Special Feature:
Plant Visit:
Expert Opinions On Auto Parts Manufacturing
An Inside Look Onsite October 2011
www.equipment-news.com M.I.C.A. (P) No. 053/06/2011
DMU 65 monoBLOCK® NEXT GENERATION – Redefining 5-axis milling with a swivel rotary table
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ENQUIRY NO 174
www.iscar.com www.iscar.com ISCAR ISCAR JAPAN JAPAN 1-5-3 1-5-3 Shinsenri-Higashimachi Shinsenri-Higashimachi Toyonaka-shi, Toyonaka-shi, Osaka Osaka 560-0082 560-0082 Tel Tel + 81+ 681 835 6 835 54715471 Fax Fax + 81+ 681 835 6 835 54725472 iscar@iscar.co.jp iscar@iscar.co.jp
ISCAR ISCAR TAIWAN TAIWAN 395,395, Da Duen Da Duen South South Rd. Rd. Taichung Taichung 408 408 Tel Tel +886+886 (0)4 (0)4 247 247 31573 31573 Fax Fax +886+886 (0)4 (0)4 247 247 31530 31530 iscar.taiwan@msa.hinet.net iscar.taiwan@msa.hinet.net
ISCAR ISCAR THAILAND THAILAND 57, 59, 57, 61, 59, 63 61,Soi 63 Soi Samanchan-Babos Samanchan-Babos Sukhumvit Sukhumvit Rd. Rd. PhraPhra Khanong, Khanong, Khlong Khlong ToeyToey Bangkok Bangkok 10110 10110 Tel Tel+ 66+ (2) 667136633 (2) 7136633 Fax Fax + 66+ (2) 667136632 (2) 7136632 iscar@iscarthailand.com iscar@iscarthailand.com
ISCAR ISCAR VIETNAM VIETNAM (Representative (Representative Office) Office) Room Room D 2.8, D 2.8, Etown Etown Building, Building, 364 364 Cong Cong Hoa,Hoa, Tan Tan BinhBinh Dist., Dist., Ho Chi Ho Chi MinhMinh City,City, Tel Tel+ 84+ 884 8123 8 8123 519/20 519/20 Fax Fax + 84+ 884 8123 8 8123 521 521 iscarvn@hcm.fpt.vn iscarvn@hcm.fpt.vn
CV MULTI CV MULTI TEKNIK TEKNIK JL. Balikpapan JL. Balikpapan RayaRaya No. No. 28 Jakarta 28 Jakarta Pusat Pusat 10140 10140 Indonesia Indonesia Tel Tel+ 62+ 21 626307303 21 6307303 Fax Fax + 62+ 21 626348062 21 6348062 multi@centrin.net.id multi@centrin.net.id
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ENQUIRY NO 001
Advertorial
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For resin-based parts, the trend is in favour of the Connex, which now accounts for over one third of production
Case Study
The power of two Jaguar Land Rover installed a Connex500 from Objet in the summer of 2008. The 3D printer was chosen for its multi-material capability, which combines two different materials and draws on their best attributes to deliver superior models.
At a Glance
Company: Jaguar Land Rover URL: www.jaguarlandrover.com Location: Coventry, UK Industry: Automotive
Challenges
Broaden in-house prototyping capabilities to enhance automotive styling and provide elastomer-like design testing
Solution
Objet Connex500™ 3D Printing System
Results
• Faster development and testing of complex and multi-material parts • Working models produced quickly in a single process for immediate style, fit and function testing
The two global premium brands of Jaguar and Land Rover have been under single ownership since the year 2000, firstly as part of the Ford Motor Company and now as the UK-based wing of the Indian TATA Group. The two marques originally started life with completely different perspectives. The first Jaguar, the SS100, was launched in 1935 as the first 100mph affordable sports car. With classic lines and high performance it became the inspiration for a remarkable lineage of Jaguar cars with a reputation for speed, comfort and race winning. In contrast, the first Series 1 Land Rover 80, built in 1948, had completely different attributes, being an ‘all-purpose vehicle’ with a rugged, no-frills design and off-road capabilities. Today, there are eight vehicle lines produced by Jaguar Land Rover (JLR). To ensure that these lines maintain their premium position in the marketplace, almost 20% of Jaguar Land Rover’s workforce is employed on product development, using the very latest CAD techniques with in-house prototyping and tooling to quickly prove designs. In addition to CNC model making and a fully equipped metalwork and toolshop, the prototyping capabilities include several RP machines using SLA, laser sintering and polymer jetting technologies. Prototyping parts direct from CAD data Jaguar Land Rover invested in the Connex500 in 2008 to broaden its resin-based RP prototyping capabilities. The ability to create models direct from CAD data with elastomer, rubber-like materials and produce working mechanisms, were other key benefits that would contribute towards reducing development cycles. To prove its capability, the Connex was initially tasked to produce a complete facia air vent assembly for a Range Rover Sport. It was modelled using rigid materials for the housing and air-deflection blades, and rubber-like materials for the control knobs and air seal. Jaguar Land Rover was able to print the complete facia air vent, as a working part, in a single process. Once printed, the model was taken from the Connex, cleaned and tested immediately, proving that the hinges on the blades all worked and the control knob had the right look and feel. The backbone of Connex is Objet’s PolyJet Matrix technology. By jetting two distinctive model materials in preset combinations in a matrix structure, it is possible to create multiple flexible and rigid materials with different mechanical and physical properties as well as finishes. Using this technology, Jaguar Land Rover’s Connex has accumulated 5000 hours of operation, printed over 2500 parts and used 600kg of resin. It’s a testament to the productivity and reliability of Objet technology that the 3D printer has required little maintenance and replacement of just five print heads throughout this time, at the intervals recommended by Objet to maintain optimum quality. The number of parts produced on the Connex has been steadily increasing as the team have found new ways to capitalise on the Connex capabilities. The figures are still only a small percentage of the 30,000 parts prototyped by Jaguar Land Rover every year, but many of these are laser sintered. For resin-based parts, the trend is in favour of the Connex which now accounts for over one third of production. Interestingly, the Connex is often used to produce single-material rigid parts due to its speed and simple post processing. When in multi-material mode it is used for a variety of activities. These include styling and HMI (Human/Machine Interfaces) concepts, such as knobs, switches & key fobs. Fit and function testing Over-moulding is also an important function of the Connex. Two materials are used, but not mixed, to create, for example, a cover with rubber seal. Once cleaned the assembly can be used directly for fit and function testing. Other key areas for Connexuse include the development of door seals and protective gaiters, where just the non-rigid TangoBlack Plus is used, and more recently the creation of parts for functional testing. The biggest user of Connex capabilities is the styling department at Jaguar Land Rover. Over half of everything produced on the 3D printer finds its way into the design studio to help finalise new design proposals. A good example was the creation of an entire telescopic headlamp washing system that extends and cleans headlamps every fifth time the windscreen is washed. The Connex-printed components proved to be robust enough for rigorous testing, allowing the design to be proved before moving into the expensive tooling stage. The different attributes of the Connex clearly come into play in different ways for the above applications, but in summary the general benefits for Jaguar Land Rover are good part definition with high accuracy and dimensional control as well as fast turnaround due to easy operation, a fast build speed and simple clean-up process. More specifically, the Connex has impressed with its ability to prototype parts direct from CAD data that would have been time consuming or expensive by other means.
info@objet.com www.objet.com
© 2010 Objet, Quadra, QuadraTempo, PolyJet, FullCure, SHR, Eden, Eden250, Eden260, Eden260V, Eden330, Eden350, Eden350V, Eden500V, Job Manager, Objet Studio, CADMatrix, Connex, Connex350, Connex500, Alaris, Alaris30, PolyLog, TangoBlack,TangoBlackPlus TangoGray, TangoPlus, VeroBlue, VeroWhite, VeroBlack, VeroGray, Durus, DigitalMaterials, Polyjet Matrix and ObjetGreen are trademarks of Objet Geometries Ltd. and maybe registered in certain jurisdictions. All other trademarks belong to their respective owners.
THe definiTive answer To aLL your proToTyping needs Compact, affordable and multi-material, the new Objet260 Connex uses the world's only 3D printing technology that can build prototypes with up to 14 different material properties in one print. So whatever your great idea, you can be sure it will look, feel and even function like the real thing.
’’
The new Objet260 Connex enables us to accurately simulate the
real look and feel of the complex watch designs that we receive from watchmakers. As the only platform able to simulate the different material properties of assembled watches, the Objet260 Connex gives us a major
’’
advantage and enables us to expand our business opportunities.
Lucien Hirschi, CEO for Zedax SA, (Swiss 3D printing service bureau)
ENQUIRY NO 176
The Power to Create
www.objet.com info@objet.com
Contents
October 2011
First Cut
24 Case Study: Thinking In Five-Axes
Using a unique five-axis approach allows a machine shop to make a bold statement and grow rapidly. Contributed by Scott Rathburn, Haas Automation
28 Think First, Cut Later
There are new approaches to part setup that will improve your five-axis capability and make machine shops more productive. By Maggie Smith, Hurco Companies
Technology Insights
32 The Green Scheme Of Things
With rising concern over climate change and dwindling fossil fuels, metalworking is moving towards green manufacturing, with the emergence of technologies that hold great promise in reducing energy and material usage. By Shahnawaz Abdul Hamid
Volvo Trucks
34 Giving An Old Truck A New Lease Of Life Making sure a material lives on and nothing else going to waste have both economic and environmental benefits. Contributed by Per Nilsson, Volvo
Software & Metrology
38 Metrology: Contact Or Non-Contact?
Augustine Quek investigates what are making waves in the tactile measurement arena and also looks across the fence where non-contact measurements are finding themselves in more applications.
42 Touch And Go
Stricter quality control measures have increased expectations on measurement processes. This has given rise to new, noncontact modes of measurement. However, it is still too early to say if this would spell the end of touch measurement. By Shahnawaz Abdul Hamid
Adelphi Lab Center
46 Last Words‌Combining Different Metrology Systems
Contact and non-contact multi-sensor 3D metrology realise faster investigation and serial inspection by capturing full-part geometry with a single system. By Venjamin Chan, Nikon Singapore
Fab & Form
48 Waterjet Cutting & Nothing Else
After discovering waterjet cutting, an Austrian company concentrates solely on the technology and on mastering the entire process. By Volker Albrecht, for Bystronic
4
metalworking equipment news October 2011
Best choice. Best choice. Affordable Affordable innovation innovation since 25 years. since 25 years. Laser | Bending | Waterjet bystronic.com Laser | Bending | Waterjet Laser | Bending | Waterjet bystronic.com ENQUIRY NO 185 bystronic.com
Contents
October 2011
Industry Focus
52 Special Feature: Auto Parts Manufacturing
Asia Pacific Metalworking Equipment News brings you the expert opinions of four individuals involved in the auto parts manufacturing business.
56 CMM Arms: Increasing Measurement Accuracy & Mobility
With an estimated production capacity of 700,000 automobiles, BYD Auto finds convenience, confidence and capacity by investing in solutions that make accurate and reliable measurement checks. By Ring Pan, Faro China
ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806. SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/ Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: irenetow@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE
Plant Visit 60 Mazak Cyber Factory Visit
Asia Pacific Metalworking Equipment News recently visited Mazak’s Cyber Factory to have a better understanding of its manufacturing activities in Singapore. By Joson Ng
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Features 66 The Age Of Mobility
Federation of Malaysian Foundry & Engineering Industry Associations
Manufacturing in Asia has entered a phase where more mobile devices have found their place in the production line. Saj Kumar, VP, Discrete Manufacturing, Industry Solution Group, SAP China shares his views. By Joson Ng
70
Engaging The Industry On A New Platform
Indian Machine Tool Manufacturing Association (IMTMA)
Converting a traditional show room into a technology cum activity centre is a fresh approach by Agie Charmilles aimed at providing the right solutions to the people who need it. By Joson Ng
China Machine Tool & Tool Builders' Association (CMTBA)
74 Events & Exhibition
Machine Tool Club (MTC)
• Event Preview: Metalex 2011 • Event Preview: Metaltech 2012 • Event Preview: Manufacturing Indonesia 2011
Regulars 10 80
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metalworking equipment news October 2011
83 Exhibition Programmes 84A Product Enquiry Card
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ENQUIRY NO 089
editor’s note
It’s
Time To Get A Move On
Published by:
Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)
Reg No: 199908196C
managing director Kenneth Tan editor Joson Ng
josonng@epl.com.sg
business development manager Randy Teo
randyteo@epl.com.sg
assistant sales manager Isabella Ong
isabellaong@epl.com.sg
editorial assistant Sharifah Zainon sharifah@epl.com.sg graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow
In modern hectic life, movement is inevitable. People move from one place to another in search of a better life. The theory is the same even when it comes to cash. Cash flow is arguably the one thing that keeps a business afloat. This idea of mobility has slowly crept into our daily lives more in recent times. One very good example is the mobile devices we carry. Intrusive the technology maybe for some but it is essential for many of us. In any case, one might think being mobile and connected these days is always better than being an immovable stationary object. Mobile devices have found their ways into offices, schools and perhaps more pertinently into factories as well. There is no denying the shift towards the use of mobile devices on the shop floor. It can range from simple bar code scanners to more sophisticated devices like the tablet or the smart phone. Dev ice s like the tablet ca n effectively display crucial production information previously only available
on the shop floor. These allow the management to have complete visibility looking at a dashboard display (visualisation tool) right from their mobile devices. In metalworking, many have jumped into the mobile bandwagon. Cutting tools makers in particular, have apps available to help machinists in their work wherever they are. With these apps, users can, with their iPhone, determine cutting parameters for tools for the required operation and also place their orders online. It can compare the cost efficiency of two tool solutions, order tools and access online content from the company. If time is money, the ability to save time brought forward by adopting mobility in an manufacturing environment has intrinsic value which may not be easily detected at first, but beneficial to an organisation in the long run. It is perhaps better to get a move on now than to be left behind.
Joson Ng Editor
8
metalworking equipment news October 2011
irenetow@epl.com.sg
contributors Scott Rathburn Maggie Smith Per Nilsson Augustine Quek Shahnawaz Abdul Hamid Venjamin Chan Volker Albrecht Ring Pan board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR
All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 053/06/2011 PPS 840/09/2012 (022818) ISSN 0129/5519
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ENQUIRY NO 162
Businessnews Delcam Achieves Record Sales & Increased Profits
Birmingham, UK: CAD/CAM developer Delcam has achieved record sales for a six-month period and increased profits during the first half of 2011. Sales increased by 13 percent over the same period of last year to £20.1 million (US$32.7 million). This continues the rising trend in sales, with the company setting new record levels in each of the last three six-month periods. Pre-tax profits have grown significantly to £1.51 million, an increase of 87 percent over the first half of last year. The company has been able to take advantage of the continuing recovery in global manufacturing to increase both the sales of new software licences and the take-up of maintenance contracts, especially in the automotive and aerospace industries. The strongest overall sales have come from the US and Germany, with the fastest growth in sales of new software licences coming from Asia, in particular from China, South Korea, Indonesia and India. Other highlights of the opening six months of 2011 included the presentation of the company’s third Queen’s Award for Enterprise in the International Trade category and the confirmation in the latest report from US analysts CIMdata that Delcam remains the world’s leading specialist supplier of CAM software, with the largest development team in the industry. The company continues to increase its investment in research and development. This investment grew to £5.4 million in the first half of this year from £5.0 million during the equivalent period of last year. Commenting on the results, Delcam chairman Peter Miles, said: “I am pleased to announce very good first half results, with record interim revenues and an 87 percent rise in pre-tax profits. Significant investment by the group in both product development and marketing has been key to these encouraging results, and supports our long-term aim of building our global competitive edge.”
10
metalworking equipment news October 2011
www.equipment-news.com
Kennametal Moves To New Office In Singapore Singapore: Kennametal’s Asia Pacific headquarters has relocated to the International Business Park at Jurong East in Singapore. The shift in location is in line with Kennametal’s plans to expand its presence in Asia to leverage business growth opportunities and enhance its presence to better serve the growing customer base regionally. The office will be located at the newly completed ICON building at the IBP. It will also service local ASEAN customers and provide technical training and focused seminars as part of the Kennametal Knowledge Centre. “The emerging markets in Asia are growth engines for the global economy and a key focus region for Kennametal,” commented John Chang, VP and sales MD of Asia. “By aligning closer to our customers across key industries such as transportation, aerospace, energy, earthworks and general engineering, we are better positioned to serve them in the region. We believe our technology, core processes, infrastructure and talent provide us a unique position to win in this market. Furthermore, we are leveraging the full power of our enterprise to deliver the promise to our customers and help solidify our market position,” he added.
