreme machining conditions.
fab&form
the end of the day â&#x20AC;&#x201D; time saving, enhanced productivity, lower scrap rates and less vibration. Better Locking, Better Result The lock system has achieved success with high-performance tools for the HSC machining of aluminium (spiral cutters) and the heavy machining of titanium (roughing cutters). According to the maker, companies in the aerospace industry have increased their removal rates by over 30 percent. In addition, one user in titanium processing was able to increase the tool life of his cutting tools threefold for roughing and seven-fold for finishing. A medium-sized supplier of the automotive segment reports that his tools now run smoothly, doubling their tool life. MEN Enquiry No. 8302 Turn to page 80a or log on to www.equipment-news.com to enquire
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Nov-Dec 2011 metalworking equipment news
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Focus
Automation:
Cutting Away
Constraints
It is now possible to process G-code directly with the integrated CNC kernel on the robot controller. By Alexander Bay, product manager, Kuka Roboter
M
achining with indu st r ia l robot s is a w ide spre ad application. The flexibility of industrial robots op e n s up a la rge ra nge of application that until now has involved primarily the finishing of series products. Taps and fittings are ground and polished under robotic guidance, injection moulded parts are trimmed and cut to size by robots, and castings are finished, fettled or deburred. While many CAD/CAM-based systems already exist for the offline programming of robots, there has never yet been an integrated approach to process data all the way to the robot controller. The prerequisite for processing programs until now was the compilation of the CNC programs into the corresponding robot language with the aid of an adapted post-processor. This automatically resulted in a loss of information, as functions from
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metalworking equipment news Nov-Dec 2011
the CNC program were not always supported in the widely differing robot languages. Out With The Old Constraints A program that allows the direct integration of a CNC kernel on the robot controller has eliminated the mentioned limitation. It gives the robotic machining system an inherent range of additional functions. Kuka.CNC can be used to execute DIN 66025 -compliant CNC programs directly with the robot controller. Direct integration of the CNC kernel on the robot controller turns the industrial robot into a machine tool with an open kinematic s y s te m t h a t co m b i n e s t h e adva ntages of a n industria l rob ot w it h t ho se of a CN C controller. T h e c o m p l e te s t a n d a r d code can be interpreted by the program and implemented by the robot. (G functions, M/H/T
functions, loca l a nd globa l subprograms, control command structures and loops) These options broaden the range of applications for an industrial robot, pa r ticula rly in the following fields: • Milling of shaped parts made of soft/semi-hard materials, such as wood, plastic, aluminium and composite materials • Polishing and grinding of shaped parts • Coating and surface treatment of complex workpiece surfaces • Trimming and cutting of complex work pie ce s a nd work pie ce contours • Laser, plasma, waterjet cutting of complex workpieces Direct integration of the CNC kernel on the robot controller
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Machining with industrial robots is a widespread application
allows the combination of the advantages of an industrial robot, such as the large workspace, high flexibility, low investment costs and six-axis machining, with those of a CNC controller, such as G-code programming, CNC user interface, tool radius compensation, extensive point anticipation, advanced spline path planning and user-friendly tool management. Integration of the CNC kernel also enables direct processing of the CNC program on the robot controller. Both CAD/CAM programmers and CNC machine operators can therefore program and operate an industrial robot with their existing knowledge. Advantages For CP Processes C N C m o de i s p a r t ic u l a rl y advantageous for continuous-path processes. Machining programs with a large number of points on the path can be executed more precisely and with shorter cycle times using the CNC kernel and its sub-functions. 44
metalworking equipment news Nov-Dec 2011
The se improvements in accuracy and cycle times are due to the advanced path planning functions in the CNC kernel. Path planning with point anticipation for more than 500 points makes it possible for the robot to maintain constant velocities during the machining process and to plan optimal acceleration/ deceleration ramps. The path accuracy is also improved by means of various spline interpolations in the CNC kernel. A k ima a nd B - Spline calculations ensure that the robot executes its set path as accurately as possible. These typical CNC functions are combined with the conventional functions of a robot controller. As such, optimal machining results are achieved. Simplicity Is Beauty Simplified robot integration holds adva ntages for the machine operator. Moreover, the use of robots in the domain of
conventional CNC machine tools redefines the possibilities of G-code processing. In automated machining systems, it will in the future be possible to program and operate not just the machine tool, but a lso the robot by means of DIN 66025-compliant code. This facilitate s robot integration and offers a crucial advantage especially for the machine operator. In the future, the operator will no longer need robot- specific progra mming k nowledge, but will be able to operate the robot using his existing CNC expertise. Machine tool and automation system are merged into a single unit. A special case in the field of automate d mach i n i n g is the processing of workpieces ha ndle d by t he rob ot. T he combination of machining and handling makes this process variant particularly efficient. Since the robot picks up the workpieces, guides them to a machining station for processing and then transfers them to a storage facility, no further transfer or handling kinematic system is required for automation of the process. In this example, the machine tool and automation system are combined to form a single unit, with a great influence on the aspect of cost-effectiveness. CNC programming opens up a whole new range of programming systems for robotics. The CAD/ CA M syste m ma rket of fers specially adapted solutions for a wide range of different machining applications. Robot programming and application possibilities will also multiply in the future. CAD/ CAM systems are increasingly recognising this development and providing their software with corresponding modules for robot programming and simulation. MEN Enquiry No. 8401 Turn to page 80a or log on to www.equipment-news.com to enquire
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Sensible Use Of Sensors In Industries Department of Business, Innovation & Skills
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Shahnawaz Abdul Hamid investigates the use of sensors that improve safety in the metalworking industry.
he field of metalworking has come a long way. Today, the cutting and joining of metals to create individual parts, assemblies and large-scale structures is no longer achieved through brute strength alone but by a combination of robotics, machinery, information systems and electronics working together. This vast discipline of manufacturing technology is known industrially as automation. The use of automation in metalworking comes as no surprise, in light of rising consumer expectations on quality and quantity. In particular, automation is expected to achieve the following goals:
• Reliability: In a highly competitive manufacturing environment, being able to work round-the-clock is crucial. Any downtime can translate into high revenue losses. The use of automation reduces the need to depend on manpower, increasing the reliability of the manufacturing system.
• Consistency: Although each product is inherently different, there should be a high degree of consistency in terms of quality, regardless of where the product was manufactured. This is especially true in an increasingly borderless world where manufacturing operations may be situated in developing countries to benefit from low labour costs.
• Flexibility: The need to reduce inventories as well as respond quickly to customer demands make the ability to instantaneously change a production line on the fly a critical asset.
metalworking equipment news Nov-Dec 2011
• High Performance: The use of robots and machinery on the shop floor allows for the analysis of complex data, the speedy repetition of tasks as well as the completion of multifunctional jobs, all of which could not be achieved through the use of human labour.
• Safety: Part of the motivation behind the use of intelligent automation is the enhancement of safety, ultimately reducing
the number of man-hours lost and injuries sustained. Common Elements In Automation What are some of the products that form this huge industry known as automation? To begin, almost all automation systems re q u i re w h a t i s c o m m o n l y termed a Programmable Logic Controller (PLC). A PLC is a computer that is used for the automation of electromechanical processes. In metalworking, it is typically used to control factory assembly lines. Unlike a normal computer, the PLC is easier to program and maintain, consisting of a series of ladder diagrams and electrical symbols commonly used by electricians. There are two types of PLCs available on the market today: fixed and modular. Fixed programmable controllers come as self-contained units with a processor, power supply, and a predetermined number of discrete and analog inputs and outputs (I/O). Unlike fixed units, modular controllers are more flexible,
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The use of sensors in automation systems to detect change has become increasingly common
offering options for I/O capacity, processor memory size, input voltage and communication type. However, these controllers may be significantly more expensive compared to fixed ones. I/O systems often serve as interfaces between devices and the PLC. To put it simply, they form the connections between wires of devices and controllers. Through the use of a cabling system and network, racks of I/O are placed closer to the process but remote from the controller. To p o w e r m a n y o f t h e devices in a factory, motors have been introduced, with various configurations that can be used for a wide range of applications. In recent years, motors have become more â&#x20AC;&#x2DC;intelligentâ&#x20AC;&#x2122; with energyefficient designs that reduce the carbon footprint of a process. 48
that they are most valued. This is especially because the risks associated with metalworking, such as cutting and turning, cannot be underestimated. Non-contact sensors, when installed properly, prevent access to a hazard or detect the entr y of personnel into a h a z a rd o u s l o c a t i o n . T h e sensor then, in conjunction with the control system, initiates a shutdown of operations to eliminate the hazard.
