APMEN Sep 2016

FINDING EFFICIENCIES ON THE PRODUCTION FLOOR

COST DOWN, PRODUCTION UP FOR HIGH SPEED MILLING

September 2016

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Asia Pacific Metalworking Equipment News • September 2016

METAL CUTTING

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Cost Down, Production Up

At the fore, high speed milling of aluminium parts for the aerospace industry. By Reuven Shapir, Iscar Industry Manager for the Aerospace Marketing Division.

Elements For Successful Face Milling Boost productivity in face milling operations with pivotal technologies. By Sandvik Coromant

GREAT GEAR & SYSTEM

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Case Study:

Smart Factory At Your Fingertips

Smart factories are an important spoke in a future decentralised society. Tools are being developed to help accelerate productivity and lower costs. Contributed by Cecilia Tan, marketing and communications manager, Schaeffler (Singapore)

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Maintaining A Proper Plasma System Proper plasma system maintenance can help prolong life and performance of system, and it requires just a little time investment. By Clayton Gould, marketing manager, aftersales, Hypertherm Inc.

Supporting Local Customers With Schunk’s Technology Centres

Mark Johnston speaks to Alexander Tjioe and Harald Dickertmann on the opening of their new technology centre in Jarkata, Indonesia. Mr Tjioe is the president (automation), Schunk (Indonesia) while Mr Dickertmann is the head of sales and business development Asia, based out of Germany.

IN DESIGN

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A Better Way: Finding Efficiencies

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Inefficiencies need to be ironed out before introducing the concept of the Digital Twin and what this means for the way goods are created and produced. By Siemens PLM Software, Aaron Frankel, senior marketing director manufacturing engineering software and Jan Larsson, senior marketing director EMEA

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Understanding PLM

The what, why and who of product lifecycle management (PLM).

By Ho Pei Ying

Addressing MEMS Challenges

Overcoming design challenges for microeclectro-mechanical systems (MEMS) in an IC-focused environment. By Nicolas Williams, product marketing manager and Qi Jing, technical marketing engineer, Mentor Graphics

FAST FAB

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Human-Robot Collaboration To Drive The Automotive Industry

Teamwork between human and machine is key in enabling manufacturers to ride on the growth of the automotive industry. By Shermine Gotfredsen, General Manager, APAC, Universal Robots

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Smart Press Shop

Networked systems can increase process reliability and cost-effectiveness. By Simon Scherrenbacher, corporate communications, Schuler.

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The Digital Transformation

With Industry 4.0, there is now an increasing trend towards digitalisation in industrial environments. Bystronic’s CTO, Dr Jürgen Hohnhaus talks about the benefits behind this development. By Oliver Hergt with photos by Manuel Stettler

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Asia Pacific Metalworking Equipment News • September 2016

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FEATURES

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Machining Centres: Measurements Made Easy

Model and mould-maker Sammer, located in Eugendorf near Salzburg, Austria, is mostly engaged in the production of moulds for the automotive industry, including cylinder heads, crankcases and transmission housings.

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Digitalisation Of The Manufacturing Sector

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How can Asian manufacturers maintain their competitive edge in the next 40 years? The answer lies in its evolution towards an Industry 4.0 manufacturing model. By Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants

Enhancing Engine Performance With Thermal Spray Coating

The advantages of using aluminium alloy engine blocks over cast iron blocks can be augmented with thermal coating spray.

By Paulo ES Rosa, manager, advanced thermal spray applications and process development, Comau

Auto Parts News & Trends

The latest happenings surrounding the automotive parts industry.

REGULARS

8 Business News 74 Product Finder 79 Exhibition Programmes 80a Product Enquiry Card For Advertiser’s Enquiry Numbers, Refer to Advertising Index in page

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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 2885 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.

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On Time, On Budget

It’s not about playing with the cost, but budgeting well in order to manufacture efficiently and maximise the margins.

By Asier Ortiz, CTO of Lantek.

EVENTS & EXHIBITIONS

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Metalex Vietnam

Industry Endorsements Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA)

Four-in-one event to mobilise the industry

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EuroBLECH: The New Generation Of Sheet Metal Working

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TMTS: Intelligent Manufacturing At Work

The fourth edition of the Taiwan International Machine Tool Show (TMTS) is set to be one of the biggest converging grounds for machine tool suppliers and buyers from all over the world.

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Exhibition Review:

MTA Vietnam 2016

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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21 Tannery Road, Singapore 347733 Tel: 65 6741 8880 • Fax: 65 6741 8998 • E-mail: marketing@smartscope.com.sg Singapore • Malaysia • Indonesia • Hong Kong • South China Thailand • Myanmar • Philippines • Vietnam • Taiwan • Australia New Zealand • Middle East • Myanmar

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

HALF EMPTY or HALF FULL? It seems predictions of gloom and doom greet us at every turn. From the copious amount of reports on the state of the industry/economy, to coffee with friends, you’ll likely be bombarded by endless moans on Brexit casting its long pall on the global economy, the slowing of Asia’s growth engine – China, softness from the US economy, you get the drift…

How do you stay positive under these circumstances, and where are the nuggets of growth opportunities in this maelstrom? Well, some perceptive individuals are shrewd enough to see things differently. To them, the glass is not half-empty, but half-full. Yes, half-full.

Britain leaving the EU: There was turmoil in the markets and a fall in the pound as Britain’s historic vote to leave the European Union caught many by surprise. Since then, business leaders have been urged to stop talking Britain down as a slew of new data suggested the economy was weathering the Brexit shock rather well.

Businesses are now more upbeat as the country is only in for a temporary slowdown due to uncertainty, and it is likely to avoid a recession. Meanwhile, latest report show that its industrial production grew by 2.1 percent in the three months to July 1 – its fastest rate for 17 years. In addition, the British Retail Consortium found that consumer spending in July rose at its fastest level for six months.

Here’s another look at the half-full/half-empty glass: Exports of Italian machine tools were down by 4.3 percent for the first three months of 2016 according to data from ISTAT-National Institute for Statistics. The “Made in Italy” deliveries went drastically down in China (-20.1 percent) and in Russia (-78 percent). Weakness in international demand spread red ink all over the industry’s spreadsheet.

However, the pall lifts when the picture is seen with a focus on its domestic front. There, Italian manufacturers saw a five-percent growth in the same period. Wait, there’s more: the average age of machinery installed in the Italian factories is almost 13 years, and there is low automation/ integration of industrial plants (only 30 percent) says a survey by UCIMU. With a new law called ‘Super Depreciation’ (designed to encourage investment in depreciable assets) more machines will be bought as factories rush to upgrade. Good news indeed.

In India, while production numbers are nothing to shout about, there’s an overhaul in the tax system to take advantage of. The landmark Goods and Services Tax Bill is one of the most significant economic reforms since the country became independent. In the long run the reform should boost growth, widen the tax base and improve the country’s business environment.

Reports coming in expect India’s industrial production to increase 6.2 percent in fiscal year 2016. For fiscal year 2017, the industrial output is expected to expand 6.7 percent says a report by FocusEconomics of India.

There are more such head-turning updates for the Asia Pacific region of course. The glimmer of hope – that silver lining found against the backdrop formed by dark clouds reminds us to be positive, be optimistic, and basically have faith and patience. Yes, there are bad news, but there are also good news…

Eileen Chan Managing Editor

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contributors

Reuven Shapir Cecilia Tan Bert Rosenheinrich Clayton Gould Mark Johnston Nicolas Williams Qi Jing Aaron Frankel Jan Larsson Shermine Gotfredsen Simon Scherrenbacher Oliver Hergt Paulo ES Rosa Imtiaz Ahmed Asier Ortiz

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

China Steel Products Exports Up By 19.9% In 2015

Beijing-Shanghai High-Speed Rail Brings In Nearly US$1 Billion Profit Shanghai, China: The Beijing-Shanghai bullet train has made a profit of close to US$1 billion for 2015, raking rare financial gains when compared to China’s other high-speed trains who are mostly running on losses.

The China Railway High-speed (CRH) line reported net profits of 6.58 billion yuan (US$982 million). It covers more than 1,300km within five hours. In 2015, it transported more than 130 million passengers, according to an official bond issuance document of one of the line’s major stakeholders. The document also revealed that the CRH line has been narrowing its deficit since it opened in 2011.

2015 was the first time it saw profits.

Beijing-Shanghai High-Speed Rail Corp’s director of the board Cai Qinghua said the fast growth of transport contributed to the quick reversal of the deficit.

Global Steel Prices Expected To Decline From July - December New Delhi, India: Global steel prices are expected to fall in the second half of 2016, after an upward rally during the January to June period, on account of decline in demand in China, said BMI Research.

The Fitch Group firm predicts however that 2017 will see steel prices edging up.

“We expect the January to June 2016 steel rally to fade and prices to head lower in the latter half of 2016 as declining Chinese steel demand growth, stemming from a slowdown of the country’s construction activity, will result in an oversupplied market,” the firm said in its report.

It expects prices for steel to trade in the range of US$450 to US$520 per tonne during the second half of 2016, with the average price for the entire year coming to US$480 a tonne.

“Over first half of 2016, steel prices rallied due to a combination of high demand from Chinese steel users restocking the metal, government stimulus measures implemented in the housing market and positive investor sentiment,” the firm added.

On the outlook for 2017, BMI Research said: “Although we forecast the JanuaryJune 2016 steel price rally to fade over the latter half, prices will gradually edge higher from 2017 onwards, due to Chinese supply moderation.” BMI Research also added that the global steel market will see a surplus of two million tonnes in 2016, a decrease from a 2015 surplus of 12.2 million tonnes.

The global steel market will tighten and shift into deficit from 2017 onwards, decreasing the stocks-to-use ratio from 13.6 percent in 2016 to 11.6 percent by 2020.

“Despite this, prices will remain subdued by historical standards. For instance, our 2016 to 2020 average of US$518 per tonne is significantly lower than the annual average of US$667 a tonne during 2011 to 2015,” the firm said.

Shanghai, China: In recent years, steel produc t s expor ted by China increa sed rapidly. In 2015, China exported 112.4 million tonnes of steel produc t s with an increase of 19.9 percent year-on-year.

Business Wire, a Berk shire Hathaway subsidiary headquartered in California, US, latest repor t on “China Steel Industry Overview, 20112020” showed that in 2015, the output volume of steel product s reached approximately 1,123 million tonnes in China (declining by 0.15 percent compared to 2014, which dropped for the first time in the past 34 years).

The major material of s teel product manufacture is iron ore. The impor t of iron ore in China highly depends on foreign countries. In 2015, China impor ted 953 million tonnes of iron ore with an increase of 2. 2 percent compared to 2014, w hic h accoun t e d f or 8 1 p er cen t of t he nat ional demand for iron ore. Therefore, the price trend of impor ted iron ore exer ted a huge impact on the profit margin of steel product manufacturers.

From 2013 on, the price of imported iron ore continued to fall. The price of iron ore impor ted by China in the second half of 2015 declined by more than a half compared to that in the first half of 2013. The decline is conducive to decreasing the costs of steel manufacturers so as to increase the profit margin.

The increase of expor ted s teel produc t s wa s s timulated by t he internat ional demand for s t e el pr o duc t s , w hic h r e f le c t e d the strengthening competitiveness of Chinese s teel produc t s in the international market. In spite of many trade barriers, the steel product s ex por ted by China are ex pec ted to keep increasing with huge price advantages, which will become one of the key factors in the development of China steel industry.

In the nex t few years, it is predicted that the economic growth of China will continue to decline.

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

However, the annual grow th rate is expected to maintain about six percent. With the implementation of such strategies as One Belt and One Road, Made in China 2025 and Yangtze River Economic Belt, there will emerge certain demand for steel produc t s, which will bring in new opportunities for the development of China steel industry.

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Aluminium Prices To Remain Stagnant in Second Half of 2016 Tokyo, Japan: Aluminium prices are likely to range between US$1,500 and US$1,700 per tonne for the latter half of this year as oversupply will cap further gains, said the Japan Aluminium Association.

The chairman of the association Akio Hamaji said the uncertainty over the European economy after Brexit is unlikely to see a strong pickup for aluminium in the global economy. He also added that aluminium supply is expected to exceed demand in the global market this year, which will impact the market.

Benchmark aluminium prices on the London Metal Exchange (LME) have gained 11 percent this year, with recent benchmark numbers hovering around US$1,680 per tonne. Mr Akio, who is also president of Mitsubishi Aluminium, commented on the outlook for Japan’s premiums, stating that they will stay near current levels.

Japan is Asia’s biggest importer of aluminium and the premiums for primary metal shipments it agrees to pay each quar ter over the LME cash price set the benchmark for the region. Japanese buyers have agreed to pay producers a premium of US$90 to US$93 per tonne for metal to be shipped in the July to September period, as much as 23 percent less than the previous quarter, on weaker spot premiums.

“Aluminium demand in Japan is steady. But as our government cut its forecast for economic growth, it’s hard to imagine local demand picking up sharply and the premiums jumping from here,” said Mr Akio.

Indonesia’s Car Exports To Grow In 2016

Jakarta, Indonesia: The Indonesian Automotive Industry Association (Gaikindo) has raised its target for Indonesia’s car exports (completely built up units, or CBU) to 220,000 vehicles in 2016. This figure shows that the association is aiming to see a six percent year on year increase in car exports from the 207,691 units last year.

Gaikindo chairman Jongkie Sugiarto said the global economy has started to stabilise and this should have a positive effect on Indonesia’s car shipments.

Despite the optimism, Indonesia’s car exports fell 17.9 percent year on year to 73,524 units in the January-May 2016 period. The previous year figure was 89,554 units. This weaker showing could be attributed to delay in exports of the new releases of the Toyota Fortuner and the Kijang Innova—both manufactured by Toyota Motor Manufacturing Indonesia.

The biggest export destination for Indonesian cars is the Asean region.

However, the country still lags behind Thailand and Malaysia for car exports.

These neighbouring countries export more than 500,000 vehicles each annually.

Mr Sugiarto commented that Indonesia’s car export performance can improve if domestic manufacturers boost the production of sport utility vehicles (SUVs) and sedans. Both vehicle types have a strong foreign demand. Currently, Indonesia mainly produces multiple-purpose vehicles (MPVs). The association chairman also noted that a government luxury goods tax cut on cars would also drive up exports.

The country is looking to become the largest car manufacturer and exporter in Asean. The government has made moves in that direction, including investments in the manufacturing of car components and spares.

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

IMF Raises GDP Forecast For China Shanghai, China: The IMF has revised its forecast of China’s 2016 GDP growth by 0.1 percent to 6.6 percent. The organisation cited the country’s recent policy support, including interest rate cuts, fiscal expansion and investment increases as reasons for the revision.

In its latest update to its World Economic Outlook released in April, the IMF said China’s near-term outlook has improved since its “benchmark lending rates were cut five times in 2015, fiscal policy turned expansionary in the second half of the year, infrastructure spending picked up, and credit growth accelerated.”

The forecast makes China one of the fastest-growing major economies. The IMF said the country’s growth could be 6.2 percent year-on-year in 2017. Despite the IMF’s upward adjustment, analysts said China still faces numerous challenges as it tries to anchor growth in the second half.

“In the second half, China faces some difficulties as it tries to achieve the whole-year growth target of 6.5 to 7 percent,” said Beijing think-tank China Silk Road iValley Research Institute’s chief economist Liang Haiming.

China’s exports will be affected by the fragile global economic and trade growth, making it hard for China’s export growth to pick up in the coming months, he said. Investment, meanwhile, may remain sluggish due to the country’s overcapacity reduction drive and economic restructuring, he said, adding that the rising labour and environmental costs may also keep investors away.

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Boeing: India Needs 1,850 New Jets In Next 20 Years Mumbai, India: Boeing has revised its earlier prediction, expecting Indian airlines to order 1,850 new aircraft worth US$265 billion over the next 20 years.

The aircraft manufacturer had earlier estimated that India would require 1,740 planes valued at US$240 billion over 20 years. This new figure revision is an increase of six percent.

This rise in demand comes amidst new aviation rules in the country, the aircraft manufacturer told Reuters.

Last month, India overhauled rules governing its aviation industry, liberalising norms for domestic carriers to fly overseas and spreading the country’s air travel boom to smaller cities by capping airfares and opening new airports.

According to Boeing’s Current Market Outlook, single-aisle airplanes such as the next generation 737 and 737 MAX will continue to account for the largest share of new deliveries. The total new deliveries in this category are estimated at 1,560 airplanes. These new jets will continue to support the growth of low-cost carriers and replace older, less efficient ones. Widebody planes will account for 280 of the new deliveries, with a total value of US$85 billion.

Boeing expects a worldwide demand for 39,620 aircraft over the next 20 years, with India carriers needing more than 4.6 percent of the total global demand. Asia Pacific alone accounted for 15,130 planes.

Asian Growth Steady Despite Weak Global Prospects, Brexit Manila, Philippines: Grow th in A sia and the Pacif ic’s developing economies for 2016 and 2017 will remain solid as firm performances f r o m S o u t h A s i a , E a s t A s ia a n d Southeast Asia help offset softness from the US economy, and near-term market shocks from the Brexit vote, s aid an A sian Development Bank (ADB) report.

ADB now forecasts 2016 growth for the developing economies at 5.6 percent, below its previous projection of 5.7 percent. For 2017, growth is seen unchanged at 5.7 percent.

“Although the Brexit vote ha s affected developing Asia’s currency and stock markets, its impact on the real economy in the shor t term is expected to be small,” said ShangJ in W e i , A D B ’s c h i e f e c o n o m i s t .

“However, in light of the tepid growth prospec t s in the major industrial economies , polic ymaker s should remain vigilant and be prepared to respond to ex ternal shock s t o e n s ur e g r o w t h in t h e r e g i o n remains robust.”

Growth in 2016 and 2017 is led by South Asia, and India in particular, which continues to expand strongly, while the People’s Republic of China (PRC) is on track to meet earlier growth projections.

In Ea s t A sia, despite muted activity in Hong Kong, China and the Republic of Korea, growth forecasts are unchanged at 5.7 percent in 2016 and 5.6 percent in 2017, with the world’s second larges t economy, the PRC, on track to meet projected grow th of 6.5 percent in 2016 and 6.3 percent in 2017. To suppor t its t ar g e t s , t h e P R C g o v e r nm e n t i s expec ted to continue using f iscal and monetary stimulus measures.

South Asia, meanwhile is expected to be the fastest growing sub -re g ion , le d by India , w ho s e economy has shrug ged of f global headwinds and is on track to meet ADB’s March fiscal year 2016 (year to

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

March 2017) projected growth target of 7.4 percent.

Pakistan, further improvements in energy supply, higher infrastructure inves tment s, and an improved security environment will help push up g row t h in 2016 and 2017, t he repor t said, while the Bangladesh economy will remain robust on the strength of its garments sector.

In Southeast A sia, grow th projec tions for the sub-region in 2016 and 2017 remain unchanged a t 4 . 5 p e r ce n t an d 4 . 8 p e r ce n t , with solid per formances by mos t economies in the first half of 2016 driven by private consumption. The exception was Vietnam where the economy came under pressure from a worsening drought that caused a contraction in the agriculture sector.

Asian Development Bank (ADB) Growth Forecasts Asia:

Country/ Region

2015

2016F 2017F

Developing Asia

5.9%

5.6%

5.7%

Central Asia

2.1%

2.8%

2.7%

East Asia

6.0%

5.7%

5.6%

China

6.9%

6.5%

6.3%

Hong Kong

2.4%

1.5%

2.0%

South Korea

2.6%

2.6%

2.8%

South Asia

7.0%

6.9%

7.3%

India

7.6%

7.4%

7.8%

Southeast Asia

4.4%

4.5%

4.8%

Indonesia

4.8%

5.2%

5.5%

Malaysia

5.0%

4.2%

4.4%

Philippines

5.9%

6.0%

6.1%

Singapore

2.0%

2.0%

2.2%

Thailand

2.8%

3.0%

3.5%

Vietnam

6.7%

6.3%

6.5%

Pacific

7.1%

3.9%

3.0%

Kyocera Builds Industrial Cutting Tools Plant In China

Kyoto, Japan: Kyocera Corp has constructed a 23,000-sq m manufacturing plant in Ganzhou City, Jiangxi Province, China for industrial cutting tools.

The plant is the fourth Kyocera manufacturing facility in China, in addition to the facilities in Dongguan, Zhuhai and Shanghai, which enables fully integrated production for industrial cutting tools in the region. The new plant will produce carbide inserts.

The joint venture between Kyocera and a tungsten refining company in China, Ganzhou Grand Sea W&Mo Group Co Ltd was established in January last year in order to meet the growing demand for industrial cutting tools in the automotive industry in China.

South Korea Reports First Auto Trade Deficit With China Seoul, South Korea: South Korea is running a trade deficit of automobiles with China for the first time due to Korean manufacturers’ increased production in China as well as the entry of Chinese low-cost players in South Korea.

As of the end of May, South Korea’s trade def icit with China in the automotive industry stood at US$2 million. This, according to the Korea Institute for Industrial Economics & Trade, is the first auto trade deficit that South Korea has with the neighbouring country.

