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Machining Intelligently ENQUIRY NO 134
ISCAR TAIWAN 395, Da Duen South Rd. Taichung 408 Tel + 886 (0)4 247 31573 Fax + 886 (0)4 247 31530 iscar.taiwan@msa.hinet.net
ISCAR THAILAND 57, 59, 61, 63 Soi Samanchan-Babos Sukhumvit Rd. Phra Khanong, Khlong Toey Bangkok 10110 Tel + 66 (2) 7136633 Fax + 66 (2) 7136632 iscar@iscarthailand.com
ISCAR VIETNAM (Representative Office) Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., Ho Chi Minh City, Tel + 84 8 38123 519/20 Fax + 84 8 38123 521 iscarvn@hcm.fpt.vn
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ISCAR HIGH Q LINES ISCAR JAPAN 1-5-3 Shinsenri-Higashimachi Toyonaka-shi, Osaka 560-0082 Tel + 81 6 835 5471 Fax + 81 6 835 5472 iscar@iscar.co.jp
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SINO TOOLING SYSTEM Blk 502, Jurong West Ave 1 #03-813 Singapore 640502 Tel + 65 6566 7668 Fax + 65 6567 7336 sinotool@singnet.com.sg
MESCO Reliance Corner Brixton St. Pasig City Metro-Manila Philippines Tel + 63 2631 1775 Fax + 63 2635 0276 mesco@mesco.com.ph
CV MULTI TEKNIK Ruko Gsa Blcok B No. 8 BN-BP, Podomoro City JL.Letjen S.parman Kav.28 Jakarta Barat 11470 Indonesia Tel + 62 21 29206242/44/45/59 Fax + 62 21 29206243 multi@centrin.net.id
INTRODUCING SQUARE T4-08 The new Square T4-08 system is an ideal balance of cost effectiveness and high performance. Strong, reliable pocket seats combined with tangentially mounted multi-edge inserts provide the strength needed for increased depths of cut with small diameters. Smooth cutting action through the use of highly positive rake angles. Test Square T4 and unlock your Efficiency & Economy.
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ENQUIRY NO 070
ADVERTORIAL
New cutting tools and solutions from Sandvik Coromant October 1st marks the launch of the latest tools and solutions from Sandvik Coromant. Stay ahead of competition. Find out what’s new in metal cutting here!
GC4325 and GC4315 – Steel turning endurance
InvoMilling™ – Agile gear manufacturing
With new technological developments emerging on the horizon, manufacturers are faced with extremely high demands in terms of quality, security and productivity. The groundbreaking insert grades GC4315 and GC4325 with Inveio™ are designed to bring endurance, predictability and long tool life to your steel turning operations.
The innovative InvoMilling solution is released as software supported by the dedicated milling cutters CoroMill®161 and CoroMill®162 as well as expertise from the Sandvik Coromant gear application team. With the CAD/CAM software InvoMilling 1.0, the CNC program is generated to produce different gear profiles with a limited range of standard-stocked precision tools. The solution has proven effective for manufacturing of gears and splines with great flexibility and high quality.
CoroCut®QD – Reliable parting and grooving Having already introduced the CoroCut®QD concept for deep external grooving and parting off, Sandvik Coromant now adds internal machining to the application range. The stable clamping mechanism on the CoroCut QD tools is now supported by the ability to use Silent Tools™ dampened boring bars for reduced vibration when machining with long overhangs. For tube-shaped components, typically found in the oil and gas industry, this is welcome news since it enables deep internal grooving with high process security.
Steel turning with GC4325 and GC4315
Parting and grooving with CoroCut®QD
CoroDrill®808 – Deep hole machining for the STS system Being the first choice for close tolerance holes, CoroDrill®808 is perfectly suited for the energy segment, for example when machining heat exchanger plates. Cladded materials such as low carbon steel with Inconel, used for these types of applications, are difficult to machine due to tricky chip-breaking and tool life maintenance. Thanks to a specially designed geometry and grade technology, CoroDrill 808 produces superior close tolerance holes even in the toughest conditions. In addition, this drill is available as a stock standard item with 24 hour delivery.
InvoMilling with CoroMill®161 and CoroMill®162
Deep hole machining with CoroDrill®808
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Uncompromised metal removal rate Steel turning grade GC4315 excels in applications that generate high temperatures. When other inserts reach a limit in metal removal rate due to high speed and long time in cut, GC4315 gets the job done. But don’t just take our word for it... ENQUIRY NO 144
y technolog
CONTENTS 28
October 2014
48
36 MAKING THE CUT 24 Gear Cutting: Investigating The Potential Of Process Integration
Process integration presents a number of benefits for gear manufacturing but it does not mean all should jump right into it. By Uli Kaiser, the Emag Group
DESIGN & MEASUREMENT 36 Vortex’s Giving CAM A Different Spin
High-efficiency area clearance produces faster machining and reduces tooling costs. By Peter Dickin, Delcam
FABRICATOR'S NOTE 48
Pressing Home The Advantage
Flexible pressing technology can make a big difference in beverage can production. By Simon Scherrenbacher, Schuler
28
Produce Gear Flexibly On Turn-Mill Centres
Software and processes can transform turn-mill centres into gear manufacturing machines for small and medium-sized batches. Contributed by Jennie Lim, DMG Mori Seiki South East Asia
SHOP TALK 32
Marked By Laser
Laser marking has significant advantages in terms of productivity and costs. It does not hurt when it produces good quality as well. Contributed by Petrina Heng, Laser Division of Trumpf Asia Pacific
4
asia pacific metalworking equipment news October 2014
42
Working Offline To Avoid Bottleneck In Bending
Why react to a situation when you can prepare for it way beforehand? By Stewart Bint, Vero Software
46
4 Reasons To Adopt Mobile CAD
With smart phones flooding the market today, there is an increasing need to look into the possibility of what mobile CAD can bring. By Daniel Huang, ZWCAD+
INDUSTRY FOCUS 52
It’s All In The Pipeline: Transporting Sour Hydrocarbons More Reliably
Abaqus FEA helps Intecsea deliver durable pipe solutions for deep-water oil producers. By Kip Hanson, for Dassault Systèmes
56
Breaking Out More Energy
For a sector that has long been told resources are fast dwindling, the news of hydraulic fracturing, or fracking, must seem heaven-sent. But what exactly does fracking entail? By Shahnawaz Abdul Hamid
www.equipment-news.com
ENQUIRY NO 136
CONTENTS 60 64
October 2014
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: samanthatan@epl.com.sg
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58
66
APMEN spoke with Marcos Rosenzvaig, Iscar’s oil & gas industry manager to dissect the energy sector from a metalworking perspective.
Analysing a huge amount of data and breaking them down into easy-to-understand visuals can help manufacturers make correct decisions quickly. By Joson Ng
Energising Metalworking With Better Tools
Making Intelligent Decisions With Smarter Data
Metalworking Readies Up For The Oil & Gas Industry
In this energy sector focus, we take a look at Singapore’s oil and gas (O&G) industry and how machine tool and cutting tool manufacturers are bolstering their product range to keep up with the advancements in the industry. By Joson Ng
Schunk Coming Into Grips With SEA
A German manufacturer of clamping and gripping solutions has recently set up a regional base in Singapore. By Joson Ng
REGULARS 10 Business News 76 Product Finder 79 Exhibition Programmes 80A Product Enquiry Card 6
asia pacific metalworking equipment news October 2014
Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA)
60
FEATURES 64
INDUSTRY Endorsements
Federation of Malaysian Foundry & Engineering Industry Associations
EVENTS & EXHIBITION 72 Event Preview: Metalex Event Preview: Manufacturing Indonesia
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For Advertiser's Enquiry Numbers
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China Machine Tool & Tool Builders' Association (CMTBA)
Machine Tool Club (MTC)
Taiwan Association of Machinery Industry (TAMI)
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Learn about the latest: “PowerMILL’s Dynamic Machine Control gives us the confidence to run parts first time on our 5-axis machines.” Brian Kerkstra, Paragon D&E
• Vortex high-efficiency area clearance • Mill/turn programming techniques • Direct modelling capabilities • Multi-axis milling innovations • Reverse engineering tools • On-Machine Verification options and much more!
Unlock the power of Delcam software
Visit www.delcam.tv/lz and see how Delcam software could benefit your business!
Delcam headquarters Small Heath Business Park, Birmingham, B10 0HJ Tel: +44 (0)121 766 5544
Delcam (Malaysia) Sdn.Bhd. Wisma UOA II, 20-1, No.21, Jalan Pinang, 50450 Kuala Lumpur, Malaysia Tel: +603-2711 0145
PT. Delcam Indonesia Perkantoran Pulomas satu Gedung-1, Lt-3 Room 12A Jl.A Yani No2, JAKARTA, Indonesia Tel: (62)-21-4894964
Delcam S.E.A. Pte. Ltd. 6001 Beach Road, #18-01 Golden Mile Tower, Singapore 199589 Tel : +65 97233095 & +65 64511124
Delcam Vietnam Representative Office Office 602, 159 Dien Bien Phu, Binh Thanh Dist, Ho Chi Minh City, Vietnam Tel : +84 8 35144078
Beijing Delcam Integrated System Co., Ltd. Rm. A411, Jinyu Jiahua Building, No.9, 3rd Street , Shangdi, Haidian District, Beijing 100085, China Tel +8610 6298 5591
Delcam (Thailand) Co.,Ltd. 11 Rama II Road Soi 54 Lane 4-3, Samaedam, Bangkhuntien, Bangkok 10150 , Thailand Tel: +66 2 899 1182-4
ENQUIRY NO 099
EDITOR’S NOTE Published by:
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Metalworking Our Way To
‘New’ Energy
senior editor Joson Ng
josonng@epl.com.sg
business development manager Randy Teo randyteo@epl.com.sg
editorial assistant Sharifah Zainon
sharifah@epl.com.sg
graphic designer Jef Pimentel
jeffreypimentel@epl.com.sg
circulation executive Nurulhuda binte Suhaimi
In physics, energy can be converted in form but not created or destroyed. What mankind did over the last few decades has seemingly gone against this rule. While man has not produced new energy, new ways to harness energy have been discovered. Biofuel, wind and geothermal energy are just some examples of the less traditional energy sources. Despite the rise of ‘new age’ energy sources, oil and gas is by no means sailing quietly into the sunset. In fact, there is still plenty of gas left in the tank, quite literally. The only difference compared to 20 years ago is that we have to look farther and deeper to strike oil. E x ploration into uncha r ted territories or simply drilling deeper into earth has placed huge demands on technology. For instance, engineers have to use FEA technology to make sure underwater gas or oil pipelines are up to the task as the pressure on these pipes can cause fatigue failure over time. In the Oil Country Tubular Goods (OCTG) segment, there are new developments, machining concepts
and machine tool designs that are relevant to the oil and gas industry. One machine tool builder has developed a shaping function on its horizontal machining centre to turn features on large, odd-shaped parts like valve bodies for the oil and gas sector. Cutting tool manufacturers are also putting in considerable resources to make sure their products are suitable for the oil and gas industry. From their point of view, exotic materials are generally used in this sector. These high temperature resistant alloys are widely utilised in offshore projects due to their mechanical and corrosion resistant properties in most acid-alkaline solutions, and chlorine bearing environments. To deal with this issue, cutting tool developers have used PVD coated tough submicron substrate that reduces the friction coefficient and amount of heat generated during machining. We will look at these issues and more in this edition of Asia Pacific Metalworking Equipment News as we focus on the energy sector in Southeast Asia.
nurulhuda@epl.com.sg
assistant circulation manager Chiang Hui chianghui@epl.com.sg
contributors Uli Kaiser Jennie Lim Petrina Heng Peter Dickin Stewart Bint Daniel Huang Simon Scherrenbacher Kip Hanson Shahnawaz Abdul Hamid Marcos Rosenzvaig 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 MCI (P) No. 037/06/2014 PPS 840/09/2012 (022818) ISSN 0129/5519
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Joson Ng Senior Editor
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asia pacific metalworking equipment news October 2014
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ENQUIRY NO 137
BUSINESS NEWS Sandvik Coromant Opens Training Centre In Indonesia
Jakarta, Indonesia: Sandvik Coromant has inaugurated a sales office and training centre in Jakarta, Indonesia on August 14, 2014. According to the cutting tool maker, the centre will provide all levels of metal cutting training and serve as a place for cooperation in solving advanced application problems as well as providing industry-specific support. Global president Klas Forsstrom said at the inauguration that the facility is the first of its kind in the Indonesian metalworking industry and it will help elevate productivity levels in manufacturing. “Sandvik Coromant's training centres are really productivity centres. We see a growing demand for these services in countries like Indonesia where there is strong awareness both at the corporate and government level of the importance of productivity gains as a driver of economic growth and development. Indonesia is on a fantastic journey, and as productivity increases and its industry moves up the value chain the country is on track to becoming Southeast Asia's most important manufacturing hub,” he said.
Japan-China Trade Value Turns Upward In Imports & Exports: JETRO Japan: JETRO says total JapanChina trade in the first half of 2014 increased by 4.4 percent to US$168.4 billion, marking an increase from the doubledigit decrea se which wa s seen in the same period of the prev ious yea r. The findings 10
asia pacific metalworking equipment news October 2014
are based on import data from ‘Trade Statistics of Japan’ by the Ministr y of Finance and the ‘China Customs Statistics Yearbook’. Exports to China increased by 2.5 percent to US$78 billion and imports also rose by 6.1
ABB Unveils The Future Of Human-Robot Collaboration London/Zur ich, The UK/ Switzerland: ABB has unveiled the world’s first truly collaborative robot: YuMi. It is a human-friendly dual arm robot designed for a new era of automation, for example in small parts assembly, where people and robots work hand-in-hand on the same tasks. The robot has been developed to meet the flexible and agile production needs of the consumer electronics industry. It will increasingly be rolled out to cover other market sectors. YuMi is a collaborative, dual arm assembly solution with the ability to feel and see. The robot’s soft, padded dual arms, combined with force-sensing technology ensure the safety of the robot’s human coworkers. S a fe t y i s b u i l t i n to t h e functionality of the robot itself so it can work cage-free. Capable of handling every thing from the delicate and precise parts of a mechanical wristwatch to the components used in mobile phones, tablets and desktop PCs, it is said the robot performs with sufficient accuracy to thread a needle. The robot will be commercially launched on April 13, 2015, at the Hannover Messe in Germany. percent to US$90.4 billion. While imports are recovering to almost the same level as those of the first half of 2012, the recovery of exports is sluggish. As a result, Japan’s trade balance marked a deficit of US$12.3 billion, an increase of 37 percent over the same period of the previous year. This sets a new record since 1995, when data recording began. www.equipment-news.com
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Secondary Spindle: 20 hp vector drive • 4000 rpm ENQUIRY NO 133
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BUSINESSNEWS
BCG Projects US$67 Billion Market For Robots By 2025 at a compound growth rate of 10.1 percent from US$5.8 billion to US$24.4 billion. “The fact that robotics and automation are crossing price, per forma nce, a nd adoption thresholds is a clear sign that the robotic megatrend is growing in relevance and a tipping point may be near,” said Alison Sander, head of BCG’s Center for Sensing & Mining the Future.
Boston, US: Spending on robots worldwide is expected to more than quadruple from just over US$15 billion four years ago to about US$67 billion by 2025 — a 10.4 percent compound annual growth rate since 2010 — according to Boston Consulting Group’s (BCG) study. The personal segment — robots used for entertainment, cleaning, education, security, and household applications — is projected to grow the fastest, at a compound annual rate of 15.8 percent, ballooning from US$1
billion in 2010 to US$9.0 billion in 2025. The commercial segment — robots used for medical and surgical purposes, agriculture, and construction, among other applications — is expected to grow at a compound growth rate of 11.8 percent from US$3.2 billion to US$17.0 billion, overtaking spending on military applications. The industrial segment — robots used in applications such as welding, assembly, painting, and material handling — will continue to be the largest, growing
Bombardier Opens Support Hub In Malaysia Berlin, Germany: Bombardier Transportation has opened a Kuala Lumpur (KL) hub to support rail projects in Malaysia and the Asia Pacific region. The office will accommodate more than 100 engineering, project management, systems integration and signalling specialists. Pierre Attendu, president of the systems division at the company said: “Bombardier is committed to meeting Malaysia’s public transport needs with cutting-edge mass transit solutions. This investment strengthens our ability to meet customer needs and ensures that we are well prepared to deliver upcoming projects in the Asia Pacific region.” 12
asia pacific metalworking equipment news October 2014
Asian Countries Top Demand Demand for robots is currently highest in South Korea and Japan. Roughly 40 percent of the industrial robots used today are in the automotive sector, in which ‘robot density’ (a metric indicating the number of robots per 10,000 manufacturing workers) already tops 1,000 in five countries — Japan, France, Germany, the US, and Italy. China is the fastestgrowing market for imported industrial robots, according to the group. “Countries with a greater number of robotic programmers and robotic infrastructure could be come more att ract ive to manufacturers than countries with cheap labour,” said Mel Wolfgang, a senior partner in the group’s Industrial Goods practice. “This rise and expanding reach of robots will fundamentally alter the competitive dynamics of the global economy.”
