APMEN Nov-Dec 2015

EMO MILANO 2015 • MEDICAL PARTS MACHINING: THE SWISS DIFFERENCE November - December 2015

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2015 CONTENTS 28

METAL CUTTING 28 From Image To Implant

Today’s machine shops, whether in the medical technology or tool and mould making sectors, can take advantage of an integrated CNC solution for everything from the design concept to the finished product. Contributed

by Tim Daro, president, Bernard & Company.

30

Crankshaft Microfinishing: New Possibilities, New Directions

Automobile manufacturers are familiar with the problems associated with crankshafts: The surface roughness results on the bearings differ from those on the transition radii, the bearing profile cannot always be adhered to, roundness improvements on the pin bearings differ from those of the main bearings, and smaller crankshafts deform as a result of machining forces and workpiece oscillation.

By Wolfgang Riedle.

33

Medical Parts Machining: The Swiss Difference

The world medical market is strong for several reasons, including the fact that it has an aging population and this presents a business opportunity for the manufacturing sector. Contributed by Tornos.

33

GREAT GEAR & SYSTEM 36

44

Advanced Vending Systems: Gearing For Increased Productivity

For over two decades industrial vending machines have provided a viable means of storing tools around the world. Raoul Rapke, director of CTMS Division, IMC Group, shares its benefits with APMEN.

39

Managing Your Data Smartly

Industry 4.0 is becoming the talk of the industry, but with all the big terms that it has spawned, manufacturers might be intimidated by this seemingly disruptive revolution, especially when it comes to data. In a nutshell, what is Industry 4.0 and how can one manage data smartly? By Michelle Cheong.

40

Let’s Get Grinding

Pat Mc Cluskey, co-founder of ANCA shares the advances in linear motor technology and how they will improve the tool grinding process.

2

IN DESIGN 41

44

Multisensor systems have evolved considerably over the years as the component technologies for motion control optics, lighting and cameras have improved.

Tim Sladden, director of marketing communications, Quality Vision International, tells us more.

Inspection software to verify potential errors on machined parts are critical to ensuring wastage and eventually improving cost savings. By Peter Dickin, marketing manager, Delcam.

Multisensor Measurement: Into A New Era

asia pacific metalworking equipment news November - December 2015

Inspect Early, Reduce Wastage

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NOV DEC

2015 CONTENTS 48

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.

FAST FAB 48

Getting All Green About It

The global sheet metalworking industry is a major user of energy and the cost of electricity is becoming more expensive every year. Paul Hillam, area export manager, SafanDarley, tells us more about energy reduction trends in the sheet metalworking arena.

EVENTS & EXHIBITIONS 64

Event Review: Vietnam Manufacturing Expo 2015

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

INDUSTRY Endorsements

52

Getting Efficient Fixtures

Singapore Precision Engineering and Tooling Association (SPETA)

The transformation in three dimensional measuring technology as well as shape inspection using optical methods, which set in years ago, is constantly setting new standards in shorter cycles. Contributed by Witte Asia.

Federation of Asian Die & Mould Associations (FADMA)

FEATURES 54

Understanding Contract Manufacturing

Contract manufacturing is popularly used in the metalworking and manufacturing world of today, but what factors are important in choosing the right one? By Michelle Cheong.

58

Towards A Data Driven Culture

For many years, manufacturers have been looking for new ways to manage their assets. In many cases, traditional financial models no longer support the needs of today’s manufacturers and this is so as we move forward in the era of digitalisation. By Badrinath Setlur, assistant vice president – consulting, manufacturing, logistics, energy and utilities, Cognizant.

60

Doubling Up On Productivity

Thanks to the implementation of a new line featuring robots which was made possible by the collaboration between SIR, a systemintegrator based in Modena, and FCA Cento, production of new engine blocks for 3000cc V6 diesel engines has doubled.

Contributed by Comau.

4

Federation of Malaysian Foundry & Engineering Industry Associations

66

EMO Milano 2015: Taking Steps To The Future Of Machining

Indian Machine Tool Manufacturing Association (IMTMA)

The premier metalworking and precision engineering show EMO takes flight to Milan, Italy. This time round, the echoes of Industry 4.0 were louder than ever. APMEN was there in Milan to soak up the sights, sounds and technology. Syed Shah reports.

China Machine Tool & Tool Builders' Association (CMTBA)

72

Machine Tool Club (MTC)

Event Review: Metalex Vietnam 2015

74

Taiwan Association of Machinery Industry (TAMI)

Event Review: Manufacturing Myanmar 2015: Plugging The Gaps

REGULARS Business News 8 75 Product Finder 79 Exhibition Programmes 80A Product Enquiry Card

asia pacific metalworking equipment news November - December 2015

80

Refer to Advertising Index

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PT. Delcam Indonesia Perkantoran Pulomas satu Gedung-1, Lt-3 Room 12A Jl.A Yani No2, JAKARTA, Indonesia Tel: (62)-21-4894964

Delcam S.E.A. Pte. Ltd. 6001 Beach Road, #18-01 Golden Mile Tower, Singapore 199589 Tel : +65 97233095 & +65 64511124

Delcam Vietnam Representative Office Office 602, 159 Dien Bien Phu, Binh Thanh Dist, Ho Chi Minh City, Vietnam Tel : +84 8 35144078

Beijing Delcam Integrated System Co., Ltd. Rm. A411, Jinyu Jiahua Building, No.9, 3rd Street , Shangdi, Haidian District, Beijing 100085, China Tel +8610 6298 5591

Delcam (Thailand) Co.,Ltd. 11 Rama II Road Soi 54 Lane 4-3, Samaedam, Bangkhuntien, Bangkok 10150, Thailand Tel: +66 2 899 1182-4 ENQUIRY NO 075

EDITOR’S NOTE

Here’s To

Published by:

EASTERN TRADE MEDIA PTE LTD (a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

Better Days In the past couple of years, just about this time of the year, there will be a lot of thoughts, predictions and projections for next year’s political, economic and social happenings.

Generally, when you pick up a business daily or publication and flip through the first ten pages, you would probably go “Oh no, when is this going to end?” From the impending bankruptcy of an entire nation to the imminent reduction in credit ratings in several others, the world’s economy seems to be heading towards more uncertainties, no?

Recently, in an interview with the CEO of a tooling specialist, he said the one line that I think every business should take note of: There is always money to be made, even in a downturn.

What he meant is that we need to look into previously unexplored territories in the marketplace and these are the thoughts of the people in the metalworking industry – instead of threading carefully with a tinge of trepidation, they are predicting great things in the coming year. Even the more conservative ones feel the current positive climate should continue well into 2015.

Previously, it was thought that the financial cycle runs differently from the business cycle in manufacturing.

H owe ve r, w it h t he a d ve nt o f digitalisation of the manufacturing floor and the use of analytics, both cycles run in tandem. The main reason – response times and demand for products and services have

upped by several notches and the metalworking guys seemed to have been able to sync with this trend.

Despite several European countries still operating dangerously in the red, the mood at EMO Milano 2015 was entirely different. Good crowds and solid results defied the financial wet blanket draped across the Euro Zone.

According to the announcement made at the press conference at this year’s EMO, world consumption of machine tools will start to grow again steadily (2.3 percent increase), further increase by 4.2 percent in 2016 and then by 4.5 percent in 2017. The word is that it will likely be worth up to US$70.5 billion then.

The orders are currently available in the market and there are no pertinent signs or talk that indicates an impending downturn. Even if there were to be one, 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.

Usually I would end with an anecdote of sorts but as I peer through a glass filled with translucent brilliant gold, the horizon is hard to make out except for a very bright light. I’ll drink to that. Happy holidays and see you next year!

asia pacific metalworking equipment news November - December 2015

syedshah@epl.com.sg

business development manager Randy Teo randyteo@epl.com.sg

writer Michelle Cheong michellecheong@epl.com.sg

editorial assistant Sharifah Zainon

sharifah@epl.com.sg

graphic designer Jef Pimentel

jeffreypimentel@epl.com.sg

circulation executive Nurulhuda binte Suhaimi nurulhuda@epl.com.sg

assistant circulation manager Nancy Lim nancylim@epl.com.sg

contributors Tim Daro Wolfgang Riedle Badrinath Setlur Paul Hillam Peter Dickin Tim Sladden Raoul Rapke

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

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

EASTERN HOLDINGS LTD EXECUTIVE BOARD

chairman Kenneth Tan executive director Lum Kum Kuen

etm Syed Shah Senior Editor

6

senior editor Syed Shah

Eastern

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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BUSINESS NEWS Singapore Airlines To Resume Non-Stop Flights To US With New Airbus A350-900

AIRBUS SAS 2015 (computer rendering by FIXION - MMS

Singapore: Airbus has just launched the new Ultra-Long Range version of the A350-900, or the A350-900ULR (ultra-long range) which will allow Singapore Airlines (SIA) to resume their non-stop flights to the US. The airline has since amended their existing order to airbus for 67 A350-900 planes, of which seven will be of the ULR variety.

Optimised for long-haul flights of up to 19 hours, the ULR aircraft also features a modified fuel system for increased fuel carrying capacity, a larger maximum take-off weight, and aerodynamic improvements. These would allow the airline for non-stop flights from Singapore to New York, which will be the world’s longest commercial passenger route with an expected flight time of up to 19 hours.

“Our customers have been asking us to re -start non-stop Singapore-US flights and we are pleased that Airbus was able to offer the right aircraft to do so in a commercially viable manner,” commented Goh Choon Phong, SIA chief executive officer (CEO).

Fabrice Brégier, Airbus president & CEO also commented: “We are excited to be working with Singapore Airlines to re-launch its premium non-stop service to the US.” According to him, the A350 is a suitably, flexible platform for such operations, offering suitable operating economics for the longest routes, and the wider and quieter cabin would also provide a comfortable environment for passengers.

Launched earlier this year, A350 -900 features the latest aerody namic design, carbon fibre fuselage and wings, and fuel-efficient Rolls-Royce Trent XWB engines. These translate to improvements in fuel efficiency, lowering fuel burn and emissions by as much as 25 percent, and also significantly reduces maintenance costs.

Singapore Airlines makes the largest customer for the A350 XWB family in East Asia, and deliveries of the carrier’s A350900ULR aircraft are scheduled to take place in 2018.

8

asia pacific metalworking equipment news November - December 2015

Frost & Sullivan: Innovation And New Business Models To Drive Singapore’s Growth Singapore: Collaboration, Innovation and Digital Transformation will provide the impetus for Singapore’s future growth, says market research analyst Frost & Sullivan. According to them, the key factors that will continue to be relevant include talent management, sustainable innovation and investment in the right infrastructure.

"Amidst a rapidly evolving e n v i r o n m e n t i m p a c te d b y socioeconomic trends and global uncertainties such as equitable economic growth, priorities will need to shift in Singapore,” noted Nitin Bhat, partner & country head, Singapore, Frost & Sullivan, in his keynote address at the 2015 GIL Asia-Pacific summit recently held in Singapore.

Only through collaboration and innovation will businesses and Singapore as a whole be able to retain and enhance its competitiveness. Businesses who invest in new models of developing and acquiring talent will synergise the workplace.

This will bring about a greater o u t f l ow o f i d e a s/p ro du c t s and new business models. In addition, harnessing the power of technology will rethink the convent iona l work place by igniting change and enable assets to be used more efficiently. This in turn allows industries to radically improve their effectiveness and to transform themselves to meet stakeholder requirements more so than before.

With this culture of innovation, companies can turn the disruption into opportunities if they are able to respond appropriately with the right tools and strategies. www.equipment-news.com

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BUSINESSNEWS Conversely, companies are likely to put their business at risk if they are not aware of changes in other industries and realign their products and services adequately.

Even global companies such as Apple and Samsung have to keep up with the challenge of innovation to meet their customers’ expectations.

In the spirit of innovation, the market research analyst also organised an inaugural ‘Investor TechVision Forum’ where quality start-ups were provided a platform to pitch their technology, product or service wrapped within scalable busine ss models w ith the potential to make national or international impact.

Convergence of technologies and industries are supporting the mega trends, which are expected to have a major impact on Singapore. For instance, under the Innovating to Zero mega trend, Singapore aims to achieve a cleaner environment by targeting zero carbon emissions.

“The next 10 years would be driven partly by our response to the global mega trends such as

Future of Energy, Urbanisation, Social Trends, Bricks & Clicks and Future of Mobility amongst others,” Mr Bhat said.

The convergence of different technolog ie s, e specia lly automation, data exchange and connectivity will transform and disrupt industries. Jobs will be affected with many skills becoming obsolete. The impact

of automation and robotics is expected to require a person to have substantially different skills.

Many jobs right now are expected to be automated in the future.

“There could be redundancies of certain jobs due to automation.

The importance of digital skills will be much more pronounced due to digital technology,” Mr Bhat added.

Thailand Gains New Technology Hub For Regenerative Energy Bangkok, Thailand: King Mongkut’s University of Technology North Bangkok has joined hands with private sector company Fah Chai Engineering Company Limited to establish a technology hub for producing regenerative energy or solar power.

Signing the momerandum of understanding(MOU) was assistant professor Dr Anirach Mingkahn, Dean, faculty of Industry Technology and Management, King Mongkut’s University of Technology North Bangkok, and Phiphat Phakhananyoothin, managing director of Fah Chai Engineering Company Limited.

The technology hub will aim to produce energy from solar power, promoting alternative energy sources according to the government policy.

The demand for power in Thailand has increased over the past few years with the expansion of economic sectors and households. To meet this increased demand, the Thai government passed the Power Development Plan 2015 to promote 10

asia pacific metalworking equipment news November - December 2015

and balance all sources of renewable energy in order for a secure and stable power system for the country.

According to Dr Mingkhan, the three-year project for the technology hub will involve the teaching of technical knowledge to students and the public with regard to design, installation and maintenance of regenerative energy or solar power, which are suitable alternative sources of energy for Thailand.

Students will also participate in competitions for design and installation of the regenerative energy or solar power systems to encourage and further promote research and development of commercially beneficial technology.

The new hub will use technology from German renewable energy technology manufacturer, KACO new energy, and Fah Chai Engineering Limited looks forward to presenting the technology to the students and community, said Mr Phakhananyoothin. www.equipment-news.com

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BUSINESSNEWS

Industrial Control And Factory Automation Market Worth US$202 Billion By 2020 Pune, India: The industrial control and factory automation market is projected to grow at a compound annual growth rate of 6.73 percent from 20152020, and will be worth US$202 billion by 2020, according to Marketsa ndMarkets in their latest market research report.

The past few years has seen a growing demand of automation in various processes of the manufacturing sector, largely due to an increasing need for op e rat iona l e f f ic ie nc y a nd productivity, as well as optimal usage of resources.

With the growing popularity of Industr y 4.0 a s well, the deemed technological revolution, more manufacturers have also adopted Internet of Things (IoT) and advanced in machine-tomachine (M2M) communication, sig nifica ntly increa sing the implementation of automation technologies in factories.

In addition, more governments are also driving this adoption of sma r t solutions through implementing policy reforms such as the smart manufacturing

12

APPOINTMENTS New Managing Director For Hoffmann Asia Pacific/India Singapore: Hoffmann Asia Pacific/India has recently gained a new managing director, Pinaki Banerjee.

Mr Banerjee brings to his new role almost two decades of experience in leadership roles at his previous employments and expertise in the Indian market. Most recently at Rational AG Germany, he served as managing director of Rational Indian Sub-continent, and led the India team to form a new Pinaki Banerjee subsidiary with a significant position in the market.

“We are delighted to welcome Mr Banerjee to Hof fmann Asia Pacific/India and look forward to using the breadth and depth of his experience to take our relationships in the Indian market to the next stage,” said Sven Lauxmann, head of overseas sales of Hoffmann Group.

Eric Koh, general manager of Hoffmann Asia Pacific also commented: “We are pleased to have Mr Banerjee joining us in Hoffmann. With his expertise, he will further advance the operation development in Hoffmann Asia Pacific.”

policies by the Chinese government, that focuses on consolidation of relationship with government and industry associations on top of enhanced re se a rch a nd developme nt innovation.

The industrial control and fac tor y automat ion ma rket involves manufacturers fo r co n t r o l s y s te m s , f i e l d comp one nt s, sof t wa re a nd system integrators, all of whom are seeing a mushrooming of new product and software launches

asia pacific metalworking equipment news November - December 2015

and developments, acquisitions, partnerships, and the like.

In 2014, the market was valued at US$135 billion. The Americas and Europe to date form the largest market, but Asia-Pacific ranks the fastest growing market.

The report by MarketsandMarkets includes more information on this market and its trends, drivers and challenges, and gives a detailed view regarding the market across four regions—the Americas, Europe, Asia-Pacific and the rest of the world.

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BUSINESSNEWS

Kasto Opens Subsidiary In Singapore Singapore: Kasto Maschinenbau GmbH and Company KG (Kasto), a German company that develops and manufactures metal sawing and storage equipment, has opened a subsidiary in Singapore.

The company is looking to strengthen its position in Asia, and with its new subsidiary, it aims to expand its presence in the Southeast Asian market.

“We’ve been active in Southeast Asia since 1991 and have had many loyal customers here for years, from Singapore to Malaysia and Thailand,” explained Armin Stolzer, managing partner of the family-owned company.

“In addition, the region has become increasingly important as a growth market. For us, it made good sense to establish a subsidiary here in order to s t r e n g t h e n o u r p o s i t i o n ,” he added.

Singapore is an advantageous location because of the excellent infrastructure and its close geographical distance to the other Southeast Asian countries, said David van Loo, area sales director of the company. Existing and potential customers alike would be able to look forward to more comprehensive and personal service, short response times, and expert local advice with the subsidiary. “ We s u p p o r t u s e r s i n every phase of a project: from planning and development of a plant through construction and commissioning all the way up to maintenance and servicing. It will be a big advantage for us to be able to get to our customers more quickly,” continued Mr van Loo. The new subsidiary is located in the German Centre Singapore, an office and business centre for German companies.

14

Global Semiconductor Sales Saw Slight Dip In August

Washington, US: The Semiconductor Industry Association (SIA) reported a 0.5 percent decrease in global semiconductor sales in August to US$27.7 billion, from that of July which recorded US$27.9 billion.

Compared to the same month of 2014, August 2015’s record was 3.0 percent less.

The association, which represents US leadership in semiconductor manufacturing, design and research, attributes the slight dip to a softening of demand in recent months and the currency devaluation and regular market cyclicality, shared John Neuffler, president and chief executive officer, SIA. “Despite recent market sluggishness, the global industry has posted higher cumulative sales through August this year than it did through the same point last year, which was a record year for semiconductor revenues,” he said.

By region, China saw a 4.4 percent increase in year-to-year sales, while others saw a decrease of varying percentages— the Americas (3.5 percent); Europe (12.4 percent); Japan (13.0 percent) and Asia Pacific/ All Other (2.3 percent).

According to SIA, the sharp declines in sales for Europe and Japan were due in part to the currency devaluation relative to the US dollar.

asia pacific metalworking equipment news November - December 2015

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ENQUIRY NO 174

BUSINESSNEWS

Global Steel Demand Down This Year But Up Next Chicago, US: The World Steel Association (worldsteel) has forecast a 1.7 percent decrease in global steel demand for 2015, but projects a growth of 0.7 percent in 2016.