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Represented by: Sutton Tools Singapore Pte Ltd No. 1, Ubi View #03-18 Focus One Singapore 408555 Tel: +65 6745-6388 • Fax: +65 6745-5080 E mail: suttontools.sg@sutton.com.au
Engineering Innovation Co.,Ltd. 3/279 Moo 9 Suvintawong Rd. Lumpakchee Nongchok Bangkok 10530, Thailand Tel: 662-9984045; 662-5435734 • Fax: 662-9984047 E mail: enginno@truemail.co.th enginno.service@gmail.com
CBN Engineering Sdn. Bhd. No, 20 Jalan 51/205 Highway Centre, 46050, Petaling Jaya Selangor Darul Ehsan, Malaysia Tel: 60-3-77852333 • Fax: 60-3-77883318 E mail: engineering@cbn.com.my
PT. Rukun Sejahtera Teknik Komplek Ruko Glodok Jaya No. 80-81 Jl. Hayam Wuruk Jakarta 11180, Indonesia Tel: 021-628 1615 (Hunting) • Fax: 021-626 5559 E mail: marketing@abrasive-tools.com www.rsttools.com
www.hoffmann-group.com
Bon Industrial Sales 35 Macopa St., Quezon City, Philippines Tel: 781-2740; 749-3672; 740-0458 • Fax: 712-4771 E mail: bonind@skyinet.net Manila Branch: 554 Rizal Ave., Cor. Raon St. Sta. Cruz, Manila, Philippines Tel: 734-2740; 733-1532 • Fax: 733-1534; 733-1569
ENQUIRY NO 122
businessnews
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SEA & ANZ Industrial Control Valves Market To Grow
Colin Smith, Colorado Springs, United States
Singapore: The industrial control valves market in Southeast Asia and Australia and New Zealand is on course to achieving the forecast revenues of US$1.85 billion in 2017, mostly due to the sustained demand from conventional end users such as oil and gas, paper and pulp, and mining, especially in Australia. The receding effects of the economic downturn have pumped up the demand for control valves again. An analysis from Frost & Sullivan, Southeast Asia and Australia New Zealand Industrial Control Valves Market, finds that the market earned revenues of US$825.0 million in 2010. “As markets gradually limp back to normalcy, end users will be attracted to control valves’ benefits of direct savings by way of fewer valve failures, reduced downtimes,
technical support, and process improvement,” says research analyst Krishnan Ramanathan. “Newer and more advanced control valves are being introduced to cater to an expanding end-user base.” Control valve manufacturers are focusing more on safety, as nuclear energy is becoming a major source of power generation in several countries. Another area of revenue generation is industrial control valve asset management, as cost avoidance is a key focus area for companies that are still shaking off the effects of the slowdown. The recovery in the control valves market is likely to be protracted, without any spurts in growth in the next two to three years, as revenues have barely reached the pre-2008 levels. As in almost every market during the downturn, the lack of credit had resulted in lower investments in R&D. Smaller participants with sparse R&D resources were especially hard hit by the competition from larger participants. However, the market is highly fragmented despite most end users preferring to obtain all their resources from a single manufacturer. “Countries such as Singapore, Malaysia, Thailand, Australia and New Zealand are home to several multinational companies in the control valves sector and companies have started investing in newer technologies,” notes Mr Ramanathan. “While retrofits can serve as a source for control valves in developed regions such as Australia and Singapore, newer projects will serve as a driver in the developing markets of Indonesia and Thailand.”
Vietnam Increasing Power Efficiency & Reliability
Hanoi, Vietnam: GE is helping power Viet na m’s e conomic growth with custom-designed fixed series capacitor banks. The technology will improve energy reliability and efficiency for Power Transmission Company No 2 (PTC2), a key subsidiary of National Power Transmission 12
metalworking equipment news October 2011
Corporation (NPT) and state utility, Electricity of Vietnam (EVN). The systems will also increase the power transfer capability of PTC2’s current transmission lines, helping engineer better control voltages and better manage increasing energy demand. Vietnam is forecasting a 7.5
to 8 percent annual economic growth over the next five years; a healthy power infrastructure is vital to supporting that growth. To help meet that goal, GE signed a Memorandum of Understanding (MoU) with NPT in March of this year that called for both companies to work together to increase Vietnam’s power transmission efficiency and expertise, and reduce the risk of power shortages. As part of the MoU, the company was certified as an approved supplier of equipment to NPT and will establish training workshops to share its global experiences and expertise in the repair and selection of equipment for NPT’s transmission activities.
TIME IS MONEY. GET MORE OF BOTH.
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ENQUIRY NO 155
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Gildemeister Continues Growth Trend In Q2
Bielefeld, Germany: The worldwide demand for machine tools is experiencing dynamic growth. Gildemeister continued its growth trend also in the second quarter: It was possible to increase order intake, sales revenues and income according to plan. Overall, at the end of the first half year, order intake reached €971.6 million (US$1,366 million) (+49 percent) (previous year: €651.5 million). Sales revenues of €774.6 million (+46 percent) surpassed those of the comparable previous year. Profitability likewise improved significantly: EBITDA amounted to €47.6 million (previous year: €4.7 million), EBIT rose to €32.5 million (previous year: €–9.3 million). EBT amounted to €2.1 million (previous year: €–26.4 million). As of 30 June 2011, the group reports earnings after tax of €1.5 million (previous year: €–19.0 million). The group is assuming that this positive growth will continue in the second half of the year. Through the intense cooperation with Mori Seiki, the group has improved its presence in Asia and in the US sustainably. With the proceeds from the capital increases, financial obligations have reduced significantly, which will have a positive effect on business development in the future. Financial year 2011 is a transitional year. It was planned — following the economic crisis — to return to a profitable growth path. From now on, due to the good progress in the first six months, the group plans
to achieve order intake of over €1.8 billion for the whole year. Based on the high order backlog and the expected ‘EMO effect’, the group is planning to increase sales revenues to more than €1.6 billion. For the whole year the group is planning clear growth in EBIT, EBT and in the annual profit. Sales revenues in the second quarter reached €397.2 million (+40 percent on the previous year’s quarter: €284.5 million). As of the end of the first half year, sales revenues rose overall to €774.6 million and were 46 percent above the previous year’s level (€528.9 million). International sales revenues rose by 56 percent to €502.7 million; national sales revenues increased by 32 percent to €271.9 million. The export share amounted to 65 percent (previous year: 61 percent). In the second quarter, order intake rose by 51 percent to €525.7 million (previous year’s quarter: €349.2 million). In the ‘Machine Tools’ core business, the order intake increased by 60 percent to €338.2 million (previous year’s quarter: €211.5 million). In the first half year order intake amounted to €971.6 million (+49 percent); it was €320.1 million above the previous year’s period (€651.5 million). Domestic orders rose by 52 percent to €376.8 million (previous year: €247.4 million). International orders grew by 47 percent to €594.8 million (previous year: €404.1 million). International orders accounted for 61 percent of orders (previous year: 62 percent).
Siemens PLM Software Named China's #1 PLM Solution Supplier Pl a n o , U S A : S ie me n s PL M Software has been ranked as the number one PLM solution supplier in China ba sed on 2010 overall market presence, according to independent global PLM management consulting and 14
metalworking equipment news October 2011
research firm CIMdata. In addition to being named the overall market presence leader, the software was also ranked number one in the multi-discipline CAD and digital manufacturing segments. Siemens PLM Software was
also named a leading supplier of collaborative Product Definition m a n a g e m e n t (c P D m) a n d specifically in the automotive industry the software was found to have a revenue lead over its competitors.
304 Yonggye 4-ri, Gachang-myeon, Dalseong-gun, Daegu 711-864, KOREA Tel: +82-53-760-7640 Fax: +82-53-768-8055 http://www.taegutec.com Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Egypt _ Finland France _ Germany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Malaysia _ The Netherlands _ New Zealand Norway _ Pakistan _ Philippines _ Poland _ Portugal _ Romania _ Russia _ Serbia _ Singapore _ Slovakia _ Slovenia _ South Africa Spain _ Sweden _ Taiwan _ Thailand _ Turkey _ Ukraine _ United Arab Emirates _ United Kingdom _ U.S.A _ Vietnam
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Trumpf Sales Jump By 51 Percent
Nicola Leibinger-Kammüller
Ditzingen, Germany: The Trumpf Group can look back on the biggest sales increase in the history of the company as it closes out the fiscal year that ended in June. The Germanybased machine tool manufacturer and laser technology specialist recorded sales of €2.02 billion
(US$2.91 billion) in the 2010/11 fiscal year. Compared to last year’s sales of €1.340 billion, this year’s sales figure represents an increase of 51 percent. “This past fiscal year was the second most successful year in our company’s history,” said company president Nicola
Leibinger-Kammüller in presenting the preliminary figures. “We succeeded in closing the gap to the record earnings posted before the fina ncia l crisis.” In fiscal year 2007/08, Trumpf posted sales valued at €2.144 billion. Ms LeibingerKammüller explains: “In view of the fact that the worldwide fina ncia l crisis brought the German manufacturing industry to its knees, these figures are good news.” In fact, for the 2010/11 fiscal year, the compa ny’s orders received reached an all-time high in value of €2.22 billion, exceeding the €2.15 billion posted for the pre-crisis benchmark year 2007/08. This positive trend was also noticeable in terms of profits. “We are expecting profits to hit triple digits in the millions,” added Ms Leibinger-Kammüller.
South Korean & Singapore Companies To Form Partnerships Singapore: The Korea Ministry of Knowledge Economy (MKE) and International Enterprise (IE) Singapore have signed a Memorandum of Understanding (MOU) at the Korea Investment Forum. This first collaboration between both parties was signed by vice minister for Trade & Energy, Ministry of Knowledge Economy, Kim Jung-Gwan, and deputy Chief Executive Officer (CEO) of IE Singapore, Chua Taik Him. The MOU promotes close collaboration between South Korean and Singapore companies through three components: a. Joint-bidding and execution of strategic platform projects with significant economic impact to both countries; b. Regular information-sharing on growth areas in emerging markets of interest to South Korea and Singapore; and, c. Identifying and developing new industrial and growth sectors. “Korea is a leading global player in the engineering and technology sector, while Singapore a strong systems integrator and master planner. By leveraging each other’s strengths and combined capabilities, we can collectively seize opportunities in fast-growing markets. We would like Singapore based-companies to 16
metalworking equipment news October 2011
broaden their network so they have more opportunities to capture growth. This is particularly important during this period of uncertainty,” said Mr Chua. Tapping Emerging Asia’s Immense Opportunities The MOU comes at a time when global firms are increasingly stepping up their engagement with Asia for their large consumer base and growth potential. By 2050, Asia is expected to surpass the US and EU as the largest economy, and its GDP projected to exceed the Group of Seven industrial economies by 2030. By 2050, Asia’s urban population will double to 3.2 billion. Emerging countries like China, India, Indonesia, the Middle East, South America, Vietnam present immense opportunities in infrastructure development, urban solutions and more. However, with globally competitive companies vying for a slice of the same pie, Singapore-based companies need to offer more robust and complete solutions. Strategic alliances like third-country collaboration should increase the chances of success in securing big projects. South Korea and Singapore have many complementary attributes and strengths. Both countries have close bilateral ties, open economies and welcome foreign investment. By partnering together on projects overseas, the benefits of a successful partnership is mutual.
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MHI-Led Consortium To Implement Feasibility Study Tokyo, Japan: Mitsubishi Heavy Industries (MHI) has reached an agreement with the Tata Group to conduct a Feasibility Study (F/S) for the creation of an environmentally friendly smart community, which an MHI-led consortium has been promoting as part of India’s Delhi-Mumbai Industrial Corridor (DMIC) development plan. DMIC is a mega infrastructure project on a scale of US$90 billion spanning an overall length of 1,483 km between Delhi and Mumbai, India’s political and commercial capitals, respectively. The master plan calls for development of the area within a corridor that will include industrial parks, power plants, airports, ports, railways, roads and commercial facilities. As part of DMIC, a smart community proposal looks to create energyconserving, low-carbon, next-generation urban infrastructure through the introduction of multiple advanced energy-saving technologies and urban transportation systems. The scope of the F/S will be focused on a smart community platform and cover broad areas, including a smart factory, energy management system, water and waste solutions, lithium-ion battery applications for electric vehicles and an energy storage system, and a concentrated solar power system that utilises solar thermal energy for power generation. The MHI-led consortium and the Tata Group will combine their respective technologies and capabilities so as to increase the feasibility of the smart community project. The consortium will submit a report on the F/S results by March 2012.
USA: July US manufacturing technology orders totaled $506.97 million according to AMTDA, the American Machine Tool Distributors’ Association, and AMT — The Association For Manufacturing Technology. This total, as reported by companies participating in the USMTO program, was up 7.3 percent from June and up 92.7 percent when compared with the total of $263.14 million reported for July 2010. With a year-todate total of $2,975.10 million, 2011 is up 102.9 percent compared with 2010. These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTO program.
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Manufacturing Technology Orders Up 102.9 Percent From 2010
October 2011 metalworking equipment news
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Walter Multiply Service Package For Avtodizel
Tübingen, Germany: Over the next three years, Avtodizel will manufacture 45,000 modern diesel engines in a factory in the Russian city of Yaroslavl using tools made by Walter. Along with selling tools, the tool maker is providing its service package from the brand Walter Multiply, and it is accompanying the entire production process at Avtodizel. Within the project, Walter is taking over the entire task of tool provision and logistics for the Russian engine manufacturer, which belongs to the partially state-owned GAZ Group. This also includes permanent, software-supported production monitoring and, if necessary, its optimisation. In this arrangement, Walter’s services are not charged at a fixed price, but according to the number of engines produced, the so-called cost-per-part principle. “The Walter project is, in this sense, a model for other German companies, since the supplier is not merely at the service of its customer here — in this case, two partners are working together on an equal footing,” says Ernst Burgbacher, BMWi state secretary and a proponent of German-Russian economic relations at the level of medium-sized businesses. “I foresee a significant opportunity for German industry: With concepts such as Walter Multiply, we can also position Made in Germany as a seal of quality in the productionrelated service sector.” In the presentation, Mirko Merlo, board member at Walter, highlights the long-term nature of the project with Avtodizel: “The contracts are designed for the long term, and we are already planning an expansion to include other organisations. After all, Russia is one of the fastest-growing markets for us.” In addition to tool provision and logistics, Walter employees — who will be employed in Yaroslavl the entire time — will also be making an important contribution to training and increasing the knowledge of their Russian Avtodizel colleagues. 18
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MTM Metalising Embarks On Project With China Power Station Singapore: MTM Metalising will be carrying out Thermal Spray Aluminium (TSA) coating works for China Power Station in Hong Kong on a sub-contract awarded by Leighton Contractors (Asia). The procedure will involve TSA coating of three pipelines and fittings which will replace three 15-year old pipelines that form the main feed lines to three of the turbines running the generators at the power plant. Bill Jordan, GM of the company, highlighted the importance of the TSA coating: “The TSA coating is being applied onto the stainless steel pipeline to prevent stress corrosion cracking which can be prevalent on stainless steel pipelines,” he noted.
Hollysys To Provide Rail Signaling System To China Beijing, China: Hollysys Automation Technologies, a provider of automation and control technologies and applications in China, has won a contract to supply its proprietary ground-based highspeed rail signaling system to Wuhan- Xianning high-speed rail line with a designed traveling speed of 200-250 km/h, valued at approximately US$3.3 million. Wuhan- Xianning high-speed rail line runs through southern part of Hubei Province, which connects Wuhan City, one of the main transportation hubs in China, and Xianning City, a famous ecological city in south of Hubei Province. Upon its operation, it only takes about 20 minutes for passengers to travel between the two cities.
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Automotive
Siemens & Volvo Car Corp Launch Electric Mobility Partnership
Gerard79, St. Gallen, Switzerland
Munich, Germany: Siemens and Volvo Car Corp (Gothenburg, Sweden) intend to jointly advance the technical development of electric cars. The companies have agreed on an extensive strategic cooperation on that field. The focus is on the joint development of electrical drive technology, power electronics and charging technology as well as the integration of those systems into Volvo C 30 Electric cars. The first vehicles in this model fitted with Siemens electric motors will already be on the test tracks at the end of this year. Beginning in late 2012, the Swedish carmaker will be delivering a test series of up to 200 vehicles to Siemens, which will then be tested and validated under real-life conditions as part of an internal test fleet. Electric power train, battery management and charging technology are considered to be key technologies in the development and production of electric cars. As part of an energy concept for sustainable electric mobility, the company is also continuing to work on industrialising the production of hydrogen for fuel cells. The goal is to convert temporary excess energy from renewable power generation into ‘green’ hydrogen. It can then be directly used in industrial applications and fuel-cell vehicles, as well as in batterypowered electric cars by means of a prior power re-conversion process.
Peugeot Set Up Manufacturing Unit In India Paris, France: Peugeot plans to invest 4,000 crores (US$915 million) on a 600 acre site in the heart of the rapidly developing Sanand automotive cluster in Western India. The company will build a manufacturing facility integrating body pa int a nd a ssembly operations with an initial capacity of 170,000 vehicles per year with options for further expansion. Additionally, an engine and 20
metalworking equipment news October 2011
gearbox plant will help constitute a fully fledged modern industrial automotive facility. This investment will directly add up to 5,000 new jobs to the automobile hub and also create further economic and employment opportunities through a supplier park adjacent to the site to provide the company with necessary parts and services. The first locally produced Peugeot car is expected in 2014.