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Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Finland _ France Germany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Lithuania _ Malaysia _ The Netherlands _ New Zealand 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
ENQUIRY NO 158
TaeguTec Ltd. World Headquarters
BUSINESSNEWS
Renishaw Invests In Indian Additive Manufacturing Technical Centre
Walter Updates Their Tool Recommendation Software
UK: Renishaw has decided to establish its first Indian additive manufacturing (metal 3D printing) technical centre in Pune. This move was announced by Nick Clegg, the deputy PM of the UK in his visit to the country. Forming part of the company's continuing investment in the development, manufacture and application of additive manufacturing technologies, the Pune Additive Manufacturing (AM) technical centre also maintains the company's long term commitment to the Indian market. It will sit alongside the company’s existing key strategic AM technical centre locations in the UK, the US, Canada, Germany & China, with additional centres also planned for other key markets.
MasterCAM Certified For Access To DMG Mori Manufacturing Suite US: CNC Software, developer of MasterCAM CAD/CAM software is collaborating with DMG Mori USA to produce an interface to the MoriAPT workflow. The machine tool manufacturer has certified the company to program their mill, lathes, and mill-turn machines that are supported within their manufacturing suite post processor. The machine tool manufacturer has provided a standard tool path format, called Mori-APT, which acts as the generic input into their manufacturing suite post processor to power a growing number of their machines. The intent of this format is that CAM packages will only have to output tool path to this format, and the DMG Mori interface will then tailor the NC code output for the target machine. With the manufacturing suite, customers will use a post processor developed and provided by the machine tool builder for any of their machines supported by the manufacturing suite. MasterCAM users will continue to program their parts in the same manner they do today, but will be able to select the Mori APT-CL for the output format, which then can be post processed to generate NC code through the manufacturing suite from the machine builder. The CAD/ CAM software program's Mori-APT output interface will be available from CNC Software and the manufacturing suite post processor will be available from DMG Mori. 14
asia pacific metalworking equipment news October 2014
Tübingen, Germany: Walter GPS, a recommendation software for metal cutting tools, has been updated. In the GPS 2.20 version, the tool navigation offers new functions for selecting the right mill, new search options for finding a suitable drill and, in addition to all of this, a product-related search with improved GUI. The developer says the 2.20 version of the tool recommendation software is now available online and it contains the company’s products for 2014. Dr Peter Müller, GPS project manager at Walter AG, says: “Virtual tools are becoming increasingly important. Hardly any production process exists today that does not call upon software at some point. More and more companies are networking their production.” www.equipment-news.com
HP-L-20.8
New Laser Scanner for ROMER Absolute Arm The HP-L-20.8 Laser Scanner is a complete rapid point cloud capture solution for the ROMER Absolute Arm. It is highly portable and easy to use. With adjustable line lengths and an increased data rate, this advanced laser scanner delivers accurate 3D point clouds at high speed, adapting automatically for excellent measurement results on even the most challenging of surfaces.
Indonesia (Representative Office) Hexagon Metrology Asia Pacific Pte. Ltd. Tel: + 65 6463 6242 | Fax: + 65 6463 8030 contact.sg@hexagonmetrology.com
Singapore Hexagon Metrology Asia Pacific Pte. Ltd. Tel: +65 6463 6242 | Fax: +65 6463 8030 contact.sg@hexagonmetrology.com
Vietnam (Hanoi Representative Office) Hexagon Metrology (Thailand) Ltd. Tel: +84 4 3936 7935 | Fax: +84 4 3936 8069 contact.vn@hexagonmetrology.com
Malaysia Hexagon Measurement Technologies Sdn. Bhd. Tel: +60 3 5632 8900 | Fax: +60 3 5632 8955 contact.my@hexagonmetrology.com
Thailand Hexagon Metrology (Thailand) Ltd. Tel: +66 2 361 3695 to 9 | Fax: +66 2 746 9607 contact.th@hexagonmetrology.com
(Ho Chi Minh Representative Office) Hexagon Metrology (Thailand) Ltd. Tel: +84 8 5445 6665 | Fax: +84 8 5445 6660 contact.vn@hexagonmetrology.com
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ENQUIRY NO 149
BUSINESSNEWS
Trumpf Reaches Sales Milestone
Platts China Steel Sentiment Index Indicates Weak Demand, Price Outlook Beijing, China: The health of China’s steel sector may be poised for a less than robust immediate future, according to the Platts China Steel Sentiment Index (Platts CSSI), which showed a September reading of 45.88 out of a possible 100 points. This is down 1.09 points from an August reading of 46.97 and is the third consecutive month the index has remained below 50, indicating that market participants see demand for steel softening. China’s steel sector expects construction steel prices to fall over September on the back of the slowdown in China’s property sector, the index survey showed.
Nicola Leibinger-Kammüller
Ditzingen, Germany: In the past financial year ending June 30, 2014, the Trumpf Group achieved sales of €2.584 billion (US$3.2 billion). In relation to the previous year's sales of €2.343 billion, this is equivalent to an increase of 10.3 percent (preliminary figures). This is the highest ever annual sales figure in the over 90-year history of the Ditzingen-based machine tool and laser manufacturer. In the past fiscal year, the company has made a series of acquisitions, including the purchase of Chinese machine tool manufacturer JFY. Even after adjustment for these effects, the company still achieved record sales of €2.507 billion, reflecting an increase of seven percent. “ We've seen ver y strong growth, especially in Asia and We ste r n Eu rop e ," sa id t he compa ny’s president Nicola Leibinger- K a mmüller. "Both regions were even weaker during the previous year, and that makes us all the happier that we've been especially successful there with our tailormade products.” The order intake was higher too. After last year's figure of €2.33 billion, it rose by 15.9 percent to €2.7 billion. The company a nt ic ip ate s a con side rable increase in earnings as well. “We're expecting a result far in excess of the previous year's figure,” said Ms Leibinger-Kammüller. In 2012/13, the company achieved pre-tax earnings of €154 million. 16
asia pacific metalworking equipment news October 2014
The Platts China Steel Sentiment Index Survey – September 2014 (a figure over 50 indicates expansion; under 50 indicates contraction) Platts China Steel Sentiment Index (Reflects New Orders)
September
Change from August
August
45.88
-1.09
46.97
New Domestic Orders
44.82
-2.62
47.44
New Export Orders
58.04
16.50
41.54
41.38
6.76
34.62
Mill Inventories
46.55
-26.53
73.08
Trader Inventories
47.02
-12.42
59.44
Long Steel Prices
18.75
-45.54
64.29
Flat Steel Prices
10.63
-18.54
29.17
Export Steel Prices
10.11
-25.50
35.61
Additional Sentiment Categories Steel Production Inventories
Price Expectations
The most positive reading in the latest index is expectations for new export orders, which rose by 16.50 points in September from the previous month. The outlook for crude steel product also improved, with the index moving up 6.76 points from August to 41.38 in September. “The Chinese steel industry has been relying heavily on the export market in recent months to compensate for very soft demand in the domestic end-user markets,” said Paul Bartholomew, Platts managing editor for steel and raw materials. “The massive fall in expectations for prices of long steel products is not surprising given the slowdown in the property sector.” The latest CSSI indicates the industry is largely expecting a drop-off in domestic orders with a reading of 44.82 points – 2.62 points lower than the previous month. The long steel prices index plunged from August’s 64.29 points to 18.75 in September, and flat steel sentiment index fell 18.54 points to 10.63. While market participants expect new export orders to increase, price expectations remain bearish, falling 25.50 points month over month to 10.11 points in September. “The market situation does not bode well for steel producers and it’s certainly not good for iron ore miners at a time of huge supply into China. Lower steel prices will put more pressure on iron ore prices which have already hit a five-year low,” Mr Bartholomew said. The monthly index is based on a survey of approximately 50 to 75 China-based market participants including traders, stockists and steel mill operators. www.equipment-news.com
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NASA Pushes The Limits Of 3D Printing Technology
NASA photo, David Olive
Sembcorp Marine To Set Up Steel Fabrication Facility
Huntsville, US: NASA has successfully tested the most complex rocket engine parts ever designed by the agency and printed with additive manufacturing, or 3D printing, on a test stand at NASA's Marshall Space Flight Center in Huntsville, Alabama. NASA engineers pushed the limits of technology by designing a rocket engine injector — a highly complex part that sends propellant into the engine — with design features that took advantage of 3D printing. To make the parts, the design was entered into the 3D printer's computer. The printer then built each part by layering metal powder and fusing it together with a laser, a process known as selective laser melting. The additive manufacturing process allowed rocket designers to create an injector with 40 individual spray elements, all printed as a single component rather than manufactured individually. The part was similar in size to injectors that power small rocket engines and similar in design to injectors for large engines, such as the RS-25 engine that will power NASA's Space Launch System (SLS) rocket, the heavy-lift, exploration class rocket under development to take humans beyond Earth orbit and to Mars. Using traditional manufacturing methods, 163 individual parts would be made and then assembled. But with 3D printing technology, only two parts were required, saving time and money and allowing engineers to build parts that enhance rocket engine performance and are less prone to failure. Two rocket injectors were tested for five seconds each, producing 20,000 pounds of thrust. Designers created complex geometric flow patterns that allowed oxygen and hydrogen to swirl together before combusting at 1,400 pounds per square inch and temperatures up to 6,000 degrees Fahrenheit.
Kennametal CEO To Retire In December Latrobe, US: Kennametal announced that chairman, president and CEO Carlos Cardoso has decided to retire from the company effective on December 31, 2014. The search process will consider both internal and external candidates. He has served as the company’s president and CEO since January 2006, and was elected chairman two years later. He joined the company in April 2003 as president of its metalworking solutions and services group and subsequently was appointed executive VP and chief operating officer. 18
asia pacific metalworking equipment news October 2014
Singapore: Sembcorp Marine has invested in a multi-functional steel fabrication facility which will enhance automation and productivity at its offshore rig building, conversion, production and ship-repair businesses. To b e l o c a t e d a t t h e Sembmarine Integrated Yard @ Tuas, the steel fabrication facility will offer a streamlined, seamless a nd automate d pro duc t ion process from steel stock yard to final assembly and finishing shop. Total investment in the fabrication facility is approximately S$222 million (US$175 million). When completed in 3Q2015, the facility will be equipped with advanced equipment and machinery, and will have a tonnage capacity of more than three times that of the existing hull shop at the group’s Tanjong Kling yard. Together with the optimal layout, overall efficiency is expected to more than double.
Using Virtual Design & Reality Capture To Improve Productivity Singapore: SIMTech & Autodesk held a virtual design and reality capture seminar on September 11, 2014 in Singapore. The event gave attendees a first-hand look on how reality capture at the factory level can lead to lean manufacturing. The presenters claim by using the Autodesk Factory Design Suite, higher productivity can be achieved while creating layouts. In addition, the product is said to improve the bidding process with better design presentation. Finally, it allows effective communications between customers and suppliers. www.equipment-news.com
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Air Compressors & Treatments Systems
BUSINESSNEWS
US: R NCOS says crude steel production in the US is anticipated to grow with a CAGR of 6.3 percent during 2015 to 2019. The business consulting service firm adds that in the global context, US steel industry plays a major role by covering 5 .4 p e rce n t sh a r e o f to t a l world crude steel production and is the third largest steel producer in the world. Steel demand in the US is attributed by increa sing dema nd from automotive, construction and oil & gas sectors. In addition, technological advancement has led to the development of cost effective steel making process which also help to boost US steel industry in a positive direction and will increase the US steel demand.
Fanuc Corporation & Rockwell Automation In Collaboration Singapore: Fanuc Corporation a n d R o c k w e l l A u to m a t i o n are in a global collaboration to provide customers with a more seamless and integrated manufacturing solution. The two companies have expa nded their initia l collaboration, which started four yea rs ago, in the CNC a nd Logix progra mmable automation controller (Logix PA C ) e n v i r o n m e n t s w i t h further integration of robotics, Robomachines and enterprise software products. The effort will have an initial impact on applications in the automotive indu st r y, where cu stomers can experience benefits of a prefer re d integ rat ion plug a nd - play automat ion a nd information solution. 20
asia pacific metalworking equipment news October 2014
BMW Group Broke Sales Record In August
BMW
US Steel Industry Poised To Grow
Munich, Germany: The BMW Group saw its most successful August ever with 145,902 vehicles delivered to customers around the world (previous year 139,650 / + 4.5 percent). Sales for the first eight months of the year are also higher than in any previous year with a total of 1,330,077 BMW, Mini and Rolls-Royce vehicles sold, an increase of 6.7 percent over the same period in 2013 (previous year 1,246,502). “Our worldwide sales continue to grow, with August maintaining the upward trend,” said Ian Robertson, member of the board of management of BMW AG, sales and marketing BMW. “Whilst external factors continue to influence some markets, all three major sales regions are delivering more vehicles than ever before this year and we remain confident that we will hit our target of breaking the two millionth mark in 2014.” Sales in Asia rose 5.4 percent in August (51,243 / previous year 48,621) and a total of 424,837 BMW and Mini vehicles have been delivered to customers in the region in the first eight months of the year, an increase of 15.6 percent on the same period last year (367,442). Sales in Mainland China continue to demonstrate growth, climbing 19.9 percent in the year-to-date (298,752 / previous year 249,160). In the same period, sales in South Korea rose to total 29,562, up 14.3 percent on last year (25,863).
Schaeffler Takes Part In All-Electric Vehicle Race Germany: Schaeffler has taken part in the world premiere of Formula E in Beijing. The company joins the Formula E grid as the exclusive technology partner of Team ABT Sportsline. This competition has ushered in a new generation of motorsport. For the first time, automobile races will be held with all-electric vehicles. The identical-specification formula cars can achieve a speed of up to 230 km/h, accelerating from zero to 100 km/h in less than three seconds. During the near 60-minute race there is one pit stop at which the car is changed. www.equipment-news.com
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BUSINESSNEWS
Singapore Airshow 2014 Generated S$319 Million For Singapore Economy
Keppel Delivers World’s Largest Jackup Rig Singapore: Keppel FELS has delivered the jackup rig XLE-2 to Maersk Drilling, on budget and seven days ahead of schedule. The rig is a XL Enhanced (XLE) harsh environment jackup rig. It has been customised for operations in the North Sea and has been chartered by Det norske oljeselskap A SA ( Det norske) for deployment in the Ivar Aasen project in Norway for five years. C o l l a b o r a t i o n s b e t we e n Keppel and Maersk Drilling span the design, engineering, repair and construction of a variety of rigs and ships. The companies have partnered on 12 newbuilding rig projects to-date, including the three XLE rigs. The XLE rig has a leg length of 206.8 m and is designed for year round operations in the North Sea, in water depths up to 150 m.
Singapore: Singapore Airshow contributed S$319 million (US$252 million) to the Singapore economy in 2014, according to a recent study by Kadence International. This represented a 25 percent increase from the 2012 edition. The growth in the show’s total contribution to the Singapore economy was supported by a substantial increase in foreign expenditure, which rose 30 percent from 2012. In 2014, S$284.9 million was accrued from spending by foreign visitors on travel and accommodation, event and exhibition space, as well as other personal expenditure such as food & beverage, leisure, shopping and transport.