The automotive industry is one that has benefited greatly from the use of sensors to safeguard workers
metalworking equipment news Nov-Dec 2011
The Art Of Sensing Another common element in automation systems is the sensor. Sensors detect and signal changing conditions, either through contact or non-contact methods. Contact sensors typically detect change through direct physical contact with target object. They are simple and reliable and can usually tolerate power line disturbances. Non-contact sensors, on the other hand, use photoelectric, inductive, capacitive and ultrasonic technologies to detect changes. Given the lack of physical contact between sensor and target, there is hardly any potential for wear and tear. Given their usefulness, s e n s o r s a re u s e d i n m a n y aspects of metalworking. It is perhaps with regard to safety
Safety Light Curtains Safety light curtains safeguard entr y into a manufacturing cell, given the various dangers associated with quick-moving robotic arms or machine parts. Although safety light curtains have been used for decades, the technology behind it has kept pace with the industryâ&#x20AC;&#x2122;s everchanging demands. In recent years, the use of corner mirrors allows the light curtain to protect all sides of an application. The curtain comprises of two primary parts: a sender and a receiver. The sender unit emits an infrared beam towards the receiver unit. Upon the receiver unit receiving and registering the beam, a light curtain is generated, allowing the machine or robot to move and do work. An interrupted safety light results in a safety stop signal being sent to the machine control circuit, which stops the machine or robot, preventing any possible injury. Laser Scanners & Vision Systems Similar to the safety light curtain is the safety laser scanner, a device designed to provide protection even in the most complex of zones. They emit very short laser pulses, while an electronic timer captures the travel time of the pulse. These laser scanners can be used
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in a wide range of mobile or stationary applications, and are mainly tasked with preventing access into a dangerous area. Perhaps more relevant to metalworking is the vision system, commonly found in press brakes. The vision system is typically mounted on the ram of a press brake and monitors the hazardous area with a camera image, evaluating the safety field. These fields can be specifically programmed based on a specific folding position. The fields are constantly monitored for any foreign objects, finger-sized or smaller. Such an intrusion results in the press being stopped immediately. Apart from providing this safety measure, some vision systems also measure the angle of bend being formed as part of feedback, allowing for a more accurate bend.
Selecting An Appropriate Sensor The act of selecting an appropriate sensor to beef up the overall safety of a manufacturing process is dependent on several criteria. National standards usually help manufacturers decide on the level of risk a specific process entails. Next, a risk reduction strategy may be crafted. The risk strategy allows the manufacturer to decide which sensor is most appropriate in the prevention of any hazards. Part of forming the strategy involves measuring the dimensions of the safety zone that require guarding as well as the shape of the zone itself. This will help in determining what type of sensor will best suit the companyâ&#x20AC;&#x2122;s safety strategy. For instance, in the automotive
industry, safety light curtains have often been used to provide a perimeter of security around robotic arms that swing to and fro as they assemble cars and other vehicles. In conclusion, the advent of industrial automation has allowed the metalworking industry to reach heights once thought of as impossible. Quality, reliability, flexibility and quantity have all improved significantly. However, it is in the field of safety that improvements are perhaps most welcome, especially for workers. The use of sensors has enhanced this, allowing for a reduced number of injuries and a greater peace of mind for those tending to milling and cutting operations. MEN Enquiry No. 8402 Turn to page 80a or log on to www.equipment-news.com to enquire
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Walter In
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The CEO of Walter Asia Pacific talks to Asia Pacific Metalworking Equipment News in this exclusive interview to dissect the company’s performance in the past year. By Joson Ng
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he metalworking industry performed admirably in 2010 following the preceding years, which were clouded by woes in the financial markets and in other industries. In 2011, it was widely believed to be the yea r of consolidation. However for Walter in Asia, it was an improvement from 2010 according to Jean-Paul Dissous, CEO of Walter Asia Pacific. Said Mr Dissous: “The sales in Asia Pacific have been growing positively in double digits in 2011 despite Japan’s triple catastrophe in March. Against the odds, business in Japan went well for us. As such, we have high expectations.” Mr Dissous felt that some of the growth in Japan may be due to the rebuilding efforts but it is the normal market demand that is more pertinent in this case. “The demand did not disappear, people still want computers, mobile phones and cars,” he said. Sales Strategies 2012 Looking forward to the year ahead, Mr Dissous revealed that the company would focus more on two markets: China and Japan. “We decided to go into these two markets and came up with a finetuned strategy. We are not talking about a strategy just for 2012 but rather a long-term one. For Japan,
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we are expecting a boost so we need to be prepared. On the other hand, for China, it still represents a big potential even though we have been based there for 15 years. We are happy with the numbers and we hope for even more,” he said. ‘All Systems Go’ In 2012 Halfway across the world in the US and Europe, the financial markets are reeling from the credit crunch and the historic downgrade of US bonds. These ripples have reached Asia and though the major Asian bourses took a hit recently, it is not exactly a major cause for concern for Mr Dissous. He said: “We have been following the situation in Europe and the US closely. While we agree world markets are linked but the timings in business cycles are not the same. I do not see a slowdown in Asia Pacific next year, mainly due to existing demands. Japan is expected to have an excellent development next year and this will be beneficial to this region because there are a lot of Japanese companies based here. The slowdowns in Asia are mainly due to the situation in Japan and China’s decision to slow growth in order to keep inflation in check.” T hou g h M r D i s sou s’ assessment of the region is positive, he felt it is important to be prepared for any eventuality.
“Whatever the situation, we always try to be ready for two extremes — blooming economy and slowdown. It is a permanent attitude.” Painting an example, he continued: “We are careful with our investments, be it the establishment of new plants, the purchase of new machines and the training of our employees.” Opportunities & Hot Spots “If the markets are shrinking, it does not mean the possibility for us is shrinking. There is still a lot of market share we can gain,” said Mr Dissous. This positive thinking is behind many of the company’s endeavours in Asia. There should however, according to Mr Dissous, be a guiding principle, ie: stay focus to avoid going off tangent. “Though there are a lot of opportunities (in Asia), we decided to focus on specific areas. We concentrate our attention on automotive, energy, aerospace and general engineering. Among them, the energy and aerospace industries will be up and coming. Just look at the aerospace industry, with the number of people flying these days, the flights are usually fully booked,” he concluded. Enquiry No. 8501 Turn to page 80a or log on to www.equipment-news.com to enquire
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In The Hot Seatâ&#x20AC;Ś Tan Soo Thong
any obvious differences between the metalworking industries/clients in the two countries? Their expectations for product quality are similar but however there are obvious differences. For example, the complexity of the machining process is one of them. This is in accordance to the maturity of the industry. For instance, the aerospace industry in Singapore is more established whereas Malaysia has got the automotive industry, palm oil machinery OEMs and some general mass production machining industries, which are not found in Singapore.
Mr Tanâ&#x20AC;&#x2122;s aim is to gear up the company for sustainable business growth Share with us your thoughts on your new appointment As a newly appointed MD of Walter Singapore, my aim is to gear up this company for sustainable busine s s grow th as a competent par tner for cutting solutions for customers in the metalworking industries.
To achieve this, our main focus is to develop our employees through training in order to enhance their skills, knowledge, application know-how and expertise level. Being the MD for both Walter Singapore and Malaysia, do you see
What is your management philosophy? I always believe in people. They are important assets of the company. It gives me great joy to be involved in the development of my employees and see them progress over the years. MEN
Enquiry No. 8502 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 191
Walter Singapore recently appointed Tan Soo Thong as MD. Also holding the same portfolio with Walter Malaysia, Mr Tan gave his thoughts on the appointment and also shed light on his management philosophy.