A surplus was seen last year, although the amount was a decrease from US$1.7 billion in 2014 to US$870 million in 2015.

South Korean automakers including Hyundai Motor, Kia Motors, GM Korea, Ssangyong Motors and Renault Samsung shipped a total of 1,231 units to China for the first five months of this year, a 94.8 percent drop year-on-year.

The countr y ’s automakers’ growing produc tion capacit y in China is the biggest reason behind the deficit. Shipment volume to China rapidly decreased since last year when the nation’s largest automakers Hyundai Motor and Kia Motors secured the production capacity of 2.1 million units in China.

Hyundai and Kia currently produce their key vehicles such as mid-size sedans and sport-utility vehicles in China, exporting only large-size cars and multi-vehicle vehicles from South Korea.

T h e r e a s o n f o r t h e t r a d e d e f i c i t i s a l s o d u e t o t h e in c r e a s in g competitiveness of Chinese automakers, who are expanding facilities and focusing on research and development. The Chinese market share for the automotive industr y rose to 41 percent in 2015, up from 38 percent the previous year.

ENQUIRY NO 088

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

Sandvik Coromant Open House

As part of Sandvik Coromant Singapore focus month on Parting & Grooving, the company held an open house for its customers from August 10 – 12. Around 20 potential cus tomer s at tended the presentation by Andrew Sim, the company’s training manager. This was followed by training and demonstrations by the product specialists.

Orders In German Machine Tool Industry Rose By 16% Berlin, Germany: The German machine tool industry is in good shape, according to the German Machine Tool Builders’ Association (VDW) who reported that order bookings rose by 16 percent in Q2 2016 compared to Q2 2015.

Domes tic machine tool orders were up by 19 percent, while demand from abroad increased by 14 percent, the German association announced.

The Eurozone contributed growth of 37 percent, and non-Eurozone nations provided a 10-percent rise in orders.

Order bookings for the first half of the year increased by a substantial 12 percent compared to the same period last year. While domestic orders rose by 10 percent, orders from abroad were also up 13 percent. The higher level of demand results primarily from good domestic business, and in particular from automotive projects in China and Mexico, commented VDW’s executive director of the sectoral organisation Dr Wilfried Schafer.

With regards to the first half of 2016, one-off effects are primarily responsible for the positive order situation. Abroad, machining centres

Made-in-Italy Machine Tools Sees 5% Growth In Domestic Market

Rome, Italy: Exports of Italian machine tools were down by 4.3 percent for the first three months of 2016 according to data from ISTAT-National Institute for Statistics—processed by UCIMU. Despite sales increases in Germany (+11.9 percent) and in the United States (+13.6 percent), the first two destination countries for the sector “Made in Italy”, deliveries went drastically down in China (-20.1 percent) and in Russia (-78 percent). Conversely, on the domestic front, the Italian manufacturers saw a five-percent growth in the same period.

In the second quarter of 2016, the index of machine tool orders, recorded a 6.9 percent decrease compared with the same period of the previous year.

The index of foreign orders registered a 10.5 percent downturn versus the period April-June 2015, showing the weakness of international demand.

Massimo Carboniero, president of Ucimu-Sistemi Per Produrre said: “First of all, the global outcome is due to the negative performance in the foreign market s, which are having an unstable period. For example, we should consider China who slowed down its growth pace remarkably, but also Russia, where sales of machine tools coming from European markets are strongly penalised by the restrictions imposed by the European Union, to the full advantage of Asian competitors.”

Mr Carboniero added that the survey proves that the Italian market is still alive and lively, contrary to what occurs in some other foreign countries. “Indeed, considering this last result, there have been 12 consecutive quarters of growth with regards to the index of orders which have certainly benefitted from special measures, such as the New Sabatini Law and the Super Depreciation.”

UCIMU asser ted that Super Depreciation should be ex tended to the whole year 2017 (like in France). Mr Carboniero said: “This measure should be applied to all technologically advanced products and/or to those connected with the improvement of one’s own production processes, purchased in Italy with orders received in 2017 and delivered within 30 June 2018; it is not only an instrument useful for stabilising domestic consumption, so that it can come back to pre-crisis levels, but it is also the most appropriate provision to foster the modernisation of industrial plants in our country.”

The average age of machinery installed in the Italian factories is high at almost 13 years, noted a survey by UCIMU at the end of 2014, and the low automation/integration of industrial plants (only 30 percent of the total). Mr Carboniero hoped that Super Depreciation would “encourage the modernisation process of production technologies installed in Italy, so that machines and factories can meet the new requirements of productivity, energ y saving, compliance with the safet y regulations, digitalisation, automation according to the criteria envisaged by the pattern of Industry 4.0 which the market more and more often requires”.

and milling machines are benefiting particularly from large-scale orders.

All other metal-cutting technologies, plus significant areas of forming technology, however, are performing less well in terms of nondomes tic order s from abroad. In Germany, by contrast, the picture is somewhat different. “Metal cutting is two percent up, and the current as-is situation gives reason to hope that a broad spectrum of technologies can benefit from this,” said Mr Schafer.

Turnover in the first half of 2016 ended up slightly better than breakeven. “In view of the encouraging development of orders in the year’s f irst six months, and the range of order backlogs, now recovered to over seven months, we are anticipating a perceptible rise in turnover for the upcoming period,” said Mr Schafer. This, he added, is conditional on demand levels remaining stable in the year’s second half as well, particularly on the domestic market.

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

Trumpf Building Demo Factory For Industry 4.0 In Chicago

D i t z i n g e n , G e r m a n y : Tr u m p f i s building a 5,000-sq m demonstration fac tor y in Chic ago, US , designed around Industry 4.0 solutions. It is slated to open to open in mid-20a17.

The digitally connected production plant will demonstrate the interaction of people, machines, storage equipment, and automation s of t ware, and will showc a s e t he en t ire she e t me t al pro ce s s . T he process will be intelligently linked via Trumpf’s TruConnect modules, its Industry 4.0 units.

CAD Users Expected To Increase Use Of CAM O r p i n g to n , U K : T h e f u t u r e C A M sof tware grow th potential is predicted to be 17 percent this year and 29 percent over the next three to five years, according to results of the Worldwide CAD Trends 2016 Survey by research specialist The Business Advantage Group.

Sur vey result s showed that 56 percent of CAD users are aware of CAM, while 24 percent use it currently.

There is a significantly higher usage of CAM in manufacturing (at 34 percent) compared to AEC or other industries (9 percent). For those that use or plan to use CAM software, 34 percent increased their usage over the past year, and 48 percent used the same amount as the previous year. Four percent saw a decrease in usage.

Six in 10 survey participants want to see “more” software development effort on CAD/CAM integration, while 70 percent think it is “impor tant ” to have machining ins truc tions automatically generated from 3D C AD model s . The mos t used C A M sof tware produc t s are MasterCAM (20 percent), NX CAM (14 percent), InventorCAM (10 percent), SolidCAM (nine percent) and CAM for Fusion 360 (eight percent).

Global Aluminium Market For Auto Industry Set To Grow London, UK: The global aluminium market for the automotive industry is expected to grow at a CAGR of 4.5 percent from 2016 to 2020, according to a market study released by Technavio, mainly due to increasing demand for energy-efficient lightweight vehicles.

“With the developing transpor t and aircr af t s ec tor, aluminium’s presence in the market is increasing due to its efficiency, cost effectiveness, sustainability, safety, durability, and performance. The growing demand for energy-efficient lightweight vehicles will also augment the growth of the global aluminium market for the automotive industry over the next four years,” said Technavio’s analyst for research on metals and minerals Chandrakumar Badala Jaganathan.

In terms of the aluminium casting and forging market for the automotive industr y, manufac turers are using aluminium forged products due to high strength, reliability and economic viability of the parts. Manufacturers are also using aluminium casting products to comply with stringent emission norms implemented by government authorities such as the US Environmental Protection Agency.

The report also noted that the global aluminium extrusion market will grow rapidly. In the past, aluminium extruded products were used only for engine mounts, brake components, radiator frames, seat frames, and other minor applications.

Now, original equipment manufacturers (OEMs) are identifying new applications of aluminium bars and tubes for high-end equipment like safety components, crash management systems, body-in-white structures, cockpit carriers, and elaborate decorative parts.

BUSINESS NEWS • THE AMERICAS Asia Pacific Metalworking Equipment News • September 2016

Pratt & Whitney To Invest US$65 Million In Jet Engine Maintenance Centre

Lantek Software To Power Promotech Pipe Cutting Machines

Connecticut, US: Pratt &Whitney has announced that it is making a US$65-million investment in its engine overhaul facility in Columbus, Georgia for the maintenance of the PurePower Geared Turbofan (GTF) engines.

Currently, the site is the first in the world for maintaining the PW1000G engines.

The jet engine builder plans for the Columbus Engine Centre to maintain PW1100G-JM and PW1500G engines, in addition to V2500, PW2000, F117 and F100 engines.

The GTF engine capabilities will include disassembly, inspection, assembly and test capability. Construction will start this year on a new test facility adjacent to the existing test cell.

The company has been investing in upgrading this facility over the past several years, including adding GTF engine MRO capabilities. “As the GTF engine continues to enter into service, it is critical that we have a strong maintenance, repair and overhaul network in place to support these engines,” said Joe Sylvestro, vice president, aftermarket operations, Pratt & Whitney.

The Pratt & Whitney geared turbofan engine design involves a gear system separating the engine fan from the low-pressure compressor and turbine so that each module operates at optimal speed, reducing fuel consumption, emissions, and engine noise, according to American Machinist.

The PW1000G series engines are used in several new jet models, including the Bombardier CSeries, Mitsubishi Regional Jet (MRJ), and Embraer’s second generation E-Jets. It is also offered as an option on the Irkut MC-21 and Airbus A320neo.

Ohio, US: L antek ha s reached an ag re emen t w i t h Polish comp any Promotech to supply its sheet metal software for the latter’s pipe profile cutting machines, which can cut pipes up to a diameter of 1,500 mm and a length of 12 m with oxy-fuel or plasma.

Promotech manuf ac ture s and supplies welding and cutting machinery.

The collaboration with Lantek will allow Promotech to of fer it s customers a simple way to generate the CNC code necessary to cut complex pipe intersection shapes by using the Lantek Flex3d Tubes software.

This system enables engineers to import CAD geometry, design tubes using a set of standard shapes or construct them from 2D outlines and generate them with any type of contour projected through the tube.

FARO Acquires Canadian BuildIT Software & Solutions Florida, USA: Faro, the 3D measurement and imaging solutions provider, has acquired BuildIT Software & Solutions, a specialist in process-configurable 3D metrology software solutions with hardware agnostic interfaces.

Faro will be introducing BuildIT sof tware in a “Your Produc t, Your

Process, Your Solution” campaign aimed at providing customisable, in-process solutions that integrate metrology devices and sensors from multiple manufacturers.

Located in Canada, BuildIT’s software is used on the production lines of five of the 10 largest aerospace and defence manufacturers. Said Dr Simon Raab,

Faro’s President and CEO. “By adding BuildIT to our metrolog y portfolio, our customers now have even greater software options for use in a variety of 3D metrology manufacturing applications to reduce inspection and assembly times and increase productivity. The BuildIT software suite is hardware agnostic.”

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METAL CUTTING Asia Pacific Metalworking Equipment News • September 2016

COST DOWN, PRODUCTION UP

At the fore, high speed milling of aluminium parts for the aerospace industry.

By Reuven Shapir, Iscar Industry Manager for the Aerospace Marketing Division.

Going Through The Gantry Throughout the world many parts are still produced on gantry machines that feature large horizontal tables and vertical spindles.

However, this machine tool arrangement of ten causes chip evacuation dif f iculties.

Also, as these machines have limited spindle p o w e r an d s p e e d c ap ab il i t i e s , l imi t e d control results in low feeds, which leads to long production times.

The aluminium removal rate ability for the common gantr y machine reaches up to 2,000 cc/min, while semi and f inishing operations is also very time consuming due to control and spindle speeds limits.

In order to reduce Cost Per Unit (CPU), manu f ac t ur er s ne e d t o inc r e a s e Me t al Removal Rates (MRR s) for roughing and to achieve faster table feeds for semi and finishing operations. To help manufacturers realise these aims, Machine Tool Builders (MTB) developed the now common 5-axis machines that have much higher spindle speeds - up to 30,000 / 33,000 rpm, combined with increased power.

T Editorial

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he milling of aluminium parts for the aerospace industry is a machining process that requires the removal of lar ge volume s of material by rough milling. As a result, semi and finishing operations of these parts are characterised by the creation of narrow walls and thin bases that lead to limited workpiece rigidity.

In spite of aluminium being a sof t material with relatively good machinability, due to the large size of many aerospace par t s and their multiple pocket s, milling operations normally involve the removal of over 90 percent of the original workpieces’ ma t er ial , a lon g pr o ce s s t ha t in v o l v e s extended semi and finish milling times.

Metal Removal Rates T he f ir s t gener at ion of t he s e power f ul machines was typically rated at 60 KW, later machine power wa s increa sed to 70K W, now 80 KW - 120 KW figures are common.

Today’s advanced 5-axis machine also often features coolant through spindle capability, resulting in much improved coolant and chip evacuation, a vitally impor tant at tribute when milling deep pockets.

When roug hing w i t h spindle sp e e ds of 30,000 rpm at 60 KW power in reliable produc tion conditions, an MRR of 4,000 cc/min aluminium is achieved, similarly an MMR of 5,000 cc/min is achieved with 80 KW of power. Machines featuring an updated reinforced spindle with 120 KW are able to remove 8,000 cc/min aluminum.

The emergence and continuing development of modern 5-axis machines with

METAL CUTTING Asia Pacific Metalworking Equipment News • September 2016

Due to the large size of many aerospace parts and their multiple pockets, milling operations normally involve the removal of over 90 percent of the original workpieces’ material. enhanced capabilities have challenged tool manufacturers to develop a range of advanced tools with the ability to function effectively in much higher, extreme cutting conditions.

Rough milling tools have an indexable inser t diameter of 50 mm (2.0”), whereby the number of inserts is dictated according to the machine’s spindle power; Z=2 for 60 KW, Z=3 for 80 KW and Z=4 for the reinforced spindle 120 KW. High-Spindle Speed & Fast Controls After rough milling operations are complete, the use of a machine capable of 30,000 rpm with fast CNC axis controls of up to 60,000 mm/min enables solid carbide endmills to be employed to significantly reduce milling times for both semi and finishing operations.

Solid carbide endmills with a 25 mm (1.0”)

diameter are commonly used to complete roughing operations within contours where a tool diameter of 50 mm (2.0”) is too large.

The result of the above milling figures under ex t reme condit ions consider ably increases the productivity and performance of high-speed, modern machines when compared

Iscar Face Mill HSM90S Mono Block

The Perfect Thread Product of the company’s R&D Depar tment, ISCAR’s new

most economical price per threading corner when compared

threading tools provide users with solutions that boost

to the popular 3 cornered threading laydown insert.

produc tion, raise qualit y and provide subs tantial cos t reduction benefits.

The following thread profile sizes are available: TTG-16E-ISO - ISO – Metric TTG-16E-UN - UN – Unified thread TTG-16E-A55 - Partial 55° profile TTG-16E-A60 - 60° profile The DECA-IQ-THREAD line provides a very precise geome t r y and accur ate edge location repeatability when corner indexing.

The inserts are made

The DEC A IQ THREAD delivers the most economical,

from the grade IC908. Field

currently available, price per threading corner. As the new

t r ial s and te s t rep or t s

product’s name implies, the tangentially clamped threading

indicate that the inser ts

inserts feature 10 cutting edges – ie: a 16 mm round insert

also provide much extended

with 5 double-sided corners, providing a total of 10 cutting

tool life when compared to

edges. This newly developed geometry delivers by far the

similar products.

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METAL CUTTING Asia Pacific Metalworking Equipment News • September 2016

The tools that carr y the new inser ts feature coolant channels that are designed to deliver standard and highpressure coolant. Four-corner indexing can be performed by only a partial opening of the lamping screw, resulting in a short and easy indexing action and efficient, time saving operation.

When the requirement is for threading operations at very high parameters, the PENTA IQ Threading line combines the benefits of a very rigid clamping system and a strong, five edged insert design. The full profile inserts are available in the following thread standards: ISO, UN, Whitworth and BSPT. Partial profile inserts are available in 60º (MT) and 55º (WT) profiles.

T he mult i- cor ner,

chipbreaker) are precision ground for a 60° (MT) thread profile.

f ive cut ting edged

The TIP inserts were designed for machining threads on

inser t provides an

short chipping materials, such as brass and cast iron. The use

advantageous price per

of flat top rake inserts on these materials result in improved

cutting edge. PENTACUT

surface quality and less chatter, when compared to the use of

threading inser ts

inserts with chipbreakers. As a result, cutting speeds can be

offer a combination of

increased and further efficiencies gained.

a ver y rigid clamping s y s t em and a s t r ong

The TIP inser t s

in s e r t d e s i g n . T h e s e

are available in

inserts can be used for

par tial prof iles

threading between walls

such as:

and close to the tail stock of the machining center, enabling a complete part production in bar feeder machines.

PENTACUT’s chipformers produce short and easily exposed

MT - Metric

threads 60°

chips and result in accuracy and surface quality of the part.

In addition, the ability to perform easy and fast indexing

WT - Whitworth

from either side of the holder enables inserts to be changed

threads 55°.

quickly in case of breakage. Also, the inserts can be rotated on their axis to enable operation to be continued with another cutting corner.

The inserts are produced from the PVD coated grade IC908 and can be mounted on standard PENTA 24 tools.

CUT-GRIP TIP inser t s with a f lat top rake (without a

Iscar Face Mill HSM90S 50mm

The TIP full profile inserts include: ISO, UN, BSW, NPT and BSPT standards.

The TIP inserts can be clamped in ISCAR’s existing standard toolholders. The tolerance range and repeatability of the cutting edge is ±0.025mm.

to the previously used machines. Today, a standard, modern machine with a powerful high-spindle speed and fast controls is much more productive than any top of the range, previous generation machine.

For ex t reme condit ions , t he modern 5-axis machine operates and contributes to higher MRR results. Although, to realize the full productive potential of these machines, suitable advanced cutting tools need to be used. To ensure the development and launch of a range of highly efficient cutting tools that are ideally suited to use on modern 5-a xis machines, ISC AR has taken a t wo pronged approach.

The company ’s R&D depar t ment ha s undertaken in-depth laboratory work and inhouse machining trials to help further refine a series of advanced cutting tool prototypes.

They have worked in close cooperation with

METAL CUTTING Asia Pacific Metalworking Equipment News • September 2016

several multi-national aerospace companies to test its products in the harshest of ‘realworld’ aluminium milling situations.

Increased Productivity & Reduced Production Costs ISC AR ’s R&D depar t ment ’s brief wa s to design a range of cutting tools that were able to resist intense cutting and centrifugal forces, to guarantee the delivery of an ultrareliable process and to ensure perfect chip evacuation while moving large volumes of chips when milling deep pockets.

Also, in order to prevent Build-Up Edge (BUE) and to enable milling in these extreme conditions, inserts with ground sharp super positive edge geometr y, combined with polished rake, must be included.

As the f irst cutting tool manufacturer to develop carbide inserts with helical and super positive polished cutting edges for milling aluminium, ISC AR developed the HSM90S style tools with indexable inserts, specifically for the efficient rough milling of aluminium, at for instance 33,000 rpm’s and 120 KW.

O f f e r in g p e r f o r m an ce , p e r f e c t c hip evacuation, lower cutting forces and the generation of less vibration, these cutting tools provide huge time savings when used on modern, power ful machines with high spindle speeds and fast feeds.

Reduced Machining Times & Lower Costs For semi and finishing milling, the company ha s developed high-per formance solidc ar bid e e n dmil l s t ha t ar e s ui t ab le f o r ex treme speed and fast feed conditions.

These tools deliver the required levels of accuracy and surface finish characteristics, and result in the highly-ef f icient milling of aerospace indus tr y aluminium par t s .

Reduced machining times and lower costs are made possible with its high-performance, solid-carbide endmills.

Having launched several advanced produc t s related to ef f icient aluminium milling, aerospace manufac turers throughout the world are now reaping the multiple benef its of ISCAR’s research and the company ’s cooperation with leading aerospace manufacturers.

Reduced machining times and lower costs are made possible with its highperformance, solid-carbide endmills.

ENQUIRY NO 050

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METAL CUTTING Asia Pacific Metalworking Equipment News • September 2016

Elements For

SUCCESSFUL

FACE MILLING

Boost productivity in face milling operations with pivotal technologies.

By Sandvik Coromant

Editorial

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6002 Turn to page 80a to enquire or log on to: www.equipment-news.com

M

ore manufacturers are faced with trying to boost the productivity of face milling operations and reduce component costs in a bid to achieve competitive gain and grow market share.

There are many notable trends in the component milling arena, particularly where batch sizes are above average and where there is a degree of component complexity that makes parts challenging to clamp. When clamping is more unstable, the application becomes prone to vibration.

Here, the typical tools used in larger volume production are double-sided inserts with many cutting edges that are able to positively impact overall productivity and cost per component. Such tools, however, are based on negative concepts that often produce a heavy cutting action, elevated cutting forces and higher energy consumption, along with greater tool wear and burr formation.

