APMEN Sept 2012 by Eastern Trade Media

Medical Manufacturing Asia 2012 • SEPTEMBER 12 - 14, 2012 • SUNTEC, SINGAPORE September 2012

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Contents September 2012

Cutting Edge 26

John Nelson On High Speed Machining (HSM)â&#x20AC;Ś

The applications manager from Haas Automation tells Asia Pacific Metalworking Equipment News (APMEN) the finer points of HSM.

Speed Up With Mark Flommer A tool specialist from Walter shares his views on High Speed Machining (HSM).

Tech Talk 34

Sounding Out Ultrasonic Machining With Alexander Wolff With the influx of exotic materials, machinists must now turn to exotic machining techniques.

Ultrasonic Machining: Hardy & Sound

Titanium has been gaining popularity due to its strength to weight ratio. However, its hardiness has given rise to material characteristics that traditional machining processes are not equipped for. This has led to the adoption of newer methods such as ultrasonic machining. By Sherlyne Yong

Tanakawho, Kanagawa, Japan

Software & Metrology 44

The New Concept Of New?

Remanufacturing is a concept that can generate cost savings and be applied to the metalworking world.

Sheet Metalworking 46 Joining: A New Look

Augustine Quek looks at welding, how emerging technologies improve the inspection and the application of a once age-old technique.

metalworking equipment news September 2012

Bystronic and Trumpf have both played starring roles in bringing up the level of sheet metalworking in Vietnam and they share with Asia Pacific Metalworking Equipment News their thoughts on market sentiments in Vietnam. By Joson Ng

Besides welding, clinching is also an effective sheet metal joining technique in its own right.

The Pulse Of Sheet Metalworking In Vietnam

Joining: Not Sticking To Tradition

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Hall: 12, Stand: A30/B30

Contents September 2012

INDUSTRY FOCUS 54 The Energy Sector Go Big In More Ways Than One

In the energy sector, the size of the investment is large, and so is the size of parts produced. By Joson Ng

ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

Executive Zone 56

Thailand Outlook: All Systems Go

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Remanufacturing Singapore

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Singapore owed much of its economic growth to manufacturing. With cost being an issue more than ever, remanufacturing has become an attractive proposition as the country tries to position itself as the remanufacturing hub of Asia. By Joson Ng

Remanufacturing Takes Off In The Aviation Industry

Jonathan Lee, director, Korea & Southeast Asia Technology of Boeing Research & Technology spoke with Asia Pacific Metalworking Equipment News in this exclusive interview on how remanufacturing is impacting the aviation industry. By Joson Ng

Bringing Germany To Vietnam

A part of the exhibition hall was transformed into Germany during the MTA show in Ho Chi Minh City. By Joson Ng

More Italian Machine Tools In Asia Asia Pacific Metalworking Equipment News (APMEN) speaks with Luigi Galdabini, the newly elected president of the Italian machine tools, robots and automation manufacturers’ Association (UCIMU-Sistemi Per Produrre) in an exclusive to find out more on his take on Asia and Europe.

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Events & Exhibition 66 • Report From MTA Vietnam

Occupying more than 8,000 sq m of exhibition space, the number of international names at the show is perhaps a fair reflection of Vietnam’s reputation for being the place to be for the metalworking industry at the moment. By Joson Ng

• Makino Asia Launches The U3 In EDM Month

The company rolled out its EDM related technologies in the month of July. By Joson Ng

• Event Review: Manufacturing Expo • Event Preview: Metalex Vietnam 2012 • Event Preview: Medical Manufacturing Asia

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INDUSTRY Endorsements SPETA

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managing director Kenneth Tan editor Joson Ng

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Picking up an old object, refurnishing it, and giving it a new life — this may be a scene played out in countless back alleys or dumping grounds in these austere times. But to the surprise of many, this is also a frequent scenario in many state-of-the-art manufacturing facilities owned by multinationals. Uncertain times this may be, but adopting a seemingly frugal attitude towards raw material expenditure and manufacturing processes is not a knee jerk reaction to cutting cost. It is much more than that, it is something more calculated. The simple act of salvaging an old part and making it good as new is potentially a game changer. It is a concept that not only helps cut cost without compromising quality, it reduces production times and some might say, also helps save the world or at least starve off its impending doom for another precious few moments. (Not that it is on top of all companies’ agenda, but it makes for good corporate image.) They have even given the concept a name. It is called remanufacturing.

By no means a new concept, remanufacturing has roots in the US and Europe and is slowly attempting to make its way to the hearts of Asian manufacturers. While it may be slightly disconcerting for some in Asia to hear they are driving a new car or flying in a new plane with ‘old’ parts in them, the business case that remanufacturing presents may help them forgo the disdain normally afforded to things that are old. For remanufacturing to have the same impact in Asia as it did in Europe and the US, indoctrinating the minds with cold facts and blinding the hearts with warm bottom lines may be the way to go. While it remains to be seen if remanufacturing will be readily embraced in Asia, one thing is certain. For those eager to push this concept through, they will have to educate the population and change traditional mind-sets. A mammoth task no doubt, but the austere times could well be an unlikely ally in this battle of old and new and perhaps more succinctly put, the new concept of what is new.

graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow

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contributors John Nelson Mark Flommer Alexander Wolff Sherlyne Yong Augustine Quek Chainarong Limpkittisin Luigi Galdabini board of consultants Wäinö A Kaarto AB Sandvik Coromant Dr Moshe Goldberg ISCAR

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor. Printed in Singapore by Fabulous Printers Pte Ltd MICA (P) No. 098/06/2012 PPS 840/09/2012 (022818) ISSN 0129/5519

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Siemens Helps NASA Usher In A New Era In Space Exploration Copyright: NASA/JPL-Caltech

Farnborough, UK: NASA director Doug McCuistion and Siemens Industry CEO Siegfried Russwurm discussed the dawning of a new era of space exploration and the critical roles that NASA engineers and Siemens software technology play in helping to make it possible. The two companies referenced the landing of the latest Mars Rover Curiosity — designed by NASA’s Jet Propulsion Laboratory (JPL) using Siemens software — as a tangible example of how modern software technology is being employed to enhance competitiveness in the aerospace industry. Part of this ongoing transformation includes public-private partnerships and a constant drive to maximise productivity and shorten development times. “Curiosity is the most sophisticated rover ever sent to Mars, and will further enhance our understanding of the Red Planet, while paving the way for future human exploration,” said Mr McCuistion. JPL used product lifecycle management software from Siemens throughout the development process to digitally design, simulate and assemble the Rover before any physical prototypes were built. The software helped ensure all components would fit together, operate properly and withstand whatever environment the mission would require.

NuVista Technologies Partners Epicor Software Singapore: Epicor Software Corporation, a prov ider of business software solutions for manufacturing, distribution, retail and services organisations, has a new partner and reseller in NuVista Technologies. Vijay Bareja, MD, NuVista Technologies said: “We are pleased to be partnering with an ERP vendor known for its innovation and industry-specific solutions. Our expertise in the Singaporean engineering sector and our knowledge of the oil and gas, petrochemical and pharmaceutical industries will prove of great benefit to Epicor and their next-generation 8

metalworking equipment news September 2012

ERP solution.” Robin Chao, regional sales director, South Asia said: “NuVista Technologies’ diverse multiindustry experience, particularly within the engineering sector, will help to increase our exposure in targeted industries across Singapore. The company has a reputation for building long-term relationships with their customers, something we pride ourselves on at Epicor. NuVista Technologies’ client-first approach drew us towards the partnership and our similar approach provides a strong foundation for the partnership to grow in the future.”

National Instruments Expands R&D Operations In Penang Kuala Lumpur, Malaysia: National Instruments, a global technology company that began operations in Malaysia in 2009 with an US$80 million capital investment, announced plans for a significant expansion of the Research and Development (R&D) centre in Penang. Over the next five years, NI plans to recruit 250 engineers in the Penang R&D centre in electrical, mechanical and engineering management. Once completed, the expansion will make NI Penang the largest R&D centre for the company outside of its headquarters in Austin, Texas. The company provides engineers and scientists with software and hardware to meet any engineering challenge, including test, measurement, control and embedded design applications.

Dassault Systèmes & SMEDI To Open An R&D Centre Vélizy-Villacoublay, Fra nce & Shanghai, China: Dassault Systèmes and Shanghai Municipal Engineering Design Institute (Group) (SMEDI), a Chinese public engineering company, will jointly open an R&D centre in Shanghai, China , to develop indust r y solution experiences for civil engineering and infrastructure constr uction profe ssiona ls, based on Dassault Systèmes’ 3DExperience platform. Dedicated to bridge projects, water supply and wastewater treatment installations, roads, rail systems, as well as open and underground buildings, the centre will open in August 2012.

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SKF To Help Industries Reduce Carbon Emissions how businesses can better align with environmental regulations and trends in the region. It also announced plans to establish a solution factory — an integrated suite of facilities to help customers improve key business processes, while enhancing productivity and profitability — in Singapore, its Asia Pacific hub in the next 12 months. The BeyondZero portfolio is able to help customers measure and work towards energy savings in specific applications. The environmental improvements provided by the portfolio are validated through a life cycle assessment methodology developed by SKF sustainability engineers and results will be reviewed yearly by KPMG. In 2011, SKF estimated the BeyondZero portfolio represented US$345 million of sales. The goal is to achieve US$1.38 billion by 2016.

Singapore: SKF, a manufacturer of engineering solutions in bearings, seals, mechatronics, lubrication systems and services, held its first business press day in Singapore, introducing its BeyondZero portfolio which enables industries to reduce their environmental impact and sharing key insights on

Stratasys Reports Record Second Quarter Financial Results Minneapolis, US: Stratasys has announced a record second quarter financial results. The c o m p a n y r e p o r te d r e c o r d revenue of US$49.4 million for the second quarter ended June 30, 2012, a 31 percent increase from the US$37.8 million for the same period last year. System shipments totalled 776 units for the second quarter of 2012, compared to 735 units for the same period last year. The company reported revenue of US$94.4 million for the six-month period ended June 30, 2012, a 30 percent increase from the US$72.4 million for the same period last year. System shipments totalled 1,598 units for the six-month period of 2012, compared to 1,302 units for the same period last year.

organisational structure for the combined company, which has been communicated to all employees, and we are nearing the completion of an integration plan that we will initiate upon the closing of the transaction.” "We are pleased with our second quarter performance, and we are very excited about the future. The interest in our industry and the potential of our new products seems to be growing daily. We believe the combination of Stratasys and Objet will further leverage this potential by establishing a portfolio of products that can help our customers revolutionise t he way new pro duc t s a re designed and manufactured," Mr Crump concluded.

"Our results represent another impressive quarterly performance driven by the strong positive growth momentum we continue to observe in our systems and consumables revenue," said Scott Crump, chairman and CEO of Stratasys. "Strong sales of our higher-end Fortus systems helped drive a 33 percent increase in system revenue during the second quarter, while a 34 percent increase in consumable revenue resulted from our expanding installed base of systems." "We are making significant progress in preparing for our recently announced plan to combine with Objet, a privately held global company that manufactures 3D printers for rapid prototyping. We recently completed the

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Delcam Rated World’s Leading CAM Software Specialist Birmingham, UK: The latest NC Software Market Analysis Report from US analysts CIMdata shows that, in 2011, Delcam had the highest vendor revenues and received the highest enduser payments of all the CAM-centric companies. This means that the company has completed 12 years as the world’s leading specialist supplier of CAM software and services, having first achieved its global leadership in 2000, despite a number of mergers and acquisitions that have created some larger competitors. The company also continued to increase its market share. Its share of total end-user expenditure grew from under 6.7 percent in 2010 to just over seven percent in 2011. A further increase in market share to around 7.5 percent is predicted by CIMdata for Delcam in 2012. Total end-user spending on NC software and services is estimated by CIMdata to have grown by 10.2 percent in 2011, reflecting the rebound in manufacturing in most regions of the global economy. This established a new record for the industry, slightly ahead of 2008 levels. CIMdata projects that the growth in manufacturing will accelerate further in 2012 and so estimates that end-user spending for NC software will increase by 12.2 percent.

ABB Wins US$24 Million Power Orders For Aluminium Complex In Saudi Arabia Zurich, Switzerland: ABB has won orders worth around US$24 million from Ma’aden Aluminium Company (MAC) to execute a fasttrack transmission substation project in the Northeast of the country. The orders were booked in the second quarter. The company will design, engineer and supply a 380 kV outdoor gas-insulated switchgear substation at the Ras Al Khair power plant that will export

800 mW of power from the plant to the national transmission grid and feed a new aluminium smelter. The project is scheduled for completion within 10 months. “This substation will enhance power capacity and improve quality and reliability of supply for critical processes a nd susta ined productiv it y at the new aluminium plant,” said Oleg Aleinikov, head of A BB’s Substations business, OFFICIAL

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Embraer Releases Second Quarter 2012 Results Brasilia, Brazil: During the second quarter of 2012 (2Q12), Embraer delivered 35 jets to the commercial aviation market and 20 to the executive aviation market (17 light jets and three large jets). As a consequence, 2Q12 revenues reached US$1,717.3 million and gross margin grew from 22.4 percent in 2Q11 to 23.6 percent in 2Q12. The 2Q12 operating performance was strong and as a result EBIT and EBITDA margins reached 11.5 percent and 15.4 percent, respectively, for an accumulated EBIT and EBITDA margin of 9.9 percent and 14.4 percent, respectively, for the first semester of 2012. The company also achieved positive operating cash generation of US$189.1 million in 2Q12. a p a r t o f t h e c o m p a n y ’s Power Systems division. “Our advanced technologies, project ma nagement capability a nd extensive experience are key factors when executing such fasttrack projects.” The compa ny’s scope of supply includes high-voltage outdoor gas-insulated switchgear, communication and auxiliary systems and IEC 61850 compliant substation automation, control and protection. These containerised systems will be factory assembled and pre-commissioned to speed up on site installation.

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APEC: Promoting SME Cooperation In The Asia-Pacific Region St Petersburg, Russia: APEC Ministers Responsible for Small and Medium Enterprises (SMEs) issued a joint statement on promoting SME cooperation to deliver greater innovative growth in the AsiaPacific region. In the joint statement, APEC Ministers endorsed a new four-year strategic plan for guiding member economies’ on-going work to address critical issues and concerns pertaining to SME growth in the APEC region. APEC’s SME focus areas for 2013-2016 will include building management capability, entrepreneurship and innovation; financing and creating business environments, market access and internationalisation. Chairing the meeting was Vladimir Simonenko, deputy minister for economic development of the Russian Federation, who said that SMEs are a key to building state of the art economies but that they require particular attention in some areas to continue to foster an environment that allows innovative firms to flourish.

“We have to strengthen the operating environment for the SME sector and to bring down the barriers on the way of developing our SMEs. We have to share best practices,” said Mr Simonenko. “The burgeoning economic development of our region shall be carried out by the young generation,” he added. “This merits special focus on start-ups and youth entrepreneurship.” APEC Ministers and officials agreed that advancing SME cooperation for innovative growth can be enhanced through promoting start-ups which were identified as the most important stage of entrepreneurship. The consensus was that the development of start-ups facilitates job creation and increases international trade that benefits APEC economies. The SME sector accounts for roughly 90 percent of all businesses among APEC’s 21 member economies and employs nearly 60 percent of their workforce. SMEs furthermore account for over 50 percent of GDP in some APEC economies.

Hurco Marks First PDP

Bandung, Indonesia: Hurco has unveiled its largest machining centre, the DCX32, at the firstever Production Demonstration Pod (PDP) in Bandung, Indonesia. Boasting quality construction components such as high-grade 14

metalworking equipment news September 2012

cast iron, dual column bridge type construction, the machining centre provides rigidity and thermal stability to enhance large parts production for scalable, industryspecific solutions. The company’s WinMax control system continues

to reinforce the importance of a control on a large machining platform. To mark the occasion of the PDP launch, a golfing get-together was organised at the Bandung Giri Gahana Golf and Country Club, with over 40 guests in attendance. Lee Wai Yip, GM for Hurco Southeast Asia said: “The Hurco PDP represents a tripartite relationship comprising Hurco, the local distributor and the customer. It showcases the capabilities of Hurco machines and efficiencies achieved in an actual manufacturing environment, and we hope that our PDP will help make domestic customers’ purchasing decisions faster and more convenient.” The president director of PT Coppal Utama, Deni Faturochmat said: “The parts on display at the PDP event have become vital to PT Coppal’s production needs. Also, the Hurco PDP has answered both parties’ business objectives through mutual collaboration.” In all, the event underlined Hurco’s commitment to invest time and resources to grow its business in the strategically important Southeast Asia market.

