APMEN Oct 2016 by Eastern Trade Media

TURBINE HOUSINGS Made Affordable p26

TIME FOR DIRECT DIGITAL MANUFACTURING? p62

Where Are You Going

INDUSTRY 4.0? p66 October 2016

www.equipment-news.com

ROLLING WITH

ADDITIVE MANUFACTURING

IN THE AUTOMOTIVE SECTOR 3D Printing:

MODULAR PROTOTYPE PRODUCTION

WITH LASERS

START FINISH

WITH FIBRE LASER

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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

ISCAR TAIWAN 395, Da Duen South Rd. Taichung 408 Tel + 886 (0)4 247 31573 Fax + 886 (0)4 247 31530 iscar.taiwan@msa.hinet.net

ENQUIRY NO 124

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

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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

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

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

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

NO 127

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ADVERTORIAL Asia Pacific Metalworking Equipment News • October 2016

DIGITAL

TECHNOLOGIES TRANSFORMING PRODUCT DESIGN

Digital technologies are transforming the ways produc t s are designed, manufactured and maintained, with the potential to radically transform business models and create new opportunities. This impacts all manufacturers including start-ups, SMBs and global enterprises. Many small companies see that digital technologies can level the playing field and that they have an advantage over larger companies when it comes to quickly adopting new technologies. SMB manufacturers are leveraging digital CAD models of their products not just in the traditional detail design and manufacturing areas, but increasingly for concept design, marketing, installation, service and maintenance. In terms of managing their designs and projects, they may start with the built-in data management capabilities in Solid Edge, but as they grow they are able to easily expand to Teamcenter when they need full PLM. Siemens supports SMB manufacturers in every step of their digital transformation and our solutions are designed to scale as the company grows and their needs evolve.

Additive manufacturing is another r apidl y growing te chnolo g y t hat enables the trend towards customisable mass production, and replacing the previous focus on the creation of individual prototypes. Siemens Solid Edge sof t ware integrates direc tly with apps like Microsoft’s 3D Builder that help manufacturers prepare their 3D C AD models for production on their in-house 3D printers, and cloudbased solutions like 3YOURMIND that allow them to submit their designs for quoting and production in a variety of materials by globally distributed service providers.

The next 10 years will be an exciting time for designers and engineers who can take advantage of new mobile and cloud technologies that are being in c re asin gl y ap p lie d to re s o urce intensive engineering sof tware applications. Designers will no longer be tied to working on heav y dut y CAD workstations in the design office; they can become more mobile as CAD software is optimised to run on mobile devices. This opens up a world of possibilities for better communication an d m or e c r e at i ve co llab or at io n throughout the organisation – and with customers and suppliers.

Local Motors is reinventing the way cars are designed and manufactured. New design concepts are crowd sourced from their global, online community, and then they build the cars, almost entirely through 3D printing, in local micro factories. Local Motor’s ability to continually embrace new digital technologies is one of the keys to their success. Local Motors uses Solid Edge for product design and development and synchronous technology enables them to seamlessly import and edit CAD models from design collaborators around the world.

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ENQUIRY NO 130

CONTENTS

Asia Pacific Metalworking Equipment News • October 2016

METAL CUTTING

Manufacturing Turbochargers:

Turbine Housings Made Affordable

Roughing and finishing turbine housings is particularly challenging in the case of passenger cars with spark-ignition engines. By Lim Gan Shu, marketing manager, Walter AG Singapore.

Acoustic Emission Sensors

The application of the acoustic emission (AE) sensor for monitoring can supply valuable information regarding the discontinuity in material. By Tim Wood, international sales manager, SBS Dynamic Balance and Process Control Systems

GREAT GEAR & SYSTEM

Maximising Productivity Minimising Waste

Efficient and cost-effective processes are crucial to creating a sustainable manufacturing industry. By Dr Chen Wei Long, director, Sustainable Manufacturing Centre, SIMTech

Making The Right Choice:

Smart Materials

APMEN interviewed Dr Tim Hosenfeldt, senior VP, corporate innovation, Schaeffler, on the importance of material choice and the application of smart materials in the manufacturing and production sector.

Why Laser Tracker Technology Is More Efficient For Aluminium Extrusion Press Alignment

Using a laser tracker, a metrology engineer can quickly capture high tolerance dimensional measurements – including conventional level and square measurements. By Hubert Meagher, director of metrology services, OASIS Alignment Services LLC.

IN DESIGN

Measuring & Machining The Bigger The Better

Overcoming the challenges of machining very large workpieces weighing over 10 tonnes. By Thomas Weber, head of customer relations, Heinrich Georg

Laser Trackers:

Accuracy In Aircraft Assembly

These trackers make extremely appealing metrology instruments, especially the ability to capture large volumes of 3-dimensional coordinate data quickly and in real-time. By Minta Chen, marketing specialist, Faro.

Precise Measurements In Record Times

What are the benefits when coordinate measuring machines (CMMs) are used simultaneously as gear measuring centres? By Sea Chiahui, regional stationary product manager at Hexagon

Manufacturing Accuracy Regardless Of Circumstances

Closed loop position measurement provides high accuracy in any situation with small series. By Helmut Kügel, Heidenhain’s product management encoder.

Keeping Pace With Production

When perfect volume cuts are required in wet or dry cutting situations, the solution lies with a high-performance automatic circular saw.

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locate us at Booth AF02 23rd - 26th november the Grand metalex 2016 Bangkok

ENQUIRY NO 113 10-year warranty on materials and manufacture of GARANT workstations and storage products, excluding regular wear as a result of mechanical stress and excluding products installed in containers. .

CONTENTS

Asia Pacific Metalworking Equipment News • October 2016

REGULARS

12 Business News 75 Product Finder 79 Exhibition Programmes 80a Product Enquiry Card

Speeding Up And Simplifying Inspections

Image dimension measurement system puts much faster in-process inspection within everyone’s reach. By Keyence

FAST FAB

Start-to-Finish Strategy With Fibre Laser

Yes, it is fast, but while fast-cutting speeds open up the potential, there are still the upstream and downstream manufacturing processes to consider. By Oliver Hergt, corporate communications, Bystronic

Voice of the Industry:

Is Now The Time To Try Direct Digital Manufacturing?

Scott Crump, chairman and chief innovation officer of Stratasys explains how 3D printing makes manufacturers rethink manufacturing.

Where Are You Going Industry 4.0?

Industry 4.0 rapidly made it to the headlines in Germany, but where does it stand in reality? By Dipl-Ing Nikolaus Fecht and Dr Andreas Thoss on behalf of Euroblech.

FEATURES

The fundamental objectives of manufacturing — improve quality, decrease cycle time and reduce costs — are the primary reasons that jigs and fixtures are so abundant. By Joe Hiemenz from Stratasys

SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/ Europe/Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2886 Singapore E-mail: nurulhuda@epl.com.sg

THE CIRCULATION OF THIS MAGAZINE THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

Industry Endorsements Singapore Precision Engineering and Tooling Association (SPETA)

Rolling With Additive Manufacturing In The Automotive Sector

A panel of experts weigh in with their thoughts on how additive manufacturing could contribute to the automotive industry.

ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 12 Hoy Fatt Road #03-01 Bryton House Singapore 159506 Tel: (65) 6379 2888 • Fax: (65) 6379 2886

IS AUDITED BY BPA WORLDWIDE.

Modular Prototype Production With Lasers

3D Printing Jigs, Fixtures & Other Manufacturing Tools

IMPORTANT NOTICE

3D Printing:

Siemens and the Fraunhofer Institute have developed a faster production process based on selective laser melting (SLM). By Dipl-Ing Jeroen Risse, Fraunhofer Institute for Laser Technology ILT

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

EVENTS & EXHIBITION

Preview: The Grand Metalex Thailand 2016

Ushering in the next generation of metalworking into Southeast Asia.

Federation of Asian Die & Mould Associations (FADMA)

Federation of Malaysian Foundry & Engineering Industry Associations

Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

Taiwan Association of Machinery Industry (TAMI)

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ENQUIRY NO 129

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

IS THIS FOR REAL? Digitalisation seems to be the buzzword that has been going on for the longest time. Having make its way across a multitude of various industries, the relentless march of technologies are revolutionising the way companies optimise efficiency, increase effectiveness and create opportunities for innovation. It’s no dif ferent for the metalworking industr y. (Drum roll please…) With recent announcements at the IMTS and other trade shows, we now have Mixed Reality rising to the fore. To bridge the gap between the physical and digital realms, there are hybrids of sorts to ponder over. From Virtual Reality to Augmented Reality and of course, Mixed Reality: Basically, what they all do is merge the two worlds in some form or another, to enable the user to visualise how the two worlds can interact and co-exist beautifully. Content-viewing hardware from head-mounted displays (think Google Cardboard), and other holographic technology enable the industry to engage and interact with design data more intuitively. From Microsoft’s HoloLens technology, and Google Tango platform, Trimble developed a mixed reality programme which could feed 3D engineering models into the mixed reality environment, including models of large or complex projects. These different technologies enables effective, even remote collaboration workflows, where geographically separated team members can join in and use table-top and immersive visualisation modes to analyse 3D models, communicate design issues, and resolve coordination problems. More importantly, external parties can easily decipher the information, exploring a project in 3D with greater understanding. Machines are becoming more powerful and notwithstanding all the bits and bytes, the machine tools themselves are becoming more and more powerful and efficient. Now, throw into the mix all the different realities going on here, and it’s not impossible to imagine a future where synthetic content will be able to react to, and even interact, with the real world in some form or other. Already many have declared that this game-changer has the potential to precipitate significant, long-term change in the metalworking industry.

TURBINE HOUSINGS ASIA PACIFIC METALWORKING EQUIPMENT NEWS

Made Affordable p26

TIME FOR DIRECT DIGITAL MANUFACTURING? p62

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

managing director

Kenneth Tan

managing editor

Eileen Chan eileenchan@epl.com.sg

writer

Jonathan Chou Hao En Jonathanchou@epl.com.sg

business development manager

Randy Teo

randyteo@epl.com.sg

editorial assistant

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graphic designer

Jef Pimentel

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circulation executive

Chang Pei Yu

peiyu@epl.com.sg

contributors

Lim Gan Shu Tim Wood Dr Chen Wei Long Dr Tim Hosenfeldt Hubert Meagher Minta Chen Sea Chiahui Thomas Weber Helmut Kügel Oliver Hergt Jeroen Risse Joe Hiemenz Scott Crump Nikolaus Fecht Dr Andreas Thoss

Where Are You Going

INDUSTRY 4.0? p66 October 2016

www.equipment-news.com

Eileen Chan Managing Editor

ROLLING WITH

VOL. 30 NO. 7 OCTOBER 2016

ADDITIVE MANUFACTURING

IN THE AUTOMOTIVE SECTOR 3D Printing:

MODULAR

PROTOTYPE PRODUCTION

WITH LASERS

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

START FINISH

WITH FIBRE LASER

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

Cover credit: Bystronic

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

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

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

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

ENQUIRY NO 136

BUSINESS NEWS

ASIA PACIFIC Asia Pacific Metalworking Equipment News • October 2016

Siemens Consultancy Launched In Singapore Singapore: Siemens recently launched its Digital Factory Manufacturing Design Consultancy, which aims to assist companies to assess the current state of their facilities, and thereafter structure an Industry 4.0 transformation roadmap to digitalise their factories. The ceremony was officiated by Minister for Trade and Industry (Industry) Mr S Iswaran, and Siemens AG chief executive officer Joe Kaeser, and took place on 16 September. With applications such as next-level automation, predictive maintenance and remote monitoring, digitalisation can help manufacturers improve their quality, productivity, flexibility, efficiency, throughput time and time-to-market. The consultancy will cover Singapore and the other Southeast Asian markets, which are also facing increasing challenges to remain competitive. Supported by the Singapore Economic Development Board, the consultancy aims to plug a capability gap in the market, as while manufacturers, especially in markets like Singapore, are keen to digitalise their factories to remain competitive, many lack the knowledge and expertise of the smaller steps they can take to do so. “We are able to draw on our expertise and strong portfolio in electrification, automation and digitalisation, and I am confident that with our help, our consulting customers will become practical showcases for other manufacturing setups in the region,” said Dr Armin Bruck, chief executive officer of lead country Singapore, Siemens.

Xinwuan To Build US$3bn Steel Plant Sarawak, Malaysia: Hebei Xinwuan Group’s Wenan Iron and Steel have proposed plans to build an integrated steel plant in the state of Sarawak in Malaysia worth MYR 13 billion (US$3 billion). The Memorium of Understanding, signed by the Sarawak state government, China Metallurgical Group Corporation and Xinwuan Group on 27 August, will be the largest ever foreign direct investment in Sarawak. Preliminary feasibility studies will be carried out for a plant with a provisional steelmaking capacity of 5 million tonnes, coking coal capacity of 2 million tonnes, cold rolled coil capacity of 1 million tonnes and welded pipe capacity of 1 million tonnes per year. The land area set aside for the plant reportedly has a natural port, and may therefore enjoy lower transportation and logistics costs. Malaysia’s Minister for industrial and entrepreneur development, trade and investment, Datuk Amar Awang Tengah Ali Hasan, said that the state government will emphasise the protection of the environment. In addition to supplying Southeast Asia, the plant could also supply East Africa, the Middle East and South Asia.

S Korea Investing In 3-D Printing Industry Seoul, S Korea: South Korea, although a relative latecomer in global additive manufacturing, is striving to boost technology and cultivate expertise in the industry. According to the Korea Institute of Science and Technology Information, the local additive manufac turing industr y was wor th 59 billion won (US$54 million) in 2014 and 82 billion won in 2015. This year, it is expected to exceed 116 billion won. Business professor Wo Jong-hyun of Chung-Ang University said: “Now is the very crucial moment that could change the industry supremacy from Asia to the West.” Presently, Korean additive manufacturing is dominated by small and medium-size companies. T h e r e p o r t b y Ko r e a H e r a l d , noted that although grow th of additive manufac turing was slow, the medical segment of the market has demonstrated much progress. It noted that the Korea’s medical sec tor forms the third highes t use of additive manufac turing (15 percent) after consumer goods and automotive industry. To s p e e d u p g r o w t h , t h e government has eased regulations and provided support since last year. The Korea 3-D Printing Association was started in the middle of 2014 with the participation of conglomerates such a s Samsung Elec tronic s . By 2020, the association hopes to raise 10 million specialists and make up 15 percent of the global market. S Korea presently accounts for about 2 percent of the world’s additive manufacturing market. Already several businesses have made progress. InssTek, established in 2001, developed the country’s first metal additive manufacturing and acquired the patent in some countries. Business professor Wo Jong-hyun of Chung-Ang University, said: “Now is t he ver y cr ucial moment t hat could change the industry supremacy f rom A sia to t he We s t . Addi t i ve manufacturing is a matter of survival for companies.”

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ENQUIRY NO 120

BUSINESS NEWS • ASIA PACIFIC Asia Pacific Metalworking Equipment News • October 2016

Manufacturing Technology Associations Announce Launch of CCIMT 2017

UPS Launch On-Demand 3D Print Singapore: UPS has announced that its partner Fast Radius, will open a 3D printing factory in a UPS facility in Singapore by the end of 2016, expanding the on-demand 3D printing network to Asia. The facility will enable customers to increase their supply chain efficiency with additive manufacturing. It also will establish an Advanced Solutions team in Asia to create a Centre of Excellence that develops supply chain solutions and promotes 3D printing with customers. Businesses can use the Fast Radius On Demand Production Platform to produce industrial parts, which are expedited for delivery via UPS. “3D printing will have a significant impact on industrial manufacturing and 21st Century supply chains,” said Ross McCullough, president of UPS Asia Pacific region. “We believe that much like ecommerce digitised and transformed retail, 3D printing will have a similar impact on manufacturing.” UPS announced the expansion during a press event that also was attended by representatives from the Singapore Economic Development Board, Fast Radius and SAP. “Having Fast Radius’ factory connected to UPS’s network means customers can send their 3D printing orders by 5pm and have them delivered to their customers in most major Asian cities within 24 hours. This vastly changes how manufacturing companies in Singapore and the region will operate, especially at the proto-typing stage, before products are taken to the market.” Wohlers Report 2016 predicts the 3D printing industry will grow from US$5.2 billion in 2015 to US$26.5 billion. The report says that if 3D printing penetrates just five percent of the world manufacturing economy, it would reach US$640 billion annually.

Indonesian Car Sales Set To Improve Jakarta, Indonesia: Indonesia’s car sales is on track to increase between 3 percent and 5 percent in 2016, buoyed by new product launches, a more positive macroeconomic environment, increased liquidity and more relaxed financing terms, international ratings agency Fitch Ratings finds. The country’s domestic car sales are estimated to reach about 1.05 million units this year, Fitch added. According to the Indonesian Automotive Industry Association (Gaikindo), car sales in the first seven months of 2016 rose 2 percent year-on-year to 594,514 units. Gaikindo also estimated car sales will rise by at least 5 percent this year. PT Toyota Astra Motor (TAM) continued to lead with a 52 percent market share through leading brands Toyota and Daihatsu, and the low-cost-green-car segment also gained momentum, contributing 18 percent to total car sales. Fitch added that Indonesia will maintain GDP growth of 5.1 percent year-on-year in 2016, supported by monetary policy easing, government programmes to accelerate infrastructure spending, and a tax amnesty plan. The government expects GDP to grow by 5.3 percent in 2016, compared with 2015 GDP growth of 4.8 percent.