As a result, in vibration-prone applications, these cutters struggle to meet the high performance levels demanded.

Single-sided insert concepts, although positive, are generally dismissed in higher batch applications due to their limited number of edges.

Positive Effect It seems clear that a face mill with double-sided, multi-edge inserts that is capable of positiveeffect cutting would prove ideal. This demand is

highlighted further as a result of another marked trend in milling strategies that is found particularly in sectors such as automotive – the shift away from fixed transfer lines towards universal, smaller machining centres that can better accommodate mixed production requirements.

While smaller, less powerful machines are a good choice from a production strategy perspective, they are not always suitable for the negative, heavy cutting concepts that these manufacturers traditionally deploy.

As a result of fierce global competition, seemingly eternal cost pressure is another factor that cannot be ignored at modern component machining facilities. However, in higher volume machining, even a small saving per component can equate to large cost reductions in term of overall production. As a result, manufacturing engineers look to optimise their processes on a constant basis, a strategy which includes close scrutiny of cutting tool selection.

Favourably Tilted To help maximise yield as well as well as to satisfy the need to reduce component costs, new milling cutter innovations are pivotal. With this in mind, Sandvik Coromant has come up with a multiedge cutter that can produce a positive, light cutting action in a host of different roughing to semi-finishing operations on steel and cast iron workpieces (ISO P and ISO K materials).

METAL CUTTING Asia Pacific Metalworking Equipment News • September 2016

Single-sided milling concept

The inserts are positively tilted in the tip seat to create a lightcutting action

The CoroMill 745 offers a total of 14 true cutting edges offering higher depths of cut than comparable existing cutters. It has an unconventional insert inclination angle, which is designed to offer a large, positive angle on the main cutting edge, which in turn enhances chip formation and delivers smooth, soft sound and low cutting forces.

Although a visual inspection of the tool will reveal that the inserts are configured negatively, their combined effect is positive. This helps

With CoroVill 745, the positive single-sided cutting edge position is transformed into a double-sided concept by modifying the insert inclination.

The result: the first face milling cutter with 14 cutting edges and a positive cutting action.

manufacturers take advantage of situations where productive yet light cutting is required, including where unstable set-ups or lower powered machines are deployed.

In essence, the tool’s positive cutting action mirrors that of a single-sided concept face mill, but instead features cutting edges on both sides of the insert to help lower piecepart costs. All face milling operations up to 5.2 mm (0.205”) depth of cut are expected to benefit.

To help maximise yield as well as well as to satisfy the need to reduce component costs, new milling cutter innovations are pivotal.

Sandvik CoroMill 745: 14-Edge Face Mill With a total of 14 true cutting edges, CoroMill 745 is of fers a solution in applications where productive face milling, low cutting forces and low cost per

Suited for applications where productive face milling, low cutting forces and low cost per component are prerequisites.

component are prerequisites. It features an unconventional insert inclination angle, which is designed to provide a large positive angle on the main cutting edge, leading to excellent chip formation, a smooth, soft sound and low cutting forces.

The insert position and heptagonal

Coromant is initially introducing the E-M30

CoroMill 745 has been developed for

(seven-cornered) insert shape make for

and E-M50 types for CoroMill 745, where

roughing to semi-finishing operations

easy replacement and indexing in line

E-M30 is the choice for steel and cast

on steel and cast iron workpieces (ISO

with modern timesaving and ‘green light’

iron workpieces, as well as in vibration-

P and ISO K materials). The upshot of

machining demands. Indexing, in fact, can

sensitive operations and when less power

deploying this double-sided, multi-edge

be performed without operators having to

consumption is required.

cutter is that production economy and

remove their gloves. In effect, the insert

Conversely, E-M50 is a tougher

cost-per-component can be improved

position can be secured before tightening

geometry for more demanding operations

considerably. In essence, the positive

the large M7 screw (deployed for extra

or when higher productivity is needed.

cutting action mirrors that of a single-

process reliability). As a further benefit, due

E-M50 should also be selec ted for

sided concept face mill, but with the

to the large screw hole, less powder is used

grey cast iron (GCI) workpieces found

new cutter there are cutting edges on

in the insert manufacturing process, thus

commonly in numerous automotive

both sides of the insert. With 14 cutting

benefiting the environment.

applications, as well as in nodular cast

edges available, face milling operations

Another useful feature for production

up to 5.2 mm (0.205”) maximum depth of

engineers is the availability of a differential

Arbor, Coromant Capto and CIS arbor

cut are expected to benefit.

pitch (MD pitch) up to 160 mm (6”) diameter for

coupling variants can be used, with

iron (NCI) machining.

CoroMill 745 inserts are purposely

roughing operations where reduced vibration

through-coolant in cutters up to 160

thick and secure with strong, sharp

is essential. This medium pitch MD design was

mm (6”) diameter. All CoroMill 745 milling

edges for high precision and a robust

developed using genetic algorithms to reduce

cutter bodies offer an entering angle

cutting process, while the precision-

vibration when machining components that are

of 42°, although among future planned

ground geometries are designed to avoid

sensitive to resonance or reverberation. Here,

additions to the range is a high-feed

workpiece frittering in cast iron, which

the insert position is compensated radially for

variant featuring a 25° lead angle, which

can often occur at the cutter exit side

an even chip load.

will offer feed rates of up to 0.7 mm/tooth

of the component.

In terms of insert geometries, Sandvik

(0.028”/tooth).

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

Case Study:

SMART FACTORY

AT YOUR

FINGERTIPS Smart factories are an important spoke in a future decentralised society. Tools are being developed to help accelerate productivity and lower costs.

Contributed by Cecilia Tan, marketing and communications manager, Schaeffler (Singapore)

Editorial

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M

achine Tools 4.0, which is part of Schaeffler’s efforts to digitise the production process, connecting existing technology, from sensors to the cloud, to new digitised components, has been deployed within it s own volume production.

The turning and milling centre, developed jointly with DMG MORI, has been in use for six months at the Höchs tadt a. d. Aisch production location in precision soft steel machining of large, customer-specific rolling

bearing rings with threads, milling, fits and so on. Just two years ago a project team started formulating the requirements for the future ‘Industrie 4.0 Production System’ in Höchstadt, Germany, which is representative of many other production processes: •

Produce small lot sizes cost efficiently

•

Have short set-up times

•

Rapid and lean engineering processes

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

By connecting machines, work pieces and systems, a network is created in which specialists will be able to collate big data to make decisions.

•

High process stability, despite very small lot sizes

•

Flexible production units,

•

Maximum delivery reliability and shortest throughput times

•

Lowest possible defect costs even with the smallest lot sizes.

These requirements not only went into the design of the Machine Tool 4.0 itself, bu t al s o de ter mined t he s elec t ion and modification of the direct environment of the machine tool. So we are talking about a 4.0-compatible production cell, which also includes a 3-D measuring machine, a tool preset device, a new kind of clamping system and a laser marking system integrated into the machine tool. With the latter, each part is clearly labeled per data matrix code. With the individual identity of each workpiece thus determined, all drawings, process data and quality data from the machine and the peripheral devices are stored in the cloud specifically created for this purpose.

forces during rough machining permit greater rates of feed and lower clamping forces during smoothing lead to smaller form tolerances more productivity with more precision at the same time truly adds value.

The specialists accomplished a similar scenario with the tool preset system: The tools are measured optically, the geometric data are digitalised and made available to the machine and/or NC program online. The NC programs are as such no longer compiled on the basis of ideal tool data but with real tool data that also includes tool wear. This result s in less adjusting and retrof itting work on the machine.

The networking of the machine with the peripheral devices and intelligent processing of the data made it possible to implement selfoptimising processes.

Predictive Maintenance 4.0 Solutions Schaeffler presented solutions for digitalised production and machine monitoring with its ‘Drive Train 4.0 technology exhibition’ at Hannover Messe 2016. These solutions are part of the company’s drive towards predictive maintenance 4.0.

Its focus on two new digital services for drive train types included an automated rolling bearing diagnostics and the calculation of rolling bearings based on real load spectra.

FAG Smar t C he ck , a ‘condi t ion moni tor ing ’ s y s t em allo w s t he condition of rolling bearings and machine components to be diagnosed

Self-Optimising Production Cell The net working of the machine with the peripheral devices and intelligent processing of the data made it possible to implement self-optimising processes. For example, the basis was established for an adjustment of the clamping forces during operation. The NC program, measuring machine and clamping system form a control loop. Higher clamping

automatically. In addition, storing the data in a cloud also permits them to be used for other calculations, such as drive train and rolling bearing simulations relating to their static and dynamic streng th.

A calculation tool retrieves data from the cloud and calculates the remaining useful life based on the dimensions of the machine and actual loads. These calculations are carried out cyclically and automatically during operation, allowing the operator to view the remaining useful life of every bearing in the machine using an internet-capable end device.

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

Automatic Lubrication Of The Linear Recirculating Guidance Systems A fur ther control loop of the produc tion cell consist s of a standard linear recirculating roller guidance s ys tem w i t h a c c e l e r a t i o n s e n s o r, e v a l u a t i o n elec tronics and the automatic lubricator FAG Concep t 8 . T he acceler at ion s ens or records minor deteriorations in the lubricant condi t ion in t he c ar r iag e s v ia minimal change s in t he os cill at ion p at ter n and

initiates relubrication with the lubricator.

The objective of this system is to lubricate as needed and no longer based on time or stroke-controlled.

Two ef fec t s are impor t ant here: The lubricant requirement is reduced by up to 30 percent and at the same time the smoothness and the oscillation behaviour of the recirculating system are constantly monitored and thereby the quality of the manufactured work pieces is guaranteed.

Smart Service Factory Setting The Standards & Methods Companies produce large volumes of data every day and this volume continues to increase. By Bert Rosenheinrich, director, engineering, SEA, Schaeffler Industrial tools, machine tools, and manufacturing machinery, as well as numerous workpieces generated in the production process, and production and service processes with a connection to relevant information systems are already continuously generating large volumes of data.

These data are collected and bundled in so-called ‘data clouds’ at the company. The problem is ensuring that an exchange of data between manufacturing companies, machine manufacturers, or logisticians for service development is carried out using a simple and secure procedure.

The aim of the project is to generate new innovations, product ideas, and in particular services that are closely related to production and to organise these together in a productive and professional manner.

Project Basis This is where the smart service factory joint project will provide assistance and ensure that all the gathered knowledge is made available in the cloud in a secure manner and according to customer requirements.

The aim of the project is to generate new innovations, product ideas, and in particular services that are closely related to production and to organise these together in a productive and professional manner.

This means, for example, that a maintenance company could acquire the product knowledge about machine components in an encrypted form, and pay for this knowledge upon each use.

This knowledge will then be offered in addition to further knowledge from other component manufactures for the preventive maintenance for an entire machine.

Generating Values The company is a project partner alongside Friedrich-Alexander University Erlangen-Nürnberg (FAU), the Fraunhofer Institute for Integrated Circuits (IIS), with its Nuremberg-based Fraunhofer working group for Supply Chain Services SCS as partner, and Siemens.

The project is part of the research programme ‘Innovations for the production, service, and work of tomorrow’ that the German Federal Ministry for Education and Research (BMBF) is promoting the development of digital services and business models from data from industrial production.

According to Dr Dennis Arnhold from Digital Factory production processes: “Data have become ‘the new gold’. How we dig it up and use it in a sustainable manner remains unclear, in particular when the data are to be used across the company. With the new project we also want to develop standards and methods for this purpose. Furthermore, the value that can be generated from the obtained data must also to be determined. It must always be ensured that the valuable data are used in a safe and transparent manner.”

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

A 4.0-compatible cell will have all drawings, process data and quality data from the machine and peripheral devices stored in the cloud for retrieval, either on the machine or online.

Real Load Data How much are machines and their components actually utilised and how long will they hold up? With the measured load data and the actual load spectra determined from it, these questions can be determined for the first time with a machine tool in volume production. The studies led to two new data-based services: The calculation of the remaining useful life of rolling bearings on the basis of real load spectra and automated rolling bearing diagnosis, which was realised with intelligent processing of oscillation data. The continuous calculation of the remaining useful life of rolling bearings opens up the following possibilities: •

Active control of machine utilisation with respect to predictive maintenance and repair

•

Greater utilisation of individual axes and whole machines

•

Needs-based maintenance intervals on the basis of real loads and

•

The use of real field data and load spectra for design optimisation and re-engineering of machines by the manufacturer

The engineers are al so implementing the FAG ProCheck, a conventional condition monitoring system that also offers optional collision detection. This is about being able to evaluate the severity of a collision in the future and creating a connection between the collision and possible initial bearing damage.

The plan: This system is intended to make recommendations available to the operator in

the future as to whether to continue operating the machine af ter a collision, whether to reduce the performance or even whether a maintenance team must be requested.

Additional Research Projects These installed and integrated technologies and concepts have created a nucleus from which further developments can grow. Most important here are the unused potentials that result from the standardised access possibilities, transparency and the processing algorithms of the data. The possibilities of generating added value from the ‘field data’ for various interest groups have as such not been exhausted by any means. In the coming months and years the company will push additional research projects, including: • T he cor rel a t ion o f op er a t ing force s with quality characteristics and process parameters, • A par t s-related and machine-related energy performance certificate and • Pro ce s s simul at ion in ad v ance a s a supplement to process monitoring, key word: digital twin.

Dipl.-Ing. (DH) Roberto Henkel, director of high-precision bearings lead segment in Höchstadt, remarked: “Our overall goal is to digitalise the value flow of the machine from the horizontal, i.e. accelerate the upstream engineering process and reduce the time to the first cut, as well as include additional machines, systems and production cells in the digital cycles.”

The possibilities of generating added value from the ‘field data’ for various interest groups have as such not been exhausted by any means.

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MAINTAINING A PROPER

PLASMA SYSTEM

Proper plasma system maintenance can help prolong life and performance of system, and it requires just a little time investment. By Clayton Gould, marketing manager, aftersales, Hypertherm Inc.

T

he lis t of items needing regular maintenance in your shop is likely long. It probably seems there is always something to be done.

Unfortunately, while most shops are great at inspec ting items like cranes, forklif t s, and air compressors, an item that tends to slip through the cracks is the plasma cutting system. It might be the old adage “the squeaky wheel gets the grease” proves true here.

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Inspect the air filter daily, and do a replacement every six months.

System Maintenance Pl a s ma s y s t em s , a t le a s t g o o d qual i t y s ys tems, don’t tend to be troublesome.

The s ys tems go about the job day in and day o u t , s l ic in g t hr o u g h w ha t e v er met al is thrown at it , but while your plasma system may appear to work ju s t f in e , f ailur e t o p r o p e r l y m ain t ain it is quiet ly impac t ing it s per formance and life.

Me chanic al p ar t s w ill s t ar t t o w e ar out , causing rough machine motion.

Par t tolerances will deviate. Cut qualit y, particularly at higher speeds, will suffer.

It is kind of like the tires on your car.

To get the best life and performance, you need to make sure your tires have the right amount of air and are rotated regularly. If you don’t do those two things, will your car still roll? Sure. Will the ride and gas mileage suffer? Will your tires last as long? No. Are you more apt to get a flat tire at the worst possible time? Yes. It ’s the same thing with your plasma system. If you don’t take good care of it, it’s going to break down when you need it most.

Like when you’re in the middle of the largest plate-cutting job you’ve ever had for your most lucrative customer. Not only have you just let down an important customer, at up to USD$200 per hour fully burdened, you’ve just cost your shop a lot of money.

The other problem is when components in the machine fail, as troubleshooting and

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

Apply a small amount of lubricant to lubricate the o-ring.

servicing can take days. This brings us to another old adage, “an ounce of prevention is wor th a pound of cure.” For tunately, it doesn’t take much to keep a plasma system up and running. A small investment of your time is often all it takes to keep your system in good shape. The key though is to establish a regular preventive maintenance routine.

Cleaning And Inspection Your routine should contain two components: routine cleaning and inspec tion, and replacement of common wear items.

Par t one of your prog r amme c an be divided into daily, weekly, and monthly tasks.

Daily Let’s start with the daily tasks. There are four things you’ll want to do for every single day your system is turned on.

1. First verif y inlet pressure of gases in both the “test pre-flow” and “cutflow” modes by making sure your regulator dial reaches the recommended PSI. 2. Secondly, inspect the air filters. You’re checking for moisture, oil, and particulates.

If you see moisture, oil, or a lot of metal dust for example, you’ll need a new filter.

If you only see a little dust or dirt, try to lightly vacuum it off. All air filters need eventual replacement, but if you’re going through more than your fair share, then you likely have an issue with the quality of your air and should check its purity.

3. The third step is to check your coolant level and condition. If the level is below the neck of the tank, add more. If the coolant looks dirty, flush out your tank and refill it with fresh coolant.

4. Finally, inspect your torch. Hypertherm recommends taking your torch into an of f ice or other clean place to do this.

Also, wash your hands. Typically, the two items requiring careful inspection are the o-ring and coolant tube.

Remove the o-rings from the torch and check for damage. If all looks good, apply a very small amount of lubricant to your f inger tips and lightly rub this lubricant onto the o-ring. The o-ring should look shiny but you should not see any lubricant. If you do, you’ve applied too much and should wipe some off.

Replace all o-rings so they fit snugly, then inspect all threaded consumables and remove any dirt that you see. You’ll

The key though is to establish a regular preventive maintenance routine

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Because plasma systems are precision machines with moving parts like torches, main contactors, relays, and such, these parts are going to wear out.

also want to inspect the water tube to make sure it isn’t out of round, bent, or pitted. Inspect the nozzle and electrode mating surface for damage, then take a clean cloth and wipe off the torch, both inside and outside. Use a cotton swab if needed to clean hard to reach areas.

Weekly Next up are the weekly tasks.

1. In the first step, inspect all air hoses, coolant hoses, and torch leads. Look out for scrapes and cuts, punctures, chemical spills and burns, or any kinks or bends that would restrict flow.

2. S e c o n d l y , c h e c k f o r g a s l e a k s b y conduc ting the built-in leak and f low tests. Before doing this last test, make sure you are using the right consumables and have selected the correct plasma process for the test.

3. Finally, check your coolant flow. If you have an auto-gas console, this can be done right from your CNC. If you have a manual gas console, go to your console to read the flow rate. If the CNC detects a problem, you’ll need to per form the specific Coolant Flow tests found in your owner’s manual.

Monthly Monthly tasks include cleaning the inside of your power supply, inspecting electrical

A cotton swab can be used to clean hard to reach areas.

components, and checking your ground and table-to-work piece connections.

1. Firstly, turn off the power to your power supply, then remove the top and side panels. You’ll likely see a lot of metal dust and other particulates that you’ll want to either blow out or vacuum. Don’t forget to vacuum build-up on the fan and fins. Next, gently remove dust and par ticulates from your circuit boards, taking extra care not to damage them.

2. Secondly, with your power still off, check the main contactor for excessive pitting, or a blackened or rough surface. If you see any of these things, replace your contactor.

3. Though you should check your coolant flow once a week, you’ll want to conduct a more thorough tes t each month.

Typically, this test is more comprehensive and should be conducted by a trained ser vice technician or other specially trained resource. At the same time, you’ll want to inspect all connection points—for example where the hose connects to the ignition console, the torch body, and the power supply.

4. The four th task is to inspect the pilot arc relay. Remove the cover, and inspect the contacts for excessive pitting. Again, if you see a lot of pitting, you’ll want to replace the relay.

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

5. Next, inspect your gas line connections by spraying them with soapy water. If bubbles appear on a gas line, tighten or replace it as necessary.

6. Lastly, inspec t your ground and work lead connections. Verify that all system components are individually grounded to a driven earth ground and that your work lead connection—particularly the connection at your cutting table—is clean and tight. There should be no paint or oil directly on the connection, as you need a clean metal-to-metal contact.

Replacement Of Common Wear Items With your routine maintenance out of the way, you’ll now want to focus on common wear items. Because plasma systems are precision machines with moving parts like torches, main contactors, relays, and such, these parts are going to wear out.

T h e f r e qu e n c y o f p ar t r e p l a ce m e n t w il l v a r y d e p e n din g o n s y s t e m u s a g e , but typically you’ll want to replace items after a set number of months or arc hours.

Recommendations are as follows: Every 6 months (or 500 arc hours) • Torch o-rings and bullet plugs • Air filter • Coolant filter Every 12 months (or 1,000 arc hours) • Torch main body • Pilot arc relay • Main contactor Every 2 years (or 2,000 arc hours) • Torch receptacle • Coolant pump • Torch leads Every 3 years (or 3,000 arc hours) • Check valves • Cooling fans • Coolant pump motor • Gas and pilot arc leads In order to make part replacement easy, s ome manuf ac turer s have put toget her comprehensive preventive maintenance programs, along with annual replacement kit s . Hyper therm ha s al so provided the information with every system sold. There is a dedicated landing page (www.hypertherm. com/preventivemaintenance) that of fers customers the ability to download a complete maintenance programme from their system.