Though 2014 saw a 0.7 percent growth, worldsteel expects to see a 1.7 percent decrease in the 2015 global steel demand to 1,513 metric tonnes. According to chairman of worldsteel Economics Committee Hans Jürgen Kerkhoff, the steel industry has currently reached the end of a major growth cycle which had been based on the rapid economic development of China.

T h e c o u n t r y ’s d e m a n d has seemed to peak in 2013, as consequent years have seen a decrease in steel demand. China is projected to have a 3.5 percent decrease in 2015, and a 2.0 percent decrease in 2016.

This year, with China’s slowdown and coupled with low investment, financial market turbulence and geopolitical conflicts in the developing regions, the industry expects to see a low-growth period that may persist until the developing regions achieve a sufficient size and strength that will result in another major growth cycle.

The association believes the Chinese economy will soon stabilise for a moderate growth in 2016, but is also concerned about the vulnerability of the emerging economies to external shocks that may affect growth rate.

Still, the steel demand in the emerging and developing countries excluding China is expected to grow by some 1.7 percent in 2015, and 3.8 percent in 2016.

In contrast, the steel demand in developed countries which is gradually recovering will see a 2.1 percent decrease in 2015, but a positive growth of 1.8 percent in 2016.

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APPOINTMENTS Kennametal’s Executive Management Team Undergoes Changes Pennsylvania, US: Kennametal Incorporated has announced two changes to their executive management team.

Effective 1 October 2015, Peter Dragich is now the Kennametal vice president and executive vice pre side nt of the infra str uc ture Peter Dragich Greg Temple business segment. In his role, he is responsible for the global growth of the company’s engineered products and surface technologies that serve the earthworks, energy and process industries.

Effective 30 September 2015, Greg Temple is now the vice president and chief supply chain officer. He leads the company’s global manufacturing operations, distribution centres and reconditioning facilities, and also oversees supply chain management, supplier sourcing, advanced manufacturing engineering and environment, health and safety.

Both Mr Dragich and Mr Temple report to the company’s president and chief executive officer Don Nolan.

Mr Dragich joined the company in 2012 and served as vice president integrated supply chain and logistics. With this experience and that of his previous employments at United Technologies Corporation and Ford Motor Company, Mr Dragich brings to his current position more than 25 years of experience in supply chain management and cross-functional collaboration.

Mr Temple previously held the position of senior vice president of global operations at Sensata Technologies. With the experience he gained there, coupled with those from his other leadership positions throughout his career at Ecolab Corporation, Avery Dennison Corporation and The Clorox Company, he brings more than 30 years of experience in operations and supply chain management.

US Cutting Tool Consumption Continues Downward Trend Chicago, US: The US Cutting Tool Institute ( USCTI) and the Association for Manufacturing Technology (AMT) report that the US cutting tool consumption for August totalled US$169 million.

This figure is a five percent decrease from that of July’s, and down 2 percent when compared to the same month of 2014.

According to USCTI president Tom Haag, he attributes this continued downward trend to the Oil &Gas/Mining industry that has similarly suffered this year due to the low oil prices. “While automotive and aerospace markets remain consistent, the cutting tool industry needs a recovery in Oil & Gas to return to broad growth.”

On the likely results for the fourth quarter this year, he sees it as a battle to surpass that of 2014, with the way the trend is going now.

asia pacific metalworking equipment news November - December 2015

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MotorBlog

2016 Green Car Of The Year Finalists Announced

Los Angeles, US: The Green Car Journal has announced its five finalists for the 2016 Green Car of the Year award, and they include: Audi A3 e-tron, Chevrolet Volt, Honda Civic, Hyundai Sonata and Toyota Prius.

The journal has been honouring the most important ‘green’ vehicles every year at the Los A ngele s Auto Show since 10 years ago, a nd the awa rd to date is se e n a s prestigious. More and more models are being considered for the programme each year; a reflection of the auto industry’s efforts for improving efficiency and environmental impacts in their latest offerings.

According to Ron Cogan, editor and publisher of the journal and

CarsOfChange.com, this year’s finalists are the strongest because each of the five nominees make a strong environmental statement in distinctly different ways.

The selection process comprises a majority vote by an esteemed jury that includes celebrity auto enthusiast Jay L eno, a nd le aders of noted environmental and efficiency orga nisations. During the vetting process, the journal’s editors consider all vehicles, fuels and technologies as an expa nsive field of potentia l ca ndidate s a nd na r rows t he se to ju st f ive f ina list s.

Factors which are considered include efficiency, E PA a nd CARB emissions certification, performance characteristics,

‘new ness’ a nd a ffordability.

Finalists are expected to be made available for sale by 1 January 2016.

T h e w i n n e r o f t h e 11t h Annual Award will be revealed by the Green Car Journal at the Los Angeles Auto Show that will be held on 19 November 2015.

Customised Grinding Concepts In Milan Milan, Italy: The Junker Group, comprising companies that develop, produce and sell precision grinding machines for the metalworking industry, showcased its products for the first time in Europe at the recent EMO Milan, together with its latest member ZEMA. The customised grinding concepts that the group showcased were for workpieces regardless of their complexity; these were the result of intensive dialogues the group had with its customers.

Newest member Brazilian grinding machine manufacturer ZEMA that joined the group in March, showcased its circular grinding machine Numerika GH 1000 which attracted attention at the show. According to the group, the sophisticated machine concept put the company’s product on an equal footing with European manufacturers.

Apart from this, another products the group had on display included the newly developed workhead of the Junker Jumat 1S that grinds the threads of ball screw nuts, and filtration solutions by LTA Lufttechnik.

The group was satisfied with the outcome of this year’s EMO, as contracts were concluded, existing customer contacts maintained and promising contacts established—also with regard to the search for new sales engineers for the Italian market.

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asia pacific metalworking equipment news November - December 2015

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

ENQUIRY NO 178

BUSINESSNEWS

The Trans-Pacific Partnership Sealed In Word Atlanta, US: Twelve Pacific Rim countries have sealed the deal on 5 October, Monday, to create the world’s largest free trade area. Ending five years of bitter negotiations, the Trans-Pacific Partnership (TPP) aims to cut trade tariffs and set common standards in trade among these countries.

The TPP first was first initiated with a trade agreement—then k now n a s the Tra ns- Pacific Strategic Economic Partnership A g reement— sig ned in 20 0 6 between Brunei, Chile, New Zealand and Singapore. The year 2008 saw an additional eight countries joining in for a broader agreement to make the 12 countries involved today: Australia, Canada, Japan, Malaysia, Mexico, Peru, US, Vietnam.

The TPP seeks to lower trade barriers such as tariffs and establish a common framework for intellectual property, standards for labour and environmental laws, as well as an investor-state dispute settlement mechanism.

By this, it hence aims to enhance trade and investment among the partner countries, promote innovation, economic growth and development, and support the creation and retention of jobs.

The partnership today is led by the US and Japan, and aims to set rules for 21st century trade and investment, and to pressure China (not one of the 12) to shape its behaviour and conform to TPP standards.

Wit h t he 12 cou nt r ie s accounting for a total population of 800 million and representing 40 percent of world trade, the TPP is definitely a trade deal on a humungous scale and its benefits are numerous.

For instance, the partnership would smooth out the existing 20

APPOINTMENTS Worldsteel Appoints New Officers

Wolfgang Eder

Eiji Hayashida

John Ferriola

Chicago, US: The World Steel Association (worldsteel) Board of Directors has elected new officers for 2015/2016 at the 49th worldsteel annual conference that was held in Chicago, US. Elected for a year until October 2016, the roles of the new officers include chairman, vice chairman and treasurer.

Appointed as chairman is Wolfgang Eder, chairman and chief executive officer (CEO), voestalpine AG; vice chairman is John Ferriola, chairman, CEO and president of Nucor Corporation; and treasurer is Eiji Hayashida, president and CEO at JFE Holdings Incorporated.

“We are very pleased that Wolfgang Eder has agreed to accept a second term as Chairman. Eiji Hayashida will also continue as Treasurer and we welcome John Ferriola as our new Vice Chairman,” commented Edwin Basson, director general of worldsteel.

At the annual conference, new members of worldsteel were also welcomed. Joining the regular members (steel companies that produce more than two million short tonnes (1.8 metric tonnes) per annum) is AK Steel Corporation, and joining the affiliated members (steel-related organisations) are Austrian Mining & Steel Association, and The Indian Steel Association.

cre a se s a nd ba r r iers to international trade, such as Japanese regulations to keep out some American-made autos and trucks or beef, or Canadian regulations on import of dairy products to protect their farmers, and it would also help to open new markets like the Internet in Vietnam.

An estimated 18,000 tariffs are expected to end in the long-term with the partnership among the 12 countries, and this would help the individual countries produce and export their specialised goods and services efficiently while continuing to import from others. In the future, this could help modestly decrease retail prices for consumers.

For the industries, the TPP is set to offer various opportunities for the countries involved. For example, Japanese automakers

asia pacific metalworking equipment news November - December 2015

are expected to gain most from the TPP, should it be ratified by the governments, according to K a l la n ish Com mo dit ie s, a n independent business media company.

They rea soned that with greater access to the US market, Japanese firms would stand to gain because steel demand for Japanese autosheet suppliers would be boosted with the TPP. Already in 2014 -2015, Japan’s vehicle exports to the US totalled 1.54 million units, translating to almost 32 percent of total exports.

For this year, from April to July, Japan’s vehicle exports have totalled about 550,000 units.

For the moment, the conclusion of the TPP among the leaders of the 12 countries is an important first step, but the deal still has to be ratified by lawmakers in each country before it can fully proceed. www.equipment-news.com

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BUSINESSNEWS

Yamazaki Mazak Launches New Products

Singapore: In early October, Yamazaki Mazak Singapore launched two of their new products, the SmoothX CNC controller and the Vertical Centre Primos 400S. On top of these, a production showroom also showcased machines the company manufactures in Singapore. One of these was a fully unmanned robot cell that features auto loading of components and part inspection, the fruit of the company’s collaboration with Nachi Robotic Systems and Renishaw.

At the event, the company also had two speakers presenting the latest development in hybrid multi-tasking technologies, incorporating additive manufacturing and horizontal boring mill technology for large parts machining for the oil & gas, energy and heavy equipment industries.

To complement this, an ‘Emerging Trend Gallery’ showcased the technological advancements each industry has achieved and the role of machine tool makers, with a key focus on the additive manufacturing, aerospace and oil & gas industries.

The event also served as a knowledge-sharing platform on which visitors and customers could discuss new ideas and share experiences.

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asia pacific metalworking equipment news November - December 2015

Vietnam Economy To Expand 6.7 Percent In 2016 Hanoi, Vietnam: The Vietnamese economy is projected to expand by 6.7 percent in 2016, riding the success of this year’s growth—the highest in past five years at above 6.5 percent, more than the initial forecast of 6.2 percent.

According to prime minister Nguyen Tan Dung at the 10th session of the 13th National Assembly’s opening session, the country will aim to keep annual inflation at below five percent in 2016.

D u r i n g t he se s sion , t he government presented a report on the socio-economic situation in 2015, five-year period of 2011-2015, directions and missions for 2016, and five-year period of 2016-2020.

This report projected the countr y’s average economic growth rate to reach 6.5-7 percent a year from 2016-2020. The gross domestic product (GDP) per capita is set to stay at US$2,450 by 2016 and US$3,750 by 2020.

To rea lise these ta rgets, the government will focus on de ve lopi n g a nd stabi l i si n g economy, creating opportunities for socio-economic development and boost economic restructure, and improve productivity and competitiveness.

The recently signed TransPacific Partnership (TPP) will also create ample opportunities and favourable conditions for the development of the country’s s o c io - e co n o m y, e sp e c ia l l y with respect to exports and foreign investment.

www.equipment-news.com

ENQUIRY NO 175

BUSINESSNEWS

Renishaw’s New Offerings Milan, Italy: Renishaw has launched three new products at the recent EMO Milano that took place in Milan, Italy early in October.

One of these is a vision measurement probe (RVP) for use with the Revo 5-axis measurement system on co-ordinate measuring machines. This ability for non-contact inspection allows thin sheet metal parts or components with large numbers of holes as small as 0.5 mm, or parts not suited for tactile measurement, to be fully inspected with the RVP system.

The company has also launched an improved version of the aforementioned Revo, with the Revo-2. The system incorporates the company’s Atom optical incremental encoder system, a minute readhead that uses filtering optics, that offers speeds up to 20 m/s and resolutions to 1 nm with a range of linear and rotary angle scales available.

Lastly, they have launched a free software suite for the company’s calibration systems, the Carto release 1.1, that supports linear, angular and straightness measurement. It also features a database system that automatically stores and organises data for the user, and has an intuitive user interface that aids new users to begin capturing and analysing data quickly without the need for training or to read lengthy manuals.

Europe Leads The Way To Sustainable Development London, UK: With its strong governmental policies, Europe is leading the world in green manufacturing technologies such as low carbon manufacturing for sustainable development, says Frost & Sullivan.

Global warming is an evergrowing concern in the world today because of its disastrous implications on climate change a nd hu ma n live s. A s such, cou nt r ie s have stepp e d up corrective efforts to create a low carbon economy. A major part of these involve the propagation of low carbon manufacturing technologies and techniques, which not only reduce the effects of global warming but also offer tremendous cost benefits in the long term.

Frost & Sullivan, in their new analysis on ‘technology trends impacting low carbon ma nu fac tu r i n g’, fou nd t hat 24

renewable energy technologies, carbon capture and storage technologies, waste management solutions, and energy-efficient technologies are among the many enablers for low carbon ma nufacturing. Pa r ticula rly energy-efficient best practices for indu st r ie s c a n dire c t ly impact their carbon footprint.

I n t he i ndu st r ia l se c tor, low carbon technologies are creating a value proposition that rivals existing highcarbon technologies in terms of the societal benefits they offer. Nevertheless, wide-scale adoption by industrie s w ill require a significant boost in the commercial value of low carbon technologies.

The industrial manufacturing s e c to r, a c r u c i a l p i l l a r o f economies today, is the biggest contributor to greenhouse gas emissions. Adopting low carbon

asia pacific metalworking equipment news November - December 2015

Revo-2 head with RSP3-3 probe

technologies is therefore vital for c re at i n g a su st a i nable , green economy globally, said Karthik Vishal Laskshmanan, TechVision research analyst.

"The rapid adoption of l ow c a rb o n m a nu fa c t u r i n g practices in this sector is thus an encouraging trend. However, strict policies mandating low carbon manufacturing practices are essential to ensure faster and widespread uptake across all industries."

In the Europea n Union, g ov e r n m e n t s' i n it i a t i v e s to promote low ca rbon m a nu fa c t u r i n g w i l l e n su re the steady uptake of enabling technolog ie s. The U K , w ith it s e a rly com m it me nt s to considerably reduce its carbon footprint by 2020, will set new standards and benchmarks in low carbon manufacturing.

For insta nce, the U K government earmarked a f u nd of one billion p ou nds ( US$1.53 billion) to promote Advanced Propulsion Centre, a www.equipment-news.com

ENQUIRY NO 169

BUSINESSNEWS collaboration of innovators and industry experts to address low carbon technologies in the automotive sector.

"With the introduction of government policies to build a low carbon economy across the globe, novel business models

and new markets for businesses have emerged," highlighted Mr Lakshmanan.

These government policies also create a huge resource pool for investment in these low carbon technologies, and with the suppor t from non -

‘Massive Change’ To Automotive Industry Coming, Says Apple CEO

Platts China Steel Sentiment Index Falls In October

California, US: In the recent Wall Street Journal’s WSJDLive conference, Apple chief executive officer (CEO) Tim Cook shared his opinion that t he automot ive i ndu st r y is bound for a ‘massive change’.

According to him, there are a few ways that this change will happen. For example, the software used in vehicles is b e co m i n g more i mp or t a nt , as is the rise in autonomous vehicles. He also predicts a shift from an internal combustion e n g i ne (wh ic h i s t he nor m today) to electrification (as in electric or hybrid cars).

W hen a sked about the rumours of the Apple car that is said to hit the roads as soon as 2019, he declined to respond. However, he did mention that the company is working to bring the ‘iPhone e x p e r i e n ce’ to t h e v e h i c l e through their CarPlay, an indash system that would create a w ay f o r u s e r s to a c c e s s their iTunes music collections and map directions without hav i n g to phy sic a l ly touc h their phones.

“We’ll see what we can do in the future. I do think that the industry is at an inflection p oi nt for ma ssive cha n ge ,” he reiterated.

26

governmenta l orga nisations a nd reg u lator y bodie s, t he strategies implemented to create a low carbon environment in all sections of the economy will bolster sustainable development and secure the future of the planet."

Beijing, China: Platts foresees a bleak outlook for new orders and prices, and inventories are expected to rise.

The China Steel Sentiment Index (CSSI) by Platts has slumped for October, recording 35.46 points out of a possible 100 points.

In contrast, that of September had been 55.64 points, and the decrease of 20.17 points could dampen price recovery hopes by Chinese steel market participants.

The CSSI reflects expectations of market participants for the month ahead. A reading of over 50 points indicates expectations for an increase in health for the industry; under 50 indicates a decrease.

With regard to new domestic steel orders, October recorded 36.09 points, down 20.89 points from September. Export order expectations also went down by 6.30 points to 28.27 points.

With the lack of domestic and export demand expectations for steel, this might explain why inventory levels held by traders are projected to increase: October recorded 71.20 points out of a possible 100, up 23.50 points from that of September.

According to Paul Bartholomew, Platts managing editor, steel & steel raw materials, the poor results could have been attributed to the fact that the October CSSI was conducted before China’s national holidays, which could have influenced steel market participants’ expectations for demand and prices to soften further.

That said, he still does not expect much of an improvement when the market restarts because underlying demand in China is weak in response to a slowing economy. Instead, the country would likely look beyond themselves for export of steel.

“The lack of confidence in domestic demand for steel explains why Chinese mills and traders are increasing looking overseas for customers,” he said. The country could potentially export around 110 million metric tonnes of steel this year, he added.

asia pacific metalworking equipment news November - December 2015

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ENQUIRY NO 176

METAL CUTTING can first be determined on a monitor using, for example, an NX CAM graphic simulation from Siemens PLM to avoid potential collisions or damage to the workpiece contours.

From Image To Implant

Today’s machine shops, whether in the medical technology or tool and mould making sectors, can take advantage of an integrated CNC solution for everything from the design concept to the finished product. Contributed by Tim Daro, president, Bernard & Company

T

he production of today’s medical implants involves an entire process chain, starting with the doctor and ending with the finished device. Doctors use the imaging data of a complex fracture, acqu i re d w it h a compute d tomography (CT) scan, to select an appropriate implant and then position it in the fracture area of the patient on the computer. Of course, this is only possible if the implant geometries are stored in a database, and the doctor has implants in stock or can access them immediately from a manufacturer.

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Simulation Of Machining Sequences In plastic surger y, however, where impla nts specifica lly manufactured for each individual patient are needed, a different process is employed. Instead of pre-machined parts, implants are custom-made with the help of 3D imaging. In this case, the machine tools are controlled using the implant geometries.

Ca lculated contours a nd shapes are acquired by the CT scan to produce implants that are literally a perfect fit.