Chongqing, China: The China Chongqing International Machine Tool Show (CCIMT) will take place from November 13 to 16, 2017 at Chongqing International E xpo Centre, Yubei, Chongqing, China. Announced by the A ssociation for Manufacturing Technology (AMT) and the China Machine Tool and Tool Builders’ Association (CMTBA), the show will showcase the lates t in manufacturing technology and bring buyers and sellers together from all over the world to the market of Chongqing and southwest China. Chongqing’s economic growth was 11 percent in 2015, the fastest growth among 31 provinces in China. The total gross domestic product (GDP) of Chongqing and the six surrounding provinces accounts for 21.7 percent of China’s total GDP, at US$231.9 billion. Not only is Chongqing China’s largest automotive producer, it manufactures one -t hird o f t he w or ld ’s l ap t op computers and is a major motorcycle manufacturing location. AMT president Douglas Woods stated, “We are thrilled to partner with China’s leading manufacturing technolog y association, CMTBA, to create a world-class manufacturing t e c hno lo g y e v en t in t he r obu s t indus trial cit y of Chongqing. Our combined research recognises that Chongqing is a major produc tion hub, and in the past 10 years we have seen more than 2,000 companies emerge — creating a huge expansion in the number of potential buyers for manufacturing technology products. AMT and CMTBA have been friends and colleagues since the first CCIMT show in 1989, and this collaboration represents a new level of commitment between our two organisations.” The CCIMT is expected to fill 35,000 square metres of exhibition space with a target attendance of 50,000 coming from foreign countries including the United States.

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ENQUIRY NO 009

apore) Pte Ltd . 151 Lorong Chuan, #06-01, New Tech Park, Lobby A, Singapore 556741 . Tel: +65 6540 8600 . Fax: +65 6540 8668 . marketing_sg@schaeffler.com Regional HQ: Schaeffler (Singapore) Pte Ltd . 151 Lorong Chuan, #06-01, New Tech Park, Lobby A, Singapore 556741 . Tel: +65 6540 8600 . Fax: +65 6540 8668 . marketing_sg@schaeffler.com

Philippines Thailand Vietnam Malaysia Vietnam IndonesiaBearings (Malaysia) Sdn. Bhd. Malaysia Philippines Thailand(Vietnam) Co., Ltd. Schaeffler Philippines Inc. Schaeffler (Thailand) Co., Ltd. Schaeffler Schaeffler PT.Wisma Schaeffer Bearings Indonesia Schaeffler (Malaysia) Schaeffler (Thailand) Schaeffler (Vietnam) Co., Ltd. 5-2 Fiamma 5th Bearings Floor Optima Bldg. Sdn. Bhd. 388Schaeffler ExchangePhilippines Tower, 34thInc. Floor 6th Floor, TMS Building.Co., Ltd. Regional HQ: Schaeffler (Singapore) Pte 5-2 LtdWisma . 151 Lorong Chuan,Village #06-01, New TechUnit Park, LobbyOptima A, Singapore +65 6540 8600 . Fax: +65 6540 8668 marketing_sg@schaeffler.com Lippo Kuningan Fiamma 5th Floor Bldg. 556741 . Tel: 388 Exchange Tower, 34th Floor 6th. Floor, TMS Building. Salcedo St. Legaspi 3403-3404 172 Hai Ba Trung Street, District 1. No 20 Jalan 7A/62A SalcedoRoad, St. Legaspi Village 172 Hai Ba Trung Street, District 1. 19th Floor Unit A & F No 20 Jalan 7A/62A Bandar Menjalara Makati City 1229 Sukhumvit Klongtoey HoUnit Chi 3403-3404 Minh City Ho Chi Minh City Jl. HR Rasuna Said Kav B - 12 BandarTel: Menjalara Makati10110 City 1229 Sukhumvit Road, Klongtoey +63 2 7593583 Bangkok, Vietnam. 52200 Kuala Lumpur Jakarta 12920 52200 Kuala Lumpur Tel: +63 2 7593583 Bangkok, 10110 Vietnam. Malaysia Fax: +63 2 7798703 Thailand Tel: +84 8 222 02 777 Vietnam Indonesia Malaysia Philippines Thailand Malaysia Fax: +63 2 7798703 Thailand Tel: +84 8 222 02 777Co., Ltd. Tel: +62 21 29110280 Tel: +603 6275 06 20 marketing_ph@schaeffler.com Tel: +662 697 0000 Fax: +84 8 222 02 776 PT. Schaeffer Bearings Indonesia Schaeffler Bearings (Malaysia) Sdn. Bhd. Schaeffler Philippines Inc. Schaeffler (Thailand) Co., Ltd. Schaeffler (Vietnam) marketing_ph@schaeffler.com Tel: +662 697 0000 Fax: +84 8TMS 222Building. 02 776 Fax: +62 21 29110281 Tel: +603 6275 06 20 Fax: +603 6275 64 21 Fax: +662 697 0001 marketing_vn@schaeffler.com 5th Floor Optima Bldg. 388 Exchange Tower, 34th Floor 6th Floor, Lippo Kuningan 5-2 Wisma Fiamma marketing_vn@schaeffler.com marketing_id@schaeffer.com Fax:20 +603 6275 64 21 Fax: 697 0001 marketing_my@schaeffler.com marketing_th@schaeffler.com 172 Hai Ba Trung Street, District 1. 19th Floor Unit A & F No Jalan 7A/62A Salcedo St. Legaspi Village Unit +662 3403-3404 marketing_my@schaeffler.com marketing_th@schaeffler.com Jl. HR Rasuna Said Kav B - 12 Bandar Menjalara Makati City 1229 Sukhumvit Road, Klongtoey Ho Chi Minh City Jakarta 12920 52200 Kuala Lumpur Tel: +63 2 7593583 Bangkok, 10110 Vietnam. Malaysia Fax: +63 2 7798703 Thailand Tel: +84 8 222 02 777 Tel: +62 21 29110280 marketing_ph@schaeffler.com Tel: +662 697 0000 Fax: +84 8 222 02 776 Fax: +62 21 29110281 Tel: +603 6275 06 20

BUSINESS NEWS • ASIA PACIFIC Asia Pacific Metalworking Equipment News • October 2016

MHPS Gets Order For Power Generation Equipment

ExxonMobil Partners Micromatic Delhi, India: ExxonMobil Lubricants has entered an official partnership with Micromatic Machine Tools to supply lubricants and other services. With the company’s services used primarily in industrial market sectors such as power generation, general manufacturing, metal working and mining, Mobil Industrial Lubricants will support will support Micromatic with industrial lubricant products and services. In addition, the joint partnership will create greater awareness of using the right oil, at the right time and at right place through training programs, customer education seminars and knowledge enhancement sessions. Mr TK Ramesh, chief executive officer of Micromatic, said: “Micromatic welcomes this partnership with ExxonMobil in light of the growing global demand for Indian-made equipment and we look to leverage our collective knowledge and expertise to bring improved performance and productivity to our customers. We also look forward to Mobil’s expertise in selection of appropriate fluids which is in line with our commitment to promote green environment.”

Toyota Lifts Investment Freeze In India New Delhi, India: Toyota will launch more cars and ramp up volumes in India, the world’s fifth biggest car market. This reverses an earlier decision to freeze investment after the Supreme Court lifted an eight month ban on sale of large diesel vehicles in Delhi. Hiroyuki Fukui, chief executive officer for the Asia, Middle East & North Africa regions at Toyota Motor, said the car maker will focus more on India and introduce vehicles to meet requirements of local consumers. The decision comes weeks after the Supreme Court verdict lifting the ban on sale of diesel cars above 2000 cc in Delhi and the National Capital Region (NCR), which encompasses neighbour states like Haryana and Rajasthan. The ban cost Toyota an estimated INR1,700 crore (US$ 254 million) in revenues from sales of about 8,500 vehicles. The Delhi-NCR accounts for seven to eight percent of sales of the car maker’s total sales in the country. Toyota, which has two facilities in Karnataka with combined capacity of 310,000 units per annum, is using 55 percent of available production, and foresees an increase in production following the Supreme Court decision.

Yokohama, Japan: Mitsubishi Hitachi Power Systems (MHPS) has received an order for one train of blast-furnace-gas (BFG) fired gas turbine power generation equipment from Shougang Jingtang Iron & Steel. T he equipmen t will be a key c o m p o n e n t o f t h e G a s Tu r b i n e Combined-Cycle (GTCC) power plant that Shougang Jingtang plans to build in the Caofeidian Phase 2 Project in Tangshan, Hebei Province. In the project, low calorific value gas that is generated by the blast furnace process will be used by the GTCC. Operations will commence in the first half of 2018. The Caofeidian Phase 2 Project, to which the GTCC power plant will be delivered, is currently being constructed on a man-made island (Caofeidian Island) of f the shore of Tangshan, facing the Bohai Sea. MHPS will supply equipment including one M701 S(DA)X gas turbine, the gas compressor and generation equipment. Mitsubishi will act as the trading company. The M701 S(DA) X gas turbine has improved performance compared to the current M701 S(DA) gas turbine due to its larger capacity, and is the latest D class model. Operations at the Caofeidian Phase 1 Project began in 2008, with an annual production of about 10 million tons of pig iron. The second phase of the project, now under construction, is planned to have an annual production of about 5 million tons of pig iron. Because gas with signif icantly lower calorif ic value than natural gas is used as a fuel in BFG power generation, advanced combustion technolog y is required in the gas turbine for stable operations. MHPS has established proprietary BFG-fired generation technology over many years, such as through the development of its own combustion chambers. It has delivered BFG-fired gas turbines to many steelworks, both in Japan and around the world, and has a global market share of approximately 70 percent, including almost 70 percent in China.

Steel milling evolution

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BUSINESS NEWS • ASIA PACIFIC Asia Pacific Metalworking Equipment News • October 2016

RS Components & ebm-papst Extend Partnership Singapore: RS Components (RS) and ebm-papst have extended their 35-year distribution partnership, continuing to supply fans and motor products from the leading global manufacturer throughout the EME A and A sia Pacific regions. ebm-papst products in the market, covering a wide range of heating, ven t il at ing and air condi t ioning (HVAC) systems, fans and thermal management products and accessories will continue to be distributed by RS throughout the EMEA and Asia Pacific regions. Steve Keep, RS global account manager, added: “This renewed agreement with ebm-papst underlines our continued commitment to provide customers with fast, easy access to market-leading motors and fans for applications across many different industries.”

Panasonic Opens Innovation Centre In Thailand Bangkok, Thailand: Panasonic opened its solution and innovation centre at the company’s Factory Automation (FA) showroom in Bangkok on September 9, to showcase its latest manufacturing technologies and equipment. Operated and managed by Panasonic Industrial Devices Sales (Thailand), the centre offers manufacturing technologies such as auto-insertion and surface mount machines, which are designed for insertion and mounting of electronic components in high-density printed circuit board. The synerg y demonstrates network compatibility and technological interconnectedness and the contribution of the Industry 4.0 and IoT-supported manufacturing line. The centre is equipped with seminar and conference rooms to facilitate technical seminars and events relating to factory automation. Panasonic opened a FA showroom in Chicago, USA, in July 2016. Jakarta, Indonesia, and Hanoi, Vietnam, are in the pipeline as the company expands its factory automation business globally.

GE Oil & Gas Gets Indian Drilling Agreement

Kakinada , India: The oil and gas subsidiary of General Electric has been awarded a Frame Agreement by Oil and Natural Gas Corp (ONGC). Under the three-year agreement, GE will provide an estimated 55 wellheads to support ONGC’s exploratory drilling campaign in shallow to medium waters off the east and west coast of India. Ashish Bhandari, CEO, South Asia at GE Oil & Gas, said: “With India’s new energy policy and gas pricing policy in place we are seeing an uptick in ONGC’s exploration and development activity. This latest award will enable GE to support ONGC as its technical partner, collaborating to improve the region’s energy supply capabilities through the discovery of new fields offshore.” The f ir s t wellhead under t he contract is predicted to be supplied in the fourth quarter of 2016, with engineering and project management supp or t f rom re g ional team s in Singapore, along with GE manufacturing part of the scope in Kakinada, India, for the first time. Mr Bhandari added, “ We have a long histor y with ONGC and are proud to be par tnering with them to support their ambition of driving local oil and gas production. As well as the collaborative effort that will be involved, what is particularly exciting for us is that this Frame Agreement provides us with the opportunity to further develop a local talent pipeline and in-country supply base, through a steady and predictable volume.”

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NO 114

BUSINESS NEWS • EUROPE & MIDDLE EAST Asia Pacific Metalworking Equipment News • October 2016

Siemens & BSH Tailoring Next Generation PLM Software Frankfurt am Main, Germany: Siemens’ product lifecycle management (PLM) software business and BSH Hausgeräte, the largest home appliance manufacturer in Europe, have agreed to strengthen their relationship to enhance PLM software for specific industry needs. Their cooperation is expected to help Siemens gain deeper insights into the special requirements of the home appliance product lifecycle process. The partnership should help both companies drive their respective strategies in Industry 4.0, and the IIoT. BSH is expanding its offering of connected home appliances and aims to integrate its products into smart home environments. Siemens could also benefit by aligning with leading customers to validate its approach in this industry. BSH is pursuing a holistic digitalisation approach that will help to accomplish a fully integrated set of PLM processes to support its Industry 4.0 vision. Siemens and its PLM software technology will continue to play a significant role in this transformation.

Trumpf Posts 3% Increase In Sales Ditzingen, Germany: The Trumpf Group registered a three percent increase in sales, with the figure amounting to €2.8 billion (US$3.12 billion), compared to previous year’s €2.7 billion. Reasons for the increase in sales included developments in some regional markets. Spain enjoyed double-digit sales growth. Growth in France was also in the double digits, regaining pre-recession levels. Sales in Germany grew by around five percent, to almost €600 million. Trumpf al so achieved signif icant sales increases in Japan and the Asia-Pacific region. In China, however, economic growth cooled. According to preliminary calculations, revenues there totaled roughly €360 million — a decrease of around two percent over the previous year.

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Creating Tool Performance

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METAL CUTTING Asia Pacific Metalworking Equipment News • October 2016

Manufacturing Turbochargers:

TURBINE HOUSINGS

MADE

AFFORDABLE

Roughing and finishing turbine housings is particularly challenging in the case of passenger cars with sparkignition engines. By Lim Gan Shu, marketing manager, Walter AG Singapore.

o w n si zing make s eng ine s mor e economical. In order to ensure that their performance is not compromised, turbochargers are increasingly being used to compensate in smaller vehicles. The market is growing – but so is the pressure on prices. Vehicle fuel consumption needs to be reduced – not just in the lab. Legal provisions from all over the world are driving the automotive industry to implement measures in almost every vehicle class. This has given rise to huge challenges for the automotive industry. An important factor: Turbochargers that squeeze high performance out of small yet efficient engines. However, the turbochargers themselves are also under pressure to be smaller, more efficient and, importantly, more cost-efficient.

Editorial

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Reducing Machining Costs “We expect – and studies by leading turbocharger manufacturers agree – that the number of turbochargers used for petrol engines will experience a 2.5-fold increase over the next five years,” says Rolf Buob, component manager for turbine housings at Walter AG in Tübingen. Currently, turbochargers for petrol engines place particularly high demands on machining when compared with diesel engines. The exhaust gases in the turbine housing reach temperatures of between 1,000 and 1,050 °C; in diesel engines, however, they reach relatively low temperatures of between 800 and 850 °C.

“Temperatures of 1,000 °C or higher require high temperature-resistant steels, typically chrome-nickel alloy steels that have a material identification number beginning with 1.48 and ending in 49, 48, 37 or 26 – with a tendency towards the material identification number 1.4826. These 1.48 steels are constantly being developed further and it is becoming more and more difficult to machine them,” explains Buob. They al so make t he turbine housing the most expensive component in terms of machining. Buob explains fur ther: “We anticipate different machining costs for each component, depending on the presence of an exhaust manifold.” Above all else, a high chrome content reduces service life. “There are applications where tools only last long enough for twenty to thirty components.” For comparison: The materials used for diesel engine turbine housings extend the service life by up to five or ten times, while also being 50 percent faster to machine. Walter machining experts have therefore developed a new milling cut ter concept especially for roughing, semi-finishing and finishing turbocharger housings. It reduces the all-important cost per finished part, while also significantly improving surface quality. Over the course of the development process, the cartridge system used for finishing, which had previously been the norm, was replaced with an intentionally simple tool design with a fixed insert seat.