Take An Active Approach Like your forklift, crane and air compressor, your cut ting s ys tem requires care to operate at peak efficiency. Regular, ongoing main tenance is t he smar te s t and mos t ef f icient way to optimise output, reduce unpl anned downt ime and minimize t he operating costs of your cutting system. It’s an active approach as opposed to a costly reactive approach. This way, you’ll not only extend the life of consumables, but also, the life of your entire cutting machine.

Clean the inside of your power supply by blowing out contaminants.

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

SUPPORTING

LOCAL CUSTOMERS

With Schunk’s Technology Centres

(L-R) Harald Dickertmann and Alexander Tjioe

Mark Johnston speaks to Alexander Tjioe and Harald Dickertmann on the opening of their new technology centre in Jarkata, Indonesia. Mr Tjioe is the president (automation), Schunk (Indonesia) while Mr Dickertmann is the head of sales and business development Asia, based out of Germany.

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Firstly, could you tell me more about yourself and this facility you are opening today?

Alexander Tjioe (AT): I joined Schunk in April 2015, and I have been in the metal fabrication industry for over 20 years. We are very interested in expanding our presence in this region.

This facility we are opening today is the first technology centre in Southeast Asia for us. We also plan on opening a technology centre in Ho Chi Minh City, Vietnam in Q4 of 2016. In addition to this, a third technology centre is being planned for Thailand. This Thai office should be open in the middle of 2017. With these three technology centres, we can support the whole of ASEAN, which consists of 10 countries , plus the Pacific region, which consists of Australia and New Zealand.

Why did you pick these three countries for your technology centres?

AT: It is our plan to be close to our customers. What

this will mean is quick after-sales support and technology transfer. The Indonesian technology centre will be serving Australia, Singapore, and Malaysia. Vietnam would be serving the Philippines, and the Thailand technology centre will serve Laos, and Cambodia. Thailand itself is a huge market for us, just like Indonesia.

These three major countries will support the whole region.

What type of functions will these technology centres have?

AT: Each one of these technology centres will have an engineer placed locally. They will each have a dedicated seminar room, with dedicated machines and all our automation components. In this way, we can serve our customers locally and send users for training seminars, and serve them better in after-sales support.

We do not do any research here. All our research and development efforts take place back in Germany. This is primarily a sales and engineering office. We have local engineers who all speak English. As such, they can solve and discuss with the customers the issues they are facing. With these facilities, we can send our engineer from Vietnam to Indonesia, and Thailand, and vice versa. We support each other in that regard.

How do you rate the success of these technology centres?

AT: The most important thing is that we are there for the customer. If we are not locally placed it is not good for our customers. We must work well with our partners, such as our automation partners, our system integrators, and so on. That is our strategy for the region.

What is the awareness like for Schunk in Indonesia?

AT: Brand recognition is an issue. When we talk about Schunk they usually only know one product, which is our tool holders. As such, branding efforts in this region is very important to get our message across and make the local populace more aware on our offerings. It is very important to put our brand out there so people are aware. My job is to educate the market that Schunk has a huge variety of products, and not only tool holders.

What are some of the other challenges in doing business in Indonesia?

AT: As I said, branding is an issue, however German products have a good reputation locally in Indonesia and this region. It should be mentioned however, that this is a very price sensitive market and it is the perception that German products

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

One for the photo album: At the opening of the technology centre in Jakarta, Indonesia on July 28, 2016

are on the higher side in regards to price. It is our job to educate them on this, as our products are competitively priced.

How do you envision Industry 4.0 impacting your business?

Harald Dickertmann (HD): This is a big topic right now. I would say for Southeast Asia it is differentiated in regards to the level of understanding regarding this. Singapore, for instance, is very close to it and is discussing it on a high level. On the other hand we have other countries where this is not a big topic yet.

Eventually it will become a big topic for all the world’s manufacturing sites.

We are working with a lot of associations and working groups for Industry 4.0. In the past, we had hydraulic grippers, which can do basic open and close operations. Today and tomorrow we are talking about intelligent grippers, which consist of sensors for measuring temperature, weight, pressure, proximity and so on. These grippers improve not just productivity, but safety as well, which is particularly important in a collaborative robotics environment that is an industry trend right now.

What are the priorities for the metalworking sector within Indonesia?

AT: Automotive is a big sector for us, not just in Indonesia but in Thailand as well. In ASEAN countries we have aerospace, automotive, pharmaceutical, medical, electronics, and on on.

With the products that we offer, we can serve these industries.

HD: I noticed a trend when I was in Singapore talking to a cus tomer of ours that local

subsidiaries of multinational companies are becoming more independent. They develop their own technology and solutions that fit to the sometimes unique requirements on their country/region.

Our industry is evolving from a copy and paste approach in which companies would transplant their offices that operated well in say, Germany, to another country with a different set of requirements, to an approach that would allow locally placed offices of multinationals to evolve organically with that environment.

This would involve training and raising up the local engineering capability within these countries so they have the capability to solve real-world problems that may be unique to their environment.

We see this on a bigger scale in China, and I also see this in Southeast Asia. At Schunk, we believe we have to be here with our technology and our knowledge to support engineering teams locally to advance and reach a higher level.

How many people do you have working here in this office?

HD: We have one engineer, one administrative staff, and we have Mr Tjioe here. There is one technical expert stationed in Singapore. He travels frequently. There will be more engineers added depending on the development of the business.

Is one engineer enough for Indonesia?

HD: I would say for a greenfield project, one engineer is good to suppor t the day-today business here. In the long run, I think the market ha s more potential for jus t one engineer.

Our industry is evolving from a copy and paste approach in which companies would transplant their offices that operated well in say, Germany, to another country with a different set of requirements.

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A BETTER WAY:

FINDING

EFFICIENCIES

Inefficiencies need to be ironed out before introducing the concept of the Digital Twin and what this means for the way goods are created and produced. By Siemens PLM Software, Aaron Frankel, senior marketing director manufacturing engineering software and Jan Larsson, senior marketing director EMEA

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roduc t realis at ion: ar g uably t he mos t vital par t of the design and manu f ac tur ing pro ce s s . I t ’s when a real product, the physical embodiment of your IP is turned from an idea into reality.

What ’s more, wit hout a well-cr af ted product design and production process – all coordinated to work together to ensure that the assembly flows seamlessly across the manufacturing floor – your idea will remain nothing more than a beautiful drawing or something les s yles s than your original vision.

For years, the way products are designed and their manufacture planned has remained more or less similar – complete with some inherent fault lines that can increase costs and delay development. Siemens has looked at the process to see if it can be streamlined.

A Remarkable Symphony To visit a modern manufacturing plant is to witness a jaw-dropping symphony of people, parts, materials, robots and machines – all working down to the minute or second to hit schedules. It looks incredible.

But behind the scenes, the way goods are designed and planned for production remains based on aged processes. This is not to criticise anyone. A great piece of design is a major accomplishment. And it can be a hugely complex task that, in some instances, can involve millions of parts and thousands of people and partners – often coordinated across countries.

Fur thermore, in key market s such as electronics (faster processors, miniaturisation), automotive (the green agenda and emissions) and aviation (the green agenda and the drive for composite-based aircraft), there’s a relentless drive for improvement that means new designs must be achieved more quickly.

Gi ven t he comple x i t y, t here’s an understandable reluctance to move beyond tried and tested development processes. This said, our customers report common problems across the development and produc tion chain with some areas susceptible to causing costly delays.

Common Challenges One of the most important issues we see is that the design team uses separate systems to their manufacturing colleagues. In practice this can mean that designers pass over their creations to the manufacturing guys who have to try to create the subsequent process plan using the sof tware they ’re used to.

In this scenario – which is quite common – information can get out of sync so it’s hard for everyone to see what’s happening. This increases the scope for failure.

IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Design: A digital twin of the Nanobox industrial PC is analysed for manufacturability by using Variation Analysis in Teamcenter to virtually build thousands of digital Nanoboxes.

During the analysis, it was discovered that 9% of the builds are out of spec due to an insufficient tolerance specification. The issue was corrected in the digital design model and warranty claims avoided.

Moving through into the creation of the manufacturing floor layout, we regularly encounter problems here too. These tend to be based around the fact that layouts are created using 2D floor plans and paper blueprints that take time and effort to create. While an essential part of the process, they are quite inflexible and we often find that any changes to the floor’s layout do not get reflected in the plans.

This can become especially problematic in fast-moving markets such as consumer electronics where production systems must be continuously extended and refreshed. Why? Because 2D plans lack the intelligence and connectedness for manufacturers to know exactly what’s in production to make smart decisions and act quickly.

Following on from the layout , the manufacturing workflow typically progresses through into process validation. Here we also find a potentially major barrier to efficiency: manufac turer s t ypically wait for ac tual equipment to be in place to see how it performs.

If it doesn’t do as well as expected, it will be too late to look for an alternative solution and, in our experience, any breakdown in this process can cause serious delays.

Finally there are two other areas at the end of the production chain where customers report challenges: throughput performance and manufacturing execution.

Because of the complexity of the modern floor and, more often than not, a lack of coordination between different software and planning systems, it can be hard to isolate areas or cells in production that are delaying the line. And, when it comes to the last piece of the jigsaw – manufacturing execution – customers often report difficulty in comparing planned process performance to actual performance.

Again the issue here is complexity, with

challenges in feeding back information from the shop floor into product design, engineering and manufacturing teams.

Enter The Digital Twin A central idea to reduce complexity in all the key steps in the production process could be the Digital Twin. A Digital Twin is a virtual copy of something that’s modelled to behave realistically. We’ve aligned our Project Lifecycle Management (PLM) tools to provide a complete digital framework around which Digital Twins can be modelled to realistically replicate the product design and assembly processes – from beginning to end. So what does this mean? Using the same stages we discussed above, we’ve highlighted some of the key capabilities we think are most valuable in this approach.

Design: Using NX software (and other CAD systems), we can create a model of our product – and open them in Teamcenter as a 3D JT model. The software can virtually build literally thousands of variations of the product, just as it would be physically built, in seconds. It uses big data techniques, descriptions of the Product and Manufacturing and Information (PMI) that specify

Process planning: Design and manufacturing work together to make more successful products by defining manufacturing process plans that link what needs to be made, how to make it, the resources required and where it’s made.

This image shows definition of the steps for installing the outer case of the Nanobox and the estimated time for the shop floor operator to complete each action.

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IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Intelligent modelling using quantitative analysis can assess all the human factors associated with the build to advise on issues such as working posture to help prevent employee fatigue and injury.

Layout: Using the manufacturing process plan information in Teamcenter, a digital twin of the Nanobox production system layout is designed in NX. The production system layout is also managed in Teamcenter ensuring the product design, manufacturing process plan and production system stay synchronised so that production starts without delay.

Process validation: A digital twin of the production system is simulated to validate that the planned process details are correct and will work properly.

Simulation models can run quantitative analyses to validate a wide range of human safety factors for the global worker population.

the product’s tolerances and components, and a basic description of the manufacturing process to determine if we have any clashes.

We trialled this approach on the design of one of our own electronics products. We were able to instantly see that the connector screws and corresponding video output connector holes had become misaligned. Unchecked, this could have resulted in warranty claims as the connector would separate from the PCB due to the manufacturing fault. Identifying design problems this early in the piece can save serious time and money – into and beyond the manufacturing process.

Process planning: The Digital Twin can improve coll abor at ion be t ween t he de sig n and manufacturing teams to better plan what needs to be made, how it should be made, the resources needed and where it can be made. Let’s take an example of an updated assembly.

Working with our tools, the planning team can use the new Bill of Materials (BOM) to input the new steps into a 3D working model of the current process. Production systems can be modelled anywhere, so a team in Paris can be planning production for a site in Rio. With time estimates available for the new processes, the team can see if the workflow will still ensure that the average unit product targets are met.

If not, the revised or new cells can be moved up or downstream and a simulation run again until the sequence ensures that production

targets are met. The revised plan can be easily accessed by all stakeholders and signed off. If there are any issues revealed during the process, the design and planning team can work together to rectify these.

Layout: With the floor layout, we recommend creating the Digital Twin – with all the mechanical, automation and resource details – and linking it to the product design and manufacturing eco-system.

Using a combination of PLM tools, the operation can be simulated by simply dragging and dropping cells, equipment and people into place on the line. It’s a very simple but effective way to design and make changes to the floor. So, if a product is changed and this requires the use of a new robot, simulation engineers can see if the robot’s size will, for example, interfere with one of the conveyors.

The layout engineer can then make the adjustment and issue a change request notifying purchasing that a new piece of equipment is needed. Furthermore, impact analysis can be run when changes are needed to avoid mistakes and inform any suppliers that might be affected.

Process validation: With process validation, the Digital Twin can be used to digitally validate the assembly process. Intelligent modelling using quantitative analysis can assess all the human factors associated with the build to advise on issues such as working posture to help prevent employee fatigue and injury. The report can be used for training with videos and process guidelines produced for staff.

Throughput optimisation: The Digital Twin can also be used to statistically simulate and assess a planned production system. It can evaluate whether to use people, robots or a combination of the two. It’s possible to simulate all workflows – even down to the how much energy is utilised by the production equipment – to streamline the process as much as possible.

IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Throughput optimisation: A digital twin of the planned Nanobox production system is used to statistically simulate and evaluate it for performance.

Close the loop: The digital twin closes the loop between the virtual and physical worlds of manufacturing so you can compare the as-design model to its as-build result. In this image, Big Data techniques are used to collect live quality data from the shop floor, which is overlaid on the Digital Twin in Teamcenter for analysis.

Manufacturing execution: The digital twin is connected directly to the manufacturing operations management system to ensure it is executed properly on the shop floor. In this image electronic work instructions, linked to the manufacturing process plan, are displayed on a SIMATIC IT shop floor console for production operators.

The analysis can show how many parts will be produced by what process to ensure schedules are met prior to creating the physical line.

Manufac turing execution: Manufac turing execution can be improved by using the Digital Twin to close the loop between the physical and virtual worlds. Manufacturing instructions are released direct to the design floor where operators can view them along with associated videos.

Operators can feed back data from the production floor (eg: the gap between two panel screws) while other automated systems can also collect performance data. This can be used to assess if there’s any difference between the build designs and results to isolate and rectify any issues.

A New Way Of Doing Things Using a Digit al Twin, which replicates a physical product, can help spot problems more quickly to accelerate production and reduce costs across the production chain.

What’s more, it ensures that the design can

be made; the plan is always up to date and synchronised; the strategies will work; and production will perform as anticipated. It also helps to see how new technologies can be integrated into production lines without the risk of buying and installing them to see how they perform.

For one of the world’s most advanced industries, manufacturing has long relied on proven but dated approaches to planning its products and lines. The Digital Twin aims for a new approach to the way design, process planning and execution is applied in the manufacturing industry.

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IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Cadac Group

40

UNDERSTANDING

PRODUCT LIFE MANAGEMENT The what, why and who of product lifecyle management (PLM).

By Ho Pei Ying

Editorial

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roduct lifecycle management (PLM) has gained much traction in recent years. CIMdata estimates that by 2017 alone, the PLM market would be worth US$50.7 billion, while Transparency Market Research posits that the market will grow at a CAGR of 8.1 percent from the 2014-2022 period to reach US$75.87 billion.

PLM is broadly defined as the process of managing together product-related ideation, design, production, maintenance, and disposal information.

CIMdata advances that PLM is not “a piece, or pieces, of technology” but rather a “business approach to solving the problem of managing the complete set of product definition information”.

Today’s understanding of PLM is also used to represent a set of software tools used in the design, review, and manufacture of products and product lines.

Benefits PLM comes with many benefits.

• Provides coherent and manageable data structure and flow • Avoids redundancies and gaps • Leads to fewer errors and rework • Enhances communication between stakeholders • Churns out better reporting and analytics • Improves productivity

• • • • • •

Minimises time-to-market Creates a more competitive edge Results in better product quality and innovation Lowers material and production costs Utilises resources fully Maximising long-term ROI

Cloud-based Solutions Despite the growing interest in PLM today, most companies have not been successful in implementing an end-to-end PLM Solution as they tend to only adopt a part of the solution.

This results in pockets of disconnected data that hampers the ability to share information quickly.

Traditional PLM is also seen as too costly and superfluous, mainly for small and medium enterprises (SMEs) who have basic requirements for engineering change and information management.

Recent developments in cloud-based PLM have enabled SMEs to jump onto the PLM bandwagon due to lower upfront costs. As information is all stored in the cloud, there is little additional investment needed for IT infrastructure or additional hosted computing services and environments.

Cloud-based system’s global access also allows personnel in multiple internal and external organisations anywhere in the world to collaborate and exchange information.

PLM Solution Providers The following is a list of top PLM solution providers and what they offer.

Arena Solutions Arena Solutions focuses mainly on cloudbased PLM solutions. While BOM management

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(BomControl) is a key aspect and a flagship of their PLM solutions, there are also offerings such as project management (Arena Projects), quality management (Arena Quality) and product demand forecasting (Arena Demand).

Autodesk Autodesk’s Fusion Lifecycle is a rebranding and repackaging of the company’s cloud-based PLM software, PLM 360, which was developed back in 2012. Fusion Lifecycle has all the capabilities of PLM 360, including BOM, tools for product introduction, quality and cost management and tight integration with supplier networks. The entire Fusion platform is set to be an integrated interface—a single, cloud-based dashboard for users to interact with the data provided.

Dassault Systèmes Dassault Systèmes’s PLM solution expands from an engineering-centric view of the product lifecycle to a more enterprise-wide understanding via its 3DExperience, which is an “experience” that users can obtain when using a variety of the company’s software and services. These include CAD (Catia) to digital manufacturing (Delmia) to Simulation (Simulia) to conventional PLM (Enovia).

PTC PTC’s PLM system simultaneously manages both hardware and software deliverables. It has both on-premise solutions as well as cloud-based services. The PLM platform that the software runs on is Windchill 11, launched in November

Victrix Enterprise Media Management

Asia Pacific Metalworking Equipment News • September 2016

PLM providers today are offering cloudbased solutions that have a higher take-up rate than traditional PLM thanks to their low investment costs.

History of PLM PLM may be around longer than you think, and its origin is found in the automobile

2015. Windchill 11 is enabled by PTC’s ThingWorx technology that integrates data from physical products, web-based resources, and enterprise software systems. Under the platform, IoT data is captured in real time during the operation of physical products.

industry. In 1985, automaker American Motors Corporation laid the foundations for the inspiration for the strategic

Siemens PLM Siemens PLM Software’s solutions include Teamcenter, their flagship product which is essentially a suite of PLM software applications based on a single platform. There’s also the NX, which represents a suite of integrated, fully associative CAD/CAM/CAE applications as well as Tecnomatix, a comprehensive portfolio of digital manufacturing solutions that synchronises product engineering, manufacturing engineering and production, among others.

business approach of PLM when it was looking for a way to accelerate the process of its Jeep Grand Cherokee production so as to better compete with their competitors.

Using a PLM model they came up with, designs,

PLM Industry: Report Shows Growth

drawings and

CIMdata, in its 2016 PLM Industry Analysis Report,

in a central

showed growth in PLM spending in 2015 as all

database that was

industries were affected by the trend towards smart,

accessible to all

connected products, either directly or because of

the departments

the effects of the Internet of Things (IoT).

involved. Issues

The global consulting and research firm’s report

documents which were stored

could thus be

noted that PLM spending is greatest in automotive

resolved faster

and other transportation, fabrication and assembly, electronics and telecommunications, and aerospace

and the costs

and defense. It is lower in the process industries and utilities arena.

of engineering

The report added that there are some good process PLM solutions available, and they are becoming

changes could be

more important with concerns about food safety, particularly in emerging economies. Growth in PLM for

greatly reduced.

medical devices, part of the high-tech sector, is driven by stringent compliance requirements that can vary

While today’s

by country, something that PLM strategies and enabling solutions can address.

concept of PLM has

During 2015, comprehensive providers continued to expand their efforts to deliver more industry-focused and functionally-packaged solutions that are easier and less expensive to acquire and deploy.

“The global PLM market grew strongly in constant currencies in 2015,” says Stan Przybylinski, its VP of

vastly taken on a more advanced understanding, what

Research. “The leading PLM solution providers are consolidating their portfolios after years of acquisitions,

American Motors

and increasing revenues in 2015, in part, by expanding their footprint at their existing clients”.

did in 1985 changed

The CIMdata PLM Industry Analysis Report, is the fourth of five modules of the CIMdata 2016 PLM Market Analysis Report Series by the company.

the engineering aspect of a product.

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IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

ADDRESSING

MEMS

CHALLENGES

Overcoming design challenges for mircoeclectromechanical systems (MEMS) in an IC-focused environment.

By Nicolas Williams, product marketing manager and Qi Jing, technical marketing engineer, Mentor Graphics Editorial

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icroelectro-mechanical systems (MEMS) have been growing rapidly ever since it became possible to fabricate MEMS devices using modified semiconductor device fabrication technologies. Layout tools that are widely used in IC design naturally become the tool of choice for MEMS layout design.

Although IC layout tools are quite mature and feature-rich for IC applications, many of them lack the capabilities to efficiently handle the challenges MEMS layout imposes. That is why unique MEMS-oriented features are needed in IC tools to address the specific requirements of MEMS layout design and to make the design process fast, easy and accurate.