However, the feasibility of the planned production process

asia pacific metalworking equipment news November - December 2015

Technology Package For Milling High-speed cutting (HSC) is a machining process with high material processing speeds.

HSC machine tools achieve high spindle speeds, combined with feed rates that are much higher tha n those of conventiona l machine tools. Consequently, they require control systems and part programs that perform equally fast. Solutions such as the Siemens Sinumerik 840D solution line CNC is specifically designed for the requirements of medical technology and this precision part HSC work. Integrated functions on board the CNC assist users with set-up and programming, thus allowing faster and more precise production sequences.

Together, the CNC system and ShopMill software form a milling technology package that allows machine operators rapid access to the functions they need. Thanks to graphic function display and plain language input dialogs, cycles can be used quickly and effectively, after a brief training period. Even the smallest errors can be corrected during operation, using multiaxis kinematic analysis.

The Siemens Safety Integrated solution fur ther prov ides protection for personnel and machinery. This software can be used to interlink emergency stop buttons and light barriers.

In the event of an operating error, dangerous movements are immediately brought to a standstill and the power supply to the motor is quickly cut.

The Use Of Measuring Probes The production of artificial knee www.equipment-news.com

METALCUTTING

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users assess the performance qua litie s of non -v ibrating carbide milling cutters, which are well-suited for machining implant materials, plus they can offer information on more costeffective and efficient machining processes.

Got a Question? Make An Enquiry.

ENQUIRY No.

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Cost-effective machining Metal parts used in medical technology are often extremely complex. Therefore, choosing the right tooling can have a great impact on the quality of the finished products. After all, proper cutting tools ensure that the parts leaving the machining centre are absolutely precise and require no further finishing work.

Although the materials used for

many medical and orthopaedic parts are often quite difficult to machine, the tools must fulfil high performance requirements with respect to the precision and surface quality of these implants.

Iscar, one supplier of such tools, offers a prog ra m for monitoring the use of precision tools on turning, drilling, milling and finishing jobs. They also help

Static Tools • Live Tools for turning and machining centers

joints on an HSC 20 linear milling centre manufactured by DMG Mori, for example, can be fully controlled and monitored by the Sinumerik CNC system. With its broad range of functions, this milling centre is particularly well suited for use in the medical technology sector. It is equipped with linear drives on all axes a n d a c h i e v e s a cce l e r a t i o n rates over 2g. The machine can also generate a surface finish down to 0.2 micrometres Ra. The liquid- cooled machining spindle operate s at speeds up to 42 ,0 0 0 r pm , t he reby covering an extensive range of potential applications in the medical sector, where materials such as titanium, chromiummolybdenum, ta nta lum a nd niobium are typically milled.

In order to achieve ma x imu m pre cision du r ing implant production, while also ma i nta i n i n g a con siste nt ly high level of product quality, parametric measurements must taken continuously from both the machine and the workpiece.

Renishaw probes, for example, on HSC production machines measure tool dimensions inprocess, detect broken tools and are used for the set-up and measurement of workpieces.

I n me d ic a l mac h i ne shop s currently, the targeted use of such measuring probes can reduce set-up times by up to 90 percent, while substantially improving process control.

November - December 2015 asia pacific metalworking equipment news

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METALCUTTING

Crankshaft Microfinishing:

New

Possibilities, New Directions Automobile manufacturers are familiar with the problems associated with the microfinishing of crankshafts: The surface roughness results on the bearings differ from those on the transition radii, the bearing profile cannot always be adhered to, roundness improvements on the pin bearings differ from those of the main bearings, and smaller crankshafts deform as a result of machining forces and workpiece oscillation. By Wolfgang Riedle

A

fter evaluating statistics from its fleet network, a well-known t r u c k m a nu fac t u re r has ascertained that a high percentage of reported crankshaft damage is due to particularly large loads on the bearings

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radii. Working closely with the German high-precision machine tool manufacturer Thielenhaus Microfinish, the manufacturer therefore decided to perform finishing work on the bearings as well as on the transition radii.

In order to achieve the same

asia pacific metalworking equipment news November - December 2015

surface quality on the crankshaft journals and radii, Thielenhaus developed a special tape contact shoe. This technology presses a finishing tape with a special profile on both sides into the radius, allowing radii to be machined up to 90 degrees. This represents a significant break-through from the previous 60 degrees. The manufacturer’s goal was thus successfully achieved.

Diameter Flexibility T h e l e a d i n g m a c h i n e to o l manufacturer for microfinishing is developing prototypes and filing patent applications for a variety of other innovative tape contact shoe systems. In addition to the conventional hard or soft shoes, Thielenhaus is developing a shoe that uses a kind of belt system to adapt to the component’s size.

With the DiaFlex technology, crankshafts with the same bearing widths but different diameters can be machined without swapping the shoes. In practice, it often happens that, due to higher torques in three- or four-cylinder motors, a few millimetres more www.equipment-news.com

METALCUTTING of bearing diameter are needed with the same motor concept and gauge. The shoe adapts to the respective diameter and can compensate for differences of up to 15 millimetres without changing shoes.

Correcting The Crown Shape Also currently under development a re tape contact shoe s for generating or correcting profile and crowning on the bearings.

With the ShapeFlex shoe, the tape contact shoe pressure can be varied over the diameters width.

This makes it possible to work on the edges of the bearing points with a slightly elevated specific pressure to support or even generate a slight crown shape, or to achieve the desired crowned shape with minimal variation in crowning and symmetry.

Multiple Systems Integration The different shoe systems can all be integrated in the CrankStar machine platform, which features horizontal and vertical versions for machining passenger car or truck crankshafts and can be adjusted to the specific needs of each manufacturer. Based on the manufacturer’s requirements regarding part handling, cycle

The new RadiusFlex tape contact shoe from Thielenhaus Microfinish can finish not only bearings, but also the transition radii with the same roughness height. www.equipment-news.com

Surface parameters before and after microfinishing

Crankshaft bearings before and after microfinishing

times, quality tolerances, part variations and machining tasks, a machine concept that is precisely tailored to the needs of the customer can be developed.

The RadiusFlex tape contact shoe, shown here in action on a CrankStar horizontal crankshaft microfinishing machine, helps to prevent crankshaft damage.

Consistent Roundness Improvements In order to achieve the same roundness improvements on ma in - a nd pin bea rings, pneumatic technology is used in the machine to counterbalance pin bearing forces of +/- 5 newton.

This ensures that the machining forces on the rotating crank pin are kept constant and that the ma ss force s that occur between the shoe and bearing are compensated. The roundness is thus improved to exactly the same extent on all bearings, whether pin or main bearings.

Negating The Risk Of Deformation When microfinishing weightoptimised, small dimensioned crankshafts for compact engines, the machining forces used to clamp and oscillate the workpiece

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METALCUTTING Thielenhaus Microfinish prepares an individual machine concept based on platform solutions as well as the operator’s requirements and circumstances.

Selection Criteria

Machine Concept

Parts handling: Gantry loader, pallet loading, manual, etc.

Single-station or multi-station solution

Cycle time and requirements Rz, Rv, Rk, Rp

Vertical or horizontal arrangment or finishing units

Diversity of parts Machining task: Centring, pin and lapped bearing, front spigot, radius, flange inner side (deburring)

Number of finishing units Single-step or multiple-step machining

Apart from mains, pin and lapped bearings, oil seal diameters can also be finished on the machines and bolt holes in flanges deburred.

can produce minor deformations.

This then has a negative impact on the crankshaft bearing diameters, including profile and cylindricity.

To counteract this, the machine regulates axial tailstock forces utilising a hydraulic servo control mechanism. The technology is able to compensate variating oscillation strokes and frequencies as well as different part lengths.

Ergonomics & Flexible Automation In the standard version, the CrankStar is capable of machining crankshafts for engines with three to six cylinders, in some cases even without major retooling.

In addition to centre- and pin bearings and thrust faces, the machine ca n finish oil sea l diameters and deburr bores in the flange. Thrust face machining occurs via a special unit while the workpiece is oscillated. Even with vertical machine concepts, the machine comes with up 32

The machine solution can be viewed via tablet or smartphone in 3D with the app, which can be downloaded for free from iTunes or Google Play Store.

ShapeFlex can produce or correct surface lines and crowning.

to 33 percent longer intervals between tool changes than the industry standard, featuring a tape capacity of over 300 metres.

The vertical solution allows a quick belt change from the front of the machine, without requiring the withdrawal of an entire tool carrier package.

What the machine can do is that it can be adapted to a variety of automation systems.

Vertical machines are designed to be loaded either from the front or the back. Thielenhaus is

asia pacific metalworking equipment news November - December 2015

Due to its large tape capacity of over 300 metres, the machine has change intervals more than 33 percent longer than the customary standard.

With the new DiaFlex tape contact shoe, crankshafts with the same bearing widths but different diameters can be machined without changing shoes.

currently examining possibilities to minimise idle time during the loading/unloading operation.

Innovative machine solutions and tape contact shoe systems open up new possibilities for e n g i ne m a nu fac t u re r s a n d their suppliers, enabling the microfinishing of crankshafts of various designs simpler, faster and more cost-effective.

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METAL CUTTING

B

eyond the growing demand for healthcare, the rising costs of healthcare are another reason why the medical sector is an attractive new business a rena for those involved in manufacturing. Insurers and hea lthca re prov iders a re creating pressure to reduce costs by increasing productivity – and this spells opportunity for manufacturers of innovative medical parts and devices.

Medical Parts Machining:

The Swiss Difference

The world medical market is strong for several reasons, including the fact that it has an aging population and this presents a business opportunity for the manufacturing sector. Contributed by Tornos

Factoring In Swiss Turning T he re a re s e v e ra l d i v e r s e segments to the medical sector and all of these can be served using the Swiss turning machining process. Interventional cardiology devices, orthopaedic devices (bone screws, implants, and joint replacement), minimally invasive surgical devices and equipment and dental (equipment and implants) segments all have parts that can be efficiently and profitably machined on a Swiss turning centre.

Micro Machining Micro machining, another type of Swiss turning useful for medical parts, requires a proper mind-set in terms of part and tool handling, i n sp e c t ion, a nd se conda r y operations. When factoring in micro machining medical parts, there are a few things to consider: 1. Machine accuracy: Even with the best tooling, if the position locations are not accurate, then it is like fighting a losing battle. Thus, it is important to re-qualify your tool positions and update the database.

2. Run-out: Run-out that might seem fine for a standard size part could likely spell disaster in micro machining main or pickoff collets and guidebush need to www.equipment-news.com

be “XP” – extra precision while ER style collets need “UP” – ultra precision.

3. High frequency spindles: This is essential for drilling or milling tiny features into parts a nd achiev ing the desired finishes, accuracy and tool life.

For example, drilling a 0.2 mm hole in stainless, 11,500 rpm is needed. But if the tool is TiN coated (Titanium nitride – a hard ceramic material often

used as a non-toxic exterior for medical implants), you need 19,000 rpm. Some spindles (such as those from IBAG, NSK, Meyrat and others) can reach speeds in excess of 150K. Spindles can be mounted various ways in the machine to meet specific needs.

These parts include features created with high frequency spindles and spindles that are mounted in holders.

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METALCUTTING

Thread whirling is often used for bone screws due to their typical challenges: long length to diameter ratio.

Internal Broaching Another key machining process for medical parts manufacture is internal broaching. It’s important to purchase the proper broaching tools. The actual broaching process is completed like this: 1. In preparation for the broaching process, it is necessary to make a pilot hole.

2. Depending on the configuration, it may be necessary to remove material for the corners with a small endmill.

Another key machining process for medical parts manufacture is internal broaching.

to the 1 deg incline, the leading edge of the tool “wobbles” with respect to the work. There are some guidelines that should be followed on this:

3. In general, wobble broaches does not cut as accurately as the punch broach so its use should be determined by the application.

1. If the tool is inclined 1 deg, the sides of the tool must have a clearance angle of at least 1 deg.

Thread Whirling Thread whirling, is generally used for cutting special form threads in difficult-to-machine materials with far fewer limitations than other thread cutting options.

Thread whirling is often used for bone screws due to their typical challenges: long length to diameter ratio; deep, high

2. Ideally, the tool advances at the same rate it cuts. For example, a ½” diameter tool should advance at 0.022 per rev. (1/2 x sin (1º) = feed

3. A 90 deg chamfer on the hole is also necessary. This prevents t he p oint s from chipping upon entering the cut. It also allows the broach to follow the centreline.

4. D e p e n d i n g o n t h e c h i p size, deburring passes may be required.

Rotary Broaching Wobble (or rotary) broaching uses a tool with a similar shape to the final shape except that it is ground with clearance. The tool axis is typically inclined 1 deg from the work axis. As the broach rotates, it is pressed against the work. Due 34

asia pacific metalworking equipment news November - December 2015

There are several diverse segments to the medical sector and all of these can be served using the Swiss turning machining process. www.equipment-news.com

METALCUTTING Some special considerations with thread whirling that need to be taken note of: 1. T he circular inserts used in a thread whirler are custom ground. If a customer does not have the means or desire to re - sharpen the circular i n se r t s, t he y c a n opt for a cut ter he ad t hat u se s indexable inserts.

2.

The setting gauge locates inserts at the proper angle prior to locking them into the head.

3. T he cutter head is mounted into the thread whirling unit.

4. T he thread whirling unit is mounted in the machine at the proper heli x a ngle by means of a graduated scale.

5. Tools rotate at very high speeds.

6. Part rotation depends on left hand or right hand threads.

Gun Drilling Cannulated (or hollow) bone screws contain a space that allows bone marrow to grow and facilitates the insertion of guide pins for bone screws used in fracture fixation. With increases in cannulated bone screw orders, many shops are purchasing cannulated material.

An alternative is gun drilling which allows these types of medical screws to be made efficiently from solid bar stock that include high drilling quality, great chip removal, high process, minimum run out and great length to diameter ratio.

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ENQUIRY NO 147

helix buttress thread forms; and extreme differences between major and minor diameters.

ID thread whirling is great for producing clean, burr-free thread contours. No residual chips are created. And it’s possible to thread right to the bottom of a hole. Thread whirling can produce threads as small as M1.4.

A lter nat ive s to t hre ad whirling include: die head (which doesn’t work with materials like titanium; thread milling (which requires pre-turning, special cutters, a nd in some ca ses, special supports; single point turning (good for short screws – but long screws need support), thread rolling (which requires accurate pre-turning and doesn’t work on “buttress” style threads of hard materials), and grinding (which can’t be done on a Swiss turning machine).

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GREAT GEAR & SYSTEM Advanced Vending Systems:

Gearing For

Increased Productivity For over two decades industrial vending machines have provided a viable means of storing tools around the world.

Raoul Rapke, Director CTMS Division, IMC Group, shares its benefits with APMEN.

I

ndustrial vending machines have b e e n prov idi n g a n efficient means of storing and issuing consumable tooling for more than 20 years. Whilst the US was the first county to seriously adopt such convenient systems, over the past two decades their use has become widespread throughout global industry. Today there are tens of thousands of units in service.

The use of these advanced vending systems continues to grow as potential users realise the multiple benefits that they deliver. Also, as multi-national co m p a n i e s d i v e r si f y t h e i r geographic manufacturing bases, a host of best practices, including the efficient dispensing of cutting tools to the shop floor, tend to migrate across borders.

Industrial vending machines, such as Matrix, bring major mutual benefits to both the cutting tool provider, in particular the distributor or integrator, and the end-user.

Sellers are eager to provide their customers with easy and reliable access to their products as a guarantee of repeat business, and are keen to exploit potential growth opportunities. A vending machine strategically located on a shop floor helps to stabilise the business relationship between the

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customer and vendor and help to ensure that business is not lost to competitors who deliver cutting tools in a traditional less convenient way.

W hereas, purchasers are seeking to guarantee the instant availability of tools to ensure that their production does not stop. In addition, they see the implementation of an industrial vending machine system as a way to minimise the cost and risk of ownership of stock, by optimising stock levels or entrusting the ownership of stock with their supplier through consignment arrangements.

In the last few years, there has been an exponential growth in vending businesses, with many of the major players investing heavily in new equipment installations.

Average return of investment (ROI) is estimated to be six to 18 months, whilst data indicates that vending based distribution returns double the growth rate of non-vending based business.

The type of systems available vary from the basic helix style machines designed for simple supply and replenishment tasks, to soph i st ic ate d , h i g h - e nd systems that provide users with full control over hundreds of stock items in a single unit, together with the advantage of powerful

asia pacific metalworking equipment news November - December 2015

The type of systems available vary from the basic helix style machines designed for simple supply and replenishment tasks, to sophisticated, high-end systems with software like Matrix.

tool management software; for instance, Matrix. The latter is particularly attractive to more advanced users and mediumto-large customers, who need the kind of innovative functions, built-in flexibility and superior reporting capabilities, and not offered by more basic machines.

Cutting-edge systems have a number of key advantages, their storage a rra ngements are based on more convenient drawers or carousels, and include multiple, individually locked bins per drawer or shelf. Each separate bin can store a different stock item - ideal for users who carry a large variety of cutting tools and other items in low-tomedium quantities. This format enables a more comprehensive management of stock, as many more products can be securely stored, and the issue of tools is effectively controlled and closely monitored. Also, the ergonomic nature of these systems means that space is fully utilised, so less hardware is needed, keeping capital costs down.

Recent advances in software functionality now provide even greater benefits to end- users. www.equipment-news.com

GREATGEAR&SYSTEM Cutting-edge systems have a number of key advantages, their storage arrangements are based on more convenient drawers or carousels, and include multiple, individually locked bins per drawer or shelf.

The more advanced vending systems, as Matrix, use clever logistics algorithms to maximise the availability of tools whilst minimising stock levels and obsole scence. In a moder n manufacturing environment the importance of tool availability cannot be understated. Machine tools that cost hundreds of thousands of dollars are chosen for their speed and performance.

Suppliers compete for orders based on speed of delivery. If the required cutting tools are not in stock, spindles remain idle leading to delays in supply of goods. The indirect costs and risk of inefficient tool management a re unacceptable. A lthough predictability is a key factor in ensuring availability, the most

recent software packages offer clever user-defined features that allow users to customise stock levels for items that are used infrequently. This can be achieved by overriding the calculated minimum stock level, or inputting changes in relevant parameters such as frequency, usage and lead time, automatically generating c h a n g e s to t he c a lc u late d minimum stock level. Changes can be achieved on the spot, rather than waiting for a weekly or month end process, so that the system is always up to date.

There have a lso been significant advances in a range of other areas that make these new generation systems extremely intelligent. It is of vital importance that only the right tools are used

The Matrix-TM tool management software not only presents the CPU data, but can also report deviations from a benchmark CPU.

for a job. The Bill of Materials normally defines the required cutting tools, however to be sure that only these tools are actually used, a limitation can be defined in the software, so that at the time of issue, the user inputs the part number, after which only the tools in the Bill of Materials can be issued for use.

The issue of items based on cost centres, such as a part, has other important implications. It allows production planners and shop floor managers to track the ‘real’ cost per unit (CPU), rather than basing decisions on a theoretical cost. When interfaced with the customer’s ERP, production batch data can be imported, and the Matrix-TM tool management software not only presents the CPU data, but can also report deviations from a benchmark CPU. In this way, changes in tool life, due to the cutting tool, coolant management, mach in ing pa ra meters or maintenance, can be identified and corrected in a timely fashion.