METAL CUTTING Asia Pacific Metalworking Equipment News • October 2016

This “plug-and-play” solution eliminates the need to carry out presetting operations, which required accuracy to between 3 and 5 µm. Reducing Pressure Further saving measures: The use of identical indexable inserts with 16 cutting edges as semifinishing and finishing inserts. Previously, the market standard was to use 12 for semi-finishing and four for finishing. This also simplifies inventories and eliminates errors when changing the indexable inserts. The indexable inserts are coated with PVD or CVD and are available in various geometries. Indexable inserts belonging to the Walter WSP45S or WSM45X grades are typically used. Shor t cut ting edges reduce the pressure on the unstable components. This results in r e du c e d v ib r a t i o n , w hi c h im p r o v e s surface quality, increasing it from the usual R z 7-8 to approximately R z 5. “O verall , t he s e mea sure s lead to improvemen t s i n h a n d l i n g a n d p r o c e s s r e l i a b i l i t y,” says Buob. As a rule, every third to fifth insert is positioned differently on the finishing tool. The

Walter has developed a new milling cutter system to meet the specific requirements of thinwalled turbine housings.

Roughing and finishing turbine housings is particularly challenging in the case of passenger cars with spark-ignition engines.

ENQUIRY NO 121

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METAL CUTTING Asia Pacific Metalworking Equipment News • October 2016

Turbine Housings:

Roughing & Finishing Interview with Rolf Buob, turbine housing component manager, Walter AG Roughing and finishing turbine housings is particularly challenging in the case of passenger cars with sparkignition engines. The material is extremely tough and difficult to machine and the walls are thin, which therefore makes the workpiece unstable and the cost pressure high. But the market is growing.

Q: Manufacturing a turbocharger requires many different machining steps. How was it decided that the process of milling the housing should be the area to give rise to new developments? RB: The proportion of tool costs for roughing and finishing a turbine housing amounts to approximately 15 percent of the total costs. In contrast to other machining processes, substitution is relatively simple. A corresponding development that both reduces the costs per part and improves quality can guarantee progress, both for the housing manufacturer and the tool supplier.

Q: What measures did you implement in order to achieve this?

position of the semi-finishing inserts can be adjusted by approximately 5° in the same way as when carrying out rough machining; the finishing inserts are inserted so as to cut in a flat plane. Rolf Buob explains: “ This is why we distinguish between semi-finishing and finishing inserts on the same tool, even when the inserts are identical. Only the insert seats are rotated differently when inserted.” The cut t ing speed when f inishing is approximately 140 m/min at a feed rate per revolution of up to 4 mm. This milling cutter is also available for machining allowances of up to 3 mm for roughing in particular. Here, the indexable inserts are aligned uniformly both axially and radially, in contrast to the finishing face mill. They all have the same function for machining operations. However, the new milling cutter concept does not mean that development has finished. Walter is expected to make further advances involving new PVD coatings that are currently still in development.

RB: We use the same indexable inserts as semi-finishing and finishing inserts. This is new for this type of tool. Additionally, the indexable inserts each have

Tiger·tec Gold in the Walter BLAXX M3024 heptagon milling cutter.

16 cutting edges with increased service lives and therefore increased usability. As a result, the costs per component for the metal cutting tool, which are all-important in the automotive industry, are reduced by up to 40 percent – in some cases up to 70 percent. The costs of cutting tool material for the turbine housing come to approximately 50 percent of the total costs of the component. In machining production environments, this is usually around 4 percent. Milling applications represent between 10 percent and 20 percent of the costs of cutting tool material – divided approximately equally between roughing and finishing. We expect to see an overall effect of approximately 4.5 - 5 percent on the costs of a turbocharger, which can be achieved very quickly.

Q: The new milling cutter is also intended to improve surface quality – how will it achieve this? RB: In this sector, a surface quality of approximately RZ 10 is usually required. We have achieved Rz 5 and have absolutely no problems fulfilling customer

Walter:

The Tiger·tec Gold WKP35G grade with its TiAlN coating.

Tiger·tec Gold

requirements with the system. This is possible thanks to the optimal cutting

Walter AG launched it s T iger·tec G old

length of 4 mm, which applies a lower pressure.

indexable inser t s at A MB in Stut tgar t ,

These housings are very unstable because their walls are only between

Germany. Compared with the C VD

2.5 mm and 3 mm thick. This quickly leads to vibration and, as a result, chatter

aluminium oxide-coated grades currently

marks. Up to now, there has always been a compromise between machining

in use, the Tiger·tec Gold with its titanium

speed and surface quality. We can resolve this conflict.

aluminium nitride (TiAlN) coating of fers improved properties – resulting in longer

Q: Why have you chosen to use a fixed insert seat instead of the customary cartridge seat?

t o o l l i f e , in c r e a s e d p r o du c t i v i t y an d greater process reliability.

RB: Adjusting the finishing inserts using the standard cartridge makes the

The TiAlN coating from Walter ha s

tool more expensive and reduces the possible number of teeth. This ability to

considerably higher wear resistance on the

adjust the inserts is advantageous for standard applications of varying batch

flank faces, reduced formation of hairline

sizes because the tool can easily be modified to meet different conditions.

cracks and greater resistance to plastic

This flexibility is not necessary in the case of large quantities, however. For

de for mat ion . Pr ac t ic al te s t s on s teel

this reason, we decided to use the fixed insert seat. With the elimination of an

and cast iron materials showed a longer

adjustment step, it almost becomes a “plug-and-play” solution. In any case,

tool life – by up to 200 percent in some

we are required to manufacture the seats for the finishing inserts extremely

instances. In addition, the gold-coloured

precisely so that they all run exactly parallel to one another.

top layer also facilitates wear detection.

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ENQUIRY NO 116

METAL CUTTING Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

Acoustic emission sensor rotor on loader spindle.

Double disk grinding process with rotary loader.

It also generally refers to the generation of transient elastic waves produced by a sudden redistribution of stress in a material. When a structure is subjected to an external stimulus (change in pressure, load, or temperature), localised sources trigger the release of energy, in the form of stress waves, which propagate to the surface and are recorded by sensors.

ACOUSTIC

EMISSION SENSORS The application of the acoustic emission (AE) sensor for monitoring can supply valuable information regarding the discontinuity in material. By Tim Wood, international sales manager, SBS Dynamic Balance and Process Control Systems Editorial

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hanges in micro-stresses within CNC machine tool structure, caused by contact between tooling and workpiece, generate high frequency signals known as acoustic emission, or AE. Itâ&#x20AC;&#x2122;s best described as the phenomenon of radiation of acoustic waves in solids that occurs when a material undergoes irreversible changes in its internal structure.

Detection & Analysis AE signals can be detected using an Acoustic Emission Monitoring System (AEMS), and used for advanced machine process control. With the right equipment and setup, motions on the order of picometers (10 - 12 m) can be identified. Detection and analysis of AE signals can supply valuable information regarding the origin and impor tance of a discontinuity in a material. Because of the versatilit y of Acoustic Emission Testing (AET), it has many industrial applications (eg: assessing structural integrity, detecting flaws, testing for leaks, or monitoring weld quality) and is used extensively as a research tool. In the case of grinding machines, this high frequency structure borne noise is created when the grinding wheel touches the part, or the diamond dresser. AE signals travel through solid materials, for example, tooling, with high velocity, meaning they are an ideal parameter for the detection of grinding wheel contact within milliseconds of time, or microns of axis travel. Double disk grinding (DDG), a form of face grinding, is no exception. The recent application of the AE system to a DDG grinding process for rolling element IR (Inner Race) bearing faces resulted in 0.5 seconds saving on a 3.6 second grind cycle - a 14 percent

METAL CUTTING Asia Pacific Metalworking Equipment News • October 2016

reduction. In this case, the saving was made by using the system to detect contact between grinding wheels and work. Eliminating The Gap The process, also known as GapElimination or GE offer the ability to detect part contact in less than 1 millisecond. It also allows higher machine feed-rates, and less air grinding time, typically saving anywhere from 10 percent to 20 percent of cycle time. Correct AE sensor location and mounting on the machine is critical. To achieve maximum sensitivity, best AE signal path and biggest cycle time reduction, a non-contact acoustic sensor was mounted on the rotary loader spindle . T he cor re sp onding s t a tor w a s mounted on the guard door of the loader. For Monitoring Purposes Acoustic emission sensors can also be used for dressing monitoring on double disk grinding machines — either point or rotary diamond unit s — giving dres ser touch detec tion, accurate machine indexing and monitoring of dressing profile.

For maximum efficiency gains the system can be interfaced with the machine CNC or PLC via hardwire, profibus or Ethernet protocols. The SBS AEMS system is a permanent in s t all a t ion on a machine t o ol , and is available to machine manufacturers or as a retrof it package to end users. SBS can combine acoustic emission signals with other measurable machine parameters such as spindle power and work-piece RPM using a system called ExactControl.

Acoustic emission sensor stator mounted on the guard door.

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MAXIMISING PRODUCTIVITY

Asia Pacific Metalworking Equipment News • October 2016

Minimising Waste

Efficient and cost-effective processes are crucial to creating a sustainable manufacturing industry. By Dr Chen Wei Long, director, Sustainable Manufacturing Centre, SIMTech A*STAR's SIMTech

Thermal spraying a rod with an environmentallyfriendly alternative to hard chrome. Editorial

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ustainable Manufac turing is d e em e d a s t h e n e w - g en er a t io n paradigm shift in the manufacturing indus tr y ’s ef for t to reduce environmental burdens, gain cost competitiveness and demonstrate responsible corporate citizenship. L a u n c h e d i n 2 0 0 9, t h e S u s t a i n a b l e Manufacturing Centre (SMC) is spearheaded b y A* S TA R ’s S i n g a p o r e In s t i t u t e o f Manuf ac turing Technolog y (SIMTech). It aims to bring together relevant government

agencies, industr y associations, research communities and companies, to develop and implement sustainable manufacturing technologies. S in c e i t s in c e p t i o n , t h e c e n t r e h a s been actively engaging the manufacturing indus tr y in Singapore to develop and implement technologies for ecoper formance improvement s in produc t s and manufacturing processes. It has rolled o u t ini t i a t i v e s t o a s s i s t co m p a ni e s t o measure their eco-per formance baseline,

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • October 2016

improve energ y and resource ef f icienc y, develop technologies to manufacture green produc t s and packaging , and rec ycle or remanufacture used products. Effor ts have also been made to create awareness of such initiatives. SMC ’s area s of re s earch and core capabilities include, but are not limited to: •

Carbon Management

•

Green Manufacturing

•

Energy Efficiency Management

Energy Efficiency Management Another main initiative is energy efficiency management . To that ef fec t , the centre spearheaded the Energy Efficiency, Monitoring, Analysis Planning Solutions (E2MAPS): a suite of manufacturing energy efficiency solutions developed to help companies achieve higher energy efficiency. This suite of solutions is developed based on a systematic approach, and integrated with features such as business processes road mapping and on-site energy monitoring software.

ENQUIRY NO 027

Carbon Management & Green Manufacturing The centre’s Carbon Management initiative aims to train companies’ in-house exper t s in carbon footprint quantif ication and communic at ion. The s e e x per t s will enable their companies to ef fec tively develop and deploy carbon footprint reduc tion strategies. Another one of its initiatives is Green Manu f ac tur ing , which assists the manufacturing industry t o r e duce c ar b on emi s sion b y adopting environmental friendly and material ef f icient technologies. A partnership with LHT saw the development of a pallet and crate de sig n s y s tem t ha t in te g r a te s product design and product life c ycle analysis. The s ys tem is us er-f r iendly and non- e x p er t s can also use it to carry out pallets and crate design in compliance with the relevant environmental standards. The system also helps t o pr omo t e g r e en lo g i s t ic s by increasing product re-use rate and recycling end-of-life products. Another example of green manufacturing was working with OE Manufacturing to develop an environmentally-friendly thermal spray coating process as a hard chrome alternative on hydraulic c y linder componen t s . T hroug h this collaboration, the company established a new plasma spray process production capability, and a range of products.

Live Tools for machining centers

• Remanufacturing

Pure passion – you are dedicated!

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GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • October 2016

A*STAR's SIMTech

With remanufacturing, a company can potentially save between 60 to 90 percent in terms of energy, materials, water and air pollutant emissions. A review of energy data will subsequently be carried out to identif y energ y ef f iciency improvement oppor tunities. Improvement ac tion plans with quantitative reduc tion goals will be proposed. This road mapping provides a clear grasp of energ y ef f iciency issues or hot spot s on the manufac turing shop floor operations. F inall y, r ele v an t domain k no w le dg e experts will be deployed to help companies in their solutions implementation.

A*STAR's SIMTech

Top: The design interface provides users data on the simulated carbon footprint of a given pallet or crate. Above: Users are able to specify information on the pallet template at various stages of its manufacturing life cycle.

The process can be broken down into four s teps . F ir s t ly, Ener g y Ef f icienc y Monitoring and Analysis System (E2MAPS) sof tware collec t s and analyses real-time power consumption dat a captured from machine s v ia commercial o f f-t he - shelf power meters. The s of t w are t hen correl ate s power and energ y consumption prof ile according to various machine s t ages unique to manu f ac t ur in g . T hi s anal y s i s o f p o w er pat terns allows users to understand the energ y consumption pattern and identif y energ y waste. Results from this step will be used to identif y area for energ y ef f iciency improvements.

Remanufacturing The centre’s remanufacturing initiative provides a platform for collaborative research and development in remanufacturing technologies. The developed remanufacturing-related capabilities will enhance companies’ competitiveness through reduced material waste, better energ y ef f iciency and total cost reduction. With remanufac turing, a company can potentially save between 60 to 90 percent in terms of energ y, materials, water and air pollut ant emissions by remanufac turing a n e n d - o f- l i f e p r o d u c t , c o m p a r e d t o manufacturing a new product. In addition, the process retains more than 80 percent of the product’s original value. This makes remanufacturing a green and high value-add industr y with enormous growth potential. Responsibility & Efficiency Environmental impact and corporate social responsibility are the forefront concerns t o d a y, a n d s u s t a in a b l e m a n u f a c t ur in g init iat ive s in all shape s and forms will continue to play an increasingly important role in establishing a way forward for the future of the industry.

Shop ﬂoor process control with the ﬂexible Equator gauging system

6 201 6 x e 2 l a Met 6.11.23 21 201 th: AE Boo

Join hundreds of automotive part suppliers who use the low cost Equator as a manually loaded system or in fully automated cells Equator provides fast data capture, highly repeatable results and easy operation, at a low purchase price and with low cost of ownership. • Operators or robots can switch between different parts in seconds • Automated cells can be easily configured with EZ-IO software • Unique ability for repeatable gauging in widely varying thermal conditions combined with flexibility

Process Monitor is built into both manual and automated systems. It allows users to view the gauging history of a part, an invaluable function for controlling a manufacturing process, along with an instant graphical view of the status of each feature tolerance. Process Monitor also enables management of the mastering process according to temperature, time or number of parts gauged.

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GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • October 2016

A fully automated assembly produces complete rolling bearings from inner ring, outer ring, balls, cage, and lubricant grease.

Making The Right Choice:

SMART MATERIALS

APMEN interviewed Prof Dr Tim Hosenfeldt, senior VP, corporate innovation, Schaeffler, on the importance of material choice and the application of smart materials in the manufacturing and production sector.

aterial choice plays a pivot al role in manufac turing . Smar t materials go one step fur ther by adding intelligence to these materials. Such materials act to increase produc t ivit y and improve s afet y wit hin production facilities.

Editorial

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ENQUIRY NUMBER

7102

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Q: How do innovations in material science impact the metalworking industry as well as automation? Prof Dr Tim Hosenfeldt (TH): This is a big challenge. For instance, for a lightweight design you need higher load capacities. As such, very tough materials with high wear resis t ance. The work ing load is get t ing

higher. This is why we develop our steel quality and its cleanliness as it is important to have lower imperfections. For our industry the material is bearing or standard steel. With nanotechnolog y in advanced surface technolog y we can establish a ver y high working load and toughness, create a high wear resistance, and increase the hardness by four to five times. We can al so create a ver y duc tile material with a low Young’s modulus with nanotechnolog y. We are opt imising t he material to our design properties; creating in this case a high ratio between hardness to Young’s modulus. With nanotechnology we can create nanostructures or nanolayers to make a material very hard without some of the negative side effects. Q: What is your take on smart materials? TH: Smart materials are important now and will be increasingly important for the future. As we develop more ways of sensing and continue to investigate the application of different materials in the development of new types of sensors, new ways of recording and acting upon external forces and stimuli, such as load, force, velocity, temperature, and so on, will become possible. Beyond this, the nex t step to get ting smart is to make use of data, and consider it

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

a valuable resource. We need to understand this data and transform it into knowledge. From the knowledge we can make smarter decisions and impr o v e h o w w e ac t and design new produc t s. The data gives us knowledge on how our tools or products are b eing u s e d e ach day which enables us to optimise it. This is important in say Dr Tim Hosenfeldt predic tive maintenance, believes smart materials will be increasingly whereby, maintenance can important for the future. be scheduled based on realtime feedback from a produc t or system, ultimately extending the product/systems lifetime. Q: Would smart materials indicate when a component needs to be replaced? TH: This is not what I understand as smar t, ie: when you have to order a new component. It is better than not knowing of course, but the best is that you have a smartness that can measure the stress or the strain for instance, and say okay if I run the bearing a certain length then we will face a problem. Q: A lot of the data collected is unstructured. How do you make use of such data? TH: Yes, of course. We have to divide between embedded systems and pass the data directly with what we are doing at the moment. We have developed for example, production machine 4.0, where we have a lot of sensors. We are able to bring this data into the cloud but this is in the development stage at the moment. This is the future to have a private or hybrid cloud, where we bring the data in and share it with our customers. We can then offer new services from this for the customers. Q: How is automation changing your business model and how you design products? TH: The increasing use of automation brings extreme change in production. This means working in networks with real-time data. Working on real-time data brings the connection between different areas on a production floor and logistics much closer together. The ability to track components, and know at every moment where some material or component is in real-time, is a great capability to have. The industry has increasingly become more automated with cooperation between human and machine being a clear trend. Machines can support humans in carrying heavier objects or working in dangerous places, for instance. Many developed countries are seeing an increase in the age of their workers, as birthrates decline and people are living longer. As people get older they may need better support for heavy work. This is one example where machines can assist humans in performing their tasks more productively and extending our capabilities.