A big difference between MEMS layout and IC layout is the use of unique, irregular shapes.

Unlike conventional CMOS IC design, where layout shapes are usually Manhattan style (such as rectangles and rectilinear polygons) or polygons with 45-degree edges for routing, MEMS design utilises a much broader variety of geometries, due to its wide applications in the mechanical, optical, magnetic, fluidic and biological fields.

The suppor t and ease of use for implementation of irregular shapes, including curves and all-angle polygons, becomes a

critical criterion differentiating MEMS-oriented CAD tools from conventional IC-oriented tools.

Most layout and verif ication tools are focused and optimised on IC designs and are not suitable for irregular shapes needed for MEMS designs. MEMS designers need layout and verification tools that can handle challenges that curved or all-angle objects presents.

Also, designers need tips and tricks on how to handle false errors that result from rules that are optimised for orthogonal geometry.

Overcoming Limitations Of Mechanical CAD Tool Unlike traditional mechanical CAD tools, where “zero-width” lines are common, MEMS layout requires all geometry to be represented as “closed” or “filled” polygons. This is needed to define the light and dark regions of the mask.

One limitation with some mechanical CAD tools is that they cannot represent a filled polygon easily and any drawing done in these tools usually results in the polygon being represented as several “zero-width” line segments.

When importing DXF files (a common format used to transfer geometry from mechanical CAD tools), MEMS can search for segments having endpoints within the user-specified tolerance and try to reconstruct closed polygons as seen in Figure 1.

If a closed polygon is found, the individual segments will be replaced by a single polygon.

The endpoints of the line segments do not have to match exactly. MEMS allows the user to specify the largest gap between segment endpoints when joining them into a polygon.

When sending the MEMS design to the foundry for fabrication, the user typically will export the design in GDSII format. Since the GDSII

IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Figure 1: Polygon reconstruction from individual line segments in Tanner L-Edit MEMS.

format does not support curves, a conversion is needed for circles, pie wedges, curved-sided polygons and tori to all-angle polygons that approximate the curve when GDSII mask data is exported.

MEMS automatically per forms this conversion, and additionally issues warnings if the design contains a wire or polygon with more than 200 vertices, since GDSII has a limit of 8,192 vertices, and 200 vertices is a traditional best practice limit. The user can then specify a maximum number of vertices that each polygon should have and if it exceeds this maximum, the polygon will be automatically fractured into smaller polygons with fewer vertices by Tanner L-Edit MEMS. All-angle polygons can also be converted back to curved polygons. Sometimes, a GDSII file, where curves are not preserved, needs to be read back in for design revision; or curves need to be recovered from the result of an advanced editing operation such as Boolean operations, making it easier to edit.

To achieve good curve recovery, MEMS searches all-angle polygons for arcs with eight or more vertices and replaces the multiple adjacent segments with curved edges, provided that those vertices lie on an arc with no more than one manufacturing unit radius error (Figure 2).

Such conversion capabilities make it much more convenient and accurate for users to re-edit curved objects.

Curve Conversion To All-angle Edges Curved polygons need to be converted to allangle polygons when doing some advanced editing operations, when running design rule checking (DRC) and when exporting to GDSII. The all-angle approximation must represent the actual curve as accurately as possible.

In some CAD tools, curves are converted based on a specific number of vertices, which

Figure 2: Curve reconstruction in Tanner L-Edit MEMS.

does not guarantee the precision between cur ves of dif ferent sizes. MEMS conver t s curves based on the manufacturing grid, which adjusts the number of vertices to use during conversion based on the size of the curves to have maximum precision.

To show the dif ference bet ween the approach of Tanner L-Edit MEMS and other CAD tools, three circles with a 5-μm, 50-μm, and 250μm radius were converted in Figure 3 to all angle polygons using a fixed number of vertices which is common in other CAD tools.

Figure 3: Curve reconstruction in Tanner L-Edit MEMS.

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IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Figure 4: Extension DRC rule.

Figure 5: False DRC errors caused by curve approximation.

They were al so conver ted using the ME M S ap p r o a c h . N o t i ce t h a t f o r s m a l l curves such as the 5-um radius circle, both approaches do a good job approximating the curve compared to the original curve and have about the same error.

For larger curves, however, the error rate increases for the fixed number of vertices method to be as much as 0.3 μm for the 250 μm circle. Since MEMS uses the manufacturing grid to calculate the number of vertices, the error is on average, less than the manufacturing grid of 0.01 μm. E ven though edges are smoothed when fabricated, this error can affect how the resulting MEMS structure performs if the error is too high.

Also, this conversion error can cause problems when doing Boolean operations on curved geometry and can cause many false DRC errors.

DRC Challenges Of Curved And All-angle Geometry Similar to IC layout, MEMS layout must pass DRC to minimise manufacturing risks and improve yield. In addition to regular DRC concerns, curved objects that are common in MEMS layout impose some unique challenges to the DRC process.

The biggest challenge is the generation of false DRC errors because the DRC rule does not handle MEMS layout well. Most DRC engines and most DRC command files are designed for IC geometry, which is mainly orthogonal, and are not intended to handle all-angle or curved geometry.

Standard rules that work fine for checking orthogonal geometry may generate many false errors when run on all-angle geometry. A few false errors can be quickly reviewed, but if there are hundreds or thousands of false errors, it is easy to miss true DRC errors especially across multiple DRC runs.

MEMS is integrated with a hierarchical DRC engine called Tanner Verify that can help filter out some of these false DRC errors. To show the challenge of false DRC errors, a simple extension rule will be used as an example.

An extension rule states that an object on one layer has to extend out of an object on another layer by at least a specific distance.

The extension rule is measuring the distance from the external side (outer) of an edge of the layer 1 object to the internal side (inner) of an edge of the layer 2 object. Typically, this type of check ignores edges that intersect or edges that intersect at a 90-degree angle, as seen in Figure 4.

The false DRC errors are generated when curved edges are approximated as multiple small all-angle edges, by breaking a long single edge into multiple small edges as seen in Figure 5. This makes it impossible to ignore intersections because the single curved edge on Layer 1 that intersected Layer 2 is converted to three edges, with one of the edges not intersecting a Layer 2 edge.

This is not because the DRC engine cannot how handle this issue but because the rule was written and optimised for orthogonal geometry and needs to be modified to handle the curved edges.

One trick to help filter out many small edges due to curve approximation is to only check edges if they project onto each other by at least a specific amount. The projection of an edge onto another edge is a perpendicular projection from the reference edge to the edge being projected onto.

Figure 6 shows an example of the layer

IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

1 edge projecting onto the layer 2 edge and vice versa. A filter length of either ten times the manufac turing grid or a tenth of the measurement distance is a good rule of thumb to use.

Unfortunately, filtering by projection length will not remove the false errors that are due to the curved edges getting approximated as multiple small all-angle edges during the extension rule. The small edges that get created and do not intersect with the other layer can have reasonable projection lengths and as a result, will not be filtered out.

The challenge is filtering out the edges that would have intersec ted if there was no approximation. The best approach is to rewrite the DRC run to only check the opposite edges and not the intersection. This can be accomplished by doing an extension check and saving the result as a polygon or region, and then performing an internal or width check that checks the spacing between the internal side (inner) of two edges of an object.

Figure 7 shows that when a true error exists, a polygon of four or more vertices is generated during the extension rule check.

The extension rule check results in triangles at locations of the false DRC errors that result from a long single edge being broken into multiple small edges. Since intersections are not checked for the width check, these triangles are ignored and are ef fec tively filtered from the results.

Round-off Issues Affecting All-angle Rotation And Node Highlighting Unlike IC layout, where DRC and LVS rely heavily on CAD tools to find and report errors, MEMS layout designers prefer a more intuitive way to check on the connectivity visually, before running verification tools, due to the intrinsic characteristics of MEMS components and the lack of a schematic netlist with which to compare.

To run node highlighting, the user first defines the connectivity by specifying names of layers that connect to each other.

Layers connect if both layers overlap with each other and overlap with a connection l a y e r s u c h a s c o n t a c t o r v i a (v e r t i c a l interconnect access) or they can be setup to connect if they touch. Objects are defined as connected, if the AND of objects on Layer 1, Layer 2 and the connection layer results in non-zero area geometry.

If a connection layer is not specif ied, then Layer 1 and Layer 2 must either overlap or touch to be considered connected. After defining the setup, the user then runs the

Figure 6: Edge projections.

connec tivit y ex trac tion engine based on these definitions.

To pick the node to be highlighted, users can either highlight the geometry connected to the selec ted objec t , or open a dialog window to specify the targeted node name.

Node highlighting works on merged objects on drawn or derived layers allowing the user to create complex connectivity rules. All the merged geometry of a node is highlighted in layout and the node name will be displayed in the status bar.

Mult iple node s may be s equent ially selected and highlighted in different colours.

When a node is highlighted, all related

Figure 7: Two-step DRC check to filter out false errors due to curve approximation.

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IN DESIGN Asia Pacific Metalworking Equipment News • September 2016

Figure 8: Node Highlighting of MEMS geometry and issues with all-angle rotation of touching objects.

When doing MEMS design, design tools need features that can handle the challenges of arbitrary shapes and structures.

connectivity throughout the hierarchy will be displayed. When highlighting, if more than one node is located at the cursor location, a list of all potential nodes are displayed and the user will be prompted to pick one.

Figure 8 shows an example of using node highlighting to check the connectivity visually.

Two nodes are highlighted in different colours displaying their connectivity so that user can quickly find erroneous connections.

When doing connec t i v i t y e x t r ac t ion and node highlighting with an all-angle rotated object, one issue that can arise is unconnected geometry due to round-off which may cause a small gap between objects in a rotated instance.

When rotating an ins tance by an allangle amount (non-90 degrees), each object is rotated individually and gets snapped to the resolution of the design database which is typically 1 nm. This snapping can cause round-off issues which may results in two objects that touch when they are not rotated becoming separated or not touching (small gap between them) when they are rotated at non-90 degree angles.

Notice in Figure 8 that for node 1, a few of the spokes are not highlighted because small

gaps arise during the rotation and snapping to the resolution of the design database. This small gap is hard to see but can be easily detected with node highlighting.

The best way to handle this issue is to either merge touching objects in the cell being rotated or to make sure there is some overlap between the touching objects. Notice that the spokes connected to node 2 are all highlighted because that spoke is a single object and not two objects that are touching.

Conclusion When doing MEMS design, design tools need features that can handle the challenges of arbitrary shapes and structures. The effects of curved geometry and how it gets approximated affects all aspects of layout from editing to DRC and Node highlighting. The key is having the right tools to efficiently operate on curved geometry and filter out false DRC errors that result from MEMS structures.

With the above features specif ically developed for the purpose of MEMS design, a MEMS layout can be accurately verified and sent to fabrication. This makes MEMS-oriented layout tools such as Tanner L-Edit MEMS a necessary assistant to MEMS designers.

FAST FAB Asia Pacific Metalworking Equipment News • September 2016

HUMAN-ROBOT COLLABORATION To Drive The Automotive Industry Teamwork between human and machine is key in enabling manufacturers to ride on the growth of the automotive industry. By Shermine Gotfredsen, general manager, APAC, Universal Robots

T

he automotive market is stronger than ever, with countries such as the United States and China experiencing rapid grow th in recent times. By 2020, global profits for automotive Original Equipment Manufacturer (OEMs) are expected to rise by close to 50 percent, with emerging markets leading the growth. In Southeast

Asia, the automotive industry is forecast to show positive signs of growth in the next few years, thanks to its growing number of middle class that is expected to more than double to 400 million by 2020.

With the rise of middle-income group, coupled with fast-paced lifestyles of today’s moder n s o cie t y, consumer pre ference s

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FAST FAB Asia Pacific Metalworking Equipment News • September 2016

find ways to ensure great efficiency while maint aining produc tion cos t s , all while ensuring a safe working environment for their employees.

Top image: Lear Corp installed and programmed a co-bot to screw together the automotive seat and rest frames with an end-ofarm screwdriver.

Above: Co-bots come with intuitive user interfaces, allowing them to be deployed and redeployed to any production stages required.

are cons tantly evolving. Automotive users nowadays not only seek high safety s t andards , t hey are al s o cons t ant ly on the lookout for new products and services that would make their driving experiences smoother and more enjoyable.

Additionally, globalisation has led to the increase in competition, which means that industry players are expected to meet higher production volumes within shorter timelines to remain competitive in the market.

In short, the automotive industry, similar to other industries, is fast-paced, labour in t e n s i v e a n d p o s e s m a n y p r o d u c t i o n challenges for manufac turers striving to succeed, or perhaps, survive. They have to

Embracing Technology One key solution to addressing all the challenges is simple—innovate.

Manufacturers have to constantly find ways to innovate, shif ting from the ways they traditionally operate in order to gain an edge amidst the competitive economic climate.

Some ways for them to do so include automating produc tion processes to increase productivity or implementing new technologies to enhance their produc t s.

In fact, market research firm Research and Market s predic t s the global automation market of the automotive industry will grow at a CAGR of 8.62 percent between 2016 and 2020.

The automotive industry is known to have pioneered the introduc tion of industrial robots to automate their production lines in order to boost productivity in factories. In fact, the first industrial robot in the world was installed by General Motors. It was used in its assembly line at one of the company’s automobile factory in the 1960s.

Fast forward to the 21st century, and the automotive industry is currently the largest market for industrial robots. According to the International Federation of Robotics, around 95,000 units of robots were sold in this industry last year.

Indus t r ial robot s are machine s t hat have been designed to operate on behalf of humans in a dangerous or repetitive setting, reducing error and providing more strength or accuracy to increase productivity.

Installing industrial robots bring a range of benef its to automotive manufacturers.

Lear Corporation, a German automotive supplier, had limited working space on the produc tion f loor and required increased productivity to meet demands. They needed a small, mobile robot that was flexible and able to work alongside its employees in a cohesive environment.

Faced with this situation, the automotive supplier deployed a collaborative robot, or co-bot, into their production process. Due to the small size of the co-bot, Lear Corporation did not have to make any expansion to the produc tion area . The co-bot wa s ea sily installed and programmed to screw together au t o m o t i v e s e a t an d r e s t f r am e s w i t h an end-of-arm screwdriver. If screws are mis sing on a seat , t he robot pick s t his product out and issues a warning signal for

FAST FAB Asia Pacific Metalworking Equipment News • September 2016

employees to rectify the issue. It currently completes about 8,500 drilling actions every day, increasing both production speed and product reliability.

Human-Robot Collaboration Co-bots are an innovative type of industrial robot s, designed to work collaboratively with humans. They are flexible, lightweight and compact, making them suitable to be easily deployed into existing produc tion layouts. In a manufacturing environment, cobots function as co-workers or assistants, supporting employees in performing daily tasks on the factory floor.

A s co -bot s come wit h intuit ive us er interfaces, they can easily be programmed by any employee to handle various tasks in the factory. The employees can also deploy and redeploy the co-bots into any production stages required, ensuring that needs are met to reduce any possible downtime or error.

Co-bots are also useful in environments that are uncomfor t able or too risk y for humans . The automotive plant , with it s heavy machine parts and metal components, can pose health hazards for workers who have to be exposed to the condition for too long. Having co-bots to perform those tasks instead of humans will minimise any potential safety hazards.

Additionally, co-bot s comply with the s afe t y s t andards for indus t r ial robot s , International Organisation of Standardisation (ISO) 10218 and new technical specification for co-bots, ISO/TS 15066. The new specification was recently developed with a set of safety requirements to ensure that all co-bots are subject to risk assessment tests to work in tandem with employees.

With the workers’ time freed up, they can take on other responsibilities that require creativity and strategic thinking. This way, they will be able to learn new things in the workplace and be more motivated to journey up the career ladder. As for the employers, having more highly skilled employees means increased produc tivit y levels, which will significantly contribute to business growth.

Changing Face Of Manufacturing The sustained development of the a u t o m o t i v e i n d u s t r y , e v e r- c h a n g i n g consumer preferences and technological advancement s of fer both challenges and oppor tunities for manufacturers. In order for companies to gain a real competitive advant age and long-term sus t ainabilit y for their business, it is critical to embrace

new technology that is changing the face of manufacturing.

According to the International Federation of Robotics (IFR), global demand for industrial robots is forecast to accelerate and pass the two million mark by the end of 2017, with the highest demand coming from the automotive industr y. This signif ies the impor tance of automation in current and future production processes. In the next few years, we will see more companies progressing towards humanrobot collaboration, creating environments where workers and robots work hand-in-hand to achieve greater quality and precision for their products and customers.

Top image: Having cobots perform dangerous or unsafe tasks can minimise potential safety hazards from occurring on the factory floor.

Above: Relieving employees for other tasks that require creativity and strategic thinking while leaving more mundane tasks for co-bots can help increase productivity.

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FAST FAB Asia Pacific Metalworking Equipment News • September 2016

The simulation of the entire system optimises output and reduces the time required for commissioning considerably.

Schuler

Servo press lines are already comprehensively networked and are equipped with interfaces for future systems.

Schuler

The correct conclusions have to be drawn from the data which is provided by the systems.

Schuler

50

SMART

PRESS SHOP

Networked systems can increase process reliability and costeffectiveness.

By Simon Scherrenbacher, corporate communications, Schuler.

Editorial

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e t wor k ing s olu t ions in for ming technolog y can increase not only process reliability, but also costeffectiveness in production.

In a modern servo press line, as many as 30 industrial PCs are networked with one another to ensure a high level of productivity and safe part transport from one press station to the next.

Single presses, laser blanking lines, and various automation components also have the necessary interfaces for comprehensive networking.

What is the maximum speed at which a specific sheet metal can be formed? Forming simulation provides valuable information for the virtual optimisation of the entire system. To stay with the example of a servo press line: long before the tool sets are clamped into place, the virtual model of the system produces one part after another.

By simulating the entire system, including all press stages and automation components,

the time needed for part transport is minimised.

The customer can also get information on the energy required for production.

The systems provide data measured by sensors installed at numerous points, for example to monitor the press force. By drawing the right conclusions from this information, this area also has huge potential. If the press force progression deviates from a particular pattern, this indicates irregularities in the process. These solutions gather important information that can be used to maintain the line, thereby preventing damage to the machine and tool.

If it becomes apparent that not everything is running smoothly, the service engineer can connect to the customer’s system online. In nine out of ten cases, problems can already be solved remotely. Condition-based maintenance can therefore help save a lot of money.

Many of these examples are already common pr ac t ice. “ Schuler ha s t he key advantage of having equipped press plants throughout the world for decades, from the decoiler through to the automatic racking system”, says Chief Technical Of f icer, Dr Stephan Arnold. “ This experience helps enormously when it comes to developing intelligent functions for the ‘Smart Press Shop’ and the press plant of the future.”

At the EuroBLECH trade fair in Hanover, Germany, at the end of October, Schuler’s “Smar t Press Shop” concept will be demonstrating how networking solutions in forming technolog y can increase not only process reliability, but also cost-effectiveness in production.

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FAST FAB Asia Pacific Metalworking Equipment News • September 2016

THE DIGITAL

TRANSFORMATION

With Industry 4.0, there is now an increasing trend towards digitalisation in industrial environments. Bystronic’s head of development (CTO) Dr Jürgen Hohnhaus talks about the benefits behind this development. By Oliver Hergt with photos by Manuel Stettler.

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t may be too early to say that it is another industrial revolution, but Industr y 4.0 represents a confluence of trends and technologies that looks set to re-shape every corner of the factory and the supply chain.

In the metalworking industry, the revolution is gathering force, and senior officials would be wise to monitor the coming changes and develop strategies to take advantage of the new opportunities.

These changes and many others like them are sure to be far-reaching. The pace of change, however, will likely be slower than what we’ve seen in the consumer sector, where equipment is changed frequently.

Industry 4.0 is currently a much-discussed topic and there are many different interpretations of it. How is Bystronic involved in it?

T he go al of Indus t r y 4 .0 is t he dig i t al

penetration of industrial business fields in order to improve the efficiency of production processes. In our case, we are talking about sheet metal processing. People, machines, and manufacturing parts that are involved in this process all become interlinked.

The company had been involved in this topic since 2010 and at that time, the term “Industry 4.0” had not yet been coined. Back then, we asked ourselves: Which Internet technologies must we integrate into our machines? And what will these technologies enable our customers to achieve in the future?

The first product that was developed based on these considerations was the Observer.

Today, it enables our customers to use their smartphone and tablet to access the status of their cutting and bending machines at any time and regardless of location.

Does this mean that these networks create greater transparency?

Precisely. With Industry 4.0, customers receive more transparency regarding their production processes. They see when and where their orders are being processed and how far their production parts have progressed.

Another benefit is increased flexibility.

In addition to large series of identical parts,

FAST FAB Asia Pacific Metalworking Equipment News • September 2016

Industry 4.0 enables customers to offer and manufacture small batch sizes with individual parts in a very short time. In the future, in addition to mass products, this will enable individual parts and small series to be produced at competitive prices. Intelligent system support makes it much simpler to adapt workflows and thus to respond more rapidly to the customers’ requirements.

Industry 4.0 comprises various aspects. Where is Bystronic setting priorities?