Nov-Dec 2011 metalworking equipment news
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Jeffrey Choon
Jiro Makino (2nd from right), president, Makino Milling Machine is very pleased with the formation of the technology centre which is in line with the company’s policy of developing technologies, driven by its extensive R&D program.
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ith more than 100 participants at the op e n i n g, J e f f re y Choon, MD, Newline Machine Tool has fulfilled one of his wishes for the centre by providing a platform for users and experts to come together for technical exchanges. “By starting this technology centre, we hope to provide an education in metal cutting and machining technology,” said Mr Choon. According to Mr Choon, the facility cost some RM6 million (US$1.9 million) and though the place was bought five years ago, development works started only recently and the company moved into its new home in July this year. For him, though the facility was built to support their clients, and partners, other OEMs are welcomed to use the centre too. It is all systems go as far as George Lim is concerned
The technology centre was something that was planned some years ago according to George Lim, VP of marketing, Makino Asia. However, due to staff allocation and location concerns, the plan was put on hold till this year. Five years on, with infrastructure now more developed, the concerns of the past were all but eliminated. This was confirmed by Mr Lim, who also sought opinions from guests at the opening. He said: “I asked
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Newline And Makino Technology Center
Grand Opening Five years in the making, the technology centre in Malaysia opened to much fanfare and optimism. By Joson Ng
All in all, the future looks bright for Newline a s Mr Choon revealed to Asia Pacific Metalworking Equipment News that the company is planning another centre in Penang. The facility is slated to open in Januar y nex t year. This can be seen as a massive vote of confidence in the economy. Though there are some signs of uncertainties in the US and Europe, Mr Choon felt that his company’s portfolio is welldiversified and as such, the
possible downturn is rated “not critical” by him. Elaborating the point on diversification, he said: “We serve industries that range from medical device manufacturing to the semiconductor industry. In addition, we are supporting major government projects such as the manufacturing of Proton cars. We have actually provided a few lines of machines for the national car maker.” Enquiry No. 8503 Turn to page 80a or log on to www.equipment-news.com to enquire
George Lim On The Present & Future… the customers and they told me it is a good location and is easy for them to send their employees here for training.” Having a technology centre has always been the company’s focus with its Singapore facility as a shining example. The technology centre in Kuala Lumpur aims to emulate the success its counterpart enjoyed across the causeway. It also helps reduce any difficulties faced in documentation when sending workers over to Singapore for training. New In 2012 “From the commercial point of view, we are very much looking at the 3C markets. They are computer, communications and
consumer electronics. Especially for the communications devices, parts are getting more precise and the production volume is getting higher. As such, we have to produce machine up to that level,” said Mr Lim. He used the EDAF as an example. The EDM machine can produce a depth control of +/- 2 micron. As for the wire side, the company is looking to develop technologies that cut tungsten carbide. For Makino Asia, Mr Lim said: “We are looking more at mass volume production. We are looking at milling machine and machining centres that can create high-performance and high-precision. It is easy to produce high performances but difficult to achieve high
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accuracy. We have to look into structural design in order to satisfy both criteria.” Positive Future Looking at the future which is clouded in some degree of uncertainties, he said: “The financial problems in the US and Europe have been there for quite some time now. It affects Asia because Asians do not understand the business politics of the West. We tend to react negatively.” Mr Lim felt the markets in the US and Europe will affect their business to a certain extent but he hopes the company’s sizable business in China can help offset any blow. At the end of the day, it is ‘all systems go’ as far as Mr Lim is concerned. “Be it R&D, the development of any new technology centres or any HR projects, they will continue. After all, when business cycle go down, it is also the best time to invest,” he concluded.
Enquiry No. 8504 Turn to page 80a or log on to www.equipment-news.com to enquire
Expert Opinion: KS Sankaran Mr Sankaran on business in Malaysia, the economic situation in the west and also the company’s push into the online world. For KS Sankaran, COO, Makino Asia, Malaysia is an attractive country to do business in. He attributed its relative low cost and the skill of the workers as positive points. However should there be a need to upgrade the skills, the technology centre addresses the issue of training. He said: “If every customers can take advantage of this technology centre, it would be a good thing.” Looking towards 2012, Mr Sankaran felt that the dark clouds that are gathering in the US and Europe pose some cause for concern but he also pointed out a shift has taken place and suggested Asia do not have to be unduly worried. “Today, China produces more cars than the US. It is an irreversible change. The high tech consumables are also being manufactured in Asia. For Makino,
Mr Sankaran sales figures in Asia have increased. It has overtaken sales in European countries. It used to be 1/3 Asia (sales figures) and 2/3 Europe but now, it has reversed,” he said. The company has also shifted their marketing efforts. It is now skewed towards the Internet. “We are now looking more at web-based marketing. For example, we are organising Webinars and other web-based training,” he said. He felt this is the current trend and embracing the Internet can increase reach and lower cost.
Enquiry No. 8505 Turn to page 80a or log on to www.equipment-news.com to enquire
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Moving Forward
Kennametal recently moved its office in Singapore and Asia Pacific Metalworking Equipment News spoke to John Chang, the company’s VP and MD of Asia in an exclusive interview to find out more about the move and also the company’s plans for Asia. By Tjut Rostina and Joson Ng
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he emerging market of Asia presents a great potential for growth for Kennametal. In order to maximise this potential, the company has looked into ways to establish a stronger presence in this region. One of its recent endeavours is to move into a new office in Singapore. “The Asia region is an emerging market that we want to focus on. Also, in order to serve the growing customer base, we decided to pick a more convenient location for our office in Singapore. In addition, this move also allows us to present a brand image consistent with Kennametal on a global basis, that is to establish a much stronger
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presence in our emerging markets with Singapore as the centre,” said Mr Chang. Cu r re nt l y, t he re a re 2 9 employees working at the facility and Mr Chang hopes to increase that number to 40 in the future. He believes that this part of the world continues to be in the growth mode and the company will continue to add selectively in Singapore for growth. He also added that there are investments in infrastructure developments in China and India. On The Growth Bandwagon With Asia firmly in the crosshair of the company, Mr Chang said they have formulated a strategic
plan in the last five to eight years to capitalise on the growth of the region. “We have consistently developed infrastructure in the region dating back to five years ago when we built our plant in Tianjin, China for our metalworking business. Since then, we have added engineering capabilities most notably in China where we built an advanced engineering centre. Last year, we opened a facility in China focused on the mining and construction industry,” said Mr Chang. “In October 2011, we are opening a new furnace for our Conforma Clad business in China. At the same time, we are opening
Tungaloy Singapore Pte. Ltd. 50 Kallang Avenue, #06-03 Singapore 339505 Tel: (65) 6391 1833 • Fax: (65) 6299 4557 www.tungaloy.co.jp/tspl/ Tungaloy Malaysia Sdn Bhd (876763-H) 50 K-2, Kelana Mall, Jalan SS6/14 Kelana Jaya 47301 Petaling Jaya, Malaysia Tel: +603-7805 3222 • Fax: + 603-7804 8563 www.tungaloy.co.jp
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John Chang
The company aims to establish a strong presence in the region
a new customer solutions centre in our Shanghai office, which will house the latest technologies. It will also include a demonstration as well as a training facility that can sit more than 80 people.” Elsewhere in Singapore, Mr Chang revealed the company has consolidated their warehousing and inventory to better serve their customers. They now have a regional hub in the Changi area whereby they are able to provide standard or customised products. Dark Clouds Ahead? The recent wave of financial uncertainties in the US and Europe has cast a shadow over the stellar economic performance in Asia last year. For Mr Chang, though it is a concern, the fundamentals in Asia are looking solid. “Firstly, the market in Asia continues to grow. If you look at the GDP growth, even though it is slower compared to last year, the economy continues to be healthy and robust. With respect to growth outlook, there is certainly a lot of concern on sovereign debt and rising interest rate in emerging markets, the obvious indicators of barriers to 56
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growth. We are watching closely at this point with respect to developments in North America, and in Europe where we see challenges,” he said. Fina ncia l ma rkets’ woes, however, are separate from industrial production. He felt that the overall global industrial production continues to be very robust. Said Mr Chang: “I think it is a matter of which industry and which sector. The global industries have a lot of aspects and cycles; as a result you will find that while certain markets are down, certain industries are up. For example, we have been reading in the press about the number of aircraft that have been launched recently. Within Singapore, we could see aerospace companies making significant investment. Our reaction to that is to place emphasis in businesses that are growing, like the aerospace industry and earthworks.” Improvements & Beyond Mr Chang remains positive when asked about the coming year. “These are exciting times for us, we survived the recession and we reorganised ourselves, upgraded the SAP system and digitised our
operations,” he said. Though the improvements have made the company stronger, he foresees some challenges coming from the workforce side of things. “My view have always been about getting the technical knowledge and skill set required. New technologies a re been developed at such a rapid pace. The rate of change our customers are demanding from us is significant. The limitation as I find over the last few years is getting the right talent, leadership and skill set. That will continue to be the challenge facing the regional markets,” he said. With that, he said the company would focus heavily on its ability to provide the right training to their employees, distribution partners and customers. Giving an example, he concluded: “We are going to offer courses in Singapore, starting early next year. This is a big need based on what we hear from our customers. When I visited a customer who had set up a facility in Singapore earlier this week, he also said that skill set is the biggest challenge.” MEN Enquiry No. 8506 Turn to page 80a or log on to www.equipment-news.com to enquire
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From The
World Of Metalworking
Six World Premieres Products Shown From GF Agie Charmilles At The EMO 2011 GF AgieCharmilles gave six milling and EDM products a world premiere at EMO 2011. They are aimed at triggering customers’ success in demanding manufacturing areas from automotive, aerospace and aeronautics, and medical and dental technologies, to electronic components and information and communications technology. Some of the products making their debut at the show were: - Mikron HSM 600U LP high-speed milling machine for prototype production, diemaking and fully-automated, low-volume series production where accuracy and surface finish are key success factors - Mikron HPM 450U milling machine with torque rotary tilting table for unlimited fiveaxis machining - Form 300 vP, a flexible die-sinking machine for greater autonomy
E
MO Hannover 2011 was staged under the motto of ‘Machine Tools and More’. The six-day event in Hannover, Germany saw some 2,037 exhibitors from 41 different nations took part and featured the latest machinery, solutions and services for every aspect of metalworking.