As customers look for new ways to improve their productivity, the intelligent vending solutions that incorporate easy to use, yet sophisticated management software, will become more popular and gradually supersede the simple traditional systems that have been previously used.

Got a Question? Make An Enquiry.

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Defense Advanced Research Projects Agency (DARPA)

GREATGEAR&SYSTEM • Virtualisation: the ability to view the entire factory and ma nu fac t u r i n g pro ce s se s virtually.

• Decentralisation: the ability of machines to ‘think’ on their own for smart decision-making.

• Real-time capability: With the smarter functions of machines, more data wou ld a lso be generated and the capability of machines to collect, analyse and provide derived insights in realtime would be an ideal asset.

• Service orientation: the ability to offer services through the Internet of Services

Managing Your Data

Smartly

Industry 4.0 is becoming the talk of the industry, but with all the big terms that it has spawned, manufacturers might be intimidated by this seemingly disruptive revolution, especially when it comes to data. In a nutshell, what is Industry 4.0, and how can one manage data smartly? By Michelle Cheong.

W

ith the fourth industrial revolution, or b e t te r k now n as Industry 4.0, beginning to show signs of incorporation in today’s manufacturing industry, there have been ma ny bomba stic terms spaw ned: Internet of Things (IoT), Industry 4.0, Smart Manufacturing, Big Data and Digital Factory. And truth be told, not all manufacturers around the world are clear of what exactly these are yet.

Defining Industry 4.0 In brief, the Industry 4.0 that originated in Germany envisions

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the adoption and execution of a “smart factory”, where all manufacturing processes would ideally be automated, less human lab ou r wou ld b e re qu i re d, operation efficiencies would be improved and customisation of products to be mass produced will be made available.

In doing this, Industry 4.0 revolve s a round si x de sig n principles: • I nte rop e ra b i l it y : hu m a n s and machines will be able to communicate via the IoT— humans will be able to operate machines remotely and at a higher machine-to-human ratio.

asia pacific metalworking equipment news November - December 2015

• Modularity: the flexibility of smart factories to accommodate changing requirements through replacing or expanding individual modules.

A Big Data Mess A s a forementioned, w ith Industry 4.0 coming into play and behaving more sophisticated machines available, manufacturers today are producing more data daily than they did some 10 years ago such as sensor data, camera images, digital gauge data, etc.

In theory, all this data that is churned out can be used to measure things. However, managing and making sense of this data—termed “big data”— in prac t ice is a cha l le nge , because while all these data can be generated or gathered, manufacturers are posed with the complexity of what to use this data for or how to even use it.

To solve this problem, data management companies are competing to create the leading data analytics programme that can best serve manufacturers of the industry. One area in which these programmes are rapidly developing in is the Industrial Internet of Things (IIoT). www.equipment-news.com

GREATGEAR&SYSTEM

How Data Can Be Used Without a doubt, a na lysing the data produced can benefit manufacturers in a myriad of ways. For one, data on processing times or energy consumption for example, provides a manufacturer with quantifiable evidence of the efficiency of the process or machine, and if an alternative is required. Processes or machines in this way can be optimised once the direction for improvement has been identified through the use of data.

According to S a l Spada , research director, ARC Advisory Group, machine tool data can also predict the quality of a production workpiece. With realtime process parameters that can be extracted from operating machines, production machinery process models can be developed a nd continuously improved upon to guarantee the quality of production workpieces. www.equipment-news.com

Data generated from machines can help manufacturers improve their processes, if they know how to use it.

Camelia.boban

The programmes developed under this serve to capture, collate and distribute data to the company’s personnel, while customising it totally so that the relevant personnel would receive only data that they would need, and in convenient ways such as through their personal devices– smart phones, tablets, or laptops.

To store the unquantifiable amounts of information pouring out from the machines, cloud storage is currently popularly being employed as a repository for la rge unstructured data sets of machine process variables, tooling and workpiece information, due to the economic viability of leveraging the cloud.

Being on the internet that can be accessed virtually from any location, data can be tackled and analysed from anywhere and at any point of time.

But how, one may ask, is using this data beneficial? How does it affect one’s manufacturing operations? Is the data important?

A lso, w ith the incre a sed connectivity between digitally-controlled machines, manufacturers can additionally collect a wide array of realt i m e p r o c e s s p a r a m e te r s .

This data can then be used to develop accurate mathematical models of machine behaviour under innumerable operating conditions that are difficult to set up in a laboratory test bed, he added. This would then allow manufacturers to virtually monitor their machines and processes around the clock.

2. Using a reliable data analytics programme, determine how the programme can be used to represent the data in a way that is easy to understand.

Smart Management Of Data Making good sense of the data produced is essential for improved productivity and efficiency of manufacturing processes, and in order for this optimisation to happen, manufacturers need to be aware of which data exactly they need or want, and how to use this data to its full potential.

An easy advice to managing data smartly is to go simple, and a reference guideline is demonstrated below:

3. M ake an informed decision— the condensed information should be able to prov ide the relevant people with the re qu ire d k nowle dge for a quick and effective decisionmaking process.

1. Determine which machines can produce what information, and from there, pick out the information that one would require.

Tip: Pick out only the most useful information.

Tip: A graph or chart would suffice, as these usually turn out to be the optimum way for people to digest information quickly.

Tip: Do not go overboard in visualising data—always keep in mind the goal for the analysis so as to not waste resources unnecessarily.

Naturally, many more things can be done with the data for further analysis, or the data can be presented in a variety of different ways, but the main message is the same: ultimately manufacturers should be clear on what kind of data they are able to get, which kinds of data they would actually need, and how exactly they can present their data in a way they would want so as to aid in decision-making.

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GREATGEAR&SYSTEM

Let’s Get

Grinding

The team at ANCA have sought to adapt another type of linear motor – a cylindrical linear motor – for tool grinding instead.

Pat McCluskey, co-founder of ANCA shares the advances in linear motor technology and how they will improve the tool grinding process.

I

n today’s ma nu factu r ing industry, machine tools are of utmost importance. More important than those still, are the technologies behind them that enable manufacturers to ensure quality in their products, either in cutting, grinding, finish, and the like. These processes however, do require different technologies for optimum performance, even though they might require the sa me components, such a s linear motors.

Linear motors in machine tools today are generally the flat bed type, which makes them work fine for laser cutters. This type of linear motor makes a poor compromise for CNC (computer numerical control) tool grinding, and so the team at ANCA have sought to adapt another type of linear motor – a cylindrical linear motor – for tool grinding instead.

The magnetic flux in flat bed linear motors are asymmetric a nd create tremendous downforces on the rails, making ever y thing wea r fa ster a nd further reduce efficiency in tool grinding, he noted.

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To ov e rco m e t h i s , t h e y designed one with a magnetic flux such that the motor uses the entire symmetrical magnetic field, delivering more efficiency than a flatbed style linear motor.

With this, they also developed a specialised servo drive software that would specially suit grinding applications.

The advantages of a cylindrical linear motor over the conventional flatbed one are many. For one, it eliminates cogging and improves surface finish on the tool when grinding. Also, being cylindrical, the linear motor is also more compact a nd would help minimise required floor space and contribute to a smaller footprint.

This is also complemented by the fact that cylindrical linear motors have improved energy efficiency, and do not need a separate chiller unit for the motors; this further reduces required floor space and saves power.

In terms of wear, an IP67 rating evidences a long tool life for a cylindrical linear motor.

With additional protection to protect magnets and winding,

asia pacific metalworking equipment news November - December 2015

and no mechanical moving parts, these machines have a smoother axis motion and are precise and accurate even over time as wear is reduced.

The company has since used one such cylindrical linear motor in series of CNC tool grinders they produced to suit light manufacturing, regrinding, and even full production. To make an operator’s life easier, they also added a touchscreen that enables swipe and multi-touch, a handheld pendant for easier set-up, and an easy-to-access front loader door.

The cylindrical linear motor improves the CNC tool grinders in several ways. It caters for an accurate axis motion for a precise performa nce a nd enhanced surface finish, allows for unmanned operation—being a fully automated solution—and has the flexibility to different tools, spindle power and automation capacity while providing high levels of speed and productivity and a long machine tool life.

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INDESIGN

M

ultisensor coordinate measuring machines that combine vision, touch a nd la ser sensors have been used in manufacturing quality control for nearly 20-years. Many still recall the early days of multisensor systems when the primary sensor worked well, but the additional sensors – sometimes added almost as an afterthought, offered limited capability and poor accuracy.

Today’s multisensor systems have advanced to the point that all sensors now offer full capability a n d a cc u r a c y. L i m it a t i o n s inherent in earlier designs have been removed through more careful integration of the sensors with the measuring axes.

Improvements in the metrology software are the greatest enabler of comprehensive multisensor capability. Measuring software has evolved in ways that allow each sensor to be truly integrated and measure with consistent uncertainty at all times.

Along the way the economic benefits of multisensor mea surement systems have become clear: reduced capital a n d c a l ib r a t i o n e x p e n s e s , shorter learning cycles, added flexibility and convenience, and most important - lower overall uncertainty in the measurements.

To highlight the full range of

Figure 1: A femoral implant being measured with a calliper.

If only it were so easy! www.equipment-news.com

Multisensor Measurement:

Into A New Era Multisensor systems have evolved considerably over the years as the component technologies for motion control, optics, lighting and cameras have improved. Tim Sladden, director of marketing communications, Quality Vision International, tells us more. capabilities of today’s multisensor measuring systems, let’s look at three types of parts and how their manufacturing processes have been improved by using multisensor measurement.

In Figure 1 we see a femoral implant being measured with a ca lliper. T his is not t hat simple orthopaedic implants are among the most complexshaped devices being machined today – there is simply no way to measure the critical dimensions and form of these parts with a single sensor system.

For st a r te r s, t he h i g h l y polished surfaces of knee implants are extremely sensitive. Even casual contact by a tool or gauge could damage the surface finish, causing friction that could lead to improper fit and ultimately pain in the patient receiving the implant. To measure these parts, a variety of non-contact or minimally invasive tools – vision

optics, lasers or very light contact probing force – are needed.

More importantly, femoral implants consist of a series of curves controlled by profile tolerances, each of which is simultaneously constrained by the material condition of one or more datum features. These geometric dimensioning and tolerancing (GD&T) conventions enable the designer to specify the form of the part exactly, but make verifying the part a challenge.

To properly measure this part, the measurement points must be collected, and then fitted to the CAD model in their entirety in order to ensure all material conditions are properly evaluated.

Data from tactile, scanning, laser and optical sensors needs to be integrated with the CAD model, and powerful software is needed to perform the GD&T evaluation.

Enter the modern multisensor system. A system with telecentric optics, through-the-lens laser, and a micro -scanning probe ca n mea sure the outside dimensions, profiles and curves without damaging the part, and compare the data directly to the CAD model.

The manufacturer of this part faced high re-work and scrap rates, in spite of careful machining, polishing and measurement.

Compounding the issue were disputes about dimensional conformance between different measurement techniques.

Multisensor measurement solved the first problem, by

November - December 2015 asia pacific metalworking equipment news

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INDESIGN

Figure 2: Orthopaedic implants measured on a multisensor system.

accurately measuring the critical features without damaging the part. True multisensor software enabled the data to be fitted to the CAD model and applied the GD&T standards properly.

This combination enabled the manufacturer to eliminate disputes about measurement accuracy between different gages, and ultimately reduce the number of finishing steps needed to produce the part to customer specs. All of which reduced scrap and re-work costs substantially.

Our next example is a large casting with a variety of machined surfaces, mounting holes and bearing ways on each of its four sides. This part has more than 50 discrete dimensions that must be controlled to ensure fit and function within the assembly it is

Figure 3: Multisensor measurement of a large machined casting.

part of. Many of these dimensions relate to datums on opposite or adjacent sides of the part. Ideally, the part would be measured in one set-up, without having to re-stage the part to enable measurement of all its surfaces.

While access and tolerance issues make a tactile scanning star probe (Figure 3) the ideal sensor for the bearing tracks, other features such as the small blind holes on the adjacent face are best measured using video, while surface flatness measurements on the mating surfaces are best made

using a laser. The custom made flip fixture in this photo automatically indexes the part to present each side to the sensor array for measurement. This casting is a component in a complex assembly that relies on machinedin precision for the reliability of the overall mechanism. Thus, measurement is critical to the overall quality of the end-product.

For the maker of this part, multisensor mea surement offered a number of benefits.

Most significant was the time savings of being able to confirm all

Figure 5: State of the art multisensor measuring software shows the relationships of parts and sensors in real time, including the range of each sensor in proportion to the part features. Above – the CAD model used as the basis for measurement.

Below, video, laser and touchprobe ranges represented directly on the CAD model.

Figure 4: Long working distance sensors are used to measure this housing

The measuring software integrated the data from all sensors seamlessly, allowing all measurements to be performed in a single routine and compared directly to the part’s original CAD model, ensuring the most faithful confirmation of the design intent.

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asia pacific metalworking equipment news November - December 2015

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INDESIGN dimensions on one system, rather than having to program, stage and measure on several different systems, then combine a nd compare the data to determine if the part met spec. Another significant benefit is that the multisensor system offered the same uncertainty regardless of the sensor used.

In our third example, we see another complex machined casting – in this case, hydraulic transmission housing. This part presents a challenge to measure in a single set-up. Not only are there dimensions along the outer stems and top flange, there are dimensions on the seal surface and spline more than six inches deep inside the part. To access all these features in one orientation, long working distance optics and a LWD laser are needed to reach features at the bottom, as well

as scanning probe capability to measure inside dimensions on the stems and interior profile.

Once again, the combination of scanning probe, laser and video measurement makes quick work of measuring this complex part. The laser quickly gathers a large pattern of data from the mating surface on the top flange.

Flatness on this seal surface is critical. The scanning probe measures the interior profile in several locations, as well as the inside diameters of the in-flow and out-flow stems to calculate interior volume and flow rate characteristics. The long working distance laser also reaches to the boss on the inside of the spline for a flatness measurement, and long working distance optics quickly measure the gear teeth and ball bearing positions in the ball spline.

Each of these three examples illustrates the value inherent in a high quality multisensor measurement: In all cases, it was possible to measure the entire part on one measuring system – saving the cost of buying and maintaining multiple measuring systems, and eliminating the differences in uncertainty between differing measurement technologies.

The range of sensors available enabled the key dimensions to be measured using the best sensor type for the feature without compromising efficiency or accuracy. Deployable and long working distance sensors help eliminate interference between sensors and minimise offsets that use up valuable measuring range.

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MICRO MARVEL Carbide Micro Endmills Sutton Tools micro endmill range eliminates the vibration produced in the cutting action, through careful tool design, micro geometry & optimized coating.

• Positive rake tool design increases metal removal rates • Micro geometry produces 60 - 70% better surface smoothness • TiSiN coating for superior wear and chipping resistance

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43

INDESIGN

Inspect Early,

Reduce Wastage

Inspection software to verify potential errors on machined parts are critical to ensuring wastage and eventually improving cost savings. By Peter Dickin, marketing manager, Delcam.

O

n-machine verification with Delcam’s PowerInspect inspection software allows initial checking of machined parts to be carried out on site on any CNC machine tool rather than having to transfer them to coordinate measuring machines for inspection. The main advantage is that any mistakes are discovered where they can be corrected – on the machine tool. Repeated cycles

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of machining and inspection, interspersed with long set-up times on the respective pieces of equipment, are avoided, meaning that overall manufacturing times can be reduced.

The most obvious benefit of on-machine verification is for those companies that do not have existing inspection capabilities.

Most modern machine tools either come with, or can be retrofitted with, probing capabilities to

asia pacific metalworking equipment news November - December 2015

assist in the set-up of the job.

With PowerInspect, this same equipment can now be used for verification at little extra cost.

On-machine verification can give huge time savings by enabling the quality of the component being machined to be monitored at each stage in the manufacturing process. This allows any errors to be detected earlier, and so corrected more quickly and at lower cost. For example, it is possible to check that the correct amount of stock has been left on the component after a roughing operation, rather than having to wait until all machining operations have been completed before discovering that an error has been made.

Similarly, the extent of any damage caused, for example, by a tool breakage, can be assessed www.equipment-news.com

INDESIGN time. However, if the whole process is considered, there is considerable potential to reduce delivery times. After all, a machine is only earning money if it is producing good parts.

W h e n a p a r t h a s to b e transferred to a dedicated CMM and the inspection shows any errors, the component must be returned to the machine tool and re-clamped in position before being machined again. This is timeconsuming for any component but can take many hours for any large, heavy item, such as a press tool for an automotive body panel. In addition, any mistakes during the set-up back onto the machine tool could result in a new series of errors in the component, and so lead to a further cycle of inspection and re-machining.

With on-machine verification, the part can be checked at each

stage without being moved.

The inspection on specialist measuring equipment only needs to be undertaken once at the end of the manufacturing process.

This more regular in-process verification ensures that there will be greater confidence that the component will be produced within specification.

Furthermore, the verification sequence can be simulated on the computer before it is run in exactly the same way as a machining program. The user can confirm that the measurements will be taken in the required areas and that no collisions will take place, so minimising the set-up time on the machine.

One user that regards onmachine verification as “a n inva luable tool� is proce ss application engineer, Stewart Seedhouse, from the Makino-

ENQUIRY NO 071

accurately and a decision made immediately to determine whether the part can still be completed within tolerance or whether it will have to be scrapped.

Of course, there are already a variety of manual methods for undertaking such checks between machining operations. However, like all manual operations, these are time-consuming and prone to human errors and inconsistencies.

Furthermore, they are based on inspection against drawings, when most design data is now issued as CAD files. On-machine verification is a more automated and more consistent process than manual measurement, and also allows checking against CAD data.

Companies that already have suitable inspection equipment might think that on-machine verification is an unnecessary operation that can lose machining

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November - December 2015 asia pacific metalworking equipment news

45

INDESIGN Five-axis measurement allows the complete part to be verified in one set-up.

NCMT Grinding Division. The technology saves the company and its customers considerable amounts of time and money.

NCMT has represented the complete range of the company’s machining centres in the UK for ma ny yea rs. In 20 0 6, in recognition of the company’s leadership in the application

of Viper grinding, the grinding division was set up in Coventry to m a r k e t t h e te c h n o l o g y throughout Europe.

Viper grinding employs small, vitrified aluminium oxide wheels in creep -feed grinding mode on the machining centres, in place of conventional, plated cubic boron nitride wheels. It is

mainly used in the production of components from nickel-based alloys, principally in the aerospace and power generation industries but also in the motorsport and medical sectors.

The technology is not only up to eight times faster than the conventional process but also reduces the cost of consumable significantly. Furthermore, the Makino range is touted to be the first to combine creep-feed grinding with milling, drilling and turning in a multi-processing e nv iron me nt, re duci n g t he number of separate operations and, therefore, the set-up times.

Even so, the process remains extremely challenging due to the use of difficult-to-machine materials, such as inconel, the complexity of the shapes that need to be produced and the high levels of accuracy that are required. In addition, many of the components are produced from forgings or castings, which can be both expensive and in very limited supply.

“In a typical project, our customer might be required to produce at least 30 conforming parts from 32 high-value castings,” e x p l a i n e d M r. S e e d h o u s e .