Cumulative Engine Production At Tianjin FAW Toyota Engine In China Reaches Two Million Mark Toyot a Cit y, Japa n: Toyota Motor Corp (TMC) announced that Tianjin FAW Toyota Engine (TFTE), an engine-manufacturing joint venture TMC established with China FAW Group Corp ( FAW ) , r e c e n t l y r e a c h e d cumulative production of two million engines. Commenting on the milestone, A k ira Sa sak i, TMC senior managing officer and regional chief officer of China, sa id: “TFTE’s cumulative production of two million engines is the result of cooperative work to produce Toyota vehicles that me et t he ne e ds of Chine se co n su m e r s. We a r e p r o u d to say that TF TE has grown hand in hand with the Chinese automobile industry and has contributed to China and its economy.” I n 19 9 6 , T M C , t h r o u g h a joint venture with Tianjin Automobile Industry (Group), e stabl i she d Tia nji n Toyota Motor Engine (TTME), its first engine production base in China. Production of ‘A’ engines began in 1998, and in 2003, a joint venture with FAW was formed, with the establishment of TFTE following in 2006. TMC will continue to meet the needs of a broad range of vehicle users in China based on its founding philosophy of contributing to society through t h e m a n u f a c t u r e o f e v e rbetter cars, while working to support the development of the Chinese automobile industry by creating jobs and developing human resources.
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Aerospace
Bombardier’s Financial Results For Q2 Montréal, Canada: Bombardier reported its financial results for the second quarter ended July 31, 2011. This is the second interim reporting period under International Financial Reporting Standards ( IFRS). Revenues increased by 17 percent to reach US$4.7 billion, compared to US$4 billion for the corresponding period last fiscal year. Earnings before financing income, financing expense and income taxes (EBIT) totalled US$296 million, versus US$249 million last fiscal year. The EBIT margin stands at 6.2 percent, the same as last fiscal year. Net income for the second quarter ended July 31, 2011
amounted to US$211 million, compared to US$138 million for the same period last fiscal year. Bombardier Aerospace Bombardier Aerospace’s revenues totalled US$2.1 billion, compared to US$1.9 billion last fiscal year. EBIT totalled US$105 million translating into an EBIT margin of five percent for the second quarter ended July 31, 2011, compared to US$101 million, or 5.2 percent, last fiscal year. Given the economic uncertainty in the US and Europe, the company expects a continued lower level of advances from customers
than initially anticipated for the current fiscal year, mainly due to the postponement of orders in the regional aircraft market. Therefore, cash flows from operating activities will be lower than the group’s net investment in capital expenditures, resulting in a free cash flow usage for the current fiscal year. A total of 56 aircraft were delivered during the second quarter ended July 31, 2011 compared to 49 for the same period last fiscal year. The company’s backlog increased by 20 percent reaching US$23 billion as at July 31, 2011, compared to US$19.2 billion as at January 31, 2011.
Business statistics
Machine Tool Orders More Than Doubled: VDW Frankfurt am Main, Germany: In the second quarter of 2011, order bookings in the German machine tool industry rose by 83 percent. Domestic order bookings increased by 72 percent and export orders by 88 percent. Overall, demand more than doubled during the first six months of 2011, 103 percent up on the preceding year’s figure. Domestic customers ordered 96 percent more than in the previous year’s equivalent period, and foreign customers 107 percent more. The order volume was even eight percent above the figure in the reference period of the record year achieved in 2008. “The continuingly buoyant level of demand has ensured a magnificent mid-year result,” confirms Gerhard Hein, head of Economics and Statistics in the VDW (German Machine Tool Builders’ Association), Frankfurt am Main. The growth rates, he added, are referenced to an already strengthened baseline from the preceding year. Best Order Backlog Level For Several Years The sustained boom in order bookings is also ensuring a high level of capacity utilisation, which most recently in July of this year was at 94.7 percent in comparison to 76.3 percent a year ago. The order backlog, at 9.7 months,
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is at its highest for several years. At some manufacturers of customised machinery, who are receiving massive orders from the very vigorously expanding automotive industry, it is even higher. “Faster deliveries are being hampered by restrictive procurement options for the components,” explains Mr Hein. The machine tool industry remains cautious when it comes to capacity upsizing, not least in view of the resurgent uncertainty generated by current financing problems in Europe and the USA. “The shock from 2008/2009 is still deeply ingrained,” says Mr Hein. On the other hand, he continues, companies also adopted a waitand-see approach to payroll downsizing during the crisis. In May of this year, there were 65,560 people working in the German machine tool industry. Since the beginning of this year, almost three percent additional personnel have been hired, corresponding to around 1,800 people. For the year’s second half, Mr Hein expects demand to be boosted by the EMO Hannover 2011. However, the growth rates in order bookings, he adds, will become significantly smaller, because an exceptionally high level of demand has already been reached. Also the increase in sales of 30 percent anticipated for 2011 is assured. Finally, during the year’s first half, sales rose by 50 percent.
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FIRST
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cut
C
ou nt le ss machining businesses face the decision ever y day: whether to take the next big step and upgrade to four or five-axis capability or not. While the transition is a major rite of passage for most growing shops, for one successful enterprise in San Diego, USA, it was never a question. “We started right out doing five-axis work,” explains Steve Grangetto. “We never considered anything else. Our company is based on the concept that we can make accurate parts more competitively with five -a xis machining than others can with more traditional techniques, whether it’s a high-pitch Inconel impeller or a simple aluminium L-bracket.” Mr Grangetto and his friend Chris Taylor co-founded 5th Axis in 2005. Today, the IS0 9001:2000and AS9100B-certified company has a list of aerospace, electronics and medical clients includes such industry icons as NASA, Raytheon, General Atomics and Amgen. Give Me A Five Both Mr Grangetto and Mr Taylor are mechanical engineers with back g rounds in automation and manufacturing, so when they bought their first machine, capability and efficiency were key requirements. “I saw my first five - a x is machine while working for a large electronics company,” recalls Mr Grangetto, “and was dazzled by its capabilities. I was equally struck by its potential to make all types of machining more efficient.” The company’s name made a bold statement in the market, and allowed the pair to immediately attract the kind of interesting work they were looking for. Besides getting the obvious work for parts that could not be made any other way, the shop’s five-axis specification allowed them to offer ‘single-mount precision’ and
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Thinking In
Five-Axes
Using a unique five-axis approach allows a machine shop to make a bold statement and grow rapidly. Contributed by Scott Rathburn, Haas Automation
Idea Corner ‘streamlined one-op production’ — even for simpler projects. “From the beginning, we stuck with our game plan,” says Mr Grangetto, “and proved our initial concept was right: Critically accurate parts can be made more efficiently with five-axis machining than with most other approaches.
Mr Grangetto says: In five-axis work, A- and B-axis movement can seriously impact Z-axis clearance. Longer tools lessen some clearance issues, but introduce problems of their own. Whenever we use longer tools, we use balanced, shrink-to-fit toolholders to reduce runout and vibration problems.
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Getting Creative In Fixturing “Fixturing may be the ultimate in problem-solving,” he continues. “If you don’t start with a good, solid fixture — in either threeor five-axis work — you’re not going to end up with a good part. More axes just add more layers of complexity,” says Mr Grangetto. “A lot of people still aren’t used to thinking in five axes when it comes to fixturing,” observes Mr Taylor. “They often design them to get a part on and off quickly, without stopping to think about clearance issues.” In five-axis work, A- and B-axis movement can seriously impact
“Critically accurate parts can be made more efficiently with five-axis machining than with most other approaches,” says Mr Grangetto.
Z-axis clearance. Careless designs invite costly crashes. Longer tools lessen some clearance issues, but introduce problems of their own. “Whenever we use longer tools, we use balanced, shrink-tofit toolholders to reduce runout and vibration problems,” Mr Grangetto explains. “We approach
our fixturing and tooling issues from an engineering standpoint, as well as a practical machining one. Generally, shorter reaches and lower momentums are best. When the process demands longer tools or more massive fixtures, we pay very close attention to how they perform.”
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Besides streamlining traditional three-axis work, we’re also getting large-quantity work for parts that were previously thought practical only as investment or die-castings.”
October 2011 metalworking equipment news
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The Numbers Game US$100,000
Less than for a complete 5-axis machine during start-up
25 To 30 Percent growth attributed to the five-axis approach.
“On-machine probing is another valuable tool,” says Mr Taylor. “Our machines are equipped with Haas probing that makes any setup easier, but when mounting irregular workpieces like castings, it’s a ‘must have.’ We make probing a part of the program, so we just load the part and hit the button. The probe accurately locates whatever feature of the casting we’ve defined as a datum, and our machining stays consistent. In these instances, we can use a simple fixture, just get the part close, and the machine does the rest.” “What we really like to do, though, is mount once, and clean up a part on all sides,” Mr Grangetto explains. “We’ll eyeball a generous-sized blank to the edge of the fixture, then machine all around it in five axes to produce the part. Coming in from all five sides with just one mounting is a big advantage. Everything is established in one operation, and we never have to worry about initial mounting accuracy.” “We’ve designed — and are offering for sale — our own line of fixtures and clamps that are made to mount directly to the Haas trunnions,” adds Mr Taylor. “They self-centre, and are installed with just a couple of bolts. They have a low-profile design to maximise clearance and part size.” “When the fixture is right at the beginning,” Mr Grangetto continues, “we can let the machine take care of most other problems.” Enquiry No. 7001 Turn to page 84a or log on to www.equipment-news.com to enquire
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metalworking equipment news October 2011
CAM To The Rescue In five-axis Today’s CAM systems, like other work, Aand B-axis ‘intelligent’ software solutions, such as movement Internet maps or GPS navigators, usually can seriously impact Z-axis get users close to where they want to go. clearance “But any software’s ‘smartness’ about our particular situation is limited,” Mr Grangetto observes. “When we increase machining complexity from three to five axes, we have to be much more aware of limitations, especially in the postprocessing from the CAM program.” The post-processor is a thirdparty software that translates, or interprets, between the CAM software and the machine. “When working in three axes,” says On-machine Mr Taylor, “there are usually one or two probing is a valuable tool ways for the machine to get from point A to point B, and it is relatively easy for the post to translate that move to the machine. When working in five axes, however, there can literally be an infinite number of solutions to get from point A to point B, which makes the job of the post much more complicated. Even a proven post will occasionally generate a move that is unexpected.” “Understanding your post is very important,” Mr Grangetto stresses. “The CAM software will do what you tell it to do, but knowing how well its instructions post over to your machine — and what you must do to ensure the code is good — is vital. It’s often the key to running parts instead of running scrap.” “When it comes to clearance issues, there’s the theoretical solution, and then there’s the real world,” Mr Taylor adds. “We use verification software to accurately proof our programs in simulation — before we run them on the machine. Even with this capability, though, we don’t completely trust them; we walk through the process directly on the machine. It’s foolish to run the program before thoroughly proofing it. Knowing your machine is the other important part of knowing your post,” he continues. “High feedrates are a real test of a machine’s ability to accelerate both the table axes and the A and B axes in perfect sync. Any hesitation or slowdown in direction change is disastrous. At the very least, it smears the part’s finish; in bad cases, sync lag can destroy the tool and the part.” Create, Not Conform “Mostly, what we bring to the table is creativity,” says Mr Taylor. “That’s one of the good things about being new: We can be creative with our approach to a problem. We start with traditional machining fundamentals and solid engineering principals, and then try to push the limits with creative new approaches and aggressive strategies.” “While a lot of shops are downsizing or shutting down altogether during this lean time,” says Mr Grangetto, “we’re on track to grow another 25 to 30 percent this year. I’d like to credit our somewhat unique five-axis approach. It seems to have opened a lot of doors for us.” MEN
Enquiry No. 7002 Turn to page 84a or log on to www.equipment-news.com to enquire
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The new benchmark for Swiss precision. k, Thailand Met alex 2011 – Bangko 16 – 19 November 2011 Hall 102, Stand J09
DKSH Technology Pte Ltd 37, Jalan Pemimpin #02-04 Singapore 577177 kelvin.low@dksh.com
DKSH Technology Co., Ltd. E-Town 2 Building 1st floor, 364 Cong Hoa Street, Ward 13 Tan Binh District, Ho Chi Minh City, Vietnam daniel.meyer@dksh.com
DKSH (Thailand) Limited 1696 New Petchburi Road, Bangkapi, Huaykhwang 10310 Bangkok thanit.s@dksh.com
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Think First, Cut Later on your investment. One customer analysed his primary part numbers and discovered that upgrading to a machine with faster feed rates and more torque would cut cycle time in half on his biggest job — from three hours to one hour and 30 minutes. Technology Solution: Software Designed To Solve Problems Beyond the machine specifications such as feed rates and torque, the control software yields the greatest opportunities to increase productivity — software features are designed to solve problems and help you be more efficient, which means you will be more profitable.
• Challenge Two: Redundancy In Posting A Five-Axis Program Each time you re-fixture, you waste valuable time re-entering the distance from part zero to the centre lines of rotation and then reposting the program. If your control has a software feature such as tool centre point management, you only have to post the program once and machine the part — no matter where it is in relation to the centre lines of rotation on the machine. The management program solves the problem for CAM s o f t w a r e to o. T h e C A M programmer generates the toolpath based on the part model’s zero location. Therefore, you can post the program independent of where the stock is fixtured on the table — a substantial time saver for a five-axis part.
• Challenge One: Multiple Part-Zero Setups For in sta nce , eve n a n uncomplicated part that is fivesided requires multiple part-zero setups. A software feature called transform part zero (see Figure 1) reduces setup time and eliminates the hassle of setting up part zero five times. The technology does the work so you can start making chips. Simply locate one part zero and you can define the remaining
• Challenge Three: Marks On The Part Simultaneous five-axis toolpaths can result in odd looping rotary moves that leave marks on the part when the program is interpolated by the machine’s control. One solution is a feature called toolpath linearisation, which is specific to five-axis, G-code programs. It eliminates the many line segments in the form of XYZBC
There are new approaches to part setup that will improve five-axis capability and make machine shops more productive. By Maggie Smith, media relations manager, Hurco Companies
S
ometimes the most i n e x p e n si v e w ay to improve productivity is to take the time to evaluate each job. Chart 1 illustrates that 24 percent of a job’s capacity is spent on fixturing. To increase efficiency, some shops try to minimise time spent on fixturing by using a row of vises and then flipping each part into the next vise. Other shops opt for the more efficient index table, but the operator is still required to handle the part to refixture it. The key to peak efficiency is finding the sweet spot — at what number of parts is the investment in a palette changing system worthwhile. More shops are investing in five-axis machining centres to manufacture parts typically machined on a three-axis machining centre. The advantage is a reduction in setup time and increased accuracy because five sides are machined with one setup. Also, evaluate whether it is more effective to machine the part from a billet versus a casting — one customer found machining from a billet not only saved time and money, but also gave his business more control over deliverables. By machining the part from a billet, the customer eliminated delays due to lead-times for the castings and saved time and money on storing the castings. Obviously, upgrading your equipment can provide even greater efficiency. The trick is to figure out how quickly you will see the return 28
metalworking equipment news October 2011
part zero locations as incremental measurements from the original location. Additionally, you can still program the geometry on each of the sides if you are programming in an XY plane.
Chart 1: Capacity chart
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Figure 1: The transform part zero software feature was designed to minimise steps.
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Figure 2: With toolpath linearisation, the tool tip and tool vector can be interpolated between tool positions with respect to the workpiece even with the tool and part rotating inside the machine.
Figure 4: With a 5-axis machining centre, the additional rotary axes will rotate about two of those three primary axes. Figure 3:Workpiece surface contact point + contact point surface normal + tool vector. XYZ = Surface contact point UVW = Surface normal at contact point IJK = Tool vector 3D tool geometry compensation.
moves that a CAM system uses to create a smooth part. With it, the tool tip and tool vector can be interpolated between tool positions with respect to the workpiece even with the tool and part rotating inside the machine (see Figure 2). • Challenge Four: Reposting To Adjust For Tool Wear On 3D Surfaces For 3D surfaces, you cut off the tool centre line to get a better surface finish. Because you have to adjust the tool diameter for wear, you are sometimes forced to repost the program. A software feature called 3D tool compensation eliminates the need to repost the part program because the control’s software compensates for the tool geometry (see Figure 3 for visual explanation). • Challenge Five: Inability To Use The Same Part Program On Machines With Differing Configurations To understand the value of the technological solution to this problem, a brief overview of five30
metalworking equipment news October 2011
A-axis equals the axis that rotates about the X-axis B-axis equals the axis that rotates about the Y-axis C-axis equals the axis that rotates about or under the Z-axis
axis machine configurations is necessary. If you think in terms of a three-axis machining centre, it has an X-axis, Y-axis, and Z-axis. With a five-axis machining centre, the additional rotary axes will rotate about two of those three primary axes (see Figure 4). The axis that rotates about the X-axis is called the A-axis and the axis that rotates about the Y-axis is called the B-axis. The axis that rotates about or under the Z-axis is called the C-axis. Therefore, a trunnion style machine is an AC configuration and a swivel-rotate machine is a BC configuration. If you have two types of configurations, you cannot use the same part program on different machines. Again, some controls have software features that solve this problem and give you flexibility. Tool vector input and universal rotary are two control features that make the part program independent of the five-axis machining centre’s configuration. For NC part programs, tool vector input allows the
part program to be machine independent. Universal rotary makes part programs machine independent for conversational programming*. With tool vector input, the machine accepts the vector code so the CAM system does not have to filter the code through a post processor. The control lets you specify the tool tip location relative to the workpiece and the tool axis vector instead of using address letters to specify the A, B and/or C axes angles. The control’s software automatically compensates for the position of the tool in part coordinates that are relative to the centre lines of rotation for the B and C axes. Therefore, the control understands where the work piece is located relative to the centre lines of rotation of the rotary axis. If you are taking advantage of five-sided machining on a five - a x is machine versus simultaneous five-axis machining, conversational programming can save time and money because you program at the control instead of using a CAM system.** The equivalent to tool vector input for conversational programs is universal rotary. The control determines the required axes motion for the desired cut. The program is independent of the machine’s configuration. You can use a part program on a trunnion style (AC configuration) five-axis machining centre or a swivel head (BC configuration). MEN Note: *Find out if your control has a similar feature, as it might be named differently. **Only a few controls with conversational programming do not require a CAM system.