CNOOC: Solid Performance In 1H 2014 Hong Kong: CNOOC Limited has announced that total net oil and gas production reached 211.6 million Barrels of Oil Equivalent (BOE), up 6.8 percent year-onyear (yoy), with 36.3 million BOE contributed by Nexen, for the first half of the year. T h e co mp a n y ’s av e r a g e realised oil price was US$106.30 per barrel in the first half of 2014, representing an increase of 2.0 percent yoy, while the average realised gas price rose 13.5 percent yoy to US$6.44 per thousand cubic feet. From the growth of net oil and gas production and increase in realised oil and gas prices, the company recorded CNY117.1 billion (US$19 billion) in oil and 22
asia pacific metalworking equipment news October 2014
company commented: “During the first half of 2014, we have actively pushed ahead different areas of our business. Good progress was made in the production and operation and a healthy financial position was maintained. In the second half of the year, we will continue to work diligently to ensure that we meet our annual production and business targets.”
gas sales revenue, a yoy increase of 5.7 percent; meanwhile, net profit fell 2.3 percent yoy to CNY33.59 billion. In the area of exploration, the company made nine new discoveries and 23 successful appraisal wells. L i Fa n ro n g , C E O o f t h e
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Smartscope Flash 200 MTL- Shaft Optical Measuring Machine
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ENQUIRY NO 138
MAKING THE CUT most impor ta nt automotive components — the gear. Local gear manufacturers will need to ramp up their production to meet this increased demand by becoming more productive and efficient — process integration is one of the key ways in which the gear cutting industry is doing so. T he co n ce p t o f p ro ce s s integ ration involve s the bringing together of a large number of individual machining processes into a smaller number of multi-functional machines. As this article will show, this has both a number of benefits as well as few limitations. This article covers both the benefits a nd l i m it at ion s of pro ce s s integration with a focus on gear manufacturing and will present two case studies to illustrate.
Gear Cutting:
Investigating The Potential Of
Process Integration Process integration presents a number of benefits for gear manufacturing but it does not mean all should jump right into it. By Uli Kaiser, business development manager (Southeast Asia), the Emag Group
T
he market for new cars in Southeast Asia over the next two years is set to grow significantly. According to a recent global survey by the market research company Nielson, while consumers in Southeast Asia currently have some of the lowest levels of car ownership globally, they also have some of the highest intentions to purchase a new car within the next two years.
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asia pacific metalworking equipment news October 2014
Even for those who already own a car, the aspiration of Southeast Asians to upgrade their existing vehicles is significantly higher than the global average. This desire for a new car is being facilitated by rising income levels in the region as more and more people are making it into the middle class. This high demand for cars will mean an inevitable knockon requirement for one of the
Benefits Of Process Integration In Gear Production Process integration presents a number of benefits for gear manufacturing. The first, and most obvious of these is the fact that fewer individual machines will be required. This can often mean a significant saving for ma nu fac tu re rs i n te r m s of capital expenditure as, generally speaking, two or three individual machines will often work out to be more expensive than a single multi-functional machine. For example, turning, grinding and gear cutting processes can quite easily be combined onto a single machine base. Other commonly associated savings from process integration include lower automation costs, reduced total part through-put time, reduced set-up time and staff required due to a lower number of clampings/set-ups, as well as a reduced floor space requirement (in ter ms of bot h machine footprint as well as parts storage space). In terms of part quality, as process integration leads to a lower number of required part www.equipment-news.com
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ENQUIRY NO 163
2014 on 3-6 December
MAKINGTHECUT
Process integration allows fewer individual machines to be used
clampings, this in turn means a reduced chance of compound errors being generated. Risks Of Process Integration In Gear Production Despite this, process integration is not without its risks and will not always be the recommended s t rate g y. W he t he r it i s or not depends on a number of compa ny- a nd work piece specific factors. These include the specific workpiece geometry, the batch size and repetition of the workpieces, companyspecific logistics concepts, and the requirement to react to unforeseen changes. These unforeseen changes can include the quantities that need to be produced, the specific workpiece, the cycle time, the quality and the process. A more integrated process could lead to a reduction in a manufacture’s ability to respond to these issues. These need to be balanced against the benefits of process integration. In deciding whether to implement process integration, and to what extent, this requires working 26
asia pacific metalworking equipment news October 2014
The high demand for cars leads to the need to manufacture more gears and gear manufacturers will now need to be more productive and efficient
closely with the machine tool builder to consider all the related factors. The following two case studies present real examples of when process integration has and has not been an effective strategy for individual gear manufacturers. Case Study 1 The engineers at Emag Koepfer were approached by the manufacturer of a lean shaft for an electric powertool. The idea was to do both turning and hobbing on one machine — known as ‘hobbing from the bar’. The expectation was that this would lead to a reduction in the investment costs for the turning and hobbing operations, reduce set-up and cycle times, and deliver a shorter ‘through the shop’ time for the parts. The initial thought was: “let’s develop a machine to hob and turn from the bar.” However, it was not quite as simple as first imagined. The engineers needed to consider the variety of the different shaft variants that needed to be machined and their geometric complexity (geometry, knurls etc.).
Results It turned out that after investigating the possibility of developing such a machine, its cycle times and required machining axes for turning, hobbing and knurling were significantly different for the various complex shafts that the manufacturer wanted to produce. While the engineers could certainly have developed such a machine, it was determined that a dedicated machine to ‘hob from the bar’ would not be cost effective. Despite this, the situation led the engineers working on this project to develop a brand new process known as ‘dry free hobbing’, which has since revolutionised the manufacturing of armature shafts. Case Study 2 Another example of a process integration project started with a gear manufacturer that was using: • Two turning machines • One gear hobbing machine • One hardening machine • One milling centre • One grinding machine www.equipment-news.com
MAKINGTHECUT
Making The Right Choice What is clear from the above exa mples is that process integration for gear manufacturing is a highly complicated issue. Numerous factors need to be considered to fully determine the optimal level to which processes should be integrated. There are a number of clear benefits that manufacturers can potentially achieve; however, due to the complexity, each individual ca se needs to be ca refully www.equipment-news.com
flexibility and versatility. If a professional analysis of the gear manufacturing process is conducted, then manufacturers ca n p otent ia lly re a lise t he significant efficiency gains that are required to succeed in today’s competitive environment. Got a Question? Make An Enquiry.
ENQUIRY No. 7001 Turn to page 80a or log on to www.equipment-news.com to enquire
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The task that the engineers were faced with was to develop a p ro ce s s t h a t wo u l d u s e just two automated pick- up multifunctional machines that could do the turning, boring, gear hobbing, measuring and grinding operations (everything except for the hardening). A study of the manufacturer’s original process indicated that the loading and unloading times for the total process added up to 117 minutes and that total cycle time came to 96 minutes. With the newly developed two-machine process, the cycle time remained the same at 96 minutes; however, the total loading and unloading time was reduced to just 10 minutes, a saving of 107 minutes. A comparison of the old and new ‘time through the workshop’ for the parts, which includes storage and transportation time, showed a reduction from the previous 169 hours to just 56 hours.
analysed with the manufacturer and the machine tool company working together closely. When faced with a range of potential process arrangements, each competing option should be analysed based on considerations of the final cost-per-part based on the individual full-cost factors of each machine, as well as the company’s desire for future
Static Tools • Live Tools forfor turning and machining centers Static Tools • Live Tools turning and machining centers
Process integration is not without its risks and will not always be the recommended strategy
October 2014 asia pacific metalworking equipment news
27
MAKINGTHECUT
Produce Gear Flexibly On Turn-Mill Centres Software and processes can transform turn-mill centres into gear manufacturing machines for small and medium-sized batches. Contributed by Jennie Lim, assistant marketing manager, DMG Mori Seiki South East Asia
I
t was not so long ago that the only way to realise complex ge a r cutting jobs wa s to use special machines that were highly complicated and required expensive tools. This meant that such orders usually rema ine d in t he doma in of specialist mass producers. It was not until the integration of different technologies in multiaxis turn-mill or mill-turn centres that it became possible to solve this problem. The interaction of the multi-tasking machining centres with tools and new process and software developments means
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that even the most complex gear geometries can now be produced economically in small and medium-sized batches. T he N T a nd N T X ser ie s included in the DMG Mori product portfolio are examples of such manufacturing all-rounders that offer up to five-axis and up to sixsided complete machining. These turn-mill centres have a flat bed design and therefore provide the basis for top performance in all technologies. The standard milling spindle achieves speeds of up to 12,000 rpm and the turning spindle up to 6,000 rpm.
Flexible Complete Machining Shortens The Process Chain “W here ma nufacturing is concerned, the machines in our NTX and NT series can accomplish virtually everything that special gear cutting machines can do. They are also more flexible, making the cost-effective capacity planning far easier,” explains Ralf Riedemann, MD of Mori Seiki Europe AG, president of Mori Seiki GmbH and GM of the European Engineering Department. H e co n t i n u e s: “A n o t h e r benefit of the machines is that the workpiece can be machined completely, from blank to gear, on a single machine; this in turn shortens the process chain, prevents errors and boosts both overall productivity and quality.” With regard to the relevant gear cutting possibilities, he first points to ‘conventional’ hobbing or gear milling with the appropriate tools where the rigidity and stability of the turn-mill machines would really come into their own. But what he finds even more impressive are the developments such as the InvoMilling method from Sandvik Coromant for spur and helical gears or the DMG www.equipment-news.com
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ENQUIRY NO 027
www.wikus.com
MAKINGTHECUT gearMill software that are now also available for turn-mill centres. Manufacture Of Spur And Helical Gears InvoMilling is a process for the manufacture of spur and helical gears. Even complicated gear geometries are produced exclusively by means of the ‘intelligent interpolation’ of the axes with this method. The special feature of this process is the use of InvoMilling milling tools w ith, in pa r t, standard indexable inserts that are fitted into the insert seats of the respective cutter bodies. The inserts are embedded in such a way that the end teeth are positioned at right angles to the rotation axis of the cutter in order to enable true orthogonal turn-milling. The combination of slot milling for roughing and turn-milling for finishing enables the production of any tooth shapes and helix angles. Chamfers on the tip diameter can be realised as well as different protuberance angles, profiles and radii on the tooth root. As each cutter can be used for several module sizes. Tooth profiles, for example, can be produced in module sizes one to four with a single tool. The largest gear wheel to be milled to date was a module 18 with a diameter of 800 mm. At the same time, quality 6 gears in compliance with DIN 3962 or higher can be produced with the InvoMilling method. In addition, surface qualities of smaller than Rz 3 can also be achieved. Manufacture Complex Gear Geometries On Standard Machines For Mr Riedemann, the key benefit of the gearMill software is that even the most complex gear geometries can be manufactured on sta nda rd machines with economical off-the-shelf tools 30
asia pacific metalworking equipment news October 2014
The turn-mill centres in the NT and NTX series have a flat bed design and therefore provide the basis for good performance.
The integration of technology in multi-axis turn-mill-turn centres enables different gears to be produced in small and medium-sized batches
at reduced costs and in shorter times. The software takes over the calculation of the geometries and the automated programming of the tool paths. Special mathematical algorithms in the calculation software make even worm gears with user-defined flanks possible. D ue to t he met hod of calculation, this kind of gear manufacturing makes it possible to define gear geometries freely and makes it easy to optimise flanks and profiles of existing types of gears. Another plus for using the software program is its quality control (including the corresponding evaluation reports) that can now be carried out in the machine using special in-process measuring cycles.
The examples mentioned above are proof of the possibilities and benefits for gear production resulting from the integration of technology in the turn-mill machining centres. La st but not lea st, the universality of the NT and NTX machines means they can handle the complete range of six-sided, five-axis complete machining without compromise, a fact that is of key importance, especially in the supplier industry, because it provides a high degree of investment security as well as opening up the option of gea r ma nufacture for ma ny service enterprises. Got a Question? Make An Enquiry.
ENQUIRY No. 7002 Turn to page 80a or log on to www.equipment-news.com to enquire
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The Art of Grinding.
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If you don’t know today what you’ll be grinding tomorrow, then the S33 will impress you with its universality and flexibility: it can be retooled from grinding between centres to live spindle grinding in the record time of under 2 minutes. You can grind even complex workpieces in a single clamping, as well as utilizing the distance between centres with each grinding wheel. This is made possible by the new wheelhead with two motor spindles. www.studer.com – «The Art of Grinding.»
DKSH Technology Pte Ltd · 625 Lorong 4 Toa Payoh #03-00 · Singapore 319519 · 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 · ngoc.thihong.vu@dksh.com DKSH (Thailand) Limited · 2106 Fantree 4 Building · Sukhumvit Road · Bangkok 10260 · Thailand · weilun.tsao@dksh.com DKSH Technology Sdn Bhd · Company No. 47709T · 46200 Petaling Jaya · Malaysia · claus.bressmer@dksh.com
ENQUIRY NO 142
SHOP TALK
Marked By Laser Laser marking has significant advantages in terms of productivity and costs. It does not hurt when it produces good quality as well. Contributed by Petrina Heng, sales manager, Laser Division of Trumpf Asia Pacific
L
aser marking units use pulsed nanosecond lasers generating a variety of wavelengths, from infrared to green and ultraviolet. The units best suited for marking m e t a l s a re d i o d e - p u m p e d , solid-state lasers with yttrium aluminium garnet or vanadate as the active laser medium. Fibre lasers are also appropriate. Different kinds of lasers offer a variety of advantages in differing applications and when marking any of a number of metals. Not only does the type of laser make a difference; the pulse duration, peak pulse power, beam quality and mean power will have an influence on the marking results. Finding The Range That is why developers are offering a broad range of marking lasers exhibiting various power classes, pulse lengths and wavelengths. Higher mean power will usually achieve higher velocities. However, not only power is important, but the beam’s quality too. High quality makes it possible to focus the laser beam on a very small spot. In this way, great power densities can be achieved on the surface of the workpiece.
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Laser Marking On Metal Lasers are suitable marking tools for metals. When marking steel, infrared light at a wavelength of 1,064 nm is normally used for processing. Metals with higher reflectivity — such as aluminium, copper and gold — will absorb only a fraction of the laser power. It is said that lasers with excellent beam quality and high peak pulse power offer advantages. Over and above that, selecting a short wavelength (green) can also bring about good marking results, since these metals will absorb a shorter wavelength more readily. When it comes to precision, shorter wavelengths are suitable in these situations, since shorter wavelengths can be focused better. The marking on the workpiece itself is in the form of a series of dots, either adjacent or overlapping, which the pulsed laser beam leaves on the material. Pulsing makes for a more carefully defined introduction of energy and subsequently the heat into the material. Only a very small area is subjected to thermal and mechanical effects. In principle, there are three processes widely used in industry to mark metals. These are engraving, ablation and annealing.
Engraving With Laser When engraving, the laser beam strikes the surface of the metal, fusing and vapourising the material. This leaves recesses in the surface of the component. One usually distinguishes between ‘black’ and ‘white’ engraving. The former is associated with higher power levels and lower advancing speeds. Black engraving leaves a depression with a dark, oxidised surface and a build-up of the flux at the edge. White engraving only roughens the surface slightly and therefore alters the visual impression. Light falling on the object is diffused when reflected and appears to be brighter than the untreated metal surface on the component. For example, a QR-code can be applied with a combination of black and white engraving. This brings about greater contrast and improves legibility. Engraving is preferable where components are susceptible to corrosion and whenever coating is to follow marking. The deeper the engraving, the longer the laser will take, since it will have to make several passes to achieve the desired depth. www.equipment-news.com
Process monitoring without the bottlenecks
Reduce bottlenecks and scrap with quick and easy process monitoring using the Renishaw Equator™ Join hundreds of manufacturers worldwide who have increased flexibility and inspection capacity with the low cost Equator comparator. • Low cost increase of inspection capacity • Flexibility to inspect multiple parts • Insensitivity to workshop temperature change
Process Monitor software for the Renishaw Equator allows users to view an instant status monitor bar chart of last measured features, historical results for the feature selected, and three status displays allowing management of re-mastering. The limit for re-mastering can be set on the basis of temperature drift, time since last master, or by number of parts measured.