On-machine verification allows parts to be measured where they can be corrected – on the machine tool.

46

asia pacific metalworking equipment news November - December 2015

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INDESIGN

The technology is not only up to eight times faster than the conventional process but also reduces the cost of consumable significantly.

Simulations of the measurement process can be carried out to ensure that the required measurements will be taken.

“Anything that can make the process more reliable and more accurate is hugely valuable.”

The first stage of most projects uses the PowerInspect software to check the machine kinematics by taking measurements from a standard sphere in a known position on the machine. This takes one to two hours but is essential to ensure that the accuracy of future measurements can be trusted.

The next stage is to inspect the datum locations of all the fixtures to be use in the process and, in some cases, their clearances. This is necessary, said Mr. Seedhouse because “although we expect to receive the fixtures in the correct state, being able to ensure they are correct to what we expect at this stage can save a whole lot of time and effort trying to find a problem later on.”

Following these checks, the first part is loaded and on-machine verification is used to measure the amount of stock to be removed. If necessary, the position of the part can be adjusted or a modification made to the datum being used in the machine-tool control to give a more even distribution of stock around the required final shape. www.equipment-news.com

The complex shapes found in many of the components would be difficult to check with physical measurement but are easy to measure with PowerInspect OMV. “With new parts and possibly mu lt iple ca st ing suppliers, we often check the amount of stock on the component prior to machining,” explained Mr. Seedhouse. “Too much stock on the component can lead to metallurgical problems such as cracking and burning, or wheel breakdown leading to geometrical problems, and, in extreme cases, even damage to the machine.

Once you know that there is more stock than expected, it is easy to add in an extra cut to remove this excess material safely.”

Another potential problem is that residual stress within a forging or casting can be released during machining and change the shape of the part. “If we think this might happen, we carry out an initial cut with extra material left on to release the stress,” said Mr. Seedhouse. “We can then check if any movement within the part has occurred with OMV and so allow the finish machining to be performed accurately.”

OMV is also used to check

fixture and part positions after any heavy cuts that might have moved the part or if any problems have occurred during machining.

“PowerInspect OMV is an invaluable tool when making any new component or installing a new machine,” claimed Mr. Seedhouse. “It gives you a high degree of confidence almost immediately because it is very, ver y quick to prov ide basic measurements on the key points of the part.”

“It can save weeks of time that might be spent waiting for a CMM to be available and for a metrologist to analyse the results,” he added. “OMV even gives us the confidence to ask the customer to check the CMM if the measurements show any errors. In my experience, if the part gives the correct results with OMV, there is not going to be much wrong with it.” This faster commissioning benefits customers because initial test batches can be produced more quickly with high confidence that the parts will be to the required standard.

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November - December 2015 asia pacific metalworking equipment news

47

FAST FAB Efficiency & Sustainability in Sheet Metalworking Machinery:

Getting

All Green About It

The global sheet metalworking industry is a major user of energy and the cost of electricity is becoming more expensive every year. Paul Hillam, area export manager, SafanDarley tells us more about energy reduction trends in the sheet metalworking arena.

T

hese days, major manufacturers are d e v e l o p i n g s y s te m s to be more ef ficient with lower operating costs, higher productivity and lower maintenance.

A modern company can be defined not only by its products but also by its attitude to energy conservation, sustainability and social responsibility. Customers and perhaps the local community e x p e c t t hat ma nu fac tu re rs have a positive and proactive approach which will help define themselves as better than the rest. With this, it is expected that manufacturers will also produce better components at a competitive cost.

R e d u c i n g o n e ’s e n e r g y consumption, the use of environmentally harmful oil and noise, all contribute to better world. For too long now people have assumed that all press brakes and guillotines have

48

the same energy requirements, productivity and maintenance costs. This is a mind-set that needs some adjustments.

W he n buy i n g a la ser or punching system, purchasers look carefully at all of these areas before making an informed choice. The purchase price is only one part of the equation because the performance and productivity of the systems can have a greater effect on the return on investment.

So it is time to employ this same decision making process when choosing other machinery.

Press Brakes The era of the electric press brake is well and truly here.

Leading the way in in the mid1990s was sheet metal working co mp a ny, S a fa n D a rle y a nd others are beginning to follow their lead in this area. Many versions are available including ball screw drives and hybrid systems but the most successful

asia pacific metalworking equipment news November - December 2015

is without doubt the servo driven belt and pulley machines.

The problems with the old technology of hydraulic systems are many fold. They are very inefficient with high energ y costs, high maintenance costs and low productivity amongst other reasons. So how is the servo driven belt and pulley system better?

Firstly, in these systems, the energy requirement is drastically reduced. Once hydraulic machines are switched on, the pump is running and using energy, this oil is heated up and so is the workshop even though one is not actually engaged in bending.

With servo electric machines the machine only really uses power when making a bend and even then they will typically use less energy than a hydraulic machine. When not bending, the only energy being used is that required to run a PC & PLC (pipe bending machine). www.equipment-news.com

FASTFAB How Much Bending Daily?

When you are programming, setting up tools, collecting material, rest breaks – all this time is wa sted energ y on a hydraulic machine and energy saved with the servo electric machines. For most companies the wasted energy is in excess of 50 percent. In job shops up to 90 percent of the operating time of a press brake is not bending it is ha ndling t he pro duct, programming, setting up tools and general preparation.

Switching off the drive of a hydraulic machine might seem to be a suitable alternative but each time you start the pump requires a large power surge often 20 times the normal flow and many power companies charge heavily for such loads.

The g raph below gives a comparison for when the press brake is actually in operation.

During the stand-by periods – which, due to breaks, sheet handling and change-over times, can be up to 90 percent – the electronic press brake can save an extra 3,000 kWh per year.

Figures based on a typical eight hour shift: Total savings: 63 percent Servo electric belt & ulley E-brake 100 T / 3100 mm Stand-By

1,0 A

x 4 hour 4,0 A

Bending stroke

12,6 A

x 2 hour 25.2 A

Return stroke

1,0 A

x 2 hour 2,0 A Daily total 31.2 A

Energy consumption data taken from hydraulic press brake 120 T / 3100 mmw Stand-By

8,6 A

x 4 hour 34.4 A

Bending stroke

17,0 A

x 2 hour 34,0 A

Return stroke

8,6 A

x 2 hour 17.2 A Daily total 85.90 A

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When you are programming, setting up tools, collecting material, rest breaks – all this time is wasted energy on a hydraulic machine and energy saved with the servo electric machines.

New Press-Brakes Operating In Identical Environmental Conditions The higher the tonnage of the hydraulic machine, the bigger the pump and so, the greater the energy consumption. This means that the savings are even greater on the larger Servo Electric systems which are available up to 300 tons. There is much talk also about the actual CO2 emissions.

Calculating from the energ y consumption of machines (kWh) to CO2 emission (kg) is not that simple as it depends on the local energy supplier how much their CO2 emission is.

For i n sta nce , i n ma ny countries the CO2 emission can vary between 0 to 500+ gr/kWh. The wind or water hydrogen energy generators can have an emission value of 0 and the coke or gas energy suppliers can have an emission value of more than 500 gr/kWh.

If we take a typical value (422 gr/kWh) and the average of the energy consumption of an 80-150 tons electric press-brake in single shift operation you could make the following assumption: - The CO2 emission for an electricpress brake at 80 tons is 2.200 (kWh) x 422 = 928 kg per year.

- T h e C O 2 e m i s s i o n f o r a hydraulic-press brake at 80 tons is 5.000 (kWh) x 422 = 2.110 kg per year.

- T he CO2 em ission for a n electric-brake press at 150/200 tons is 3.960 (kWh) x 422 = 1.671 kg per year.

So the CO2 reduction for the electric-press brake with an 80 ton capacity compared with a hydraulic press brake of 80 tons is = 1.182 kg per year. That makes it more than 55 percent.

November - December 2015 asia pacific metalworking equipment news

49

FASTFAB From an energy perspective guillotine shears have similar problems as the press brakes in that they are powered on all of the day and even in a high production environment are not actually cutting most of the time.

What To Maintain On A Press Brake?

Most of the focus would be on the hydraulic system which means changing oil, seals, filters, valves – the servo electric machine has none of these, so the benefits are obvious. In addition, the time normally set a side for maintenance can be used for production and there is only environmentally harmful oil to dispose of now.

More Productivity Using The Servo Electric System Let’s use the analogy of an F1 racing car. Some cars have a higher top speed than others 50

so are great in a straight line race ove r a lo n g d i st a nce .

However, most races are around tracks with many corners and short straights so often they never re ach the top speed.

Therefore the speed at which they can accelerate out of a corner and the later they can break into the corner becomes more important.

T h is is whe re t he se r vo e le c t r ic s y ste m s a re at a n advantage because they have much b et ter accelerat ion and deceleration times than a hydraulic machine. So the bigger the machine, the slower the hydraulics. The ser vo

asia pacific metalworking equipment news November - December 2015

electric system can typically increase productivity by up to 30 percent.

It is now possible to purchase a servo electric belt and pulley machine with up to a 300 ton capacity.

So the key features of an electric press brake include a ser vo - electric drive system, increased productivity, high accu rac y b e c au se t he b e lt and pulley system distributes t he bending force over t he whole bending length, lower power consumption, hardly any maintenance needed and no harmful oil.

Making The Cut: Guillotine Shears Some might find this surprising but guillotines usually use even more energy than press brakes.

Even though many companies laser cut or punch from full sheets there is still no more efficient and low cost way of cutting regular shaped blanks than shearing.

From an energy perspective guillotine shears have similar problems as the press brakes in that they are powered on all of the day and even in a high production environment are not actually cutting most of the time.

In normal use with an average use of 80 percent of the duty time the guillotine is not actually cutting. Much time is used in loading and unloading, making adjustments and programming.

One way of addressing this is with a hybrid system for the cutting movement. In the hybrid systems the pump only runs when the cutting beam is in motion with the result being that the energy consumption is minimised when not cutting.

In this standby mode the only power consumed is for running the control.

An added benefit is that these systems typically have only www.equipment-news.com

FASTFAB around 22 litres of oil compared w it h t he 15 0 - 2 0 0 l it re s o n conventional machines. This results in reduced and simpler maintenance and less use of environmentally harmful oil.

Shear with conventional hydraulic drive system

Guillotine shear with hybrid drive system

Standby current (drive system started, no cutting movement

7.6 Amp.

1.1 Amp.

Energy consumption

4.575 kWh

0.662 kWh

Energy saving One year (40 hours per week, 45 weeks, 80 percent of time no cutting movement)

7,043 kWh/year

Servo Electric Punching Systems The early steps towards the i nt ro du c t io n o f t he s e r vo electric punch presses happened in the late 1990s.

The servo electric punching systems combine energ y savings with productivity.

Purcha sing a n electric pu nc h i n g s y ste m i s a w i n win situation for the user and for sustainable development combining ma nufacturing efficiency with productivity.

In summa r y it is ev ident t hat e ne rg y e f f icie nc y a nd sustainability will be at the forefront of product development for the more innovative manufacturers.

- Greater efficiency - Low maintenance - Fewer consumables

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ENQUIRY NO 082

Benefits of using a hybrid drive system.

Fibre Lasers Compared to CO2 lasers the fibre la sers with high la ser conversion efficiency consume less electricity. The electricity costs during sta ndby ca n typically be reduced by around 70 p e rce nt i n add it ion t he relative costs of assist gas is also reduced.

These systems also require significantly less maintenance.

With the CO2 Laser systems the optical system comprises a syste m of m ir rors t hat require period cleaning and replacement.

The fibre lasers use optical fibre thus no maintenance or replacement mirrors necessary.

Its key features include:

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November - December 2015 asia pacific metalworking equipment news

51

FASTFAB

Getting

Efficient Fixtures

The transformation in three dimensional measuring technology as well as shape inspection using optical methods, which set in years ago, is constantly setting new standards in shorter cycles. Contributed by Witte Asia.

A

Targets for Alufix Light bar

52

asia pacific metalworking equipment news November - December 2015

lthough the potential of this technology cannot yet even be evaluated, t he se system s a re already being used more and more in industry, as well as for serial checking. In the past, this type of process has been reserved for research type areas or financially strong industrial users.

Innovation a nd tradition are closely linked when optical systems are used, because the component to be assessed or measured must still be positioned or fixed somehow for the process.

The basic concept of a holding or measuring fixture remains unchanged and is complemented by additional features, which are based on special requirements of visual processes.

Due to cooperation with the manufacturers of optical systems, the trend was spotted early on and companies like Witte have risen to the challenge. System elements and concepts have been developed that are downward compatible and can be integrated into existing devices for optical measurement technology.

A n essentia l element for photogrammetry is referencing by means of optical targets within the holding or measuring fixture, as well as on the measured components themselves.

The company Witte offers optical reference markers (targets, which fit directly into holes of the “Alufix� - system, as well as target cubes for positioning in holes of parts or other fixed geometry elements. Targets and target www.equipment-news.com

FASTFAB cubes can be attached to fixture frames and components quickly and without any extra elements or adapters.

In addition, the modular system also provides suitable conditions for the specific characteristics of optical measuring systems.

Fix tures v ir tua lly free of interfering contours for fullsurface accessibility or multi functionality for different or similar components (also called folding fixtures) are just a few examples.

Example of a universal frame for side panels, shown mounted on an accurate, rigid sandwich plate for in-house transport. The supports for each part are exchanged quickly and repeat-ably.

Target frame for photogrammetry system.

Fixtures In “Photo Frame” Style With Mounted Targets All “Alufix” standard bars can be equipped with reference points a nd indiv idua lly adjustable targets thereby converting a fixture simultaneously into a reference and orientation guide.

Target Frame For StandAlone Parts Or Vehicles / Extension Rods When no fixture is necessary a target framework is used, which can be equipped with reference points and targets. The components can be connected to a flat frame network or to spatial devices by connecting multiple frames.

All the elements are combinable with each other and equipped with coded target rings, Measuring accessories with coded dot-matrix for measuring with photogrammetry system.

Further target holders can be clipped on. Rails or foot plates form the basis for positioning and fixing of telescopic columns. Alternatively set up on an “Alufix” fixture or a sandwich plate is possible.

Integrated joints can be used to follow the angled line of a car roof.

All cross bars are designed as telescopic tubes (in several “Fixinspect PG” measuring accessories in use.

basic lengths with appropriate ranges of adjustment). This enables maximum flexibility in design and dimension of frame size. In order to ensure a repeatable build of framework or subgroups after i.e. transport or removal of the vehicle, all rails and telescopic columns are equipped with millimetre scales.

Use Of Target Cubes “Fixinspect PG” adapters (target c ub e) s e r v e a s m e a su r i n g accessories for easy and accurate measurement of component bores. The cubes, existing in three clearly distinguishable variations, have coded matrix dots on five visible sides. Magnets or finger pins hold the target cubes in place on work pieces. Spring-loaded cones guarantee exact centring in holes. Specially shaped adapters are available to mount on work piece edges and corners.

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FEATURES

Understanding

Contract Manufacturing Contract manufacturing is popularly used in the metalworking and manufacturing world of today, but what factors are important in choosing the right one?

By Michelle Cheong.

T

he manufacturing sectors o f to d ay ’s co u n t r i e s cont r ibute to a la rge portion of national gross domestic product (GDP), regardless of country status— developed or emerging.

To cope with mass or even small productions of products across va rious industrie s such as aerospace, computer, semiconductor, or automotive, contract ma nufacturing— or outsourcing— plays an important role. Popular types of contract manufacturing include those for CNC (computer numerical control) machining, complex assembly, aluminium die casting, grinding or forging, depending on what the hiring company’s job at hand requires.

C o nt r a c t m a nu fa c t u re r s (CMs) are those that are hired b y co m p a n i e s to p r o d u c e components or products, mainly because of t he adva nta ge s contract manufacturing can offer:

companies can save on costs of capital since they do not need to pay for the manufacturing facility or equipment when they use CMs. Also, companies can choose overseas CMs based in countries where labour costs are lower, such as India, Vietnam or Indonesia, in order to manufacture their products at lower costs.

Further, as CMs tend to serve more than one company, they can help companies save costs through purchasing raw materials together in bulk especially if they have good connections within raw material suppliers, or by increasing the number of units per shipment thus lowering costs, and hence achieve greater economies of scale.

Small Quantities: For example, should a company require only small quantities of a certain product to be produced as a one-off project, or for a short period of time, contract manufacturing would be the ideal way to go.

Cost-Savings: I t a l so o f fe r s co st- s av i n gs i n m a nu fa c t u r i n g b e c a u s e 54

asia pacific metalworking equipment news November - December 2015

But despite the advantages contract manufacturing offers, not all firms are actively or fully utilising CMs even when they can. The reason behind this lies in some myths of contract manufacturing or selecting a CM, that exist even till today.

Common Myths: • CMs with the most technical competence should be chosen.

• Or, the CM offering the lowest quoted price should be chosen.

While technical competence and price do matter when selecting a CM, companies should not be swayed but these single factors, but instead consider all other factors to the equation such as the quality of products the CM is able to produce, how quickly they can produce them, or if the volume capacity they are capable of producing matches what is required.

• This CM’s presentation was the best, therefore they must be good.

A common mistake of companies is to fall for the marketing strategies of the CM, and overlook other more important factors. Similar to aforementioned, all factors

CMs tend to serve more than one company, and can thus help companies save costs through purchasing raw materials together in bulk. www.equipment-news.com

FEATURES of the equation should be taken into consideration when choosing a CM.

• I just need to find the right CM, and everything else will be fine.

Selecting a suitable CM is a great step forward, but what would also be important from that point on would be active

and effective management— companies should structure their own operations organisation in order to manage this outsourced manufacturing.

Considerations When Choosing CMs Aforementioned were the myths of cont rac t ma nu fac tu r ing, but what exactly should one consider when choosing CMs? These are four general factors to be taken into consideration, in no particular order.

Location Where the CM is located, generally speaking in the geographical sense, is important. In today’s world where labour costs might be a large factor, companies may be tempted to look for CMs overseas in countries that offer cheaper labour costs, such as

ENQUIRY NO 068

• A “Tier 1” CM would be best.

CMs are generally grouped in tiers from one to four, and this is done by the financial markets in order to help explain difference in valuation multiples across the country, according to Ron Keith, chief executive officer for Riverwood Solutions.

However, these tiers merely represent how big a production a CM is capable of, not how good their performance is, per se. Therefore, if one were to need only a small quantity of product to be produced for example, there would actually be no need to engage such a large company. Finding the right fit for your manufacturing needs is hence important.

• The CM that I choose should not be one that caters to my competitor.

Competition can be a strong driving force in business, but when it comes to contract manufacturing, this does not really matter. What is important in a CM is that they have the te chnica l e x p er ience a nd skills, suitable quality control standards, a reasonable price, and they understand your needs among others. And if they have these, even if your competitor is using them too, why not choose them as well?

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55

FEATURES

What is important in a CM is that they have the technical experience and skills, suitable quality control standards, a reasonable price, and they understand your needs among others.

India, Vietnam or Indonesia.

While there is nothing wrong with working in these places, several things should be noted.

Firstly, an overseas location would generally mean that onhand access to production, or onsite visits to the manufacturing facility would be more difficult simply because it is further away than say, a local facility.