Enquiry No. 7003 Turn to page 84a or log on to www.equipment-news.com to enquire
METALEX THAILAND 2011 Botth No: E17, Hall 101 October 16 - 19, 2011 Bangkok, Thailand
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Hexagon Measurement Technologies Sdn.Bhd 11 Jalan PJS 7/21 (758921-A) Bandar Sunway 46150 Petaling Jaya, Selangor, Malaysia Tel : +603 5632 8900 Fax : +603 5632 8955 contact.my@hexagonmetrology.com
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Insights
The
Green Scheme Of
Things With rising concern over climate change and dwindling fossil fuels, metalworking is moving towards green manufacturing, with the emergence of technologies that hold great promise in reducing energy and material usage. By Shahnawaz Abdul Hamid
I
n 2007, the Intergovernmental Panel on Climate Change (IPCC) released a report which made it unambiguously clear that the earth was warming up and that humans were the cause of it. Much of the blame seems to point towards manufacturing, a sector which accounts for 19 percent of the world’s greenhouse gas emissions (30 percent if one were to include electricity usage for manufacturing processes). Fortunately, it appears many of the industry’s best and brightest are turning to green technologies in their quest to mitigate the harmful effects of climate change. Principles Of Green Manufacturing The process of manufacturing can be thought of as an equation involving the combination of materials and energy to produce a 32
metalworking equipment news October 2011
Tambako The Jaguar, Switzerland
physical output. Each element of this equation leaves its own carbon footprint, which the principles of green manufacturing seek to minimise. From a materials viewpoint, green manufacturing strives to employ materials which are nontoxic and come from sustainable sources. Recycled materials are often used, helping to reduce the environmental impact of the ‘new’ product. Materials should also be durable enough to make the final product long lasting, reducing the need for wastage. Near Net Shape Manufacturing Admittedly, green manufacturing is still in its infancy. However, the technologies associated with it hold much promise, prompting governments and companies to pour funds into its research and development.
One such technology is near net shape manufacturing. In metalworking, it involves forging the metal in a die that is as geometrically close to the final product as possible. This reduces the need for further energy-consuming processes such as casting and rolling, reducing the overall carbon footprint of the manufactured part. In addition, near net shape manufacturing reduces the amount of materials used. It achieves this by injecting the exact amount of material into the mould or die, minimising excesses which would have been present in other manufacturing processes. A near net shape manufacturing method that is quickly catching on is Laser Engineered Net Shaping (LENS). This involves fabricating metal parts directly from Computer Aided Design (CAD) solid models using a metal powder directly injected into a molten pool created by a highfocus laser beam. The LENS process is unique, given that it can go from raw material to finished product without the need for secondary machining steps, such as casting and forging. This reduces the energy cost of the process. However, near net shape manufacturing still has some kinks which need to be ironed out before it can be adopted across the industry. Firstly, in some metals, the quality of the finished product may be compromised. This is usually because of tiny air particles that have been trapped inside the powdered spaces of the metal during forging. Secondly, near net shape manufacturing may involve high upfront costs. This may be the result of having to purchase metal dies and moulds used, as well as the costs involved in training the company’s employees.
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Remanufacturing Another concept with huge potential for growth is remanufacturing. This practice converts end-of-life products into ‘new’ ones that are equal in performance and expected lifespan to original new products. The remanufacturing process consists of several stages. First, the product is completely disassembled. Next, every component is thoroughly cleaned, often removing years of dirt and grime. Worn components
are either replaced or reworked. Finally, the product is assembled and put through a series of tests to deem its usability. Remanufacturing is gaining traction in the transportation i n d u s t r y, w i t h t r a n s p o r t operators preferring to remanufacture certain types of vehicles, instead of scrapping them entirely. Dr Song Bin, Director of the Sustainable Manufacturing Centre (SMC) of the Singapore Institute of M a n u f a c t u r i n g Te c h n o l o g y (SIMTECH) had this to say about the benefits of remanufacturing i n e a s i n g t h e p ro b l e m s o f climate change, “Compared with manufacturing a new product, the remanufactured product reduces 60 to 90 percent of energy, materials, water and air pollutants while retaining more than 80 percent of value. This makes remanufacturing a green and high value-add industry with enormous growth potential.” However, he cautions that some “components of end-oflife products have experienced v a r i e d s t re s s e s a n d o t h e r damages under individually different conditions.” He therefore feels it is “crucial” to be able to gauge the remaining lifespan of components before they are used in remanufacturing. Also, there are times when parts may not be salvaged, despite the most earnest of efforts. Green Manufacturing’s Future Dr Song Bin is part of a growing group of researchers concerned with the impact of manufacturing on the environment. Organisations like the SMC develop and implement innovative technologies that minimise emissions, wastes and toxicity in manufacturing while keeping the industry competitive. MEN Enquiry No. 7101 Turn to page 84a or log on to www.equipment-news.com to enquire
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Additive Manufacturing Another technology that has been associated with sustainable design is Additive Manufacturing (AM). This is the consolidation of two or more parts into a single design, reducing scraps and other energy-intensive materials. Like near net shape manufacturing, there are potential savings in AM from the absence of machining methods such as milling and turning. Furthermore, in conventional machining, metal is smelted to form ingots, which then become billets. Billets are machined to produce the final part. The energy required to manufacture these ingots and billets is saved in AM. Some AM techniques that are used include laser processing, electron beam melting and 3D printing. Never theless, AM technology still has several issues that require attention b e f o re i t c a n b e m a r k e t e d widely. For example, multimaterial flexibilities need to be developed. Also, the capability for large-volume production needs to be realised although currently, niche production of direct parts for the automotive, dental and medical industries does take place. Such production does not have to produce parts in batches, hence is well suited to the current breed of AM.
October 2011 metalworking equipment news
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Volvo Trucks
Giving An Old Truck A
New Lease Of Life
Making sure a material lives on and nothing else going to waste have both economic and environmental benefits. Contributed by Per Nilsson, Volvo 34
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A
truck straight off the factory assembly line may not be quite as new as it seems. One-third of the vehicle’s total weight consists of recycled metals. At least this is the case with Volvo Trucks. The Swedish manufacturer’s production system embraces the recycling of old trucks, whereby old becomes new in a sustainable process that benefits both economy and ecology. The gate slides up slowly and a 2002 Volvo FH 460 Euro 3 rolls into the workshop. The truck has covered about 1,000,000 km and its active days are now over. Here at the Volvo Truck Centre just outside Göteborg, Sweden, trucks like this are dismantled down to their last nuts and bolts and their materials recycled. “The biggest advantage of t h i s a p p ro a c h , f ro m b o t h environmental and personal perspectives, is that the materials live on,” says sales representative Mikael Olofsson as he surveys the workshop and the truck that is about to be stripped down to its smallest components. The newly arrived truck will continue to be useful. Its best parts will be sold on the used vehicle market. All materials removed from the truck that cannot be sold will be put into containers marked separately for iron, aluminium, brass, copper, plastic, combustible and so on. All parts that are too worn out will be sent away for melting or incineration, to be re-used in the form of new products or district heating. Nothing goes to the landfill. Doing Its Bit For The Environment Volvo Trucks works hard to reduce the company’s environmental footprint, and has applied a recycling strategy since the mid-1990s. “We have to consider the environment, our resources and future generations,” says Volvo Trucks’ environmental affairs director
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melted down are more suitable than plastics that are incinerated, while for other purposes the opposite applies,” explains Mr Mårtensson.
Lars Mårtensson. “What is more, there are sound financial reasons for the customer to recycle the truck. We try to aid that process as much as possible, for instance by providing detailed instructions with each truck on how it is to be recycled.” Every truck is designed and built at the factory to take account of what will happen on the day the truck is withdrawn from service. “We tailor the technology needed for subsequent dismantling and recycling into the design and production of new trucks. For example, we use plastic rather than metal clips to attach wires and hoses, since metal clips take far longer to remove,” explains Mr Mårtenssson. The materials used are also carefully selected. “The challenge is to balance usage demands against recycling properties. For some purposes, plastics that can be
As Good As New In terms of weight, roughly 50 percent of the wrought iron used in a new truck comes from recycled metal, while 97 percent of the cast iron is recycled metal. Since it takes less energy to manufacture products from recycled material than from new raw materials, the environmental gains are considerable. Moreover, recycling also has financial advantages. If, for instance, there is a shortage of certain metals and prices rise, recycling becomes even more important. At present, just over 90 percent of a scrapped Volvo truck is recycled. When a Volvo FH is scrapped, more than nine tonnes of various materials are recovered for recycling.
The newly arrived Volvo FH is carefully inspected by Kenneth Olsson and Jimmy Gustavsson in the dismantling workshop. “We’re primarily looking for oil leakage, but we also look for other easily identifiable faults.” All dents and rusty panels are marked with a large yellow arrow and the truck’s ID number before the dismantled parts are placed in a container that is also marked with the vehicle’s ID number. Every single part that can be sold must be traceable back to the exact truck model, year of manufacture and production series. Simply speaking, the trucks are dismantled from the front to the rear. Mr Olsson and Mr Gustavsson get to work immediately. To take this particular truck apart, they have to struggle with the bolts because rust is holding them securely together. The bolts usually need to be heated with a welding torch to get them to
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work loose. It takes the team six to seven days to dismantle a truck and clean all the parts that are to be sold on. In all, the workshop takes in about 30 to 40 trucks a year. The cab of the truck is judged to be in good condition. It will be cleaned up and resold. Cabs older than 10 years, however, are seldom saved. Instead, they are melted down to make new metal components. Everything on and around the cab is first removed. Mr Olsson attaches a hose to the small refrigerant reservoir and transfers the gas to a cylinder that is carefully weighed to verify that the reservoir has not leaked. “Draining off the refrigerant is perhaps the most important part of the whole dismantling operation, because it is so environmentally hazardous. Here we can see that 880 grams of refrigerant remains, which is OK considering the truck’s age,” he explains. The toxic-green glycol and engine oil drain off into two containers placed below the vehicle. All environmentally hazardous fluids are poured into sealed tanks that are put in the yard outside and will later be sent for destruction. After the cab has been lifted off using a roof-mounted traversing crane, all its interior fittings are removed. Seats, steering wheel, wall and roof panelling and all electronic components are removed and sold individually, if they are in good enough condition. The rest is recycled. After the cab, it is time for the gearbox to be removed, followed by the truck’s 12-litre engine. “We often send gearboxes and rear axles for renovation, but engines are often regarded as too expensive to rebuild. Instead, we clean them thoroughly. They look good, we’re really proud of them,” says Mr Olsson. Enquiry No. 7102 Turn to page 84a or log on to www.equipment-news.com to enquire
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metalworking equipment news October 2011
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Volvo Trucks
Every Volvo truck is designed from the ground up to take account of what will happen on the day the truck is withdrawn from service.
Jimmy Gustavsson (left) and Kenneth Olsson (right), guide the cab to ensure it does not strike against and damage the radiator and engine.
Volvo Trucks
Facts On Environmental Benefits According to Volvo Trucks’ environmental product declaration calculator, a recycled truck reduces carbon dioxide emissions by just over four tonnes. This is because it takes less energy to manufacture new products from recycled materials than from entirely new raw materials. If a Euro 3 truck were replaced by a Euro 5 truck that consumes almost eight percent less fuel, particulate emissions would also be cut by 80 percent. Moreover, the more modern truck would also release 86 tonnes less carbon dioxide during its lifetime than its older counterpart. This corresponds to more than 20 return air trips between Stockholm in Sweden and Bangkok. A trip of this kind is calculated to produce emissions corresponding to four tonnes of carbon dioxide equivalent. A carbon dioxide equivalent is a measurement of greenhouse gas emissions. This measurement takes account of the fact that different greenhouse gases have different greenhouse impacts, and specifies how much carbon dioxide can be emitted to produce the same climate impact as all the other greenhouse gases put together during the course of a given journey.
Enquiry No. 7103 Turn to page 84a or log on to www.equipment-news.com to enquire
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SUMITOMO ELECTRIC HARDMETAL ASIA PACIFIC PTE LTD ENQUIRY NO 069
software&
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Metrology
Metrology:
Contact Or Non-Contact
?
Augustine Quek investigates what are making waves in the tactile measurement arena and also looks across the fence where non-contact measurements are finding themselves in more applications.
T
he art and science of measurement has been part of humanity since p r e - h i s t o r y. To d a y, measurements have become indispensable in many facets of life, especially in the advancement of knowledge and industrial manufacturing processes. Product quality necessitates knowledge of products’ dimensions, a n d m e e t i n g c u s to m e r s’ specifications is paramount to profitability. Once machined, each workpiece exhibits varying degrees of deviation from the geometrically ideal form. Even the slightest deviation from the reference form can significantly affect a component’s functionality. Process variation is the enemy of competitiveness and profitability. It causes waste and inefficiency, leads to high quality costs and manning levels, and results in late deliveries and poor traceability. Therefore, measurements in manufacturing processes are necessary, including pre-, postproduction inspections and in-line monitoring. It provides information on the quality of the finished components and enables conclusions to be drawn on the quality of the overall production process, thereby helping to reduce costs. Contact Measurement Contact measurements usually 38
metalworking equipment news October 2011
use tactile touch probes to cover surface geometries. Most touch probes incorporate the same ba sic mecha nica l functions regardless of style. The touch probe system includes some form of spring-loaded device to sense contact, a hard-wired or wireless system for feedback to the CNC control, compensation for overshoot, calibration and recording of position, usually on a software program. During measurement, the stylus of the probe will be deflected upon contact with a measurement point. The contact switch internal to the probe will be turned on and activates a signal that is sent to the CNC control, commanding that axis motion be halted. Making Good Contact The main advantage of contact measurement methods is its speed. Contact measurement methods are best suited for measuring large sample sizes associated with production and receiving inspection. Another advantage is that it allows evaluation of optically hidden surfaces and parts such as water jackets, cooling holes, deep
pockets and cylinders. Non-contact full-field measurements may not pick up as much details as pointbased touch probes. C o n t a c t p ro b e s u su a l l y measures position and roughness form. In roughness measurement, the stylus moves across the profile of a part at a constant speed. The result of the measurement is based on the vertical displacement of the stylus and recorded by a distance measurement system. When a surface is described using such a tracing system, standardised roughness parameters are usually obtained from the measurement profile. Similarly, form and position deviation on all components plays an important role, especially for the smooth interaction of several workpieces with common functions. The ruby ball or diamond tip is used depending on the measuring task concerned. In either case, the scanning system automatically sets the correct probe force. Movement Aided For example, the Renscan5 by Renishaw uses an articulating head that moves in two rotary axes as it measures. This system allows the CMM to move at constant velocity in a single vector while measuring. As the head is much lighter and more dynamic than the CMM, it is able to quickly follow changes in the part geometry without introducing dynamic errors, which results in faster surface speeds and shorter measurement cycles. The maker claims that the fiveaxis scanning technology can provide 900 percent throughput improvement. For exa mple, scanning two head gasket faces and
Lapses in quality can lead to serious performance and safety impairments, especially in the automotive and aerospace industry
Robbie Sproule, Montreal, Canada
software&metrology
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Non-Contact Automated, non-contact videoba se d me a su r i n g not on ly allows multiple edge-to-edge measurements to be made on large numbers of simple pressed metals components, but also the position, diameter, depth and profile of apertures on lower volume, complex work pieces produced as a result of a number of drilling and machining processes.