GF AgieCharmilles: Hole-Drilling EDM Machine The Drill 300 by AgieCharmilles has a compact fixed table design with X x Y of 600 x 400 mm and Z x W travel of 450 (650 optional) x 450 mm. Its generator and dielectric unit are integrated into the machine, and various automation and additional axis options are available. The hole drilling machine is equipped with the ISPG generator with maximum mean current 30A (60A optional) and a pulse duration down to hundreds of nanoseconds. The form of current pulse is optimised for EDM drilling, with ISPG generator for low electrode wear and an affected layer less than 10 μm was obtained. The machine has a range of technologies for various electrode for workpiece materials like Inconel, titanium, steel and carbide.
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- Form 200 mS die-sinking EDM machine that masters the details for geometric quality - Cut 2000 OilTech, which uses oil as a dielectric to make surface protection the top priority
Enquiry No. 8601 Turn to page 80a or log on to www.equipment-news.com to enquire
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Fine Cutting: Cut 1000 The Cut 1000, though not a new product on show, has been retrofitted with an Integrated Vision Unit, to deliver optical access to details that a 3D probe does not. The vision unit now adds in-process measurement to its accuracy and fine cutting ability, cutting down process and set up timings.
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Special Report
DMG/Mori Seiki: A Show Of Strength DMG/Mori Seiki showcased 97 machines at EMO, including 25 world premieres from all areas of technology on a total exhibition area of 7,600 sq m. Cooperation Sustains Innovation In the press conference held by the company during EMO, Dr Ruediger Kapitza, chairman of the board of Gildemeister and Dr Masahiko Mori, president of Mori Seiki gave some updates on the cooperation as well as the current economic climate. On the economic front, Dr Kaptiza said that the machine market worldwide is growing and the economic woes that happened some two years ago “will not be repeated.” He also cited Germany as the growth driver for Europe in 2011. Speaking on the cooperation efforts between the two companies, Dr Mori said cooperations would be in production components, procurement, R&D, sales & services and customer financing. The main aim is to make gains in efficiency for the companies’ customers by bundling resources and expertise. The pair also spoke at length on the formation of DMG/Mori Seiki Deutschland. The “super team available” at the new partnership will receive 100 percent support in sales and services. R&D Efforts Away from the economics, the two companies also made good their promise at JIMTOF 2010 and presented a jointly developed machine at EMO. Dr Mori revealed the NHX 4000 was a joint development alongside the CTX 310 Ecoline, which is currently being produced in Shanghai, China at a rate of 150 to 200 machines a month. The first joint development however was the Milltap 700. The vertical milling and boring centre achieves top values in all processes with its combination of work capacity and chipping performance. It also achieves good performance on the tapping centre market. Productivity and efficiency were at the core for development of the machine. For this reason, the companies have concentrated their innovative power and equipped the vertical milling and boring centre with a series of technical details. The high machining speed usual in the field of tapping centres is supported by a high-speed tool changer, which achieves chip-to-chip times of 1.5 seconds and so enables an efficient process. There is also a special feature: The complete drive of the magazine — it takes 15 or optionally 25 tools — is integrated into the spindle head.
New Products From Ecoline…
CTX 310 Ecoline & CTX 510 Ecoline The combination of functionality, efficiency and user comfort make the two universal lathes in the CTX Ecoline family an option. The turret equipped with a ser vo-synchronous-motor reported a 100 percent reduced tool change time (a tool change of two 60 deg tool stations, for example, in just 0.4 seconds) and hydraulic interlocking that ensures top dynamics and stability.
Enquiry No. 8603
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Ecoline: Quality & Economics Combined The Ecoline turning-milling machines on show came in a new design that ensures functionality and ergonomics plus an enhanced performance due to faster rapid traverses and more powerful spindles. A feature of the design is the Progressline, whose display allows the operator to see at a glance the remaining running time of the workpiece and the quantities of the machining job. The introduction of the DMG Slimline Panel with Siemens 840D solutionline with program navigation and 3D simulation is the fastest control in the entry level, according to the manufacturer. The control portfolio has been expanded to include the DMG Slimline Panel with Heidenhain 620 and MAPPS VI from Mori Seiki.
Enquiry No. 8604 Turn to page 80a or log on to www.equipment-news.com to enquire
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DMU 50 Ecoline The CNC universal milling machine DMU 50 Ecoline has an optional 10,000 motor spindle for optimum surface quality and a 30-piece tool magazine for more flexibility during five-sided-machining.
Enquiry No. 8605 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 192
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Special Report
Koerber Schleifring: On The Up
The upturn in the economic situation, which started in the second half of 2010, has also had an impact on grinding machine manufacturers and has continued into 2011. The pent-up demand in almost all customer industries ensured that during the first half of 2011, the Schleifring Group too experienced an increase in orders of nearly 70 percent, compared to the same period last year. The technology division of tool grinding was the first to benefit from this boom and now the surface grinding, profile grinding and cylindrical grinding divisions are also showing comparable growth rates. This trend has had a positive effect on turnover, which rose by almost 70 percent compared with the previous year. With its eight corporate brands, the group is the world’s largest supplier of
Ewag Laser Line
grinding machines. As a result, it has established an international market presence, which is customer-oriented and efficient. As described by Stephan Nell, the CEO of Koerber Schleifring, the company’s major strength is the global presence that they have and they are a “reliable partner” who will “improve the competitiveness of their customers.” In recent years, the companies of the group have continued to invest in research and development resulting in newly developed machines, like the Ewag Laser Line, the Blohm Orbit precision surface and profile grinding machine and the Studer S41 universal cylindrical grinding machine.
Enquiry No. 8606 Turn to page 80a or log on to www.equipment-news.com to enquire
Taiwanese Offensive Executives from some of Taiwan’s largest machine tools companies discussed trends in the industry at this year’s EMO Hannover.