• Easy integration into automated cells • Low cost of ownership - no periodic calibration or maintenance
For more information visit www.renishaw.com/equator
Singapore Thailand Malaysia Indonesia
T +65 6897 5466 T +66 2 746 9811 T +60 3 5631 4420 T +62 21 25504567
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E singapore@renishaw.com E thailand@renishaw.com E malaysia@renishaw.com E indonesia@renishaw.com
ENQUIRY NO 157
SHOPTALK
Lettering an endoscopic instrument by annealing.
Ablating With Laser A further technique used for laser marking is the ablation of a layer on the workpiece. Repeated passes will result in differing ablation depths. Once the layer has been removed, the substrate becomes visible. This is the situation for anodised aluminium, painted metals, or where there is a film covering. Marking lasers can, however, also be used to prepare for other steps in the production process. Laser welding and bonding are just two examples. If, for instance, a component with an oily, dirty or oxidised surface is to be joined, then the laser beam can be used to remove the contaminant. In this way, a uniform and defined surface can be prepared so that the subsequent welding procedure can be carried out correctly. Applications such as these are being requested more than ever. This is because not only good joints are achieved, but cleaning agents can be eliminated. That is easy on both the environment and the wallet.
phenomenon. The laser can be used to induce heat in a closely defined area on the surface of a workpiece. An oxide layer is formed and it determines what colour will be seen. Differences in annealing hues arise from differing temperatures on the surface of the workpiece. This process leaves the surface of the part intact — making it suitable for labeling surgical instruments or implants. Meeting Requirements In Medical Technology The surface remains smooth
and clean and complies with the stringent requirements prevailing in medical technology with regard to biocompatibility and corrosion resistance. Here, the annealing procedure utilises its advantages to the full. Metals like titanium and stainless steel are suitable for marking by annealing. An essential prerequisite for success is closely defined energy introduction. This is guaranteed by the precise power regulation incorporated into marking lasers. It is even possible during annealing marking to achieve certain nuances in the change of colour. In addition to its uses in the fields of medical t e c h n o l o g y, a n n e a l i n g i s increasingly being used to create design elements on metallic surfaces and to enhance and individualise products. With the examples discussed in this article, it is easy to see that laser marking is one reliable technology that not only helped produce quality parts, it is a good cost saver as well. Got a Question? Make An Enquiry.
ENQUIRY No. 7101 Turn to page 80a or log on to www.equipment-news.com to enquire
Engraving is preferable where components are susceptible to corrosion and when coating is to follow marking.
Annealing With Laser One property of metals is that they will discolour when heated and subsequently cooled. Laser annealing makes use of this 34
asia pacific metalworking equipment news October 2014
www.equipment-news.com
DESIGN & MEASUREMENT
F
or at le a st 10 ye a rs, developers of CA M softwa re and manufacturers of cutting to ols have promote d hig h speed machining techniques, especially for area clearance. These strategies have typically been based on achieving greater metal-removal rates by using much higher feeds and speeds with small step-overs and step-downs. Now, strategies are being introduced that use the deeper cuts that are possible with solid carbide tooling to achieve even greater productivity. Since the speeds and feeds are lower than with high-speed machining, the new techniques are called high-efficiency strategies to reflect the increased efficiency that they make possible. The other distinguishing feature of these new strategies is the complexity of the toolpath. They often include trochoidal moves to clear out corners and other features in the part where heavy engagement might occur with more conventional strategies. Such increased engagement ca n e a sily da ma ge or even break the tool. The increased comple x it y me a ns t hat t he toolpaths can only be generated with a CAM system; equivalent programs cannot be produced with manual programming at the machine tool control. A New Approach To HighEfficiency Area Clearance Delca m’s strateg y for high efficiency area clearance is called Vortex. Like other highefficiency roughing strategies, the technology is particularly effective with solid carbide tooling and aims to give the maximum possible material-removal rates by making deeper cuts that use as much as possible the flute length as the cutting surface. However, unlike other highspeed roughing technique s that aim to maintain a constant
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Vortex’s Giving CAM
A Different Spin High-efficiency area clearance produces faster machining and reduces tooling costs. By Peter Dickin, marketing manager, Delcam theoretical metal-removal rate, the strategy produces toolpaths with a controlled engagement angle. This strategy is included in the company’s PowerMill, FeatureCAM, Pa r t Ma ker a nd D elca m for SolidWorks software where it can be used for two- and three-axis roughing, three-plus-two-axis area clearance and for rest machining. The strategy gives benefits when machining all types of materials, including titanium, tool steel and alloys such as Inconel, as well as softer metals like aluminium. Benefits Of The Vortex Strategy The main benefit of using the area-clearance strategy is the
increased metal-removal rate that can be achieved by using deeper cuts and the consequent reduction in the overall machining times. The extent to which time can be saved will vary depending on a number of factors, including the material and shape being cut, and the machine tool and cutting tools being used. A series of trials run by Delcam on different machine tools has shown that a time saving of at least 40 percent is not untypical, with the biggest percentage savings being found when cutting a sample part in tool steel. The cycle time for the part was reduced from 121 minutes to 34 minutes, a reduction of 71 percent. www.equipment-news.com
Tokyo Seimitsu (Accretech)
Tokyo Seimitsu (Accretech) established in 1949, is a global leader in CMMs, Surface Roughness, Contour and Roundness Measuring Instruments and other high precision gauges and sensors. Cairnhill Metrology is the authorized distributor for Tokyo Seimitsu (Accretech) in Singapore, Malaysia, Indonesia and the Philippines.
XYZAX mju
Compact 3D CMM with the smallest footprint in its class and hybrid guide way technology.
Applications: Replaces fixed and complex gages and measures with flexible work piece changes.
Surfcom NEX
Rondcom 54DX3
Integrated measuring instrument with new high precision dual detector for roughness and contour measurements and analysis in one measuring run.
CNC roundness measuring for high productivity with increased accuracy and measurement speeds. Rotation accuracy: 0.02+3.7H/10,000μm.
Applications: Contours and roughness of small automotive and high precision components.
Applications: Precision printer shafts, camera components and various high precision cylindrical components.
GE Phoenix
GE Phoenix is a world leader in advanced industrial X-ray computer tomography (3D) based on nano-focus and micro-focus X-ray technologies. Applications include complete 3D part inspections, materials analysis, porosity and materials inclusion, fiber analysis, 3D measurements and metrology and fluid simulations. Cairnhill Metrology is the authorized distributor for GE Phoenix in Singapore, Malaysia, Indonesia, the Philippines and Thailand.
v|tome|x s
nanotom m
Versatile high-resolution x-ray system for 2D and 3D inspections and analysis and simple metrology.
NanoCT® system for scientific and industrial CT and 3D metrology requiring highest CT resolutions.
Applications: Extreme high-resolution scans of low absorbing materials to 3D analysis of high absorbing objects.
Applications: Small biological and geological samples to medium sized industrial components.
v|tome|x c
Compact high-voltage CT system with low maintenance and production oriented design features e.g., one-button CT automation.
Applications: NDT and quality assurance labs in foundries or aerospace industries. ENQUIRY NO 161
Singapore • Malaysia: Johor Bahru, Kuala Lumpur, Penang • Indonesia: Jakarta, Medan, Surabaya Philippines: Manila, Cebu • Thailand: Bangkok, Rayong
sales@cairnhill.com
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DESIGN&MEASUREMENT Other examples included a reduction of 67 percent when cutting a number of pockets in a stainless steel part, a 63 percent time saving on a titanium part and a 58 percent saving when cutting an aluminium component. The control of the engagement angle that is possible with the a re a cle a r ing strateg y a lso makes the performance of the tool more predictable since it is operating closer to the optimum cutting conditions associated with a straight-line cut. This means that it is easier to adjust the feeds and speeds when machining a particular part such that a tool can be relied on to cut, for example, 10 components before it needs to be changed. A tool change can then be added into the program where appropriate so that lightsout machining can be undertaken safely and consistently on a long series of parts either overnight or across a weekend. In addition, the stability of the cutting conditions gives more consistent edge temperatures. This prolongs the life of the tool coating and reduces heat damage to the surface of the part. Finally, the ability to use stepdowns of at least two or three times the tool diameter spreads the tool wear evenly over the cutting surface of the tool, again contributing to longer tool life. The benefits of using the strategy can be heard as well as be seen. Conventional roughing produces a sound of varying
The roughing strategy adopts trochoidal movements to clear out corners. The machining time for this titanium part was reduced by over 60 percent by using the strategy
pitch, which indicates that the optimum cutting conditions are not being used and could even be a sign of tool overload or chatter. In contrast, Vortex roughing toolpaths give a constant pitch, showing that the tool is operating under consistent conditions. Like the reduction in machining time, the exact effect on tool life varies from project to project. In one example, where 2,000 stainless steel components were being produced every month, the number of tools used was reduced from around 300 to close to 100 each month. The replacement tools were more expensive but the overall costs were still reduced by
A series of trials run by Delcam on different machine tools has shown that a time saving of at least 40 percent is not untypical - Peter Dickin on the Vortex Strategy 38
asia pacific metalworking equipment news October 2014
around 50 percent for every part. In another case, the user was able to produce a similar number of parts with a smaller cheaper tool costing around half as much, ÂŁ80 (US$136) instead of ÂŁ180. With almost 900 parts being produced each month and both tools able to cut nine parts before needing replacement; the saving was almost ÂŁ10,000 per month. Controlled Engagement Angle T he c r it ic a l proble m w it h conventional area- clearance strategies is that the optimum cutting conditions only occur during a straight-line cut. Any interna l corners w ithin the model significantly increase the engagement angle of the cutter. To protect the cutter, this increase needs to be balanced by setting a lower feedrate. The user then has the choice of using this lower rate over the whole toolpath, which increases the machining time, or varying the feeds and speeds as the cutter moves around the model, which increases wear on the cutter and www.equipment-news.com
GF Machining Solutions
MIKRON HSM500 No compromises on technology, no compromises on ergonomics Mikron HSM customers appraise the highest accuracy, extreme dynamic and best surface quality of their machining centres.
For more information, please contact: GF Machining Solutions Pte Ltd 130 Joo Seng Road # 04-01 Singapore 368357 Phone: +65 6380 4100 Fax: +65 6284 0415 Email: infosingapore@georgďŹ scher.com www.gfms.com/sg
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ENQUIRY NO 155
DESIGN&MEASUREMENT
The Vortex strategy was the winner of the MWP Award for Best CAD/CAM or Control System.
spindle, and the stress on the machine tool. The key difference with the Vortex strategy is that it produces toolpaths with a controlled engagement angle for the complete operation. This maintains the optimum cutting conditions for the toolpath that would normally be possible only for the straightline moves. As a result, higher feedrates are possible so the cutting time will be shorter, while cutting will be undertaken at a more consistent volume-removal rate and at a constant feedrate, thereby protecting the machine. T he consta nt fe e drate achieved with area clearing s t r a te g y i s a f u n d a m e n t a l difference from other high-speed roughing techniques. These other strategies vary the cutting feedrate in corners to maintain a constant removal rate while the engagement angle increases due to turning in corners at a fixed stepover. The strategy has a different approach based on modifying the shape of the toolpath in corners to reduce the stepover taken 40
asia pacific metalworking equipment news October 2014
by the tool in these regions. Trials at Delcam have shown that this is more reliable as it can otherwise be difficult to predict how machine tools will react to changing feedrates. Because Vortex toolpaths have a controlled engagement angle, tools should never be overloaded so breakages will be minimised. The constant feedrate extends tool life further and also reduces wear on the spindle and other machine-tool components. In addition, shock loading caused by changes in the contact angle is minimised, preventing chipping of the flutes. The high- speed roughing technology also uses a minimum radius parameter calculated automatically to make sure that the machine tool can keep up the cutting feedrate in corners and, more generally, any turning part of the toolpath. This also makes things more predictable in that the machine should run at the programmed feedrate all along and not slow down like it could on other kinds of toolpath. Machine tools typically slow
down on any sharp direction changes or too tight arc spans to make sure they can follow the programmed path geometry. The high-speed roughing technology does not have this problem as the toolpath geometry is calculated from the start to avoid such sharp turns to make sure that the machine tool will not unexpectedly slow down. Conclusions Area clearance is often seen as a less important part of any machining operation as finish mac h i n i n g u sua l ly t a ke s a much bigger part of the overall production process. Even so, the opportunities to save time with new high-efficiency strategies should not be overlooked. Customers a re a lways de m a nd i n g fa ste r de l i ve r y times to the extent that offering faster delivery will often allow machinists to charge a premium price for their services. In today’s competitive env ironment, a ny thing that ca n help win business and obtain higher prices must be considered a worthwhile investment. The possible savings in cutting tool wear and breakages are another reason to investigate high-efficiency area clearance. T h e s e s av i n g s c a n g i v e a significant increase in the profit from a project. Alternatively, they can be used to win extra business as companies can now quote lower prices. The savings achieved t h r o u g h r e d u c e d we a r o n m a c h i n e - to o l co mp o n e nt s , especially the spindle, are more difficult to quantify as they will vary from machine to machine. While they are unlikely to match the savings in tooling costs, they will still contribute to reduced overall costs. Got a Question? Make An Enquiry.
ENQUIRY No. 7201 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 139
DESIGN&MEASUREMENT
Working Offline To
Avoid Bottleneck In Bending Why react to a situation when you can prepare for it way beforehand? By Stewart Bint, communications officer, Vero Software
T
he bending operation can often be the cause of bottlenecks on many metalworking companies’ shop floors. Although a laser or punch machine only cut one part at a time, it is generally cutting a nest of parts from a single sheet, and the process of moving from one part to another is extremely quick. However, the press brake is much more labour intensive and time consuming because it is normally managed by an operator pushing the part into the machine. As only one part can be folded on a
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press brake at once, it is difficult to keep up with the increasing speed of the cutting process before it. In the past it has been difficult to overcome this bottleneck — other than buying more machines or working additional shifts — both a costly and not totally effective solution. So whenever a process line is being produced for a delivery order, it is generally found that the press brake is the sticking point. Do It Offline But now, with offline programming sy ste m s, such a s R adb e nd
integrated into the manufacturing process, throughput is increased on each machine, speeding up the process and improving efficiency. The system offers an increase in ‘green light time’ on the machine. No longer will the machine sit idle while an experienced press brake operator interrogates the print and performs the necessary calculations. With customers d e m a n d i n g m a d e - to - o r d e r products, this causes an increase in the amount of new jobs that need to be set up on the press brake. Offline programming speed up this process, generating more throughput on the machine. Lone programmer can provide jobs for several machines without any downtime in the programming process. It also checks the ‘bendability’ factor. With online programming, many metalworkers would give the operator some ‘safety stock’ to produce several test pieces for a new job, running through the process until they got the part programmed correctly on the machine. This comes at an added cost of material for those extra trial parts, as well as cutting and handling time on the shop floor. Offline programming is proving to be valuable in testing whether www.equipment-news.com
SYSTEMS AND SOLUTIONS FOR TOOL MACHINING
Insert production or manufacturing and resharpening of rotary tools, HSS, CBN or super-hard materials, grinding, EDM, laser or measuring – WALTER and EWAG offer all technologies from a single source! Together with software and services we provide the best fit for your requirements – you can feel secure with the competence and precision of the experienced partner! ENQUIRY NO 156
DESIGN&MEASUREMENT The bending operation is a bottleneck in many metalworking companies
it is possible to bend a part that is currently being designed, without ever actually creating it in metal. Carrying out such ‘virtual’ testing with CAD/CAM is a powerful tool. Putting The System To The Test A company manufacturing crop processing machines recently eradicated a production bottleneck by installing the system to drive its four Amada press brakes. Alvan Blanch have even fitted mini PCs on the press brake controllers, and with Radbend Viewer linked to the server, the operator can interrogate the 3D model, rotate the part and query anything at the machine. They also see a full animation of how the part should be fed in, along with its orientation and step-bystep of each fold. With the system automatically calculating everything the operator needs to know, the company only use engineering drawings as backups now, rather than being a necessity as they were before. The offline programming and simulation system examines the part to be programmed and automatically determines a bending sequence, taking part geometry and best machinery practice into consideration. In addition, the finger-stop positions are set automatically to provide reliable positioning. When a press brake program is 44
asia pacific metalworking equipment news October 2014
Offline programming systems ensure that machines will no longer sit idle
being created on screen with the system, users see a simulation of the bending process — the machine and tooling coming down to create the bends and the part being folded, bend by bend. While the program shows that, it also checks to see if any aspect of the part will collide with any aspect of the machine. Without this offline simulation, the first indication of a problem is when the part hits the machine. Integrating Radbend into the software driving CNC cutting provides the following efficiencies: Increase in speed • Reduces downtime through efficient offline programming • Reduces lead times due to improved efficiency • Reduces machine tool set up times from the availability of manufacturing information Improvement in quality • Fewer design errors due to the 3D simulation • Collision checking reduces manufacturing errors Better flexibility • Being machine-independent, the system can be used on any number of press brake machine tools
• Production planning is improved through the ability to prepare work offline, meaning the press brake is only used for its actual purpose of bending metal. Reduction in costs • Ensures maximum utilisation of all press brake machines • ‘Right first time’ approach to manufacturing • Reduces bottlenecks at the press brake. An important factor driving the switch to offline press brake programming is the increasing difficulty in finding experienced operators who can look at a part and work out the best way to fold it. The scrappage rate can be extremely high, as the parts end up the wrong shape, or one bend has been done out of sequence, meaning the part cannot go back in the machine. A shopfloor audit can reveal the amount of scrappage and holdup s c re ate d by on l i ne prog ra m m i n g, wh ich helps companies understand the true cost of this traditional way of running their press brakes, in terms of time and waste. Got a Question? Make An Enquiry.