Key Techniques For QC Of Metal Products • Stereomicroscopy • Non-Contact Z-Height Measurement • Non-Contact Video Measuring Systems • Twin-Ring LED Illumination • Through-The-Lens Laser Autofocusing • Laser Scanning • Automated Edge Detection
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Combining Measurements Many different surface measurements can be integrated. The simultaneous measurement o f rou g h ne s s a nd contou r characteristics on curved or inclined surfaces for example, can be performed via an optomechanical measuring system. The mechanical measurements are transferred onto an optical gauge, combining the benefits of contact measurement with the efficiency of optical metrology. For instance, the nanoscan 855 combines roughness and contour measurements all in one complete measuring pass. A product from the Industrial Metrology Division of the Jenoptik Group, HommelEtamic, it uses an opto-mechanical me a su r i n g s y ste m . Tac t i le workpiece scanning is transmitted to an optical scale by a mechanical pick-up, which is then interpreted by a laser interferometer. The probe arms are detected electronically and automatically assigned to each measuring task. This eliminates measuring errors due to incorrect probe arms. Its electronic stylus tip protection device uses an electronic speed limiter to prevent abrupt contact with the workpiece. Probe force can be electronically adjusted, depending on the stylus tip, to avoid measuring errors or stylus tip damage.
With the correct microscope illumination a nd automated edge detection, video-measuring systems can also compensate for burrs left as a result of the manufacturing process. G e n e r a l l y, n o n - c o n t a c t measurement is much slower than contact measurements. Noncontact measurement is best suited for measuring small sample sizes
©
five sections for all eight cylinder bores typically takes 50 to 55 minutes. The system can complete the job in five minutes.
October 2011 metalworking equipment news
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software&Metrology
Scanning Works New innovations in 3D scanning technolog y and point cloud processing software have made the non-contact 3D laser scanner capable of being an entirely digital inspection process. A 3D laser scanner essentially projects a laser stripe on a specimen while its built-in digital camera captures the projected laser line under a fixed angle. As they reconcile high point cloud density with scanning speed, they digitise freeform surfaces and geometric features at high speed. Line scanners with a smaller field of view suit detailed inspection of smaller parts by offering measurement accuracy down to five micron. To scan surfaces with varying colour or high reflectivity, digital la ser sca nners adapt la ser source intensity point-per-point. This capability can deal with different sample materials and surface finishes without operator interaction or powder spraying and is also effective for shiny surfaces and abrupt transitions under any lighting condition. 3D laser line scanning and point cloud processing drive a digital inspection process that improves CMM productivity while accelerating design-throughmanufacturing by providing full geometry feedback. Quality control is paramount not only in the metal manufacturing industry, but in almost all production processes. Lapses in quality can lead to serious performance and safety impairments, especially in the automotive and aerospace industry. Quality control measures range 40
metalworking equipment news October 2011
from ensuring key dimensions are within tight specifications to other criteria such as checking surface finish and grain/crystal size, which can be vitally important since they can have a dramatic effect on quality and performance.
It is in t his re ga rd t hat measurements, both contact and non-contact, play an increasingly important role in industry. Enquiry No. 7201 Turn to page 84a or log on to www.equipment-news.com to enquire
A Touch Too Many? Obey Newton’s Law One particular disadvantage of touching metal surfaces is that there would be an equal and opposite reaction, according to Newton’s third law. When sheet metal springs back, this can affect the entire shape of parts and not just a few geometric features. Even for a limited number of measurement points, CMMs require considerable programming overhead. In addition, tactile measurement falls short on soft and fragile parts. To a certain extent, three- and five-axis tactile scanning overcomes the limitations of discrete touch trigger measurements. High-speed bridge CMMs equipped with this touch sensor speed up dimensional inspection on prismatic driveline parts. Also on the aerofoil surface of a turbine blade and other freeform surfaces, five-axis analog scanning is an improvement compared to traditional tactile inspection.
Enquiry No. 7202 Turn to page 84a or log on to www.equipment-news.com to enquire
Taking A Closer Look… The size of grains and/or crystals of a metal can be vitally important since they can have a dramatic effect on quality and performance. Tensile strength of metals is inversely proportional to grain or crystal size. As such, controlling and checking that the correct size during the manufacturing process is crucial in the manufacture of components such as bearings and The size of grains can have serious crankshafts. Imperfections within the bearing on material quality and crystalline structure will determine performance how it performs when loaded, making techniques to detect them a key aspect of quality control. One such technique is episcopic microscopy, and in particular polarising techniques. Polarised light microscopy exploits the properties of polarised light to identify and characterise the structure and properties of materials. Changes in the brightness and/or colour of the incident light can be observed when anisotropic materials are rotated. This is in contrast to isotropic materials, such as unstressed glasses and cubic crystals, which demonstrate the same optical properties in all directions. This measuring principle plays a key role in measuring grain size and spot imperfections at the interface between adjacent grains. Manual micorscopy provides a mean to assess prototypes, check the performance of CNC drilling systems and perform lower volume quality control checks. Non-contact, z-height measurement can also be a useful asset on manual measuring microscopes used for lower volume quality control work. MEN
Anthony D’Onofrio, William H Fowle, Eric J Stewart and Kim Lewis, Lewis Lab, Northeastern University
associated with mould approval, problem-solving, and referee measurements. However, digitising pa r ts up - front a nd running inspection on the digital copies of the samples streamlines metrology operations and embeds them into the CAD-centric design-throughmanufacturing process.
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Enquiry No. 7203 Turn to page 84a or log on to www.equipment-news.com to enquire
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software&Metrology
Creative Tools, Halmstad, Sweden
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Stricter quality control measures have increased expectations on measurement processes. This has given rise to new, non-contact modes of measurement. However, it is still too early to say if this would spell the end of touch measurement. By Shahnawaz Abdul Hamid
E
ver y ma nu fac tu r ing related industry from oil and gas to aerospace uses measurement tools to determine how close a manufactured part is when compared to its initial design. Too large a deviation between the actual and ideal parameter can result in systemic errors further down the supply chain. In recent times, these components and their accompanying systems have grown increasingly complex, while measurement standards have at times fallen behind. This sometimes results in manufacturers having to recall huge batches of ‘possibly defective’ products, as we have seen the past few years, particularly in the automotive sector. Metrology Nevertheless, new technologies in the measurement industry, broadly termed as metrology, have improved the capabilities of manufacturers to gather relevant data from the outputs of their production line, sending feedback
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metalworking equipment news October 2011
into the system to tweak its characteristics. The International Bureau of Weights and Measures defines it as ‘the science of measurement, embracing both experimental and theoretical determinations at any level of uncertainty in any field of science and technology.’ Essentially, metrology is a pervasive and broad field, with its over-riding objective the credibility and functionality of measureable components, big or small. Anything from the length of a high-speed bullet train to the thickness of a coating on a piece of metal can be subjected to measurement. In the field of metalworking, quality control processes are mostly concerned with measurement of an object’s external dimensions, such as its length, breadth and width. The choice of measuring device to be used is dependent on the resolution and range of desired measurement. Often, to achieve a precise and accurate reading, a CMM is used. It is a computer-controlled digitiser of three-dimensional geometric data. It is able to observe and interpret
the contours of an object placed on a flat table, which forms part of the machine. Two Categories Of Measurement Generally, a touch probe is used to record the data of the specimen being measured on the CMM. This probe would typically be attached to an arm that is able to travel the length of the table. Smaller specimens may require smaller arms while large specimens may involve wireless probes. CMMs can be customised to meet the measurement needs of the manufacturer. However, in recent years, me a su re me nt may a l so b e achieved through non-contact methods, which can be broadly defined as any method which does not involve touching the surface of the specimen being measured. These non- contact methods are usually more appealing to manufacturers, given that they do not damage the surface being measured and do not lead to probe wear and bounce. Nevertheless, contact methods are still retaining their share of fans. A recent survey on APMEN’s Facebook page indicated that some 67 percent of people prefer contact to non-contact methods of measurement. This could be due to two reasons. One, contact methods of measurement can be used in a multitude of situations where features to be measured may not be captured by the non-contact method. Two, when measuring glass or other transparent materials, using non-contact methods is usually unreliable. Evolution Of Touch Probes Given the complexities involved in measurement, touch probes used in contact measurement have had to constantly evolve. In this regard, a technology that needs highlighting is the touchtrigger probe.
The touch-trigger probe is a sensitive device that generates an electronic signal each time the probe comes in contact with a point on the specimen the CMM is measuring, recording the dimension of interest. It allows the CMM to work without the presence of an operator. Also, touch-trigger probes are highly flexible and can be used to measure just about anything, from the very small to the very large. Given this, touch-trigger probes are the most common in the CMM industry. There are two key touchtrigger probe technologies that are of interest to manufacturers: kinematic resistive probes and strain gauge probes. The former incorporates a spring-loaded kinematic mounting arrangement of rods and balls to position the stylus holder, providing repeatability while the latter uses a series of strain gauges to measure contact force on the stylus, generating a signal. Analog scanning probes are another type of contact probe used in measurement. They are typically found in factories where sheet metal assemblies are performed, allowing the probe to remain in contact with the specimen being measured as it moves. These probes produce continuous a nalog readings instead of point-by-point digital one s a nd a re considered a relatively new technology. Such scanning allows the u se r to acqu i re more dat a compared to the traditional touch probe a nd is used in applications such as the surfacemapping of complex shapes: engine blades, cra nk sha fts, cams, and the chassis of an automobile. Scanning software are equipped with filtering ability to distinguish between subtle changes in surface direction and variability in the surface finish, such as on a rough area of a turbine blade.
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A recent survey on APMEN’s Facebook page indicated that some 67 percent of people prefer contact to non-contact methods of measurement.
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October 2011 metalworking equipment news
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software&Metrology
Non-Contact Mode Non- contact modes of measurement involve the use of any device that does not touch the specimen being measured. This helps prevent damages to both the specimen being measured and the probe itself, from pressure applied by probe and the possible knocks the prob e su f fers re sp e ct ively. O ve ra l l, u si n g non - contac t modes help in reducing the cost of having to maintain the CMM or rework the dented component. However, non-contact modes are not the be-all, end-all of measurement. As mentioned ea rlier, non - contact probe s may not easily capture certain features on a specimen such as crevices and edges. Also, materials that are transparent or shiny may be difficult to measure using non-contact methods. What are some non-contact methods ava ilable in the industry today? In triangulation, laser light emitted from a sensor is shone onto the surface of the specimen. The reflected laser is then passed through an imaging lens and the subsequent image is formed on a detector. As the laser traces the surface it is measuring, its projected image on the detector changes location, re f le c t i n g t he d i me n sio na l characteristics of the surface. Vision probe s constitute another form of non- contact measurement. They are useful where high-speed measurement is needed, particularly microscopic dimensions on small, two-dimensional parts. T he v ision probe work s by utilising a camera to capture a pic tu re of t he sp e cimen. This picture is then scanned, extracting the dimensions of the specimen. Which To Use? Users may a sk , g iven the multitude of options available 44
metalworking equipment news October 2011
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Where components have grown increasingly complex, so too have measurement systems
NASA Goddard Space Flight Center
Non-contact methods of measurement, such as laser, may be seen as more appealing to manufacturers
Adelphi Lab Center
when it comes to measuring dimensions on a specimen, which option is best? Will noncontact methods spell the end for touch probes? Unfor tunately, que stions like these illustrate a lack of appreciation for the complex range of specimens that require me a su rement. Me a su r ing a component with deep crevices that are not immediately obvious may be impossible with noncontact probes, while measuring a specimen that is constantly being moved via a conveyor belt may require a n a na log
scanning probe. For a surface with microscopic features, a vision or laser probe may be more suitable. U lt imately, whet her one belongs to the contact or noncontact mode of measurement camp, many will agree that CMMs will need to constantly keep up with expectations from the metalworking industry. Anything less than perfection during the measurement process can result in more lapses in quality in future. MEN Enquiry No. 7204 Turn to page 84a or log on to www.equipment-news.com to enquire
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Techno Machinery (S) Pte Ltd No. 23 Kaki Bukit Industrial Terrace Singapore 416103 Tel: +65 6417 9973 Fax: +65 6745 9166 Email: sales@techno.com.sg
BME Industries (M) Sdn. Bhd. D-G-2 & D-1-2, Persiaran Relau Sungai Ara, 11900 Bayan Lepas Penang, Malaysia Tel: +604 640 8686 Fax: +604 640 8688 Email: bme@henko.com ENQUIRY NO 160
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Combining Different Metrology Systems
The multi-sensor head incorporates LED illumination, shape from focus, laser autofocus and zoom, and touch probe
Contact and non-contact multi-sensor 3D metrology realise faster investigation and serial inspection by capturing fullpart geometry with a single system. By Venjamin Chan, senior sales and marketing manager, Nikon Singapore
A
s components get smaller a nd more comple x , a nd the dema nd for high precision rises, manufacturing companies are challenged to produce highquality products in a shorter time. Relying solely on tactile inspection requires excess overhead in terms of measurement preparation and execution, and it covers only a small portion of the entire part surface. This makes it necessary to use other metrology systems to gather additional geometry information. However, it is not exactly the ideal recipe for errorfree data consolidation and fast, automated inspection. Instead of getting partial inspection results from different metrology systems, one company combines multiple non-contact 3D technologies in a single inspection system. An example of such
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metalworking equipment news October 2011
system is the HN-6060 by Nikon Metrology. Equipped with a laser scanner measurement head, the system digitises components at a rate of 120,000 points per second. To access the complex geometry of a spiral bevel gear or any other sophisticated part, the five-axis CMM can position the head and tilt and turn the specimen exactly as desired. Furthermore, the multi-sensor head incorporates proven optical image processing with built-in LED illumination, Shape From Focus (SFF), laser autofocus and zoom, and tactile probing. Video Measuring To complement 3D laser scanning, certain system also feature high numerical aperture zoom optical system, a CNC video measuring system. Advanced edge detection by image processing increases
measuring speed and confidence. In addition, the HN-6060 is equipped with the Shape From Focus (SFF) inspection sensor. Using an active texture pattern projection mechanism, the system can perform high-precision shape acquisition for surfaces that are devoid of texture, such as the surface of a mirror, while TTL laser AF enables level difference and profile measurement. Synchronised Motion Control The full potential of non-contact 3D inspection is reached by having a two-axis rotary stage present the part for inspection. The unit can apply the optimum rotation and tilt angles to scan around ribs and flanges, and to fully capture pockets, slots and notches. Important in this regard is the concurrent movement of the measuring head, which is optimised by an orthogonal drive system. A system console provides control over full five-axis synchronised head and specimen motion. It features a straightforward configuration that includes switches for changing between sensors and buttons for carrying out simple inspection. The adoption of five-axis synchronised hardware control is particularly useful for spur, helical, spiral, and other gears. MEN Enquiry No. 7205 Turn to page 84a or log on to www.equipment-news.com to enquire
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Waterjet Cutting & Nothing Else After discovering waterjet cutting, an Austrian company concentrates solely on the technology and on mastering the entire process. By Volker Albrecht, for Bystronic.