ENQUIRY NO 126

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22.09.2016 10:02:07

GREAT GEAR & SYSTEM Asia Pacific Metalworking Equipment News • October 2016

MORE EFFICIENT

Why Laser Tracker Technology Is

For Aluminium Extrusion Press Alignment Using a laser tracker, a metrology engineer can quickly capture high tolerance dimensional measurements – including conventional level and square measurements. By Hubert Meagher, director of metrology services, OASIS Alignment Services LLC. Editorial

Got a Question? Make An Enquiry.

ENQUIRY NUMBER

7103

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he mis alignment of component s within an aluminium extrusion press can cause significant issues such as inconsistent die performance, uneven wear, premature failure or excessive wear of dummy blocks, and in extreme cases, damaged and/or broken stems, containers and tie rods. Misalignment in the press not only causes equipment damage and increased downtime, produc t issues such as out-of-spec wall thickness and other product defects can occur leading to increased scrap levels, higher costs and ultimately, unhappy end customers. Inspection & Alignment For many years, aluminium extrusion press alignment was performed using traditional alignment methods such as machinist levels, trammel rods, plumb bobs, piano wires and optical tooling. Though these traditional methods and tools have stood the test of time and are still often used today, they can be limited and extremely time consuming (which means longer downtime!). Fortunately, with the capabilities of the newer, innovative 3D metrology tools, such as laser trackers, the inspection and alignment of aluminium extrusion presses is much more efficient, quicker, and cost effective. Laser trackers work exceptionally well for aluminium extrusion press alignment. Using

a laser tracker, a metrolog y engineer can quickly capture high tolerance dimensional measurements – including conventional level and square measurement s. Additionally, because laser trackers work seamlessly with metrology analysis software, data is presented in real-time, allowing for necessary adjustments to be made swiftly. One of the problems associated with the maintenance or alignment of extrusion presses, is their operating temperature. Traditionally, a long cool-down period had to occur before an alignment could be performed. Although extrusion presses still cannot be serviced while in operation, with laser trackers adapted with next-gen components, specifically the T-Probe technology used with the Leica AT960 laser trackers, metrology engineers can now attain measurements in hot areas that could not be measured before. This capability allows the manufacturers of aluminium extruded products to significantly reduce press downtime – one of the greatest benefits of using modern 3D metrology tools for press alignment. More Than Replacements Laser tracker technology can do more than replace traditional tooling and methods, using these instruments metrology engineers can inspect for: • Platen-to-platen vertical and horizontal offset • Platen-to-platen “twist” • Centreline coincidence of ram, container, and die • Travel profile of ram, crosshead, and stem • Ways wear and alignment • Container and die platen movement • Tie rod length • Tie rod extension under load • Dynamic movement of components • Foundation stability studies

About the author Hubert Meagher, B. Eng, spent many years in the field as an alignment engineer specialising in precision measurement prior to his role as Director of Metrolog y Ser vices at Oasis Alignment Services, LLC. He is an expert in using both optical tooling and portable metrology tools in manufacturing facilities. Oasis Alignment Ser vices LLC is Nor th A mer ic a’s l ar g e s t pr o v ider o f pr e c i sion m e a s ur e m e n t , m a c hin e a l i g n m e n t , a n d maintenance/installation services.

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IN DESIGN Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

Siemens AG

complex, large workpieces, such as forged heavy parts or rolls, turbines, crankshafts and generator rotors as well as compressors or pumps for oil and gas production. The machine offers special characteristics for inside machining of components, such as turn-milling machining or proces sing of complex inside contour s , which are not parallel to the workpiece centre axis.

MEASURING & MACHINING

THE BIGGER THE BETTER Overcoming the challenges of machining very large workpieces weighing over 10 tonnes. By Thomas Weber, head of customer relations, Heinrich Georg

Editorial

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7201

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achining o f l ar g e w or k pie ce s are a matter of scale; The larger the workpiece, the big ger the machining centre. But a lot of time is wasted in transpor tation to other machines needed for mea surement and quality control. Companies aiming to increase produc t i v i t y are lo ok ing for machining centres with integrated mea surement systems, while being able to handle large workpieces weighing close to 200 tonnes. S i e m e n s AG r e ce n t l y co mmi s s i o n e d Heinr ich G e or g for a machining cen t r e capable of complete machining of large, complex workpieces weighing up to 180 tonnes with a diameter of 1,100 mm to 4,000 mm and length of up to 10,000 mm. Called the ultraturn MC, the horizontal machining c e n t r e (H M C ) c o m b i n e s a l l m a c h i n i n g functions, such as turning, drilling, milling, while incorporating workpiece measuring in one machine. The HMC is designed for machining of

No Reclamping Required A new aspect for machining of ver y large parts is integration of quality control into the produc tion process. Instead of using one probe, the moving two-point automatic workpiece measuring system operates as a big micrometre screw with two probes and measures the workpieces direc tly in the machine with high precision. While the diameters or axial run-out measuring at workpieces of up to 2,000 mm may take several hours by using measuring machines, the integrated system requires only a few minutes. The front mea suring arm is made of carbon fibre. Thus, it is very light, resistant to vibrations and at the same time stable to temperature fluctuations. The measuring s ys tem calibration in the machine is an additional benef it of the integrated mea surement . A multi-s t age calibration disk is f ixed to the tailstock, so that the calibration process can be per formed at different diameters. T h e l ar g e s t b e n e f i t s o f h a v in g o n e machining centre carrying out the complete machining and measuring procedure is the simplif ication of the production planning process. This reduces time on transportation to other machines for measurements, which also means reduced delivery times by weeks or even months. Two more machining centres have been ordered by companies in Eastern Europe and the Czech Republic.

ENQUIRY NO 056

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

Inspection of aircraft tooling jigs with the laser tracker.

Laser Trackers:

ACCURACY In Aircraft Assembly These trackers make extremely appealing metrology instruments, especially the ability to capture large volumes of 3-dimensional coordinate data quickly and in real-time. By Minta Chen, marketing specialist, Faro.

Editorial

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ENQUIRY NUMBER

7202

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he accuracy of an aircraft assembly jig directly affects the precision of a piece that it produces, which, in turn, affects an aircraft’s flight safety and the safety of its crew and property. Typically, laser trackers are used to inspect the aircraft assembly jigs which form part of the production line. Once component parts of the jig are manufactured, they are put together to become the tool on which aircraft assembly takes place. These trackers are extremely appealing metrolog y instrument s due to their size, por t abilit y, repeat abilit y and accur ac y. In addition, the abilit y to capture large volumes of 3-dimensional coordinate data quickly and in real-t ime, appeal to t he technicians involved. Through accurate measurement s taken, a technician can check to ensure that various component par t s are in the r ig ht posi t ion and wi t hin toler ance, a s stipulated by design. Without the tracker, these measurements would not be possible with common measurement methods such as fixed coordinate measuring machines or traditional tools.

Manufacturing Applications Not too long ago, manufac turers had to per form test s on par t s and component s using stationar y coordinate measurement machines (CMMs). This proved vexing and di f f icult i f you were t r y ing to mea sure large parts or parts still on the production mac hin e . W i t h t h e p or t abil i t y o f l a s er tracker s , 3D mea surement s can now be completed with unprecedented speed and minimum disruption. The aerospace industry was one of the earlier adopters in the technology. Using one or more laser trackers, metrology engineers could rapidly and accurately deliver 3D measurements and process improvements. Tianjin TQM Feiyue Aviation (a subsidiary of Tianjin Motor Dies) based in Tianjin, China, focuses on aviation equipment technology development , trans fer and consult anc y, as well as the manufac turing of aviation equipment such as spare parts and aircraft sheet metal parts. The company purchased a Faro Laser Tracker back in 2008. Tianjin TQM Feiyue’s project manager, Yan Zhichao, said: “At that time, Airbus was using the Faro Laser Tracker on their shop f loor. That prompted us to purchase from Faro, because we wanted to ensure consistency between us and our customer.” Seven years later, the company purchased a Laser Tracker Vantage, the CAM2 Measure software, as well as the Prime from Faro. Two additional laser trackers and a FaroArm in were added in 2015.

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

Making Full Use At TQM Feiyue, the team’s work revolves around different assembly jigs and transportation jigs. Despite the wide-ranging measurement needs of between 8 – 16 m, and accuracy requirements of 0.05 – 0.08 mm, the laser trackers were able to meet the company’s variety of needs. Separately, the FaroArm is used to verify smaller-sized tooling at time of delivery, or used to complement the Laser Trackers in measuring difficult-to-reach areas. In 2015, TQM Feiyue built and commissioned a complete set of aircraft assembly line for General Aviation International (Xi’an) Aircraft Technology (Gavin) line of private jets. The laser trackers were used to perform measurements

and inspections, especially in the final stages of the project, before handover. The company found that its usage of the laser trackers increased over time, with its team clocking as much as 12 hours on the devices each day. The increase in frequency is linked to the need for accuracy on the assembly jigs. The team would bring the laser tracker on-site to take pre-deliver y measurements. In addition, as a post-sales service, TQM Feiyue would deploy the laser trackers at their customers’ premises 60 percent of the time, using the device on a variety of work environments.

Faro Laser Tracker Vantage

Left: Tooling for a Bombardier C-series hatch door. Right: Inspecting a LE700 small aircraft assembly jig with a laser tracker.

ENQUIRY NO 125

For accurate and large volume measurement, Faro’s Vantage offers a complete laser tracking solution that melds disruptive new features in a portable design. Smaller and lighter than it s predecessor, the Vantage is one step ahead with its ability to capture more measurements with fewer device moves and shorter routines. With a measuring range of up to 80m (160m spherical working volume) and accuracy levels of up to 0.015mm, the device features infinite rotation, supports in-line optics, and also offers TriMap encoders. The Vantage possesses a IP52 water and dust resistant rating, which allows it to perform even under demanding industrial conditions. Its SmartFind system allows the Vantage to find the desired target whenever its beam is lost or broken, and its Integrated Wi-Fi eliminates the need for the Vantage to be tethered to laptops. Common applications of the Vantage include tasks such as alignment, part inspection, tool building, manufacturing, assembly integration, and reverse engineering.

The New Standard for Stamp Tooling

Round fine centering system The rolling round fine centering for the positioning of two mold halves garantees a precise guidance and maximum load capacity already at centering start. Made of hardened, wear-resistant bearing steel, it is suitable for the production of very high precision parts. The built-in cage positioning system allows to fully exit the preload and enables the use in hybrid and transfer tools. Find out more. EuroBlech – Hall 13, Booth E174 Agathon AG Gurzelenstrasse 1 | 4512 Bellach | Switzerland Phone +41 32 617 45 02 | Fax +41 32 617 47 01 normalien@agathon.ch | www.agathon.ch

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

With production orders rapidly expanding in 2014, they found their current existing measuring procedures would soon reach a bot tleneck , and being unable to keep up with the increased demand was a very real possibility. The company set out to nip the problem in the bud. “We were looking for a high-precision and ex tremely fas t high-end coordinate measuring machine with a large measurement range which would also be an ex tremely powerful gear measurement centre for our cams,” explained Marius Grosse, qualit y manager at Weiss.

PRECISE MEASUREMENTS

IN RECORD TIMES

What are the benefits when coordinate measuring machines (CMMs) are used simultaneously as gear measuring centres? By Sea Chiahui, regional stationary product manager at Hexagon

Editorial

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ENQUIRY NUMBER

7203

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eiss, a manufac turer of automation solutions, needed a reliable and ef f icient way to measure their produc tion out put , e specially c am drive s . Throug h t he t hread and gear wheel of t he c am, massive driving forces are translated into fine rotational motor movements of the rotary indexing table and parts of the linear assembly system. The need for accurate measurement was therefore paramount. At this point of time, the cam drives had to be tested in two separate runs: Once on a gear measurement device and a second time on a coordinate measuring machine for the remaining geometry.

Precision & Speed They found what they were looking for with two measurement machines from Hexagon: the Leitz PMM-F and the Leitz Reference HP bridge measuring machine. The Leitz PMM-F offered some advantages over their previous measurement methods. The coordinate measuring machine (CMM) was designed to test medium-sized components and gears accurately and quickly, with a maximum permissible error for measurement range lying within a temperature range of 18 to 22 deg C at 2.3 + L/400 μm. Working with a rotary table meant no more centring and alignment of gears, and the machine was also able to measure gears on long shafts up to 3,000mm in length. However, the primary CMM used for gear measurement was the Leitz Reference HP. Its LSP-S2 3D scanning system enabled both fast single-point probing for all typical measuring tasks, as well as high-speed scanning for form and profile measurements. Measurement Options The deciding factor was the Quindos software. With the software installed, the CMMs could measure over 30 types of gears: cylindrical gear s , s t r aig h t and spir al b evel gear s , cylindrical worms, stepping gears, coupling gear s , gear rack s , cur vic coupling s and more. To measure them, only the respective parameters need to be entered. All traversal paths, probes and scan lines are generated automatically. The CMMs were able to keep up with increased production, and are still in use presently. When it comes to complex gear mea surement , slow proces ses and high programming expenditure can eat away at efficiency. Finding the right machine that suits the needs of production requirements can result in a dramatically improved measurement throughput.

ENQUIRY NO 115

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

MANUFACTURING ACCURACY

REGARDLESS OF CIRCUMSTANCES Closed loop position measurement provides high accuracy in any situation with small series. By Helmut Kügel, Heidenhain’s product management encoder.

Editorial

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ENQUIRY NUMBER

7204

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ccuracy often suffers in small series production with constantly changing tasks and processing procedures. In many cases the reason for this are the permanently fluctuating and unforeseeable temperature changes in the machines and drives, which lead to the thermal expansion of the ball screw drives. Closed loop position measurement with Heidenhain linear encoders eliminates these fluctuations in the drive train. It determines the exact position of the machine table at all times. This results in consistently accurate workpieces and strict adherence to tolerances. Flexible small series continue to demand a lot of even the most up-to-date enterprises if they are to run economically and accurately. The organisation and logistics, in particular, devour time and personnel. After all, the preparations as well as the production and further processing steps all have to be synchronised with the greatest of accuracy. If the actual machining is much faster than the setting up of the machines and plant, then delays have serious consequences. The calculation is torpedoed just as much as the time-consuming and intricate planning of subsequent machine occupation. No wonder that with all this organisation and fine-toothed planning, the topic of accuracy is prominent in flexible small series production. In fact, modern machines usually do have an acceptable intrinsic accuracy. However, the devil is often in the details and in this case, thermal

expansion due to internal heat sources in the machine, and therefore from the machining itself. Thermal Expansion Has Surprising Effects We all know that materials expand when heated. In the case of the linear axes, it is mainly the ball screw drive which is affected. Due to the initial stress and associated friction between the ball screw and the nut, it heats up each time the machine table traverses during machining. The so-called fixed/floating bearings of the ball screw drive allow for the associated expansion, so as to prevent damage to the bearing. The expansion for a steel ball screw drive can be easily calculated by taking the thermal expansion coefficient of steel of 10 µm per metre length and degree of temperature difference. In the case of a ball screw drive one metre long, a rise in temperature of 1°C causes a deviation of 10 µm. Since temperatures of 45°C are quite common on the ball screw drive — an increase in temperature of 25°C above the ideal temperature of 20°C — it is easy to imagine the actual dimensions of the deviation. Scrap Due To Overheating On Monday morning, the machine is at its ideal temperature of 20°C after a weekend of standing idle. Now setup and preparation begin for a small series production run of 40 parts. It involves machining of average difficulty without any particularly high traversing speeds for the machine table. The maximum feed is 3.5 m/min. Two holes 350 mm apart are to be drilled in the parts, and the

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

Ball screw drive in action: The ball screw reaches temperatures of up to 45 deg C.

contour milled. The machining takes five and a half minutes; the tolerance for the distance between the holes is ±0.02 mm. The subsequent quality control shows that of the 40 parts to be produced, only the first 25 are within the specified tolerance. About 40 percent of the production is scrap—what a catastrophic result! What happened? The ball screw drive heated up continuously during machining. After the 25th part the heat increase had reached the critical point when the thermal expansion of the ball screw drive causes the tolerance of ±0.02 mm to be exceeded. The deviation on the last part was even 70 µm. You can clearly demonstrate this deviation with a simple trick: After machining of the 40th part, the first part is put back on the machine and the feed setting in Z direction is halved. The second holes made in this way in the finished part leave a clearly visible edge in the existing holes, likewise the second milling operation on the contour. This is the result of the 70 µm deviation due the thermal expansion of the ball screw drive. Unpredictable Expansion However, the problem in small series production is not the linear expansion, which is easy enough to calculate. The problem is caused by the permanently changing requirements and conditions, which makes the temperature development unpredictable. For the first small series production on Monday morning is followed in the afternoon by a quick change of settings for the next machining run. But what are the temperature conditions in the machine now? Has everything cooled down again to 20°C during the switchover or is there still residual heat in the ball screw drive? Nobody knows, and with every subsequent small series production the conditions will become increasingly inestimable. There is no way that you can derive values for future machining runs. The same machining run could produce more or less rejects the next time round, depending on the initial temperature of the ball screw drive at the start of machining and how the temperature develops.