ENQUIRY No. 7202 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 077
DESIGN&MEASUREMENT
4 Reasons To Adopt Mobile CAD With smart phones flooding the market today, there is an increasing need to look into the possibility what mobile CAD can bring. By Daniel Huang, product manager of ZWCAD+
S
ince the first mobile CAD applications hit the small screens of our PDA’s in the early 90’s, designers have been liberated from their offices, enabling them to take their designs anywhere. It was only recently that consumer mobile devices have reached a level that enables these applications to operate in a wider range. With the increased competition between Samsung and Apple in the smart phone and tablet markets, the speed of development has increased dramatically, leading to highly advanced mobile devices. This makes it possible for CAD software developers to produce mobile applications that feature all the tools that users need in order to make changes and annotations effectively. Functionality Vs Practicality Regardless of recent developments in mobile technology, some observers have questioned the
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decisions behind switching from a computer with full functionality to a smart phone where functionality is going to be limited. Well, as Steve Jobs once explained, it is like a small Swiss Army Knife attached to a key chain. The most useful tool is the one that we always have with us, and it is the portability that is said to be the main benefit of CAD on mobile devices. Design On The Go The need for designers to work outside their office is of unparalleled importance in almost any other office based profession. Whether it is site visits or product inspections, all designers will, at some point, be required to leave their desk and work without their desktop CAD software. With mobile CAD software such as ZWCAD Touch, designers can now take their designs out of the office with them, instead of printing drawings or taking
notes the old fashioned way. This enables them to make even more accurate examinations of their designs, and annotate directly on the go. Some applications even allow for vocal annotations, making mobile CAD an even more appealing proposition. With recent developments in 3G, 4G and even 5G mobile data, users can have their entire design portfolio available to them, wherever they are through ‘the cloud’. Since most CAD applications are linked up to third party cloud software, this can be done automatically. Furthermore, with the growing capacity of smartphones’ hard drives, high data charges can be avoided by simply loading drawings directly on to devices with even faster speeds. Greater Productivity At Reduced Costs Ralph Grabowski, managing editor of Tenlinks.com, has suggested that price is a key factor that promotes CAD on mobile devices. Compared to the high prices of desktop CAD software, the monthly subscriptions for most mobile CAD software is an affordable investment, while some CAD applications are free to download and use. In addition to the price advantage, companies can also save money by making changes to their design process. Money can be saved on reduced printing costs, as designers do not need to have designs on paper when working away from the office. Meanwhile labour costs are also reduced since users do not have to transcribe annotations or alterations, as notes or changes to the drawing on site will automatically be updated on the desktop version. Collaborating With Ease A d d i t i o n a l l y, m o b i l e C A D simplifies procedures and makes it more cost efficient, favouring collaboration. In the past, users www.equipment-news.com
DESIGN&MEASUREMENT
Mobile CAD enables designers to take their designs out of their office.
Mobile CAD applications have come a long way since their inception in the early 90s, from a mere novelty into an absolute necessity. With the development of mobile devices, who
knows what surprises they will bring in the future. Got a Question? Make An Enquiry.
ENQUIRY No. 7203 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 127
had to print drawings and present them in person, while they can now email them to clients or collaborators, wherever they are. Annotations can then be added and returned to the designer. An important factor is that the client or collaborator does not need expensive CAD software, or extensive CAD knowledge to view and annotate the drawings, leading to significantly reduced costs of collaboration. Putting things into perspective, it is believed CAD on the mobile devices is not likely to replace desktop CAD software. Mobile CAD applications, however, as a supplement to desktop software, has become truly effective. With enhanced ease of use and cost savings, what mobile CAD applications can provide is incredible, and will only improve with new mobile technologies.
www.equipment-news.com
October 2014 asia pacific metalworking equipment news
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FABRICATOR'S NOTE
Pressing Home The Advantage
Schuler
Flexible pressing technology can make a big difference in beverage can production. By Simon Scherrenbacher, corporate communications, Schuler
G
uangxi Beihai Jinmeng Zhiguan (Beihai Jinmeng) supplies C h i n a’s b e s t- k n ow n beverage bra nds, such a s Qingdao beer or the herba l tea Wanglaoji with beverage cans. One key enabler for the co mp a n y i s it s s t a b l e a n d flexible pressing technology, which forms the cornerstone of t he compa ny’s b evera ge can production line at the €80 million (US$108 million) facility established last year. Most of the beverage cans p ro du ce d by t h e co mp a n y have a dimension of 330, 355 or 500 ml. With a press force o f 14 0 m e t r ic to n s a n d up to 3 0 0 st roke s p er m i nute ,
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the Schuler DA 140 cupping press allows the flexible and economic production of highquality beverage cans. At the same time, it is also suitable for particularly thin cans and complex production processes. Stable & Flexible Pressing Technology The hook-in die change
brackets, hydraulic roller bars, and motorised slide adjustment all ensure fast die change times. “If there are fluctuations in the thick ne ss of the a luminium used, for example, this can lead to problems with the pressed can bodies,” project manager Tan Jintu of Beihai Jinmeng’s P r o d u c t i o n Te c h n o l o g y division explains.
Apart from regular minor servicing, our production line can operate continuously around the clock — Tan Jintu www.equipment-news.com
ENQUIRY NO 160
FABRICATOR'SNOTE
“The press enables us to react to this within just a few minutes — we simply have to adapt the parameters by changing the inner and outer slide height,” he adds. Apart from flexibility, he also points out that the press displays a high degree of stability in continuous operation, with relatively low operating costs and maintenance investments. This low maintenance cost can be attributed to the way the machine deals with wear, which is a considerable factor as it is a significant issue. He explains: “Because of the comparatively higher wear, similar machines with sliding jib systems require reg ula r adjustment and maintenance — or even the replacement of the sliding jibs — to ensure stable operation.” According to the press machine manufacturer, the cupping presses are wear-free and do not require maintenance. Play-Free Pretensioned Slide Guidance Due to the immense dynamic loads involved, cupping presses operating at high speeds and with heavy weights always run the risk of unevenly distributing t he pre ss force ac ro ss t he 50
asia pacific metalworking equipment news October 2014
Schuler
Schuler
The turnkey delivery of the production line included a coil line, feed device, coil lubrication unit and dies.
Tan Jintu (extreme right)
t wo side s — w it h ne gat ive consequences for the quality of the die s a nd products. To avoid this problem, the cupping press at the beverage can production plant is equipped with a counterbalance system, which balances out the machine vibrations caused by high press forces during operation. A s a re sult, the machine neither needs a solid concrete foundation nor for its base to be screwed to the floor — only the line’s own weight has to be taken into consideration. The play-free pretensioned
sl i d e g u i d a n ce g u a r a n te e s precise slide motions with only minimal tilting, significantly prolong ing die ser v ice life. Moreover, the maintenance free direct drive and the clutch/ brake combination ensures the cupping press operates with a high degree of efficiency. “Apart from regular minor servicing, our production line can operate continuously around the clock,” says Mr Tan. Got a Question? Make An Enquiry.
ENQUIRY No. 7301 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 049
INDUSTRY FOCUS It’s All In The Pipeline:
Transporting Sour Hydrocarbons
More Reliably
Figure 1: FEA analysis of pipe response to stress. The diagram at the top shows the pipe at rest. As bending force is gradually applied, ripples begin to grow in the CRA liner. At the bottom, the pipe is beginning to buckle.
Prior to initiation
Contact pressure zero
Abaqus FEA helps Intecsea deliver durable pipe solutions for deep-water oil producers. By Kip Hanson, for Dassault Systèmes
I
t is not that the world is running out of oil. The problem is getting to what remains of it, at a price that consumers can accept. A September 2013 Oil Ma rket repor t from the International Energy Agency (IEA) said that global demand for oil and liquid fuels will rise to 93 million barrels per day in 2014, an increase of over two percent. This comes at a time when most experts agree that the days of ‘easy’ oil are over. Petroleum companies are now forced to drill in areas deeper and more remote than ever before. In the case of deep -water production, this means very high and unpredictable pressures coupled with severe temperature gradients both inside and outside the pipe. Worse, the wellstream fluids coming from these depths are increasingly ‘sour’, a corrosive witch’s brew containing high levels of hydrogen sulfide, CO2, and volatile organic compounds that make short work of regular carbon steel pipe. The oil industry has responded with calls for better pipeline material.
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Initiation of rippling
Making Pipe Corrosion-Resistant The clad pipe has been used in highstrain environments for decades. By metallurgically bonding a thin layer of Corrosion Resistant Alloy (CRA), typically 316L or Alloy 625, to the inside of C-Mn structural steel pipe, a robust combination of strength and corrosion resistance is formed. However, a clad pipe suffers from long lead times and high cost. Sherif El-Gebaly, lead pipeline engineer at Intecsea, a company within the WorleyParsons Group and a player in subsea production systems, says that clad pipe can cost 10X that of regular C-Mn Steel. “A n a l te r n a t i v e i s C R A mechanically lined pipe using a weld overlay at the ends,” he says. “This is both easier and quicker to manufacture, presenting cost savings of 30 to 50 percent over clad pipe.” However, concerns over the weld overlay to liner interface joint have prevented wide use of CRA mechanically lined pipes due to the Technology Readiness Level (TRL) not meeting operator requirements.
Growth of rippling
Start of final buckling shape
Figure 2: FEA model of pipe girth weld.
The company has been working to resolve and increase the confidence in CRA mechanically lined pipes for use in harsh environments. Making The Weld Stronger Than The Pipe Pipe sections are manufactured in www.equipment-news.com
INDUSTRYFOCUS and if repairs have to be made at this point, it can seriously impact production rates.” Regardless of how much pipe gets laid in a day, environmental and safety considerations mandate zero tolerance for failure once the pipeline is in the water. This is because deep-sea flow lines are subjected to tremendous stress as they transport a gloppy mix of oil, water, gas and sand from the wellhead to the offshore storage facility (FPSO) or onshore processing terminal. This fluid alternately heats and cools the pipeline, causing expansion, bending and potential buckling. High velocity ‘slugs’ of liquid and gas within the pipe create vibration, leading to fatigue. Even the weight of the pipe itself as it crosses the uneven terrain of the seafloor is a cause for concern. “The movement of the pipeline
under production conditions is similar to your garden hose when you turn on the tap,” says Mr Cooper. “You’ll get wiggling and sideways motion due to the pressure. This is why fatigue performance and strain capacity in this environment is so important.” The oil industry demands thorough testing of any component used in deep-sea oil production, and CRA-lined pipe is no exception. Because of its two-layer design, some experts were concerned over the possibility of ‘ripples’ forming in the liner material under bending stress which presents a risk of premature failure (Figure 1). Equally important was ensuring the integrity of the girth welds used for the weld-overlay-style pipe. But since sticking your head inside a 12” diameter pipe one mile under the ocean is clearly not an option, the company’s design
ENQUIRY NO 146
lengths of about 12 m, called pipe joints. These joints are then ‘girth’ welded together end-to-end to create a pipeline. For mechanically lined pipes, each CRA joint is slid inside a carbon steel joint and plastically expanded in the radial direction to ensure a tight fit between the carbon steel and the liner. The fitted CR A joint is shorter in length, leaving a distance of about 50 to 150 mm at each end; this gap is filled with a weld overlay of a CRA material, bonding the CRA layer to the carbon steel pipe and enabling the joint-to-joint girth weld to be performed. “Girth welds are critical,” says Intecsea global technology director Philip Cooper. “Some of these installation vessels are running at a million dollars a day. The weld joints are inspected prior to lowering the pipe into the sea,
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INDUSTRYFOCUS engineers have been employing realistic simulation with Abaqus Finite Element Analysis (FEA) software from Simulia. Visualising Deep-Sea Conditions FEA lets the team query the geometr y a nd behav iour of co mp u te r m o d e l s o f t h e i r pipe designs, simulating every condition from production to performance thousands of feet below the ocean surface. Mr El-Gebaly’s team had a number of factors to consider when setting up their FEA models to predict lined pipe and weld behaviour. “One challenge was a potential problem with undermatching,” he says. “Imagine that you have two 12 m long pieces of pipe and you’re welding them together (Figure 2). The weld is basically just a ring, one that is stronger than the pipe on either side. Normally when you bend the whole system, you don’t have to worry about this small ring, you’re concerned more with the pipe materials. But if at some point the yield strength of that ring becomes less than that of the pipe on either side — for example, under certain high temperature operating conditions, or where the consumable selected for welding exhibits a lower yield strength at certain temperature than the base material — the joint will actually become more flexible than the pipe and then all the strain flows into it. FEA helped us investigate such cases.” There were other scenarios to check within the assembled pipeline itself. Aside from the garden-hose phenomena described by Mr Cooper, Mr El-Gebaly was concerned with the development of ripple-type deformations induced in the liner layer during spooling and subsequent installation. “You have to understa nd the behaviour of liner under 54
asia pacific metalworking equipment news October 2014
Figure 3: CRA-lined pipe wrapped in insulating material. The test demonstrates a pressurised and heated pipe placed under a 1.5 percent strain load.
bending moment, the wrinkling onset conditions, as well as the fatigue performance of the girth weld during the installation and design life,” he says. A Day In The Life Of Lined Pipe Much of the data needed to accurately capture such behaviour with FEA models comes from extensive land-based testing. Sections of CRA-lined pipe are put through numerous physical tests, monitored by strain gauges used to mea sure a x ia l a nd radial force, and piezoelectric and Bourdon gauges to monitor pressure. Hydraulic rams, heating coils, and various other devices are then applied to sections of pipe to simulate the severe conditions at the bottom of the sea (Figure 3). Using test data, combined with industry-standard material properties for X65 pipe lined with 316L CRA, the company created FEA models of their pipe and carried out parallel ‘virtual tests’. Multiple simulation runs were performed using both pressurised pipe models replicating production conditions, and unpressurised ones that reproduce the conditions expected during transport and installation. Reducing Both Development Costs & Long-Term Risk Results to date have been promising. Ultrasonic tests show close correlation between FEA and real-
Figure 4: The inside of a heated pipe that has been reverse loaded with a 0.58 percent strain. Several ripples can be seen in the upper left-hand corner of the photo.
world behaviour, demonstrating that the company’s pipe and weld designs are performing well. Better yet, internal rippling of the CRA liner has been demonstrated to be minimal for certain design conditions, even when subjected to high buckling forces and temperatures of 130 degrees C (Figure 4). According to Mr El-Gebaly, once the models have been fully validated, using the FEA software will help the company reduce real-world testing costs. But there is more to it than better front-end savings: FEA helps to assess design risks and possible failures. “For pipelines, it only takes one joint to fail for a release of contents event to occur, so it is crucial to assess every failure mechanism,” he says. M r C o op e r a g re e s. “O i l production is far more challenging today than it was 20 years ago. We weren’t often faced with the sour fluids and harsh environments we’re currently dealing with; many of the projects we’re doing now wouldn’t have been possible back then, whereas today these challenges are quite manageable. Some of that is due to greater k nowle dge in t he indu st r y and better technology overall, but it wouldn’t be practical without simulation tools. It’s a real enabler.” Got a Question? Make An Enquiry.