It being further away would a l so me a n t hat t he h i r i n g company would have less control over production, and a generally slower response rate in the event things should go wrong and require a management’s de cision im me diately. T his would consequentially affect the hiring company’s response time to disruptions in the supply chain or demand fluctuations, and hence possibly negatively influence customer service and image portrayed by the company.

These of course, might be rectified if the hiring company had an office or reliable staff near the manufacturing site to oversee production and make the calls as required.

Secondly, depending on where 56

the products are going to be shipped, the location of the CM and hence manufacturing facility could also influence delivery time of components. If the parts were going to somewhere nearer the CM site than the hiring company’s headquarters though, that would no doubt be an advantage there as the delivery time for products would be shortened.

Lastly, using CMs that are based in places such as India, Vietnam or Indonesia for example, might pose other problems b e side s acce ss to site s or delivery time. While assuring lower costs at least in terms of labour, these places might pose language barriers, or there might be cultural differences that might make working together a slightly more difficult job.

As in all businesses, it is crucial that one understands one’s partner sufficiently in order for the business to be a smooth one. Establishing good relationships with the overseas C M sh o u l d t h e r e fo r e b e a priority, on top of understanding how the local businesses are run and their work cultures.

asia pacific metalworking equipment news November - December 2015

Volume And Capacity Constraints When choosing a CM, one should always bear in mind that the CM would have other customers to think of as well, not just one’s company alone. How much volume of products does one require the CM to make? Does the CM have the capacity to cope with that volume at the present time? How long would they take to produce it?

These are questions that should be asked and answered first before choosing the CM. Especially during periods of high production, if one only had a small quantity required to be produced for example, the CM might deprioritise one’s work lo ad i n order to work on another company’s larger workload first.

Pricing And Quality Cost is always important in any business. How much would the CM charge for raw materials, and for the production of what is required? How much would they charge for delivery? If they are based overseas, how much more would this cost? These would be important questions to consider.

On the other hand, savings are also equally important. How much savings can this CM bring in terms of saving capital costs (e.g. lower labour costs), or can they achieve greater economies of scale because they are able to pull together shipments, or purchase raw materials in bulk?

If the savings balance out or are even greater than the costs, the CM may be worth considering.

The costs are one of the more important factors in choosing a CM, but quality should be on par in importance. No matter how much the savings a CM can offer, if the products are not of an acceptable quality, the CM would not be a suitable choice. www.equipment-news.com

FEATURES Nex t to consider a re the CM’s quality control standards.

Ultimately, the CM is a company that one outsources to, and they, being in charge of the production, would also have quality control standards in place. It is essential that these standards and those of the hiring company are similar so as to ensure the desired quality in products.

Also, the CM should possess t h e te c h n o l o g i c a l o r s k i l l ex per tise in ma nufacturing that is required to produce the desired product that the hiring company needs. Different CMs all over the world may specialise in the manufacturing or type of manufacturing for different things; these specialisations should be considered if the hiring company desires a superior product to be made.

A diversified supply chain

would also be a plus in a CM, as this not only broadens the expertise of the CM, but also what the CM can offer, more than just production of products. As CMs have well-established networks, working with one that can offer more than just production would be advantageous.

Finally, the relationship the hiring company can build with the CM is important. In business, essential factors for businesses to be successful are trust and understanding. Both parties should be clear on what exactly the other wants and is able to deliver, and both should trust and be able to trust the other in terms of manufacturing without the need to micromanage, which can strain the relationship on both ends.

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The Contract Manufacturer The CM as a company would de f i n itely b e a n i mp or ta nt factor to consider. As a business partner, both parties would need to be in agreement in several areas.

The first area, might be in values. What values does the CM uphold and are they a reliable compa ny when it come s to confidential matters? One of the risks in contract manufacturing is the risk of intellectual property t hef t. Be cau se con fident ia l documents are shared during the collaboration, it might be easier for any employee to download these confidential files if there is no proper security system in place. The va lue s of the company and its employees, and the reliability of the company are therefore important when choosing a CM.

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FEATURES

Towards A Data Driven Culture

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geing assets and workforce, an influx of networked micro-grids, and the proliferation of intelligent devices that form the smart-grid on the traditional power g rid a re cha lleng ing ut ilit ie s to ide nt if y more effective and efficient processes to manage and monitor their critical assets – and to do so with high safety, reliability and compliance. Traditional and smart asset management have a common objective – aid in the reduction, minimisation and optimisation of asset lifecycle costs across all phases, from a sset inve st ment pla n ning, all the way to operation and maintenance. Optimising the costs a ssociated w ith e ach phase will remain among the key objectives of an asset-intensive utility organisation.

At present, preventive maintena nce schedules prescribed by manufacturers a re not enough to help utilities avoid asset failures. In order to improve customer satisfaction, utility orga nisations need to work towards avoiding unexpected outages, managing asset risks and maintaining assets before failure strikes. According to a sur vey, reducing outa ge s a nd shor te n ing re storat ion times are the most significant

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For many years, manufacturers have been looking for new ways to manage their assets. In many cases, traditional financial models no longer support the needs of today’s manufacturers and this is so as we move forward to the era of digitalisation. By Badrinath Setlur, assistant vice president — consulting, manufacturing, logistics, energy and utilities, Cognizant. challenges in the area of power distribution, with 58 percent of re spondents recog nising the need for a mechanism to predict equipment failure.

M o re t h a n e v e r b e fo re , utilities are looking towards predictive analytics to extend the life of assets, as well as to bring greater predictability to performance and health. By applying predictive analytics to smart asset management, utilities can realise asset lifecycle cost reduction while improving the accuracy of their decisionmaking, allowing them to plan and prioritise maintenance activities.

Making A Business Case For Analytics By working proactively to collect and distil historic and current information to create predictive m o d e l s fo r f u t u r e e v e n t s , utilities can enhance customer satisfaction, reduce total cost of ownership, optimise the field force as well as improve compliance.

• Improve customer satisfaction a nd reliabilit y of power : Customer satisfaction a nd p ower rel iabil it y a re t wo important measures of a u t i l i t y ’s p e r f o r m a n c e .

Unexpected equipment failures can impact both. Customers expect planned outages to be communicated in advance for

asia pacific metalworking equipment news November - December 2015

the purposes of planning for electricity consumption. As a result, utilities also require proact ive ma intena nce of assets prior to failure, so as to avoid penalties governed by strict outage regulations.

• P r i o r i t i s e m a i n t e n a n c e activities and reduce TCO (total cost of ow ner ship): Each a sset ha s multiple a s s o c ia te d co s t s , m a i n l y in ter m s of pro cu rement, installation, operations and m a i n te n a n c e , a s w e l l a s failure and decommissioning.

Unexpected failure cost is the leading expense component of any asset. These costs include the expense of the asset in ser vice, collateral damage co s t , re g u lator y p e n a lt y, disposal of damaged asset, lost revenues and intangible co st s. B y pre ve nt i n g ke y equipment failure, utilities can save a sizeable amount of money through predictive ma intena nce practice s.

Accurate modelling techniques utilise historical data from multiple sources, enabling the generation of predictions and risk scores. They also produce interpretable information to allow the understanding of implications of events, thereby enabling the right response to be implemented. www.equipment-news.com

FEATURES • Optimise field crews with bet ter r oute pla n ning: A comprehensive understanding of asset health can serve utilities well in terms of work planning, prioritisation and scheduling.

Unexpected equipment failure often requires reallocation of crews from other work locations to restore the outage, hiring of extra labour and often, an entire rescheduling of other planned maintenance activities.

The percentage of work done in reactive activities can be effectively applied for predictive maintenance – improving crew response time and utilisation, while a lso re ducing tota l maintenance duration and asset downtime.

• An asset model: A statistical module is required to analyse the historic event information to create an asset model. Realtime information can then be contrasted against the reference asset model in predicting the failure event.

• I m p r o v e o v e r a l l s a f e t y and compliance: Predictive asset analytics proactively addresses potential safety risks by integrating data from mu lt iple sou rce s — S CA DA (sup e r v i sor y cont rol a nd d a t a a c q u i s i t i o n) , E A M GIS ( Enterprise A sset Management — Geographic Information System), online monitoring systems, weather cha n nels a long w it h non op e ra t io n a l da t a , a n d s o o n . T he y e n a b l e u t i l it i e s to identify safety risks and deploy suitable operational actions to mitigate these risks in a shorter span of time.

• Prediction notification: A su m m a r y v i e w o f re ce nt notifications in the main screen can easily draw the attention of the utility operator, thus enabling quick response time to avoid downtime. A detailed view of predictive alerts will support the utility operator to explore the nature of alerts in greater detail and facilitate informed decision-making.

Integrating the EAM system with a predictive system allows the user to view asset-specific work-order status, triggering new work orders directly from the predictive solution based on these predictive alerts.

Constructing The Predictive Analytics Asset Management Anatomy I n o rd e r to a c h i e v e t he s e objectives, key solution components of the predictive asset analytics platform are:

With this in mind, the core part of the solution architecture is the analytics engine, which ca n either be a part of the platform or be integrated via a third-party component. An ideal solution should support desktop and mobile interfaces, with the aforesaid key solution components.

• An operations dashboard: Business users will appreciate a GIS-enabled, intuitive summary dashboard displaying a quick summary of alerts and work orders. www.equipment-news.com

• Rules setup: Organisations must provide an intuitive interface to help users pull information from multiple systems and configure known alerts and actions rules for meaningful asset management. The same functionality can be applied to configure alerts and actions rules ba sed on statistica l a na lysis derived from the asset model.

Adoption Of A Data Driven Culture As organisations venture forward

on their predictive analytics journeys, the need to ensure that a predictive asset analytics solution fits into the overall strategy and future business requirements is vital. Clearly define the immediate objectives of the solution; understa nd future business requirements; a nd a s se s s t he sc a la b i l it y prere quisite s to suppor t additional applications. Once these aspects are established, t he a na ly t ic s plat for m a nd s t a t i s t ic a l m e t ho d fo r t he solution will naturally flow.

Additionally, most utilities might not have the right processes and data needed to support analy tics solutions.

Therefore, it is imperative to improve business processes and upgrade IT infrastructure to supp or t a ny a na ly t ic s solution before it is deployed.

For instance, utilities can take a step-wise approach – implement the analytics capability, then address existing process and infra structure needs, a nd gradually roll out advanced analy tics functionalities to fit w ith ongoing proce ss improvement and IT system upgrades.

In deploy ing predictive a na ly tics, implementation quality determines how well ut i l it ie s ac h ie ve proje c te d results from predictive analytics programs. In order to mitigate the implementation risk for comprehensive endto - end predictive solutions, an effective way is to harvest the be st- in - cla ss solution f r o m m u l t ip l e p r o v i d e r s – data ma na ge me nt, sy ste m s integration, analytics engines a nd operationa l technolog y integration. The time has come for organisations to adopt a data-driven culture.

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FEATURES

Doubling Up

On Productivity

Thanks to the implementation of a new line featuring robots, which was made possible by the collaboration between SIR, a system integrator based in Modena, and FCA Cento, production of new engine blocks for 3000cc V6 diesel engines has doubled. Contributed by Comau.

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he goal was challenging: to double the production of the new V6 engine blocks made in Ferrara by FCA Cento. Yet the Modena-based system integrator successfully a c h i e v e d t he ob j e c t i v e by designing and installing a line that puts two twin cells together and integrates them with the help of Comau’s robots designed to assist in the production floor.

Since 1947, VM Motori has been known worldwide for the production of high-performance diesel engines destined to supply a wide variety of companies within the automotive, agricultural and naval sectors, as well as for power generation

a ppl ic a t io n s. T he pl a nt i n Fe r r a r a h a s a l o n g - l a s t i n g partnership with the Modenabased system integrator SIR SpA, through which they develop and supply high-tech industrial automation solutions.

The integration with the FCA Group has allowed the company which is now known as FCA Cento, to further optimise its production. Following what is viewed as a sound manufacturing philosophy, the compa ny is increasingly strengthening the strategic connection between the group’s design offices and working departments. Aligned w i t h t h e p e r sp e c t i v e o f a continuous implementation of its

production capacity, and thanks to its long-time collaboration with SIR, the company installed a new automated line featuring the robots. The result is a significant increase in the production of crankcase panels for the new three litre V6 diesel engines.

Ramping Up The Automated Lines T h e re qu e s t m a d e by F C A Cento to the system integrator was precise and clear – the creation of an automated plant that would be able to double the production rate of new cast iron engine block s. A n additiona l requirement wa s to utilise reliable machines, i n te r m s of t he me c ha n ic s and electronics, which would ensure good value for the money.

“The company had an old rob ot ce l l for lo ad i n g a nd unloading that was equipped

Comau Smart NJ 110, the machine used by Sir Automazioni to automate the FCA Cento Plant.

The new cell realized in the FCA Cento plant uses a robot with a high payload, 110 kg, suitable for lifting heavy engine blocks of about 21 kg each.

Comau Smart NJ 110, the machine used by Sir Automazioni to automate the FCA Cento Plant.

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asia pacific metalworking equipment news November - December 2015

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FEATURES cells where they are recognised by a sensor and loaded inside the machining tool centres that then implement, in parallel, t he me cha n ic a l op erat ion s necessary for the production of the engine blocks. At the end of the cycle, the robots pick up the pieces and place them on a rotating table for a dimensional control and, if the pieces meet the parameters and tolerances required, they are transferred to an industrial washing machine to complete the process.

Right Implementation, Greater Rewards Thanks to the new systems, the company has been able to optimise their production, ensuring even higher production capacities, which today are around 60,000 engine blocks per year for a single line.

The operation implemented

by SIR was developed in different stages, ending with the installation of the second robotic cell in January 2015. This automated system has presented several advantages over the last few months. By automating the loading and unloading of pieces with the robots, it was possible to convert the work of employees who were no longer needed for heavy and repetitive operations, and could be assigned to more specialised and less burdensome tasks, such as maintenance or general management of the line.

Since the line is not expected to implement excessively strict cycle times – which last around 20 minutes per cell with the process divided in two phases at the end of which the piece is taken back – it was also possible to optimise the robots with

ENQUIRY NO 095

with a machine tool and a Smart H 2 robot,” e x pla ins Dav ide Passoni, Head of R& D at SIR SpA. “To meet the company’s needs, we optimised the existing cell by replacing the mechanical system with a new, two-spindle machining center and keeping the same robot that had been used for years to produce the engine blocks. We also created a new twin cell that was connected to the first and designed for the same operations. This new cell was set up with a similar machining centre and connected to a new generation Smart NJ 110 robot. This intervention has allowed FCA Cento to double the production of engine blocks that used to be carried out with a single robot cell.”

The process involves a co n v e yo r b e lt t a ke s t he unprocessed pieces to the two

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November - December 2015 asia pacific metalworking equipment news

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FEATURES

With a payload of 110 kg, the robot can lift heavy engine blocks weighing about 21 kg each. particular attention to the care required for the handling of finished pieces such a s the engine block.

Reliability The Key For the automation of the second line installed was the Smart NJ110 model robot was used. With a payload of 110 kg, the robot can lift heavy engine blocks weighing about 21 kg each. Given that it also has a reach of about 3 metres, it can easily perform the machine tool tending operations as well as all the other handling operations required to carry out the production process as efficiently as possible. The system installed by SIR covers a significant part of FCA Cento’s

Comau Smart NJ 110, thanks to its outreach, carries out both the machine tending operations and any other movement required within the cell.

production, which today serves clients such as Jeep, Chrysler, L a ncia, LT I ( L ondon Ta x is) and Maserati.

The line is dedicated to the production of engine blocks and crankcase panels for new 3000cc V6 diesel engines which are mounted on vehicles such as the Maserati Ghibli and the Jeep Grand Cherokee, to name

Another strong point of Comau robotics solutions is the ease of use, thanks to a simple and intuitive control unit management.

a few. Thanks to the 60-degrees V6 architecture, this engine is particularly compact and versatile, and can be customised to meet the customer’s requirements for both transverse and longitudinal applications. The eng ine is therefore ideal for sedans, SUVs and high-end vehicles for markets with EU 5 and NAFTA emission regulations.

In addition to the new V6 diesel engine, FCA Cento is also developing new versions of V6 engines that can deliver even higher power and lower emissions.

The 2015 production capacity of V6 engine blocks is 115,000 pieces per year, although the company is working to further improve their performance. This is accompanied by the production of the historical 4-cylinder engine, which is also intended for the automotive market, with 15,000 units per year and, last but not least, engines for naval and industrial applications, with the production of an additional 15,000 pieces per year.

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ENQUIRY NO 171

EVENTS& EXHIBITIONS

Event Review:

Vietnam Manufacturing Expo 2015

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here was an all-round positive atmosphere at the closing of the 2015 edition of “The 6th Vietna m Japan Exhibition on Supporting Industries in Hanoi” (SIE 2015), “Vietnam Manufacturing Expo” and “Industrial Components & Subcontracting Vietnam” at I.C.E. Hanoi (Cung Van Hoa) from 10 – 12 September 2015 with the active participations of 9,277 visitors who have found the right technology they were looking for and established new business alliances.

Exhibitors were happy to meet ta rget customers a nd distribute their products. The

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pla stics, mould ma k ing a nd supporting industries in Hanoi and nearby have been fired up to evolve with dynamic momentum.

Increasingly confident from the networks they established and knowledge they have gained, industrialists here are more ready for the coming of larger business opportunities following (ASEAN Economic Community) by the end of this year.

Mr. Vu Tri Toan, marketing manager, Oristar Corporation mentioned, ““Joining VME 2015, we wish to gain more customers and suppliers. Oristar Group is proud of being among Vietnam leading suppliers of non-ferrous

asia pacific metalworking equipment news November - December 2015

metals specialized in cooper, aluminium, stainless steel.”

Mr. Jeffery Wee, marketing executive, Creatz3D, said, “We are the distributor of StratasysTM and Materials, with the usage of 3D printing technology in our products. We expect to introduce this new technolog y to new customers to help them make their ideas come true and enhance productivity and effectiveness.

Our 3D printer offers two new printing technologies: Fused Deposition Modelling ( FDM ) and Poly Jet. They could help manufacturing process become more time-saving, cost-saving and more effective. ” Look out for the return of this exceptional platform to boost your productivity and profitability at “Vietnam Manufacturing Expo 2016” and the debut of “Sheet METALEX Vietnam 2016” during 6 - 8 April 2016 at I.C.E. Hanoi (Cung Van Hoa). ICE Hanoi, Vietnam September 10 – 12, 2015 Got a Question? Make An Enquiry.

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With the support of...

Association of Metalworked and Machinery

Indonesia Precision Tooling Industry Association

Indonesian Automotive Parts & Componenst Industries Association

Indonesian Machine Tool Industries Association

Indonesian Mould & Dies Industry Association

Indonesian Foundry Industries Association

Federation of Indonesia Metalworks & Machinery Industries Association

For further information please contact the office closest to you:

Maysia Stephanie PT Pamerindo Indonesia Jakarta T: +62 21 2525 320 F: +62 21 2525 482 / 522 9268 E: maysia@pamerindo.com W: www.pamerindo.com

Carolyn Lee International Expo Management Pte Ltd Singapore T: +65 6233 6777 F: +65 6233 6768 E: carolyn@iemallworld.com

Leonie Brooker Overseas Exhibition Services Ltd London T: +44 20 7840 2134 F: +44 20 7840 2119 E: lbrooker@oesallworld.com www.allworldexhibitions.com

ENQUIRY NO 179

EVENTS&EXHIBITIONS

EMO Milano 2015:

Taking Steps To The Future Of Machining

The premier metalworking and precision engineering show EMO takes flight to Milan Italy. This time round, the echoes of Industry 4.0 were louder than ever. APMEN was there in Milan to soak up the sights, sounds and technology.