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A products launch featuring Taiwanese machines took place at a press conference at the show. According
Walter Ewag unveiled the company’s development for complete tool machining using laser ablation. Supported by existing technologies for grinding, electrical discharge machining, and measuring, the company is now a full range manufacturer for tool machining technology. In d e v e l o p i n g t h e L a s e r L i n e , application flexibility was a major priority right from the start. A kinematics concept was pursued that superimposes threeaxis laser beam guidance (U/V/W) on a five-axis machine kinematics (X/Y/Z/ B/C). This enables the laser processing of tool cutting edges as well as the laser ablation of complex chip grooves to be performed in one clamping operation. An integrated 3D measuring sensor is used to accurately measure the soldered diamond blank. This enables bumps created during the soldering process to be compensated for and guarantees an accurate lens position.
Enquiry No. 8607 Turn to page 80a or log on to www.equipment-news.com to enquire
to recent estimates made by the Taiwan Association of Machiner y Industr y, the total output value of Taiwan-made machine tools could hit US$4 billion by the end of 2011, making Taiwan the world’s third largest machine tools exporter. The island currently stands at the fourth spot globally. As the demand of the emerging Asian markets for national economic construction continues to increase, experts predict that Taiwan’s machine tool exports to the global market will expand to US$7 billion in 2015.
Enquiry No. 8608 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 133
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Special Report
Developments At Grob Trumpf
The Grob Group embarked upon this year at the EMO Trade Fair with a range of technical innovations. They are hydraulic-free CNC machine tools in five-axis technology with an additional sixth axis for workpiece clamping, along with other new developments in hydraulic-free machine tools. Loading & Automation Concept With Part Changer The part changer is secured to the front of the machine and has two linear axes. The first linear axis moves the workpieces with two loading forks in an X direction from the raw part position to the loading position, or from the loading position to the finished part position. The second linear axis is designed as a telescopic axis and transports the workpieces from the loading position to the working area and back again. Compact Linear Gantry The part changer is loaded and unloaded with the aid of a smaller linear gantry. The X beam is about 3.2 m above the floor of the plant, making it much lower than was previously the case. The vertical suspension of the carriage and of the loading arm on large castors underneath the X beam is another new development. Program For The Modular Special Machine A modular machining unit has been
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developed by the company, which also supports clamping positions for two workpieces â&#x20AC;&#x201D; for short cycle times and during pre-machining processes on the workpieces. This makes the units and the combined machines more high-performing and efficient, and more compact and more space-efficient in terms of their dimensions. Milling, Turning & Machining Centre Taking the G-module series as a basis, a type of machine has been developed in the form of a milling, turning and machining centre, combining the cutting tasks of milling and turning in a single clamping action. In the development of this, the engineers attached particular importance to the axial arrangement of the single-spindle five-axis series G 350 and G 550. Electromechanical Pallet Changer As a complementary model to round off the hydraulic-free machine tool, the company has developed a fully electromechanical pallet changer. The pallet is clamped and held in place mechanically on the loading/unloading station and work area side. It also enables the cycle time of the loading process to be shortened and accelerated.
Enquiry No. 8609 Turn to page 80a or log on to www.equipment-news.com to enquire
Trumpf showcased the laser deposition welding at the EMO as a manufacturing method for wear protection, repairs and prototyping which reduces the usage of materials and energy. Two applications for laser deposition welding were seen at the show. A deep-drawing tool used in automotive manufacturing shows how effectively laser deposition welding can protect surfaces against wear and tear. This heavy-duty tool is used for hot-forming and presshardening elements such as the B-pillars on bodyshells. In the case of presshardening, the components need to be quenched; this is done by cooling the tool. The more efficient the cooling, the shorter the cycle time. With this deep-drawing tool, pipes are integrated in globular gray cast iron. The advantage is that the pipes can be routed close to the tool surface. The disadvantage is that the cast iron is very soft. As such, the tool needs to be armoured with a hard wear layer. Following forming, the components are so hard that they substantially improve the safety of the passenger cell. The hard deposition-welded protective layer ensures long tool life. This cooling technique reduces the cycle time of a component by up to 35 percent.
Enquiry No. 8610 Turn to page 80a or log on to www.equipment-news.com to enquire
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Mikron Unveils Machining Concept
Mikron SA Agno
Pama
At the centre of the presentation at EMO was the machining system Multistar NX-24. Presented under the heading ‘The best of productivity with CNC flexibility’, a machining concept was introduced, which combines productivity with flexibility and precision. The company still offers the Rotary Machining System among its line of Transfer Machines. It achieves up to 150 cycle steps per minute and can produce up to 520 parts per minute when equipped with four cycles per machine. The machine is designed for high output, large volume production but because it is fully mechanically controlled, change-over can take time. The system increases flexibility and this with only slight reduction in the output capability. Therefore it is especially suitable where different types of work pieces must be produced in quantities from a few hundred up to many thousands of parts, within accuracies in the hundredths of a millimeter range.
Enquiry No. 8611 Turn to page 80a or log on to www.equipment-news.com to enquire
Walter Demonstrates New Products At EMO Faster, deeper and more efficient — this is Walter’s motto for EMO 2011. All customers from the automotive industry, aerospace industry, energy sector, mechanical engineering and rail transport sectors, and also from other metalworking sectors, can draw benefits from the products. Tiger·tec Silver On The Advance Tiger·tec Silver technology can now also demonstrate its strengths during turning. A generation of indexable inserts for steel chip removal during ISO turning was on display with the Tiger∙Tec Silver ISO P generation for the first time at EMO. According to the maker, it can give an increase in output of up to 75 percent.
Records For Speed & Depth The Alpha 4 XD drill from Walter Titex has set a world record. The solid carbide drill with internal cooling is the only spiral drilling tool which offers a drilling depth of 70xD, without pecking. The company is producing solid carbide blanks by applying a new method, which makes this type of long solid carbide twist drill possible. The drill is suitable for machining steel, cast iron and non-ferrous metals. It is available in a range of diameters from 5 - 12 mm as a special tool. Compared to the gun drill, the XD drill offers a ten-fold increase in performance.
With the annual revenue of €147 million (US$195 million), the Italian manufacturer large machine tools is going places. With over 80 percent of production exported mainly to China, India, Russia, Germany and the US, the company revealed at the press conference at EMO that their new plant in Lingang, Shanghai will be ready in 2012. With the motto: Winning the challenge of market, the company showcased its Speedram 3000 at EMO. It is a floor type boring and milling machine. The structure of the machine has been designed to increase rigidity, without increasing mass, to maintain the dynamic characteristics of the machine. Machine is also equipped with a headstock balancing system that evenly dissipate the forces acting on the column, minimising its deflection effect. In addition, an adaptive system has been introduced to the machine, which integrates the spindle absorbed power reading with signals provided by a tri-axis accelerometers.
Enquiry No. 8612 Turn to page 80a or log on to www.equipment-news.com to enquire
Time & Costs Savings The ConeFit modular solid carbide milling system from Walter Prototyp has been gradually extended. With ConeFit Spade Type, the company introduced a doubleedged, pressed modular tool for the ConeFit system at EMO. It is suited to copy milling, plunge milling, chamfering, centring and spot-facing holes. Also new are versions that have been developed for graphite machining.
Enquiry No. 8613 Turn to page 80a or log on to www.equipment-news.com to enquire
Nov-Dec 2011 metalworking equipment news
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Products
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Aicon: Simulation Module For Bending Machines
Renishaw: Versatile Gauging System
With the launch of the software version 4.7, Aiconâ&#x20AC;&#x2122;s optical tube measuring system TubeInspect will be extended by a practical function: Now the operator has the possibility to simulate the bending process considering individual correction values, and to verify their effect on accuracy to gauge by means of a virtual gauge check. With the help of high-resolution digital cameras, the system determines the tube geometry within seconds. Beyond that, the system shows in detail which bending points deviate from the desired values, and suggests correction values. These correction values can be transmitted directly to the bending machine, whereby the system allows the connection to up to 100 benders.
The Equator gauging system from Renishaw is billed as an alternative to traditional dedicated gauging that cuts purchase, maintenance and fixture costs, can be pre-programmed for multiple parts, and reprogrammed in minutes for design changes. The system, which is capable of high-speed comparative gauging for inspection of high-volume manufactured parts, has reportedly been developed on the shop-floor in collaboration with industry-leading companies in the auto, aerospace and medical sectors. The result is a lightweight, fast and repeatable gauge that operators can apparently use with push-button simplicity. Since the solution can switch between parts in seconds, it is seen as suitable for flexible manufacturing processes or accepting parts from multiple machines.