Clearly visible after the second machining: The deviation of 70 µm due to the thermal expansion of the ball screw drive.

Invisible second drilling with closed loop control: A twice machined part with no corners and edges.

Everything Under Control On the other hand, position measurement with a linear encoder is independent of the thermal expansion of the ball screw drive—and any other influences. This so-called closed loop control always determines the precise position of the machine table. The result is stable production with a constantly high level of workpiece quality. A comparative machining run demonstrates the example described above. There is no scrap from a machine with closed loop control; all the parts are within the specified tolerance. A second machining run with the first part after machining of the 40th part with half the feed setting in Z direction leaves no visible edge. In particular for companies who specialise in small series productions, the implementation of a machine with closed loop position measurement with a linear encoder could be a profitable investment.

Accuracy often suffers in small series production with constantly changing tasks and processing procedures.

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

KEEPING PACE With Production

When perfect volume cuts are required in wet or dry cutting situations, the solution lies with a high-performance automatic circular saw.

hanks to references from the steel market, circular saw manufacturer Behringer Eisele from Weilheim/Teck succeeded in submitting the winning bid to supply and install an HCS 160 Multifluid high-performance circular machine to an international market leader in quenched and tempered steel. The company’s most important customers are steel trading corporations worldwide, in particular in Europe. “This international tender for a sawing system was decided in our favour because Behringer Eisele scored highest when it came to the key factors quality, technology and price”, explains Manfred Grüninger, head of sales at Behringer Eisele, Weilheim/Teck, Germany. In the magazine of the highperformance circular saw HCS 160 Multifluid, a single bar with a diameter range of 20 – 160 mm is separated from the bundle and cut. The bar with lengths of up to 13 m is cut to customer’s order to lengths between four and 12 m. Variability & Adjustability Their customer was able to cut 10

tons of raw materials in bundles of 20 with a starting length of 12.5 m and a diameter of 80 mm made of 42CroMo4. It took them less than 40 minutes to create two bundles with a vending length of 6 m. The process included both, a front and a rear cut, as well as the dividing cut in the middle. The HCS 160 Multifluid was able to keep up pace with production delivering precision, supplying perfect volume cuts. Whether for wet or dry cutting, the carbide circular saw was able to offer both variability and adjustability. In addition, the HCS 160 Multifluid can be adapted to suite the processing task and requirements of the sawing cut: From workpiece cooling using emulsion, through to the use of different micro-spraying devices to active saw blade cooling during dry cutting. It is also designed to handle high-alloyed heat-resistant steel qualities over 1200 N/mm2. While the standard speed range of 20 to 250 rpm allows it to cover most conceivable sawing assignments even using standard equipment.

Flexibility & Support The machine provides additional support during both wet and dry cutting: A chip conveyor with integrated coolant pump, for instance, ensures rapid disposal of produced chips. During wet cutting, a trough integrated into the machine frame captures the cooling lubricant emulsion. “To improve vibration damping, our engineers opted to add greater rigidity to the machine concept”, explains Manfred Grüninger. The result is an increase in service life and an improved cutting surface for precise, rapid cuts in both wet and dry conditions. As a fully automatic highperformance circular saw, the HCS 160 MF is designed to ensure production-oriented and flexible integration into the downstream production process. “This is why we maintain a lively dialogue with the customer to ensure that the system is performing at all times”, says Grüninger. He regularly calls in to enquire how things are going on site. After all, process reliability is crucial when it comes to volume sawing.

ENQUIRY NO 133

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

SPEEDING UP AND

SIMPLIFYING INSPECTIONS

Image dimension measurement system puts much faster in-process inspection within everyone’s reach. By Keyence

Editorial

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ENQUIRY NUMBER

7205

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imex is America’s leading watchmaker and is present in more than 80 countries. Fralsen, i t s Fr e n c h e n t i t y, m ake s w a t c h movement s using t hree technolog ies — plastic injec tion moulding of small par t s with ver y f ine details; turning and cutting of par t s such as wheels, pinions, arbors a n d r i v e t s ; a n d c u t t in g a n d co il in g o f complex spring s . These precision par t s mus t be inspec ted with contac t sensors (co mp ar a t o r s , C ar y e quip m en t , f e e lerspindles) and optical systems.

“ We wanted more modern and more efficient optical inspection equipment. In other words, we wanted to be able to inspect more parts in less time,” said Sylvain Scotto of Fral sen’s qualit y control depar tment . “We also wanted a machine that could be operated by non-specialists and be able to log measurements.” Saving Time The tolerances and accuracies are 15 μm for concentricity and ± 10 μm for centre-to centre spacings and distances. There are at least five critical points per part. “With conventional inspection equipment, measurements took too long. As a result, we couldn’t measure many parts and there was a risk of overlooking significant variations within batches. Before obt aining the IM Series, we used a variety of equipment. Our optical measuring device, which, although very accurate, is not very practical for quick measurements on a daily basis. Furthermore, it requires a high level of skill to operate. The shop microscopes provide accurate measurements, but are tricky to operate and severely limit the number of measurement s and par t s. In addition, a reference point for truing-up has to be created. Lastly, due to the sometimes long inspection times, our templates and projectors allow only a limited number of parts to be measured and there is a risk of misinterpretation,” added Mr Scotto. “The IM Series is simpler to operate, saves time and eliminates variations of interpretation of measurements. Results are conveniently displayed in green (for good) or red (for bad). Keyence’s solution allows several parts to be measured simultaneously. The size of the parts and the number of elements making up the program are the only limits. There is no need for manual truing-up because the system does it all by itself by recognising each part’s geometry. Furthermore, results can be saved and s t at is t ic s t racked. Par t prof iles c an be compared against master profiles imported from CAD files. As a result, we no longer need to position templates on parts and measure differences in shape by eye. The machine does

IN DESIGN Asia Pacific Metalworking Equipment News • October 2016

so automatically and extracts an image of the contour showing the difference with the tolerance. All in all, measurements are fast and do not require special skills.” Average Inspection Time Conventional inspection methods

Part Type/ Number Measurements of parts

Total time

(minutes)

IM Series

Number of parts

Total time

(minutes)

Cut wheel/ Concentricity

Stator/ Shape and dimensions

Wheel corrector/ Concentricity

Plate/Centreto-centre spacing

User-Friendly Programming The new IM-6700 series image dimension measurement system is able to measure up to 99 points in a matter of seconds with a repeatability of ± one micron. Targets are found and measured regardless of their position or orientation and there is no risk of measurements being affected by variations in operator skill levels. Thanks to the iPASS shape detection method, the system determines the position and angle of targets, making measurements automatic. “Getting to grips with the system was easy because all you have to do is adjust the focus and load the program for the part being inspected. All the QC technicians in the quality department use the machine for final inspection of parts before their placement in stock. The operators in the cutting shop also use it to measure certain parts during production. The programming is completely user-friendly. The faster inspection times enable us to track dimensions better and thus improve the quality of a large number of the par t s we deliver. What’s more, we haven’t received a single complaint from clients about any of the parts measured on the machine. For example, we use Keyence’s IM-6700 to inspect the concentricity of every single cut wheel and automatically record the measurements,” said Mr Scotto.

The contour of the stator is superimposed on the CAD file. With the old method (template and projector), this process was long. Now, three parts can be inspected in less than one minute instead of five in five minutes. The profile also allows the Mechanical Engineering Department to see where parts need reworking. The red contour shows that the stator is at the tolerance limit in places (blue zone).

Wheel corrector: inspection of the concentricity of the toothing with the inner bore. With a profile projector and a template, three parts were inspected in three minutes. With the IM Series, Timex can inspect (and record) more than 10 parts simultaneously in the same amount of time.

Cut wheels: inspection of the concentricity of the toothing with the bore.

Inspection of centre distances of gear train bores on plastic plates. Less than three minutes are needed to inspect two parts.

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

STARTTO-FINISH STRATEGY With Fibre Laser Yes, it is fast, but while fast-cutting speeds open up the potential, there are still the upstream and downstream manufacturing processes to consider. By Oliver Hergt, corporate communications, Bystronic

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ibre laser technology has had a profound impact on sheet metal processing of many users. Modern fibre lasers achieve excellent cutting results, and this at breath-taking speeds. One could even go so far as to say that the fibre laser enables metal to be cut at the level of Formula One, that is to say, to the highest technical standards. But a fibre laser or a fast car alone do not automatically make a champion. Fast cutting speeds merely open up the potential, which must be capitalised on during the upstream and downstream manufacturing processes.

A fast laser increases the throughput of the entire production. All of the sudden, more parts flow through the manufacturing chain in a shorter time. For users this means that it now becomes relevant, for example, as to how fast their software can convert customer enquiries into cutting jobs. And, how cutting programmes can be used to cut out as many parts as possible from the metal sheets. Fast, value-adding, and high-quality production â&#x20AC;&#x201D; these are the foundations for a competitive edge. Maintaining High Throughput Typically, within the manufacturing chain, the next step after laser cutting is bending. Here too, the systems must be able to keep up in order to maintain the high throughput. With press brakes, it is important to decrease the set-up and programming times. Modern bending systems offer features t hat c an achieve t his , such a s : O f f line p r o g r a m m in g , f a s t s e t- up s y s t e m s , o r even fully automatic set-up. Intelligent cor r e c t ion and s a fe t y f unc t ion s r ound of f the range of bending solutions. They suppor t the user in manufac turing highquality produc t s with high precision and without errors. But how can this high throughput be maintained as constant as possible? Or in other words, how does the racing car achieve peak times lap after lap? In the sheet metal processing business, automation is a key

FAST FAB Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

Fibre lasers are able to cut in sheet thicknesses of up to 30 mm.

factor. This is why, for example, users upgrade their fibre lasers with automatic loading and unloading systems that ensure a suitable supply of materials to the machines and unload the parts after the cutting process. The analysis of process data in real time is another important factor for users. Digital services collect and analyse complex data and provide the users with a clearly organised overview. This allows users to monitor their production processes: Similar to how the racing team in the pits monitors how the racing

car, the motor, and the brakes perform on the racetrack. Optimally Aligned In a nutshell, successful fibre laser cutting means ensuring that all the production processes relating to the laser are optimally aligned. Champions win thanks to a comprehensive start-to-finish strategy. To achieve this, users require the right partner who supports them with innovative technology, effective features, and professional service.

Digital services collect and analyse complex data and provide the users with a clearly organised overview. ENQUIRY NO 118

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3D Printing:

MODULAR PROTOTYPE PRODUCTION

WITH LASERS

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he long lead time of turbine blades and vanes presents a big challenge to the validation of new part designs in engine tests. Conventional vane production through casting is unsuited for the fast iteration cycles required today in the development of hot path components. In a join t proje c t , Siemens and t he Fraunhofer Institute for Laser Technolog y ILT have now developed a faster production process based on selective laser melting (SLM). Components are manufactured in a modular way in the new process chain, resulting in additional benefits. Last year, Siemens commissioned its Clean Energy Centre, a new combustion test centre in Ludwigsfelde near Berlin. The centre plays a major role in developing and refining gas turbines as a facility for conducting realistic tests on various turbine components with liquid or gaseous fuels. Rigorously optimising

Fraunhofer ILT, Aachen, Germany.

Siemens and the Fraunhofer Institute have developed a faster production process based on selective laser melting (SLM). By Dipl-Ing Jeroen Risse, Fraunhofer Institute for Laser Technology ILT

Fraunhofer ILT, Aachen, Germany.

the combustion processes involved is the key to achieving greater energy efficiency in the turbines. During the tests, individual turbine parts are exposed to temperatures of 1,500 deg Celsius or more. Such components are usually manufactured from super alloys in a precision casting process, in which each iterative loop may last several months and incur significant costs. Thus far, this has severely curtailed the number of tests possible. Fast Prototype Production E x p er t s f rom t he Siemens g a s tur bine manufacturing plant in Berlin and the Fraunhofer Institute for Laser Technology ILT in Aachen, Germany, have now developed a laser-based technology that considerably speeds up the manufacturing process for turbine vanes slated for the hot gas area of the engine. To withstand the high temperatures over

FEATURES Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

long periods of time, the turbine vanes require complex internal cooling structures. Selective laser melting (SLM) has proven itself to be up to the challenge, especially for prototypes or small batches featuring complex geometries. Similar to using a 3D printer, special alloys are melted by laser on a powder bed. The components are then built up layer by layer. Over the past several years, Fraunhofer ILT has built up considerable expertise in the use of additive laser techniques and alloys for components exposed to high temperatures. With this wealth of experience, the scientists were able to develop special processes that made it possible to produce the relatively large parts (up to 250 mm) at Siemens with a high degree of dimensional accuracy and superior surface quality. New Production Chain Securely mounted on the turbine housing, guide vanes channel the hot ga s to the movable rotor blades. The guide vanes consist of two massive platforms plus an air foil with a delicate cooling structure. The latter presents a major manufacturing challenge;

even production using SLM required additional internal supports. A modif ied process chain solved the problem: the plat forms and the air foil are manu f ac tured s ep ar ately and t hen subsequently brazed together. This makes it possible to not only eliminate the supports in the blade, but also to improve the surface qualit y. The result is a fully func t ional component that can be used in hot path rig testing in order to deliver quick feedback to the design engineers. Siemens optimised various production steps in preparation for this idea. After manufacturing via laser, the parts are precisely measured, subjected to finishing, and then joined using high temperature brazing. T his modul ar produc t ion o f tur bine blades offers significant potential for other components as well. It would make it possible to connect cast and SLM-made parts, leaving just the complex or variable par t s to be produced using SLM. At the same time, it would also facilitate the production of parts with difficult geometries that are currently too large for the SLM process.

Rigorously optimising the combustion processes involved is the key to achieving greater energy efficiency in the turbines. ENQUIRY NO 050

FEATURES Asia Pacific Metalworking Equipment News • October 2016

3D PRINTING

Jigs, Fixtures & Other Manufacturing Tools The fundamental objectives of manufacturing — improve quality, decrease cycle time and reduce costs — are the primary reasons that jigs and fixtures are so abundant. By Joe Hiemenz from Stratasys

Even though manufac turing tools are widespread, many manufacturing facilities do not use these tools to their fullest. Making them takes time, labour and money. To stretch limited resources, there is an option: 3D printing, also known as additive manufacturing. It is simple and automated, fast and inexpensive. This allows you to deploy more jigs and fixtures while gaining the ability to optimise their performance. Lowering The Barrier By simply substituting 3D printing for your current methods of making jigs and fixtures, you can reduce their cost and accelerate delivery. In these terms alone, 3D printing systems are easily justified with short payback periods. But this ignores the larger impact on the bottom line. 3D printing lowers the threshold for justifying a new tool, which allows you to address unmet needs throughout the production process. If you were to look around the manufacturing floor, assembly area and quality control lab, how many new opportunities would you find for a jig or fixture? What would the value be? Could it:

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t does not mat ter if the operation is fully automated or entirely manual; jigs and f ix tures are deployed throughout m anu f a c t ur in g o p e r a t i o n s w i t h t h e goal of reducing cost s while accelerating production processes. When expanded beyond jigs and fixtures to include all manufacturing tools that serve as operational aids, they are even more widespread. They range from organisational bins and tool holders for 5S (a workplace organisational methodology) to templates, guides and gauges. They include sophisticated robotic endeffectors (grippers) and rudimentary trays, bins and sorters for conveyance and transportation. No matter the name, description or application, manufac turing tool s increase prof it and efficiency while maintaining quality.