Syed Shah reports.

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MO Milano 2015 began on 6 t h O c tob e r w it h much excitement amidst beautiful fall weather in Milan. At the gates, there were tons of visitors each day waiting to be given entry to the one international show dedicated to the metal-working world at the exhibition centre of fieramilano Rho up to the 10th of October.

In the spotlight of EMO Milano 2015 there were a touted 1,600 exhibitors from 42 countries on 120,000 sq m of net exhibition area and altogether 6,600 machines representing the best of the worldwide production in the sector. At the end of the event, it was indeed a record breaking event in terms of visitor turnout according to the organisers. While scouring the many halls with much difficulty due to the sheer amount of people present, that is somewhat a legitimate claim to that.

The international character that traditionally features EMO

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Milano is attested by the large attendance of foreign visitors a mounting to 51 percent of the total.

In the 12 completely fitted-out halls at fieramilano, the whole production spectrum has been presented: from metal forming to metal cutting machines, from robotics to automation, from tooling to auxiliary technologies, to me chat ronic s. I n t his framework, additive technologies made their debut: they are a rapidly developing sector that may be of great interest, also for those who operate in the field of production systems.

Moving Ahead With The World Of Tools The event opened with the inauguration ceremony, having the special participation of Pier Luigi Streparava, commissionergeneral of EMO Milano 2015.

Other special guests in the meeting included was Enrico Zanetti, Undersecretary of the

asia pacific metalworking equipment news November - December 2015

Ministry of Economy and Finance, President of CECIMO, Corrado Peraboni, managing Director of Fiera Milano and Luigi Galdabini, president of UCIMU - Sistemi Per Produrre.

The meeting saw the discussions that were of great interest to the Italian and European industry manufacturing machine tools, robots and automation systems. These discussions were of course interesting in a way because there are a large number of European companies who have set up shop here in the Asia Pacific. In the crowd that attended the opening ceremony were many Asian delegates who presumably were interested to hear about the latest with regards to the technologies available – aside from the Japanese, most East Asian technology has been based off European ones. Interestingly during the show, there were some exhibitors who were somewhat adverse to photo ta k ing of their products, presumably to www.equipment-news.com

EVENTS&EXHIBITIONS

The international character that traditionally features EMO Milano is attested by the large attendance of foreign visitors amounting to 51 percent of the total.

The largest machine tool builders continue to make improvements and expand their product lines to compete for new applications and this is seen in the increased amount of spending on research and development.

prevent copying of designs by potential competitors. “ T his ent r u st ment is a n acknowledgement of the value and of the importance of the Italian sector industry on the international stage, where it ranks third worldwide among exporting countries and fourth in the ranking of manufacturers” stated Mr Streparava.

Before the representatives of Italian and EU institutions, Mr Galdabini highlighted the ne ce s sit y o f i mple me nt i n g co nc re te me a su re s a i m i n g at stabilising the recovery of production systems consumption, which started in 2014 and is now strengthening.

“From this year on, the world consumption of machine tools will start to grow again steadily (2.3 percent increase), it will then increase by 4.2 percent in 2016 and by 4.5 percent in 2017, when, according to the figures processed by the econometric institute www.equipment-news.com

Oxford Economics, it is likely to achieve €64 billion (US$70.5 billion).”

“In particular considering the long standstill of consumption in Ita ly a nd a lso in a la rge part of Europe, the machine tool manufacturers ask for a provision – at a national and later on at an EU level - that may foster the replacement of obsolete machinery, enabling a modernisation of the machinery stock in the factories, while meeting the requirements of compliance with stricter and stricter regulations in terms of energy saving and improvement of sa fet y sta nda rds at t he workplace,” said Mr Galdabini Coming To Life With Industry 4.0 & Other Advancements During the event, there were several key trends that were spotted. In an increasing move towa rd s d ig it a l i sat ion a nd Industry 4.0, many brands are

looking towards automation and dash-boarding their tools.

This was the general sense of things as I moved through the halls. I managed to catch up with a few product managers from the different segments of the metalworking world. Martin Rabus, product manager from the Komet Group commented, “With the advent of technology, the way in which we manufacture our tools have changed too in order to cater for more efficient cutting.

It is all about productivity and cost savings and we are already moving in that direction.”

The largest machine tool bu i lde rs cont i nue to ma ke improvements and expand their product lines to compete for new applications and this is seen in the increased amount of spending on research and development.

Current CNC product lines are being re-tooled and streamlined to shave off legacy costs while there are advances in tooling

November - December 2015 asia pacific metalworking equipment news

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EVENTS&EXHIBITIONS technologies like reducing heat at the metal cutting surface, therefore, reducing the volume of cooling lubricants in the machine cavity, saving costs and minimising waste.

There is a n increa sing complexity in cutting with the installation of state of the art “avoidance systems” to precent tools from getting in each other’s’ way. Last but not least, we are seeing more sensors are being installed within machines to support higher precision stability requirements while making critical tolerance cuts in the material – and every detail of data from these measurements to precision cuts are being captured, analysed and eventually customisable according to customers’ needs.

The Growth Of Other Sectors O ne major conce r n a mon g machine builders is that the industry growth is mainly due to the rise of the automotive space. Some reports indicate that roughly 70 percent of job creation in the machine tools industry is related to the automotive space.

Despite much shop talk about the coming of 3D or additive manufacturing, the general feel in the show amongst manufacturers is that it is limited very much still to prototyping and there is still many years ahead before it will make headway. This is interesting because many heavy industries are already looking to additive manufacturing to cut costs especially in the aerospace sector. Thus this conflicting views is something to be looked out for in the coming months and years.

The EMO Following The ex hibition will a lso be remembered for all side events organised as a complement: institutional and B2B meetings, presentations, press conferences, conve nt ion s a nd te c h n ic a l seminars. But, in addition to that, 68

EMO Milano 2015 will be recalled for its concurrence with EXPO, the Universal exposition a few steps from the exhibition centre: the venue of EXPO welcomed a large number of operators of the world machine tool exhibition for a unique “After EMO”.

Even the social community of EMO Milano 2015 is large, counting on 2,771 followers in total on Facebook, Twitter and LinkedIn. Only in the period between the beg inning of

September and the end of the trade show, the 2,000 published posts generated more tha n 80,000 views of news dedicated to t he world me ta lwork i n g machine tool exhibition, equally distributed between Italian and foreign viewers.

The next edition of EMO Milano will take place in six years: from 4 to 9 October 2021.

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EMO HIGHLIGHTS Omax:

Setting The Tone

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teve Ulmer, vice president of international sales from Omax, a waterjet cutter maker commented that the Asia Pacific market is something that they are focusing on a s pa r t of their overa ll strategy especially in ASEAN with several installations in the region. So they are putting a bit more energy in Indonesia to get that territory developed. Thus the areas around ASEAN are definitely growth potential areas for their brand.

“What we have here are at EMO are more standard XY cutting machines. In the ASEAN

asia pacific metalworking equipment news November - December 2015

Expanding their presence in ASEAN.

region, it really depends what the customers need. In Singapore, we have sold several Omax machines but in other places, we have had more orders of the XY machine.

For our waterjet cutters we focus very much on the software that controls the cut because that is what we feel is critical – precision.

If you have no control over the jet, you cannot make a precise part. Ever since Omax was formed more than 20 years ago, one of our primary focuses has been the controlling of the jet.”

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EVENTS&EXHIBITIONS

EMO HIGHLIGHTS Wenzel:

Innovative Measuring Solutions

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t EMO Milano, Wenzel had an array of mea suring dev ices on show. T he fo cu s of the machines is on optical solutions which generate highly precise measurement results in ever shor ter cycle s. The optical non-contact 3D sensor Phoenix reportedly captures point clouds a nd geometr y elements in one work ing cycle. The Shapetracer 3D line scanner achieves extremely fast scanning speeds for efficient reverse engineering, verification and analysis. In addition the Revo 5 -Axis scanning system in combination with a Wenzel LH Series coordinate measuring machine achieves significantly shorter cycle times compared to conventional solutions and offers excellent measurement flexibility without loss of accuracy.

DMG Mori:

Sprinting Ahead

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t E MO M ila no, DMG Mori made quite the appearance (as usual) with a huge amount of offerings and reportedly seven world premiers (machine s).

While it we would love to put up all seven new machines, we can only afford the space for one. So

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Fra nk Wenzel, president and CEO, Wenzel, said, “In terms of reaching our globa l sa le s target, I would say we are successful this year and I’m positive that we will end 2015 on Frank Wenzel, a positive note as president and CEO, Wenzel. well. Traditionally, Europe is still our innovate on our offerings. The biggest market but right now there speed of production is getting is a lot of effort being put into the faster and faster on the work floor growth strategy for Asia especially today. So metrology devices need for Malaysia and Indonesia in the to keep up with the pace while ASEAN region. Here in EMO, not compromising on the existing we are displaying our current accuracy and we at Wenzel have range of machines like the Revo and will continue to be up to and are looking to educate more customers about our offerings as speed and even ahead of the competition in this respect.” they come along.”

“For us it is all about accuracy Got a Question? Make An Enquiry. and we are constantly improving ENQUIRY No. to improve it as we continue to Turn to page 80a or log on to www.equipment-news.com to enquire

8504

The Sprint 32|5 is designed for both short and long turning of workpieces.

in the spirit of fairness, APMEN has picked one – the Sprint series machines.

The Sprint 32|5 is designed for both short and long turning of workpieces of up to a diameter 32 x 600 mm. With a base area of less than 2.8 sq m, the new development is an extremely compact production

facility. The Sprint 32|5 machines materials in rod form up to 32 mm in diameter using two spindles and a 2-channel controller. DMG Mori keeps part costs to a minimum in this way. 22 tools on two independent workpiece carriers also make it possible to carry out complex machining processes.

The automatic lathe also machines demanding workpieces radially at the main spindle with four driven tools. In total, the machine is equipped with five linear axes and on C-axis for the main spindle.

Other options are the unloading device for workpieces up to 600 mm in length, and the high-pressure coolant supply with 120 bar.

Got a Question? Make An Enquiry.

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8505

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69

EVENTS&EXHIBITIONS

EMO HIGHLIGHTS Hainbuch:

Chucking Technology

F

or a long while mini chucks were not compatible with the Hainbuch building system. At EMO 2015, all these have changed because it is now the case for the two sets of chucks: round models and those Spanntop hexagonal ToPlus. For its low interfering contours and to use the flexibly build system, mini Spanntop chuck comes with an adapter ring with no extra adapter required. The expanding mandrel Mando Adapt existing module and the jaw are perfectly adapted to the new mini Spanntop.

Peter Zeiher, sales manager, Hainbuch

Peter Zeiher, sales manager, Hainbuch commented, “For the past year up to now, it has been quite exciting for Ha inbuch with a lot of orders for the new product range – it has proven to be popular. There is however an interesting trend leading up to large shows like EMO because customers are always expecting something new to be launched at the show so about two months before the show,

there will be a dip in sales for most tooling manufacturers and then a sudden spike after the show. This is because customers are saving their investments for what they think is the latest release. So this time round with our range of offerings, we are looking forward to bigger orders after the show.”

Got a Question? Make An Enquiry.

ENQUIRY No.

8506

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Schunk:

Productivity Through Innovation

A

t EMO Schunk was firing on all cylinders like its official spokesperson, exArsenal goalkeeper, Jens Lehmann did during his playing career. Schunk’s offerings ranged from the robotic Vero-S-pallet handling the automated loading of the Prismo3 Tool grinding chucks and to the fully automated Pronto quick jaw change system for lathe chuck. The company presented its two high-performance hydraulic expansion tool holder live under tension to the test. Especially in the volume machining ensured the vibration damping high-performer Schunk Tendo E compact and precision chucks Schunk Tendo Aviation with mechanical pull-out protection.

The highlight was still the world premiere of the Vero-S modular system for direct workpiece clamping. With its tension, stacking

70

and balancing modules allow mould plates, freeform parts and other workpieces to in seconds, directly that is, without additional clamping means and thus without interfering with the contours, tension in the finest gradations height on the machine table. This is especially in the production of individual parts and small series – the system program will continue to bring significant productivity increases of clamping technology experts.

Harald Dickertmann, head of sales and business development Asia, Schunk mentioned, “If you want to invest in high precision machining, then there is a need to pump in a reasonable amount of money. What we provide is products that are designed to drastically reduce set up times.

This means what you are looking at is the highest level of productivity because you nearly eliminate the

asia pacific metalworking equipment news November - December 2015

Harald Dickertmann, head of sales and business development Asia, and Hea Jeong Hwang, senior area manager, Asia, Schunk

set up process. In the ASEAN region, I believe that this knowledge needs to be spread to the industries so besides setting up base in Singapore, we are also looking to expand into Indonesia where there is great potential for our products to benefit the various verticals. It is important, I feel, to share that knowledge that we have from the automation and work/tool holding side of things. As a plus point, those who seek quick returns of investments will find that we have solutions that bring about tangible returns within the span of a year.”

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ENQUIRY NO 172

EVENTS&EXHIBITIONS

Event Review:

Metalex Vietnam 2015 T he “Business Alliance for Supporting Industry 2015”, “Metalex Vietnam 2015” “Electronics Assembly 2015 ( E A)”, a nd “Industr ia l Components & Subcontracting Vietnam 2015 (ICSV)” have finally ended with business connections beyond bounda ries while prompting metalworking and supporting industries in Vietnam to be fully armed with the right technologies to venture into the new age of ASEAN Economic Community (AEC). From 8 – 10 October 2015, all the delegates engaged in business discussions, exchanging contacts, catching up with new solutions and learnt new trends that could elevate their manufacturing processes to the next step of productivity.

A ll visitors enjoyed solid contents ranging from innovative machineries and networked with business partners they desired.

There are 13,777 industrialists and 267 group visits from local and other 33 countries around the world including Australia, Cambodia, China, Colombia, Denmark, Egypt, Finland, France, Germany, Hong Kong, India, Indonesia, Iran, Italy, Japan, Korea, Lao P.D.R., Lebanon, Malaysia, Myanmar, Netherlands, New Zealand, Philippines, Portugal, Russia, Singapore, South Africa, South Korea, Switzerland, Taiwan, Thailand, United Kingdom, and United States.

72

Over the course of three days of business, thousands of industrial manufacturers engaged in faceto-face business connection and discovered extensive networking opportunities. Mr. Taveesak Srisuntisuk, managing director of Hexagon Metrology (Thailand) said, “The exhibition is one of the best marketing strategies to raise awareness for our brand and technologies as we can reach thousands of business visitors and buyers at the same time”.

Metalex Vietnam 2015 was an efficiently platform for investors and foreigner manufacturers to meet to right targeted local customers and expand their business to Vietnam, it also the great chance for local manufacturer to generate sales leads, gain new grounds to be able to serve more demands from international customers.

Mr. Nguyen Quang Ha, HCM vice manager of Amada-Hason Technology and Trading Co., Ltd. said that “I believe that Vietnam’s market will develop stronger, especially the metal processing sectors since the market demands quality. Therefore, it is important for manufacturers to gain efficiency and competitive abilities by upgrading technologies that sharpens the competitive edge through productivity and lower production cost”.

asia pacific metalworking equipment news November - December 2015

This year, Metalex Vietnam has gained the great success with the participation from 8 i n te r n a t i o n a l p av i l i o n s to showcase highlight technologies from China, Germany, Japan, Ko re a , S i n ga p o re , Ta i w a n , Thailand and Tokyo Metropolitan.

M r. L a m J o o n K h o i , secretary – general of Singapore Manufacturing Federation (SMF) shared “With business cost in Singapore rising, emerging markets such as Vietnam present attractive for our investment oppor tunitie s for our loca l enterprises to venture into. I am confident that Metalex Vietnam 2015 will help our exhibitors to foster business ties and expand their networks into Vietnam.”

Next year, Metalex Vietnam 2016, Vietnam’s international exhibition on machine tools and metalworking solutions for production upgrade, will return with more and more modern technologies and rich contents alongside with NEPCON Vietnam 2016 during 6 – 8 October, 2016 in Ho Chi Minh City.

Ho Chi Minh, Vietnam 8 – 10 October 2015 Got a Question? Make An Enquiry.

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EVENTS&EXHIBITIONS

Manufacturing Myanmar 2015:

Plugging The Gaps

G

over nment officia ls, industry associations, and trade professionals f rom Mya n ma r’s manufacturing and oil and gas sectors were gathered at the Myanmar Event Park last week to attend the second editions of Manufacturing Myanmar and Oil & Gas Myanmar. The only dedicated trade events in the country, both Manufacturing Myanmar and Oil & Gas Myanmar concluded on Saturday, 17 October at the Myanmar Event Park.

The events saw a total of 4,290 attendees, comprising special guests, conference speakers and delegates, trade visitors and press members. In addition to offering local buyers a display of quality machines, tools and equipment from around the world, they also had the opportunity to engage with international peers and experts, tapping their knowledge of the latest trends and developments currently impacting today’s global economic and manufacturing scenes.

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Enhancing Industrial Productivity Gathering key international brands in one place, Manufacturing M y a n m a r 2 01 5 s a w l o c a l manufacturers getting the chance to check out new and best-selling products brought to the Myanmar market by leading international manufacturers and distributors.

Many exhibitors, especially ones entering Mya nma r for the first time, got to meet with p ote nt ia l lo c a l a ge nt s a nd distributors. Through networking and interactions with local buyers at Ma nu factur ing Mya nma r 2015, they were able to amass valuable insights into the local manufacturing landscape and business environments.

“The show is a great launch pad for Trumpf in Myanmar, allowing us to create awareness a nd to build more business partnerships,” said Mr. Edward Yu e n , g e n e r a l m a n a g e r o f Trumpf, Singapore.

Trade attendee, U Aung Tun Naing, Managing Director from

asia pacific metalworking equipment news November - December 2015

Asia Rex commented that “it was a fruitful visit and I saw many new machines that are more efficient to provide fast turnaround for my organisation.”

In a speech at the opening ceremony, U Zaw Min Win, c h a i r m a n o f t he M y a n m a r Industries A ssociation said, “Myanmar is considered one of the most attractive destinations for economic cooperation and the last frontier for investment.

With the state’s enactment of new special economic laws and foreign investment law paving the way for greater participation of overseas investors in the economic development of o u r c o u n t r y, n e w m a r k e t opportunities are available. The manufacturing and oil and gas industries are booming and I am sure that our industrialists will have a lot to learn from the exhibitions to enhance their professional competency.”

“We provided an effective busine ss platform for loca l companies to connect with, and benefit from an international gathering of manufacturers, suppliers and service providers.

Honoured to have the support of the local government and i ndu st r y orga n i s at io n s for our events, we look forward to continue to build on these valued partnerships, to help Myanmar in the development of its core industries,” said Ms. Lindy Wee, chief executive o f o r g a n i s e r, S i n g a p o r e Exhibition Services.