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Singapore: MTA 2013 returns to Singapore Expo from April 9 to 12, 2013 together with MetrologyAsia2013, to serve industry verticals such as aerospace, electronics, energy, and oil & gas. With the demand for fully integrated capabilities in the most demanding manufacturing environments and sophisticated processes, it is important to provide fast, reliable and highest level of precision. The show gathers technologies and cost effective solutions while optimising resources to deliver consistent performance. Singapore Expo Singapore April 9 â&#x20AC;&#x201C; 12, 2013

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New Titanium Machining Record

Erlanger, US: Mag’s XTi profiler takes aerospace machining to a record altitude, demonstrating a 90-cubic-inch-per-minute metal removal rate in titanium. According to Chip Storie, the company’s executive VP, the three-axis, fivespindle machine is engineered and built for maximum dynamic stiffness and sustained power in titanium roughing operations to meet processing requirements. “ADI’s goal was to set a new standard for producing titanium parts at the lowest cost per piece, and the XTi Profiler provides that capability and more,” he emphasised. “This machine is equipped with a cross rail and robust spindle design that enable it to perform at this high rate on a sustained basis.”

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Frost & Sullivan: Higher Demand For Sophisticated Soldering Equipment From Medical & Automotive Verticals Mountain View, US: The rising popularity of smartphones and greater use of computing technology is spurring the sales of Surface Mount Technology (SMT) soldering equipment. Complicated design architecture and electronic components with smaller footprints require complex soldering techniques, opening up a plethora of opportunities for new soldering equipment with advanced features. An analysis from Frost & Sullivan, Global SMT Soldering Equipment Markets, finds that the market earned revenues of US$411.4 million in 2011 and estimates this to reach US$634.0 million in 2017. Meanwhile, the 'green' trend is creating a large market for products such as energy-efficient lighting ballasts and wind power. These technologies, in turn, are giving an advantage to the mature SMT soldering equipment market. "Mixed technology assemblies that include Surface Mount Devices (SMDs) and through-hole devices are driving sales of wave soldering equipment," said research analyst Nupur Sinha. "Oddform components, such as connectors and transformers, make wave soldering equipment a viable solution because both reflow and wave equipment are required for some lines." The market will receive an extra boost by higher investments in the automotive industry and the medical devices sector, especially with the ageing of the baby boomer generation. The market's potential has attracted a large number of competitors, fostering competition and consequently, price wars. Further, the influx of Chinese participants has lowered the profit margins of major participants. To offset price-based competition, participants have to distinguish their products through continuous innovation. Participants will seek higher investments in R&D to enable technical developments that meet customer and industry requirements.

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Rockwell Automation To Acquire Medium Voltage Drives Business Milwaukee, US: Rockwell Automation has agreed to purchase the assets of the medium voltage drives business of Harbin Jiuzhou Electric. The purchase price is RMB 530 million (US$83 million). Closing is expected in October. The acquisition strengthens Rockwell Automation's presence in the Asia-Pacific motor control market by adding capabilities in design, engineering and manufacturing of medium voltage drive products. It also provides access to grid-tie inverter technology. Jiuzhou has successfully served as Rockwell Automation's contract manufacturer for seven years, in addition to

its own customer base. "Jiuzhou's medium voltage drives business accelerates our emerging markets strategy," said Mike Laszkiewicz, VP, GM, Rockwell Automation power control business. "It will enhance our position in the critical Asia-Pacific region by strengthening capabilities in the mid- and higher-power rated product lines." "This acquisition demonstrates an evolution and commitment to growing the long-term customer relationships we established as a contract manufacturer for Rockwell Automation," said Dr Li Yin, Jiuzhou chairman of the board.

Kennametal Achieves Record 2012 Results

Latrobe, US: Kennametal has reported fiscal 2012 fullyear and fourth-quarter results, noting annual performance records in sales, profitability and returns. For fiscal 2012, the company reported Earnings per Diluted Share (EPS) of US$3.77 on US$2.7 billion in sales, compared with EPS of US$2.76 earned on US$2.4 billion in sales during the prior year. The currentyear earnings included acquisitionrelated dilution of US$0.09 per share, while the prior year comparison included restructuring and related charges of US$0.22 per share. For the fiscal fourth quarter, the company reported EPS of US$1.06 on US$739 million in sales, compared with EPS of US$1.04 on US$694 million in sales reported in the same period last year. The current-quarter results included acquisition-related dilution of US$0.02 per share, while the prior-year results included US$0.07 per share in restructuring and related charges. "Fiscal 2012 was an excellent year for Kennametal," said chairman, president and CEO Carlos Cardoso. "We outperformed our markets, set new records, and delivered 15 percent Earnings Before Interest and 18

metalworking equipment news September 2012

Haimer Inaugurates Technical Centre In Indonesia

Ta xe s (EBIT) margin and 15 percent return on invested capital, a full year ahead of schedule. This performance marks our second straight year of record profitability and returns. Consistent with our strategies, we established clear goals, realised ongoing improvements in operational efficiencies and successfully managed multiple headwinds." Mr Cardoso added: "The June quarter represented our 10th consecutive quarter of organic growth, reflecting successful execution of our strategies across the diverse markets and geographies we serve. In addition, we further increased sales and strengthened our core business as a result of the recent Stellite acquisition. Our company-specific initiatives continue to position Kennametal to achieve significant margin and earnings expansion. We remain committed to delivering shareowner value."

Alexander Tjioe (extreme left)

Indonesia: Haimer Asia Pacific recently opened a technical centre in Serpong, Indonesia on June 19, 2012. According to Alexander Tjioe, VP of the company, the centre will serve the region’s dealers as well as the customers. T he t hre e - stor ie d hig h facility played host to many dealers and customers from Indonesia and the region on the opening day. The VIP of the day, Andreas Haimer, came to Jakarta for the all-day event, which included short seminars a nd live demonstrations a ll day long. The technical centre currently houses five machines i n to t a l — t w o b a l a n c i n g machines and three shrink fit machines — with many tooling and grinding samples.

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All of the latest news available at: www.dmgmoriseiki.com DMG / MORI SEIKI South East Asia Pte Ltd No. 3 Tuas Link 1, Singapore 638584, Tel.: +65 66 60 66 88, Fax: +65 66 60 66 99, info@dmgmoriseiki.com, www.dmgmoriseiki.com

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Bombardier Announces Financial Results For The Second Quarter Montréal, Canada: Bombardier reported its financial results for the second quarter that ended on July 30, 2012. Revenues totalled US$4.2 billion, compared to US$4.7 billion for the corresponding period last fiscal year. Earnings before financing expense, financing income and income taxes (EBIT) totalled US$220 million, versus US$296 million last fiscal year. The EBIT margin was at 5.3 percent, compared to 6.2 percent last fiscal year. Net income for the second quarter ended June 30, 2012 amounted to US$182 million, compared to US$211 million for the corresponding period last fiscal year. “As anticipated, our revenues were lower in the second quarter. However, we expect revenues for the full year to be in line with last year’s,” said Pierre Beaudoin, president and CEO, Bombardier. “In transportation, revenues were lower due to the timing of completion of certain large contracts while major new orders are still in the start-up phase. We continued to see a good level of activity with US$2.9 billion of new orders in the quarter, especially in North America and Europe.” “In aerospace, revenues for the quarter were higher at US$2.3 billion compared to US$2.1 billion last year, with overall deliveries of 62 aircraft compared to 56. The level of new orders in business aircraft was quite strong and the momentum continues in commercial aircraft with 174 orders and other agreements announced so far this year. Our new aircraft development programs are achieving major milestones and both the CSeries and the Learjet 85 are driving towards entry into service by the end of 2013.” “Our very large backlog of US$56.9 billion positions us well for the years ahead and is a testament to the success of our overall portfolio of products,” concluded Mr Beaudoin.

Alcoa Helps Brunei Shell Petroleum Navigate Complex Offshore Drilling Well Seria, Brunei & New York, US: Alcoa’s oil & gas business has deployed 1,800 m of Aluminium Alloy Drill Pipe (AADP) in the Iron Duke Well C offshore Seria, Brunei. Alcoa partnered with Brunei Shell Petroleum (BSP), the largest oil and gas producer in Brunei, and Amrtur Corp, Alcoa's service partner, on the project. The well is considered among the most complex and deviated in the BSP system, with three ‘S’ curves and a long horizontal section of approximately 5,000 m, or about three miles long. It was drilled to a total depth of 7,485 m in about 60 m of water. “We are constantly challenged to push the drilling envelope further to maximise recovery and minimise cost,” said Shayne Dustin, BSP’s senior well engineer. “Light alloy pipe was listed as a performance opportunity to help us tackle some of the challenges we face with reduced cantilever loading, high torque, high drag, high sideforce, and casing wear concerns. Without a light alloy alternative, the furthest reaches of the platform would require a modification to well design.” Brunei Shell plans to use AADP on additional wells in Brunei. Shell is also planning a drilling project using AADP in New Zealand. 20

metalworking equipment news September 2012

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General Motors Sales In China Set July Record Shanghai, China: General Motors and its joint ventures sold a July record 199,503 vehicles in China, a 15.1 percent increase from last year’s previous high for the month. Shanghai GM’s sales in China rose 5.7 percent on an annual basis to a July record 97,064 units. SAICGM-Wuling’s sales reached 98,694 units, an all-time high for July and an increase of 26.6 percent year on year. FAW-GM’s sales were up 3.1 percent to 3,379 units. For the first seven months of 2012, sales by GM and its joint ventures in China were up 11.7 percent on an annual basis to 1,616,550 units, surpassing last year’s previous record for the period. Shanghai GM’s domestic sales grew 6.5 percent to 736,613 units. SAIC-GM-Wuling had domestic sales growth of 17.4 percent to 844,121 units. FAW-GM’s domestic sales were down 2.9 percent to 32,551 units.

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Nissan Reports Operating Profit Of JPY 120.7 Billion For Q1 FY12 Yo ko h a m a , J a p a n : N i s s a n Motor ha s a n nou nce d a n operating profit of JPY 120.7 billion (US$1.5 billion) for the first quarter of fiscal year 2012, ending March 31, 2013. Compa re d w it h t he first quarter of 2011, operating profit declined 20 percent due to the worsening foreign exchange impact of an abnormally strong yen, along with higher one-time selling costs, particularly in North America, linked to our product renewa l cycle. The general pricing environment was also less favourable than in the prior year period, during which vehicle prices were distorted by supply constraints caused by the March 2011 Japan earthquake and tsunami. Nissa n sold a tota l of 1, 210,0 0 0 ve h ic le s g lob a l ly i n t h e f i r s t qu a r te r o f t h e current fisca l ye a r, up 14.6 percent compa red w ith the sa me per iod in 2011.G loba l ma rket sha re i ncre a se d by 0.4 percentage points to 5.9 percent. “ N i s s a n h a s de l i ve re d a respectable performa nce in the first qua r ter de spite challenging macro - economic c o n d i t i o n s ,” s a i d N i s s a n pre side nt a nd C E O, C a rlo s Ghosn. “Our innovative models remain in high demand, with fur ther exciting vehicles due for launch. Against that b ac k g rou nd , we re ma i n on t r a c k to a c h i e v e o u r f u l l year forecasts.” Net revenue increased 2.6 percent to JPY 2.1364 trillion, while ordinary profit came to JPY 111.5 billion yen and net income totalled JPY 72.3 billion. 22

metalworking equipment news September 2012

Honda Hits 20 Million-Unit Mark In Thailand

Bangkok, Thailand: Thai Honda Manufacturing (Thai Honda), a Honda motorcycle and power products production company in Thailand, held a ceremony to commemorate the 20 million unit milestone in power products production that was reached on July 28th, at the production plant opened last August. T ha i Honda , which bega n power products production in 1987, achieved the 20 million-unit milestone only four years and nine months after achieving the 10 million-unit milestone in October 2007. Power products manufactured by Thai Honda are not only being sold in Thailand and the Asia Oceania region, but also exported to 80 countries worldwide including North America, Europe and Japan.

Business Statistics Negative Machine Tool Order Index For The Second Quarter Italy: During the second quarter of 2012, the machine tool order index, processed by the Studies Department of UCIMU-Sistemi Per Produrre has recorded a 20.6 percent decrease, when compared with the same period of last year, with an absolute total of 71.5 (2005=100). The result is due to the negative performance of manufacturers on both the domestic and the export markets. In particular, the domestic index of orders shows a 11.5 percent decrease when compared with the same period of the previous year, with an absolute total of 52.4. This result demonstrates the weakness of domestic demand, and what has now become a structural crisis of the Italian market, which has drastically reduced its levels of investments in production technology. As far as the export market is concerned, the index of orders shows a 23 percent down-turn when compared with the April-June 2011 period, bringing the absolute total down to 78.5. On the other hand, the 2012 forecast shows that at the end of the year, export sales will show a 12.3 percent increase, when compared with the closing figure of 2011. This figure, together with the export/production level result, which will reach 73.3 percent, shows the importance of the activities carried out by manufacturers abroad, and the impact of foreign demand on the business of Italian companies.

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Monthly Machine Tool Orders Up 3.6 Percent: JMTBA Japan: The total value of machine tool orders in June was JPY 108.7 billion (US$1.4 billion). It was an increase of 3.6 percent compared to May and marked the first month of growth in three months. This figure also showed a decrease of 15.5 percent compared to the same month of the previous year, with June posting the second consecutive month of year-onyear declines. Total orders showed a doubledigit year-on-year decline. This decline reflects the exceptional rebound posted in June last year, which marked the peak monthly amount of orders of this recovery phase. However, total orders have still exceeded JPY 100 billion for five consecutive months. Nonetheless, it is necessary to keep a close watch on the effects on the investment climate caused by instability in the European economy and the slowdown of China’s economy. Domestic orders rose by 6.8 percent over May, amounting to JPY 34.8 billion. This resulted in an increase, a first in three months. However, domestic orders decreased by 16.5 percent from the same month of the previous year, marking the first month of year-on-year decline in four months.

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Crude Steel Production Down Slightly

Brussels, Belgium: World crude steel production for the 62 countries reporting to the World Steel Association (worldsteel) was 128 million tonnes (Mt) in June 2012, a decrease of -0.1 percent compared to June 2011. World crude steel production in the first six months of 2012 was 766.9 Mt, a slight increase of 0.9 percent compared to the same period of 2011. North America and Asia showed an increase of 7.2 percent and 1.6 percent respectively (USA 8.4 percent and China 1.8 percent) while the EU (27) and South America recorded negative growth of -4.6 percent and -3.5 percent each. China’s crude steel production for June 2012 was 60.2 Mt, an increase of 0.6 percent compared to June 2011. Elsewhere in Asia, Japan produced 9.2 Mt of crude steel in June 2012, up by 3.5 percent compared to the same month last year. South Korea’s crude steel production for June 2012 was 5.9 Mt, an increase of 4.3 percent compared to June 2011. In the EU, Germany produced 3.7 Mt of crude steel in June 2012, a decrease of -4.0 percent on June 2011. Italy’s crude steel production for June 2012 was 2.4 Mt, down by -7.9 percent on June 2011. In June 2012, France produced 1.3 Mt of crude steel, down by -2.1 percent compared to June 2011. Spain’s crude steel production for June 2012 was 1.3 Mt, -8.8 percent lower than June 2011. Turkey’s crude steel production for June 2012 was 2.9 Mt, an increase of 4.0 percent compared to June 2011. The US produced 7.3 Mt of crude steel in June 2012, up by 0.8 percent on June 2011. Brazil’s crude steel production for June 2012 was 2.7 Mt, -8.5 percent lower than June 2011. The world crude steel capacity utilisation ratio for the 62 countries in June 2012 rose slightly to 80.4 percent from 79.7 percent in May 2012. Compared to June 2011, it was 2.5 percentage points lower.

Manufacturing Technology Orders Up 12.1 Percent McLea n, US: Manufacturing technolog y orders tota lled US$473.92 million according to AMT — The Association For Manufacturing Technology. This total, as reported by companies participating in the USMTO program, was up 14.5 percent from April and up 19.0 percent 24

metalworking equipment news September 2012

when compared with the total of US$398.10 million reported for May 2011. With a year-to-date total of US$2,235.37 million, 2012 is up 12.1 percent compared with 2011. “The latest USMTO figures indicate both sound health and continued expansion in durable goods manufacturing,” said AMT

president Douglas K Woods. “This is backed up by other key economic indicators, including an upward revision in housing starts and a strong showing in durable goods orders. While the latest PMI saw a slight dip, overall indications are that manufacturing will continue to lead the way in the general economy.”