I see four areas of focus. The first is automation, which will be augmented with ar tif icial intelligence. The next step is the interconnection of the intelligent machines with the production parts to form a digitally integrated factory, the “smart factory”.

The third area is big data. That is, the question as to how we can ensure the secure handling and meaningful analysis of data. The fourth topic is about new service solutions made possible through the advanced data analysis possibilities.

What opportunities does this open up for the customers’ processes?

In the future, customers will be able to examine their entire process chain before production begins, for example. Production planning and control systems provide them with support when scheduling jobs and co-ordinating their resources accordingly. In addition, simulations help them analyse the planned processes before they are carried out.

Where does Industry 4.0 begin for customers?

It starts when our customers prepare an offer for their customers in order to tender for an order.

A successful offer requires a lot of know-how.

Imagine your company receives an invitation to tender. You have received a sample part or a drawing. Now, what is important is to quickly assess: Which process steps are necessary? How long will it take to manufacture the part? And what price can you offer?

What solutions are available for support with the preparation of offers and orders?

Today, we are already able to simulate the process costs and manufacturing time of parts.

This enables our customers to define the costs for an order in advance, which they can use to prepare the offer. In the future, we want to process this simulation data in digital form in order to subsequently automatically generate an offer. This will make our customers’ offer process even faster.

Okay, let’s assume the customer is awarded the order. What happens next?

The next step is the cutting preparations. This step is about cutting the ordered parts out of a metal sheet as efficiently as possible. Bystronic offers a cloud service for this, the ByOptimizer, which groups the parts that are to be cut on the metal sheet in space-saving clusters and plans the optimal cutting strategy in order to process the parts in as little time as possible. This service is available as a subscription that can be adapted to the customer’s cutting requirements.

Now we are in the middle of the cutting process. What, in terms of laser cutting, is already possible today that was not possible without the intervention of Industry 4.0?

For the time being, the actual cutting process will not change. But all the data that is generated during the cutting process on a laser cutting system can now be analysed. This allows customers to see if their machine is working optimally or not. If the cutting quality changes, they can immediately identify the cause. This is a new development.

The customer’s parts have been cut. The next step is bending. What innovations are available here?

We are currently transferring the Detection Eye function, which we have already successfully implemented on our laser cutting systems, to bending. This function recognises the tools in the press brake’s upper beam. It detects whether the operator has selected the correct tools and whether they have been inserted properly. If not, the function displays a message and suggests what corrections the operator must carry out.

Will there be radically new types of products in the future?

The greatest potential for brand-new products lies in the field of software. In the future, laser cutting systems will autonomously monitor and control themselves. We have already taken the first step in this direction. In the next step, we will introduce intelligent functions into the process by means of software applications.

Intelligent system support makes it much simpler to adapt workflows and thus to respond more rapidly to the customers’ requirements.

Bystar Fiber laser profiling machines have Industry 4.0 readiness and a newly designed control system, including Detection Eye, Power Cut Fiber and Observer functions.

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FEATURES Asia Pacific Metalworking Equipment News • September 2016

Machining Centres:

MEASUREMENTS

MADE EASY

Model and mould-maker Sammer, located in Eugendorf near Salzburg, Austria, is mostly engaged in the production of moulds for the automotive industry, including cylinder heads, crankcases and transmission housings. By Winfried Weiland, head of marketing, Blum-Novotest GmbH.

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M

odel s are mos t ly milled from a special plastic known in the in du s t r y a s U r e o l . I t i s a P U resin soaked with f iller and is used primarily in model and mould making.

The milled moulds are then encased in a moulding box f illed with moulding sand and compre s s ed by s t amping , pre s sing or machine vibration. When the model is

removed, a negative mould is left in the sand into which the molten metal is then poured to make the prototype.

Sammer, whose customer base includes leading corpor ate name s such a s BMW, AV L a n d N e m a k u s e s B l u m - N o v o t e s t ’s FormControl measuring software that was installed in its seven 3- and 5-axis machining centres in Eugendorf.

FEATURES Asia Pacific Metalworking Equipment News • September 2016

Using BLUM’s FormControl software, Johann Pucher creates measuring programmes for processing by the machine.

Measuring Software The software is used to measure every milled item in the machining centre. It measures contours, bores, angles or distances. “A big benefit of the software is that we are able to measure our workpieces in their original clamp f ix tures in the machining centre,” says produc tion manager Johann Pucher, who has been working for Sammer for 40 years. “So the time-consuming process of unclamping, transporting to the measuring machine, measuring, re-clamping, aligning and reworking is now a thing of the past.”

The range of highly complex moulds which Sammer makes for its customers is widespread and tight tolerances of f ive hundredths are the norm. The measuring sof tware, a complete package, enabled each production operative to design, machine and measure each component himself.

First the CAD data is imported into the programme. In the programme, the measuring points can be optimised and new ones added or existing ones moved by a mouse-click on the PC. Ready For Export Automatic PC-based collision control prevents unintentional collisions between the workpiece and probe. The NC programme is transferred to the controller and the measuring sequence can be started. After the measurement, the results are sent back to the PC, then the individual measuring points can be colourcoded, enabling tolerance evaluations to be made easily. At the end, a measuring report

presenting the individual measuring points in tabular form can be exported.

B e f o r e t h e s o f t w ar e w a s in s t al le d , Sammer relied on the quality of the milled moulds. This was sometimes problematic, because setting errors, tool wear or machine temperature drift could quickly cause the tight tolerances to be exceeded. Today, by contrast, the Austrian company is able to verif y the quality of the workpieces it mills. Previously, if an error occurred in the customer’s casting process, the mould was sent back to Sammer for reworking. Now the model and mould maker has the measuring rep or t do cumen t ing t he quali t y o f t he milled moulds.

Managing director Günter Sammer adds: “The reports are now an essential tool for us, not least because some customers actually stipulate them. And a report is produced and

The graphical view of the workpiece permits a quick assessment of the component's quality.

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FEATURES Asia Pacific Metalworking Equipment News • September 2016

Sammer mostly produces for the automotive industry.

Seen here is the plastic mold for a cylinder head cover.

Sammer mills complex molds from special plastic and measures them in the machine.

saved for each workpiece we mill, enabling us to react to any refer-backs. It is especially beneficial as it entails no additional work for the production staff. Quite the opposite: the reports are generated almost entirely autonomously, and can be immediately edited as necessary.”

Tight Tolerances The material properties of the plastics for the milling process enable ultra-fast cutting

speeds. Nevertheless, some moulds spend as much as 50 hours in the machining centre being milled. Such components are of course very expensive – due to the long machine running times alone – so it is essential to avoid any machining errors.

L arge component s can ea sily have more than 100 measuring points on them.

When work ing to ver y t ig ht toler ance s , Sammer sets several points manually, as a precaution. Other moulds are made of steel.

Tool wear is a bigger concern in those cases than when machining plas tic s. For s teel component s, the workpiece is measured during machining, so as to guarantee perfect quality. Lots of different plastic moulds are made, however – sometimes f ive to eight per day.

T he co s t s v ar y w idel y, b e c au s e t he specialists at Sammer not only collate milling data and mill the components, but often also prepare the CAD data and design components prior to milling, and sometimes also fabricate and assemble slit dies and ejector or closure systems. In view of such complex processing and the associated high cost, it is essential to install safeguards and monitor quality.

Sammer has been using the software since 2010 and appreciates its user-friendliness.

Blum-Novotest: FormControl V4 FormControl V4 is developed for production control in machining centers. The software enables the operator to perform contour measurements in the machine, as well as fast workpiece control.

The software allows the detection of machining errors directly in the machining center, eliminating the need for resetting of the workpiece on a separate measuring machine. Re-work is done within the initial set-up.

If a workpiece should be measured, the operator simply identifies the measuring points with the mouse on the 3D model. Also the real measuring sequence is executed with a single mouse command. The data transfer between NC and PC takes place via ADIF (automatic data interface).

FEATURES Asia Pacific Metalworking Equipment News • September 2016

DIGITALISATION

Of The Manufaturing Sector

F

or the past 40 years, the Asia Pacific region has played an important role in the global industrial manufacturing sector. The region adopted a modern indus trial infra s truc ture quickly and developed knowledge and aptitude in order to sustain success and adapt to the changes of global demand.

As a result, manufacturers in the region built a competitive edge over their global counterpar t s and have been creating highly sophisticated products that require technologically advanced equipment and competence. This begets the question - how can A sian manufac turer s maint ain their

How can Asian manufacturers maintain their competitive edge in the next 40 years? The answer lies in its evolution towards an Industry 4.0 manufacturing model. By Imtiaz Ahmed, Asia Pacific Mobil SHC Brand Manager, ExxonMobil Lubricants Editorial

competitive edge in the nex t 40 year s?

To enjoy continued grow th and success, manufacturers in the region need to think about how to stay ahead and differentiate themselves from their competition globally and regionally by focusing on productivity and proficiency.

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FEATURES Asia Pacific Metalworking Equipment News • September 2016

PwC states that more than half the manufacturing companies in Asia Pacific are expected to invest up to 6 per cent of their revenue on digital solutions in the next five years.

Companies unfamiliar with the testing process could encounter delays in production.

To achieve this, the nex t s tep would be to evolve towards an Indus tr y 4.0 manufacturing model. Otherwise known as the fourth industrial revolution, Industry 4.0 describes how manufacturing technologies will undergo automation and digitisation and will see the shift towards the development of “smart factories”.

Evolutionary Integration This evolution will require greater levels of integration among information, communication, and manufac turing processes that we’ve never seen before. The first two industrial revolutions introduced mechanisation to fac tories and mass production respectively. The third revolution automated the manufacturing process due to the proliferation of digital computing in factories.

Indus tr y 4.0 is the nex t pha se of digitis ation within the manufac turing sector made possible with cyber-physical sys tems, such as Internet of Things and cloud computing.

Big data analy tics and ver tical system integration are some of the technological adv ancement s we c an ex pec t to s ee in Indus tr y 4.0. Digitis ation and advanced an al y t i c s in t h e m an u f a c t ur in g s e c t o r enables indus tr y player s to get more accurate and practical insights at a faster

r ate to improve t heir produc t i v i t y and performance.

This also includes gathering insights and looking for solutions to improve equipment per formance, address environmental concerns, and minimise health risk s .

However, not many companies are fully aw are o f t he te chnolo g ie s av ail able . A McKinsey survey reported that only 48 per cent of manufac turing leader s consider themselves prepared for Industry 4.0.

Another report cited how the manufac turing industr y may have experienced some of the most tumultuous t ime s w i t h t he re cen t e conomic cr i s e s in 2001 and 2008 . Companies who were quick to inve s t in new te chnolo g ie s to improve productivity and performance found themselves facing slow returns on their technology investments when the markets suddenly crashed.

Manuf ac turer s today are inclined to exercise caution given global economic uncer t aint ie s . However, e x per t s ad v is e t hat de spi te t he r isk s involved, manufac turing indus tr y players need to embrace the technological revolution that is transforming modern factories. As early adopters, they should seize the opportunity to get head of the cur ve in terms of productivity and provide a competitive edge to their customers who are also looking

FEATURES Asia Pacific Metalworking Equipment News • September 2016

Digitisation and advanced analytics in the manufacturing sector enables industry players to get more accurate and practical insights at a faster rate to improve their productivity and performance.

to gain from innovation and technological advancements.

In a separate repor t, PwC states that more than half the manufacturing companies in Asia Pacific are expected to invest up to 6 per cent of their revenue on digital solutions in the next five years. Additionally, according to the IDC Manufacturing Insights Spending Guide, manufac turing spend in the A sia Pacific region, with the exception of Japan, will grow at a CAGR of 4.8 per cent between 2015 and 2019.

This includes an increase in technology spending due to t he changing focus on oper at ional ef f icienc y and t he need to combat environmental and safety issues in manufacturing.

Digitising Analysis Data Ver t ic al s y s tem integ r at ion in Indus t r y 4 . 0 dig i t i s e s and in t e g r a t e s pr o ce s s e s across the organisation. Data managed and analysed for operational planning, efficiency an d qual i t y manag em en t c an b e mad e available in real-time and optimised in an integrated network.

Data analy tic s in ver tical integration provides valuable insights that facilitates produc tivit y and improves equipment maintenance. It is reported that 82 per cent of companies in Asia Pacif ic expec t data analytics to have a significant influence on their decision-making in five years’ time.

T his inc lude s dig i t ising oil analy sis data to simplif y and improve the paperreliant process. The traditional oil analysis process is laborious and costly, and may cause unscheduled downtime and reduced operational efficiency. Companies unfamiliar with the testing process could encounter

delay s in produc t ion. Fur t hermore, t he diag nosis f rom t he analy sis could al s o im p a c t t h e ir p r o d u c t i v i t y, s a f e t y, a n d environmental goals.

Industrial lubricant and greases makers have come to realise that their customers are shifting towards the Industry 4.0 model and are looking to help improve processes and increase efficiencies too.

Ex xonMobil has always played par t in the progress of the industrial revolutions, where indus trial lubrication ensured optimum equipment performance. For 150 years, innovation had been a core focus in providing the best lubricant solutions for manufacturers.

Mobil Serv Lubricant Analysis ExxonMobil has introduced a mobile-enabled used-oil analysis platform in Asia Pacific region recently.

Described

as

a

solut ion manufac turer s need to take to move towards Industry 4.0 and digitisation, the Mobil Serv Lubricant Analysis (MSLA) platform is designed to improve efficiency and simplify the oil healthy analysis process by replacing a paperwork-heavy approach.

MSLA streamlines the entire analysis process and helps to identify issues that can be mitigated with minimal downtime, reduce the amount of lubricant needed to operate machinery, and improve overall machine life.

It replaces Ex xonMobil’s Signum Oil Analysis and customers can also leverage application-specific analysis options to access results and perform customised equipment recommendations directly on their mobiles or tablet devices.

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FEATURES Asia Pacific Metalworking Equipment News • September 2016

The Early Solution: Cast Iron Sleeves The classic solution has been to sleeve the cylinder bores of an aluminium block with cast iron. Generally, this solution can compensate for the poor tribological characteristics of aluminium. The issues that arise from using cast iron sleeves include packaging the liner into the block, the weight, and poor interface of the liner to the block itself.

The most significant disadvantage of a cast iron liner is the thermodynamic properties of the liner and its interface with the aluminium.

Not only is the thermal conductivity an issue but also the thermal capacitance, which can hamper the ability to maintain efficient piston and bore temperatures for optimal combustion.

This may be further degraded if the interface of the liner to the block material is not ideal, the insulation points between the liner and block become hotspots on the bore that may cause pre-ignition events. Even if the insertion of the liner to the block material is ideal, thermal conductivity and thermal capacitance can result in less-than-optimal engine performance.

ENHANCING ENGINE PERFORMANCE WITH

THERMAL

SPRAY COATING

The advantages of using aluminium alloy engine blocks over cast iron blocks can be augmented with thermal coating spray. Contributed by Paulo ES Rosa, manager, advanced thermal spray applications and process development, Comau.

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educing vehicle weight and frictional losses in the power train can help improve overall vehicle efficiency, w hic h i s o n e r e a s o n w h y man y manufacturers have adopted aluminium alloy engine blocks as an alternative to traditional cast iron blocks.

The primar y advantage of aluminium is the reduc tion in weight . Yet , because typical casting aluminium alloys do not have similar characteristics of cast iron for wear, many automakers have spent signif icant time engineering solutions to address the t r ibolog ic al de f iciencie s int roduced by aluminium cylinder blocks.

Plasma Transferred Wire Arc Thermal Spray A more recent solution to address these tribological issues is the utilisation of Plasma Transferred Wire Arc (PTWA) thermal spray coating to coat aluminium cylinder bores with a fine controlled deposition of molten metal particles.

A critical step in the successful production of thermal spray coating is the substrate surface preparation, in other words, preparing the uncoated bore wall. There are a number of commonly available surface preparation techniques available, with notable differences in terms of bond strength, ease of application and cost. The most common of which for aluminium blocks are water jet and mechanical roughening.

Both of which have consistently demonstrated high bond strength.

It should be kept in mind that consistent bond strength is required for all engine bore applications. Depending on the manufacturing preparation processes, bond strength has historically been from 35 to 70MPa, although generally anything above 25MPa is sufficient. By adopting mechanical roughening in a standard boring machine or machining centre, a process which engine manufacturers are familiar with, manufacturers can generate a robust surface preparation with the lowest processing and investment costs.

Process configuration also becomes a key variable when implementing a thermal spray coating solution, as manufacturers need to determine whether to build a new line or retrofit an existing line.

FEATURES Asia Pacific Metalworking Equipment News • September 2016

The SmartSprayComau is a thermal spraying solution for high-volume, liner-less aluminium engine blocks and engine re-manufacturing.

The PTWA process enables the coating of aluminium cylinder bores with a fine spray of molten steel particles at a high speed.

Implementation within a greenfield site provides obvious advantages in terms of flexibility and optimal integration, whereas an existing (brownfield) manufacturing operation requires the manufacturer to insert the spray coating system into the existing line. In this case, the setup recommended is one that integrates fine boring with surface preparation, coating, and then a rough hone bore finish.

Automakers should carefully balance their manufacturing goals, prioritising the relative importance of simplicity, engine performance and overall investments.

The SmartSprayComau system has been designed to support manufacturing priorities and seamlessly integrate within the existing processes. The reason why the thermal spray technology is surprisingly easy to implement, even within a high-volume production line, is because it essentially substitutes one process with another.

The coated block eliminates the additional investment and processes needed to insert the cast iron sleeves in the aluminium casting, which streamlines the casting process and improves the casting suppliers’ efficiency. At the same time, the machining process of the PTWA-coated aluminium engine is identical up through the final bore steps. Here, instead of finishing boring the cylinder bores, the bores are roughened and sprayed with a thin layer, that are 0.1 to 0.15 millimetres thick (final thickness), of molten steel. Once sprayed, the process continues as before with the final finishing processes.

Benefits Of PTWA Whether designing a new line or retrofitting an existing one, thermal spray coated cylinder bores is becoming an essential solution for advanced light alloy engine production.

Among the many advantages of PTWA, the plasma coated cylinders are more durable than non-coated cylinders, and the treatment can ensure a reduction up to 0.5 kg per cylinder according to the engine’s geometry.

In terms of thermodynamics and tribology, P T WA deliver s NVH, k nock and fric t ion reductions, and performance enhancements including reduced heat loss, emissions and consumption. And because it can easily coat cylinder bores measuring from 70 millimetres in diameter and upwards, new engine models can be seamlessly inserted into the line with minimal modification of the PTWA production cell. At most, there may be minor adjustments related to the interfaces with the new block.

A critical step in the successful production of thermal spray coating is the substrate surface preparation, in other words, preparing the uncoated bore wall.

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AUTO PARTS

NEWS & TRENDS The latest happenings surrounding the automotive parts industry.

Singapore Selects Delphi for Autonomous Driverless Vehicles Singapore: Delphi Automotive has be en s ele c ted by t he Sing apore Land Transpor t Authority (LTA) as a s trategic par tner to implement autonomous mobility concepts.

T h e pr o g r amm e o f t e s t in g i s being coordinated by the LTA and will take place in an urban, pointto-point, low-speed, autonomous, mobility-on-demand service area in One-North, Singapore’s R&D cluster.

It will feature a fleet of self-driving vehicle s (SDVs) f rom D elphi and

locally-based autonomous operator nuTonomy. Delphi will also develop a cloud-based mobility-on-demand software (AMoD) suite.

D e l p h i ’s A M o D d e v e l o p m e n t program and autonomous vehicle demonstration is par t of the S i n g a p o r e A u t o n o m o u s Ve h i c l e Initiative (SAVI), which was formed in 2 0 14 t o o v e r s e e an d m an a g e autonomous vehicle (AV) research, test-bedding, and the development of applications and solutions by

industry partners and stakeholders.

O f p ar t ic ul ar in t er e s t t o t h e Singapore LTA is the potential for automated driving solutions to make it easier for commuters transiting t h e “ f ir s t mile ” an d “ l a s t mile ” b e t w e en a ma s s t r an s i t s t a t ion and their home or work place. By addre s sing t his need, t he us age of the mass transit systems could increase; reducing overall traf f ic congestion and vehicle emissions.

“LTA has been facilitating selfdriving vehicle trials with singlevehicle protot ype s in one -nor t h since 2014,” said Chew Men Leong, LTA’s chief executive.

During trials in the US last year, an Audi SQ5 prototype using Delphi technolog y completed a coast-tocoast drive from San Francisco to New York with 99 per cent autonomy.

In Singapore, Delphi will provide five SDVs initially, with the potential to scale up the operation to include self-driving shuttle services that can serve an entire town. According to the automotive giant, it s autonomous solution is vehicle agnostic and can be applied in passenger cars, buses, commercial vehicles, purpose-built mobility pods and electric vehicles.

According to a report by McKinsey & Co, full automation (Level 4) could reduce up to 90 percent of US motor vehicle crashes caused by driver e r r o r. T h e co mp an y i s u s in g i t s participation in SAVI to develop new products and capabilities to serve its global customers.

T h e Sin g ap o r e LTA p ilo t programme will las t for three years with plans to transition into an operational ser vice by 2022 timeframe.