Manufacturing Myanmar will return in September 2016. Oil & Gas Myanmar will return in October 2017.

Myanmar Convention Centre Yangon, Myanmar October 15 – 17, 2015 Got a Question? Make An Enquiry.

ENQUIRY No.

8509

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PRODUCT FINDER Aicon 3D Systems: 3D Scan Software

Delcam: PowerMILL CAM Software

The updated version of Aicon 3D Systems’ Optocat c a n sig n i f ic a nt ly facilitate and speed up t he work f low of 3 D me a su r i n g processes. Single captures of the process can now be aligned automatically without the need for photogrammetric index markers or even manual processing by the user.

A new feature is the stereoSCAN neo, a combination of high-resolution sensor technology and digital projection unit, which is fully integrated with the software. It allows adaptive full colour projection not only for scanning an object, but also for accurate measurements as deviations from the CAD are visualised in colour on the object surface.

Delcam has enha nced its PowerMILL CAM software fo r f i v e - a x i s and high-speed machining for mouldmakers, enhanced collision checking that enables warnings to be flagged for near misses, and improvements to the Vortex high-efficiency area-clearance strategy for safer toolpaths and shorter cutting time that hence extends tool life and protects the machine.

A lso enabled is toolpath simulation and verification that ensures a tool’s capability of running the proposed strategy. An added module for machining ribs into tooling now increases ease and safety of programming machining of cavities for narrow ribs, even when the cutter’s length exceeds its diameter.

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ENQUIRY No.

8601

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ENQUIRY No.

8602

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endless flexibility

18-21 Novem ber Hall 1 – Boo 2015 th H25

Next challenge, please !

Versatile, high-performance, capable of operating with or without a guide bush and performing operations with high added value, the Swiss GT 26 is a machining solution that offers standard equipment at a competitive price.

TORNOS SA, TORNOS TECHNOLOGIES ASIA LTD. MALAYSIA REPRESENTATIVE OFFICE Tel: +6(04) 642 6562/642 6563, www.tornos.com TORNOS SA, THAILAND REPRESENTATIVE OFFICE Tel: +66 2746 8840-1, www.tornos.com

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ENQUIRY NO 157

Hall 1 – Booth H25

November - December 2015 asia pacific metalworking equipment news

75

PRODUCTFINDER DMG Mori: Vertical Machining Centre

Indusoft: InduSoft Web Studio v8.0 Software

The ecoMill V series from DMG Mori is a new se r ie s of vertical machining centres that a re part of their Ecoline product range. It come s in three models— ecoMill 600V, ecoMill 800V, a nd ecoMill 110 0V that can accommodate workpieces weighing 600, 800 and 1000 kg respectively.

The series features an increased cutting speed by up to 25 percent and has an optimised structure with finishes made from anodised aluminium and powdercoated metal claddings for enhanced durability, and gives value stability during machining.

With a finite element method (FEM) optimised cast iron C-frame design and weighing around a tonne, the series makes for one of the smallest footprints in its class.

The latest version of InduSoft Web Studio

by InduSoft includes several enhancements.

Supporting the latest demands of Industr y 4.0, the software offers enhanced Internet of Things (IoT) capabilities through its new runtime, t h e I oT V i e w , t h a t provides more scalability to design solutions with the software.

It also now allows multiple screens to be opened simultaneously on the Studio Mobile Access Thin Client solution, so manufacturers’ can view multiple screens on a variety of devices from smartphones to tablets.

T here a re a lso ot her p er for ma nce a nd functionality improvements for the Collaboration Server add-on for revision control and application lifecycle management.

Got a Question? Make An Enquiry.

ENQUIRY No.

8603

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8605

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Dormer Pramet: EMO 2015 Range

Kennametal: Beyond Drive Cutting Inserts

Dormer Pramet showcased a range of rotary and indexable tooling at EMO Milano 2015. Tools for drilling, milling, threading and turning applications were displayed, as well as specific p ro du c t s fo r t he railway sector and heavy machining. These included products that were launched in April 2015 which are for heavy turning, scarfing, chamfering and heavy milling, including the new tangential milling cutters. PFX deep hole drills, MPX multi-application drills, such as the new R459 8xD drill, and Hydra replaceable head drills formed part of the Dormer product range at EMO. Pramet’s general milling range, including Penta HD, Penta HF, Econ LN and Force AD were also featured at EMO, along with the recently launched ADMX07 inserts and cutters.

Kennametal’s Beyond Drive cutting inserts come in a range of grades and geometries and suit turning applications.

The titanium oxycarbonitride outer coating ( TiOCN ) coating increa ses wear- and abrasionresistance for lower temperatures and prolongs tool life. The bronze colour also acts as an effective wear indicator that enables the inserts to serve up to 30 percent more parts per edge.

The inser ts thus cut costs, avoid wa ste a nd produce more qua lity pa r ts per edge, thus increasing capacity and productivity of manufacturers for critical turning applications involving steels, stainless steels, cast irons and high-temperature alloys.

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ENQUIRY No.

8604

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Got a Question? Make An Enquiry.

ENQUIRY No.

asia pacific metalworking equipment news November - December 2015

Got a Question? Make An Enquiry.

ENQUIRY No.

8606

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PRODUCTFINDER

Addison Co. & Ltd used a r e g u l a r I S O VG 3 2 hydraulic fluid in their Vickers hydraulic power pack of the flute grinding machine. This hydraulic fluid required 30 minutes of idle running during start-up to achieve sufficient fluidity and hydraulic efficiency. As the plant operated on a shift basis, machines were stopped after each shift resulting in excess power consumption.

ExxonMobil engineers recommended the switch to Mobil DTE 10 Excel 32, a shear stable high VI hydraulic fluid that can operate under high temperatures and pressures and has “ultra-keep clean� technology.

The result is reduced oil consumption by 50 percent, increased reliability including productivity and energy savings of six percent.

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8607

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ENQUIRY NO 085

Mobil: Mobil DTE 10 Excel 32

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November - December 2015 asia pacific metalworking equipment news

77

PRODUCTFINDER Renishaw: Inspection Plus with SupaTouch Software Renishaw’s Inspection Plus with SupaTouch software package optimises on-machine measurement cycles to minimise cycle time and maximise productivity.

Eliminating the need for manual optimisation, it can automatically determine and select the highest feedrates a machine tool can achieve while maintaining measurement accuracy, and intelligently make in-cycle decisions to implement either a one or two-touch probing strategy for each measurement routine.

The package reduces cycle time by up to 60 percent on CNC machine tools, and also features an automatic calibration process, corrective action remeasuring function so as to improve measure repeatability and ensure maximum accuracy while the machine is in use.

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ENQUIRY No.

8608

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Seco Tools: Boring Heads

Got a Question? Make An Enquiry.

8609

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78

T h e Ta e g uTe c T- B u r s t h i g h pressure coolant tool was developed to aid in groove-turning and parting of difficult-to-cut materials like titanium, Inconel and other heat-resistant alloys.

Releasing the coolant onto material with a pressure up to 300 bar, the tool thus provides lubrication, cooling and efficient chip breaking while ensuring longer tool life. Two holder types, TTER/LTB, TTER/L-SH-TB and TQHR/L QuadRush, are available for the tool.

With inserts’ width of cut ranging from 3.0 to 8.0 mm, TTER/L-TB holders are available in 20 and 25 mm square shank size, while the TTER/L-SH-TB holders that additionally feature a side clamping design are available in 12 and 16 mm square shank size. QuadRush holders are available in 12, 16, 20 and 25mm square shank size with inserts’ depth of cut ranging up to 5.2mm.

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ENQUIRY No.

8610

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Tongtai Group: SH-4000 Horizontal Machining Centre

The EPB 610 rough boring heads and EPB 620 radial type fine boring heads extend the versatility of Seco’s Steadyline vibration damping system as they can be used in combination with Steadyline turning bars.

They allow the same bar to be used for both static turning and rotating boring operations in deep machining applications of up to 10 x D. Mounting the boring heads is made easy and fast with the precise GL connection that enables the strong fast-locking capability of a single integrated clamping ring on the machine, drawing in the tool head for a secure, stable taper-face contact.

ENQUIRY No.

TaeguTec: T-Burst High-pressure Coolant

asia pacific metalworking equipment news November - December 2015

To n g t a i G r o u p ’ s SH- 4000 horizontal m ac h i n i n g ce nt re suits mass production line formation and fast aluminium alloy parts machining. With a more compact design t ha n it s prev iou s model, the new machine has a 35 percent smaller footprint.

The machine is equipped with a powerful 30 horsepower, 15,000 revolutions per minute built-in spindle, a 400 mm square table, and coolant through the spindle. Its automatic tool changer holds 60 tools with a tool-to-tool change time of 1.4 seconds, and a chip-to-chip time of 2.6 seconds.

When integrated with a robot for either a floortype motion axis rail system or overhead gantry, it can aid manufacturers catapult production and streamline manpower costs.

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ENQUIRY No.

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EXHIBITION PROGRAMMES

2015-2016

NOVEMBER

JUNE

OCTOBER

BITEC Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th

Bangkok International Trade & Exhibition Centre (BITEC) 8 Bangna-Trad Road (Km.1), Bangna Bangkok 10260 Thailand Reed Tradex Company

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

18 – 21 Metalex

DECEMBER

22 - 25 Intermold Thailand 2016

25 – 29 Euro Blech 2016

2–4 International Metal Technology Taiwan

22 - 25 Manufacturing Expo 2016

2–5 Manufacturing Indonesia 2015

22 - 25 Nepcon Thailand 2016

Jakarta International Expo (JIExpo), Indonesia PT Pamerindo Indonesia maysia@pamerindo.com www.manufacturingindonesia.com

Bangkok International Trade & Exhibition Centre (BITEC) 8 Bangna-Trad Road (Km.1), Bangna Bangkok 10260 Thailand Reed Tradex Company

2016

JULY

Kaohsiung Exhibition Centre Kaohsiung, Taiwan KAIGO imt@kaigo.com.tw www.imttaiwan.com/main.php?lang=en

APRIL

26 - 28 MTA Vietnam Hanoi 2016 I.C.E. Hanoi (Cung Van Hoa) Cultural Palace 91 Tran Hung Dao Str. Hanoi, Vietnam Singapore Exhibitions Services Pte Ltd

Bangkok International Trade & Exhibition Centre (BITEC) 8 Bangna-Trad Road (Km.1), Bangna Bangkok 10260 Thailand Reed Tradex Company

DECEMBER 2–5 Manufacturing Indonesia 2016

Jakarta International Expo (JIExpo) Gedung Pusat Niaga Lt. 1 Arena PRJ Kemayoran Jakarta 10620 Indonesia PT Pamerindo Indonesia

13 – 15 Indometal 2016

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

27 – 30 Manufacturing Surabaya 2016

Grand City Convention & Exhibition Centre JL. Walikota Mustajab Kusuma Banja Surabaya 60272 Indonesia PT Pamerindo Indonesia

MAY

11 – 14 Intermach Thailand 2016 Sheetmetal 2016 Subcon 2016 UBM ASIA (Thailand) Co Ltd. 503/23 K.S.L. Tower 14th Floor Sri Ayuthaya Road Kwaeng Thanon Phayathai Khet Rajathewee, Bangkok 10400, Thailand UBM (Thailand) Co Ltd

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To be considered for inclusion in the calendar of events, send details of event to:

The Editor (APMEN) Eastern Trade Media

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79

ADVERTISING INDEX Page No.

Enquiry No.

AGMACHINE TECHNO CO LTD

77

081

BENIGN ENTERPRISE CO LTD

25

169

BYSTRONIC PTE LTD

03

181

DEES HYDRAULIC INDUSTRIAL CO LTD

55

068

DELCAM LTD

05

075

DMG ASIA PACIFIC PTE LTD

FC

184

HAAS AUTOMATION INC

09

165

HEIMATEC GMBH

29

162

HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD

11

173

HWACHEON ASIA PACIFIC PTE LTD

13

168

ISCAR LTD

IFC

180

KENNAMETAL INC

BC

166

LICO MACHINERY CO LTD

51

082

LIEN CHIEH MACHINERY CO LTD

57

067

OKUMA CORPORATION

IBC

177

OPTICAL GAGING (S) PTE LTD

15

174

PEER ENERGY SINGAPORE PTE LTD

77

085

PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA 2015)

65

179

RENISHAW (HONG KONG) LTD

21

182

SCHUNK INTEC PTE LTD

17

183

SECO TOOLS (S.E.A) PTE LTD

01

117

SINGAPORE EXHIBITION SERVICES PTE LTD (MT HANOI 2016)

71

172

SUTTON TOOLS SINGAPORE PTE LTD

43

167

TAIWAN EXTERNAL TRADE DEVELOPMENT COUNCIL/MT DUO 2016

63

171

TAIWAN EXTERNAL TRADE DEVELOPMENT COUNCIL/TAITRA

23

175

TAIWAN TAKISAWA CO LTD

61

095

TORNOS TECHNOLOGIES ASIA LTD

75

157

TUNGALOY SINGAPORE PTE LTD

19

178

UBM ASIA (THAILAND) CO LTD (INTERMACH 2016)

27

176

WALTER AG SINGAPORE PTE LTD

07

170

YIH CHUAN MACHINERY INDUSTRY CO LTD

45

071

ZWCAD SOFTWARE CO LTD

35

147

Advertiser

80

asia pacific metalworking equipment news November - December 2015

Manufacturers and advertisers that are featured in this issue will send you free information about their products and services. Fill up the Product Enquiry Form on-line at www.equipment-news.com.

ADVERTISING SALES OFFICES HEAD OFFICE SINGAPORE EASTERN TRADE MEDIA PTE LTD 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/2806 E-mail: apmen@epl.com.sg FOREIGN REPRESENTATIVES JAPAN Ted Asoshina ECHO JAPAN CORPORATION Tel: 81-3-3263 5065 Fax: 81-3-3234 2064 E-mail: aso@echo-japan.co.jp

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SWITZERLAND Rene Bachmann MEDIALL SA Tel: 41-56-442 14 40 Fax: 41-56-442 27 77 E-mail: rb@mediall.ch

TAIWAN Robert Yu WORLDWIDE SERVICES CO., LTD Tel: 886-4-2325 1784 Fax: 886-4-2325 2967 E-mail: sales@wwstaiwan.com

U. KINGDOM Eddie Kania ROBERT HORSFIELD INT'L MEDIA REP. Tel: 44-1663-750 242 Fax: 44-1663-750 973 E-mail: ekania@btopenworld.com

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ASIA PACIFIC METALWORKING

No. 8 2015

The Engineering Journal For Manufacturing,Automation & Quality Control

From: (Surname)_________________________________ (Given Name)______________________________ Job Title:_______________________________________ Company:______________________________________ Address:_______________________________________

Do you want to receive (continue to receive) Asia Pacific Metalworking Equipment News? ❑ YES / ❑ NO (Not valid without signature) Signature___________________ Date_________________

_____________________________________________

Country: _________________ Tel: _________________ Fax:_________________ E-mail: _________________

ENTER ENQUIRY NUMBER (S)

(Refer to Advertising Index for Advertisers’ enquiry numbers)

Note: This form must be duly completed and signed._____________ TYPES OF PRODUCTS TO BE PURCHASED IN THE NEXT 12 MONTHS ❍ Cutting Tools ❍ Machine Tools ❍ Software

❍ Metrology

TYPE OF BUSINESS (Please ✔ ONE box only) Do you use METAL in your production/manufacturing process?

Do you use machine tools and related equipment?

Do you use automation systems & equipment?

❑ Yes ❑ Yes ❑ Yes

❍ Others_____________

❑ No ❑ No ❑ No

YOUR METAL PROCESS USED ? (Please be specific)

❑ 300 ❑ 303 ❑ 306 ❑ 309 ❑ 315 ❑ 318

CNC Machining Milling Gear Cutting Grinding Stamping Shearing

❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310

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

❑ 313 ❑ 316 ❑ 319 ❑ 322 ❑ 302 ❑ 305

Forging Rolling Die Casting Welding Turning Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 OTHERS (Please specify)_____________________________________________________________________________________________

YOUR BUSINESS ACTIVITY (Please be specific) ❑ 221 ❑ 150 ❑ 222 ❑ 120 ❑ 223 ❑ 122 ❑ 123

Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg.

Dies & Moulds mfg.

Motor Vehicles Parts Shipbuilding

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

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

❑ 028 Testing & Inspection ❑ 030 Sales & Marketing

❑ 022 Production Engineering ❑ 024 Quality Control/Assurance

❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

❑ 027 OTHERS (Please specify)

SIZE OF COMPANY ❑ 001 1 – 10

❑ 002 11 – 30

❑ 003 31 – 50

❑ 004 51 – 100

❑ 005 101+

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Name: (Surname)____________________________________ (Given Name)__________________________ Company: _________________________________________ Job Title:______________________________ Address:_________________________________________________________________________________ Country: __________________________________________ Telephone No: _________________________ E-mail:____________________________________________ Fax No:______________________________ Signature _________________________________________ Date_________________________________ SUBSCRIPTION RATES

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AIRMAIL (1 YEAR – EIGHT ISSUES)

■ *Singapore/Malaysia S$60.00

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TYPE OF BUSINESS (Please ✔ ONE box only) Do you use METAL in your production/manufacturing process?

Do you use machine tools and related equipment?

Do you use automation systems & equipment?

❑ Yes ❑ Yes ❑ Yes

❑ No ❑ No ❑ No

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

CNC Machining Milling Gear Cutting Grinding Stamping Shearing

❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310

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

❑ 313 ❑ 316 ❑ 319 ❑ 322 ❑ 302 ❑ 305

Forging Rolling Die Casting Welding Turning Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 OTHERS (Please specify)

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

Basic Metal/Foundaries/Mills Electrical & Electronics production Telecommunications Equipment Manufacturing Aircraft maintenance/components mfg.

Dies & Moulds mfg.

Motor Vehicles Parts

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

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

❑ 028 Testing & Inspection ❑ 030 Sales & Marketing ❑ 027 OTHERS (Please specify)

❑ 022 Production Engineering ❑ 024 Quality Control/Assurance

Send this Fast SUBSCRIPTION FORM to Circulation Department, Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-02, Singapore 169206 or Fax: 65-6379 2806 Note: This form must be duly completed and signed.

❑ 026 Design Engineering ❑ 029 Purchasing/Sourcing

ENQUIRY NO 177

Simply a smarter insert. That’s Beyond Drive.

That’s ™

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With Wear Detection Technology Black Insert

Hard to detect wear.

BEYOND™ DRIVE™ Our most advanced surface treatment: • Bronze outer layer simplifies wear detection • Reduces coating stresses • Improves coating adhesion

At Kennametal, our inspiration is driven by asking “what if?” Engineering a complete portfolio of inserts that utilizes advanced wear detection technology while also increasing metal removal rates — is a result of that drive.

A simply smarter insert. Now That’s Different Thinking, That’s Better Thinking. That’s Kennametal.

Beyond™ Drive™ inserts coupled with NOVO ™ — our suite of powerful digital tools — will lead to increased performance. To receive your FREE Test Insert, call +1 800 835 3668 or visit www.kennametal.com/BeyondDrive

ENQUIRY NO 166 ©2015 Kennametal Inc. l All rights reserved. l A-15-04413EN

www.kennametal.com/BeyondDrive