Enquiry No. 8614 Turn to page 80a or log on to www.equipment-news.com to enquire
Mitutoyo: High-Speed Scans
Seco: Making Milling Simpler
Mitutoyo presents a generation of the series of coordinate me a su r i n g machines with the models Cr ystaApex S 500, 700 and 900. Compared with the previous versions, the current models of the series feature a higher scanning rate with a high accuracy. This increase is made possible by the integration of the UC400 controller. These CNC-controlled coordinate measuring machines, which were designed and built especially for the demands of the European market, are versatile and have a wide range of applications. With their capabilities and comprehensive equipment, they offer much more than usual in this class. Enquiry No. 8615 Turn to page 80a or log on to www.equipment-news.com to enquire
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metalworking equipment news Nov-Dec 2011
Enquiry No. 8616 Turn to page 80a or log on to www.equipment-news.com to enquire
The modern tool system Minimaster Plus by Seco with replaceable fluted inserts makes milling simpler and more productive. A manufacturing te c h nolo g y a l low s he av y - dut y, versatile usable milling cutters show convincing performance with regard to high precision and long tool life. The most significant innovation of Minimaster Plus is the precise and secure interface between the replaceable carbide insert and the steel shank. The insert has an internal thread and external taper, while the shank has an internal taper with a threaded centre pin both giving additional reliability as well as high run-out precision and high stability. Enquiry No. 8617 Turn to page 80a or log on to www.equipment-news.com to enquire
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System 3R: Automation In Pallet Changing
Widia: Deep-Hole Drills
The addition to Sy s te m 3 R’s automation program is WorkPartner 1+, a robot characterised by a design that is tuned to match modern tool machines in efficient production cells. T h e s y s te m i s a compact unit for changing pallets (of up to 50 kg in the standard format) on machine tables and at machine spindles in one or two machines. The served machines may be of the same type and make. They can also just as easily use different machining technologies and come from different manufacturers. It offers magazine capacity in minimum floor space. The modular magazines give flexibility that can be adapted to each user’s needs.
In deep-hole drilling applications up to 30XD, solid-carbide WidiaRübig deep -hole drills remove between three and four times the metal compared to gun drills, in addition to delivering good hole quality and cycle times. Length ratios for the deep-hole drills are available in 15XD, 20XD, 25XD, and 30XD. Available diameters range from 3.0 to 13.0 mm. Along with increased performance, the solid-carbide deep-hole drills increase process versatility by not requiring special drivers or guide bushings. And where gun drilling machines are dedicated to gun drilling only, the deep-hole drills can be used in machining centres, eliminating the need for specialty capital equipment.
Enquiry No. 8618
Enquiry No. 8620
Turn to page 80a or log on to www.equipment-news.com to enquire
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Walter: Solution For Cast Iron Workpieces
Enquiry No. 8619 Turn to page 80a or log on to www.equipment-news.com to enquire
Manufacturing Indonesia 2011 Stand 8917 Hall D
Metalex 2011 Booth 6P04
Smart Hybrid Finishing
New OptiRough Toolpath
New Dynamic Milling Techniques
Easier Multiaxis Machining
New Plunge Turn Toolpath
Mastercam Machine Simulation
Design Enhancements See Mastercam X6 in action at www.mastercam.com.sg
Techtown Pte Ltd
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ENQUIRY NO 112
T h e X t r a · te c m i l l F4045 is fitted with indexable inserts with 14 cutting face s a n d h a s been optimised for the machining of cast iron materials. Walter has adapted this tool with a medium p itc h to we a ke r machines and unstable clamping conditions. Stable machines, workpieces and clamping arrangements are required for achieving maximum cutting rates. Only in such conditions can a tool achieve its highest performance. Because workpieces with complicated shapes do not always permit rocksolid clamping, many operators prefer to use less stable, yet movable machining centres due to their flexibility, and so a tool like the heptagon cutter is used to its full potential.
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EVENTs&exhibitions
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CAD/CAM Partnership Continues To Blossom With Product Launch SeaCAD and Dassault Systèmes SolidWorks release the 2012 version of the design software. By Shahnawaz Abdul Hamid
Conrad A Montgomery
S
eaCAD Technologies, in association with Dassault Systèmes SolidWorks hosted the ‘SolidWorks 2012 Product Launch’ at the Megu Event Hall, located at the Singapore Flyer on October 4, 2011. The event gave approximately 300 design professionals from 115 companies in industries as diverse
as aerospace and defence to office equipment a sneak preview of SolidWorks 2012. The event began with the founder of SeaCAD Technologies, Conrad A Montgomery; recounting before the audience the early experiences he had trying to singlehandedly sell a virtually unheard of SolidWorks to the manufacturing industry.
Today, more than a decade later, the company, where he is president and CEO, boasts a 520 sq m office at the Enterprise Hub. It is ‘home’ to 31 specialists; all dedicated to selling the same product, albeit one that has grown more popular over the years. The company, Mr Montgomery is proud to add, has commercial licenses amounting to 3,000. His opening address was followed by a speech by Kelvin Ang, the territory technical manager for Dassault Systèmes SolidWorks. Mr Ang spoke on the changing world of CAD. “Gone are the days when we only use CAD. We now use product design, together with design validation, together with product data management.” Indeed, it appears SolidWorks 2012 aims to seamlessly integrate design data across all work functions. Initial reports indicate the 2012 version will continue to do well in the CAD/CAM industry. The product features over 200 customer-driven enhancements. The event concluded with the SeaCAD technical team demonstrating to the audience the various features of the software. Enquiry No. 8621 Turn to page 80a or log on to www.equipment-news.com to enquire
SolidWorks 2012 To Help Companies Make Better Cost Decisions In an exclusive interview with Asia Pacific Metalworking Equipment News, Sharon Toh, GM of Dassault Systèmes Singapore, shares how her company’s most recent offering will help design engineers make better decisions.
Sharon Toh Ms Toh told APMEN: “Prior to launching SolidWorks 2012, we had a beta testing exercise. Previously, we told users to download the beta version and test, and submit any issues they had to us. But for this version, we did something different. We actually organised a group-level test. Our R&D engineers went to Pune, India to meet a group of SolidWorks users. The testing of the 2012
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software was done in front of these engineers. This helped the user directly communicate his concerns to the engineer.” When asked which new features would be most exciting to the design engineer, Ms Toh cited the Feature Freeze and Costing Tool. The Feature Freeze increases the speed of designing complex models where rebuilding specific features is not needed while the Costing Tool allows designers to make more informed cost-based decisions throughout the design process.
“The process of engaging the customer has led us to realise that design engineers make a lot of decisions. However, they lack the tools to make good cost-related decisions. They don’t see how their decisions impact the cost of the product. Therefore, in this latest version, we have a costing module. This allows the design engineer to accumulate the company’s costing information when making design decisions,” she added.
Enquiry No. 8622 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 172
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Event Review:
Vietnam Manufacturing Expo 2011
F
or the first time in Vietnam, ‘Industrial Components & Subcontracting Vietnam 2011’, ‘SI Exhibition: Vi e t n a m - J a p a n S u p p o r t i n g Industries Exhibition 2011’ and ‘Vietnam Manufacturing Expo 2011’ joined forces at ICE Hanoi and showcased today’s technologies as well as high quality parts to support the growth and improvement of supporting industries in Vietnam. Over 9,774 visitors came to visit the shows to source for suitable machineries to expand their productivity and diversify their range, while also meeting up with potential partners from many countries including Thailand, Singapore, Japan and others to create a new market. T h e a t m o s p h e re o f t h e shows was lively and provided a positive sign for the future of supporting industries in Vietnam. Moreover, with more intense level of cooperation among different associations and companies from different countries, the way to the international market for Vietnam supporting industries was opened. The number of visitors this year is an increase of 32 percent when compared to the last. Voices From The Industry Chanin Khaochan, director of BOI Unit for Industrial Linkage Development (BUILD) said: “There are lots of exhibitors from within Vietnam, Thailand and Japan at these exhibitions with all kinds of supporting industries products to offer. Visitors get the
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opportunity to gain access to new technologies and improve their industries. I expect that exhibitors of these shows will get to increase the level of cooperation to produce higherquality products while visitors can learn new technologies which would help them in their own business.” Vivien Yen, project manager, International Trade Development S i n g a p o re M a n u f a c t u re r s ’ Federation said: “These exhibitions are very well organised and useful for both exhibitors and visitors. Currently, supporting industries in Vietnam have a lot of advantages and opportunities for future development. Through our participation in these shows, the Singapore Manufacturers’ Federation hopes it will increase the chance for our members to get more exposure and contacts with the local companies as well as Japanese companies here.”