• Reduce scrap and rework? • Decrease direct labour time? • Improve process throughput? • Improve process control and repeatability? And with respect to the bottom line, how much more profit would the company gain? More importantly, why aren’t jigs or fixtures currently being used in these operations if they have value? Most likely, they were not justifiable. Although there is a benefit in having the jig or fixture, the return on investment (ROI) is not large enough to warrant the effort. You may have found that your time and money were better spent elsewhere. Path Of Least Resistance Since there is never enough time in the day or

FEATURES Asia Pacific Metalworking Equipment News • October 2016

money in the budget to do everything you would like to do, the decision to build a manufacturing tool puts priority on the: • Processes that are not possible without a jig or fixture. • Most obvious and urgent needs. • Largest threats and most likely problems. • Quickest to implement and produce results. • Easiest to implement. Deciding when and where to use a jig or fixture is no different from any of the other daily decisions we make. Action is taken when value outweighs investment, or when the path has little resistance. 3D pr in t ing low er s t he jus t i f ic at ion t h r e s h o l d b y in c r e a s in g y o ur R O I a n d decreasing the obstacles between a great idea and a solution. It does this by simplifying the process, lowering the cost and decreasing lead time.

When using fused deposition modelling (FDM) as the 3D printing approach to make jigs and fixtures, the process has just three steps: prepare the CAD file, build the tool and postprocess it. Unlike conventional fabrication methods, FDM requires little experience and minimal direct labour. In many ca ses , jig s and f ix tures are manufactured with only 15 minutes of hands-on labour. More importantly, they are manufactured with little training on how the process works

By using 3D printing to recreate a gripper with internal vacuum channels, Digital Mechanics eliminated five external hoses that hampered operations.

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FEATURES Asia Pacific Metalworking Equipment News • October 2016

machine shop wanted US$1,500 for the fixture. I made it for less than US$200 in materials,” says Ms Williams.

Top: When machined fixtures were quoted at $12,000 and seven days, Thermal Dynamics opted to make them with FDM to save $10,000 and several days. Above: According to Thogus’ quality control a, it is simpler, faster and less expensive to make its own FDM fixtures than to outsource them to a machine shop.

and no need for prior experience. Combined, this makes FDM an ideal “self-serve” option for jigs and fixtures. According to Natalie Williams, quality manager at Thogus, an injection moulder that specialises in low-volume manufacturing and highly engineered materials “is so much easier for me to model a fixture and print it myself than it is to design it and work through an outside machine shop.” For Thogus, 3D printing is easy and fast. “For one 12-cavity CMM fixture the lead time, if outsourced, was seven to 10 days. I built it overnight,” she says. Manufacturers using FDM to create custom manufacturing tools often experience leadtime reduction from 40 to 90 percent. 3D printing also can increase ROI substantially by reducing the cost of a jig or fixture. Typically, companies realise savings of 70 to 90 percent when compared to outsourced fixtures that are machined or fabricated. For Thogus’ 12-cavity fixture, the savings were 87 percent. “The

Re-Designs & Revisions Making the tool fabrication process faster and more affordable, 3D printing will increase the number of jigs, fixtures and other manufacturing tools, which will improve the bottom line. 3D printing can also optimise manufacturing tool performance. Before 3D printing, designs that were sufficient to do the job were acceptable for jigs and fixtures. Due to the expense and effort to redesign and re-manufacture them, revisions were reserved only for those that did not work as specified. Although “good enough” may have added a few seconds to an operation or increased the scrap rate by a small percentage, the savings might not have warranted further investment in the tool. 3D printing changes that thinking. For a few dollars, it can deliver the next-generation manufacturing tool and have it in service the next day. A tool that has marginal performance requires only a little time and initiative to redesign it. Doing so may only drive out a few seconds from an assembly operation, for example, but that time adds up. If the fixture makes 500 items per day per worker, a two second savings reduces direct labour by 70 hours per person per year. For the same part, a one percent reduction in scrap would save 1,250 parts per year. The bottom line: 3D printing lowers the threshold so that manufacturers can put more jigs and fixtures, with optimised designs, into service. This drops more money to your company’s bottom line. Implementing A 3D Printing Approach Before creating your first 3D CAD model and uploading it to a Fortus 3D Production System, take materials and dimensional tolerance into account. While 3D printing is ideal for many manufacturing tools, it is not right for all of them. The main consideration for materials is whether plastic will suffice. Traditionally, jigs and fixtures have been fabricated in metal. For some, metal may be a requirement. For others, metal may have been just a practical option because it is conducive to milling, turning, bending and fabricating. In this case, 3D printing may be an option. The range of FDM materials can offer chemical resistance (petroleum, solvent s), thermal resistance (up to 200 deg C) and resilient mechanical properties. Plastic manufacturing tools may also deliver

FEATURES Asia Pacific Metalworking Equipment News â&#x20AC;˘ October 2016

some unexpected advantages. For example, Thogus uses FDM-made robotic attachments that absorb impact. In the event that the robot arm crashes into an obstacle, the FDM part is likely to isolate the arm from damages, which prevents expensive repairs and downtime. In another example, BMW uses plastic, hand-held tools because they are lighter and easier to handle, reducing worker fatigue. When deciding whether to try 3D printing on some initial toolmaking projects, for dimensional accuracy, pick tools requiring tolerances larger than 0.005 inch (0.127 mm). Tighter tolerances are possible, but as a rule, stick with this value when keeping the process simple. Rethinking Design Your current inventory of jigs and fixtures were designed with consideration for the capabilities and limitations of the fabrication methods used to create them. By adhering to design for manufacturability (DFM) rules, you made them practical, kept cost to a minimum, and made lead times reasonable. These rules do not apply to 3D printing. They have no bearing on time, cost, quality,

performance or practicality. In some cases, adhering to old DFM rules may actually have the opposite effect. The additive nature of the process gives you unmatched freedom of design. What may have been impractical is now realistic and reasonable. Jigs and fixtures can have complex, feature-laden and freeform configurations without adding time and cost. In fact, added complexity may even reduce cost and time. For example, pockets, holes and channels reduce material consumption, build time and total process time. To leverage 3D printing, let the function and performance of the jig or fixture dictate the design. Follow the lead of companies like Digital Mechanics AB and BMW. Digital Mechanics capitalised on the freedom of design for a vacuum-assisted robotic gripper. Conventionally made, the gripper had external hoses hanging off it. With 3D printing, each finger of the gripper was given an internal vacuum channel that eliminated the hoses. For BMW, freedom of design allows assembly line workers to have a tool that reaches under, behind and inside the rear of the bumper.

The bottom line: 3D printing lowers the threshold so that manufacturers can put more jigs and fixtures, with optimised designs, into service. ENQUIRY NO 043

FEATURES Asia Pacific Metalworking Equipment News • October 2016

Advantages of integrating jig or fixture parts into a single component: • Eliminate tolerance challenges. Holding tight tolerances is costly. If two mating parts are combined into one, then all costs and concerns about controlling the tolerances of the mating parts are eliminated. • Eliminate assembly time. Assemblies, obviously, must be assembled. This takes time, especially for one-off items like jigs and fixtures, where perfect fits are not guaranteed. Top NASCAR team, Joe Gibbs Racing, uses FDM to make fixtures, some of which have been in service for more than two years and have cut lead time and expense by an average of 70 percent.

Ergonomics Of Tools Manufacturing engineers focused solely on the function, which resulted in an organically shaped bumper-reach tool. Design freedoms can also improve the ergonomics of manufacturing tools. The weight, balance and position of the tool have direct effects on technician comfort, process cycle time and ease of access and storage. To achieve optimal ergonomics, simply design it into your tools. For example, BMW redesigned a badge alignment fixture to improve balance and reduce weight. This reduced worker strain and improved the cycle time for badge attachment. One very simple way to leverage the freedom of design is to consolidate assemblies into single parts. Often, jigs and fixtures are composed of many pieces. This is unnecessary with 3D printing. If reproducing an existing tool, star t with a redesign that consolidates as many components as possible into one piece. If designing a new item, create it as one piece. Only split off parts when it is advantageous to the operation of the jig or fixture.

Stratasys Fortus 450mc For high-requirement prototypes, rugged jigs, f ixtures and tooling, and custom production parts in familiar standard, e n g in e e r in g an d hi g h - p e r f o r m an ce thermopla s tic s, the For tus 450mcTM 3D Printer s et s t he pace for speed, performance and accuracy. Powered by Stratasys’ FDM 3D printing technology and with a build tray of 16 x 14 x 16 inch, the Fortus system jets layers of engineering or production-grade thermoplastic, such as ABSplusTM, Polycarbonate (PC) onto a build platform to realise three-dimensional models. The Fortus 450mc 3D production system can be installed anywhere as it does not produce noxious fumes, chemicals or waste.

• Minimise documentation and overhead. The sum of the parts is less than the whole when it comes to time and cost. Consolidating parts reduces costs for actions such as design, documentation, quoting, ordering and inventory management. Improve Management No longer consider your jigs, fixtures and other manufacturing tools as assets. Instead, think of them as expenses, and disposable. As assets, jigs and fixtures are stored (inventoried) between uses. They remain in inventory until the product line is retired or they are worn beyond repair. With the time, cost and effort of making manufacturing tools through conventional methods, they are too valuable to be discarded as a disposable item. This approach carries many indirec t costs, however. There is cost for shelf space (warehousing expense); cost to manage and track the inventory; and cost to locate a jig or fixture when needed. For sporadically used tools, these costs can be quite significant. The opposite can be true with 3D printing. Often, it takes more to inventory the jigs and fixtures than it does to re-make them. So companies adopt a management approach called digital warehousing where only the digital f ile is carried in inventor y. It may seem unthinkable to scrap a perfectly good manuf ac turing tool , but for t hos e wit h infrequent use, this approach reduces cost and labour. Make a fixture when it is needed. When its job is done, send it off with the scrap material for recycling. Then digitally warehouse its design between uses. This print-on-demand approach is also handy when a replacement is needed for a broken manufacturing tool or duplicates are needed for increased production to meet an unexpected surge in sales.

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Voice of the Industry:

IS NOW THE TIME

TO TRY DIRECT DIGITAL MANUFACTURING ? Scott Crump, chairman and chief innovation officer of Stratasys explains how direct digital manufacturing, otherwise known as 3D printing, is fast emerging as a disruptive technology that may make manufacturers rethink manufacturing.

ver t he pa s t 20 year s addi t i ve manu f ac t ur ing t e chnolo g y ha s migrated from use in rapid protot yping to a full-f ledged manufacturing solution, which is referred to as “direct digital manufacturing” (or rapid manufacturing). Increasingly, companies are applying it to manufacturing applications, and with each success, they prove that it is a viable alternative. While the general concept of additive manufacturing is the same as when it was int roduced 20 year s ago, t he change is in it s intended use: produc tion, not just prototyping. So, while the concept of direct digital manufacturing has been around for a while, in the minds of many, it can still be a new thing and sometimes difficult to understand.

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What Is Additive Manufacturing? Additive manufacturing is the generic name given to processes that create a par t by building it up in layers – as opposed to milling or machining, which are subtractive proce s s e s . Addit ive manuf ac turing w a s developed as a way to automate the creation of prototypes, and it was therefore originally known as rapid prototyping. It also goes by various other names, including 3D printing,

which is one of the most popular. Digit al manufac turing is the proces s of using C AD or ot her dat a to drive an additive manufacturing machine that makes usable parts. Examples are the components that go into sellable produc t s, pieces of production machinery, replacement parts or manufacturing tools, such as jigs and fixtures. Besides C AD data, which is the over whelming majorit y of dat a used, other types of data may be used to drive additive manufac turing machines. Among o t her s i t inc lude s 3D s c an da t a (for reverse engineering) and DICOM data (for making a physical represent ation of 3D medical imagery). Digital manufac turing eliminates moulding, machining, casting and forming. Instead of material removal or shaping, a company’s finished goods are produced by adding material one layer at a time. Other than a few minutes of pre-processing to prepare a production run and some light post-processing to clean up a part, digital manufacturing progresses directly from CAD data to final part. Eliminating the up-front and back-end operations common to traditional methods means that there is no extraneous time, cost or labour.

FEATURES Asia Pacific Metalworking Equipment News • October 2016

One Process, Many Technologies Digit al manufac turing is a proces s , not a technolog y. A nd it c an be per formed with various additive manufac turing technologies with diverse capabilities. The additive manufacturing technologies that per form digital manufac turing share the fundamental technique of producing par ts direc tly from a C AD dat a f ile. However, additive manufacturing processes function in diver se ways; to determine digit al manufacturing’s suitability for your project, you must f irst evaluate the project against your chosen technolog y. Whichever technolog y you choose, di g i t a l m a n u f a c t ur in g o f f e r s p o w e r f u l advantages over traditional manufacturing methods. The most of ten cited are: • Eliminating investment in tooling. • Speeding up design cycle and time to market. • Expanded design possibilities.

• Quicker, less expensive redesigns. • Custom parts and low-volume production. Collec tively, these benef it s translate to ef f icienc y, f lexibilit y, responsiveness and affordability. Digital manufacturing is a manufacturing proces s t hat int roduces alternat ives in product design, manufacturing methodology and bu sine s s op er a t ion s . A s an adde d b e n e f i t , m a n y a d di t i v e m a n u f a c t ur in g technologies are fairly “green” processes. They produce very little waste compared to milling pro ce s s e s b e c aus e t he y us e only the material needed. No unnecessary inventory is produced because there is no benefit to building more than you need at any time. Most additive processes require no harmful chemicals and vent no harmful fumes into the environment . Additive manufac turing also requires a relatively small amount of electricity to produce parts, another green benefit.

Instead of material removal or shaping, a company’s finished goods are produced by adding material one layer at a time. ENQUIRY NO 061

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FEATURES Asia Pacific Metalworking Equipment News • October 2016

Oreck uses direct digital manufacturing to create production aids, such as this fixture, which secures a component during CMM inspection.

Producing manufacturing tools presents the ideal opportunity to try digital manufacturing. These tools are deployed to make manufacturing and assembly fast, efficient, repeatable and cost-effective.

Digital manufacturing essentially rewrites the rulebook for making manufac turing decisions. In many instances, it is a polar opposite to conventional produc tion methods. This makes it a disruptive technology and makes it more difficult to appreciate and comprehend. Application Diversity In the manufacturing environment, digital manufacturing often performs one of two roles. Companies can use the process to manufacture the products it sells or to make the devices that aid in the manufacturing of the products. Digital manufacturing is best suited for low volume manufacturing. However, even companies that focus on mass production can use digital manufacturing to save time and costs — every manufacturer has lowvolume needs, such as hand tools, gauges and jigs and fixtures. Producing manufacturing tools presents the ideal oppor tunit y to tr y digital manufac turing. These tools are deployed to make manufacturing and assembly fast, ef f icient , repeatable and cos t-ef fec tive. In t h i s m a n u f a c t ur in g c o n t e x t , di g i t a l manufac turing becomes a low-risk, highreturn alternative to standard prac tices. Because the tools are used by the company, not the customer, and the time and cost to produce them is small, an unsuccessful

attempt has little consequence. But when successful, digital manufac turing greatly improves productivity, quality and the cost of producing parts. Digitally manufac turing tools is currently more popular than using digital manufac turing for end-use par t s. That’s par tly because it’s such a low-risk opp or t uni t y, and p ar t ly b e c aus e ever y manufacturer has a need for such tools. Digital manufacturing benefits industries in addition to manufac turing a s well . Because of the inherent need for custom fitting devices such as orthotics, prostheses, hearing aids and dent al bridges, the medical and dental professions have been early adopters of digital manufac turing. Companie s have dis covered t hat it c an be a power ful alternative, rather than a direc t replacement , to the conventional manufacturing processes. Digital manufacturing presents a nearly limitless range of opportunities. Companies have only begun to uncover all that it can do. It is exciting to realise that the scope of oppor tunities and potential is enormous. It is also good news that there are so many technolog ie s and material s from which to choose. A Fundamental Shift Digit al manufac turing is a fundament al shi f t in t he appro ach to mak ing par t s , w h i c h u s e s a d di t i v e m a n u f a c t ur in g t o make end-u s e p ar t s dire c t ly f rom C A D data. Digital manufacturing is a promising manufacturing alternative that accelerates production and reduces costs while creating new possibilities and new business models. It is unique because it avoids moulding, machining and forming, and it eliminates the cons traint s that these conventional manufacturing methods impose. Mos t likely, your company ’s produc t development depar t ment ha s eit her an in-house additive manufac turing sys tem f or r apid pr o t o t y ping or i t ou t s our ce s prototypes to a service that uses additive manufacturing. In either case, talk with the design engineers in product development, and ask about a sample project. Ask if they will build you a simple manufacturing tool like a small jig, fixture or gauge. Compare the cost of digitally m anu f a c t ur in g t h e t o o l t o t h e co s t o f producing it via traditional means: Think how this cos t ef fec tiveness can benef it your company as it has many other leading companies.

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FEATURES Asia Pacific Metalworking Equipment News • October 2016

WHERE ARE YOU GOING

INDUSTRY 4.0?

When Industry 4.0 took off in Germany it rapidly made it to the headlines. With the digital agenda of the federal government it received highest political priority. But where stands Industry 4.0 in reality? By Dipl-Ing Nikolaus Fecht and Dr Andreas Thoss on behalf of EuroBLECH.