P
recision and reliability were decisive criteria in choosing which particular machine to buy. This is more pertinent for a new company. Johann Feichter, coowner of Cecon Fertigungstechnik consciously decided on a waterjet cutting machine, Byjet 4022, with a large cutting area for his company. On it, sheets of raw material of up to 4,000 by 2,250 mm can be processed using two cutting heads. And since, as newcomers, they wanted to be outfitted as broadly as possible in order to
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be prepared for all enquiries. The system was additionally equipped with a rotary axis for processing tubes and profiles, as well as a CNC-controlled drill spindle. The latter is a useful addition particularly with fibre composite and laminated materials, where it can be used to avoid delaminating, ie: the separation of the individual layers, during piercing. According to Mr Feichter, the beginning was very difficult but subsequently, Cecon grew steadily. Today, the business has a developed customer base. The
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original plan to offer other forms of cutting at a later date has been dropped because the demand for current services is good. Furthermore, the know-how gained over the years is an asset that should be fully exploited, since waterjet cutting is more complex than other cutting processes, not least because of the wide range of materials. Every material behaves slightly differently under the waterjet, and so the corresponding practical experience must first be acquired over a period of time. Almost Unlimited Possibilities Mr Feichter is always surprised to find that the possibilities and the limits of waterjet cutting are still little known, even among experienced factory foremen. A s s u c h , h e s t i l l re c e i v e s enquiries for parts that are typically produced by laser cutting, where the hardening of the outer surface presents no problem and which could be cut far more economically using a laser. “Waterjet cutting is, however, absolutely ideal when thermal neutrality is called for,” he explains. On the other hand, many factories are not aware that they can save a great deal of time and money by using waterjet cutting to replace or to complement mechanical cutting processes such as milling. The situation is similar with expensive wire eroding, which is often used even though the level of precision that this method offers is really not required. In this area, the future will certainly see a number of changes, he believes. Waterjet cutting is a cold, erosive cutting process using a compressed jet of water at 3,800 bars. Depending on the hardness of the material to be cut, cutting involves a pure jet of water, for example with foam rubber or plastics, or a mixture 50
metalworking equipment news October 2011
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Johann Feichter on Waterjet Cutting…
“It’s not always a simple process, but a very interesting one”
of abrasive material and water. The jet with a thickness of 0.8 to 1 mm hits the surface of the workpiece at around 300 m/s. Nevertheless, the reactive forces in the workpiece are so small that in many cases, it is unnecessary to clamp the workpiece. Accordingly, the edges remain undistorted and thermally unaffected. The machine covers a spectrum of what is possible. They include parts of thick and high-tensile steel for the machine industry, stainless steel, aluminium, and copper parts, parts of hard lightweight construction materials such as titanium alloy, foam rubber sheets, and natural rubber parts, which are cut at up to 25 layers one on top of the other. Other processed parts are cut from foam and insulation materials, cardboard, carbon fibre reinforced plastic, composite materials, and stone. Especially with soft materials, which are pressed together by the clamps with cropping or punching, the force-free cutting power of the waterjet increases the cutting accuracy. For very hard and brittle materials such as carbon fibre reinforced plastic, glass, or plastic, which can easily break off on the cutting edge, waterjet cutting is often the only option. Second Machine With complex orders that other job shops were forced to refuse, a part of the task is to work out the solution using trial cuts and
to involve the customer in this process. “In some 90 percent of the cases, we find a solution,” says Mr Feichter. And these special orders often turn into series production orders and long-term business relationships. However, what is good for the reputation and can later generate a profit can also block orders that are today already financially lucrative. For this reason alone, the thought of buying a second system has been under consideration for some time. “An additional system that allows us to carry out trial jobs or the cutting of individual parts in parallel to existing orders simply makes us more flexible,” says Helga Feichter-Leitinger, who is responsible for the commercial aspects at Cecon. This is especially true since job orders with tight delivery schedules are steadily on the increase. In this situation, the ByJet Classic 3015 was acquired. The machine uses the same components as the Byjet 4022. The two cutting heads are the same, the high-pressure pump is the same, and the control package is essentially the same, but newer and faster than the previous model. Only the frame is somewhat different, since the bridge with the two cutting heads is arranged at right angles to the basin and the working table can accommodate raw material sheets of up to 3,000 by 1,500 mm. MEN Enquiry No. 7301 Turn to page 84a or log on to www.equipment-news.com to enquire
look closer
Do you think all measuring systems are identical? That is not true. Look closer at SmartScope® dimensional measuring systems from Optical Gaging Products (OGP®), and you will see the difference. OGP® is the world leader in video and multisensory metrology, and our machines can measure a variety of parts with optical, laser, touch probe, and micro-sensor technology. With tens of thousands of OGP systems installed in more than 65 countries, manufacturers everywhere rely in OGP systems and trust us for expert advice and service, for innovation, for productivity, and for reliability. See for yourself how OGP® can help you solve your measurement challenges. Our new range of products include 3D Laser Scanners and X-Ray Scanners.
Optical Gaging (S) Pte Ltd www.smartscope.com.sg
21 Tannery Road, Singapore 347733 Tel: (65) 6741 8880 Fax: (65) 6741 8998
Email: sales_epl@smartscope.com.sg
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Special Feature:
Auto Parts
Manufacturing
Asia Pacific Metalworking Equipment News brings you the expert opinions of four individuals involved in the auto parts manufacturing business.
Peter Dickin Marketing Manager Delcam
What is your assessment of the automotive industry and how does it affect your industry? Where are the likely hot spots for further growth?
The automotive industry and its supply chain remains the largest market for Delcam’s CAD/CAM software. The fastest growth is in China, India and the other Asian countries. However, we are also seeing a good recovery in more established markets, like the USA and Europe.
Do you have any plans to further expand into or explore the auto part making industry? What are the challenges from the business and technology point of view?
Despite the recovery in the industry, there is still a lack of confidence, which is limiting investment. Companies know that they need to improve their productivity and that newer equipment and more powerful CAD/CAM software will achieve this. At Delcam, we need to reassure customers that they will achieve a rapid return on their investments by becoming more efficient and winning more business.
In your opinion, name one product you can identify most with the auto part making industry and why.
All of Delcam’s software is used by the auto part industry. Currently, there is most interest in our PowerMill CAM software, as more companies invest in five-axis machine tools and so need a more powerful CAM system to program these machines. Enquiry No. 7401 Turn to page 84a or log on to www.equipment-news.com to enquire
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Thomas Vetsch Regional Sales Manager (Asia Pacific) Trumpf
What is your assessment of the automotive industry and how does it affect your industry? Where are the likely hot spots for further growth?
The automotive industry is currently in a very good position. This industry is very global with production sites around the world. As a technology supplier we benefit from that as well and we have to follow the global movements to be locally present. Next hot spots in Asia will be after China and India countries like Indonesia, Malaysia and Vietnam.
Do you have any plans to further expand into or explore the auto part making industry? What are the challenges from the business and technology point of view?
As the OEM’s are regionalising their production, suppliers will have to do the same. Car factories are highly automated and down time cannot be accepted even in low cost production. The challenge is, to find locally and skilled manpower to keep such production sites running. Logistic, import-export and other local circumstances have to be considered to be successful.
In your opinion, name one product you can identify most with the auto part making industry and why.
Car body, because everything else is attached to it and it gives the shape of car, the identification. Enquiry No. 7402 Turn to page 84a or log on to www.equipment-news.com to enquire
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Gidi Drori Business Development Manager Iscar
What is your assessment of the automotive industry and how does it affect your industry? Where are the likely hot spots for further growth?
The automotive industry is going to sustain steady growth, due to the increasing demand in China and India, as well as other parts of the world. The global size of this industry, together with the fact that this industry is turning a high volume of metal into chips, has the highest effect on the consumption of cutting tools. In fact, the automotive industry is the biggest consumer of cutting tools. The larger growth of the automotive industry will be generated in the emerging markets, which of course include China, India, Indonesia, Brazil and Russia.
Do you have any plans to further expand into or explore the auto part making industry? What are the challenges from the business and technology point of view?
The automotive industry, as the largest user of cutting tools, is naturally seeking productive tooling. Consequently it is one of the main targets for our new tools development. We are constantly researching and developing new high productivity tools, to help this industry produce more with a lower capital investment. The business challenges regarding the automotive industry are to provide a faster service level, by placing special tool engineering and production in proximity to the automotive production facilities.
In your opinion, name one product you can identify most with the auto part making industry and why.
The most popular Iscar product in the industry is the TangMill. This product continues the trend of tangential inserts which have been used heavily for many years, but with the major change of positive cutting rake, which reduces the cutting forces and allows for increasing cutting speed and feed, to provide high productivity and savings to the industry. Enquiry No. 7403 Turn to page 84a or log on to www.equipment-news.com to enquire
What is your assessment of the automotive industry and how does it affect your industry? Where are the likely hot spots for further growth?
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Choy Kin Man Assistant VP T端v S端d PSB
Singapore offers excellent development potential and opportunities for the global automotive components and modules manufacturing industries. It has positioned itself as the regional centre for manufacture and design of high-tech auto components for OEMs and the replacement parts market. The Singaporean automotive-related companies engage a wide range of sophisticated manufacturing technologies such as in-process x-ray inspection, vision control assembly machines and various industry-leading hybrid technologies. As such, a broad variety of industry-leading automotive components and modules are being produced here. They include electronic sub-assembly (like ignition control modules and pressure sensors), engine parts (such as gaskets and oil seals), compressor parts and automotive audio systems, and transmission components (such as universal joint kits).
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Do you have any plans to further expand into or explore the auto part making industry? What are the challenges from the business and technology point of view?
Tüv Süd is stepping up the expansion of its global network of testing facilities for e-mobility, with plans to build two further laboratories for the testing of high-voltage automotive batteries in South Korea and China in 2012. Further improvement of our strategic services in the fields of homologation, safety and the environment has top priority. Another key issue concerns the expansion of our business activities in Asia Pacific. Our core business there focuses on homologation and functional safety — particularly also in the field of electromobility. In addition, we will open a testing laboratory for tyres and wheels in Thailand before 2011 is out, further strengthening our presence in the strategically significant region Asia Pacific. We will also plan our full suite of testing, certification, inspection, auditing, training and auditing services around the initiatives, which Singapore has put in place to bolster our competitive position in three key areas. They are design and engineering, alternative energy solutions and intelligent transport system.
In your opinion, name one product you can identify most with the auto part making industry and why.
This year will be critical to test the success of plug-in hybrid and electric vehicles, as a number of manufacturers begin to bring these vehicles to dealerships. Enquiry No. 7404 Turn to page 84a or log on to www.equipment-news.com to enquire
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CMM Arms:
Increasing Measurement Accuracy & Mobility
With an estimated production capacity of 700,000 automobiles, BYD Auto finds convenience, confidence and capacity by investing in solutions that make accurate and reliable measurement checks. By Ring Pan, marketing manager, Faro China.
T
he car manufacturing process is an active assembly point, where a large number of components of all shapes and sizes are brought together to create a final product. For BYD Auto, some parts are manufactured in-house, while others are outsourced. A s a re s u l t , m e a s u re m e n t checks for quality control and assembly pose a challenge, as the metrology needs are different every step of the way. 56
metalworking equipment news October 2011
In the welding line alone, body assembly fixtures of a few metres in length need to be measured alongside dowel pins of a few millimetres in diameter. Zhou Jie, the company’s auto test engineer, said: “The sizes and features of the items that we need to measure are significantly different. A host of ‘traditional’ measuring tools such as calipers, hand gauges, and height/geometric rulers would typically be required to fulfill the variety of inspection
DIFFICULTY: There are very different metrological needs in the production line with parts in wide-ranging sizes. Current measurement equipment are not able to provide sufficient accuracy.
SOLUTION: Introduce CMM arms to the production to improve measurement accuracy and mobility.
CONCLUSION: Increase in measurement efficiency. Decrease in man-hours.
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ENQUIRY NO 187
WIKUS-Sägenfabrik Wilhelm H. Kullmann GmbH & Co. KG Melsunger Str. 30 34286 Spangenberg Germany Tel.: + 49 5663 500 – 0 eMail: info@wikus.com
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needs on the shop floor. To switch from one tool to the next between measurements would then involve a lot of time, while still not providing the accuracy and precision that we require.” In fact, for truly accurate measurements, it is virtually impossible to rely solely on traditional tools. This is especially true for large auto par ts, as they cannot be measured accurately or properly with most traditional instruments. Measurement errors will inevitably be in the unacceptable range of millimetres, instead of microns, even with repeated attempts. Improving Accuracy With A Touch Of Mobility To s o l v e t h e p r o b l e m o f m e a s u r e m e n t a c c u r a c y, the company considered fixed-position Coordinate Measuring Machines (CMMs) as an option. Fixed CMMs are systems that enable high measurement accuracy and repeatability, but with ver y limited portability and mobility. Each unit typically requires a hefty investment, and on top of that, dedicated large measuring rooms with controlled-environments are necessar y to house and operate these types of CMMs. This also makes the manufacturing process more labour-intensive because parts have to be moved back and forth between the production l i n e a n d t h e m e a s u re m e n t rooms for inspection. While fixed CMMs would give the company a much greater level of measurement accuracy compared to traditional measurement tools, the high cost of setup, maintenance, and operator inconvenience made the option unattractive as a 58
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viable solution. What the company needed was the accuracy and precision of a fixed CMM, but not the physical limitations that it entailed. Mr Zhou continued: “ We w a n t e d a s y s t e m t h a t could be deployed anywhere, is easy-to-operate, and most importantly, one that provides accurate and consistent measurements in order for us to uphold the quality of our products.” The solution was a portable, articulated-arm CMM — a manually operated measurement arm that offer a c c u r a c y, r e l i a b i l i t y a n d convenience to users. The ball probe at the end of the arm is directed at various positions on an object to collect individual 3D data points that are then processed by CAD/ CAM software on a computer. Instead of bringing parts to the device, the por table CMM can be deployed in an auto assembly line. This has savings on time, labour, and cost, all at once. “After careful analysis of major factors such as capital i n v e s t m e n t , p r o d u c t i v i t y, measurement accuracy and convenience, we decided to go with a portable CMM for our quality inspection needs,” Mr Zhou said. Higher Confidence, Improved Capacity Currently, the company owns around 20 sets of the Faro Platinum Arm. All collected data is processed with CAM2 software, and also Geomagic software. With the CMM arms on the shop floor, the company is able to use one tool to measure all its auto parts — regardless of size and shape. Mr Zhou added: “With the flexibility of the arm, we are
able to measure and control the quality of not just the smallest auto components, but also much larger par ts w i t h re m a r k a b l e a c c u r a c y. The equipment is also robust enough for our harsh shop floor conditions; and precision a n d re l i a b i l i t y i s p o s s i b l e e v e n w i t h o u t a c o n t ro l l e d environment.” For BYD, the CMM arm combined all the benefits that the company sought. He indicated: “We really like the freedom of movement that the six-axis of rotation provides. The infinite rotation allows us to measure everything and anything — even hard-to-reach spots or awkward angles. Also, the power-packed software is easy to master, which saves us a lot of time.” With the solutions in place, the company boasts a complete inspection and testing process. Engineers are able to ensure structural stability of fixtures early in the design stage and quality-control personnel are able to ef fectively and objectively assess, correct a n d m a i n t a i n t h e p l a n t ’s production. “With shor t equipment set-up time and user-friendly controls, data collection and repor ts can be generated swiftly for each quality inspection,” Mr Zhou said. “This has really helped streamline our manufacturing process on the whole.” Measurement efficiency has increased, yet man hours have decreased. Mr Zhou explained: “A quality check that would have taken us an entire day with a fixed CMM actually takes us only three to four hours to complete.” MEN Enquiry No. 7405 Turn to page 84a or log on to www.equipment-news.com to enquire
ENQUIRY NO 179
Tungaloy Singapore Pte. Ltd. 50 Kallang Avenue, #06-03, Singapore 339505 Tel: (65) 6391 1833 • Fax: (65) 6299 4557 www.tungaloy.co.jp/tspl/
Tungaloy Malaysia Sdn Bhd (876763-H) 50 K-2, Kelana Mall, Jalan SS6/14, Kelana Jaya 47301 Petaling Jaya, Malaysia Tel: +603-7805 3222 • Fax: + 603-7804 8563 www.tungaloy.co.jp
Plant
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Visit
Walking alongside Mr Lee, he pointed out the web cams mounted strategically along the elevated footpath. He felt “they aid productivity.”
Mazak
Cyber Factory Visit
Asia Pacific Metalworking Equipment News recently visited Mazak’s Cyber Factory to have a better understanding of its manufacturing activities in Singapore. By Joson Ng
S
ituated in Jurong, the Western par t of Singapore, the Mazak Cyber Factory is designed to be an advanced manufacturing facility where total factory integration is the key. The facility has a total production floor area of 5,442 sq m and manufactures 11 models of non-control machines (no more than three-axes) including the Quick Turn 6, QT Smart and QT Nexus. Leading the plant visit was Stephen Lee Y W, the deputy GM. According to him, the company transformed the production facility into a cyber factory back in 2005. “Before 2005, we were in mass production and we did not really go into digitising our production. Right now, we rely on computers for most of 60
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the control and management. As such, we can access information in real time. In addition, the system also allows our Japanese counterparts in the HQ access. We have web cams in the factory and also in machines. They (HQ) can study our machining processes that way,” said Mr Lee.
Factory Organisation The layout of the Cyber Factory is divided into three areas. They are the machine shop, assembly plant and fabrication shop. Mr Lee said: “The main task of the machine shop is to machine components for the assembly department. For instance, they make the machine bed, headstock, turret, turret base, carriage and tailstock. The fabrication shop on the other hand manufactures sheet metal covers, the main body and machine door. It also consists of a paint shop, which uses both wet painting and powder coating.” “ We a l s o h a v e a n R & D department. They specialise in customisation. For example, they can design software for a barcode reader and incorporate them into the machine,” he added. According to Mr Lee, the factory produces three to four machines a day (from assembly line onwards), which works out to about 75 machines a month. In order to achieve this, the assembly area is organised into three main areas. They include the A-Line, which handles the assembly of headstock, linear guides, turret module and ball screw. The individual components are checked by CMMs and the
Cyber factory established in
5,442sq m
2005
Total production floor area
Total manpower in factory
254
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Machines manufactured per month
Produces
62
11
models of machine tool
alignments of the assemblies are measured by a millimess. Farther down the line is the general assembly area where sheet metal covers are assembled. Last in line is where the electrical and mechanical setting assembly takes place.