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Edge

John Nelson On

High Speed Machining (HSM)

APMEN: Please define HSM and share with us what the advantages of HSM are? In your opinion, are there any competing technologies? John Nelson (JN): HSM means different things to different people. It can define a machining strategy that employs light depths of cut with high spindle speeds and high feedrates. In the case of Haas CNC milling machines, it also refers to our optional motion control algorithm. This algorithm is called â&#x20AC;&#x2DC;acceleration before interpolationâ&#x20AC;&#x2122; and takes advantage of full look-ahead to allow contouring at very high feedrates without risk of distortion to the programmed path. The algorithm determines the fastest feedrate one stroke can be blended to the next without stopping. The analogy I like to use is Formula One racing. If I climbed into an F1 car on a track, I would 26

metalworking equipment news September 2012

The applications manager from Haas Automation tells Asia Pacific Metalworking Equipment News (APMEN) the finer points of HSM. be horrible. I would not know where to brake and where to accelerate to get around the course efficiently. I would likely run off the course numerous times. A Formula One driver knows exactly when and where to accelerate and brake to get around the circuit in the fastest possible time. Our HSM algorithm is analysing the program ahead of time and determining exactly where it needs to slow to stay on the programmed path and where it can accelerate to the programmed speed. APMEN: What are the key differences between HSM and traditional machining? JN: I consider depth of cut to be the key difference. By taking shallower cuts, machining strategies can

take advantage of high spindle speeds. High spindle speeds, in turn, allow higher feedrates. Tooling manufacturers have worked closely with key customers and machine tool builders to develop tooling geometries and coatings that allow cutting tools to survive machining at much higher surface speeds and feedrates than traditional machining. APMEN: Please explain the key factors that impact the successful application of HSM with reference to the following points. a. Spindle Speed JN: Spindle speed is where HSM begins. Generally, higher spindle speed allows material to be removed faster. Selecting the correct spindle speed

CuttingEdge

starts with the material being cut. Then, it is a matter of determining the capability of the cutting tools used. b. Spindles For HSM JN: I typically consider a spindle capable of at least 7,500 rpm as being capable of HSM, but that is not always the case. Roughing harder or tougher materials with larger diameter cutting tools may only require 3,000 rpm. On the high speed end, 30,000 rpm is usually sufficient for most HSM applications. c. Cutting Tool Selection JN: Cutting tool selection is very important. The correct geometry and coating on the cutting tool for the material being cut will be the difference between success and failure. Most HSM strategies produce

more heat than traditional methods. Tools that excel in cutting aluminium are usually not effective cutting steels. I always recommend contacting tooling engineers to evaluate specific applications. d. Cutting Material Selection JN: Selecting a cutting material is usually not decided by the person developing an HSM cutting strategy. The material is one of the primary factors that affect decisions about how to approach a cutting strategy but selecting the material is usually left to the design engineer. e. Toolholder Balancing JN: Balancing toolholders is important for two primary reasons. The first is surface finish. An unbalanced toolholder running at high speeds produces

a vibration that will, in some way, adversely affect the surface finish. The second reason is the spindle itself. Running an unbalanced toolholder above 7,000 or 8,000 rpm is not good for the spindle bearings. Over time, this could cause premature spindle failure. f. Toolholders For HSM JN: Because balanced toolholders are so important for HSM applications, it is important that the holders be quality components. The actual process for balancing toolholders by either drilling to remove weight or adding lead to increase weight can be frustrating and time consuming. Many holders have balance rings that easily change the weight distribution to ease balancing. Shrink-fit toolholders are the ultimate toolholder for solid

ENQUIRY NO 139

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September 2012 metalworking equipment news

CuttingEdge

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Depth of cut is the key difference between HSM and traditional machining

They may seem like hurdles while you are in the starting blocks, but by the time the ‘race’ is over, they will feel like small bumps. John Nelson’s take on the ‘hurdles’ to implementing HSM

Material removal rates are higher using HSM strategies, bringing many benefits to job shops

carbide cutting tools, because of their excellent concentricity. The drawback is the added expense of buying the induction heating machine to get cutting tools in and out of the holders. APMEN: Some say HSM is the greatest breakthrough in metalworking since NC. Would you agree with that statement? JN: I do agree with this statement. I do not think I can make any argument to the contrary. APMEN: Have you encountered any resistance in adopting HSM, taking into account the ‘hurdles’ to implementation (eg: training operators, buying the right machines and using the correct software programs)? Does this open the door to retrofitting an older machine tool and giving it new HSM capabilities? JN: No. I would not use the term ‘hurdles’. Yes, there are new processes and procedures to being successful in implementing HSM 28

metalworking equipment news September 2012

strategies, but the rewards are so great in terms of productivity, that a shop owner cannot afford not to go on this route. To carry your ‘hurdle’ analogy further, they may seem like hurdles while you are in the starting blocks, but by the time the ‘race’ is over, they will feel like small bumps. APMEN: Many OEMs claim that HSM can help small die/ mould shops compete in the global marketplace by reducing cycle times and lead times and lowering labour costs with unattended machining.

Please share how exactly HSM accomplishes that? JN: Many studies have already proven that material removal rates are higher using HSM strategies. CAM software and verification programs are so good at optimising tool paths that NC programs can be run with confidence the first time through. You can have the computer tell you if a program is going to gouge a mould before you even cut a chip. MEN Enquiry No. 6001 Turn to page 80a or log on to www.equipment-news.com to enquire

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CuttingEdge

APMEN: In your opinion, what is the recipe for successful HSM? Mark Flommer (MF ), Milling Round Tools Specialist, Product Management: Due to the fact that HSM is a mixture of HPC and HSC, there are several reasons for successful HSM. First, you need an excellent tool concept with the latest well-engineered technology and co -ordinated geometries. Then you need very stable tool clamping and also a stable machine. It is very important to have a highly dynamic process and a dy na mic machine tool to ensure the continuation of high feedrates. Also important is adequate workpiece clamping, a nd not to forget the r ight m a c h i n i n g s t r a t e g y, l i k e trochoidal milling, and the right CAD/CAM software to reduce non-productive time. If these factors work efficiently together, you should be able to have a successful HSM.

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Speed Up

With Mark Flommer

APMEN: Please share with us the latest development in your company, with respect to HSM. MF: When it comes to the area of solid carbide milling, we have developed our high feed endmill called Protostar Flash. This is a tool with a specific geometry, at the front. Due to that geometry, the medium chip thickness will be reduced during the machining process, which allows customers to increase their feedrate. As we know, high feedrates are one key to having a good HSM process. Another tool is our Protoâ&#x20AC;˘max Ultra for machining 3D contours in highly hardened materials up to 70 HRC. These tools are available from diameter 0.1 up to 12 mm. So in this specific case (70HRC), we are able to give the customers a solution with the smallest tools. In the indexable cutting tools area, we have developed specific 30

metalworking equipment news September 2012

A tool specialist from Walter shares his views on High Speed Machining (HSM).

tools and grades. We used the same geometry design as explained for the Protostar Flash tool and transferred it to an indexable milling cutter. The Xtratec cutter F4030 is a high feed cutter starting from diameter 25 mm up to 100 mm. Two insert sizes allow depth of cut from 1 mm or 2 mm and feed per tooth up to 3.5 mm. For hard machining up to 63 HRC, we offer a carbide grade WHH15 for semi-finishing and finishing with round inserts or copy milling inserts. The substrate is micro grain, which produces

high stability of the cutting edge and a good resistance against abrasive wear as well as against plastic deformation. The PVD-TiAlN coating offers wear resistance and a good ply adhesion also on the sharpest geometries. APMEN: When designing a cutting tool for HSM, what are the main considerations? MF: It is always a mix of all. The macro and micro geometry has to be designed for specific applications. For example, in

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(Representative Office) Hexagon Metrology Asia Apcific Pte. Ltd. Tel: + 65 6463 6242 Fax: Fax : + 65 6463 8030 contact.sg@hexagonmetrology.com

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Hexagon Measurement Technologies Sdn. Bhd Tel: +603 5632 8900 Fax: +603 5632 8955 contact.my@hexagonmetrology.com

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(Hanoi Representative Office) Hexagon Metrology Asia Apcific Pte. Ltd. Tel: +84 4 3936 7935 Fax: +84 4 3936 8069 contact.vn@hexagonmetrology.com

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(Ho Chi Minh Representative Office) Hexagon Metrology Asia Apcific Pte. Ltd. Tel: +84 8 5445 6665 Fax: +84 8 5445 6660 contact.vn@hexagonmetrology.com

CuttingEdge

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When it comes to HSM, dynamic machines with higher spindle speeds are needed

APMEN: Have you developed special locking mechanisms for indexable inserts for HSM application, bearing in mind that they are running at higher rpm compared to traditional machining? MF: W hen it comes to high p e r for m a nce m ac h i n i n g o f aluminium integral parts for the aerospace industry, we offer a indexable milling cutter F3040 with a locking mechanism in the pocket seat. The tools are designed for high speed machining and high metal removal rate. They can run between 23,000 rpm and 36,500 rpm depending on the tool diameter and insert size. APMEN: Do you have any tips for machinists who are involved in HSM, on how to prolong tool life?

hard machining, it is better to have a more negative geometry, and the micro grain substrates and coating must be very heat resistant to run at a higher cutting speed. For soft materials, the geometries are more positive to reduce the cutting forces and avoid vibrations. APMEN: How do you design a cutting tool to achieve better heat resistance and surface finish? MF: First of all, you have to pay attention to the cutting grade, which means the combination of 32

metalworking equipment news September 2012

carbide substrate and coating. With grades like Tigertec silver, you reduce the friction and have a better behaviour against plastic deformation. Also, our TAS coating for the Proto â&#x20AC;˘max Ultra has good characteristics when it comes to thermal behaviour. This is a problem for HSM because of the high cutting speed. So, to achieve better heat and wear resistance, you have to use the right cutting material and of course, it is also very important to make the correct edge treatment.

MF: When it comes to HSM, you need, as mentioned, dynamic machines. These machines mostly have the possibility to achieve higher spindle speeds due to specially designed motor spindles. These spindles are very dynamic but also very sensitive. One solution to solve machining problems is to change the strategy from a higher cutting depth to a smaller cutting depth. Reduce for example, the depth of cut but also increase cutting speed and feed per tooth. With this solution, you will reduce the spindle load. Another solution is to do exactly the opposite with regard to the depth of cut. This is especially the solution for solid carbide endmills. Use a high cutting depth (use the total cutting length of the tool) and a very low cutting width. If you use this method, it becomes trochoidal milling. With this strategy, you will also reduce the spindle load. MEN Enquiry No. 6002 Turn to page 80a or log on to www.equipment-news.com to enquire

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Talk

Sounding Out Ultrasonic Machining With Alexander Wolff

APMEN: Ultrasonic machining is known for machining extremely hard and brittle materials. Explain from the working principle point of view, how this is achieved? Alexander Wolff, marketing for Ultrasonic & Lasertec, Sauer (a subsidiary of the Gildemeister gr oup) (AW): For example, Sauerâ&#x20AC;&#x2122;s Ultrasonic-HSK-Actuating System, based on a standardised HSK 32 / 40 / 63 / 100 tool holder (depending on the machine type), sees the company implementing the whole ultrasonic-generating elements inside this holder. The transfer of the ultrasonic high frequency (nominal frequency: 20 kHz) 34

metalworking equipment news September 2012

With the influx of exotic materials, machinists must now turn to exotic machining techniques. from the spindle to the HSK-tool holder has been realised via an inductive transmission system. When clamping the HSK-holder inside the spindle, the piezoceramic elements inside the holder get excited by the ultrasonic high frequency. Based on an inverse piezo effect, a controlled oscillation in longitudinal direction is generated. The result is a high-frequency vibration in the Âľm-range directly at the cutting edge of the diamondcoated tool. When the tool is expanding, the diamond grains get in contact with the material

â&#x20AC;&#x201D; smashing the material surface into very small particles. When the tool tightens, the internal coolant supply through the tool as well as the basic tool rotation of the spindle guarantees an optimal flushing of the removed material particles out of the working zone. Ultrasonic-grinding is the only existing technology to machine hard and brittle materials such as technical ceramics, glass, zerodur, sapphire or tungsten carbide in an economical way. Due to the fact that the ultrasonic vibration is overlaying the rotating tool, the

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smallest possible inside radius is therefore defined by the smallest possible tool diameter of 0.5 mm.

Ultrasonic machining allows the machining of hard and brittle materials in an economical way

APMEN: How challenging is it to find a stable oscillation frequency for new users given that there is no precedent?

ULTRASONIC - Oscillation

AW: Our machines are equipped with our easySonic-Control — a software feature. When clamping a new HSK-holder plus tool inside the spindle, the optimal individual working frequency is detected automatically in milliseconds. APMEN: Are there special arrangements required as far as workholding and toolholding are concerned?

tool is not continuously working on the material surface. This contact interruption leads to a reduction of the process forces — which itself results in reduced micro-damages, excellent surface finishes of Ra ≤ 0.2 µm, as well as a longer tool life.

quality as well as the resulting tool-life.

APMEN: How does the diamond-coated cutting tool play a role in ultrasonic machining?

- It allows economical machining of materials such as silicon nitride, SiC, sapphire and tungsten carbide in the best possible quality

AW: Apart from the optimal ultrasonic parametrisation of frequency and amplitude and the given machine facts, I think that the tool specification plays a major role for the whole course of the process. Choosing the wrong grain size, an improper diamond grain concentration or just an unsuitable binding system in combination with a special material — all these factors can influence the machining process regarding the final material 36

metalworking equipment news September 2012

APMEN: What are the advantages and limitations of ultrasonic machining? AW: The advantages are:

- It reduces the process forces, which results in excellent surface finishes, reduced microcracking and longer tool-life - It causes a ‘self-sharpeningeffect’ on the diamond tools - It allows the machining of thin walls < 1 mm The technology is however limited by its usage of rotationsymmetric grinding tools. The

AW: Basically, there is no significant difference in the kind of workholding required for this technology compared to the conventional milling technology. We are also using standardised mechanical or zero-point-clamping systems. Sometimes you have to think about how to fix the part to the fixture (especially when machining glass materials). We often use wax, glue or even vacuum devices to fix the work-piece to the fixture. APMEN: Do you see ultrasonic machining gaining popularity in Asia especially with more micro machining and ceramics parts coming to the fore? AW: Yes, so far we have more than 150 installed machines in Asia that are used in several different market segments such as optical industry, pump and fittings industry, dental and even machine engineering. The latest trend actually shows that the main focus is on large work-pieces made from glass and even ceramics. MEN Enquiry No. 6101 Turn to page 80a or log on to www.equipment-news.com to enquire

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Ultrasonic Machining: Tanakawho, Kanagawa, Japan

Hardy

&Sound

Titanium has been gaining popularity due to a high strength to weight ratio. However, its hardiness has given rise to machining characteristics that traditional machining processes are not equipped for. This has led to the adoption of newer methods such as ultrasonic machining. By Sherlyne Yong

n t he per petua l race of building products that are increasingly efficient and durable, eng ineers have taken to using materials with high strength to weigh ratio such as titanium. The result of this development is a parallel shift in machining methods, as newer techniques are used to handle different sets of material characteristics. One such instance is ultrasonic machining. Machining Titanium For starters, titanium maintains 38

metalworking equipment news September 2012

its strength and stiffness in elevated temperatures, and is corrosion and oxidation resistant. However, the material is not suited for conventional machining methods for the ver y sa me reasons. Instead, manufacturers are using untraditional processes like Electric Discharge Machining ( EDM ) and laser machining. Nonethele ss, the se newer methods are not perfect and each has their limitations. In addition, titanium alloys have poor thermal conductivity a nd he at dissipat ion. T h is

generates high temperatures between the interface of the tool and work piece, resulting in hastened tool wear and a change in structural quality. As the material is chemically reactive to high temperatures, it could cause the tool to dissolve, heightening the cha nce s of chipping and tool failure. To top it off, titanium has a low elastic modulus, which makes it harder to machine. Although not impossible to machine with, the short tool life created and potential need for secondary processes has racked up manufacturing costs. The Ultrasonic Alternative All is not lost, however. A solution ca n be found in U ltra sonic Machining ( USM ), which is typically used for hard and brittle materials. It is suitable for fragile materials such as glass, ceramics, silicon, and materials that are harder than HRC 40. This method makes use of high frequency mechanical vibrations, together with a shaped tool and abrasive slurry to create eroded holes in machined parts. As a result, it does not require conductivity and eliminates all heat-induced issues due to the lack of contact between tool and work piece. Consequently, materials are not altered chemically or metallurgically. Particularly for titanium and its alloys, USM creates better heat dissipation with the high volume of fluid used. The slurry doubles up as an abrasive and a cooling agent, while helping to transfer heat and reduce cutting forces between the tool and work piece at the same time. It provides a smooth surface quality and enables components to be machined without the need for a finishing process. USM has therefore been touted as an economical option for machining these materials, even though it has low material removal rates.

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also made available generators that adjust their frequency to match the resonance of the tool and horn. Apart from being able to accommodate small margins of error, this flexibility reduces heat generation and the loss of acoustic energy.

USM has evolved in time to match new machining characteristics.