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heor y describes Indus tr y 4.0 or the fourth industrial revolution as full integration of production and communication technologies. It creates a so-called “smart factory”, where people, machines and processes are well connected by internet technologies for the purpose of increased cost ef f iciency, higher process stability and greater f lexibility. Af ter all, technological innovations should save time and money. How does that look in real life? On one hand, there is an approach to scrutinise whole factories and to re-think and optimise all processes, from the first customer request to after-sales services. On the other hand many SMEs offer solutions for separate business processes. With special software tools, efficiency can be increased dramatically. Beside consequent digitisation of processes, there is a second trend coming up: While product lines are unified the single product is increasingly personalised. While this can lead to smaller lot sizes (even down to one), the new tools will help to retain profitability even then.

A Management Issue Friedhelm Loh, the sole proprietor of the Friedhelm Loh Group with more than 11,000 employers, spoke on his experiences with the introduction of Industry 4.0 in the Rittal, Germany, factory for industrial control cabinets. The product portfolio had been adjusted, until 2015 they reduced the number of products from 465 to 110. Five product lines were combined into one. In future, customers will define their purchase using an online configurator. The data from this configurator tool go directly into SAP and NC programmes. From initial material supply up to final distribution all logistic processes are fully automated. The whole process from “customer to customer” is digitally organised. The cost savings in the process steps are between 15 percent (purchasing and sales department, after-sales service) and 50 percent (manufacturing). Mr Loh’s conclusion: “Only an integrated end-to-end solution which is consistently based on configuration and data, results in a continuous process.” Within the Trumpf group, a new production unit Sheet Metal Processing has been set up as

FEATURES Asia Pacific Metalworking Equipment News • October 2016

a fully connected factory. It is comparable to a conventional sheet metal job shop which is completely converted into a smart factory. They use and develop software tools from Trumpf ‘s proprietary solution portfolio TruConnect and their digital business platform Axoom. For a further optimisation of the production process they introduced a MES (Manufacturing Execution System)-system from the TruConnect tool box. As the heart of the production planning, it evaluates the machine conditions and allows a paper free production with digital accompanying documents. Also, the topic intra-logistics will be optimised towards Industry 4.0 to automatise error-prone routine tasks.

Costs for material planning may shrink by up to 75 percent in a smart factory surrounding.

Festo

Solutions For All Not every company can or wants to implement Industr y 4.0 in the form of an entire new factory. Today there are many solutions for separate processes, which ser ve the idea of higher ef f icienc y by connec tivit y and specialised software. It starts with indirect processes, that are all the steps in a job that take place before or after the actual manufacturing of the part, regardless of the batch size. As batch sizes shrink due to increasing individualisation, these indirect processes are no longer in proportion to the actual productive work (ie: production itself). A study conducted by Fraunhofer-IPA (S-Tec) in collaboration with Trumpf found out that the costs for material planning may shrink by up to 75 percent in a smart factory surrounding. Dominik Weibel and Marco Wüst, two Swiss entrepreneurs, have implemented a similar tool for a sheet metal processing job shop.

Within their company eMDe Blechfabrik AG they developed an online system based on Trumpf’s online quotation calculator WebCalculate. Here customers can upload drawings and set material parameters and they receive a full quotation immediately. After placing an order, customers can track the order throughout all processing steps including delivery. eMDe saves a lot of time with small lot sizes and retains an opportunity for price negotiations with larger orders. More such tools (or actually apps) can be expected soon when Trumpfs spin-off Axoom becomes fully operational. Smart software may also save money in manufacturing processes. For example Bystronic has developed a special software for planning a sheet metal cutting job. The online service ByOptimizer calculates an optimised cutting plan for the laser machine based on more than 300 parameters. Parts are grouped so closely on the metal sheet that the gaps (ie: raw material offcuts) are reduced to a minimum. The online service connects seamlessly with existing software, it needs just a few clicks to upload data and online service takes care of everything else. Cutting paths of the laser are reduced by half when a common cut allows for one cut instead of two. Bystronic promises material savings of up to 10 percent depending on contour shape and lot size. It becomes more challenging if you have a new process and you want to find process parameters for cutting or drilling processes. It needs a well experienced operator and a number of trials to find optimal laser process parameters for a new material. Researchers from

The technologies and learning systems for Industry 4.0 are used within the Festo Didactic CP Factory, the cyberphysical research and learning factory, as well as in schools, universities and at companies.

FEATURES Asia Pacific Metalworking Equipment News • October 2016

Fraunhofer ILT

The simulation app from the Fraunhofer ILT allows dynamic adjustment of the process parameters, immediately returning process changes in the adjacent window.

Industry 4.0 is much more than hype; Many of its ideas are implemented already.

the Fraunhofer Institute for Laser Technology ILT have collected simulation know-how for such processes for many years. Adequate simulations usually require a workstation and hours of calculation time, but experts have developed a simplified simulation tool for tablet use. In this app the user can play around with beam parameters such waist diameter and see, the processing result directly. This may reduce make-ready times considerably. The simulation app from the Fraunhofer ILT allows playing around with process parameters with immediate return of the process changes in a neighboring window. Another example of smart production will be shown by the Schuler AG at EuroBLECH trade fair. With their concept of a “Smart Press Shop” they want to show how networking solutions in forming technology can increase not only process reliability, but also cost-effectiveness in production. For this purpose the entire system is simulated and optimised, including all press stages and automation component s. The systems provide data measured by sensors installed at numerous points, for example to monitor the press force. This data also allows for a continuous operation control and allows for condition-based maintenance. Alliances & Initiatives Industry 4.0 is a key issue for German politics and so there are plenty of projects and events arranged in a national and international frame. Particularly engaged are the German Federal Ministry of Economics and Technology (BMWi) and the Federal Ministry of Education and Research (BMBF). Together with indus tr y organisations and companies they have pooled activities and offerings for small and medium sized companies within the “Plattform Industrie 4.0”. I f you t hink human s w ill di s app e ar completely from the shop floor, you may consider

a look at the so-called “Innovationsallianz 3Dsensation”. Founded within the founding initiative “Zwanzig 20 – Par tnerschaf t für Innovation” of the BMBF companies and research institutions meet here to think about the future man machine interaction. It’s about making men machine interaction more intuitive, safer and more efficient. With a budget of €100 million (US$112.2 million), partners of the consortium want to work on projects in the fields of manufacturing, m obil i t y, h e al t h c ar e and s e c ur i t y. O f particular focus are 3D technologies that help machines to capture and interpret complex scenarios rapidly. Risks & Side Effects? Putting more services on the net and into the cloud brings a number of new risks on the table. So far, viruses and theft of data are more common on office computers. But with the Stuxnet worm that targeted industrial control systems, it is apparent that machine controls are not secure from fraud. On a recent meeting of the Association of German Engineers VDI the association’s director Ralph Appel said that the number of cyberattacks on industrial plants or infrastructures of larger and smaller companies is much larger than the news reports, since many companies do not even recognise such attacks. Accordingly, safety concepts are in high demand. One place where such concepts are developed is the Fraunhofer Institute for Secure Information Technolog y SIT in Darmstadt. There they built a Trusted Core Network (TCN) which tests the integrity of network knots to ensure that there are no foreign invaders. New participants such as robots, computers or machines are verified continuously and can be connected to the network. Industry 4.0 is much more than hype; Many of its ideas are implemented already. Solutions for separate processes are in widespread use but the conversion of full complex process chains is still rare. The conversion of indirect processes promises quick wins, in particular if you try to drive profits for small lot sizes. Detlef Zühlke, head of the technolog y initiative SmartFactoryKL eV and leader of the group Innovative Factory Systems (IFS) at the German Research Center for Artificial Intelligence, DFKI, said recently at a large Industry 4.0 conference in Anaheim, CA, USA, that it will some more two or three years until the first systems will be running. But then it will become a global competition: “It’s a worldwide movement. Those who are too late with it will finally be the first to die on the market.”

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FEATURES Asia Pacific Metalworking Equipment News • October 2016

ROLLING WITH ADDITIVE MANUFACTURING

IN THE AUTOMOTIVE SECTOR

Automotive manufacturers are under great pressure to develop vehicles which are due to go into production from now to 2020. A panel of experts weigh in with their thoughts on how additive manufacturing could contribute to the automotive industry.

Dr –Ing Martin Hillebrecht Head of competence centre for lightweight design, materials and technologies

EDAG Engineering GmbH

Sergio Raso

Head of strategic marketing laser products

BLM Group

Prof Dr-Ing Claus Emmelmann

Frank Herzog

Laser Zentrum Nord GmbH

Concept Laser GmbH

Chief executive officer

Q: Is it becoming more difficult in the automotive sector to achieve sustainability targets? If so, how can additive manufacturing contribute? Sergio Raso (SR): Sustainability is the overriding aim for the automotive industry. Various core technologies for the future of automotive production have so far been looked at. For example, there is a lightweight hybrid design to achieve weight reduction and fuel efficiency, use of additive methods for a bionically optimised design, and employing tubing and profiles to ensure that the vehicle frame can be manufactured in a highly flexible way.

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Dr –Ing Martin Hillebrecht (MH): Toolless additive manufacturing and the profiling method with minimal use of tools may make it possible in future to design all bodywork versions to suit the level of loading and manufacture them “on demand”. New bodywork structures should weigh less, have high stiffness to ensure performance and satisfy demanding load scenarios in the event of a crash. Whatever happens, there is definitely potential here.

President and chief executive officer

Q: Conservation of resources is a key aspect. How does the automotive manufacturer view this? MH: With smart lightweight design, particularly with composite construction, vehicles should be roughly 100 kg lighter than their predecessors, depending on the segment of the market. Further weight savings of 10 to 20 percent can be achieved in the bodywork and addon parts. Many manufacturers have already succeeded in reversing the spiralling trend for increased weight. But there are still ambitious targets to meet for weight reduction, comfort, functionality, sales criteria and new safety requirements from international legislators. These do not favour lightweight construction. It is a balancing act that we are trying to achieve. Q: What are some of the advantages and disadvantages of conventional body designs? MH: In a typical car body with a monocoque construction, panels, reinforcements, mounting plates and profiles are connected together using joining technology. All components act

FEATURES Asia Pacific Metalworking Equipment News • October 2016

as shells. The required rigidity is produced by cross-sections of metal sheets. The advantage of this design is the low manufacturing costs associated with industrial mass production, which is the same worldwide. As well as inexpensive semi-finished products made from sheet metal, tried-and-tested and robust technologies such as forming and spot welding are used. The disadvantage here is that tooling and plant investments only make economic sense if there are large quantities and make it difficult to produce a wide variety of different versions. In addition, tool-specific parts are associated with tooling costs and periods of preparation for the tooling technology are required. Ultimately, the tools have to be available across the full life cycle of the product. Q: The NextGen spaceframe was produced recently in a project by EDAG, BLM, Laser Zentrum Nord, and Concept Laser, and is part of the EDAG “Light Cocoon” concept car. What features and new processes does this spaceframe have? Prof Dr-Ing Claus Emmelmann (CE): The jointlydevised spaceframe concept combines the advantages of 3D printing, such as flexibility and the potential for lightweight construction, with the efficiency of a proven conventional profile design. “Selective laser melting” plays the key role in both technologies. The process yields bionically optimised nodes enable the ma ximum light weight construction and a high degree of functional integration. Both the nodes and the profiles can be adapted to new geometries and load requirements without any additional outlay. This means that they offer the possibility of designing every single part to cater for the level of loading, and not dimensioning the component s to ref lec t the greates t

motorisation, as was previously the case. The basic idea then is to have a frame design which can be optimally customised to reflect what the particular model requires.

The “Light Cocoon” concept car by EDAG, is a compact sports car with a completely bionically optimised and additively manufactured vehicle structure.

Frank Herzog (FH): Hybrid construc tion is also already being used in other sectors. Relatively simple or excessively long geometries are produced by traditional machining , and more complex geometries are then manufactured additively. This phenomenon reflects the economics. Composite construction is of interest in many sectors where there is a need to bridge a gap between function and economic efficiency. Q: What new manufacturing strategies and potential for automation will emerge from this in the future? What potential do you see in construction and manufacturing? CE: The potential for construction resides in flexible design that caters for specific load situations. There is also the opportunity to use the bionic structures that have been highlighted to engage in the maximum possible level of lightweight design on a scale that was not previously possible. At Laser Zentrum Nord we develop design guidelines to be able to successfully transform bionic prototypes such as a bamboo structure or bird-bone structure into sophisticated technical lightweight components with weight savings of generally from 30 to 50 percent. MH: In addition, being able to respond to fluctuations in sales volumes and “updateable” components during the life cycle of a vehicle should be emphasised. These are completely new ideas for the industry, and are some of the considerations going in to the adaptive “Industry 4.0”. We are excited to see how customers react to this.

The fact is that 3D printing on space stations is already being explored by NASA. And whatever happens, from a cosmic perspective there is a great deal of future ahead of us.

FEATURES Asia Pacific Metalworking Equipment News • October 2016

Presently, additive processes provide great potential in prototyping and tooling, as well as the production of spare parts.

FH: The core aspects of “Industry 4.0” such as automation, digitisation and interlinking play a fundamental role in our recently presented “AM Factory of Tomorrow”. The objective is to automate and thus minimise manual processes in order to prevent any downtime in the production of components. Any desired number of machines which were previously designed to be standalone solutions will increasingly be linked together to embrace the notion of a smart factory. There will also be automation and interlinking of additive and conventional technologies, in particular in the reworking of the components that are produced. Traditional manufacturing methods will then operate alongside additive methods. This is aligned with the requirements of the basic idea behind Industry 4.0. In the future, this will also make our process economically attractive for the mass production of metallic components, and also apply to the automotive industry, where it is primarily all about large volumes and quantities. Q: What significance does the powder-based laser melting of metals have today and what significance will it have in the future in the automotive industry?

The bionically optimised and lightweight vehicle structure is produced by hybrid additive manufacturing, highlighting a new way in which an adaptable and extremely flexible production concept can be implemented.

SR: Additive manufacturing techniques are today employed primarily in the automotive industry to manufacture small numbers of functional parts. However, as the aerospace industry has already demonstrated, we can see that the move over to additive manufacturing strategies significantly enhances product and process performance. The introduction of the “Manufacturing for Func tionalit y ” paradigm, along with “just-in-time manufacturing” and precision concepts instead of the rather restrictive “Design for Manufacturing” as well as have already begun to establish a foothold in

the automotive indus tr y. We are seeing the foundations of something completely new here. MH: Presently, additive processes provide great potential in prototyping and tooling, as well as the production of spare par ts. These processes have so far not caught on in automobile production yet, likely due to the high prices of materials and machine technologies. We await the future with keen interest, and would be delighted if the sector were to embrace our ideas of tool-free manufacturing in combination with traditional manufacturing m e t h o d s . T h e r e ar e d e f ini t e l y lo t s o f opportunities here. Q: Spare parts for cars are regarded as a logistical and costly challenge. Global availability, warehousing, life cycles and the pressure of time are all challenges for the spare parts experts. Not least, spare parts are currently a blessing for automotive suppliers that operate as OEMs or retrofitters or even duplicators. How can additive manufacturing change this situation? MH: Additive manufacturing makes it possible above all to fabricate components spread out and at different locations. This means that local advantages can be exploited, and different versions can be produced later and close to production. There are thus no transports and logistics costs, different versions of components no longer need to be kept in stock, and production close to the market and customers shortens the delivery time. CE: Additive manufacturing makes it possible to simply send CAD data records instead of physical components around the world, and if necessary, print out spare parts at a local level. One option is

The bodywork produced by hybrid additive manufacturing can be implemented to produce bodyworks that are designed to be suitable for different load stages.

FEATURES Asia Pacific Metalworking Equipment News • October 2016

The X line 2000R from Concept Laser (build envelope: 800 x 400 x 500 mm3), equipped with two lasers producing 1kW.

to have decentralised manufacturing, the effects of which we can only imagine. This approach will radically alter the supply of spare parts – delivery times could be reduced significantly and warehousing costs will be completely removed. This scenario is currently being actively implemented with the aviation industry. The foundation is thus being laid for this approach to be transferred to the automotive industry too. SR: Car frames based on 3D-bent and cut profiles and nodes produced from additive manufacturing will also enable new paradigms for the management of spare parts and their logistics. Fully automatic production of profiles and nodes based on “just-in-time” approaches would enable a drastic reduction in costs, also assuming that new guidelines for the repair of vehicles will be adopted. Q: Let’s look at the issue of quality of 3D components. How do you assess the standard of traditional manufacturing methods compared to additive methods? MH: Standards and quality requirements are being drawn up by industry experts and will undoubtedly also be based on the standards used for traditional manufacturing methods.

manufacturing will make it possible to create very complex, functionally integrated and highly eff icient structures that cannot be produced using other methods. So it is worth exploring niche areas and, apart from motor racing and ultra-lightweight construction, looking for future solutions in the context of specific requirements, such as electric mobility. They can then be fleshed out with us as the independent development company for the automotive industry.