The plant benefitted from automation
Situation Under Control Walking in the plant, I noticed there are not many operators working in the factory considering its size. This, explained by Mr Lee, can be attributed to the Cyber Scheduler and the Cyber Monitoring System. The scheduler tells the stacker crane to move the palletech system to the designated machines. Their movements are wholly controlled by the scheduler and human input is only necessary at the loading
An intuitive system gives an overview of plant operations
metalworking equipment news October 2011
stage. The monitoring system on the other hand allows clear plantwide view of operations in real time. Mr Lee told me he monitors the processes from his office using the intuitive system. “Basically, when all the indicators are green, everything is ok,� he said. Ta k i n g a s t e p t o w a r d s unmanned operations, the company’s monthly production
schedule is hosted in the Cyber Scheduler, an in house software program. The program is then automatically downloaded into individual machines, allowing production to run seamlessly. Overcoming Difficulties In his 20 years with the company Mr Lee has seen his fair share of changes within the company. In
ENQUIRY NO 173
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2005, the company adopted the lean concept. Though the system has its merits, it was however difficult to implement at first. Looking back, he said: “The first obstacle was the mentality of the operators. There were a lot of resistances because we were taking them away from their comfort zone. The main challenge to overcome in implementing such a system is the human m i n d s e t . To s p e e d u p t h e implementation process, we
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gave them (operators) a lot of training in order to educate them and let them know the benefits of the new system.” In 2009, during the height of the global financial crisis, Mr Lee saw the benef its of automation. That too was difficult to implement at first. “Factory automation for me is about getting the right people to handle the right machine. As these are all sophisticated machines, we need time to
train the operators. During the crisis, we had to reduce manual labour input and that is when automation proved its worth to me. During that period, we ran production day and night without human interference. It cut down on a lot of fixed costs,” he said. Today, the factory is fully automated where robot arms are a common sight. Enquiry No. 7501 Turn to page 84a or log on to www.equipment-news.com to enquire
Working In The Cyber Factory
We take a look at the people working in the Cyber Factory as well as the people running it. T he op e r ationa l hie r a rc hy at the C ybe r Fac tor y ha s f ive levels a s Mr Lee explained. The production director heads the division, followed by the managers, superintendents, supervisors (line leaders) and finally the operators, who are usually trained ITE graduates. Total manpower in factory is 254 (Engineering: 23, Sales Division: 58, Administration: 18 and production: 155). For Mr Lee, he likes to stay in contact with his shop floor colleagues. As such, he meets his supervisors in the morning and after lunch on a daily basis. In addition, there are weekly and monthly meetings. Over on the shop floor, we came across Chee Kun Leing, a technician working at the assembly unit. A veteran with 11 years of experience, he went through many different technical courses that allow him to be multi-skilled. This, he revealed is one of the philosophies adopted by the management as they seek flexible staff deployment. Mr Chee has seen many changes in his time and his favourite addition is the touch screen computers that allow him to key in his input from the shop floor and keep track of production in a synchronous manner. Though his job has been made easier by modern technology, his greatest difficulties in recent times are beyond the control of technology to a certain extent, that is, part shortages. “We sometime have
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Mr Stephen Lee to wait for the parts to come while the clock continues to tick. When they arrive, we have to rush,” he said. Staff Training The company has a comprehensive incentive and training package for their staff to make their stay an enriching one. For instance, they are entitled to attendance allowances and for some of the best performing operators, training courses (two to three weeks) in the Japanese plants in Oguchi (Horizontal machining centre), Minokamo (Turning machine) and Seiko (Vertical machining centre) respectively are available.
Some operators were sent for metrology courses locally at Mitutoyo, the metrology equipment manufacturer. Typically, new recruits will undergo three months of on-the-job training. “We let them familiarise themselves with the machines and the equipment we are using. It is not really that difficult to operate our system. As such, we only deploy our skilled workers for more specialised operations like test cutting and system fault finding. These are usually the Diploma graduates,” said Mr Lee. MEN
Enquiry No. 7502 Turn to page 84a or log on to www.equipment-news.com to enquire
ENQUIRY NO 183
FeatureS
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The
Age Of
Mobility Manufacturing in Asia has entered a phase where more mobile devices have found their place in the production line. Saj Kumar, VP, Discrete Manufacturing, Industry Solution Group, SAP China shares his views. By Joson Ng
APMEN: The future of manufacturing in Asia seems to be moving towards mobility. Can you explain this shift? Saj Kumar (SK): What I am seeing is a shift towards the use of mobile devices on the shop floor. It can range from simple bar code scanners to more sophisticated devices like the tablet or the smart phone. Since the very nature of manufacturing is mobile, with people always moving around the shop floor having no access to their desktop computers, there is a good business case for people to implement mobile technology on the production level. APMEN: Tell us about Dashboards (visualisation tool) in production. 66
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SK: In terms of mobile technology, various activities of people on the shop floor can be adapted to a particular mobile infrastructure. When you go to any factor y you will see display broads and production charts. Some of them are simple b l a c k b o a rd s a n d s o m e a re electronic display boards. Instead of displaying information on those platforms, w e c a n p ro v i d e t h e m o n a tablet/smar t phone format. For example, the president of operations in a company can have complete visibility looking at a dashboard right from his phone. He can identify ver y conveniently which plants are operating below standards and likely to fall short of meeting KPI targets. A plant manager, can have plant and operator information, for instance, how
many workers are on leave on a particular day. APMEN: With the influx of tablets and smart phones in the manufacturing environment, does it take away the human touch? SK: It does to a certain extent. It takes away the human touch to the extent where you do not need to speak to a person to get relevant information. That is one aspect that has to be taken into consideration before implementing this technology because manufacturing is all about teamwork. If face-to-face interaction is taken out, the team dynamics is somewhat changed because there may be other subtle information that can be extracted during verbal communications. So I
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Since the very nature of manufacturing is mobile, with people always moving around the shop floor having no access to their desktop computers, there is a good business case for people to implement mobile technology on the production level.
think it is important to maintain daily meetings. For the rest of the time, information can be obtained off the tablet, without wasting time speaking to people for extracting information. This is extra pertinent for tracking operations after office hours. At the end of the day, it is about finding a good balance between maintaining the human touch and leveraging technological innovations for efficiency. APMEN: Is manufacturing in Asia ready for mobility? SK: Mobile devices as a consumer product have already been embraced in Asia. With such high adoption rates, it is a matter of time before those devices find their way into manufacturing. I would say in a year, you would find this technology pervasive in manufacturing. After all, it has only been 18 months since tablets have been launched. For SAP, in the last one year, we have seen some 6,000 tablets deployed in our company. APMEN: Do you foresee any problems in implementation? SK: The devices right now are still very fragile. Maybe you will see a ruggedised version being used on the shop floor in the future. 68
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APMEN: What are the advantages of having mobility in manufacturing? How can that be translated into dollars and cents? SK: The number one concern in manufacturing is while moving to low cost countries in Asia, how do you balance cost against efficiency? In USA, you have higher ef ficiency but high cost. However, over here (in Asia), you get lower efficiency and lower cost. While keeping the cost low, improvements must be made on efficiency. Having visibility into issues on the floor will help you achieve that. An example would be quality control. If there is a particular problem on a machine during a shift, technology can allow instantaneous feedback. Another example can be illustrated in equipment utilisation. Equipment up-time, especially in the semiconductor i n d u s t r y w h e re e x p e n s i v e machines are often deployed, is crucial. The plant operator would want to make sure the maintenance is up to the mark. This is where automation can help. It tells you when you need to do preventive maintenance to help you keep the machine up.
APMEN: Do see any flaws that come with the usage of mobile devices in manufacturing? SK: The problem with introducing any new device o r t e c h n o l o g y f ro m t h e I T p e r s p e c t i v e i s s e c u r i t y. Moreover, these devices are not tested on a large scale. As such, there is this question of how do these devices scale up to an enterprise level where you can easily have more than a thousand people using it. For security, the management will need to decide on the right employees to arm with mobile devices. They would also need to think about decommissioning procedures should someone lose the device. APMEN: ERP — how does it help manufacturing in Asia? SK: Thir ty-eight years ago, we started off as a business applications company offering financial sales, distributions and procurement applications. We realised that while awareness of ERP was high in the management level, this was not the case on the shop floor level. We identified the gaps that existed. ERP helps businesses to connect financial and manufacturing arms, regardless of geographic locations. For example, an ERP would help to seamlessly connect manufacturing operations in India and China to HQ operations in Singapore. This direct link between manufacturing and finance, helps to foster greater efficiency and transparency in the system. This trend is going to be m o re v i s i b l e i n t h e f u t u re especially with mergers and acquisitions. MEN Enquiry No. 7601 Turn to page 84a or log on to www.equipment-news.com to enquire
ENQUIRY NO 156
Features
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Engaging Industries
On A New Platform
A
Mr Armando Pereira (L) and Mr Teo Tian Seng
Converting a traditional show room into a technology cum activity centre is a fresh approach by Agie Charmilles aimed at providing the right solutions to the people who need it. By Joson Ng
gie Charmilles Southeast Asia hosted the members of the precision engineering industry in its Singapore facility to present their revamped centre of expertise as well as providing a platform to launch their initiative that focuses on machine enhancement and total solutions. The event that took place on July 27 – 28, 2011
Quick Bites…Partners’ Thoughts
The company invited some partners from the cutting tool, metrology and software sectors to show how their products can complement Agie Charmilles’. Blum Candy Ong, regional manager
Haimer Alexander Tjioe, VP (Asia Pacific)
Open Mind Eric Chua, regional applications engineer
Seco Tools Errol Lim, technical sales engineer
Wenzel C P Chuah, regional sales manager
The objective for taking part in this event?
To show our partnership with GF Agie Charmilles.
Our main objective is to put our name out there because we are relatively new.
To show support for our machine tool partner and gain exposure for our software.
To promote our cutters. In fact we have new cutters that are suitable on Agie Charmilles machines.
We hope to forge a long-term partnership so we can have future cooperations.
Your view on the turnout of the event.
Fantastic, I am very satisfied with the turnout.
The first day was good but the second day turned out better for us.
There were more visitors from abroad on the first day. We saw our fair share of customers over the two days.
The event was good, Agie Charmilles invited a lot of customers ; some of them are quite interested in our cutters as well.
The turnout was tremendous. Good responses all round.
Any leads from this event?
So far we have pretty good leads, in fact we foresee good orders coming in.
We have about 8 to 10 leads.
We have some leads from the machine users.
Yes, we do have some leads and we will follow up on them closely.
Lead wise, it is quite positive.
Enquiry No. 7602 Turn to page 84a or log on to www.equipment-news.com to enquire
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showcased seven machines and also some partners’ products to drive home the concept of machine enhancement, where a suite of product and equipment is key to providing a complete solution. The centre is not a typical show room as far as Teo Tian Seng, president of Agie Charmilles (SEA) is concerned. Said Mr Teo: “This event is a platform to kick off the new design and concept of our activity centre. Over here, we encourage members of the industry to visit us and familarise themselves with our machines.” Mr Teo revealed to Asia Pacific Metalworking Equipment News in an exclusive interview that the facility is available to anyone “as long as there is a genuine interest to test out Agie Charmilles’ machines.” In addition, the company welcomes industry partners, such as those who are manufacturing accessories, to work with them in order to provide total solution. This concept of total solution personifies itself as modular measurement
equipment mounted in machines to allow time saving in-process measurement as pointed out by Mr Teo. Fresh Concept Back in 2010, the centre was an ordinary show room. Looking back Mr Teo said: “It was a different concept back then, the room was enclosed and there were not so many machines. Last year we decided to revamp the show room in order to have more space to show our products as well as our business partners’.” In the future, the company will invite smaller focus group to their activity centre. The idea behind this is specificity. “The group can focus more on specific segments, in Singapore, it would be the IC mould industry and the aerospace industry. As such, the participants will have common topics to share,” said Mr Teo. Enquiry No. 7603 Turn to page 84a or log on to www.equipment-news.com to enquire
Established Powers Still Have Much To Offer “The last 10 years, China has continued to attract a lot of industries. This trend will remain but I think it will not be as obvious as it was before,” said Armando Pereira, head of Asia sales and marketing. “In China, we will face the same situation that we are facing in Europe and certain parts of Southeast Asia, ie: increase in costs and the lack of skilled labour for the industry,” he added. Appointed by Agie Charmilles in 2009 to head sales in South Asia, Mr Pereira took charge of Southeast Asia, Taiwan and South China then. In the middle of 2010, he was appointed as the head of Asia region. “I believe in the more advanced countries like Japan, South Korea, Taiwan, Thailand, India, Malaysia and Singapore. They can still contribute a lot to the industry. For example, you can see Switzerland and Germany still among the strongest industrialised nation in the world, despite the emergence of China and India. Germany is still contributing to a large portion of our annual turnover. A huge amount of income for us is still attributed to one of the more expensive region in the world — Europe, where they develop high quality product,” he said. MEN
Enquiry No. 7604 Turn to page 84a or log on to www.equipment-news.com to enquire
ENQUIRY NO 178
Agie Charmilles’ Armando Pereira On The Future…
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EVENTs&
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exhibitions
Event Preview:
Metalex 2011
B
ack for its 25th edition, Metalex will put visitors at the centre of the metalworking industry and community as it brings together the latest solutions, important innovators and influencers, and conferences. Visitors will get to evaluate competing solutions across every product category and discover, more costeffective solutions to existing processes. In addition, they can test the latest products and experience live demonstrations. The show is also a place for networking. Visitors can book face-to-face appointments with key suppliers. With that, they can connect with new suppliers, customers and business partners. For those who are looking to improve their business and find out more on industrial trends, they can get expert advice on the specific challenges faced by businesses at the show and stay up-to-date with emerging or changing trends.
Inaugural Launches In Asia
New Ideas At Conferences New business ideas will be available at conferences and seminars, organised both pre-show and on-site. Participants can learn new know-how and best practices, and find solutions to questions from experts. There are some 500 sessions of conferences — endorsed and supported by respected international trade associations and organisations. At the conferences, where keynotes from thought-leaders and innovators are delivered, lies an opportunity to upgrade skills, knowledge and on-the-job effectiveness. It is also a good
As ASEAN’s metalworking exhibition, the organisers are working to bring high precision technology from 50 countries in response to ASEAN’s opportunity to become the world’s production base for automotive and parts. The show will be a recognised launch pad for tomorrow’s technologies for today’s challenges. Below are some of the latest technologies making their Asian debut at the show: • The CNC punching machine MTX FLEX 6 from Euromac for small size bores will be shown for the first time in Asia. • Okamoto will exhibit the precision surface grinder ACC-SA. The machine performs surface grinding with high precision similar to nanotechnology used in medical equipment. • Fukuzaan will show their cross rail bridge type five-face machining centre AWEA MVP 5032 with automatic multi-face cutting power.
• Hankwang will bring the laser-cutting machine that offers up to 115 percent additional power and a monitor to display results in graphic format for modeling the workpiece before cutting. • Matec’s 30L travelling column machining is their latest machining centre with high speed and high accuracy, to be shown for the first time in Thailand. • Okuma’s VMC uses hybrid lubrication, mixing oil with air, for economical operations.
Enquiry No. 7701 Turn to page 84a or log on to www.equipment-news.com to enquire
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place to gain ideas and insights, as well as engage with the industry’s community locally and regionally.
Enquiry No. 7702 Turn to page 84a or log on to www.equipment-news.com to enquire
ENQUIRY NO 180
BITEC Bangkok, Thailand November 16 – 19, 2011
ENQUIRY NO 112
Exclusive Forums & B2B Meetings Uncover competitive intelligences with two forums dedicated to further the investment strategies and industrial advancements with ASEAN Investment Forum and Nano Metalex Forum. Both of which will gather contents on investment landscape for years to come. Nanotechnology for metalworking on the other hand, helps to handle the upcoming challenges. Business inducing activities such as BUILD Market Place and Business Online Matchmaking Program are available to widen the horizon of business connections. The face-to-face contacts with the innovators and influencers in industrial community can expand network, recruit new agents, seek new or alternative suppliers and explore new business opportunities.