Damian Searles, Brisbane, Australia

Electrical To Mechanical In USM, a power generator with power ratings from 50 W to 3 kW produces high frequency electrical energy that is later conver te d into me cha n ica l vibrations through the use of a transducer. Consequently, the vibrations are amplified through a horn and passed to the tool, both of which are directly connected to each other. As this happens, the tool starts vibrating along its axis, most often at a frequency of more than 20 kHz. Meanwhile, a continuous flow of slurry is supplied around the cutting area, which comprises of abrasive grains, most commonly silicon carbide, alumina or boron carbide suspended in water or oil. As the tool vibrates, the abrasive grains are being pounded against the work piece, creating small fractures on the surface that eventually lead to chipping. The tool is typically made of a ductile material that absorbs the impact. Because material removal is solely based on the impact of abrasive grits on the surface, there is less stress and USM 40

metalworking equipment news September 2012

is therefore thought to be a gentler process as compared to alternative machining methods. Components machined this way have a smoother surface as a result, and also perform better in downstream machining processes. All Charged Up The power source comes from a sine wave generator that produces high frequency electrical power after converting it from low frequency signals (from 60 Hz to approximately 20 kHz). Most times, the generator and tool/horn set up are interdependent, so as to achieve optimum resonance. The general rule of thumb for this relationship is: the greater the power supplied, the larger the cutting area of the tool will be. Subsequently, a transducer, which can be either piezoelectric or magnetostrictive, is used to transform electrical power into mechanical motion. Most machines now use the former as it has a more efficient conversion rate of up to 96 percent. In addition, they do not require water-cooling. Recent developments have

Amplified Effects When it comes to supporting roles, the tool holder is an important accessory to the entire process. Also known as the horn, it comes in various materials and sizes, ranging from being cylindrical, exponential, tapered or stepped, depending on its application. Most times, the horn transfers the ultrasonic waves to the tool while amplifying the vibrations to the necessary amplitude, sometimes as much as 600 percent. Non-amplifying horns are cylindrical in shape, whereas amplifying ones are modified at the cross-section and tend to widen out towards the end. The tool holder should be made of metals that have high fatigue strength, resistant to wear, and low acoustic losses. It is commonly made with materials like tungsten carbide, steel, monel, and recently, polycrystalline diamond. It can be attached to the tool either through soldering, brazing or screw fittings. Conventionally, threaded joints are used because it facilitates easy tool changing. However, it is also more prone to self-loosening and fatigue failure. Tools & Materials Tools on the other hand, can be made in complicated shapes and are typically made of materials that are stronger and less brittle than the work piece. It is also one of the main parameters affecting material removal rate, depending on what it is made of. For instance, researchers have found high carbon steel to produce better results when it comes to machining titanium. This is due to the greater hardness that it has

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Titanium is favoured in aircrafts, airframes and jet engines due to its reputation as a structurally efficient metal that is lightweight but strong.

Jaakko Hakulinen, Edinburgh, UK

over titanium, as using a harder tool creates more indentation in the work piece. However, size matters as well. Bigger tools are less efficient as the greater mass absorbs more sonic energy, while longer ones might cause overstressing. To o l we a r r a te s h o l d a perennial relevance in USM, as they are directly proportional to material removal rates. While materials like cement carbide are harder, they are also more brittle and wear out faster. Contrastingly, titanium as a tool lasts longer as it has a higher tolerance for deformation before fracturing. Contrary to normal situations, titanium tools have been found to produce better surface quality with an increase in material removal rates (tested with abrasives with grit sizes of 220 and 500). Slurry Slurry composition is the main factor responsible for surface coarseness of the work piece. Mostly made up of abrasive grits suspended in a fluid, the size and 42

metalworking equipment news September 2012

amount of grits determine the surface finish intended on the material. Doubling up as a cooling agent, it is also important for the fluid to possess low viscosity, good wetting properties and high thermal conductivity. Grit sizes for the slurry can range from 100 to 800, the selection of which depends on the type and hardness of material machined, the desired material removal rate and surface finish. For instance, coarser grains are utilised for greater removal of material. They provide more impact and remove larger bits as a result. While concentrations of grits typically range from 20 to 60 percent, the best results have been achieved with a concentration of about 30 percent. In terms of material, silicon carbide has been found to have 50 to 60 percent more cutting power than alumina. Generally, the coarser the grits, the rougher the surface will be as well. As such, smaller grits are used for a finer surface finish, while those with a greater focus on removing material would use larger grits. Researchers

have also found that USM produces a better surface finishing than most other processes used when machining titanium. Rotary Ultrasonic Machining A imed as a development from USM, Rotary Ultrasonic Machining (RUM) is an alternative, hybrid method that combines diamond grinding and USM. Working mostly with the same principles, RUM does away with the slurry. Instead, abrasive grains are bonded to the tool, which rotate as well as vibrate in a direction perpendicular to the work piece. Meanwhile, coolants are pumped through the drill to flush away debris and maintain temperatures. The variations in RUM have also led to benefits such as improved accuracy, faster machining rates (6 to 10 times higher tha n conventiona l grinding), low tool pressure, as well as the ability to drill deep and small holes. This is especially useful as the drilling of small holes has been one of the most common concerns in machining tougher materials. However, the main difference in RUM from USM is the rotational motion. With this addition, there is a much faster material removal rate, which increases together with rotational speed. One other improvement is also that of tool wear rate, as the abrasive grits are not bouncing back and forth between the tool and work piece. W it h a n e ve r- i nc re a si n g demand for parts that are lighter and stronger, the manufacturing industry is seeing the rise of materials that are harder to machine. In tandem with this phenomenon, there is a greater adoption of non - traditiona l machining processes such as USM, which has evolved in time to match these new machining characteristics. MEN Enquiry No. 6102 Turn to page 80a or log on to www.equipment-news.com to enquire

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Metrology

The

New Concept Of New? Remanufacturing is a concept that can generate cost savings and be applied to the metalworking world.

Rajiv Ghatikar

emanufacturing is a much talked about process these days and its advantages have been thoroughly analysed and debated. It has, against all odds, found a unique place between a good business case and preserving our fragile environment. This has given adopters reasons to shout about their improving bottom line and their equally impressive ascent in moral standings. For a solutions provider like Siemens Industry Software however, things are not as clear-cut compared to a parts manufacturer. For them, remanufacturing becomes something a little more abstract, it deviates from the financial and environmental concerns a typical manufacturer has. Remanufacturing for a solutions provider is, documenting the life cycle of a part in its previous life, resetting it and

metalworking equipment news September 2012

then continuing to document its new life. Said Rajiv Ghatikar, VP and GM of Siemens Industry Software (ASEAN/ Australasia): “You learn from a remanufactured part what happened from the actual production. While making sure the initial design is maintained, you strengthen it and put it back to production mode again. The advantage is you are not starting from scratch and I think it is a great opportunity for the world to remanufacture rather than dispose. In addition, I think this concept will apply very nicely to the metalworking world.” Is Asia Ready? Remanufacturing is popular in the US and according to the Automotive Parts Remanufacturers Association (APRA), it has a firm grounding in Europe as well.

The association has in fact just celebrated 25 years in Europe by holding an educational symposium in Krakow, Poland, which attracted over 150 key personnel in the remanufacturing industry from all parts of the world. With the remanufacturing bandwagon well and truly rolling along in the US and Europe, Asia is seen as playing catch up although there are signs that Asia is beginning to take remanufacturing seriously. For instance, Singapore recently established an Advanced Remanufacturing & Technology Centre (ARTC), which is touted as the ‘first-of-its-kind’. Mr Ghatikar believes remanufacturing will sell itself in Asia because the facts and figures highlight the benefits the technology will bring. “I do not think there is going to be a problem selling the concept in Asia. I think people are looking to save cost and reduce waste in production, so they would prefer to remanufacture rather than start from scratch. In addition, there are plenty of reasons to do so because the cost savings are quite significant,” he said. His statement was supported by Dr Lim Ser Yong, CEO of A R TC , wh ic h w i l l le ad t he rema nufacturing drive in Singapore. I n h i s p re s e nt a t i o n , h e used an example of worm gear remanufacturing to prove the benefits of the process. In terms of productivity, remanufacturing required four processes that took 7.7 hours compared to 35 processes amounting to 28.3 hours when manufacturing the worm gear from scratch. There were no materials consumed in remanufacturing, compared to the 8.67 kg (when manufactured from scratch). Energy consumption also showed a reduction of 2,000 kW. Identity Issue Although the worm gear example

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put remanufacturing in a good light, Mr Ghatikar sounded a warning — remanufacturing is not without its unique set of challenges. He said: “The challenge to remanufacturing is, no part that comes back has the exact same problem with another part you have looked at before, making the process very adaptive. The other challenge is developing the expertise to identify the parts for remanufacturing. This adaptive technology is something we, as a software vendor are working on. You have to have the skills needed and you must have the right process to manage it. Otherwise, you end up fixing what you think is wrong and create problems somewhere else.” The Moral Vs Money Debate For the romantics, remanufacturing

helps make certain industries more sustainable, promising a greener future for the next generation. For the pragmatist, the cost savings are significant, fueling hopes of a better next financial quarter. Mr Ghatikar took a philosophical view on this issue. He said: “I believe the bottom line will come about naturally if you are successful in what you do. When you produce the right product, there will be commercial reasons to keep doing it. A good and clean environment is also a byproduct of good and smart business decisions.” The financial side of remanufacturing is an attractive proposition for the company, but Mr Ghatikar made it clear that they are in it for the long run. He said: “Remanufacturing and its green impact are all very well, but at the end of the day, we are a

company and we exist to make a profit. This is what we ultimately want to achieve but this is not our short-term goal. The company’s philosophy is to be involved for the long term.” Is It New Or Old? Beneath the benefits and positive impact remanufacturing brings to the industry, a lingering question remains; are remanufactured parts new or old? Not prepared to sit on the fence, he concluded: “Remanufactured parts are not new, I think they are better than new because they have survived actual production use, and now they have come back to be touched up in order to go back into action again. It is a paradigm shift that people have to accept.” MEN Enquiry No. 6201 Turn to page 80a or log on to www.equipment-news.com to enquire

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MetalWorking

Joining:

Augustine Quek looks at welding, how emerging technologies improve the inspection and the application of a once age-old technique.

etal joining is essential to all kinds of metalwork. There are three main methods for permanently joining metals. They are welding, brazing and soldering. The earliest known item to exhibit metallic joining was a sword found in Ur (in modern day Iraq), made by the Sumerians using hard soldering during the Bronze Age (3600 - 1200 BCE). However, it was not until the late 1800s that gas welding and cutting was developed. Today, other forms of welding have emerged. They include Shielded Metal Arc Welding (SMAW),

metalworking equipment news September 2012

Guru_1234, India

New Look

Submerged Arc Welding (SAW), Metal Inert Gas welding (MIG, GMAW), Tungsten Inert Gas arc welding (TIG, GTAW), Electroslag welding (ESW), Plasma Arc Welding (PAW), Resistance Welding (RW), and Gas Welding (GW), Using Laser Laser welding is one of the latest welding processes that are also commonly used. Laser’s continuous stream of highly concentrated energy is a powerful heat source. It has been used for cutting metals and non-metals alike, as straight beams or pulses. A more advanced form of

welding combines the principles of laser beam welding and arc welding, called hybrid laser welding. This means that a laser beam and an electrical arc act simultaneously in one welding zone, influencing and supporting each other. The laser beam offers deeper welds in one pass, whereas the arc energy is used to increase welding speed and to fill the fit-up defects between the pieces to be joined. Used since the 1970s, there are now three main types of hybrid welding process, depending on the arc used: TIG, plasma arc or MIG augmented laser welding. Hybrid laser welding is characterised by very narrow, deep welds that are produced at high speeds. Another recent example of hybrid laser welding is ESAB’s Hybrid Laser Arc Welding (HLAW) system. The Hybrio range of equipment uses an automated welding processes that combine laser welding and Gas Metal Arc Welding (GMAW). Hybrio uses GMAW along with the laser. For tightly controlled gaps, the system adds filler metal. Using GMAW also enables users to add filler metal to adjust the weld’s metallurgical properties and create beads and fillets, while the lower cooling rate reduces weld hardness. The UK supplier of welding and cutting solutions claims it requires 80 to 90 percent less heat input and less distortion, and is tolerant of variations in joint gap. As accurate real-time weld process information and control is vital to quality control; yield, productivity and weld monitoring have improved considerably. In welding, basic process control includes the monitoring of input parameters like: number of welds, duration of each weld, real-time welding inputs like amperage, voltage, wire feed speed, and gas flow. These parameters can be monitored using a large variety of sensors available on the market, with weld quality software programs. Therefore, according to ESAB,

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a key feature of the Hybrio process is the MPC, a PC-based, real-time control system that manages a variety of critical components. The MPC monitors the weld joint, the operating environment and all of the process-related subsystems. It also uses pre-seam inspection data to guide the process and to predict the parameters needed to achieve the required weld profile and quality. By monitoring actual welding conditions and finished weld geometry on the fly, the system is able to fine tune the process parameters and maintain consistent weld quality and weld geometry along the length of the weld. Making Sure It Sticks However, not all welding processes require sophisticated control monitoring. In fact, simpler weld measurements are commonly used, with the latest portable systems capable of measuring more weld parameters. Most weld monitors (or checkers) on the market today can measure pulse frequency, power input, current, voltage, force and displacement. They can also display graphically the waveforms of the measure parameters. Some can also do simple waveform analysis and printer output as an option. Examples include the Portable Monitor from WeldComputer Corporation, the MM series from Miyachi Unitek, and the ARCAgent series from Impact Engineering. Therefore, all production welding processes, large or small, can benefit from a certain degree of process control and monitoring.

A recent innovation is Kistler Instrumentsâ&#x20AC;&#x2122; 5825A2 welding and fastening monitor, a battery powered portable measuring system for analysing joining methods such as spot welding, clinching and riveting. The analyser plots electrode force against time during the welding process, and measures and records the force-versustime and force-versus-distance curve for post-cycle evaluation directly on production machines. By switching modes and using suitable inserts in the welding force calibration transmitter, the instrument can also record and analyse the clinching or riveting force curve. Laser weld monitoring is another innovation. Servo-Robot, a manufacturer of laser vision systems, has a several systems for real-time joint tracking of joining processes. An example is its Auto-Trac laser-vision seam-tracking system, which features a digital high-speed laser camera head with a large field of view and high resolution that handle products ranging from thin sheet metal to 50 mm-thick steel. Weld inspections can be done in real time with a camera located behind the welding torch or by using a second pass scan. It also features real-time adaptation to part welding for joint variability. The controller can run two cameras to simultaneously track the joint and inspect the weld. Lastly, Auto-Trac can be installed onto new equipment or retrofitted to existing welders that are manually operated.

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Laser welding is one of the latest welding processes that is commonly used.