ENQUIRY No. 7401 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 151
INDUSTRYFOCUS
Breaking Out
Patrick Moore, Oklahoma City, US
More Energy For a sector that has long been told resources are fast dwindling, the news of hydraulic fracturing, or fracking, must seem heaven-sent. But what exactly does fracking entail? By Shahnawaz Abdul Hamid
E
nergy is the fuel for life. It makes plants grow, keeps animals alive and, in the modern world that we live in today, drives devices from air-con compressors to desktop computers, medical equipment to space shuttles. Since ancient times, humans have been finding ways to harness energy: burning wood to cook food and smelt metals, using animals to pull ploughs, utilising the wind to move sailboats over the oceans and seas. As technology became more sophisticated, so too did the effectiveness of energy sources. As any engineer worth his salt will tell you, fossil fuels — coal, oil and natural gas — are used because of their energy density, which is the amount of energy stored in each litre of fuel. For instance, a litre of coal contains more than twice the energy as the same volume of wood. Oil & Energy Of all the energy sources, perhaps none is more useful than oil. It is of no surprise then that the nations with the most oil reserves often tend to be the richest. Oil has a high energy density, is easily transported and can be distilled and separated to power anything from an entire city to a four-wheel SUV. Since the 1930s, oil has been
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integral to providing energy to the world. The International Energy Agency estimates that in 2011, oil contributed 31.5 percent of the total energy supply. The next two biggest contributions were from coal at 28.8 percent and natural gas at 21.3 percent. Nevertheless, this contribution from oil is actually a drop from 46 percent in 1973. Back then, other fuel sources such as biofuels, nuclear, hydro and natural gas were not as prominent, but recent advances in technolog y has changed this. Today, oil does not shoulder the bulk of powering the world. However, an overall increase in global energy consumption means that we now need more oil than ever before. How It’s Done It is therefore no surprise that many industrialised countries are excited at the prospects provided by hydraulic fracturing, or fracking for short. Fracking is used to retrieve oil from shale, a type of rock, located deep beneath the earth’s surface. It is an unconventional and complicated process, but increasing crude oil prices and the advancement of extraction technology mean that it has now become a reality, in countries like the US and Canada. But how exactly does fracking work? In the beginning, the process looks like any other conventional
drilling operation. A hole is drilled straight down using a drill bit, cooled by fresh water-based fluids to prevent any heat-induced deformation. The fluids also work to ‘carry’ the rock cuttings back to the surface. After the hole has been drilled, the drill is removed and replaced with a steel pipe, commonly known as surface casing. Next, cement is pumped down the casing, taking up space between the casing and hole drilled, commonly known as a wellbore. This stabilises the structure, preventing groundwater from seeping into and mixing with the oil that is to be transported through this casing. In extracting oil from shale formations, horizontal drilling is employed. The drill hole extends downwards to a point beneath the earth’s surface, then curves 90 degrees to extend horizontally. Horizontal drilling is used partly because it makes it possible to drill several wells from only one drilling pad. This reduces the impact to the ground surface. Once the hole has been drilled and the surface casing has been cemented in place, a metallic device known as a perforating gun is guided through the casing to the depth where the oil formation exists. This may be anywhere from several hundred to several thousand meters. The gun contains explosives which can be fired from the surface. Upon explosion, holes are created in the surface casing and cement and into the shale rock. These holes connect the wellbore to the oil formation. The perforating gun is removed and the next step can take place: hydraulic fracturing. This step, from which the name of the entire process is derived, involves pumping a liquid mixture of sand, water and a small percentage of chemicals into the oil formation under high pressure through the holes which were previously made. The injecting of this mixture creates ‘fractures’ in the rock, allowing the oil that was www.equipment-news.com
INDUSTRYFOCUS previously trapped within it to flow out into the wellbore. Precision Metalworking Needed This step is repeated along the horizontal wellbore, allowing for multiple sites in the formation to be tapped for oil. The fluid mixture is then pumped back out through fluid end blocks, or pump housings. This is where hydraulic fracturing equipment manufacturers need the help of precision metalworking tools. These f luid end block s typically require higher- end milling tools in their manufacture, which often are quite complex. Usually, there is a need to reduce the vibrations that can be caused by more standard tools. Such vibrations have a tendency to eat into tool life, without the right result being achieved. As such, the use of damped tools becomes increasingly important. Such a tool
would typically have rubber springs, a heavy metal body to reduce movement and a lubricating system. The use of the right type of coolant is also important when manufacturing these fracking blocks. A coolant with extreme pressure additives can help increase tool life and provide a superior surface finish. China & Asia While all this technology to aid fracking is well and good for the oil and gas industry, how exactly will Asia benefit, especially if much of the fracking is done in the US and Canada? Fortunately, China has recently gotten on the hydraulic fracturing bandwagon, much to the relief of environmentalists hoping for lesser reliance on coal as a source of fuel. It is estimated that China’s technically recoverable shale gas
reserves are almost 50 percent higher than the number two nation, the US. Other countries have also been quick to attempt this foray into fracking. Indonesia too possesses much shale gas, with resources estimated at 574 trillion cubic feet. However, recent problems with regulation and lack of investment have hampered efforts, though some are still optimistic. In a world where oil and gas resources power our daily lives, perhaps such optimism may be necessary, thanks in part to the technology that is hydraulic fracturing. It will be interesting to see where the technology goes from here and how it affects metalworking in Asia for the next decade or so. Got a Question? Make An Enquiry.
ENQUIRY No. 7402 Turn to page 80a or log on to www.equipment-news.com to enquire
YOUR FIRST CHOICE
for finishing solutions.
Professional cleaning
Brushes for the oil and gas industry
Polishing tools and compounds
Power Brushes
Brush rolls & non-woven rolls for metal processing
Phone.: +65 6863 0318 Fax: +65 6863 4318 sales@osborn.com.sg
www.osborn.com anzeigeSingapor.indd 1 www.equipment-news.com
ENQUIRY NO 162
Osborn Singapore Pte Ltd 206 Tuas South Avenue 2 West Point Bizhub Singapore 637208
23.09.2014 18:37:48 October 2014 asia pacific metalworking equipment news
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INDUSTRYFOCUS
Energising Metalworking With
Better Tools APMEN put spoke with Marcos Rosenzvaig, Iscar’s oil & gas industry manager to dissect the energy sector from a metalworking perspective. APMEN: From the cutting tool manufacturer’s point of view, what are the market and technical trends in the energy industry that are significant to you? Marcos Rosenzvaig (MR): There is a fast growing demand for machining exotic materials, such as stainless steel, duplex and superduplex, Inconel and titanium in the energy sector, mostly in the upstream oil and gas segment. These non-standard materials are normally categorised as high temperature resistant alloys. These exotic and expensive materials are widely utilised in offshore projects due to their mechanical and corrosion resistant properties in most acid-alkaline solutions, and chlorine bearing environments. In order to optimise cutting conditions and tooling technology, it is important to consider the mater ia l prop er t ie s of t he workpiece and how they can affect machining. For example, when machining Inconel, there are major factors to be addressed which are characterised by the very high temperatures on the cutting edge of the insert, due to the abrasive elements in the material composition (high nickel content of 50 to 55 percent and chrome content of 17 to 21 percent), resulting in high wear rates, chipping, notching and insert breakage. APMEN: What are the common metal cutting techniques in these sectors? What are the 58
asia pacific metalworking equipment news October 2014
challenges and solutions from a cutting tool producer’s perspective? MR: Iscar has recently launched a renewed Isoturn line offering. These carbide grades are for turning stainless steels at medium to high cutting speeds. On high-temperature alloys, IC806 is the first recommendation. This PVD coated tough submicron substrate has surface treatment that reduces the friction coefficient and consequently, the heat rate decreases during machining. For semi-finish and finishing operations at high cutting speeds on Ni-base super alloys like Inconel, the whiskers ceramics IW7 is the first option. Its main advantages are high hardness, high fracture toughness, good thermal shock resistance and good oxidation resistance due to the alumina substrate. For he av y dut y rou g h applications, the Doveiqturn line is suitable. The dovetail pocket features a lever clamping mechanism that prevents the double-sided insert from being lifted during machining and eliminates the need for the conventional top clamp, which interferes with the chip flow. In drilling, the Sumocham drill family is suitable for shallow, me d iu m a nd de e p d r i l l i n g applications in a diameter range from 6.0 to 32.9 mm. Its standard line offers up to 12D depth to diameter ratio. This line features different standard drill head geometries, such as ICP for use on carbon and steel alloys (ISO P), ICM for use on stainless steel and high temperature
Figure 1
alloys (ISO M) and the HCP geometry which is capable of drilling straight into the material without any prehole or guide drilling. For large diameter drilling applications, the Combicham drilling system is one of the solutions to boost productivity and efficiency in oil & gas deep drilling applications. In milling, we have developed the ECK-H4M-CF. This Chatterfree solid carbide endmill is our recommendation for machining titanium at high metal removal rates. These solid carbide endmills feature four flute different helix and variable pitch, which enables the cutter to achieve results at high feed rates up to 2xD full slotting applications in titanium. The line offers a diameter range from 4 to 20 mm in grade IC900, which is a tough submicron PVD coating suitable for milling heat resistant alloys, austenitic stainless steel, hard alloys and hard carbon steel at medium to high cutting speeds. APMEN: What new technology/ concept do you have to help operators improve productivity when they make parts for the energy sector? M R : T he I nco ne l c l a dd i n g machining process has become very popular among the companies related to the upstream exploration sector, due to the excellent corrosion-resistant properties. We recommend choosing the carbide insert SNMG 432-EM-R from the ISO line, designed for machining high temperature alloys. One of the most important features www.equipment-news.com
INDUSTRYFOCUS of this IC806 PVD coated insert is the lack of radius. Its 45 deg approaching angle reduces notch wear and allows the increment of both cutting speed and feed, yet achieving long-lasting tool life (See Figure 1). In addition, we have launched the Doveiqmill 845 line. This line is for face milling application in austenitic stainless steel, featuring milling cutters in a diameter range from 50 to 315 mm, carrying square double-sided inserts with eight cutting edges. The combination of the pocket inclination on the IQ845 FSY cutter and high-positive cutting edges on top rake angles of the inserts results in a soft cut and smooth entry into the machined surface as well as a gentle exit from the component. Got a Question? Make An Enquiry.
ENQUIRY No. 7403
Going deeper and deeper into the sea and sea bed is driving demand for high-quality and steel grades diversity on OCTG products. Seamless tubes are the most common in the oil and gas upstream sector. The main components during drilling well operations are tube and coupling. On both, the cut-off operation is one of the most important applications for cutting tools. The following case study shows how the Tang-grip system measures up against conventional and popular brazed carbide blades.
Iscar (TAG N9.5C IC830) Vc = 300 SFM (90 m/min) f = 0.012" ipr (0.32 m/min) Cycle time: 9 sec/cut Material: P110 Diameter: 5 ½" WT: 0,361"
Vc = 223 SFM (67.7 m/min) f = 0.008" ipr (0.20 m/min) Cycle time: 18 sec/cut
Carbide Tool Life
Blade Tool Life
Productivity
65
1500
20
60
1100 1000
55 500 100 45
0
Cutting Time (sec) 18
15 10
50
Brazed Iscar
Brazed tool
9
5 0
50% Productivity Increment
ENQUIRY NO 147
Turn to page 80a or log on to www.equipment-news.com to enquire
Case Study
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INDUSTRYFOCUS
Metalworking
Readies Up For The Oil & Gas Industry
In this energy sector focus, we take a look at Singapore’s oil and gas (O&G) industry and how machine tool and cutting tool manufacturers are bolstering their product range to keep up with the advancements in the industry. By Joson Ng
S
i n gap ore , a cou nt r y with no oil reser ves, is the undisputed oil hub in Southeast Asia and also one of the world’s top three export refining centres. According to EDB, the country’s economic development board, the city state is aiming higher. In fact, the country is looking to kick-start bio-diesel production and develop next-generation technological capabilities in harnessing renewables. A not her a re a where t he country has found success is in the production of offshore structures for the O&G industry, an area that is of immense interest to the metalworking community in the region.
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Accord i n g to K S Chon g, director of sales and marketing at Yamazaki Mazak Singapore, Singapore is the number one producer of oil-rigs in the world. While many may struggle to come up with business reasons to explain why a small country is able to outgun larger competitors like China and South Korea, the reason is actually quite simple. Speaking at a seminar on innovative machining solutions for the O&G industry jointly held by his company and Sandvik Coromant, he said: “It is hard to work outside in the cold of winter, that’s why the delivery is longer.” According to him, as China a nd South Korea both have va ried sea sons, outdoor
temperatures fluctuate greatly. This becomes a problem for the welding proce ss a s low temperatures make joints too cold for welding to be done properly. As such, there is only a window of about nine and a half months for welding to take place in those countries, unlike in Singapore, which has no such problems. The country’s climate is quite constant throughout the year, making the conditions ideal for welding, a process that is used extensively in the O&G industry. Singapore's infrastructure and expertise in project management are also crucial success factors in this segment. It is therefore no surprise that the city state is holding some 70 percent of the world’s market share in the manufacture of offshore oil-rigs. Machining Centre With TurnFace Headstock “All these three areas related to O&G — the oilfield equipment manufacturing, the production of offshore rigs and global oil refining, have certain synergies within each area of business,” he said. This synergy is obviously good news for the metalworking industry as there are plenty of metalworking applications in the O&G space. “A l o t o f c o m p a n i e s i n Singapore are doing what we call OCTG,” he said. OCTG, or Oil Country Tubular Goods consist of pipe and tube products used in the petroleum industry, such as drill pipe, pipe casings and oil pipes. He said that in this space, there are new developments, machining concepts and machine tool designs relevant to the O&G industry. He said when it comes to machining very large diameters on irregular shaped parts which are typically difficult to setup on a turning machine, the operator may have to use a HMC to turn www.equipment-news.com
INDUSTRYFOCUS
Sim Chee Siong
While the technology is said to have the ability to generate turned features such as phonographic finishes on flange surfaces, he cautioned that the technology is only for large diameter machining where roundness requirement is not critical.
KS Chong
Silence Is Golden Another popular and challenging segment in the O&G industry is deep hole machining. This process involves the machining of holes deeper than 10 times the hole diameter. While it is common k now le d g e t h a t de e p ho le
ENQUIRY NO 064
the part. Calling HMC “basically a milling machine”, he said his compa ny ha s developed a n Orbiturn (shaping) function. What this technology does according to him, is it allows a HMC to ‘turn’ a large diameter on a part using the interpolation of the X and Y axes in synchronisation with the spindle orientation with a single point cutting tool on the HMC. This technology allows turned features on large, odd-shaped parts like valve bodies for the O&G industry, which can be a challenge. When these types of parts spin or revolve around a stationary tool, out-of-balance conditions arise due to their masses and often lopsided shapes, leading to poor part quality and safety concern. “The advantage of this is you are able to machine multiple step diameters or taper boring at an affordable cost,” he said.
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INDUSTRYFOCUS machining is a tricky proposition, nickel and super alloys such as Inconel 718, 625, 925, and super duplex have joined the fray to make a difficult task even tougher. The success of this process is dependent on satisfactory chip breaking and the removal of chips from the cutting edge without damaging the tool or work piece. Sim Chee Siong, product and application specialist of Sandvik Coromant, gave a brief introduction on deep hole drilling. While deep hole drilling of bigger holes from 65 mm and above are effectively done by STS drilling, gundrills are designed for deep hole drilling of smaller holes from 1.9 mm to 40 mm. Gundrills are asymmetric in design and the point of the drill is displaced from the centre. In order to absorb the resulting radial cutting forces, these unbalanced drills are provided with ‘support pads’ or circumference shapes to support and guide the tool during the operation. While machine tool manufacturers have a role to play, cutting tool producers h ave lo oke d i nto e f fe c t i ve chip evacuation and vibration management to make sure that deep hole drilling ca n be a Silent tool damper
The circumferential shapes are specially tailored to the respective application.