Ronnie Wong, president of The Association of Electronic Industries in Singapore (AEIS) said: “This year, the Association of Electronic Industries in Singapore has brought machines for electronic, connectors and battery as highlights for the electronics industry. We are looking forward for companies from Singapore to network with local companies in Vietnam and promote our products to be known here. Although the supporting industries in Vietnam are now at an early stage, I believe that this scenario will change in the next five years through the set up of factories, purchase of new machines, as well as technologies and human resource training.” ICE Hanoi Hanoi, Vietnam September 15 – 17, 2011 Enquiry No. 8623 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 205
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Event Review:
Wire/Tube Southeast Asia 2011
W
ire / Tube Southeast Asia recorded figures of 392 exhibitors and more than 5,300 trade visitors from about 60 countries, of which some 40 percent came from outside Thailand. The exhibitions, which took place at BITEC (Bangkok International Trade and Exhibition Centre) from September 13 - 15, 2011, exceeded expectations with visitorship that saw an increase of 20 percent from 2009. ASEAN visitors’ inclusive of Thailand accounted for about 80 percent of the total visitor attendance, signifying that ASEAN buyers view the event as the forum for trade and business and the gateway to Southeast Asia for product distribution for wire, cable, tube and pipe sectors in the region. The strong visitor attendance, particularly from Indonesia, Malaysia, Singapore, and even India also further highlighted the increasing significance of ASEAN as a ‘collective whole’ and dynamic common market moving towards a single economic community by 2015. Information Exchange Numerous discussions took place on the show floor during all exhibition days, together with visiting delegations from China, Malaysia, Japan, Philippines and Vietnam boosted the professional atmosphere of the show. The response from the local, regional and international sectors to the exhibition this year has propelled it to yet another important stage in its strategic development. Gernot Ringling, MD of Messe Düsseldorf Asia commented: “The results of this year’s wire and Tube Southeast Asia proves that business in the wire, cable, tube and pipe sectors in the region is expanding strongly, driven by continued economic growth in Thailand and the Southeast Asian region.” Highlights Of The Show Highlights from this year’s exhibitions, included eight national pavilions and groups from Austria, China, Germany, Italy, Singapore, Taiwan, UK, and USA. There was also a creative design showcase on stainless steel industrial products presented by members of the Thai Stainless Steel Development Association. The growth in the number of international visitors attending was due in no small part to the success of the technical seminar series held in July this year in Jakarta, Taipei and Seoul which placed a spotlight on leading companies.
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Messe Düsseldorf Asia has announced dates for wire / Tube Southeast Asia 2013. It will be held on September 17 - 19, 2013 at BITEC, Bangkok. BITEC Bangkok, Thailand September 13 - 15, 2011 Enquiry No. 8624 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 194
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ProductFinder Autodesk: Cloud Services
Faro: Measuring Software
Autodesk has developed Autodesk Cloud, a collection of more than a dozen web-based capabilities, products and services. It enables customers to extend their desktops with greater mobility, new viewing and sharing capabilities, and more computing power, helping them better design, visualise and simulate their ideas. Additional cloud services exclusive to subscription customers give designers, engineers and digital artists new capabilities, such as high-performance 3D visual communication, simulation and collaboration that were once limited to organisations with privileged access to expensive, high-end supercomputing centres.
CA M2 Mea sure 10, the measuring software for the FaroArm, ScanArm and laser tracker has been developed by Faro. The software is built on the foundation of the previous CAM2 Q while also introducing key features like Live Colour Scan for point cloud inspection, Shortcuts and the Easy Move Wizard. These functionalities are designed to improve the measurement processes, whether tactile or scanning. D e sig ned to ma ke tact ile a nd sca nning measurements easier, the software also features an interface that enables users to customise the layout window optimising the measurement workflow.
Enquiry No. 8701 Turn to page 80a or log on to www.equipment-news.com to enquire
Delcam: Enhancements To Feature-Based Machining Software
Heller: Five-Axis Machining With Turning Function
Delcam has launched the 2012 version of its FeatureCAM feature-based CAM system, with a range of enhancements to enable faster and easier programming, and produce more efficient toolpaths to give greater machine productivity. A number of the improvements will make the program even easier to use. For example, a range of keyboard shortcuts has been added, including isometric view options that will allow faster programming. It has been made easier to select multiple items from the operations tree and to move all the features in a group, for example, a network of similar holes or all the operations on a particular spindle.
Usually a five-axis machining centre does not provide a turning machineâ&#x20AC;&#x2122;s capability of horizontal or vertical turning or tilted turning with A and B axis. However, the cutting performance of Hellerâ&#x20AC;&#x2122;s C series will make it possible to perform such operations on a machining centre. This machine series provides economically efficient cutting data to enable workpiece rotation of up to 1,000 RPM for performance-oriented pre-machining and finishing true to the final contour. The manufacturer offers the C series in two sizes: C 2000 and C 4000. Options include a version with direct manual loading onto the table of the machine (CT) or with integrated pallet changer (CP) and hydraulic clamping.
Enquiry No. 8702 Turn to page 80a or log on to www.equipment-news.com to enquire
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Enquiry No. 8703 Turn to page 80a or log on to www.equipment-news.com to enquire
metalworking equipment news Nov-Dec 2011
Enquiry No. 8704 Turn to page 80a or log on to www.equipment-news.com to enquire
productfinder
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Matrix Machine Tool: CNC Internal Thread Grinder
Mitsui Seiki: Machining Centre For Power Generation Parts
Matrix has developed a small footprint C N C i n te r n a l thread grinder — Model 3060. The grinder includes features like torque motor driven workhead and HF wheel head motor among others. The machine, which has a swing capacity of 300 mm and a maximum grind length up to 150 mm makes it suitable for a variety of applications within a diverse range of industries such as the automotive, aerospace, metrology, automation and oil/gas. The manufacturer has also released the Matrix Profilemate, which is the company’s own thread profile generation software.
With the continuing evolution of machining re qu i re me nt s to satisfy new power generation production needs, Mitsui Seiki has developed the HU63 -T 5 -xis CNC Machining Centre. Typical applications include critical rotating components (blisks, impellers, and turbine disks) for gas turbine power generation systems. Features and specifications include up to 800 mm work diameter capacity on its vertically oriented table, 300 kg work / fixture weight capacity, variety of increased axis stroke options, high torque spindles (1,081 Nm – 800 lb-ft continuous), tuned structure for heavy cutting in hard metals, and the Fanuc 30iM control with enhanced features for five-axis simultaneous machining. Enquiry No. 8706 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 068
Enquiry No. 8705 Turn to page 80a or log on to www.equipment-news.com to enquire
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Open Mind: CAM Software Program
TMT: Turn/Mill Machine
Open Mind Technologies has released hyperMill 2011. Automated functions and technologies in the release helps to reduce machining costs and times. The features include intelligent macros, 64-bit support, application programming interfaces and customised process features. New strategies such as five-axis shape offset roughing and finishing allows for even more efficient programming. The programming environment offers forwardlooking solutions for 2D, 3D, HSC and five-axis simultaneous machining. Users can draw from a range of functions for optimised processes, time-saving, comfortable workflows and efficient machining.