September 2012 metalworking equipment news

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Laser applications are fast becoming popular in sheet metalworking

Training Equipment The use of virtual reality for welding training, while no longer new, has improved over the years. Training on a virtual reality machine is safer, as the student is placed in a computergenerated environment that is incapable of causing any physical harm. As students are not fearful or inhibited in a digital environment, a tremendous amount of interaction and learning takes place. When using each electrode type, students can experience arc behaviour, welding sounds, hand vibrations and weld results characteristic of that electrode type. Using virtual reality also minimises material waste, reduces the overall energy consumption of the welding training process through spending less time on a traditional welding machine, feeder and weld fume control system. Virtual reality welding training results in a lower environmental footprint and reduces costs. Lincoln Electric, for example has a training tool called the VRTEX 360. Developed in partnership with VRSim, this system is a 48

metalworking equipment news September 2012

successor to an earlier version, the SimWelder, introduced 10 years ago. The current virtual reality arc welding educational training tool by the company from Cleveland, Ohio, is designed to accelerate welding training. It can be used to simulate SMAW (stick), GMAW (MIG), F CAW (fluxcored) welding processes and AWS E6013 stick electrode. The training tool also offers multiple weld joint configurations and welding positions in a variety of welding environments, including construction sites, welding booths, desert military base and process piping manufacturing virtual welding environment. It offers a combination of realistic puddle simulation and arc-welding sound tied to a welderâ&#x20AC;&#x2122;s movements. Using Robots From laser welding to laser weld measurement, robotic laser welding is the third innovation involving lasers in metal joining processes. A typical robotic laser welding system consists of a servocontrolled, multi-axis mechanical

arm with a laser cutting head and faceplate mounted on it. The welding head usually consists of focusing optics for the laser light, an integral height control mechanism, with an assist gas delivery package that distributes a gas to the welding head. Most systems use a laser generator that delivers the laser light to the robot cutting head through a fibre-optic cable. Well-known examples include ABBâ&#x20AC;&#x2122;s FlexArc welding cells, Panasonic PerformArc series robotic arc welding systems, Trumpf TruLaser Robot 5020, FanucWelding Robots, Motoman ArcWorld welding work cells, and Nachi Weld Wizard robot system. According to ABB, welding costs can be reduced by up to 50 percent when robots are used. Based on the companyâ&#x20AC;&#x2122;s experience in the welding of metal sections, it claims metal manufacturers have typically reduced their overall welding costs by over 50 percent of the overall product cost. With cycle times typically reduced from 30 minutes to three minutes, ABB claims that a robot welding cell can replace 10 manual stations, saving the manufacturer the cost of 10 welding sets and any accompanying fume extraction equipment, as well as floor space. A key growth area is the automation of welding systems, as greater integration of various stages of the welding process becomes more common, increasing productivity and reducing time-tomarket. By looking to automated welding technology, metal manufacturers can reduce operating costs and increase production output rates. Robotic technology is one way metal joining processes can benefit, from improvement in the health and safety of workers while encouraging sustainable development and ultimately, business survival. MEN Enquiry No. 6301 Turn to page 80a or log on to www.equipment-news.com to enquire

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The Pulse Of

Sheet Metalworking

In Vietnam

Mr Nauer feels the ByVention laser-cutting machine is suitable for a market like Vietnam

Dr Laubscher (second from right)

he sheet metalworking i n d u s t r y i n Vi e t n a m has grown over the last few years. Previously dominated by punching machines, the lack of it in a recent exhibition in Vietnam is a telling sign that punching technology has matured in the country. Sheet metal machine tool manufacturers have something new for the Vietnam market. With Bystronic and Trumpf bringing the ByVention laser-cutting machine with a 4.4 kW laser power and the TruLaser 1030 to the exhibition floor respectively, they effectively ushered in the laser age for the country. 50

metalworking equipment news September 2012

D a n i e l N a u e r, M D , h e a d of market region SEA, ANZ of Bystronic said: “We see a shift. The technology of laser is getting known, we have more a n d m o re d i re c t t e c h n i c a l questions coming (regarding laser technology). They are however not ‘How is the process different, what does this machine do?’ With our competitors, I think we have done a good job in educating the population on laser technology. We will gradually see a shift away from punching towards laser here in Vietnam.” “I think by showing the B y Ve n t i o n , w e a re s e t t i n g

the stage for many of these machines here. This machine is our smallest and most economical of its range, quite suited for the domestic market here where working hours is typically five to eight hours a day,” he added. Also noticing a shift towards laser technology, Dr Hans-Peter Laubscher, MD for Trumpf Asia Pacific decided to show the 2D flatbed laser cutting machine TruLaser 1030 at the exhibition. “It is a dedicated machine for thin sheet cutting suitable for customers starting to run laser operations and an appropriate solution for markets

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like Vietnam. The machine can also be equipped with a pallet changer. Vietnam in the past is well equipped with punching machines and the laser cutting technology is only starting to be more widely used recently. I would say punching in the country is a mature market with its technology quite well known,” he said. According to Dr Laubscher, the size of the machine was also a consideration. He said: “This machine has a small footprint of only 25 sq m. It does not occupy a lot of space. I understand from a lot of customers in Vietnam that space is getting more expensive.” Looking Ahead Despite having a reputation as one of the fastest growing economies in the region in recent years, Vietnam is now going

through a period of economic challenges according to Dr Laubscher. He said: “We noticed that many companies have difficulties in getting funding from banks or the government and the interest rate is not very favourable for investment at the moment. These scenarios will show their effect in business expansion. However, Vietnam is an alternative production place to Singapore, Malaysia and even China and some of our customers are thinking of relocating or expanding their businesses to Vietnam other countries in the region. The country, to my understanding, has a good future but needs to further improve its overall infrastructure.” With positives outweighing the negatives, both companies have pledged to do more in the country. Said Mr Nauer: “We have two

offices, one in Ho Chi Minh City and the other in Hanoi. They both have sales and technical staf f. This is because it is important to have a receiving team and offer good product service. Without this, I think you have no chance because these are prerequisites.” In addition, Mr Nauer stressed on the importance of having local technicians, as technicians holding other citizenships may need visas to enter the country. For Trumpf, Dr Laubscher revealed that the service engineers to machine ratio is higher in Vietnam as compared to many other countries, as the company pledged to support the local market “to a great extent”. MEN Enquiry No. 6302 Turn to page 80a or log on to www.equipment-news.com to enquire

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September 2012 metalworking equipment news

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Joining:

Not Sticking To Tradition Besides welding, clinching is also an effective sheet metal joining technique in its own right.

here a re ma ny ways of joining metal p e r m a n e n t l y. T h e popular methods are soldering, brazing and welding, which include the introduction of heat to the process. A permanent mechanical fastening process like riveting is also an alternative and has found great use in the aerospace industry over the years. Apart from these traditional methods, there are other ways of joining metals, namely clinching and using strong adhesives. Clinching is a relatively new joining technolog y in which sheet metal parts are joined without the use of any additional element. It is strictly a subset of the fa stening fa mily a nd many riveting techniques are slowly incorporating clinching. Although this method of joining is arguably not as widely used, it is fast making inroads into the automotive sectors. 52

metalworking equipment news September 2012

Two layers of metal are fastened by using a punch and die

â&#x20AC;&#x2DC;Clinchingâ&#x20AC;&#x2122; The Trust C l i n c h i n g (m e c h a n i c a l i n te r l o c k) i s a m e t h o d o f joining different metal parts (mainly sheets) by a process of local deformation with the application of a punch and a die. It does not generate sparks or fumes like in welding and the strength of a clinched joint can be tested non-destructively. In

addition, the life expectancy of clinching tools is long enough fo r it to b e co n side re d a n economical process. According to Norlok Te c h n o l o g y , a C a n a d i a n company that manufactures clinching machines, the stronger and thicker the material, the stronger the clinch. There are t wo way s to me a su re joi nt strength, ie: pull strength and peel strength. Using mild steel as an example, the typical pull and peel strength of a piece 0.070 inch thick is 550 and 225 lbs respectively. The tests administered can be destructive or non destructive. A destructive test will entail pulling a joint apart whereas a measurement of the diameter of the joint is the non-destructive approach. Clinching allows the fastening of dissimilar materials, pre painted, coated, or multiple layers of materials within a thickness range. The joints, which can be quickly created, are usually clear of burrs with no rework required. The technique however, has some limitations. It work s best when the two layers are similar in thickness and it does not produce a flat, smooth joint. Enquiry No. 6303 Turn to page 80a or log on to www.equipment-news.com to enquire

A Short Word On Laser Welding In Asiaâ&#x20AC;Ś Dr Hans-Peter Laubscher, MD, Trumpf Asia Pacific: Laser Welding is a well established technology nowadays. It is used wherever high volume production or high quality requirements are required. Significant costs reductions can be achieved over the whole process due to fast welding speed, less after work requirements, reduction of material as well as smarter design of the parts. Laser is a small and efficient tool. By implementing this technology into production, precise working steps are needed, leading to an improvement of quality processes and opens the door to enter new markets. In addition, laser welding can incorporate robotics and produce perfect seam lines that require no grinding or rework. That gives users a chance to market the seam line as a feature. MEN

Enquiry No. 6304

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4-6 October 2012 09.00-17.00 hrs.

Discover the Right Machinery & Solutions for Your Production Upgrade

Saigon Exhibition & Convention Center (SECC) 799 Nguyen Van Linh Parkway, District 7 Ho Chi Minh City, Vietnam

An exhibition where Japanese parts buyers and Vietnamese parts makers can meet to seek business opportunities

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Starting October, your industrial and electronics manufacturing can be faster with high precision and cost efciency. You can make products with more order value with the right technologies, the right knowledge, and the right people in one place, three mega shows! For Industrial Manufacturers: • Find the right machinery & solutions for your production upgrade. 500 brands from 25 countries in METALEX Vietnam. • Become representative of global brands • Learn new knowledge in Seminars & Technology Presentations For Electronics Manufacturers: • See the most comprehensive range of technologies for SMT Line manufacturing. 200 brands from 25 countries in NEPCON Vietnam. • Expand your network in the only event for the electronics community • Catch the trend in the only center of industry knowledge For Parts Makers: • Sell your parts to 53 Japanese buyers exhibiting parts they want • Source new subcontractors. 50 Vietnamese parts makers will exhibit their products.

ENQUIRY NO 152

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Focus

Large Part Machines In Asia

Energy Sector The

Michele Archenti

In the energy sector, the size of the investment is large, and so is the size of parts produced. By Joson Ng

he power generation industry typically harnesses the energy present in the sun, wind, and water for power. With rising oil prices, more has been done to make this industry a good alternative to oil and gas. Renewable power generation is expected to continue its growth over the next five years, according to a report from the International Energy Agency. It says that despite economic uncertainties in many countries, global power generation from hydropower, solar, wind and other renewable sources is projected to increase by more than 40 percent to almost 6,400 terawatt hours (TWh). The Medium-Term Renewable Energy Market Report 2012, says that renewable electricity generation should expand by 1,840 TWh between 2011 and 2017, almost 60 percent above the 1,160 TWh growth registered between 2005 and 2011. Renewable generation will increasingly shift from the OECD to new markets, with non-OECD countries accounting for two-thirds of this growth. Large Machines For Large Parts In order to convert the raw energy found in nature, man has developed and built windmills, dams and solar panels. These parts, particularly the turbines, are large in nature and

metalworking equipment news September 2012

when it comes to machining large parts, certain points should be taken into consideration. Asia Pacific Metalworking Equipment News spoke with Michele Archenti, marketing department manager of Pama to find out more on the idiosyncrasies that come with machining large parts. There is a need to analyse different sectors separately in large part machining. Said Mr Archenti: “In wind power, the typical parts made on our machines are in fact the largest parts — that means the hub, nacelle and the blades. Smaller generators, those below 2 mW power, tend to be machined on milling machines as the machining process is not so heavy duty to justify the jump to large machines.” Large machines like Speedram 2000 floor type boring and milling machine are used to produce hydroelectric components and wind generators blades. In the oil and gas industry, large machines are needed to manufacture large valves and for the hydro power industry, typical large parts are the blades. Buying A Large Machine? The obvious difference between a large machine and a typical machining centre is size. This difference may seem like a simple matter of space in the factory but according to Mr Archenti, there are more to it. “Large machines require

Andrea Kratzenberg, Münsterland, NRW, Germany

Go Big In More Ways Than One In Asia, Pama is particularly active in China and India. A good portion of our large machines have been sold to power generation companies. Shipbuilding is also definitely an area of interest for us, along with ship repair to an extent. Shipbuilding has moved from South Korea to China and now to Vietnam.

Enquiry No. 6401 Turn to page 80a or log on to www.equipment-news.com to enquire

significant space for operations. In addition, there is a need to prepare the foundation, typically a flat slab of concrete under the machine,” he said. Even before the decision to invest in a large machine is made, Mr Archenti felt that the productivity of the machine that is being evaluated is important. He said: “Large parts require a lot of time in setting up the machine. This is not conceivable these days. As a result, a palletised system is introduced to keep the production process going.” The machines can be equipped with single table, automatic pallet change system or linear pallet shuttle system, even serving multiple machines to make sure the machine is utilised to the optimum. In addition, users of large machines are looking to run the machines unmanned during weekend, putting reliability as one of the important factors to consider before buying a large machine. MEN Enquiry No. 6402 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 135

Executive

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zone z

Thailand Outlook:

Chainarong Limpkittisin, MD of Reed Tradex spoke with Asia Pacific Metalworking Equipment News (APMEN) on how Thailand is looking to consolidate its position as the leader in manufacturing in the region. APMEN: Please share your thoughts on the Thai metalworking industry for the rest of 2012 and early 2013, taking into account the financial uncertainties in Europe. Are there any good news domestically to counter any external influences? What is the outlook for Thailand’s suppliers to the automobile giants like Honda/Toyota? Chainarong Limpkittisin (CL): I believe a main user of metalworking technologies like the automotive and auto-parts manufacturing sectors will be able to counter the effects from the crisis in Europe with increasing domestic demands and export to new markets. Automobiles and auto parts are number-one export products whose key markets are not in Europe. The main markets of automobile are Australia, Indonesia, Japan, Saudi Arabia, Malaysia, and the US, accounting for 48.9 percent of the total export value, followed by the UAE, Oman, the Philippines, and Chile. For auto parts, they are mainly exported to Indonesia, Malaysia, India, and Brazil, accounting for 56

metalworking equipment news September 2012

Holger Dieterich, Berlin, Germany

All Systems

51.18 percent of the total export value, followed by the US, Vietnam, the Philippines, South Africa, and Argentina. These are strong markets with both existing and new opportunities. Having fully recovered from the floods, Thailand’s auto industry has set new records in terms of production, domestic sales, and export, twice within the first half of this year. In June, the auto production made the highest record in 50 years by producing 205,600 units — 33.81 percent increase when compared to the same period of last year — while its domestic sales also broke its 50 years record and its export broke its 25 years record. The domestic demand for new cars has risen from the higher purchasing power of the people, the government’s ‘First-Car-Buyer’ scheme providing an incentive for those who buy cars for the first time,

and the need to replace the damaged cars. Giant auto makers also have plans to expand or introduce new models, eg: Chevrolet is upgrading three factories in Thailand, and Mazda plans to introduce the first SkyActiv model in the country next year. These trends indicate continuing growth that auto-parts suppliers of all tiers can enjoy. So, I believe that we will still see continuing growth in the metalworking industry and the auto-parts manufacturing sector throughout the rest of this year and well into 2013. APMEN: Besides the automotive industry, which are the other industries in Thailand that drives the metalworking industry? Are there any other ‘hot spots’ in Thailand worth mentioning? CL: The electrical and electronics industry is another driver of the metalworking industry. It is one of Thailand’s largest manufacturing sectors. It is also one of the industries that generate the highest investment value in the country, according to Thailand Board of Investment (BOI), which revealed that those industries include metal products, machinery and transportation equipment; electronic and electrical appliances; and service and public utilities. The electrical and electronics industry is also a major driver of export growth. Recently, the Ministry of Industry has disclosed the plan to make Thailand the hub of ASEAN for auto-parts and electronic-parts production and assembly. These strategies would reinforced BOI’s strategies to endorse Foreign Direct Investment (FDI) for key industries including

We will see continuing growth in the metalworking industry throughout the rest of this year and well into 2013.

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CL: Machinery import consists of three groups of machinery, ie: machine tools, industrial machinery, and agricultural machinery. K a si kor n Re se a rc h Ce nte r (KResearch) has forecasted that the value of machinery import will grow, partly as a result of the need to replace the machines that were damaged by the deluge. In the first quarter of this year, the import of machine tools grew continuously with the total value of US$1.04 billion, an increase of 24.2 percent when compared to the previous quarter. It is forecasted that the total import value could reach US$9.96 billion or an increase of 22.5 percent year-on-year. The majority of the imported machine tools were CNC machinery including cutting, grinding, bending, and press brake machines. We have seen that, in addition to those machine tools I just mentioned, there have also been more demands for CNC drilling and EDM machines, as well as sheet metal technologies including stamping, folding, and laser cutting machines. We are also experiencing upwa rds trends for high p r e c i s i o n te c h n o l o g y a n d metrolog y technolog y since the manufacturers are focusing more on upgrading precision in their production, adding value to their existing products, and manufacturing products that have more value.

CL: Almost all of the factories have fully recovered. All of the automotive assemblers are back to normal production. Production of auto parts is at 80 percent capacity and is expected to fully recover by the third quarter. All industrial estates in the flooded areas are required to build flood-protection barriers, and the government is supporting them with

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ENQUIRY NO 113

APMEN: Looking at import figures, are there any particular types of machine tools and cutting tools that are popular in Thailand?

APMEN: Are the factories affected by the flood last year back to full production? What has been done to prevent the same from happening? Are there any updates on the master plan to tackle future flooding announced by deputy prime minister Kittirat Na Ranong at Metalex last year?

automotive, rubber, electronics, ICT, logistics and air transport, as well as the policy to promote outwards FDI by Thai entrepreneurs to neighbouring countries that would lead to tighter cooperation and mutual economic growth.

September 2012 metalworking equipment news

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eco cars, so we can expect to see more and more eco cars running around in Thailand. More new models that can run on eco-friendly fuel can also be expected.