First Choice Circumferential form G60 Standard form suitable for most materials and drilling jobs.
For Narrow Tolerances Circumferential form C This form is the preferred choice for narrow tolerances in terms of the bore diameter and finish.
Troubleshooting
For Soft Materials
Circumferential form A
Circumferential form D45
Form for awkward approaches to drilling work or cross drilling, machining of soft materials and poor performance of cooling lubricants. Also suitable for emulsion.
The form is almost exclusively used for soft materials, such as grey cast iron, graphite; especially in conjunction with narrow bore tolerances.
controlled and stable process. “ T h e ke y to su cce s s i n gundrilling is coolant pressure. An 8 mm gundrill will require more than 60 bars of coolant pressure for the effective evacuation of the chips,” said Mr Sim. “If you don’t have high-pressure coolant, it is a bit risky when the depths go to more than 40xD.” He a lso adv ised the use of good holders such as high precision hydraulic chuck which gives good concentricity that can help increase the tool life of the gundrill. He added that a sealed collet used with hydraulic chucks will minimise coolant leakage problem and ensure good coolant
pressure, unlike in some of the side locks adapters. In terms of vibration control, he said his company’s Silent Tools or anti vibration bars are designed for boring from 7xD up to 14xD. The dampening system in the tool consists of a heavy dampening mass body, springs and some viscous liquid. It is said that the kinetic energy induced by the vibrations will be absorbed by the dampening system. “The difference between the Silent Tool and normal boring bars is that when the cutting insert engages the material, it (Silent Tool) will trigger the (dampening) mechanism and cut off the vibration frequency. For the normal steel bar, the vibration frequency will just go on and on until it stops.” Finally, he shed light on how this system fared in real life applications. In the manufacture of gate valve bodies, the presence of interrupted cuts is a real vibration generator. He said special elliptical damped bars with optimised shape were used to achieve productive machining as well as smooth surface finish and better insert life. Got a Question? Make An Enquiry.
ENQUIRY No. 7404 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 154
FEATURES
Schunk
Coming Into Grips With SEA A German manufacturer of clamping and gripping solutions has recently set up a regional base in Singapore. By Joson Ng
I
n order to establish a stronger presence here in Southeast Asia, Schunk has set up an office and distribution centre at the German centre in Singapore. The company began operations on July 1, 2014 and Asia Pacific Metalworking Equipment News paid Koh Keng Lim, regional sales manager in charge of Southeast Asia, a visit to gain a better understanding of the company’s plans for the region. A PMEN understa nds that the 170 sq m office in Singapore is the company’s fifth in the Asia Pacific region. Apart from the office, the company also has an 80 sq m warehouse to house critical stock. With the initial startup investment of S$800,000 ( US$638,000), the company is looking to expand their headcount in 2015 from the current three. The operation here may not be the largest compared to other locations in Asia Pacific (a region that is responsible for roughly 10 percent of the company’s total revenue in 2013), but there is potential for growth. “We see strong potentia l for growth. We are looking at a 30 to 40 percent growth in tota l revenue from ex isting revenue across Southeast Asia,” said Mr Koh. The reasons for t his opt im ism stem f rom a few factors, but na mely the company’s distribution network in the region.
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Local Presence Mr Koh revealed that the main functions of his office are to give a stronger support to the distributors as well as establish a direct relationship with key strategic customers. “We set up an office here to increase the awareness of our products in Southeast Asia. Another reason is to support the distributors over here,” he said, before telling APMEN that he has distributors in Singapore, Malaysia, Thailand, Indonesia and the Philippines. Balluff and Eureka Tools represent the company in Singapore while SK-Tec and Precisetech cover the Malaysian market for him. Brainworks, PT Metaltech and Bon Industrial take care of business in Thailand, Indonesia and the Philippines respectively. For Mr Koh, the distribution network is crucial to the success of the company in this region and it is very much an arrangement that is mutually beneficial. “We need our distributors
Mr Koh believes the distributor network is crucial to the success of the company in this region.
to increase our network across Southeast Asia. The synergy between the distributor and our office here will be getting stronger. We want to work closely with them, not forgetting that we also want to have more knowledge of new markets,” he said. This thirst for knowledge also extends to Vietnam, where Mr Koh hopes to break into sooner rather than later. “We went to MTA Vietnam in July as we wanted to create our presence over there. We want to be there as early as possible. We are looking for suitable candidates over there and we are targeting the first quarter of 2015 (to get distributors in Vietnam),” he said. Market Outlook & Future Plans Southeast Asia is a region with a high level of diversity. While language is one such area, the fabrics that make up each economy are very different from country to country. As a result, it is important to consider each country individually rather
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FEATURES
The company’s solutions fall under clamping and gripping devices.
of the way. As such, the economy will pick up soon and we will see a brighter 2015,” he said. The year 2015 will be a very important one for the company’s unit in Southeast Asia. As such, Mr Koh has plans to accelerate his company’s footprint across this region. He revealed that the company will conduct technical seminars,
first for their employees and distributors before organising one for their customers sometime in the first half of the year, possibly in Singapore. This is in line with his company’s ethos in providing good before and after sales services. Got a Question? Make An Enquiry.
ENQUIRY No. 7501 Turn to page 80a or log on to www.equipment-news.com to enquire
ENQUIRY NO 152
than treat them as a whole. “While dealing with five different countries, the type of investment might be slightly different. Thailand and Indonesia focus on the clamping portion (work and toolholding), they belong to the end user market along with the Philippines. Singapore and Malaysia on the other hand, have more machine integrators and makers. As such, we see more automation there,” he said. Although each country has its own idiosyncrasy, they all have one common trait according to him, ie: they all have room for growth. Having said that, Mr Koh picked out Indonesia as the country with the largest potential. “Among the five (nations), the revenues are pretty even. However, Indonesia is the fourth most populous country in the world and they just got the election out
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FEATURES
Mr Telford feels modern business intelligence systems need to be more flexible and have the ability to interrogate data.
physical flow of materials. A lot of time they use ERP (system). Using the data available, better decisions can be made with regard to material flow.” According to him, some users ca n avoid mov ing materia ls across borders unnecessarily if they interpret the data available intelligently.
Making Intelligent Decisions With
Smarter Data Analysing a huge amount of data and breaking them down into easy-to-understand visuals can help manufacturers make correct decisions quickly. By Joson Ng
D
ata used to mean endless stacks of papers. It used to be easy to picture them and most people know what they are in the physical sense. Data in the digital age is far more of an abstract entity. I picture matrices — random numbers that do not mean anything to some but are highly important to others. The key here is making sense of data (how we analyse them) and making use of data (how we leverage the power of data to improve our businesses). I n to day’s bu sine ss a nd manufacturing world, transforming raw data into meaningful and useful information for the purpose of business analysis is crucial and this
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by default makes it a big business. This is particularly true as we enter the age of big data and an ever competitive manufacturing environment. “Information is the one thing that CIOs increasingly need to be content with. They are under pressure from CEOs to make better decisions out of the assets (data) they already have,” said David Telford, senior director, manufacturing & service (industries group lead), Qlik. He gave an example where using data in an intelligent manner can allow people to make sound decisions and cost sav ings. “Manufacturers traditionally manage many different kinds of
Overcoming Challenges The manufacturing space has evolved tremendously. While innovations can be breath-taking at times, the business aspect of manufacturing can be very unforgiving and demanding. “The global manufacturing industry needs to be more agile and manage cost and efficiency better, at the same time, face increasing level of competition and cost pressure,” said Mr Telford. These challenges, combined with the necessity to understand customers better and get to markets quicker while reducing obsolescence has made many business owners rev isit the notion of business intelligence. After all, according to Mr Telford, the ability to analyse data and make timely decisions based on that is what gives companies a competitive advantage. Dusting Out The Cobwebs Since the 1990s, many companies have migrated certain business or manufacturing functions into ERP www.equipment-news.com
FEATURES
Data is the raw material of our time – David Telford need more flexibility and the ability to interrogate data and expect answers,” said Mr Telford. This trend has given rise to associative features in business intelligence software programs. What that means is a user can take data from multiple sources, combine them in memory and link
them around a common attribute, which incidentally is the basis for building applications in QlikView, a business intelligence software developed by Qlik. These apps allow users to look at cell performance and see which product performed well and the associative factors around that
ENQUIRY NO 066
systems or various other business management suites to collect, store, manage and interpret data from various business activities like inventory management and shipping & payment. It is fair to say they have amassed a huge amount of data and there is growing pressure to tap into these data to gain a competitive edge. Instead of archiving the data in the inner reaches of the server and make little use of it, some companies have turned to selfservice business intelligence tools that allow data visualisation and collaboration, helping such business intelligence suites gain a reasonable market share in recent years. “ Tr a d i t i o n a l b u s i n e s s intelligence is more report-centric. Reports are defined by IT and users are served static reports. In today’s context, users increasingly
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FEATURES QlikView provides a collaborative platform that allows users to share information even if the party is not a license holder.
particular performance. This can be likened to going back to the IT department and asking them for a new report in the static reporting environment. In terms of building apps, users can pull data from any source (eg: ERP). The program allows the use of structured, unstructured, internal and external data. The company also has consultants to help users build their unique applications. Typical use of the app includes S&OP process. Mr Telford added that the product provides a collaborative platform that allows users to share information even if the party is not a license holder. Know What You Are Doing Although such self-service business intelligence tools are powerful platforms for businesses, Mr Telford cautioned that users need to know what they are doing with it. “Some early customers, they try to boil the ocean. They were trying to measure the entire process from engineering concept to customers’ return, trying to get everything into a single app. It is important you construct an app that is consumerable and breaks processes into logical steps,” he said. At the end of the day, the message here is to eliminate risks by careful design and proper understanding of what the user is trying to manage. 68
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Business Intelligence For SMEs Words like ‘big data’ and ‘business intelligence’ may put SMEs off but according to Mr Telford, his applications are suitable for SMEs and contract manufacturers in Southeast Asia to help them digest big data into something manageable. “QlikView is deployed by organisations of all sizes so in our initial growth as a company, it was
driven by mid-markets and small businesses. The kind of challenges SMEs face in terms of managing brands, customers, production processes, and operations tend to be identical to an organisation 20 times their size,” he said. Despite the suitability of the product for SMEs, it is not to say that the company had it easy at the start. “In Europe initially, we put in quite a significant effort to help the market learn the difference between the two approaches (business discovery or data discovery) to business intelligence,” he said. For Asia however, he felt that things will go smoother. “My take on Asia is everything is rapidly accelerated as it is a much more dynamic and responsive market place,” he said. He revealed that in Asia, the company is “doing well” in India, particularly in its automotive sector. Got a Question? Make An Enquiry.
ENQUIRY No. 7502 Turn to page 80a or log on to www.equipment-news.com to enquire
Two Ways How Data Visualisation Can Help Businesses Mercedes-Benz (India) The company has the densest network among all luxury car manufacturers in India and they needed a more effective reporting process to senior management. Solution Deployed QlikView across sales, plant operations as well as HR departments. Results The company managed to speed up the process of data analysis, making reporting to senior management more effective, and helped to steer the aftersales business to success.
Kobe Steel (Japan) The company needed to understand the challenges of factories located in different places in Japan and ensure operational optimisation. Solution They developed an app to collect data from operational systems located in different places, and shared this information across the enterprise. The app helped analyse purchase results to plan/predict purchase estimates, in order to implement strategic operational activities. Got a Question? Make An Enquiry.
ENQUIRY No. 7503 Turn to page 80a or log on to www.equipment-news.com to enquire
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Shifting Metalworking’s Paradigm
19-22 NOVEMBER 2014
BITEC BANGKOK THAILAND ASEAN’s Largest International Machine Tools and Metalworking Technologies Trade Exhibition & Conference - 28th Edition
ASEAN metalworking landscape is about to change. As we are crossing into the new era of the AEC, becoming ready for new opportunities and challenges has become a critical quest of industrialists’ across Southeast Asia. As an Exhibitor of METALEX 2014, you will play a vital role in the preparation process of your customers. Equipped with the latest technologies from you and over 2,700 brands plus new knowledge and regional collaborations the event will provide, the 70,000 Visitors at the show will definitely be ready to shift into the more dynamic environment of the AEC. Come join METALEX 2014 to grow your business and ASEAN’s pride as the manufacturing hub of the world.
ENQUIRY NO 129
For more information: Tel. +66 2686 7299 e-mail : metalex@reedtradex.co.th
w w w. m e t a l e x . c o . t h
Officially Supported by:
Organized by:
EVENTS& EXHIBITIONS Event Preview:
Metalex
A
t the 2014 edition of Metalex, the theme will be ‘The Pride of ASEAN. Shifting Metalworking Paradigm’. According to organiser Re e d Trade x , so me 70,0 0 0 manufacturing industrialists will discover new ways of upgrading their productivity at the show. T h i s i s p o s sib l e a s t he exhibitors are expected to bring over 4,000 new machineries and technologies to the show where there will also be live demonstrations. All in all, the show will house over 2,700 brands from 50 countries including nine international pavilions. The organiser also promised a number of products making their ASEAN debuts. Away from the show floor, t here w ill be t hre e a n nua l industry conferences, namely ‘Metalex Congress’, ‘Metalex Nano Forum’ and ‘Metallurgy Forum’. Together, they will help attendees uncover new industry direction, business strategies, and industrial advancements. According to the conference organiser, not only participants get to learn new know-how and best practices, the conferences are good platforms for business networking. Finally, the show is also a place for visitors to broaden their business connections with the innovators and influencers in the industrial community. There will be business inducing activities such as BUILD Market Place, Business Matchmaking Program where participants can expand network, recruit new agents, seek new or alternative suppliers and explore new business opportunities. BITEC Bangkok, Thailand November 19 – 22, 2014 Got a Question? Make An Enquiry.
ENQUIRY No. 7601 Turn to page 80a or log on to www.equipment-news.com to enquire
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EVENTS&EXHIBITIONS
Metalex Providing A Platform For Die & Mould Industries To Strengthen Collaboration The role of Metalex is to promote knowledge a n d te c h n o l o g y o n metalworking in the ASE AN region. This year, there is an added sweetener for visitors from the Philippines. Not only do they get to come into contact with new technologies and know-how while participating in networking functions, Thailand Convention and Exhibition Bureau (TCEB) is offering a ‘Connect Businesses Big Bonus’ for visitors from the Philippines. Both Thailand and the Philippines have well-developed mould and die production industries. As a matter of fact, the show organiser says the two leading mould and die associations
are looking for ways to collaborate in the tooling industry. In the talk on ‘Mutual benefits of the Philippines-Thai Die and Mould Industry Moving Together’, Kamon Nakasuwan, president of Thai Tool and Die Industry Association (TDIA) and Phillip C Ang, president of the Philippines Die and Mold Association, emphasised the trade benefits coming from AEC and how this will lead to growth of export of moulds and dies to other countries in the region. Thailand’s mould and die industry was developed over the past 35 years and has highly skilled workers for a wide variety of mould and die making in response to demand for tooling from many industrial sectors such as automotive parts, engine parts, electrical parts and electronic parts. Its strong automotive sector has pushed the mould and die sector to adopt the latest technologies available and to continuously improve workers skills. The Philippines too has seen similar development, as the Japanese investors in the automotive industry have introduced modern mould and die making technologies to the country. Got a Question? Make An Enquiry.