The L-290M from TMT is a heavy duty, precise, versatile CNC turning and milling machine for customers who need machines with comprehensive machining capabilities and accuracy. The machineâ&#x20AC;&#x2122;s X and Z axis are box guideways. They present accurate and durable characteristics for various turning applications. The 125 mm X axis and 500 m Z axis allows a maximum cutting diameter up to 250 mm. The spindle uses the NN type bearings (double-row cylindrical roller bearings) for high precision, even under heavy cutting loads, and its 66 mm bore accommodates larger bar capacity up to 52 mm.
Enquiry No. 8707 Turn to page 80a or log on to www.equipment-news.com to enquire
SolidAce: Structural Steel Design & Engineering Application
SolidAce has released the version 2.0 of BuiltWorks, a structural steel design and engineering add-in application for SolidWorks CAD environment. Version 2.0 fully support the corresponding version of 3D CAD platform â&#x20AC;&#x201D; SolidWorks 2011. The maker also decided to continue the support of previous platform version of BuiltWorks 2010 for SolidWorks 2010 due to multiple requests from user community. Some of the features in the software program are the improved performance in trimming operations and some functions working with plates and full support of cardinal points without changes to offset value in placement of steel members. Enquiry No. 8708 Turn to page 80a or log on to www.equipment-news.com to enquire
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Enquiry No. 8709 Turn to page 80a or log on to www.equipment-news.com to enquire
Tungaloy: Double-Sided Inserts
Dorec from Tungaloy is a family of double-sided inserts with four helical cutting edges and tools for 90 deg milling. The insert construction is thick and strong, with a wiper, which leaves a good surface finish. In addition, clamping into a dovetail inclined pocket provides rigid clamping. The tool features durability, low cutting forces and long tool life, due to its strong construction and chip deflector with positive cutting angles. It is suitable for machining steel, stainless steel and cast iron at high machining parameters. Enquiry No. 8710 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 193
We are an Australian medical device company that requires specialized one-off machines to make patented, unusual products. We are seeking to outsource the construction of several machines. We will be providing significant amount of design input. Also, we require manufacturers with ISO 9001 to operate our machines. We will provide all raw materials and training. You will need approximately 500m2 of space, container access and preferably located in Thailand, Indonesia, Vietnam, Singapore or Malaysia. We are also looking for: • Polyurethane with 14kg/m3 density • PET or Polypropylene 180 micron sheet with high quality optical properties. Clear without scratches, with coating for a surface tension appropriate to print. • Service supplier who can print and die cut PET approximately 4-6 tonnes per month.
craig@erskinetech.net
DEES' Taiwan and China Factories are all ISO-9000 Certified 1600 tons Front Runner with 2 x 1000 tons and 2 x 800 tons
DEES HYDRAULIC INDUSTRIAL CO., LTD. TAIWAN HEADQUARTERS / FACTORY: Tel.: +886-2-2601-8661
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Contract Manufacturers Quality Value Toolmakers
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Over the course of this year, we have rolled out new initiatives and products to bring you to the forefront of metalworking. For more information, please contact:
apmen@epl.com.sg
tel: (65) 6379 2888 â&#x20AC;˘ fax: (65) 6379 2805 www.equipment-news.com
Exhibition Programmes November Nov 29 – Dec 2 Euromold Frankfurt, Germany DEMAT Info@demat.com www.euromold.com
Nov 30 – Dec 3 Manufacturing Indonesia 2011
Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com
December 21 – 24 Metalex
BITEC Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th
2012
January 19 – 24 IMTEX
BIEC Bangalore, India Indian Machine Tool Manufacturing Association imtma@imtma.in www.imtex.in
February 21 – 22 SAMPE Asia 2012 KL Convention Centre Kuala Lumpur, Malaysia SAMPE SAMPEAsia@sampe.org www.sampe.org
21 – 23 Composites 2012 Las Vegas, USA ACMA www.acmashow.org
2011-2012
March
May
International Center For Exhibition Hanoi, Vietnam SES mta@sesallworld.com www.mtahanoi.com
JIExpo Jakarta, Indonesia PT GEM Indonesia info@gem-indonesia.net www.inamarine-exhibition.net
28 – 30 MTA Hanoi
9 – 12 INAMarine 2012
28 – 31 Inapa 2012
15 – 19 Metaltech 2012
April
17 – 20 Intermach 2011
JIExpo Kemayoran Jakarta, Indonesia PT GEM Indoneisa info@gem-indonesia.net www.inapa-exhibition.net
11 – 13 Indonesia Oil & WGas Expo 2012 JIExpo Jakarta, Indonesia Fireworks info@asiafireworks.com www.indonesiaoilgas.com
17 – 22 SIMTOS 2012 KINTEX Seoul, South Korea KOMMA intl@simtos.org www.simtos.org
18 – 21 InterMold
Intex Osaka, Japan Japan Die & Mold Industry Association iminfo@itp.gr.jp www.itp.gr.jp
PWTC Kuala Lumpur, Malaysia Trade Link info@tradelink.com.my www.tradelink.com.my
BITEC Bangkok, Thailand UBM Asia intermach@intermachshow.com www.intermachshow.com
July
3–6 MTA Vietnam
SECC Ho Chi Minh City SES mta@sesallworld.com www.mtavietnam.com
November 7 – 10 Indo Aerospace 2012 JIExpo Jakarta, Indonesia www.indoaerospace.com
www.equipment-news.com Nov-Dec 2011 metalworking equipment news
79
advertising index Advertiser
80
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Enquiry No.
ASIA PACIFIC METALWORKING
The Engineering Journal For Manufacturing,Automation & Quality Control
4T TECHNOLOGIES PTE LTD
33
126
ACCUWAY MACHINERY CO LTD
37
177
AGMACHINE TECHNO CO LTD
75
068
BRUDERER PRESSES (FAR EAST) PTE LTD
57
153
BYSTRONIC PTE LTD
03
195
DEES HYDRAULIC INDUSTRIAL CO LTD
77
057
DELCAM PLC (INTERNATIONAL DIVISION)
05
111
ERSKINDENTAL
77
193
EVERGREEN INTERNATIONAL CORP. (MT DUO SHOW 2012)
61
192
EVERISING MACHINE CO LTD
59
198
EXXON MOBIL ASIA PACIFIC
31
173
HAAS AUTOMATION INC
11
189
FOREIGN REPRESENTATIVES
HEIMATEC GMBH
77
204
GERMANY
HEXAGON METROLOGY ASIA PACIFIC PTE LTD
19
142
HOFFMANN GMBH
09
122
HONG CHEK CO (PTE) LIMITED
53
128
IDEMITSU LUBE (SINGAPORE) PTE LTD
17
197
ISCAR LTD
IFC
200
KENNAMETAL INC
BC
135
KUKA ROBOT AUTOMATION (M) SDN BHD
27
157
LICO MACHINERY CO LTD
49
073
LMT ASIA PTE LTD
21
046
LVD COMPANY NV
45
077
MMC HARDMETAL (THAILAND) CO LTD
47
134
NATIONAL INSTRUMENTS
43
201
OBJET AP LIMITED
FC
196
PAMA SPA
29
190
PRO RICHYOUNG INDUSTRIAL CO LTD
41
180
PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA 2011)
63
133
RENISHAW (HONG KONG) LTD
15
207
SECO TOOLS (S.E.A) PTE LTD
01
001
singapore exhibition services pte ltd (MTA Hanoi 2012)
69
172
TAEGUTEC CO
13
202
TAIWAN TAKISAWA TECHNOLOGY CO LTD
39
148
techtown pte ltd
67
112
TSUNGLIN MACHINERY TECHNICAL CO LTD
25
199
trade-link exhibition services sdn bhd (metaltech 2012)
71
181
TUNGALOY SINGAPORE (PTE) lTD
55
206
UBM ASIA (THAILAND) CO LTD (INTERMACH 2012)
73
194
WALTER AG SINGAPORE PTE LTD
07
170
WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG
23
187
YAMAZAKI MAZAK SINGAPORE PTE LTD
IBC
208
YIH CHUAN MACHINERY INDUSTRY CO LTD
51
191
ZWCAD SOFTWARE CO LTD
77
203
metalworking equipment news Nov-Dec 2011
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ASIA PACIFIC METALWORKING
No. 8 2011
The Engineering Journal For Manufacturing,Automation & Quality Control
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From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction. Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call (65) 6265.9222 or visit www.widia.com.
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