Chainarong Limpkittisin

loans to raise the road levels and to build dikes. The government is implementing a flood-protection plan, building 3,000 check dams at the origins of the waters and planting Burmuda grass to slow down the waters. They are also dredging canals to free the water flows. There is also a plan for rehearsals in communities to be prepared for all kinds of disasters. I think we all have learned an expensive lesson. The damages the disaster brought were unprecedented, and we were not at all prepared. We are reviewing all risks from all angles. APMEN: Thailand has had impressive economic growth in recent years particularly in the automotive sector. What are the government policies in place to help maintain this growth? Are there any new plans to attract new foreign investments? CL: Despite all the challenges in the past few years, Thailandâ&#x20AC;&#x2122;s economy has indeed been in good health. The countryâ&#x20AC;&#x2122;s GDP Per Capita has increased three times in the past decade. Export value increased from US$97 billion to US$230 billion. Our foreign exchange reserves has increased from US$30 billion to US$180 billion. As for the automotive sector, the industry is in a fast lane with the high rate of production and demands. For export, the government has set the target 58

metalworking equipment news September 2012

for growth at 15 percent, the total of one million units, which will make Thailand the sixth or seventh top auto manufacturing hub of the world. The government and the private sector has held a workshop and set up working committees to tackle possible challenges and push exports. Six working committees have been set up to work on rules and regulations to monitor export markets including Europe and ASEAN and to realise FTA between the EU and Thailand; to study individual industries in order to gain insights on factors that could obstruct exports; to work on trade relations with neighbouring countries; to take care of existing markets such as China, Japan, South Korea and the US; and to explore opportunities in new markets such as South Africa, Chile, Peru, and the BRIC countries. With histor y dating back 50 years in the auto industry, good infrastructure, abundant raw materials, skilled labours, and strong support from the government, Thailand is aiming to produce three million units by the year 2015. The BOI has been working hard to attract foreign investors to locate plants in Thailand. Chine se ca r ma kers a re coming while Japanese, American, and European assemblers are expanding here. The eco-car trend is rising as the production and sales are good. The BOI also offers incentives to manufacturers of the

APMEN: With operating cost gradually becoming a factor in Thailand, do you foresee Thailand keeping faith in manufacturing or diversifying its economic endeavours? CL: Manufacturers have solved the problem by turning to factory automation technology which has played more important roles in production lines. They are training their workforces to control the technology. Thai manufacturers are well aware of how new machineries and technologies can help them save costs of production; including energy cost, and can help increase the efficiency of their lead time management. The government is also supporting the manufacturers in cost saving; for example, the Department of Alternative Energy Development and Efficiency (DEDE), Ministry of Energy, has recently launched a scheme to subsidise 20 percent of the cost of machinery or equipment that will help save energy in factories. There are efforts from both the public and private sectors driving the strength and growth of the manufacturing sector, whose export value accounts for one-third of the total GDP. Many foreign investors have made Thailand their manufacturing hub for decades, and more are coming. I think Thailand will keep faith in this sector and that the government will continue working with the private sectors to sharpen the sectorâ&#x20AC;&#x2122;s competitive edge and attractiveness to spotlight Thailand on the map as an important investment destination in ASEAN. MEN Enquiry No. 6501 Turn to page 80a or log on to www.equipment-news.com to enquire

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Special Feature On Remanufacturing

Remanufacturing

Singapore

ENQUIRY NO 047

he Renaissance was a cultural movement that spanned about 400 years from the 14th to the 17th century. It began in Italy and later spread to the rest of Europe. Fast-forward 300 years, another renaissance is happening, this time in Asia, and in manufacturing. A popular technology in the US and Europe, remanufacturing has been knocking on Asiaâ&#x20AC;&#x2122;s door for sometime now and for Singapore at least, the door has been truly opened. The country recently established the Advanced Remanufacturing & Technology Centre (ARTC) to look into R&D of remanufacturing technologies that can be adopted by the industries. The centre is modelled after successful manufacturing R&D centres in the UK and will provide a platform for SMEs to work with MNCs to develop capabilities and ultimately seize business opportunities in remanufacturing. It will also tap on A*STARâ&#x20AC;&#x2122;s SIMTech R&D expertise in automation, manufacturing systems and processes along with capabilities from local universities.

September 2012 metalworking equipment news

Special Feature On Remanufacturing

LAAM adds material in the form of powder or wire to produce fully dense components

Three Tiers Of Partnership The structure of the consortium is divided into three tiers with the MNCs holding tier one and two positions and the SMEs, which currently stand at eight, grouped into tier three. The tier one companies will no doubt provide the main thrust in terms of technology and finances. Currently, Rolls-Royce, Gamesa, Boeing and Siemens Industry Software have committed themselves to the project. For the big hitters in the aviation industry, Rolls-Royce and Boeing, this is only part of their strategy in developing a global network of advanced manufacturing research centres. Said Dr Hamid Mughal, chairman of ARTC programme board, who is also Rolls-Royce’s executive VP in manufacturing engineering and technology: “Rolls-Royce have joined hands with universities, research organisations and industrial partners such as Boeing to promote a collaborative model of manufacturing research. The advanced manufacturing research centre at Sheffield (UK) is an example of this model. In the last few years, we have championed the development of a global network of these centres, we call these the AxRC network.” Siemens Industry Software is another company that has prior collaborative experience in a remanufacturing research facility. “We have had successful relationship in a similar context in other places in the world, namely the US and UK. They are similar collaborations between governments and the industries. We participated in those ventures because we have enough ambition as a company to be in the forefront of initiatives,” said Rajiv Ghatikar, VP and GM, ASEAN/Australasia, Siemens Industry Software. Green Is The New Gold Remanufacturing impacts the environment in a 60

metalworking equipment news September 2012

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positive way with many pointing to the reduction in pollution, material depletion and landfill demands. In addition, it also helps save energy. Although saving the environment is a worthwhile cause, attaching a good business proposition to it makes pursuing remanufacturing all the more compelling. According to a report by Global Industry Analysts, the global automotive remanufacturing market is to reach US$104.8 billion by 2015. When going green is rewarded with gold, in this case billions of dollars, it is easy to see why people are jumping onto the remanufacturing bandwagon whatever their motivations are. In addition to business and environment, the technology is also apparently useful to the economy as it is believed to create more high value employment and plays a supporting role to other industries. The Automotive Parts Remanufacturers Association (APRA) estimates that there are more than 500,000 jobs in the remanufacturing industry and they include products as diverse as automotive and truck parts, toner cartridges, electronic equipment, cell phones, office furniture, locomotive, electrical transformers, air conditioning compressor units for office buildings, offroad construction equipment, agriculture and mining equipment, hydraulic pumps for all types of applications, and the list goes on. Technologies On Offer With remanufacturing defined as the practice that recovers products from commercial usage and transforming them into like-new goods to be reintroduced into the marketplace, repair and restore have become the key enablers for remanufacturing to take place. Coupling these with the centre’s mission in providing the evolution of high-value technologies in repair and manufacturing and bridging the gap between innovative ideas and production ready solutions, it comes as no surprise that ARTC is loaded with such technologies in order to enable the complete repair of valuable and complex parts. • Repair & Restoration The centre is expected to provide three technologies, namely Laser Aided Additive Manufacturing (LAAM), laser coating removal and adaptive machining dynamics. LAAM adds material in the form of powder or wire to produce fully dense components. This enables the repair of aero-engine components and machine tools among others. Laser coating removal uses laser beam to ablate unwanted materials such as coating and surface contaminants. Finally, adaptive machining dynamics develop a toolkit to identify optimal machining parameters. It can help eliminate chatter

Special Feature

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On Remanufacturing

marks on machined surfaces and result in better surface integrity. â&#x20AC;˘ Surface Enhancement Surface enhancement is also an important part of remanufacturing. The ARTC provides three technologies in this respect. They are physical vapour deposition system, magneto-rheological finishing and drag finishing. The physical vapour deposition system involves the transfer or deposition of coating material on an atomic level in a vacuum chamber. PVD coating is used to reduce friction or improve tooling performance. Rapid magneto-rheological finishing uses magneto-rheological fluid-based media for surface finishing of external freedom surface. It contributes to improvement in the uniformity of product quality and reduction of production cost through automation. Drag finishing is able to provide both aggressive deburring and pre-coating finishing. It is a precise mass finishing technique for surfaces that complements other abrasive process. It provides a solution for components that cannot tolerate part on part contact.

Remanufacturing restores expensive used parts to their original luster and give them a new lease of life. With support from both the public and private sectors, this technology targets real problems and provides real solutions and fits nicely into Singapore, a country that is seeking to reinvent itself. It would be two years before the completion of ARTC at Greentech Park two but the remanufacturing die has been well and truly cast in Singapore. With more companies poised to join in the future, this green movement looks set to gain real momentum in the country. MEN Enquiry No. 6601 Turn to page 80a or log on to www.equipment-news.com to enquire

ENQUIRY NO 143

â&#x20AC;˘ Product Verification Inspections are essential in almost every stage of remanufacturing. Technologies like intuitive robot teaching, sonic NDT and predictive health monitoring will no doubt be of use. Intuitive robot teaching can be implemented on an industry robot for many processes. Sonic NDT is a hand-held NDT system that allows users to scan a composite for detecting defects like delaminations, disbands, kissing bonds and crushed core. Finally, predictive health monitoring uses processing algorithms and a statistical model to detect faults in machine tools. Used to detect faults in spindles and cutters, the quality of the machining process and the tool usage can be prolonged.

September 2012 metalworking equipment news

Special Feature

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On Remanufacturing

Remanufacturing Takes Off In The

Aviation Industry

Jonathan Lee, director, Korea & Southeast Asia Technology of Boeing Research & Technology, spoke with Asia Pacific Metalworking Equipment News in this exclusive interview on how remanufacturing is impacting the aviation industry. By Joson Ng APMEN: Please give our readers a brief introduction to remanufacturing. Jonathan Lee (JL): The traditional definition is for a part or a component to reach the end of its service life, where instead of recycling it, you remanufacture and put it back into production. We are looking at remanufacturing from a more technolog ica l standpoint. From our perspective, there are a lot of common processes and technologies in manufacturing as well as remanufacturing that we would like to take advantage of in our production. APMEN: Which aspect of the aerospace industry is applicable to remanufacturing? JL: I t cou ld b e a ppl ie d to almost anything. Having said that, the decision on what to remanufacture is usually driven by the business case. For example, if it is an inexpensive part, it may be better to just scrap it. We like to focus more on expensive parts, parts made with expensive materials or parts that require extensive manual labour input. Certain decisions are also driven by the possible impact a process can have on the environment. For us, we typically deal with the remanufacturing of gears. APMEN: What are the metalworking processes used in the course of remanufacturing? JL: The usual metalworking processes of welding, surface 62

metalworking equipment news September 2012

treatment and coating would be investigated as part of the remanufacturing technolog y resea rch. There a re a lso many different aspects of our manufacturing processes where we can incorporate remanufacturing into, such as inspection and diagnostics. APMEN: Why is Boeing taking part in the Advanced Remanufacturing & Technology Centre (ARTC) project in Singapore? How do you think remanufacturing will affect the MRO industry in Singapore? JL: Boeing is already actively engaged in a relationship in Singapore with A*STAR, starting back in 2005. We have a long history that has been a very positive experience for us in improving our productivity and efficiency. So when the opportunity in ARTC consortium came to expand our technology collaboration and leverage off Singapore’s strong MRO capabilities, we did not hesitate to jump on the opportunity. The Singapore government has been very supportive. In addition, the country also has ver y experienced a nd wellskilled researchers, on top of the advanced technology it has to offer in manufacturing and its MRO sector. Combine that with Boeing’s manufacturing capabilities and knowledge that we gained from our 96 years of airplane manufacturing, along with Rolls-Royce engine manufacturing, and we have high expectations for the innovative solutions in remanufacturing that

would benefit all participants in the consortium. APMEN: How do you fit remanufacturing into productivity? JL: We expect remanufacturing to help us in productivity and efficiency. For instance, in the many levels of product verification, (eg: component and assembly parts) it allows us to detect defective parts early on, saving us a lot of time and money further downstream. We like to improve the buy-to-fly ratio of the raw materials by developing repair and restoration technologies that would maximise the use of materials we procure. APMEN: In your opinion, which is a bigger drive for the aviation industry’s interest in remanufacturing, the environment or a healthy bottom line? JL: You have got to have a balance. Money and bottom line are important, but being responsible for the environment is equally important too. In fact, we are looking to find a way to reduce or eliminate hazardous materials during manufacturing. Collaborating with A RTC is one way to find solutions to eliminate those materials in our manufacturing processes. Reducing the usage of those materials is good for productivity as well, as we are striving to reduce potential health risks to our skilled workers. MEN Enquiry No. 6602 Turn to page 80a or log on to www.equipment-news.com to enquire

Features

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Bringing

Germany To Vietnam

Ms Ruffert (L) and Dr Engels

A part of the exhibition hall was transformed into Germany during the MTA show in Ho Chi Minh City. By Joson Ng

he Baden-Württemberg Pavilion was out in full force at MTA Vietnam, showcasing German technologies and companies. Although the companies are from the same country, they all have different reasons to exhibit in Vietnam. Dr Astrid Engels, in charge of foreign trade in the German Engineering Federation (VDMA),

said: “There are different aims. Some companies are seeking market information whereas some are totally new in Vietnam and Southeast Asia.” For Christina Ruffert, executive manager of international business cooperation (ASEAN) of BadenWürttemberg, it is important to “be here regularly”, indicating the need for continuous engagement.

Exports To Vietnam Focusing on Asia, and Vietnam in particular, Dr Engels revealed that German exports figures have grown consistently since 2008. Figures from VDMA, an organisation that represents over 3,000 mainly small/medium size member companies in the engineering industry, showed that German machinery exports to Vietnam were worth some €563 million (US$690 million) in 2011, a 30.5 percent increase from the previous year. This figure also cemented the fourth spot for Germany in Vietnam’s total import of machinery, behind China, Japan and South Korea. Much would be done to try to close the gap on the top three nations and attending shows in the country is one way of doing so. MEN Enquiry No. 6603 Turn to page 80a or log on to www.equipment-news.com to enquire

Sphinx Tools Ltd. Gewerbestrasse 1 CH-4552 Derendingen

Phone +41 32 671 21 00 Fax +41 32 671 21 11 www.sphinx-tools.ch

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September 2012 metalworking equipment news

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APMEN: Why is UCIMU taking part in MTA Vietnam? Does this signify the organisation’s intent to focus more on the Vietnamese market? Luigi Galdabini (LG): Today, Vietnam can be considered a ‘New China’. More and more Chinese companies are in fact setting up production units in this country. Therefore, demand for our sector has strongly increased. UCIMU-Sistemi Per Produrre keeps a close look and analyses the country, to ensure a way in for Italian companies by facilitating meetings between Italian manufacturers and local end users. These are targeted meetings, where possible customers are selected through a detailed screening process carried out by local agents. APMEN: From the association’s point of view, which type of machines are in demand in Vietnam and Southeast Asia? Do you see this demand increasing? 64

metalworking equipment news September 2012

Luigi Galdabini

LG: Southeast Asia is a market that offers great potential. In 2011, Vietnam alone bought machine tools for a total value of over €3 billion (US$3.6 billion). This included all kinds of machines. Vietnam is a country that is currently starting from scratch in what is for them a new industry; the country lacks know-how and machines. And for this reason, it is important that the Italians are ready to ‘go and conquer the market’. In 2011, Italy was the country that increased its exports to Vietnam the most: + 256 percent compared with the previous year. Japan, the second in line, recorded a + 56 percent increase, while countries like Germany and South Korea suffered a decrease of over 20 percent. Southeast Asia offers great opportunities, but is also very well guarded by the Japanese and the Chinese; from this point of view, the Italians still have a long way to go.

APMEN: What is the association’s marketing strategy for Southeast Asia? Do you have any programs or incentives for Italian machine tool manufacturers who are interested to come to Asia? LG: One of the main missions of UCIMU is to support companies in their export activities. This applies to every country, but it is even more critical for emerging markets. Regional studies are required to gain an understanding of what strategies that should be implemented. Analysing demand, competition, distribution channels, direct presence at sector trade exhibitions, and close collaborations with banks to facilitate the availability of funds for exporting companies are only some of the solutions consistently chosen by the association to promote the Italian sector, and consolidate the position of its companies.

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APMEN: What is the strength of Italian machine tool/ technology? How do you compete with manufacturers from Germany, the US, Japan, South Korea and Taiwan? LG: From a technological point of view, Italian machine tools are just as advanced as the German and the Japanese ones. In fact, Italy is the third country in terms of exports. In order to compete with other manufacturers, we need to continue investing in innovation and in promoting the advantages that set our offer apart: customisation and flexibility.