ENQUIRY No. 7602 Turn to page 80a or log on to www.equipment-news.com to enquire
THINK PARTS THINK TORNOS
CT 20 From simple to mid complex components, the CT 20 is designed to meet your requirements. 4 or 5 linear axes Up to 26 tools ■ Up to 10 rotating tools ■ FANUC control ■
Your nearest representation : Tornos Malaysia Penang Tornos Thailand Bangkok
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ENQUIRY NO 010
■
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EVENTS&EXHIBITIONS
Event Preview:
Manufacturing Indonesia
M
anufacturing Indonesia Series 2014 is scheduled to return from December 3 – 6, 2014 at the Jakarta International Expo Centre, Kemayoran, Jakarta. The manufacturing and engineering trade event is into its 25th series and will feature the latest cutting edge technologies, innovations and practical solutions from around the globe, providing a perspective on the multitude of application opportunities to engage Indonesia’s evolving industrial developments. The largest and most international manufacturing event in Indonesia will span across all available halls at the venue including two supplementary custom constructed halls to occupy over 34,000 sq m of exhibit space. In total, the show is expected to gather over 2,200 exhibiting companies from 40 countries, with more than 20 group pavilions from China, Germany, India, Japan, South Korea, Malaysia, Singapore, Taiwan, Thailand, Turkey and the UK. The event’s strategic bedrock — Machine Tool Indone sia, is hosting participation from
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global brands such as DMG/ Mori Seiki, Haas Automation, Hurco, Mitsubishi Electric, Sodick, Shenyang Machine Tool, Trumpf, and Yamazaki Mazak. The event is now into its 28th staging. Ma nufacturing solution inte g rators f rom I ndone sia presented at the event include Altama Surya Asa, Angsa Putih Kurnia Kharisma , First Machinery Trade & Co, Indah Jaya Teknik Presisi, Jaya Metal Teknika, Kawan Lama Sejahtera, Somagede Indonesia and Rukun Sejahtera Teknik, among others. Concurrent events are Industr ia l Automation & Logistics Indonesia and Tools & Hardware Indonesia. They a re prima r y gateways themselves but together they reinforce the integrative nature of Ma nufacturing Indone sia Series 2014 as a comprehensive a nd progressive end to end manufacturing platform, facilitating heightened engagements between solution providers and users, buyers as well as trade professionals. “With its combination on depth and breadth of exhibits, the
Manufacturing Indonesia Series 2014 has emerged as an important focal point for the manufacturing and engineering community,” said Maysia Stephanie, senior project manager for the organiser PT Pamerindo Indonesia. “Manufacturing needs and expectations have been evolving. It is therefore important for manufacturers to consider the relevance of available innovations and practical approaches that can enable them to address prevailing production and engineering challenges. Through the exhibition we are hopeful that the manufacturing and engineering community at large will be able to identify with effective production solutions that they may pursue as they expand on production bandwidth. Exhibitor participation is a testament, in particular, to the commitment of the many technolog y a nd solution providers in partnering Indonesia’s manufacturing and industry developments,” she added. The event is supported by the Ministry of Industry, Republic of Indonesia, A ssociation of Metalwork and Machinery (ASPEP), Indonesia Precision Tooling Industry Association (A I PPI N D O), I n do ne sia n Automotive Parts & Components Industries Association (GIAMM), Indonesian Machine Tool Industries A ssociation (ASIMPI), Indonesian Mould & Die Industry Association (IMDIA) and Federation of Indonesian Metalwork & Machinery Industries Association (GAMMA). Jakarta International Expo Centre Kemayoran, Jakarta December 3 - 6, 2014 Got a Question? Make An Enquiry.
ENQUIRY No. 7603 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 052 ENQUIRY NO 055 www.equipment-news.com
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PRODUCTFINDER Agathon: Increasing Efficiency In Production
Delcam: Inspection Software Enhanced
Agathon has developed backlash-free, round fine centering units used for the centering of parting plates/mould halves in tool construction. Due to the integrated cage retaining system, the preload can be exited at every stroke movement. According to the manufacturer, users can benefit from the unit’s lower total cost. They also claim the centering units require little to no maintenance, can be used in a clean room environment, has high initial load capacity and has longer lifespan than sliding systems. Four standard sizes are available from stock.
Delcam’s PowerInspect inspection software has a new interface with new icons that make the software more intuitive and easier to use. Other enhancements in this version include the ability to create compound items, and so speed up and simplify repetitive measurements. There are also enhancements to the measurement dialogs and a further increase in the range of geometric features that can be inspected. In addition, the software program now has the ability for users to create custom toolbars, which allow frequently-used commands to be grouped together in one convenient place, and so improve speed and ease of use. It is possible to export and import toolbars, so users can transfer their set-up to a different PC or share their toolbars with other operators. Finally, the product now includes improved support for the Renishaw PH20 probe.
Got a Question? Make An Enquiry.
ENQUIRY No. 7701 Turn to page 80a or log on to www.equipment-news.com to enquire
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Autocrib: Object Recognition Capabilities For Automated Inventory Control
Faro: Fast Scanning Speed & High-Definition Data Clarity
AutoCrib’s Ver tica l Lift Modules (VLM) can reach a height of up to 40 feet with the option to ascend in 6 -inch increments. Within the elevated racking systems, the automated inventory control system offers lifting and storage capacity of parts, equipment a nd supplies up to 50 0 pounds per tray. The storage system’s three standard VLM models are said to deliver the industry’s first object recognition capabilities integrated into a vertical lift system. The optional real-time tracking of objects works to record items as they are issued or returned to the storage tray. The module occupies a minimal footprint (5 feet 9 inches wide and 8 feet 3 inches deep) and the control system allows the operator to retrieve parts by tray, part number or description.
Fa r o Te c h n o l o g i e s h a s developed the Faro Edge ScanArm HD (Laser Line Probe HD). According to the developer, the product delivers rapid point cloud collection with good resolution and high accuracy. The functionalities enable users to scan across diverse surface materials regardless of contrast, reflectivity or part complexity and without any special coatings or target placement. The product is suitable for product development, inspection, and quality control and offers capabilities such as point cloud comparison with CAD, rapid prototyping, reverse engineering, and 3D modeling.
Got a Question? Make An Enquiry.
ENQUIRY No. 7702 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY No. 7703
asia pacific metalworking equipment news October 2014
Got a Question? Make An Enquiry.
ENQUIRY No. 7704 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY NO 115
PRODUCTFINDER
Rollomatic: Three-Axis Peel Grinder EURO BLECH
Got a Question? Make An Enquiry.
ENQUIRY No. 7705 Turn to page 80a or log on to www.equipment-news.com to enquire
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PURE BRED EFFICIENCY FOR TOOLING DESIGNS.
STANDARD GUIDING ELEMENTS THAT ARE ANYTHING BUT STANDARD: High-precision standard and special design guiding elements.
WWW.AGATHON.COM AGATHON AG | CH-4512 Bellach phone +41 32 617 45 01 | fax +41 32 617 47 01 normalien@agathon.ch | www.agathon.com RENOWNED FOR EFFICIENCY AND PRICE!
ENQUIRY NO 148
Rollomatic ha s developed a peel grinding machine. The ShapeSmart NP3 is a singlewheel cylindrical grinder with peel and traverse g r i ndi n g c apabil it ie s. Particularly suited as a versatile peel grinder for manufacturing blanks for the cutting tool industry, precision punches and other similar parts, this machine is suitable for competitive grinding houses to produce the highest quality round products with total cost-efficiency. The manufacturer says the machine is equipped with a 8.5 kW spindle motor and a wheel diameter of 250 mm and it allows grinding parts requiring high material removal.
2014: Hall 13/Booth D76
October 2014 asia pacific metalworking equipment news
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PRODUCTFINDER Schunk: Fast, Efficient & Precise Quick-Change Pallet Systems
Thomson: High Performance Miniature Linear Motion Component
T h e Ve r o - S NSE plus 99, NSE plus 10075 and NSE-M plus 138 (manual) quick-change pallet systems offer a range of additional features, says developer Schunk. According to the company, the products feature pull-in force (standard) of 4 kN. Designed entirely in stainless steel, the systems have fully sealed module and clamping pins compatible with all NSE plus modules. Finally, with a uniform clamping pin size for the entire series, the system has flexibility and is for universal use with all the company’s quick change pallet modules. At the same time, users profit from more than 500 workpiece clamping device variations in combination with the company’s range of stationary clamping vises.
Thomson Industries, a manufacturer of linear and rotary motion solutions, has expanded its range of miniaturised components. The precision TSI Rolled Ball Screws offer high load capacity, smoothness, and quiet operation which can be customised. Its design offers up to two times more load capacity than alternate ball screws, resulting in longer life and better return on investment. The Miniature Metric Ball Bushing Bearings on the other hand, offer smooth and rapid operation in a light, compact package — lasting up to 27 times longer than conventional linear bearings.
Got a Question? Make An Enquiry.
ENQUIRY No. 7706 Turn to page 80a or log on to www.equipment-news.com to enquire
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Seco: Turning Superalloys & Hardened Steels
Widia: Universal Hydraulic Chuck
Seco has widened its range of solutions for demanding materials with further additions to its turning grades. The TH1000 and TH1500 are available in both negative and centre-locked-styled inserts. A TiSiN-TiAIN nanolaminate PVD-coated grade, TH1000 is suitable in operations involving lower cutting data and interrupted cuts. It brings toughness and high chip resistance to the turning of hardsurfaced components and finish turning of hardened steel parts (HRC 50-62). Intended to handle higher cutting data, TH1500, which features the company’s Duratomic coating, brings a combination of wear resistance and edge toughness to continuous cut operations involving hardened steel components (HRC 40-55).
Widia now has the HydroForce, a hightorque universal hydraulic chuck. With a more compact and stable design, featuring a 40 percent thicker front wall cross-section, the chuck provides the increased rigidity necessary for improved cutting parameters and better results. Clamping force is up to three times better than regular hydraulic chucks, and with improved vibration dampening, runout is three microns at 2X diameter overhang. Balance quality of G2.5 is achieved at speeds up to 25,000 rpm. The manufacturer says it is more cost-effective than thermo shrink-fitting operations; up to four times more clamping force compared with collet chucks; and higher balancing quality performance than power milling chucks.
Got a Question? Make An Enquiry.
ENQUIRY No. 7707 Turn to page 80a or log on to www.equipment-news.com to enquire
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ENQUIRY No. 7708
asia pacific metalworking equipment news October 2014
Got a Question? Make An Enquiry.
ENQUIRY No. 7709 Turn to page 80a or log on to www.equipment-news.com to enquire
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EXHIBITIONPROGRAMMES
EXHIBITION
PROGRAMMES
2014-2015 OCTOBER
NOVEMBER
SECC Ho Chi Minh City, Vietnam Reed Tradex metalexvietnam@reedtradex.co.th www.metalexvietnam.com
JI Expo Kemayoran Jakarta Jakarta, Indonesia PT Napindo Media Ashatama yulisa@napindo.com www.indoaerospace.com
9 – 11 Metalex Vietnam 2014
13 – 15 AMB China
Nanjing International Expo Centre Nanjing, China Messe Stuttgart China ambchina@messenanjing.cn www.ambchina.com
21 – 25 Euroblech
5–8 Indo Aerospace 2014
11 – 13 Indometal
5–8 Indo Marine 2014
2015
JI Expo Kemayoran Jakarta Jakarta, Indonesia PT Napindo Media Ashatama yulisa@napindo.com www.indomarine.org
5–9 TMTS 2014
Exhibition Grounds Hanover, Germany Mack Brooks Exhibitions info@euroblech.com www.euroblech.com
GTIEC Taichung, Taiwan TMBA ricky@tmba.org.tw www.tmts.tw
29 – 31 Intermach Myanmar
12 – 14 Welding Busan Korea 2014
Tatmadaw Exhibition Hall Yangon, Myanmar UBM Asia (Thailand) info@intermachmyanmar.com www.intermachmyanmar.com
29 – 31 Indonesia Mining & Engineering
Jakarta International Expo Jakarta, Indonesia Reed Mining Events hanung.hanindito@reedpanorama.com www.miningandengineeringindo.com
Oct 30 – Nov 4 JIMTOF 2014 Tokyo Big Sight Tokyo, Japan JMTBA www.jimtof.org
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BEXCO Busan, South Korea Metal Network Korea Company www.weldingasia.org
19 – 22 Metalex
BITEX Bangkok, Thailand Reed Tradex metalex@reedtradex.co.th www.metalex.co.th
DECEMBER
3–6 Manufacturing Indonesia Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com
JI Expo Kemayoran Jakarta Jakarta, Indonesia Messe Dusseldorf Asia beattrice@mda.com.sg www.indometal.net
JANUARY
14 – 16 NEPCON Japan Tokyo Big Sight Tokyo, Japan Reed Exhibitions Japan inw@reedexpo.co.jp www.nepconjapan.jp
MARCH 3–8 TIMTOS
TWTC Nangang Exhibition Hall Taipei, Taiwan TAMI timtos@taitra.org.tw www.timtos.com.tw
APRIL
14 - 17 MTA 2015
Singapore Expo Singapore SES mta@sesallworld.com www.mta-asia.com To be considered for inclusion in the calendar of events, send details of event to:
The Editor (APMEN) Eastern Trade Media
1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Email: josonng@epl.com.sg Tel: +65 63792888
October 2014 asia pacific metalworking equipment news
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ADVERTISING INDEX Advertiser
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AGATHON AG
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148
AGMACHINE TECHNO CO LTD
59
147
AWEA MECHANTRONIC CO LTD / GOODWAY MACHINE CORP
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049
BENIGN ENTERPRISE CO LTD
41
139
BYSTRONIC PTE LTD
05
136
CAIRNHILL METROLOGY PTE LTD
37
161
DEES HYDRAULIC INDUSTRIAL CO LTD
75
055
DELCAM PLC
07
099
DOOSAN MACHINE TOOLS (PT FRISINDO MITRA USAHA)
25
163
EVERISING MACHINE CO
55
151
FRITZ STUDER AG
31
142
GANRO INDUSTRIAL CORP
67
066
GF MACHINING SOLUTIONS PTE LTD
39
155
HAAS AUTOMATION INC
11
133
HEIMATEC GMBH
27
153
HEXAGON METROLOGY ASIA PACIFIC PTE LTD
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149
HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD
17
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HWACHEON ASIA PACIFIC PTE LTD
21
143
INGERSOLL-RAND SOUTH EAST ASIA (PTE) LTD
19
141
ISCAR LTD
IFC
134
KENNAMETAL INC
BC
102
LICO MACHINERY CO LTD
75
052
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53
146
LVD COMPANY NV
35
140
OPTICAL GAGING (S) PTE LTD
23
138
OSBORN SINGAPORE PTE LTD
57
162
PALMARY MACHINERY CO LTD
61
064
REED TRADEX COMPANY (METALEX THAILAND 2014)
71
129
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33
157
SANDVIK SOUTH EAST ASIA PTE LTD
80
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SCHUNK INTEC PTE LTD
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SECO TOOLS (S.E.A) PTE LTD
01
070
SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2015)
65
152
SOFIMU SRL (EMO MILAN 2015)
63
154
SUMITOMO ELECTRIC HARDMETAL ASIA PACIFIC PTE LTD
45
077
TAEGUTEC CO
13
158
TAIWAN EXTERNAL TRADE DEVELOPMENT COUNCIL / TAIWAN IMAGE
69
159
TAIWAN TAKISAWA CO LTD
77
115
TORNOS TECHNOLOGIES ASIA LTD
73
010
TUNGALOY SINGAPORE (PTE) LTD
IBC
135
UBM ASIA (THAILAND) CO LTD (INTERMACH 2015)
49
160
WALTER AG SINGAPORE PTE LTD
09
137
WALTER EWAG ASIA PACIFIC PTE LTD
43
156
WIKUS SAGENFABRIK WILHELM H KULLMANN GMBH & CO KG
29
027
YIH CHUAN MACHINERY CO LTD
47
127
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ASIA PACIFIC METALWORKING
No. 7 2014
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CNC Machining Milling Gear Cutting Grinding Stamping Shearing
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is Better Thinking. ™
INTRODUCING
The Stellram Platform
®
7792VX High feed milling cutter designed to yield the highest levels of productivity by increasing metal removal rates — as much as 90% — in titanium and other mission-critical metallics. ™
X-Grade Carbide inserts with up to 3 times the normal tool life for high-temperature heat resistant alloys. Designed for use on nickel-, cobalt-, and titanium-based alloys. ™
Different Thinking is the leadership to transcend what customers need — and deliver solutions they can’t live without. Kennametal’s unique perspective, forged from more than 75 years of experience, allows us to see beyond the expected and engineer perfect solutions. Different Thinking is Better Thinking — and this powers our continued commitment to delivering productivity in the most demanding environments.
www.kennametal.com ©2014 Kennametal Inc. l All rights reserved. l A-14-03805
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