October 2011 metalworking equipment news
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ENQUIRY NO 181
EVENTs&exhibitions
Event Preview:
Metaltech 2012
M
etaltech has started opening its doors to exhibitors who wish to participate in the exhibition in 2012. It is the 18th ASEAN International Metalworking, M a c h i n e To o l , C A D / C A M , Metrology, Mould & Die, Surface & Heat Treatment, Sub-Contracting, Foundry, Industrial Automation, Robotics, Precision Engineering and Welding Technology Exhibition. The event incorporates Weldtek, the 12th Malaysian International exhibition on welding equipment and technology, welding services and welding competition together with Automex, the Malaysia international exhibition and conference on process automation, factory
automation, industrial automation, instrumentation and control, bus and wireless technology, hydraulics and pneumatics, and robotics. In 2011, the exhibition attracted more than 20,000 visitors and the organisers are confident that there will be more visitors in year 2012 as the exhibition has managed to attract the movers and shakers of the industry to participate in the show next year. This annual event is also a favourite among countries such as Austria, China, Germany, South Korea, Singapore, Taiwan, and the UK. The 2012 edition has so far garnered the support of Selangor and Federal Territory Machinery Merchants Association (SAFMA),
S i n g a p o re M a n u f a c t u re r s ’ Federation (SMa), National Institute of Compressed Air Malaysia (NICAM), Malaysia’s Hardware, Machinery & Building Materials Dealers’ Association (MHMBA), North Malaysian Small & Medium Enterprise Association (SAMENTA), Taiwan Machine Tool & Accessory Builders’ Association (TMBA), Singapore Industrial Automation Association (SIAA) and the Welding Institute (Malaysia). The exhibition is fully endorsed by Malaysia External Trade Development Corporation (MATRADE), The Global Association of the Exhibition Industry (UFI) and Sirim. PWTC Kuala Lumpur, Malaysia May 15 – 19, 2012 Enquiry No. 7703 Turn to page 84a or log on to www.equipment-news.com to enquire
ENQUIRY NO 177
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Event Preview:
Manufacturing Indonesia 2011
M
anufacturing Indonesia 2011 will return November 30 - December 3, 2011 at the Jakarta International Expo Centre, Kemayoran, Jakarta. This year’s event, the 22nd in the series is the biggest to date filling all available space at the exhibition centre. This exhibition will occupy all halls including halls B1, B2, C1 and C2, which were previously used to host Plastics and Rubber Indonesia. A temporary structure, Hall F will be built to accommodate the excess demand for space. Said Ian Rober ts, MD of PT Pamerindo Indonesia, the organiser of show: “We have taken out our Plastics and Rubber show and held it at a different time yet the venue is still not big enough to
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accommodate the extra demand for space. A temporary structure hall F will once again need to be constructed. The huge demand for space is testament to the expanding manufacturing sector in Indonesia and we have seen growth across the board both from Indonesian companies wanting bigger stands and overseas exhibitors.” Major companies participating include Amada, Autonics, DMG/Moriseiki, Haas Indonesia, Mitutoyo and Trumpf among others. They will be joined by national and regional pavilions from China, Germany, Japan, South Korea, Malaysia, Singapore, Taiwan, Thailand, Turkey and the UK. The Manufacturing Indonesia series of exhibitions will incorporate Machine
To o l I n d o n e s i a , I n d u s t r i a l Automation Indonesia, Tools and Hardware Indonesia and Vehicle Manufacturing Indonesia. A number of conferences and individual exhibitor seminars will be held in conjunction with the exhibition. Over 40,000 professional trade visitors are expected to throng the aisles of this four-day exhibition in search of ideas, technology and equipment that can be used to increase production and expand their business operation in the country. Jakarta International Expo Centre Jakarta, Indonesia November 30 - December 3, 2011 Enquiry No. 7704 Turn to page 84a or log on to www.equipment-news.com to enquire
ProductFinder
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ProductFinder Accuway: Heavy-Duty Turning Centre
Accuway has developed a heavy-duty turning centre UT-400 that is powered by a 30/37 kW spindle motor with two-speed gearbox, featuring chip removal capability especially for large diameter parts. The machine base is made from FC350 Meehanite cast iron. All C3 grade precision ground ball screws on all axes are pre-tensioned, ensuring high accuracy and durability. The machine is also fitted with an environmentallyfriendly oil mist lubrication system that removes heat generated by spindle bearings and transmission gear trains during heavy cutting process with precisely metered volume. Enquiry No. 7801 Turn to page 84a or log on to www.equipment-news.com to enquire
Fluke Corp has developed the 750 Series documenting proce ss ca librators. These field tools calibrate temperature, pressure, voltage, current, resistance, and frequency and have three operating modes — measure, source, or simultaneous measure/source — enabling technicians to troubleshoot, c a l i b r a te o r m a i n t a i n instrumentation with just one tool. The equipment features an easy-to-follow, menu-driven display that guides users through tasks. Programmable calibration routines enable technicians to create and run automated asfound/as-left procedures to ensure fast, consistent calibrations. The recorded results can then be downloaded to a PC via the USB port, eliminating the need for manual transcription. Enquiry No. 7803 Turn to page 84a or log on to www.equipment-news.com to enquire
Femco Group: Boring & Milling Machine
Pro Richyoung Industrial: CNC Lathe With 3 & 4 Guide Ways
Femco has developed a series of boring and milling machine (BMC), including the table type, the travellingcolumn type, the heavy-load type (loading capacity up to 20 tonnes), the facing-head type and the high speed spindle type (8,000 rpm). Moreover, to improve machining efficiency, the company released its Automatic Pallet Changer (APC), which is suitable for all Femco’s BMCs. Currently the company is developing a floor-type BMC for large workpieces and wide machining needs. One example of its BMCs is the BMC-110 APC. It has 1,100 mm x 1,100 mm worktable which is capable of bearing a workpiece up to 3 tonnes.
The RIC-TC4300/5200/6200 series teach-in CNC lathe from Pro Richyoung Industrial features a swing over bed of 1,100 mm, 1,300 mm, or 1,600 mm with distance between centres from 1,500 mm to 7,000 mm, and a spindle bore of 153 mm to 400 mm. The machine can perform heavy loading of 5,000 kg as a result of its stronger body. For heavier loading than 5,000 kg, it can be offered upon request. The headstock features three step auto-speed change gears and can also have a C-axis function with a power turret as an option to do spindle indexing at any speed.
Enquiry No. 7802 Turn to page 84a or log on to www.equipment-news.com to enquire
80
Fluke: Perform Field Calibration Operations Faster
metalworking equipment news October 2011
Enquiry No. 7804 Turn to page 84a or log on to www.equipment-news.com to enquire
productfinder
ENQUIRY NO 073
www.equipment-news.com
10 to 6,000 Ton Capacity DEES' Taiwan and China Factories are all ISO-9000 Certified
DEES HYDRAULIC INDUSTRIAL CO., LTD. TAIWAN HEADQUARTERS / FACTORY: Tel.: +886-2-2601-8661
Fax: +886-2-2601-8936
E-mail: sales@spc.com.tw
www.deesgroup.com.tw
ENQUIRY NO 057
ENQUIRY NO 040
1600 tons Front Runner with 2 x 1000 tons and 2 x 800 tons
October 2011 metalworking equipment news
81
productfinder
www.equipment-news.com
Renishaw: Wireless Product With Volumetric Testing Capability
Renishaw has developed a successor to its QC10 ballbar system; a tool for the assessment of machine tool positioning and servo control performance. The QC20-W ballbar features a linear sensor and Bluetooth wireless technology. This design offers benefits in ease of use and enhanced durability and allows the system to be used for testing even in ‘closed door’ manufacturing, where access for wiring can raise safety and procedural issues. The design also allows testing in three orthogonal planes through a single reference point. A single, simple hardware set up means quicker testing and the ability to produce a representative volumetric measurement of positioning accuracy. Enquiry No. 7805 Turn to page 84a or log on to www.equipment-news.com to enquire
Following X·treme solid carbide micro drills DM20 and DM25 for deep drilling depth from the Walter Titex speciality brand, the tool specialist has developed further variants: the types X·treme M, X·treme DM8 and X·treme DM12. The Walter Titex X·treme M covers drilling depths of up to 5xD, and its two ‘companions’ X·treme DM8 and DM12 can drill depths of up to 8xD and 12xD. The diameter range available is from 2 mm to 2.95 mm. All features of the solid carbide drills are designed for process reliability, which is particularly important where small diameters are involved. Optimised tip geometry ensures precise positioning on entry. Internal cooling and polished flutes with special profiling guarantee rapid heat dissipation and reliable chip removal. Enquiry No. 7807 Turn to page 84a or log on to www.equipment-news.com to enquire
Seco: Turning Of Large Steel Components
Yih Chuan: Articulated Head Machining Centre
Developed specifically for applications requiring a high degree of heat and wear resistance, the TP0500 turning grade by Seco delivers high productivity. As well as being suitable for applications with long engagement times, the Duratomic coating gives long tool life in both wet and dry machining. The grade extends the Duratomic line up for steel machining. Together with the three basic grades; TP1500, TP2500 and TP3500, the manufacturer now provides performance in every steel turning operation.
SU-85 is an articulated head machining centre that supports 4+1 and five axis simultaneously by different control software. The machine is fitted with programmable articulated head (B axis) to give a cost effective large machining operation when compared to tilting rotary table package machine. The machine includes a movable ATC system, which allows more room for work piece and machining. The high torque and built-in spindle is designed with 17 kw/15,000 rpm spindle motor. Finally, there is a three-axis linear guide to support rapid feed and smooth movement.
Enquiry No. 7806 Turn to page 84a or log on to www.equipment-news.com to enquire
82
Walter: Small Diameters, Deep Holes
metalworking equipment news October 2011
Enquiry No. 7808 Turn to page 84a or log on to www.equipment-news.com to enquire
Exhibition Programmes 2011-2012
October 6–8 Metalex Vietnam
Nov 29 – Dec 2 Euromold
November
Nov 30 – Dec 3 Manufacturing Indonesia 2011
SECC Ho Chi Minh City, Vietnam Reed Tradex contactcenter@reedtradex.co.th www.metalexvietnam.com
1–5 MWCS
Shanghai New International Expo Centre Shanghai, China Hannover Milano Fairs mwcs@hmf-china.com www.metalworkingchina.com
1–5 CIIF 2011
SNIEC Shanghai, China Shanghai World Expo www.ciif-expo.com
16 – 19 Metalex
BITEC Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th
Frankfurt, Germany DEMAT Info@demat.com www.euromold.com
Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com
2012 February 21 – 22 SAMPE Asia 2012 KL Convention Centre Kuala Lumpur, Malaysia SAMPE SAMPEAsia@sampe.org www.sampe.org
21 – 23 Composites 2012 Las Vegas, USA ACMA www.acmashow.org
March 28 – 31 Inapa 2012
JIExpo Kemayoran Jakarta, Indonesia PT GEM Indoneisa info@gem-indonesia.net www.inapa-exhibition.net
April
17 – 22 SIMTOS 2012 KINTEX Seoul, South Korea KOMMA intl@simtos.org www.simtos.org
18 – 21 InterMold
Intex Osaka, Japan Japan Die & Mold Industry Association iminfo@itp.gr.jp www.itp.gr.jp
May
15 – 19 Metaltech 2012 PWTC Kuala Lumpur, Malaysia Trade Link info@tradelink.com.my www.tradelink.com.my
APMEN goes on the road... Visit our booth at:
• Metalex • Manufacturing Indonesia 2011
www.equipment-news.com October 2011 metalworking equipment news
83
advertising index Advertiser
Enquiry No.
4T TECHNOLOGIES PTE LTD
33
126
ACCUWAY MACHINERY CO LTD
77
177
AGIE CHARMILLES (SEA) PTE LTD
21
162
AGMACHINE TECHNO CO LTD
79
068
BYSTRONIC PTE LTD
05
185
CARL ZEISS S.E. ASIA
41
184
CIMCOOL FLUID TECHNOLOGY
61
169
DEES HYDRAULIC INDUSTRIAL CO LTD
81
057
DELCAM PLC (INTERNATIONAL DIVISION)
07
089
DMG ASIA PACIFIC PTE LTD
FC
186
EVERGREEN INTERNATIONAL CORP / TAITRA – MT DUO SHOW 2012
67
161
EVERISING MACHINE CO LTD
65
183
EXXON MOBIL ASIA PACIFIC
63
173
FAR EAST MACHINERY CO LTD
19
182
FLOW ASIA CORPORATION
25
093
FRITZ STUDER AG
27
171
HAAS AUTOMATION INC
13
155
HEIMATEC GMBH
79
165
HEXAGON METROLOGY ASIA PACIFIC PTE LTD
31
142
HOFFMANN GMBH
11
122
HURCO (S.E. ASIA) PTE LTD
47
168
HWACHEON ASIA PACIFIC PTE LTD
45
160
ISCAR LTD
IFC
174
KENNAMETAL INC
BC
135
KOMET PRECISION TOOLS INDIA PVT LTD
53
054
KUKA ROBOT AUTOMATION (M) SDN BHD
43
157
LICO MACHINERY CO LTD
81
073
MAWEA INDUSTRIES SDN BHD
81
040
MITUTOYO ASIA PACIFIC PTE LTD
35
167
MMC HARDMETAL (THAILAND) CO LTD
29
134
NEWELL RUBBERMAID (M) SDN BHD
49
065
NIKON SINGAPORE PTE LTD
23
158
OBJET AP LIMITED
84
Page No.
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.
02/03
176
OPTICAL GAGING (S) PTE LTD
51
159
PAMA SPA
39
166
PRO RICHYOUNG INDUSTRIAL CO LTD
75
180
PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA 2011)
72
133
REED TRADEX COMPANY (METALEX THAILAND 2011)
69
156
SECO TOOLS (S.E.A) PTE LTD
01
001
SINGAPORE EXHIBITION SERVICES PTE LTD (MTA HANOI 2012)
73
172
SUMITOMO ELECTRIC HARDMETAL ASIA PACIFIC PTE LTD
37
069
SUTTON TOOLS PTY LTD
17
175
TAIWAN TAKISAWA TECHNOLOGY CO LTD
19
148
TAEGUTEC CO LTD
15
163
TECHTOWN PTE LTD
75
112
TORNOS TECHNOLOGIES ASIA LTD
55
164
TRADE-LINK EXHIBITION SERVICES SDN BHD (METALTECH 2012)
76
181
TUNGALOY SINGAPORE (PTE) LTD
59
179
WALTER AG SINGAPORE PTE LTD
09
170
WENZEL ASIA PACIFIC PTE LTD
71
178
WIKUS-SAGENFABRIK WILHELM H. KULLMANN GMBH & CO KG
57
187
YAMAZAKI MAZAK SINGAPORE PTE LTD
IBC
188
ZWCAD SOFTWARE CO LTD
79
147
metalworking equipment news October 2011
ASIA PACIFIC METALWORKING
The Engineering Journal For Manufacturing,Automation & Quality Control
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Multi-Tasking Machine Machine Multi-Tasking
The complete fusion of a CNC turning and machining center
The completefusion fusion of of a CNC turning turning and machining center The complete fusion of aa CNC center The complete CNC turningand andmachining machining center
INTEGREX i series
INTEGREX i series [INTEGREX i-200, i-200, 200S, 200S, 300S, 300S, 400, 400, 400s] 400s] [INTEGREX [Chuck Size: Size: 8", 8", 8", 8", 10", 10", 12", 12", 12"] 12"] [Chuck
[INTEGREX i-200, 200S, 300S, 400, 400s] [Chuck Size: 8", 8", 10", 12", 12"] Innovativesupport support Innovative for operators for operators
Designed with environmental Easeof ofoperation operation Designed Ease with environmental considerations considerations
Example Application Application Example
Innovative Ease operation toDesigned with environmental The support INTEGREX designed efficiently machine The INTEGREX ii isisofdesigned to efficiently machine for operators considerations applications found in any industry
INTEGREX i-200 i-200 INTEGREX
applications found in any industry
Example Application
The INTEGREX i is designed to efficiently machine applications found in any industry
Aerospace Aerospace Aerospace Workpiece: Impeller Impeller Workpiece: Workpiece: Impeller Material: Aluminum Aluminum Material: Material: Aluminum
Aerospace General machinery Workpiece: GeneralImpeller machinery General machinery Workpiece: Workpiece: Material: Aluminum Workpiece: Vacuum component component Vacuum Vacuum component Material: S45C Material: S45C Material: S45C
Aerospace Aerospace Aerospace Workpiece: Housing Housing Workpiece: Workpiece: Housing Material: S45C S45C Material: Material: S45C
Aerospace Food beverage Workpiece: Housing Food and and beverage Food and beverage Workpiece: Workpiece: Material: S45C Workpiece:
Processing machinery machinery Processing Processing componentmachinery component component Material: Tool Material: Tool steel steel Material: Tool steel
INTEGREX i-200
Medical Medical Medical Workpiece: Workpiece: Workpiece: Thigh Prosthesis Prosthesis Thigh Thigh Prosthesis Material: Titanium Material: Titanium Material: Titanium
Power Power Generation Generation Power Generation Workpiece: Turbine blade blade Workpiece: Turbine Workpiece: Turbine blade Material: SUS303 SUS303 Material: Material: SUS303
Power Generation Automotive Workpiece: Turbine blade Automotive Automotive Workpiece :: Stator Stator Workpiece Material: SUS303 Workpiece : Stator
Material: Aluminum Aluminum Material: Material: Aluminum
Medical Workpiece:
Industrial machinery Thigh Prosthesis Industrial machinery Industrial machinery Workpiece: Gear Titanium Material: Workpiece: Gear Workpiece: Gear Material: SCM SCM Material: Material: SCM
YAMAZAKI MAZAK MAZAK SINGAPORE SINGAPORE PTE PTE LTD LTD YAMAZAKI
21, Joo Koon Circle, Jurong Singapore 629053 21,Joo JooKoon KoonCircle, Circle,Jurong JurongSingapore Singapore629053 629053 21, General machinery Tel: +65 +65 6862 6862 1131 1131 (12 Lines) Lines) Fax: +65 +65 6861 6861 9284 9284 Tel: (12 Fax: Tel: +65 6862 1131 (12 Lines) Fax: +65 6861 9284 Workpiece: Vacuum component Material: S45C
Food and beverage Workpiece: Processing machinery component
ENQUIRY NO NO 188 Automotive
Workpiece : Stator Material: Aluminum
Industrial machiner Workpiece: Gear Material: SCM
Our complete portfolio. Your complete satisfaction.
ENQUIRY NO 135
From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction. Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call (65) 6265.9222 or visit www.widia.com.
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