â&#x201A;Ź750 million. Asia and Europe are the two regions taking most of Italian expor ts, reaching together, almost 65 percent of the total. However, trends are ver y different in the two continents: Asian demand of Italian machine tools is strongly on the increase, from 14 percent in 2007, to 26.4 percent in 2011; on the other

hand, European demand is down, from 60.7 percent in 2007, to 37.8 percent in 2011. In 2010, the gap between the two markets was even wider, but it narrowed in 2011, due to a decrease in Asian imports, and a small increase in activity in Europe. MEN Enquiry No. 6604 Turn to page 80a or log on to www.equipment-news.com to enquire

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APMEN: In terms of export, how many percent of Italian machine tools are exported to European countries and how many to Asia? LG: In the first three months of 2012, exports grew by 19.2 percent when compared with the same period of 2011, nearing

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LG: After the 2008 - 2009 crisis, the European machine tool market showed great recovery, driven by the number of orders secured by German manufacturers, much higher than the European average. But then we experienced a downturn during the third quarter of 2011. According to the forecasts, this contraction will continue until the middle of the year, after which orders will start to increase again. The year 2013 will be a year of recovery; although the levels will not be particularly exciting, the European market will begin to take orders again.

September 2012 metalworking equipment news

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exhibitions

Report From

Ricky Hwa

MTA Vietnam Occupying more than 8,000 sq m of exhibition space, the number of international names at the show is perhaps a fair reflection of Vietnam’s reputation for being the place to be for the metalworking industry at the moment. By Joson Ng

ollowing MTA Hanoi in March, MTA Vietnam opened on July 3, 2012, to cater to the manufacturing industry in the surrounding areas of Ho Chi Minh City. Well-stocked with sheet metalworking machine tool, the show boasted the participation of sheet metal ‘big boys’ Amada, Bystronic and Trumpf. In sheet metal processing, laser technology is in focus this year where the exhibitors opted to showcase their laser machines. Bystronic exhibited the ByVention laser cutting machine with a 4.4kW laser power. According to Daniel Nauer, MD, head of market region SEA, ANZ, the model is the company’s smallest and “most economical”, therefore making it “quite suited” for the Vietnamese market. Small seems to be popular in Vietnam as Trumpf also showcased a machine with small footprint. Dr Hans-Peter Laubscher, the company’s MD for Asia Pacific, told Asia Pacific Metalworking Equipment News that the company brought the TruLaser 1030 to the

metalworking equipment news September 2012

show. Apart from the size, the machine can be equipped with a pallet changer as well. To s a y t h e s h o w i s predominantly on sheet metal would not do it justice, as other segments of metalworking were well represented with the machine tool and metrology companies showcasing various machines and equipment. Yamazaki Mazak had a sizable presence at this year’s edition. The company showed Vietnam their Vertical Center Smart 430A S, Integrex j-200 and the quick turn smart 150FZ (500U). At the opening press conference, Ricky Hwa, chief representative of the company’s operations in Vietnam, said that the company’s business in Vietnam has grown significantly since 2007, when they established a representative office in Ho Chi Minh City. He believes the growth will continue despite some uncertainties in the country. He said: “The automotive industr y is experiencing a slowdown in Vietnam. From

speaking with our customers, we gather that there has been some 30 percent drop. However, when one industry suffers a slowdown, some others will experience an increase. On a whole, I think the growth will sustain until 2013.” This faith can be easily seen in the company’s plans and strategy in Vietnam. They plan to convert the current operation from a representative office to a full company status within a year, and set up a technology centre with a show room and part/service support capacity. Another aspect of the show is its internationality. With international pavilions out in full force, the show is effectively made up of pavilions from Germany, Italy, Japan, South Korea (two), Taiwan (two), Thailand, Singapore and the UK. Although the booth size of participating companies in such national pavilions are relatively small, many are looking for local agents to help them expand their business in Vietnam. Finally, a glance at the show’s conference lineup revealed that lean manufacturing is very much in vogue in Vietnam at the moment. With topics tailored to improve processes, it is clear that Vietnam is beginning to move from a good place for low cost production to a more mature manufacturing nation. SECC Ho Chi Minh City July 3 – 6, 2012 Enquiry No. 6701 Turn to page 80a or log on to www.equipment-news.com to enquire

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Exhibitors’ Thoughts On The Vietnam Market Yuichiro Kimura Sales Manager Okamoto Our main customers in Vietnam are the Japanese companies based here. Our products are used for maintenance and mould making. We will try to target the motorcycle manufacturing plants in Vietnam like Honda and Yamaha as we feel there should be a demand for Okamoto’s product. The plan in Vietnam is to improve our local service support, which will see us carrying out training for the locals to be technically proficient.

Enquiry No. 6702

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Charles Tay Senior Sales Manager, Mechatronics Department (Factory Automation & Industrial Division) Mitsubishi Electric There are three markets that are very hot in this region. They are the VIPs — V for Vietnam, I for Indonesia and P for the Philippines. That is why we are launching for the first time in this region, our wire cut machine MV1200R. This is a machine we feel will be the most suitable for Vietnam, as the country has a healthy mould and die market. The industry in Vietnam will see substantial growth, at least till 2013. The Singapore government also recently expanded an industrial park near Hanoi. If we in the precision industry take the cue and move to where the wind is blowing, so to speak, we should be in relatively good standing.

Enquiry No. 6703

ENQUIRY NO 086

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CP Chuah Regional Sales Manager Wenzel Asia Pacific The situation in Vietnam in my opinion is uncertain. Our strategy here is to work with a local partner and dealership. We will provide support from Singapore as our technology centre/headquarters (Asia Pacific) is still based there.

Enquiry No. 6704 Turn to page 80a or log on to www.equipment-news.com to enquire

Hiromiki Goto Assistant Manager (Sales Department) Sodick (Thailand) At the moment, the economy in Vietnam has slowed but we will still setup a company in the country as we have been conducting business here for the last six years. As we have many customers in Vietnam, there is a need to serve them fast and take care of them better. We are going to have a show room as well. The facility will be ready at the end of this month (July 2012). Our strategy is to educate the users. As such, we have customer visitations conducted by our service engineer rather than the sales personnel. We need to let the users know more about maintenance and basic things like where to buy the consumables, (ie: wires). That is the most important thing.

Enquiry No. 6705 Turn to page 80a or log on to www.equipment-news.com to enquire

Steve Bell GM ASEAN Renishaw (Singapore) We are showing a range of products for CMMs, calibration, machine tool, and also our Equator measuring gauge. This is because we see a lot of potential but at the moment, we are restricted by the funding available so we see a lot of customers who want to buy equipment but do not have the funds to do so right now. Financing, affordable loans and government aid are required. We plan to support Vietnam from Singapore at the moment, as we have a very established distributor here. However, we plan to have our own presence here, eventually.

Enquiry No. 6706

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Patrick Pfister MD Microtest I think Asian economies on a whole are booming, much more than Europe. There are opportunities to sell our products (internal measuring equipment) in smaller Asian countries, like Vietnam, Thailand, Indonesia, and Malaysia, as they are fast growing and developing. As such, it is a good time for us to come in. We are looking at precision engineering, machine builders, work shops and the automotive industry. We are thinking about establishing a sales network and we are looking for retailers and distributors. We may set up a small production plant in Vietnam in the future.

Enquiry No. 6707

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metalworking equipment news September 2012

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Makino Asia Launches The U3 In EDM Month The company rolled out its EDM-related technologies in the month of July. By Joson Ng

akino Asia hosted its inaugural EDM Month from July 12 â&#x20AC;&#x201C; 31, 2012, at its facility in Singapore. On the opening day, the company launched the U3, a wire EDM. At the launch, KS Sankaran, the COO of the company said the machine was designed and built with precision, ease of operation, high performance and easy maintenance in mind. The launch was attended by some 120 visitors, who were mostly from the mould and die industry. Also in attendance were the companyâ&#x20AC;&#x2122;s partners from the metrology, metalworking fluid, workholding systems and EDM accessories field. Asia Pacific Metalworking Equipment News understands that the EDM Month is a focused event by the company to bring both existing and potential customers from all over the world to witness the companyâ&#x20AC;&#x2122;s R&D capabilities and manufacturing quality standard in the EDM field. Technical Seminars Visitors at the opening day were able to attend two technical seminars on high efficiency diffuser holes in turbine blades and vanes machining and EDM for medical parts manufacturing. In the first seminar on diffuser holes machining, the speaker explained that the blades and vanes located near the back of jet

and turbine engines are subjected to extreme heat and as a result, it has to be cooled fast. In order for this to happen, diffuser holes are machined on the blades. As these blades are made up of Inconel, it is difficult to apply the milling method to machine the holes. Moreover, each blade carries some 200 holes so it is important to find an effective and quick way to machine them. Currently, these small holes are drilled with EDM sinkers at various angles for cooling, which is a slow process. He then revealed a new machine that allows fast-hole EDM drilling, designed for the high-speed drilling of metering holes and diffuser shapes in blade and vane sections. This machine has the ability to produce diffuser holes at rates

that are up to 10 times faster than traditional machining, using off the shelf electrodes. The second seminar on medical part manufacturing touched on issues like the importance of ensuring there is no recast layer while using EDM to machine medical parts. As such, users must take precautions to minimise oxidation and reduce surface rust to the work piece. EDM is used in the manufacturing of medical parts because they can offer a broad spectrum of applications, including the direct production of medical and dental parts, tools and implants, as well as the indirect production of plastic moulds, dies and fixtures. In addition, its ability to machine materials typically used for medical parts like titanium, stainless steel, and cobalt chrome, makes EDM a suitable candidate, as these materials are difficult to machine with conventional machines. The uptake of medicine, surgical tools, equipment, transplants and dentistry is increasing rapidly due to the ageing population and the accessibility of healthcare. This increasing demand calls for the advancement of engineering technology behind medical component production manufacturing. Enquiry No. 6708 Turn to page 80a or log on to www.equipment-news.com to enquire

Makino: Delivering Fine Surface Finish At High Speed Makino has developed the U3 wire EDM, which is touted by the manufacturer to improve productivity through its 3 umRz/ 3 pass technology. According to the company, it can deliver a surface finish of Ra 0.4 um in three pass machining. Other notable features include the Pico precision guides, high pressure twin jet system to guide wire threading, enhanced pecking feed system and the thermal cutter system, which cuts the wire without burrs and has a pointed tip to ensure high repeatability of success during auto wire threading. The machine also comes with a guide maintenance system that eliminates the need for re-alignment work with the reinstallation of guides.

Enquiry No. 6709

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September 2012 metalworking equipment news

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Event Review:

Manufacturing Expo 2012

anufacturing Expo, the machinery and technology trade event for the autoparts manufacturing industry, concluded its 2012 edition on June 24, 2012. As the formation of ASEAN Economic Community (AEC) is near, manufacturers are preparing to handle a new level of opportunities, challenges, and fiercer competitions. Organised by Reed Tradex during June 21 – 24, 2012 at BITEC, Bangkok, the expo responded to those needs and questions with the latest machineries, technologies, tools, parts, and solutions, as well as knowledge and networking opportunities. More Technologies For AutoParts Making The event, some 26 percent larger, according to the organiser, was the centre of a comprehensive range of technologies — including machine tools, metrology technologies, plastics injection machineries, factory automation, and many others — for manufacturing every type of auto parts.

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First Time In Asia: NAO, The Intelligent Humanoid Robot The event’s participants experienced the future of automation by meeting NAO, the next generation of humanoid robot from Europe, performing while inspiring the industry with its face and voice recognition software and more.

Innovations from 30 countries as well as pavilions from China, Japan, Singapore, Taiwan, and Vietnam, were on show. Bringing The Manufacturing Community Together Manufacturers and industrialists from 14 countries participated in the show, which attracted some

42,862 participants, resulting in a five percent growth of visitor number when compared to last year. It is expected that the event has generated five billion baht (US$164 million) worth of investment in Thailand. Officially opened by Thailand’s Industry minister, the show welcomed A-list executives such as deputy permanent secretary of Ministry of Transport; secretary general of Thailand Board of Investment; vice chairman of Toyota Motor Thailand; president and chief representative for ASEAN & South Asia of Japan External Trade Organization (JETRO); p re s i d e n t o f A l l i a n c e f o r Supporting Industry Association and Thai Tool and Die Industry Association; president of Thai S u b c o n t r a c t i n g P ro m o t i o n Association; president of Thai

Autopar ts Manufacturers Association; and many more. Priceless Knowledge At Conferences Industrialists learned how to upgrade production line and work effectiveness, while expanding business network, f ro m k n o w - h o w s h a re d b y industry icons and technology experts in such seminars. They ranged from Automotive Summit, Surface and Coating Forum, Engineer Master Class, and 50 other seminars. According to the organisers, the official number of attendees stood at 3,681. BITEC Bangkok, Thailand June 21 – 24, 2012 Enquiry No. 6710 Turn to page 80a or log on to www.equipment-news.com to enquire

3M Abrasives Systems Division

Grinding with Winterthur: robust solutions for ww.winterthurtechnology.com 3M Thailand Ltd. Phone: +66 2 260 8577, Ext. 1378 nkregnavakul@mmm.com

Winterthur Technology Korea Ltd. Phone: +82 31 298 1777 sales@winterthurtechnology.co.kr

P.T. 3M Indonesia Phone: +62 21 4288 8550 jmargiano1@mmm.com

Winterthur Technology (Malaysia) Sdn Bhd Phone: +603 7724 2611 michael.lee@winterthurtechnology.com.my

Winterthur Technology (Taicang) Co. Ltd. Phone: +86 512 8161 6802 kristy.yin@winterthurtechnology.com.cn

3M Philippines Phone: +63 2 878 3674, Ext. 550 Lyuseco1@mmm.com

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ENQUIRY NO 148

lean processes

8/7/12 10:35 AM

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Event Preview:

Metalex Vietnam 2012

he Metalex franchise is once again paying Ho Chi Minh City, Vietnam a visit from October 4 – 6, 2012 at the Saigon Exhibition and Convention Center (SECC). According to Reed Tradex, the exhibition organiser, the show generated 10,578 visitors and an 84 percent rebooking rate in 2011. In this year’s edition, the show will be co-located with NEPCON Vietnam 2012 — Vietnam’s exhibition on assembly, measurement and testing technologies for electronics manufacturing. In addition, the organiser has lineup some onsite activities to induce trading activities in order to enhance exhibitors’ and visitors’ experience. The notable activities are business matchmaking, seminars and factory visits.

metalworking equipment news September 2012

production output for export has continuously increased, along with the need to have high precision. In view of the formation of AEC (ASEAN Economic Community), the company has a plan to expand the business both in domestic and international markets. For foreign markets, Hexagon Metrology (Thailand) oversees the markets of Cambodia, Vietnam, Laos, Myanmar, the Philippines, Indonesia, and Pakistan. Out of these markets, the outstanding ones are Indonesia and Vietnam, which automotive and industrial parts makers have invested in. “The Vietnamese industry has attracted many international investors and has a high growth potential. Therefore, the Vietnamese government should promote their industry in terms of technologies and human resources,” said Mr Taveesak. Featured Exhibitors Realising the potential of the industrial sector in Vietnam especially in metalworking, automotive parts manufacturing and automotive assembly, the Department of International Trade Promotion of Thailand will be at the show to bring technology and machinery providers from Thailand. Metrology solutions provider Hexagon Metrology will also be at the show this year. Taveesak Srisuntisuk, MD of Hexagon Metrology (Thailand) revealed that, currently, the automotive parts manufacturers in Thailand pay more attention to the enhancement of production efficiency in response to growing demand for export. As a result, the metrology tools and equipment have become more necessary, particularly in the automotive industry where the

Japanese Interest Japan External Trade Organization (JETRO) has confirmed its colocation at the show and will cooperate in the organisation of ‘The fifth Exhibition on Supporting Industries in HCMC’ with Metalex Vietnam and NEPCON Vietnam 2012. Touted as ‘The Power of One’, it is a trade exhibition to upgrade productivity, reduce costs, and increase profits in developing Vietnam’s supporting industry. Chainarong Limpkittisin, MD of Reed Tradex said that presently, many foreign investor are confident enough to invest in Vietnam. One of them is Japan, the leader in automotive and electronics appliances, as well as many other countries from Europe and the US. The continued foreign direct investment in Vietnam proves that

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the manufacturing and supporting industries in the country not only have a bright future but also play a vital role in the wellbeing of the economy. There is no wonder why the government has spared no efforts in developing the sector. Yoshida Sakae, MD of JETRO, Ho Chi Minh office said that the organisation in Ho Chi Minh City has been working towards trade and investment development between Japan and Vietnam for a long time. “Our major targets are to support Japan’s direct investment in Vietnam, promote Vietnam and Japan trade relations and support development of market economy in Vietnam. Now 1,200 Japanese companies operate in Vietnam, half of them in manufacturing, and they need locally sourced feedstock and parts to reduce costs. For foreign companies in the manufacturing

industry, they need raw material, parts and subcomponents to make or assemble their final products. So they need various kinds of suppliers of raw materials, subcomponents, and services,” he said. According to a survey conducted last year, local procurement by Japanese companies in Vietnam for industrial materials and subcomponent is only 28.7 percent. This figure is much lower compared to other major Asian countries. For example, local procurement in China and Thailand is 59.7 and 53.0 percent respectively. Low rate of local procurement means investors need to import more materials and components from abroad. As a result, production cost will be higher than in those countries with high local procurements rate and made-inVietnam products become less competitive. So increasing the local

procurement is strongly required for Vietnam to keep its products competitive among Asian countries. Here comes the strong need for Vietnam to enhance suppliers of raw materials and subcomponents. However, incubation and development of supporting industries takes time. Suppliers always need to improve its price and quality through various kinds of evaluation process by buyers. Vietnamese companies as suppliers need good buyers. On the other hand, Japanese companies in Vietnam need good suppliers. So business matching is strongly required for both sides. SECC Ho Chi Minh City, Vietnam October 4 – 6, 2012 Enquiry No. 6711 Turn to page 80a or log on to www.equipment-news.com to enquire