Indian Auto Component Industry Grows By 8.8% New Delhi, India: The turnover of India’s auto component indus tr y stood at Editorial U S $ 3 9 Got a Question? billion for Make An Enquiry. t he p er iod ENQUIRY NUMBER April 2015 to March 2016, regis tering Turn to page 80a to enquire or log on to: a growth of www.equipment-news.com 8.8 percent

6404

over the previous year and a CAGR of 6 percent over the last six years.

The report released by Automotive Component Manufacturers Association of India (ACMA), detailed Industry Performance Review for the fiscal 2015-16.

Commenting on the performance of the auto component industry, the association’s president Arvind Balaji said: “Despite a challenging year,

the auto component industr y has registered a satisfactory growth of 8.8 percent in 2015-16.” He added that the “component sector is expected to witness growth in early double digits this year.”

OEMs are expected to increase locally sourced components in their vehicle s , dr i ven by cos t s av ing s and protec tion from currenc y fluctuations. The high taxation on

FEATURES Asia Pacific Metalworking Equipment News • September 2016

imp or t s is al s o a dr i v ing f ac tor behind increased localisation.

Key f indings of the repor t showed exports of auto components g r e w b y 3 . 5 p e r ce n t t o U S $ 1 0 . 8 billion from US$11.2 billion in 201415, registering a CAGR of 18 percent in the last six years.

Europe accounted for 36 percent of exports followed by Asia and North America, each at 25 percent. Exports to Central America and North America increased by 30 percent and 3 percent respectively, over the previous fiscal.

The key export items included engine par t s , transmis sion par t s , brake system and components, body parts, exhaust systems, turbochargers, etc.

India’s Automotive Mission Plan (A MP 2026) ha s set a t arget of a turnover of US$223 billion by 2026 for the auto component sector backed with exports ranging between US$80 to US$100 billion.

The automotive industr y is an eng ine of g row t h for t he Indian e c o n o m y. T h e a u t o c o m p o n e n t industr y contributes 25.6 percent to the manufac turing GDP and 3 . 8 p e r c e n t t o n a t i o n a l G D P, prov iding dire c t employ men t t o 1.5 million people.

Figures in USD Billion

2010-11

2011-12

2012-13

2013-14

2014-15

2015-16

Turnover

41.3

42.2

39.7

35.1

38.5

39

Growth rate (%)

34.1

2.2

-5.9

-11.5

9.6

1.3

Export

6.6

8.8

9.7

10.2

11.2

10.8

Growth rate (%)

58.6

32.3

9.9

5.4

10.0

-3.7

Imports

10.9

13.8

13.7

12.8

13.5

13.8

Growth rate (%)

36.3

26.2

-0.6

-6.3

6.1

1.8

Investment

2-2.5

1.6-1.9

1.2-1.7

0.530.73

0.330.46

0.440.66

Note: Turnover data represents the entire supplies from the auto component industry (ACMA members and non-members) to the on-road and off-road vehicle manufacturers and the aftermarket in India as well as exports. This also includes component supplies captive to the OEMs and by the unorganised and smaller players.

Schuler Receives Systems Order From Daimler Stuttgar t , Germany: Schuler is supplying it s ser vo pres s lines and ser vo tr yout presses t o Daimler at it s Mercedes-Benz sites in Bremen and Sindelfingen.

The systems are scheduled to be commissioned at the end of 2018.

The press lines, with a press force of 91,000 kN each, are used to form car body parts from steel and aluminium, while the tryout presses are used for optimising and maintaining the dies required for this.

Equipped with the company’s ServoDirect technolog y, the six-station press lines feature an automatic quality inspection system and automatic racking system.

After the last forming station, two robots equipped with special sensors monitor specific spots on the produced trunk covers, engine hoods or doors for any faults. If all quality requirements are fulfilled subsequently to the surface inspection, the last working step is performed without a break in production: eight other robots stack the parts, which are accruing depending on size every second, into the transport container.

Menon Bearings To Invest US$2.2 Million In Auto Parts Plant Ko l h a p u r, I n d i a : A u t o p a r t s manufac turer Menon Bearings is planning to inves t R s 15-crore (US $ 2 . 2 million) in a f ac tor y for au tomobile comp onen t s , E TAu to reported. The factory will be located at Kolhapur, where the company is headquartered.

The line is set to produce bearings, bushes and washers, said Menon Bearings’ managing director RD Dixit.

The company produces 2.5 million auto components annually. With the new unit, the production capacity is expected to reach four million per annum. Mr Dixit also added that the company is diversifying its business and is concentrating on high value added products.

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FEATURES

ON TIME, ON BUDGET

Asia Pacific Metalworking Equipment News • September 2016

It’s not about playing with the cost, but budgeting well in order to manufacture efficiently and maximise the margins. By Asier Ortiz, CTO of Lantek.

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hen providing on-demand cutting services, we need a good budget calculation system that ensures that it can ensure the predictability of costs and the profitability of each order.

If we base the cost calculation for an order request solely on experience, we may make a mistake because we are not taking into account all of the components. On the other hand, we are leaving behind one of the company’s most important processes when we take on a workload outside of the company’s control.

To lose someone who has this experience, whether temporarily or permanently, or someone simply suffering from peak workload, will turn what should be a fluid and agile process, such as taking on work while also ensuring the quality of the work and that it provides profitability to the company, into a nightmare for the organisation. Many organisations end up assigning this task (or at least the review) to management in order to ensure profitability.

Thus, they lose many highly valuable hours that should be dedicated to managing or developing new business capabilities and possibilities.

Making Informed Decisions When budgeting, we must take into account the geometry, material, and technologies with which we will be performing the cutting or punching operation and, depending on this, all of the technological components for machining.

Sometimes it is feasible to use multiple blowtorches for the machining process. This decision will mean that the same production can be completed in half or even a quarter of the time, depending on whether we use 1, 2, 4 or even more blowtorches. Using blowtorches divides the machining time directly by the number of blowtorches that we use.

However, nesting the parts so that they can be machined with multiple blowtorches means that the consumption of material can be excessive, as it is not as efficient. Finding the point where the savings in time does not entail an overrun in

FEATURES Asia Pacific Metalworking Equipment News • September 2016

materials and where it does not make sense to use multiple blowtorches is fundamental when we are budgeting technologies such as plasma or oxy-fuel.

Another option that we can explore is whether we will be able to use common cutting technologies, which make it possible to reduce both material consumption and cutting time.

Occasionally, budgeted jobs are of such a magnitude that a detailed and in-depth analysis of a cost calculation may make sense, since it will enable us to adjust the prices more accurately.

Customised Systems What happens when the job is not big enough and the most likely outcome is that it must be cut together with other jobs in order to achieve efficiency once a machine is loaded with a certain material? Moreover, what happens if the client demands the same part or another part with similar specifications and my experience-based calculation system is giving me significantly different prices? Starting with the same base, employee time, machine, consumables, and raw material costs, along with a similar geometry, should we not achieve similar costs?

A customised system that is supported by a CAM software package is what may give us that dif ferentiation, when adjusting prices and having control over the margin that we will obtain with each order.

We will calculate the cost and from that the price. Using the same strategy, finally we will be able to perform the actual manufacturing, once the budget is accepted.

In its development of the Lantek Factory concept, Lantek has built a platform on which software systems use the same algorithms that were used in the generation of the machining and the budgeting. As a factory, the plant must have an accurate reflection in the budget and, if it is incorrect, it needs to analyse its costs. The solution is not to play with the cost to achieve a particular price for an order that ultimately may not be profitable.

On the contrary, the solution is to budget well in order to manufacture efficiently and maximise the margin.

“A customised system that is supported by a CAM software package is what may give us that differentiation�, says Asier Ortiz, CTO of Lantek

ENQUIRY NO 061

Efficient, versatile and easy to use Featuring a bar capacitiy of 25.4 mm diameter, the Tornos Swiss GT 26 is a Swiss-type lathe equipped with six linear axes and two C axes.

Versatility, high performance in value-added operations, and ability to work with or without a guide bush make the Swiss GT 26 a comprehensive bar turning solution.

Discover more : www.tornos.com

Your advanced machining solution

Swiss GT 26 We keep you turning

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EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • September 2016

METALEX VIETNAM 2016 A

Four-in-one event to mobilise the industry

Metalex Vietnam 2016 Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam October 6 – 8, 2016

s Vietnam’s international machining tools and metalworking solutions trade fair, METALEX Vietnam 2016 is set to open the stage with over 500 brands from 25 countries and 10,000 industry professionals. A total of seven national pavilions from China, India, Korea, Japan, Taiwan, Thailand and Singapore will be housed within the event.

Kasinee Phantteeranurak, Project Manager of Reed Tradex added that there will be industrialist outreach programmes, international roadshows, seminars, on-site features, business matchmaking service, business delegation packages for attendees to the occasion.

In addition, there are three other co-located exhibitions where the focus will be on precision and cost-efficiency. These include:

Editorial

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•

Business Alliance for Supporting Industry 2016

by Japan External Trade Organization (JETRO), Ho Chi Minh City Office and Investment & Trade Promotion (ITPC).

Hirot ak a Ya suzumi, t he chief representative of JETRO said: “With our support through the Business Alliance for

Supporting Industry, parts manufacturers can become effective suppliers that meets the requirements of Japanese and foreign enterprises. This, in turn, can influence investors’ decision to tap Vietnam’s booming manufacturing sector. Besides the latest machine tools and metalworking solutions, participants will be able to meet 15 Japanese and 50 Vietnamese auto and industrial-parts buyers and sellers”

• NEPCON Vietnam has returned to its fold with 200 brands from 20 countries and six international pavilions (China, Japan, Korea, Malaysia, Taiwan and Singapore). Offering a range of solutions for SMT line manufacturing, from feeding to testing, complete with activities for networking among electronics entrepreneurs.

• Industrial Components & Subcontracting Vietnam 2016, will of fer business oppor tunities for par ts manufacturers and subcontractors in the automotive, electronics, and industrial sectors.

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • September 2016

EuroBLECH:

THE NEW

GENERATION OF SHEET METAL WORKING

W

ith this year’s theme “The New Generation of Sheet Metal Working”, EuroBLECH 2016 will reflect the trend towards smart manufacturing in sheet metal working.

Visitors will find an extensive variety of products, from conventional systems to high-tech solutions, and gain an insight into advancements in the industry itself. From a trend towards digitalisation and smart manufacturing, a total of 1,410 exhibitors from 40 countries will be on-hand to display, demonstrate and present the latest and the best in modern sheet metal processing, The 24th International Sheet Metal Working Technology Exhibition, will cover a net exhibition space of 89,000 sq m across eight halls at the Hanover Exhibition Grounds, and increase floor space of 3 percent. Major exhibitor countries are

Germany, Italy, China, Turkey, the Netherlands, Switzerland, Spain and Austria.

Wit h today ’s produc t ion under going major changes, smar t manufac turing has now become an integral part of sheet metal working process. From automated production, machine-to-machine communication, intelligent process chains, data exchange along the entire production value chain paves the way for an optimised manufacturing process.

EuroBLECH reflects the prevailing development in production technology as it highlights the large variety of tailor-made solutions for optimising and modernising production processes. The exhibition profile includes sheet metal, semi-finished and finished products, welding and surface treatment, processing of hybrid structures, tools, quality control, CAD/CAM/CIM systems and R&D.

EuroBLECH 2016 Hanover, Germany October 25 – 29, 2016 Editorial

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ENQUIRY NO 105

HBE DYNAMIC The dynamic way of sawing

Behringer GmbH · 74912 Kirchardt Phone (0 72 66) 207-0 info@behringer.net www.behringer.net

Behringer and Behringer Eisele - world leading producers of high-performance band- and circular sawing systems offer a wide range for every kind of metal - inclunding stainless and special alloys.

The HBE Dynamic series by BEHRINGER provides performance, ease of use and energy efficiency.

Use the potential of innovative High-Performance Band- and Circular Saws of BEHRINGER and BEHRINGER EISELE. Experience machines and solutions for high precision and profitability.

True to the motto „RED HOT EFFICIENCY“.

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EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • September 2016

TMTS:

INTELLIGENT

MANUFACTURING AT WORK The fourth edition of the Taiwan International Machine Tool Show (TMTS) is set to be one of the biggest converging grounds for machine tool suppliers and buyers.

Editorial

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B

y global s tandards, Taiwan rank s seventh in the world for its machine tool industry, with a value of US$4 billion in 2015. It is ninth in the world in terms of machine tool consumption.

Looking at exports alone, it ranks fourth. A considerable 78 percent of machine tools production is exported.

As a major producing and consuming market for machine tools, Taiwan’s main production and consumption area are concentrated in the Greater Taichung area. Some 90 percent of its estimated 1,600 manufacturers are located in this area.

While statistics published by the Directorate General of Cus toms and Depar tment of Statistics and compiled by the Taiwan Machine Tool & Accessory Builders’ Association (TMBA) showed that the export value of machine tools in the first quarter of 2016 had fallen 20.3 percent year-on-year from the same period in 2015, the total export value in the first quarter this year was still pegged at a substantial US$636 million.

This year’s Taiwan International Machine Tool Show (TMTS) edition promises to be bigger than ever, with an eight percent increase in overall scale from the previous edition held in 2014.

The exhibition area is expected to span 78,000 sq m with 700 companies in more than 4,000

booths, showcasing an extensive selection of high precision machine tools, components, accessories, tools and automation equipment.

The organisers of the show expec t to attract over 75,000 visitors, with some 2,500 from overseas markets. Post-show orders are anticipated to be over US$250 million.

The theme for this year’s event: “Activating Intelligent Manufacturing: Heading Towards Industry 4.0” highlights the achievement of advanced products. These include: sensing technology, machine-to-machine (M2M), data driven decision making, robot-controlled manufacturing, human-robot collaboration, and intelligent control of flexible (custom) manufacturing system.

There will be four main pavilions, clustered under machine tools; components, parts and accessories; tool measurement s and test instruments; and overseas exhibitors.

FATEK Exhibitor Fatek, a division of Far East Machinery Group (Femco), markets and promotes CNC lathes, horizontal boring and milling machines, vertical lathes and wheel turning lathes under the brand name Femco.

Fatek will be introducing the BMC-110R1F, a horizontal boring and milling machine that comes with an auto-tool exchanging function to increase the flexibility and efficiency of processing and is specially designed for multiprocessing. The company is also showcasing the NVL-16M, a vertical lathe with a worktable diameter of 1,600mm that can hold up a load of up to 10,000kg. The machine’s maximum swing diameter is 2,000mm, while its turning diameter is 1,600mm. It is designed with a fully enclosed hydrostatic system with an artificial granite casting.

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • September 2016

GOODWAY MACHINE TOOLS GROUP Goodway Machine Tools Group (GMT) comprises Goodway Machine Corp, Awea Mechantronic Corp and Extron.

Goodway Machine focuses on the research and development of CNC turning centres that include multi-axis turning centres, Swiss turning centres, and horizontal and vertical turning centres.

Awea, on the other hand, produces bridge type machining centres, 5-face and 5-axis machining centres, vertical and horizontal machining centres, and boring mills.

Like Awea, Extron’s main products and services are also machining centres although the latter focuses on medium to small sized models while the former develops machines for the upper to intermediate market.

One of the main product highlights at this year ’s GMT booth is the GT W-1500Y turning centre. The machine combines a Y-axis rotary tool turret with Y-axis rotary g ang tooling , ser ving the main and sub spindle simultaneously to make it suitable for small high precision part turning, milling, offset drilling and small hole tapping to be completed all at once in the machine.

Fatek’s newest models include the NVL-16M vertical lathe and the BMC-110R1F horizontal boring and milling machine.

One of the product highlights by Goodway Machine Tools is the GTW-1500Y turning centre.

GSA TECHNOLOGY CNC rotary table and CNC turret producer GSA Technolog y (GSA+) is also among the exhibitors at TMTS 2016. Making appearances at international trade shows is one of the ways the company continues to stay relevant in the industr y while also increasing it s standing as a global manufacturer. To GSA+, the TMTS exhibition is an important avenue to reach out to potential clients in the region and beyond.

At this year’s edition, they will be showing their CNC direct drive rotary table DDR-170, which offers a diameter of 170mm.

HARTFORD Har tford, which specialises in machining centre manufac turing, research and development, is keen to showcase its latest 5-axis machining centre at the event. It will be unveiling its new 5A and 5BC series, and as these new machining centres are also AS9100 certified, they are highly suited for the aerospace industry.

The design of the 3-axis feed system in its 5A series removes thermal deformation while ensuring that positioning accuracy of the machine is stable.

C o n v e r s e l y, t h e 5B C d o ub le co lumn 5-axis machining centre has a 240-degree f ive a xes high rigidit y fork s wivel head

GSA Technology’s core products include CNC rotary tables.

Hartford’s new 5-axis machining centres, the 5A and 5BC series, will be showcased in this year’s TMTS.

s t ruc ture to deliver t he ver s at ilit y and cutting flexibility needed to handle large complex components machining.

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cross roller bearings and industrial robots.

The highlight of their products will be their robots. The company’s emphasis on intelligent automation has led them to develop an extensive line of industrial robots comprising delta robots, articulated robots, and single axis robots.

KEYARROW Machine components manufacturer Keyarrow specialises in products such as bellows, bellows with lamella, telescopic covers, chip conveyors and machine guard systems. The company sources for their raw material, mainly sheet metal, directly from a steel supplier in Taiwan.

Not only does this enable better quality control, it also allows them to translate the cost savings to their customers.

By supplying these related components, Keyarrow hopes to become a convenient onestop solution for their customers. This would essentially reduce the need to visit multiple manufacturers to source for components for the machines.

Expounding on this convenience, Stephie Wu, the section supervisor at Keyarrow said: “All customers need to do is to tell us that they are planning to develop a new machine and to tell us what they need. They will just have to give us their casting drawings and we will be able to design the machine for them; they don’t have to spend a lot of time communicating with different suppliers.”

Hiwin’s single axis robots utilise a motor driven ballscrew or a linear guideway system.

Among the products that Keyarrow will be displaying include their range of chip conveyors and filtering systems.

Litz is debuting its TM2500 turning and milling machine as well as displaying its popular Lu series of 5-axis machines

HIWIN TECHNOLOGIES CORP Also among the companies exhibiting this year is Hiwin Technologies Corp. The company, which focuses on the development and manufacturing of motion control and system technolog y products, also has an electronic subsidiary called Hiwin Mikrosystem. Hiwin manufactures servo motors, torque motors, linear motors, and linear actuators.

The firm intends to offer visitors a selection of their comprehensive collection of products. ranging from ball screws and linear guides to

LITZ HITECH CORP Litz Hitech Corp is a firm which is dedicated to the research and development and the manufacturing of CNC machining centres. Its core products include CNC vertical machining centres, 5-axis high precision machines, CNC turning centres, CNC horizontal milling centres, high-speed tapping centres, boring centres and ultrasonic applications.

The machines they have chosen to display are selected based on the concept of “doin-one”, to illustrate the multifunc tional capabilities of their products. They come with the capabilities of one-time loading and clamping, multi-faces production and process intensification—all in a unit.

Debuting at the show is Litz’s TM-2500, a turning and milling machine that is suitable for workpieces that are complex in shape and for the manufacturing of small yet precise medical and measuring devices that require high performance and accuracy. Litz also plans to showcase its popular Lu series of 5-axis machines, which are equipped with high-speed contour control in order to achieve the surface accuracy within the shortest machining time.

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • September 2016

POSA MACHINERY P o s a M a c hin e r y, w h o s e p r o du c t r an g e comprises over 100 spindle types including lathe spindles, machining centre spindles, grinder spindles , and boring machine spindles, has made concer ted ef for t s to research and develop intelligent spindle designs, with plans to further enhance the high-end technology of precision spindles.

In this respect, the company set up an intelligent spindle tes t lab in Taiwan in 2000. They also cooperated with Taiwan’s Feng Chia University and National Chinyi University of Technology to build a spindle stimulation lab.

One of their main product highlights, is the PHB series of boring and milling machine spindles, which have a standalone W-axis feed func tion for deep-hole boring and milling applications.

The series comes with a variety of sensor functions, providing more comprehensive spindle information to allow a bet ter understanding of the spindle situation.

TONGTAI MACHINE & TOOL CO A familiar face at TMTS is Tongtai Machine & Tool Co. The company provides turnkey solutions, and its main product of ferings include customised machine tools that are designed for the automotive and aerospace industries, machining centres, CNC lathes, and PCB drilling machines.

The company plans to exhibit six machines including the VTX-7 (CNC milling and tapping centre), VP-8 (vertical machining centre), VC610 (vertical machining centre for high-speed contouring), MT-2000 (CNC lathe), TD-2000Y (multi-tasking turning centre), and SH-4000P (horizontal machining centre). These will be demonstrated as NC+PC structures, and will be equipped with the Tong tai Intelligent Manufacturing System (TIMS).

T he T IM S do e s four main f unc t ions : manufac turing control, intelligent monitoring, ins trument s monitoring and workpiece monitoring. Using a specially developed computer program, it upgrades exis ting operating environment s and conduc t s monitoring for information and produc tion, making each operation more efficient.