The NextGen spaceframe nodes can be configured to be highly functionally integrated thanks to additive manufacturing.

SR: All I want to say is that in the future, we will have to accept solutions which cannot be transmitted today. The fact is that 3D printing on space stations is already being explored by NASA. And whatever happens, from a cosmic perspective there is a great deal of future ahead of us.

Bionic Design in Manufacturing With additive manufacturing, there are many possibilities regarding the future of the automotive sector. In the aerospace sector, Airbus, a proponent of bionic design, recently

FH: It has to be said though: We have a more or less “blank canvas” as far as the additive manufacturing solutions of the future are concerned. But the NextGen spaceframe sends a sufficiently bold signal to the automotive industry to look at the issue more closely in terms of design.

introduced a design for the A320’s passenger-to-gallery partition. This mimicked cells and bones’ structure, and weighs 45 percent (30 kg) less than current designs. The use of 3D-bent and laser-cut tubes and profiles for structural assembly has already proved to be a way of saving weight in assembly while still retaining mechanical properties. The load-specific matching of lasermelted 3D nodes and laser-welded 3D profiles has an important role to play

Q: Let’s look ahead to the future. Which additive parts will be conceivable in the automotive sector in the next decade?

in this design. Nodes produced by traditional casting technologies proved to be a trusted solution in the past. Bionics, hollow spaces and lattice structures built from additive manufacturing allows 3D nodes to have even more options for design,

MH: Besides the traditional production of prototype par t s, like cast par t s, additive

variations and safety aspects.

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • October 2016

Preview:

The Grand Metalex Thailand 2016

PRODUCTION EFFICACY AND COMPETITIVENESS

Ushering in the next generation of metalworking into Southeast Asia.

W Grand Metalex Thailand Bangkok International Trade & Exhibition Centre (BITEC) Bangkok, Thailand Nov 23 – 26, 2016 Editorial

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ith over 3,300 brands from 50 countries, the Grand Metalex 2016 is 45 percent larger in scale compared to the previous year. Taking place from November 2 3 to 25 in Bangkok, Thailand, the exhibition will cover the breadth and depth of machine tools and metalworking technologies such as cutting, milling, bending, welding and measuring, including the launches of 30 new technologies which will activate the next level of production efficacy and competitiveness. Thailand’s Minister of Industry Atchaka Sibunruang recently noted that the requirement s for Thailand’s Industr y 4.0 will come into ef fec t during the second phase of their efficiency and productivity enhancement master plan, including measures to upgrade big industries and SMEs to bring down manufac turing cos t s and enhance long-term competitiveness. The exhibition will present fully-functioning examples and

concrete solutions that Thai companies can use to improve their competitiveness, with over 100,000 professionals from all over the world expected to attend. Platforms such as the Engineer Forum and Business Matchmaking Service enable learning of new know-how, while expanding business networks. Experts will also impart business strategies and industrial advancements at the exhibition’s various other panels and conferences, such as the Metalex Congress, Metalex Nano Forum and Metallurgy Forum. Tawiwat Reongpunyaroj, general manager, Trumpf Limited Thailand said, “We strongly believe t hat t he sheet met al market in Thailand is def initely not on a standstill as manufacturers and job shops alike are constantly looking into updating their machine tools technology in order to stay competitive. The Grand Metalex 2016 is one of the biggest sheet metal exhibitions in the region that we give highest priority.”

Asia Pacific Metalworking Equipment News • October 2016

PRODUCT FINDER

Bosch Rexroth: Drive System For Machine Innovation

5ME: Freedom 4.0 Shop-Floor Management Software

5ME’s Freedom 4.0 updates the Freedom eLOG software, focusing on manufacturing efficiency, including asset utilisation, performance, quality and OEE. The new SmartBoards (Smart Dashboards) allows users to configure customised screens and the ability to embed images, websites, work instructions, spec sheets, or any other salient information. The IoT software can connect with ERP, MES, CMMS, and other business systems and can be accessed anytime via any device with a browser. Freedom 4.0 is fully MTConnect compliant.

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7601

For industries ranging from offshore to plastics to metal forming, developing applicationspecific, modular machines is the ultimate goal. The way to achieve that goal is with optimised drive technologies. Electric solutions such as Rexroth’s IndraDrive ML can provide an alternative, especially when high power outputs are required. Used in a variety of industries such as marine and offshore, automotive, aerospace, material handling, metal forming and metal process, the IndraDrive ML extends the series into the upper power range. This modular inverter can individually power from 110 kW up to 500 kW and up to 8 devices can be connected in parallel for power up to 4 MW. Whether for electric, hydraulic or hybrid drive solutions, the drive system is the scalable in terms of power, performance control and connectivity. The modular inverters can be used as a mains power inverter or as a motor inverter. The universal inverters are particularly suitable for complex multi-axis applications.

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7602

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PRODUCT FINDER Asia Pacific Metalworking Equipment News • October 2016

Esab: Rebel Welding System

Esab’s latest welding system, the Rebel EMP 215ic features multi-process arc per formance, location f lexibilit y, portability and an easy to use operator interface. The Rebel provides an industrial quality arc for MIG, fluxcored, Lift TIG and Stick welding, including performance with difficult-to-weld E6010 electrodes. Operators interact with the system using a control that combines traditional weld parameter adjustments with the functionality of a smart phone. It accepts 100 and 200 mm diameter wire spools, runs 0.6 to 1.0 mm diameter wires and enables users to run on 230 V to 120 V primary power. The unit comes ready-to-weld for MIG and TIG welding processes. Rebel’s interface offers six different local languages.

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7603

Ingersoll Rand: RS37n Rotary Screw Air Compressor

Ingersoll Rand’s RS37n Rotary Screw Air Compressor has variable speed drive technology, increasing air flow output by up to 15 percent while reducing energy costs by up to 35 percent. The compressor can run continuously in ambient temperatures of up to 115 deg Fahrenheit. The starter panel meets NEMA 12/IP55 protection ratings to provide protection against circulating dust, falling dirt, and dripping or splashing liquids. Other design enhancements include a NEMA 12 rated enclosure and standard pre-filter allowing the compressor to operate in harsh application environments.

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7605

Holroyd Precision: CS700E Tool Management Centre

The CS700E Tool Management Centre allows grinding of profile forms on finish milling cutters of up to 700 mm in diameter. Cutters with up to 29 blades can be sharpened, while the cutter indexing process is carried out automatically. The maximum profile height is 120 mm. The machine incorporates automatic dressing stations, which are equipped to dress aluminium oxide, CBN and diamond grinding wheels, with use of HSK-A160 arbors (as fitted to 8EX rotor milling machines). Additionally, the touch screen programming system provides control over production accuracies, as well as on-screen modification of profile forms for the evaluation of new prof ile shapes during the development and prototyping stages.

ENQUIRY NUMBER

7604

Okuma: MU-8000V 5-Axis Vertical Machining Centre

This VMC features standard ball-screw cooling and a highly rigid left-right mobile trunnion table that supports high precision and cutting power. They are available with a standard No. 40 or 50 spindle, providing a configuration for nearly any five-axis job. An in-machine coil chip conveyor allows for safe, reliable chip discharge. The unique design places the pallet changes at the back of the machine, allowing easy connection to a Palletace flexible manufacturing system, pallet pool, large capacity ATC and robots.

ENQUIRY NUMBER

7606

PRODUCT FINDER Asia Pacific Metalworking Equipment News • October 2016

ENQUIRY NO 134

ARNO® Flip-Through Catalogues ARNO-Werkzeuge for sliding head auto lathes

SSAB: Hardox HiTemp

Hardox is a wear-resistant steel already known for its hardness and toughness. SSAB, the Nordic and US-based steel company, has extended the Hardox family with the introduction of the HiTemp wear plate. Traditional quenched and tempered wear-resistant steels experience a loss of hardness at the 300-500°C range. Hardox Hitemp wear plate is SSAB’s solution, given its high temperature performance. Able to stand up to abrasive conditions in high heat environments, the material can be cut, welded, machined and cold-formed by the same kind of workshop machinery and technology as other grades of conventional steel. It is suited for high temperature wear applications, particularly in process industries such as steel, cement and coal power plants, and recycling and asphalt industries.

ENQUIRY NUMBER

7607

Accurate – versatile – efficient Originating from the watchmaking industry sliding head auto turning is ideal for producing relatively long and slim components from bar material. Today components from sectors such as automotive, electronics, jewellery and medical are widely produced using this way of machining. These ARNO tools are ideal for manufacturing small, thin-walled and accurate parts. The sharp and precision ground inserts with small nose radii, high cutting efficiency and excellent tool life ensure outstanding productivity, making sliding head auto lathes ideal for mass production. Have a look at the Arno sliding head auto tooling.

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

www.arno.com.sg

134 Arno.indd 1

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PRODUCT FINDER Asia Pacific Metalworking Equipment News • October 2016

Vernet Behringer: HD-S 412 Drilling-Milling Machine

Vernet Behringer’s HD-S 412 compact drilling-milling machine is dedicated to small/medium-sized steel fabricators looking for a versatile machine with compact footprint. It can also be used by larger companies that require an additional line for lighter profiles (400 x 300 mm capacity). The HD -S , a 3-spindle machine, is able to drill simultaneously the web and both flanges of H-beams, and, process channels, angles, flats as well as right hollow sections. Jansen steel profiles for windows and doors can also be machined with an optional adaptation kit. The machine has a clamping system with CNC controlled x-axis with 150 mm stroke. It is available with a wide range of infeed/outfeed loading and transport systems and can be installed in line with a Behringer band sawing machine for straight and mitre cuts.

ENQUIRY NUMBER

7608

Walter: BLAXX For Finishing Operations

The new XNGX0705ANN-F67 f inishing inser t has been developed for the Walter BLAXX M3024 heptagon face milling cutter. The large number of cutting edges – 2 + 2 on the finishing inserts and 16 on the roughing inserts – offers cost efficiency. A p p l i c a t i o n s l ike s e mi-f ini s hin g an d f ini s hin g operations can be combined into a single operation using a single tool. The combination of milling cutter and indexable inser t s are suited to industrial series production of components such as exhaust turbochargers or turbine blades, or any other components made from stainless steels, cast materials or steel.

ENQUIRY NUMBER

7609

Zimmerman: FZ33 Compact Portal Milling Machine

The FZ33 Compact Portal Milling Machine has a Y-axis that travels up to 4,000 mm, with a Z-axis of up to 1,500 mm. This machine is suited for the machining of small and medium sized components for the aeronautical and automobile industries, tool and mould making, and other special applications. New features include the cast-iron cross slide, and stiffer drive trains in the X-consoles, increasing stability in operation. In spite of the larger working area, the footprint has been reduced by 120 mm. The operating platform can be pushed apart, thus providing better access to the portal milling machine and enabling operators to load the machine more easily without using a stacker truck.

ENQUIRY NUMBER

7610

Zeller+Gmelin: Prelubricant Multidraw PL 61 SE

Multidraw PL 61 SE by Zeller+Gmelin is suitable for the basic oiling of all steel surfaces from the rolling mill and helps to reduce zinc abrasion during the forming process of hot-dip galvanised surfaces. The product also has draining-off inhibition, as well as compatibility with all non-coated and coated sheet metal surfaces. The corrosion protection with forming properties allows preservation of semi-finished products for storage and transport. The prelubricant is suited for chipless forming, such as stretch forming and ironing. Automotive industry requirements on removability and paint and adhesive impact are also taken into account.

ENQUIRY NUMBER

7611

EXHIBITION PROGRAMMES 2017

2016 - 2017 Asia Pacific Metalworking Equipment News • October 2016

OCTOBER 25 – 27

JANUARY 18 – 20, 2017

Jakarta International Expo

Tokyo International Exhibition Center (Tokyo Big Sight)

Indometal 2016

Gedung Pusat Niaga Lt. 1 Arena PRJ Kemayoran Jakarta 10620 Indonesia Messe Dusseldorf Asia

25 – 29

Euro Blech 2016 Deutsche Messe Hannover

Messegelände D-30521 Hannover Germany Mack-Brooks Exhibitions Ltd

NOVEMBER 23 – 26 Metalex Thailand 2016

Bangkok International Trade & Exhibition Centre

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

23 - 27

Taiwan International Machine Tool Show Greater Taichung International Expo Center

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

NOVEMBER 30 – DECEMBER 3

Manufacturing Indonesia 2016

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

NEPCON Japan 2017 3-21-1 Ariake, Koto-ku Tokyo 135-0063, Japan Reed Exhibitions Japan

JANUARY 26 – FEBRUARY 1, 2017

IMTEX 2017

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

MARCH 7 – 12, 2017 TIMTOS 2017

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

4 - 7, 2017 MTA 2017

Singapore Expo

1 Expo Drive,Singapore 486150 Singapore Singapore Exhibition Services Pte Ltd

MAY 11 – 14, 2017

MACHINE TOOLS THAILAND 2017

Bangkok International Trade & Exhibition Centre

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

17 – 20, 2017

INTERMACH 2017 SUBCON Thailand 2017 Sheet Metal Asia 2017

Bangkok International Trade & Exhibition Centre

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

APRIL 5 – 7, 2017

Vietnam Manufacturing Expo 2017 I.C.E. Hanoi (Cung Van Hoa) 91 Tran Hung Dao Str. Hanoi,Vietnam Reed Tradex Company

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

The Editor (APMEN)

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ADVERTISING INDEX

Asia Pacific Metalworking Equipment News â&#x20AC;¢ October 2016

Page Number

Enquiry Number

AGATHON AG

125

AGMACHINE TECHNO CO LTD

044

ARNO WERKZEUGE S.E.A. PTE LTD

134

BEHRINGER GMBH

121

BENIGN ENTERPRISE CO LTD

119

BYSTRONIC PTE LTD

119

COMPRO PRECISION MACHINERY CO LTD

049

CREAFORM

132

DEES HYDRAULIC INDUSTRIAL CO LTD

045

10/11

136

EVERISING MACHINE CO

056

FRITZ STUDER AG

114

HEIDENHAIN PACIFIC PTE LTD

112

HEIMATEC GMBH

027

HOFFMANN QUALITY TOOLS ASIA PACIFIC PTE LTD

113

HWACHEON ASIA PACIFIC PTE LTD

070

HYPERTHERM (S) PTE LTD

129

ISCAR LTD

IFC

124

KASTO MASCHINENBAU GMBH & CO KG

126

KENNAMETAL INC

122

LIEN CHIEH MACHINERY CO LTD

043

PT PAMERINDO INDONESIA (MANUFACTURING INDONESIA 2016)

137

REED TRADEX COMPANY (METALEX THAILAND 2016)

133

RENISHAW (HONG KONG) LTD

135

SANDVIK SOUTH EAST ASIA PTE LTD

123

SCHAEFFLER (SINGAPORE) PTE LTD

009

02/03

130

TAIWAN ASSOSCIATION OF MACHINERY INDUSTRY (TAMI)/ TIMTOS 2017

115

TAIWAN TAKISAWA CO LTD

050

TORNOS TECHNOLOGIES ASIA LTD

061

TRUMPF PTE LTD

116

TUNGALOY SINGAPORE (PTE) LTD

127

UBM ASIA (THAILAND) CO LTD (INTERMACH 2017)

128

WALTER AG SINGAPORE PTE LTD

117

WALTER EWAG ASIA PACIFIC PTE LTD

131

WIKUS SAGENFABRIK WILHELM H KULLMANN GMBH & CO KG

IBC

064

ZWCAD SOFTWARE CO LTD

118

Advertiser

DMG ASIA PACIFIC PTE LTD

SIEMENS INDUSTRY SOFTWARE PTE LTD

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ASIA PACIFIC METALWORKING

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Forging Rolling Die Casting Welding Turning Coil Forming

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Innovative band saw blades for your requirements of today and tomorrow Customised band saw blades and support for higher efficiency

With more than 50 years of experience in the development and production of high-performance tools, WIKUS is Europe‘s largest manufacturer of band saw blades and global technology leader in metal sawing. Precision band saw blades from WIKUS represent innovation and productivity with the objective of higher efficiency for the customer.

WIKUS is offering you: Innovative band saw blades, optimised for all kinds of sawing tasks · Competent and individual customer service in the entire sawing process · Cutting tests directly on location of the customer

Made in Spangenberg, made in Germany.

ENQUIRY NO 064

WIKUS-Sägenfabrik Wilhelm H. Kullmann GmbH & Co. KG Melsunger Str. 30 34286 Spangenberg Germany Tel.: + 49 5663 500 – 0 eMail: info@wikus.com

www.wikus.com

GROOVING, CUT-OFF AND MULTI-DIRECTIONAL TURNING MADE...

Face Grooving

Grooving

Deep Grooving

Beyond Evolution is the new single-sided grooving and cut-off tool that also performs multi-directional turning.

Cut-Off

Side Turning

CALL

+65 6572 4465 / 66 (SGP) 02 203 5800 (THA) 03 55699080 (MYS)

Chamfering

Profiling

kennametal.com/BeyondEvolution Facing

www.kennametal.com

ENQUIRY NO 122