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Medical Manufacturing Asia 2012

he Inaugural exhibition on manufacturing processes for medical technology, Medical Manufacturing Asia 2012, will take place from September 12 to 14, 2012, at Suntec Singapore. The show will bring together 150 companies from 20 countries and 5,000 trade visitors from across Asia and beyond. It aims to showcase the latest solutions from the medical manufacturing industry. Strong Industry Support The show will provide a platform for the medical technology segment, in collaboration with Singapore government agencies, IE Singapore and Spring Singapore. The exhibition will be jointly organised by Messe Düsseldorf Asia and the Singapore Precision Engineering & Tooling Association (SPETA), organiser of Medtech Manufacturing 2010.

metalworking equipment news September 2012

Johany López, Maracaibo, Zulia, Venezuela

The exhibition will also be supported by Messe Düsseldorf (Germany), organiser of Compamed, an international trade fair for suppliers of the medical manufacturing industry. Buoyant Medical Technology Market Singapore is a leading site in Asia for global medical technology companies, with biomedical science companies including established medical device makers, such as, Baxter, Becton Dickinson, and Siemens locating their regional and global headquarters and manufacturing bases here. “These positive market developments, coupled with Singapore’s strategic location, close proximity to key growth markets, access to a skilled workforce and strong government partnerships, have translated into an increasing demand for a specialised trade

exhibition to serve the needs of Singapore’s industry and beyond,” says Gernot Ringling, MD, Messe Düsseldorf Asia. Relevance Of MMA 2012 “Through Medical Manufacturing Asia, we hope to facilitate industry growth and procurement needs, create business opportunities, and promote knowledge exchange for all involved in the medical technology manufacturing industry in Singapore and the region,” adds Mr Ringling. Elaborating on the relevance of this first ever exhibition, SC Koh, executive director from joint organiser SPETA says: “Medical Manufacturing Asia 2012 is timely as the Asia Pacific medical device market is experiencing unprecedented growth and is estimated to account for 25 percent of global market share and reach US$62.3 billion in revenue by 2012.” Concurrent Activities The show is a key meeting place for procurers, practitioners and professionals in the medical technology industry to source products, meet and network with trade professionals, and learn emerging trends and developments. Exhibitors and visitors can look forward and benefit from these activities: • Global Asia Trade Exchange (GATE) 12 - Medical Technology • Medical Manufacturing Asia Conference 2012 • M e d i c a l F a i r A s i a 2 0 1 2 (9th Edition) Suntec Singapore International Convention and Exhibition Centre Singapore September 12-14, 2012 Enquiry No. 6712 Turn to page 80a or log on to www.equipment-news.com to enquire

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ABB: Arc Welding Robot

Blum-Novotest: Analogue Touch Probe

ABB Robotics has developed the IRB 1520ID, a robot with integrated process dressing designed specifically for arc welding. All cables and hoses are routed inside the upper arm, simplifying programming and providing protection for all media, including welding power and wire, shielding gas and pressurised air. The integrated dressing design increases accuracy, extends hose life by 50 percent, and allows for more flexible movements, such as those needed for single-motion welds around cylindrical objects or hard to reach weld seams.

In the shape of the TC76 Digilog, Blum-Novotest has developed a touch probe for robust use in machine tools, combining digital and analogue technology in a 25 mm diameter device. A typical application is the inspection of valve seats in car cylinder heads. The touch probes however, have a broader range of uses â&#x20AC;&#x201D; automatic calibration of workpieces or zero point detection are examples of this. Temperature drift or imprecisely mounted workpieces can be detected. When mechanically connected, the touch probe is compatible with typical 25 mm touch probes with a M16 fastening screw thread, digital measurement continues to be possible without restriction. Enquiry No. 6802

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Enquiry No. 6801

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ExxonMobil: Lubricant Selector ExxonMobil Lubricants & Petroleum Specialties has developed Looble, a user friendly, online industrial lubricant selector designed to help maintenance professionals make informed lubricant decisions for opt i m i si n g e qu ipme nt performance and minimising unplanned downtime. The selector simplifies the choice of lubricant by providing targeted Mobil-branded product re co m me n da t io n s w it h performance ratings based upon usersâ&#x20AC;&#x2122; specific industries, applications and equipment. It also enables users to access lubricant recommendations and application guidance based on their specific applications and operating conditions for a wide range of industries, as well as formulating printable recommendation reports. Enquiry No. 6803 Turn to page 80a or log on to www.equipment-news.com to enquire

The Harting Han-Modular system incorporates options which would otherwise require expensive, specially developed connectors or separate solutions. Currents from a few milliamps to 200 A, voltages from 50 to 5,000 V, pneumatic hosing, data lines, shielded bus signals and optical cables made of POF or fibre glass can be provided with plug-in designs with the system. The series is constantly being expanded. The additions are the Han-Eco plastic housing, the HanModular docking frames and several modules, for example, an Ethernet module for high data transmission rates of up to 10 GBit/s and the Han-E module suitable for on-site assembly with Han-Quick Lock termination technology. Enquiry No. 6805 Turn to page 80a or log on to www.equipment-news.com to enquire

Hainbuch: Chuck With Hexagonal Core

Jet Edge: Modular Waterjet Pump

Machining cast parts can be trick y because dust, chips and dirt impair the function of the clamping device. Due to radius displacement of the chuck cone and clamping head, it has not been possible in the past to fully seal certain chucks. With Toplus, however, Hainbuch has a chuck that has a hexagonal core made of concrete polymer. This clamping device is lighter than steel chucks and also has a lower mass inertia torque, which is advantageous especially during high acceleration. Not to mention the positive dampening properties of the material. Due to the pyramid shape, as opposed to the conventional cone shape, all surfaces fit tightly, leaving no gaps.

Waterjet manufacturer Jet Edge has developed the iP36-50 Modular Waterjet Intensifier Pump. Designed for ease of portability, the 36KSI (2,500 bar), 50hp waterjet pump features a modular design that makes it easy to move into tight spaces, such as small passageways, ship engine rooms and ballast tanks. The pump produces up to 1.8 gpm (6.8 L/m) of 36KSI (2,500 bar) ultra-high pressure water for precision cutting, cleaning and surface preparation applications. It includes three modules with lifting eyes. The modules can be stacked to save space during operation or storage.

Enquiry No. 6804 Turn to page 80a or log on to www.equipment-news.com to enquire

Harting: Tailored Connectors For All Applications

metalworking equipment news September 2012

Enquiry No. 6806 Turn to page 80a or log on to www.equipment-news.com to enquire

productfinder

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Open Mind: Reducing Machining Times

When Second Best Won’t Cut It.

Family of Products

See Mastercam X6 in action at www.mastercam.com.sg

MedTech 12 to 14 Sept 2012 • Booth #C25 www.medmanufacturing-asia.com

MTT2012(Surabaya) 19 to 21 Sept 2012 • Booth #216 www.mtt-indonesia.com Techtown Pte Ltd

www.techtown.com.sg • info@techtown.com.sg Tel : +65 6636 8215 • Fax : +65 6636 8221

ENQUIRY NO 147

Open Mind Technologies has developed its 2012 version of hyperMill CAM solution. Highlights of the CAM software include automatic programming options for rectangular pockets, optimisations for 3D roughing and strategies for five-axis machining of impellers and blisks. Other changes improve calculation times and programming times. The ‘adaptive pocket’ machining mode allows for automatic programming of rectangular pockets. Within a machining job, classification occurs automatically in closed and open pockets and rectangular levels. According to the various accessibility conditions for the tool and relative sizes of the tool and pocket, the program automatically selects the most suitable machining method. Enquiry No. 6807 Turn to page 80a or log on to www.equipment-news.com to enquire

ited pany (Pte), SinLgaim m o C k e 409032 h re po C g n ing o H g Factory Build Tel: +65 6746 1308 #09-07 Yi Guan 180 Paya Lebar

Road,

60 Fax: +65 6747 17om gchek.c Email: sales@honngchek.com Website: www.ho

ENQUIRY NO 081

ENQUIRY NO 052

r application; Laser systems fo cutting, , ng ki drilling, mar ing on av gr en , ng di wel c material ni ga or organic, nonn metals. and metal and no

September 2012 metalworking equipment news

productfinder

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Seco: Cost-Efficient Milling Cutter

Tornos: Machine For Complex Parts

The Square 6-04 is a smaller addition to Secoâ&#x20AC;&#x2122;s successful line of Square 6 square shoulder milling cutters. It includes tool diameters down to 20 mm, allowing the benefits of the cutter to be applied to an even greater range of applications. It is suited for small and medium milling machines, and incorporates trigonal inserts with six cutting edges to achieve improved cost-efficiency and increased productivity. The 90-degree setting angle ensures a true 90-degree square in one operation, saving valuable production time. Different pitches are available to maximise machine usage.

To address the need for a mid-range machine capable of producing relatively complex parts, Tornos has created the Swiss ST 26. Everything suggests that this machine, with its seven linear axes, two C axes, machining capacity and competitive price, will be up to the task. With a capacity of 26 mm and two totally independent tool systems which can be equipped with more than 50 tools, including special devices, the machine can be used to produce moderately complex parts with large diameters. Other notable features include optimised operating procedures, a responsive and efficient spindle and good ergonomics.

Enquiry No. 6808 Turn to page 80a or log on to www.equipment-news.com to enquire

Siemens PLM: Customer-Driven Productivity Enhancements Siemens PLM Software has released Solid Edge software ST5 (Solid Edge ST5), with advances in core design capabilities aimed at helping users develop better products faster. The release also contains more than 1,300 customer-driven productivity enhancements. The developer also announced Solid Edge Mobile Viewer, a free 3D viewer mobile device application (app) for the iPad portable digital device, which broadens access to design data to help companies enhance collaboration. The software program continues to leverage synchronous technology to provide enhanced support for multi-body modelling, which lets users import parts and assemblies from virtually any CAD system. The resulting imported geometry can be combined into a single part or multiple parts depending on manufacturing requirements. Enquiry No. 6809 Turn to page 80a or log on to www.equipment-news.com to enquire

metalworking equipment news September 2012

Enquiry No. 6810 Turn to page 80a or log on to www.equipment-news.com to enquire

Walter: Solid Carbide Thread Former

The advantages of thread forming come fully to the fore with the Protodyn HSC solid carbide thread former by Walter, which also enables the process to be performed at high speed. The tools are supplied in different variants. Depending on the purpose for which a thread is developed, a former with or without cooling can be used. With the use of lubrication grooves, it can be used universally, particularly for deeper threads over 3xd. For applications that do not require lubrication grooves, the lower-priced variant can be used. Since there is no swarf to dispose of, the same forming tools can be used for basic threads and through-hole threads. In applications that require large numbers of threads to be produced in series â&#x20AC;&#x201D; for example for processing connecting rods, special tools are the equipment of choice. Enquiry No. 6811 Turn to page 80a or log on to www.equipment-news.com to enquire

Exhibition Programmes

September

2012-2013

10 – 15 IMTS

McCormick Place Chicago, USA AMT@AMTonline.org www.imts.com

6 – 10 China International Industry Fair 2012 SNIEC Shanghai, China www.ciif-expo.com

12 – 14 Medical Manufacturing Asia

Suntec Singapore Messe Dusseldorf mma@mda.com.sg www.medmanufacturing-asia.com

19 - 21 MTT Expo

7–9 Indonesia Oil & Gas Expo 2012

Balikpapan Int'l Sport Arena Balikpapan, Indonesia Fireworks info@asiafireworks.com www.indonesiaoilgas.com

7 – 10 Indo Aerospace 2012 JIExpo Jakarta, Indonesia www.indoaerospace.com

Grand City Convex Surabaya, Indonesia ECMI info@mtt-indoneisa.com www.mtt-indonesia.com

7 – 11 TMTS 2012

GTIEC Taichung, Taiwan TMBA ricky@tmba.org.tw www.tmts.tw

October

4–6 Metalex Vietnam SECC Ho Chi Minh City, Vietnam Reed Tradex rtdx@reedtradex.co.th www.metalexvietnam.com

21 – 24 Metalex

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

23 – 27 EuroBlech 2012 Exhibition Grounds Hanover, Germany Mackbrooks Exhibition info@mackbrooks.co.uk www.euroblech.com

December 5–8 Manufacturing Indonesia 2012

November 1–6 JIMTOF 2012

Jakarta Int'l Expo Kemayoran Jakarta, Indonesia PT Pamerindo www.pamerindo.com

Tokyo Big Sight Tokyo, Japan JMTBA www.jimtof.org

The Editor (APMEN)

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

Eastern Trade Media 1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206 Email: josonng@epl.com.sg Tel: +65 63792888

2013 January 24 – 30 Imtex 2013

Bangalore International Exhibition Centre Bangalore, India IMTMA imtma@imtma.in www.imtex.in

February 20 - 23 Indometal

Jakarta International Expo Kemayoran Jalarta, Indonesia Messe Dusseldorf (Asia) shirley@mda.com.sg www.indometal.net

27 Feb – 1 Mar ASX 2013 Singapore Expo Singapore AAIS asx@aais.org.sg www.asx.sg

March 5 – 10 TIMTOS

TWTC, TWTC Nangang Taipei, Taiwan TAITRA timtos@taitra.org.tw www.timtos.com.tw

April

9 – 12 MTA 2013

Singapore Expo Singapore SES mta@sesallworld.com www.mta-asia.com

May

21 – 25 Metaltech 2013

PWTC Kuala Lumpur, Malaysia Tradelink info@tradelink.com.my tradelink.com.my/metaltech

www.equipment-news.com September 2012 metalworking equipment news

Advertising Index Page No.

Enquiry No.

AGIE CHARMILLES (SEA) PTE LTD

146

BENIGN ENTERPRISE CO LTD

085

BLUM PRODUCTION METROLOGY PTE LTD

153

BYSTRONIC PTE LTD

144

DEES HYDRAULIC INDUSTRIAL CO LTD

081

DELCAM PLC (INTERNATIONAL DIVISION)

075

Advertiser

DMG ASIA PACIFIC PTE LTD

155

EVERGREEN INTERNATIONAL CORP. (TAITRA) / TIMTOS 2013

136

FACTORY AUTOMATION TECHNOLOGY CO LTD

093

GREENLEAF CORPORATION

IBC

140

HAAS AUTOMATION INC

132

HEXAGON METROLOGY (THAILAND) LTD

157

HONG CHEK CO (PTE) LTD

052

HPMT INDUSTRIES SDN BHD

042

HWACHEON ASIA PACIFIC PTE LTD

133

FC / IFC

150 / 151

JYOTHI CNC AUTOMATION PVT LTD

047

KENNAMETAL INC

128

LICO MACHINERY CO LTD

086

LVD COMPANY NV

134

MITUTOYO ASIA PACIFIC PTE LTD

145

ISCAR LTD

www.equipment-news.com

NATIONAL INSTRUMENTS

120

OPTICAL GAGING (S) pTE lTD

125

PAMA SPA

113

PT PAMERINDO INDONESIA

135

REED TRADEX COMPANY (METALEX THAILAND 2012)

130

REED TRADEX COMPANY (METALEX VIETNAM 2012)

152

RENISHAW (HONG KONG) LTD

054

SCHAEFFLER (SINGAPORE) PTE LTD

154

SECO TOOLS (S.E.A) PTE LTD

065

SINGAPORE EXHIBITION SERVICES PTE LTD (MTA 2013)

143

SODICK SINGAPORE PTE LTD

077

SPHINX

008

SUTTON TOOLS PTY LTD

149

TAEGUTEC CO

138

TAIWAN TAKISAWA TECHNOLOGY CO LTD

058

TECHTOWN PTE LTD

147

TORNOS TECHNOLOGIES ASIA LTD

137

TRUMPF PTE LTD

023

TUNGALOY SINGAPORE (PTE) lTD

142

UNISIG

156

WALTER AG SINGAPORE PTE LTD

039

WINTERTHUR SCHELEIFTECHNIK AG

148

metalworking equipment news September 2012

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ASIA PACIFIC METALWORKING

No. 6 2012

The Engineering Journal For Manufacturing,Automation & Quality Control

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ENQUIRY NO 140

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ENQUIRY NO 128