YOU JI MACHINE INDUSTRIAL CO For You Ji Machine Industrial Co, the aerospace industry is top on the company’s industries to pursue. According to Jerry Wu, who is part of the sales team at You Ji, the aerospace industry, along with the automotive sector,

Posa’s PHB series of boring and milling machine spindles have a standalone W-axis feed function for deep-hole boring and milling applications.

Tongtai’s TD series of multi-tasking turning centres come with single power turret, 12-tool stations and a linear Y-axis to process milling functions.

You Ji’s VHL series of CNC vertical turning centres is designed to manufacture components for the aerospace industry.

is where most machine tool builders are focusing their attention on, mainly because of the burgeoning market potential. Because the components in aircraft are getting lighter and more intricate, equipment has to evolve to become more stable and produce with higher accurac y in order to create such components.

The company wants to promote machines that have the neces s ar y capabilities to produce parts for the aerospace industry at this year’s TMTS. One of which is the VHL series of CNC vertical turning centre with side head, specially designed machines for the aerospace components manufacturing sector.

The machines have a horizontal RAM to reach past wide diameters to turn machining areas that are difficult to access. The benefit is that the part does not have to be moved to another machine, which helps to reduce steps in the machining process.

Taiwan International Machine Tool Show Greater Taichung International Expo Centre (GTIEC) Taichung, Taiwan Nov 23 - 27, 2016

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THE GRAND

STEPPING UP TO GLOBAL STANDARDS

NOV 23-26, 2016 BITEC, BANGKOK, THAILAND +66 2686 7299

metalex@reedtradex.co.th

www.metalex.co.th

www.facebook.com/metalexpage

ENQUIRY NO 101

T

his 14th edition of MTA Vietnam played host to some 416 exhibitors from 24 countries. With a total of 13 international group pavilions of Germany, Japan, Korea (6), Singapore, Taiwan (3) and Thailand spread over some 11,000 sq m of exhibition space, this year’s event was the largest and most comprehensive to date.

The event recorded an attendance of 12,626 participants from some 24 countries. Singapore Exhibition Services, Deputy Chief, Vietnam Representative Office, B T Tee said: “We had some fantastic technical seminars and an OEM vendor quality information sharing session which saw an impressive industry turn out.”

Platform Into Market Making their debut into the Vietnamese market were DMG Mori Vietnam’s ecoMill 800V Vertical machining center; Trumpf’s TruMark 1000 Laser marking machine; GF Machining Solutions’ AgieCharmilles FORM 200 EDM machine; Guhring’s RT 100 Trigon drills; Awea Mechantronic’s FCV620 5 Axis machining center; and Optical Gaging’s Flash 200 measurement system, amongst the many others.

Vietnamese exhibitors including cutting tools and tooling system YG-1, found the event helpful a s a plat form to t ap into the countr y ’s manufac turing market . It s director, Lee Joon Ho said: “It also helps us connect with plenty of potential customers as well as gain more crucial insight about our competitors.”

The presence of big brand names and variety of machinery was a draw to many, resulting in successful sales and deals. “Sold @ MTA” signs were displayed on equipment like the Quick Turn Primos 150S from Yamazaki Mazak, Vertical Machining Center PS65 and Wire EDMs from Makino, AgieCharmilles FORM 200 from GF Machining Solutions, Sec tion Bending Machine RC MI130 from Taiwan Combitech.

Local exhibitors like ASADA Vietnam were also proudly displaying the “sold” signs across its pipe threading machine and pipe cutting machine. Other inked deals included CNC Machining Center from HAAS (Bao Son Tech), Welding/ Cutting Equipment from Weldtec, Cutting Machines Seibo M50B and Accutex from Vietnam Precision Industrial Company.

Workshops Galore T he four- day t r ade e ven t al s o o f fere d e duc a t ional pro g r amme s or g anis e d by local and international associations. The six technical workshops were attended by more than 520 delegates. Highlights of the

EVENTS & EXHIBITIONS Asia Pacific Metalworking Equipment News • September 2016

MTA VIETNAM 2016 Exhibition Review:

workshops included: Development cooperation in the integration process, Computerised production control systems for industrial manufac turing, and Material requirement planning in operations management.

Additionally, Samsung Electronics was on-board with a technical sharing session that was jointly co-ordinated by the Korea International Trade Association and the event organisers, Singapore Exhibition Services and VCCI Exhibition Service.

The nex t edition of MTA VIETNAM will be held from July 4 to 7, 2017 at the Saigon Exhibition and Convention Center, Ho Chi Minh City, Vietnam.

Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam July 5 – 8, 2016 Editorial

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PRODUCT FINDER Asia Pacific Metalworking Equipment News • September 2016

Faro: Design ScanArm Portable 3D Scanning Solution PLM

ABB Robotics: IRB 1660ID Compact Robot

ABB Robotics’ compact robot for arc welding and machine tending, the IRB 1660ID, is a versatile robot in the midsize class. Its Integrated DressPack makes it easier to programme and simulate predictable cable movements, creat ing a more compac t foot print while reducing maintenance costs by 50 percent thanks to reduced wear and tear on cables.

The IRB1660ID’s compact, hollow wrist is ideal for applications requiring work in tight spaces such as arc welding and machine tending. It can handle payloads up to 6 kg and has a reach of 1.55 m.

ENQUIRY NUMBER

6601

The Faro Design ScanArm is a portable 3D scanning s o lu t ion t ailor e d f or 3D modelling, reverse engineering and C AD-based design applications across the PLM process.

The device features a blue laser technology with fast scanning speed to deliver high-resolution point cloud data, and the ability to seamlessly scan challenging materials without the need for spray or targets.

The Design ScanArm is lightweight and manoeuvrable for convenient desktop mounting in the design studio or engineering lab. It features a simplified user interface that makes it easy to operate.

It is suitable for organisations who may have the need to manufacture parts without existing CAD models, develop aftermarket products that need to fit tightly with existing products, reverse engineer legacy parts for design changes or replacement, or leverage the ENQUIRY power of rapid prototyping.

NUMBER

6603

CNC Software: Mastercam 2017

Mastercam 2017 has a suite of programming tools for machining jobs.

It features a new ribbon interface, making it easier to find functions to complete tasks. The ribbon tabs group similar functions and displays them in order from simple to more complex.

The dynamic motion technology cuts machine time by as much as 75 percent. New micro lifts also use a lineof-sight approach to move the tool where it needs to go through unobstructed areas. This results in reposition moves that are more efficient and less complex.

In addition, the maximum stock engagement feature for select 3D high speed finishing toolpaths limit how deeply the cutter engages uncut material and protects smaller tools from taking too ENQUIRY heavy of a cut.

NUMBER

6602

Flexicon: Bulk Bag Lifting Frame With Arms

Flexicon bulk bag lifting frame with telescoping arms accommodates bulk bags produced in a range of sizes. It is available at up to a two-tonne capacity.

The telescoping arms can be adjusted using clevis pins and safety clips to different settings to accommodate bulk bags from 81 to 119 sq cm at the upper sew seam. This adjustability also allows the lifting frame to work safely with rectangular bags.

Available in carbon steel with durable industrial coatings or stainless steel, the adjustable frames are equipped with Flexicon’s Z-Clip strap channels that hold the straps securely while allowing quick insertion ENQUIRY and removal.

NUMBER

6604

PRODUCT FINDER Asia Pacific Metalworking Equipment News • September 2016

F Zimmermann: FZH400 5-Axis Horizontal Machining Centre

F Zimmermann’s first 5-axis horizont al machining centre is par ticularly useful for cost-effective machining of s t andard components for the aircraft industry. The machining centre has two features – the pallet handling and the travelling column.

T h e w a t e r- c o o l e d travelling column has a rigidity that increases with increa sing penetration into the material . This ensures a perfectly constant geometry along the Z axis as well as maximum rigidity in sensitive areas of the workpiece.

The machining centre also has a pallet handling system with an area for setting up pallets during machine time.

The handling system enables reliable transport of pallets wi t hou t s ag g ing , mak ing i t suitable for long pallets.

ENQUIRY

NUMBER

6605

Fluke: 279 FC Thermal Multimeter

The 279 FC Thermal Multimeter is the first test tool to integrate a full-featured true RMS (TRMS) digital multimeter (DMM) with a thermal camera in one device to speed troubleshooting.

The tool allows users to check for hot spot s in fuses, wires, insulators, connectors, splices, and switches with the imager and then troubleshoot and analyse issues with the DMM. The thermal multimeter features 15 electrical measurement functions including ac/dc voltage, resistance, continuity, capacitance, diode test, min/max, and frequency.

The wireless tool is part of Fluke Connect, a system of wireless test tools that can communicate via the Fluke Connect app or Fluke Connect Assets software, a cloudbased solution that gathers measurements to provide a comprehensive view of critical equipment status.

ENQUIRY

NUMBER

6606

ENQUIRY NO 000 049

Half Page Horizontal 171mm x 122mm

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PRODUCT FINDER Asia Pacific Metalworking Equipment News • September 2016

Jet Edge: Mid Rail Gantry Waterjet

Designed for industrial environments, Jet Edge’s Mid Rail Gantry waterjet is able to operate up to four abrasive jet or water-only waterjet cutting heads for increased productivity.

It holds +/- 0.001” linear positional accuracy per axis and +/- 0.001” repeatability (bi-directional). Moving elements are supported on THK linear ways, precision ball screws are directly coupled to servomotors, and critical motion components are protected with metal covers, brushes, labyrinth passages, lip seals, and high-volume low-pressure filtered air.

The mid rail gantr y separates the motion system from the waterjet cutting table, eliminating vibration.

Motion is controlled with the Aquavision Di industrial PC controller. It is available in a wide range of sizes, from 1500 mm x 1500 mm to 7300 ENQUIRY mm x 3900 mm.

NUMBER

6607

Nord Drivesystems: Helical Inline Gearboxes

Featuring high torsional rigidity, the new single-stage helical inline gearboxes from Nord Drivesystems are wellsuited for pumps, mixers and fans.

The produc t s are light weight , ef f icient and run smoothly. The nsd tupH surface treatment is optionally available to make the units more highly resistant to corrosion, par ticularly suitable for long-term use in aggressive ambient atmospheres.

IEC and NEMA motor mounting options as well as various shaft, bearing, and lubrication variants enable versatile customised configurations. The new products are available in five sizes.

ENQUIRY NUMBER

6609

Kemper: PlasmaFil Compact System

Kemper’s PlasmaFil compac t s ys tem protects users ag ains t f ine dus t during the cutting process. The extraction system for combustion and pla sma cut t ing applications has a longer service life than conventional systems thanks to its plate filter technology. The solution is suitable for medium to large amounts of dust. Hazardous substances are cleaned automatically.

The plate filter technology prevents individual filter elements from sticking. The full f ilter area is always available when polluted air enters the system during the down-flow process in which the polluted air is guided from top to bottom.

PlasmaFil Compact is available in six different versions - with an extraction performance from 2500 m³/h up to 11,000 m ³/h.

ENQUIRY NUMBER

6608

Open Mind: Hypermill Maxx Machining Package

The Hypermill Maxx Machining performance package by Open Mind, developers of CAM solutions for machine and controller-independent programming, offers strategies for roughing, finishing and drilling.

The package incorporates a 5-axis tangent machining of any arbitrary faces with conical barrel cutters. Features include the application of cutting tools that have radii of up to 1000mm. This allows the tool to conduct greater stepover distances that reduce tool paths while improving the theoretical roughness. The result is fast production times with optimum surface quality. In addition to this module, the package includes solutions ENQUIRY for roughing and drilling.

NUMBER

6610

PRODUCT FINDER Asia Pacific Metalworking Equipment News • September 2016

ENQUIRY NO 106

ARNO® Flip-Through Catalogues

Renishaw: Vionic Digital Incremental Encoder

Renishaw is adding to its optical encoder range with the launch of the Vionic series of digital incremental encoders.

Designed for demanding motion control applications, the encoders bring together the company’s filtering optics with a new custom interpolation and monitoring ASIC (ApplicationSpecific Integrated Circuit) that enhances dynamic signal processing and improves signal stability.

All necessary interpolation and digital signal processing are combined inside the read head to eliminate the need for additional interfaces.

The standard read head features a Sub-Divisional Error (SDE) of <±30 nm, a range of available resolutions from 5 µm to 20 nm, and speeds beyond 12 m/s. For most demanding per formance requirement s, there is the Vionicplus, with SDE of <±10 nm, low jitter to 1.6 nm RMS and resolutions from 100 nm ENQUIRY down to 2.5 nm.

NUMBER

6611

The ARNO® catalogues now also as flip-through catalogues With the new flip catalogues we offer our customers an even better service when searching for products. Whether you sit in front of your PC, a laptop, tablet or mobile phone, the flip catalogue will adjust to screen size. Use also the other advantages which the flip catalogues offers: • • • •

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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

106 Arno.indd 1

28/8/16 1:56 pm

Rofin: Manual Welding Laser

Performance Unlimited of fers a high degree of flexibility in parts handling and a closed, laser-safe working chamber. The laser workstation can be operated without cos t ly addit ional technic al precautions. Laser safety is provided by a combination of a mechanical rocker, which also doubles as a hand rest, and a laser-proof multilayer safety curtain.

The hand rest/mechanical rocker is made of wood and adapts to the operator’s working position. As an option, both side walls can be equipped with brush inserts which can be mounted horizontally and vertically, especially useful for welding on circumferential surfaces of long pieces or tubes of arbitrary lengths.

ENQUIRY NUMBER

6612

Schuler: LoadMaster Assist Robot Cell

LoadMaster loading systems from Schuler increase the productivity of turning and milling centres by automatically transporting parts to and from the machines. The LoadMaster Assist robot cell improves efficiency even further, as it also carries out tasks such as clamping of raw parts in the devices or cleaning and deburring of parts, thereby taking the load off from operators to focus on more important tasks.

The degree of automation of the machine allows lights-out shifts as well as continuous operation over the weekend. It can also remain in operation for several days without an operator having ENQUIRY to intervene.

NUMBER

6613

77

78

PRODUCT FINDER Asia Pacific Metalworking Equipment News • September 2016

TaeguTec: CFPR Tooling Solutions

Seco: Secomax PCBN Grades

Seco’s Secomax PCBN grades are designed for precision machining of hardened steel workpiece materials for continuous to heavy interrupted cuts.

The product range includes CH0550, CBN060K, CH2540 and CH3515 to cover a wide range of applications from ISO H05 to H35. The grades use a new bimodal substrate with coarser grains to maximise toughness and wear resistance for high productivity and long tool life in various machining conditions.

They are well suited for the automotive segment for components such as gears, shafts, rings, CV-joints and pinions that go in the gearbox and driveline of motorcycles, cars and trucks. Other application areas are in the mould and die and bearing segments. Each grade is available in common ISO insert geometries, ENQUIRY with or without wipers.

NUMBER

6614

C o mp o s i t e s l ike CFRP (carbon fibre reinforced plastic) are 70 percent lighter than steel and 40 percent lighter than aluminium alloy. The polycrystalline (PCD) milling inserts and diamond-coated solid carbide end mills and drills are suitable for the cutting conditions presented by difficult materials.

They have been designed to combine the specific grade, required geometry and high technology diamond coating for processing composite materials.

The PCD inser t s allow for fast speeds and feeds, while prevent ing prevent sur f ace delaminat ion of composite materials.

The end mills come in four types: RRFE for splitter routers, RCFE which is used on multi flute routers, RCOM for finishing applications, and low helix RDCF. The two grades in the CFRP line are TD830, with its ultra-fine diamond grit size PCD grade, and TTD610 that comes with an advanced nano ENQUIRY diamond coating.

NUMBER

6616

Sunnen: Automated Lapping Machine

S u n n e n ’ s S V L-2 1 1 5 automated lapping machine brings increased productivity and part consistency to what is traditionally a manual process. It provides single setup processing of hydraulic valves, sleeves, fuel system components and other parts that are prone to distortion when honed.

T h e w a l k a w a y s y s t e m u s e s a n in d e x t a b l e t o automatically lap and air gage bores throughout the cycle.

Gage readings are fed back to the control and the cycle is repeated until the parts are within spec.

It handles workpiece diameters from 6.5 to 20 mm and lengths up to 12 times the bore diameter, not exceeding 200 mm. Spindle speed range is 100 to 2000 rpm during lapping, but is capable of slow speeds for non-powered steps. Stroker speed is 0-350 SPM, with stroke length optimised to achieve a high ENQUIRY degree of cylindricity.

NUMBER

6615

Walter Tools: MC341 Supreme Milling Cutter

Walter’s MC341 Supreme milling cutter is a new solid carbide milling cutter for steel machining. The initial offering will have six dimensions in the diameter range of 6 to 20 mm.

The optimised cutting edge microgeometry ensures improved operational smoothness and a longer tool life.

Back cutting prevents whiteness marks from forming on the surface of the workpiece when the tool moves at the cutting depth.

The WK40TZ grade is applied in a special coating process, allowing for high abrasion resistance, smooth, homogenous surface layer hardiness and a modulus of elasticity, resulting in a considerably longer tool life.

The combination of both a high-performance coating and a proven geometry makes the MC341 Supreme suited for tasks requiring high cutting speeds when machining large batch sizes.

ENQUIRY NUMBER

6617

EXHIBITION PROGRAMMES 2016/2017 Asia Pacific Metalworking Equipment News • September 2016

SEPTEMBER 22 – 24

NOVEMBER 23 – 26

Myanmar Event Park

Bangkok International Trade & Exhibition Centre (BITEC)

Manufacturing Myanmar 2016

Shin Saw Pu Rd, Yangon, Myanmar Singapore Exhibition Services

Metalex Thailand 2016

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

OCTOBER 6–8

Metalex Vietnam 2016 Saigon Exhibition & Convention Center (SECC)

23 - 27

2017 JANUARY 18 – 20, 2017

NEPCON JAPAN 2017

Tokyo International Exhibition Center (Tokyo Big Sight) 3-21-1 Ariake, Koto-ku Tokyo 135-0063 Japan Reed Exhibitions Japan

JANUARY 26 – FEBRUARY 1, 2017

799 Nguyen Van Linh Parkway, District 7, Ho Chi Minh City, Vietnam Reed Tradex

Taiwan International Machine Tool Show (TMTS)

IMTEX 2017

25 – 27

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

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

Indometal 2016

Greater Taichung International Expo Center

Jakarta International Expo (JIExpo)

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 30 – DECEMBER 3

Manufacturing Indonesia 2016

Jakarta International Expo (JIExpo)

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

Bangalore International Exhibition Centre (BIEC)

MARCH 7 – 12, 2017 TIMTOS 2017

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

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

The Editor (APMEN)

Eastern Trade Media

12 Hoy Fatt Road, #03-01 Bryton House Singapore 159506 Email: eileenchan@epl.com.sg Tel: (65) 6379 2888 Fax: (65) 6379 2885

79

80

ADVERTISING INDEX Asia Pacific Metalworking Equipment News • September 2016

Advertiser ARNO WERKZEUGE S.E.A. PTE LTD

Page Number

Enquiry Number

77

106

BEHRINGER GMBH

67

105

BENIGN ENTERPRISE CO LTD

13

110

BYSTRONIC PTE LTD

03

102

COMPRO PRECISION MACHINERY CO LTD

75

049

FB/IFC

109

KENNAMETAL INC

BC

104

OKUMA CORPORATION

IBC

100

OPTICAL GAGING (S) PTE LTD

05

099

ISCAR LTD

REED TRADEX COMPANY (METALEX THAILAND 2016)

73

101

TAEGUTEC CO

09

107

TAIWAN EXTERNAL TRADE DEVELOPMENT COUNCIL (TAITRA/ TIMTOS 2017)

17

108

TAIWAN MACHINE TOOL AND ACCESSORY BUILDERS’ ASSOCIATION / TMTS 2016

15

088

TAIWAN TAKISAWA CO LTD

23

050

TORNOS TECHNOLOGIES ASIA LTD

65

061

TUNGALOY SINGAPORE (PTE) LTD

01

111

WALTER AG SINGAPORE PTE LTD

07

103

WIKUS SAGENFABRIK WILHELM H KULLMANN GMBH & CO KG

11

064

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ASIA PACIFIC METALWORKING

No. 6 2016

The Engineering Journal For Manufacturing,Automation & Quality Control

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Forging Rolling Die Casting Welding Turning Coil Forming

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

CNC Machining Milling Gear Cutting Grinding Stamping Shearing

❑ 321 ❑ 324 ❑ 301 ❑ 304 ❑ 307 ❑ 310

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

❑ 313 ❑ 316 ❑ 319 ❑ 322 ❑ 302 ❑ 305

Forging Rolling Die Casting Welding Turning Coil Forming

❑ 308 ❑ 311 ❑ 314 ❑ 317 ❑ 320 ❑ 323

Broaching Plastic Moulding Pressworking Automated Assembly Beading Electroplating

❑ 350 OTHERS (Please specify)

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

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

Dies & Moulds mfg.

Motor Vehicles Parts

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

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ENQUIRY NO 100

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

SEPT

EMBE

R 12-

17

EE US AND S !

E M CO ICAGO IN CH BOOT

H W-1

522

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 104