Consumer Electronics:
ASIA PACIFIC METALWORKING EQUIPMENT NEWS
Good News For Metalworking
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The Productivity Multiplier July-August 2009
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VOL. 23 NO. 5 JULY/AUGUST 2009
Precision Technology:
Versatile Measurement HMC:
New Horizons In Machining
M.I.C.A. (P) No. 119/12/2008 • PPS 840/10/2009(028102) • ISSN 0129 5519
Plasma & Laser Cutting:
Making The Precise
Increasing Your
ProFITABILITy
Cutting Down Production Costs with Winning Combinations for Optimal Productivity ISCAR JAPAN 1-5-3 Shinsenri-Higashimachi Toyonaka-shi, Osaka 560-0082 Tel + 81 6 835 5471 Fax + 81 6 835 5472 iscar@iscar.co.jp
ISCAR TAIWAN 395, Da Duen South Rd. Taichung 408 Tel +886 (0)4 247 31573 Fax +886 (0)4 247 31530 iscar.taiwan@msa.hinet.net
ISCAR THAILAND 57, 59, 61, 63 Soi Samanchan-Babos Sukhumvit Rd. Phra Khanong, Khlong Toey Bangkok 10110 Tel + 66 (2) 7136633 Fax + 66 (2) 7136632 iscar@iscarthailand.com
ISCAR VIETNAM (Representative Office) Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., Ho Chi Minh City, Tel + 84 8 8123 519/20 Fax + 84 8 8123 521 iscarvn@hcm.fpt.vn
CV MULTI TEKNIK JL. Balikpapan Raya No. 28 Jakarta Pusat 10140 Indonesia Tel + 62 21 6307303 Fax + 62 21 6348062 multi@centrin.net.id
SINO TOOLING SYSTEM Blk 502, Jurong West Ave 1 #03-813 Singapore 640502 Tel + 65 6566 7668 Fax + 65 6567 7336 sinotool@singnet.com.sg
ENQUIRY NO 092
Grooving & Turning Intelligently
MESCO Reliance Corner Brixton St. Pasig City Metro-Manila Philippines Tel + 63 2631 1775 Fax + 63 2635 0276 mesco@mesco.com.ph
From years of working closely with customers, we’ve learned what it takes to turn a new machine into a winner. Our specialists can supply you with customized tool packages and will stand by your side right from the start, from tooling to full production, all to guarantee peak performance fast. What’s more, our consulting services are free! Why? Because there’s nothing sadder than a machine that isn’t reaching its full potential. Get in touch with your Sandvik Coromant representative and we’ll tell you more.
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ENQUIRY NO 063
We don’t make machines. We make them better.
Contents July-August 2009
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 #04-02 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.
22 FIRST CUT Plasma Cutting: Unveiling The Fourth State
The mask is off the reclusive fourth state of matter as plasma makes its presence felt in cutting. By Joson Ng
24
Upping The Ante
Investing in right machineries can rapidly transport a company to a whole new playing field. By Matthew Fowles, marketing manager, LVD Group
Thailand Office: Thai Trade & Industry Media Co Ltd. 16/F Italthai Tower, 2034/73 New Petchburi Road, Bangkapi, Huaykwang, Bangkok 10310, Thailand Tel: 66(0) 2716 1722 Fax: 66 (0) 2716 1723 SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: irenetow@epl.com.sg IMPORTANT NOTICE THE CIRCULATION OF THIS MAGAZINE IS AUDITED BY BPA WORLDWIDE. THE ADVERTISERS' ASSOCIATION RECOMMEND THAT ADVERTISERS
28 TECHNOLOGY UPDATE Precision Technology: Versatility Personified
Parts of different shapes and sizes require a more multi-functional approach to measurement. By Kelly Ho, GM, Optical Gaging, Singapore
34
Working Backwards
High tech metrology products and reverse engineering are generally deployed in a traditional industrial setting like in metalworking but that is no longer the case. By Soafara Menke, regional marketing coordinator, Faro
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INDUSTRY
Endorsements
SPETA
Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA)
36 SOFTWARE & MEASUREMENT Applications & Software: Putting The P In Productivity
Application software packages catalyse the reaction commonly known as productivity. By Peter Dickin, marketing manager, Delcam
38
Federation of Malaysian Foundry & Engineering Industry Associations Indian Machine Tool Manufacturing Association (IMTMA)
China Machine Tool & Tool Builders' Association (CMTBA)
Metrology: Making The Right Choice
Material selection is the first and arguably the most important choice in constructing a reliable CMM. Contributed By Mandy Wong, regional MarComms and PR manager, Carl Zeiss
40
Soft On Applications
Placing increasing emphasis on software applications can reap healthy rewards in machining, metrology and manufacturing. By Derek Rodriguez 2
metalworking equipment news Jul-Aug 2009
Machine Tool Club (MTC)
Taiwan Association of Machinery Industry (TAMI)
DMG – technologies for tomorrow
CTX gamma TC
Complete machining with a turning/milling spindle! A quantum leap in innovation: Turning/Milling Centres with a B-axis milling spindle and a tool magazine.
CTX gamma 1250 / 2000 TC Highlights: DMG ERGOline® Control with a 19" screen: Detailed information, optimal user comfort, reduction of programming time with easy shop floor programming with Siemens 840D SL ShopTurn or Heidenhain Plus iT with DINPlus Turning / Milling spindle with an NC-controlled B-axis with a torque motor Stable control stand installed across the Z-axis for optimum power discharge Y-Hub with 400 mm, turning lengths to 2,000 mm, turning diameter up to 630 mm (700 mm with a chain magazine) Disk magazine with 24 or 36 stations and an optional 120x chain magazine Max. power with up to 770 Nm on the main and counter spindles Technical data and machine subject to modifications. Our standard terms and conditions apply.
Workpiece illustrated: Connecting plate; Machining time: Approx. 25 min.
All top NEWS on the CTX gamma TC series is available online at:
www.dmgasiapacific.com
DMG Asia Pacific Pte Ltd.: No. 3 Tuas Link 1，Singapore 638584, Tel.: +65 66 60 66 88, Fax: +65 66 60 66 99, E-Mail: info@dmgasiapacific.com, Website: www.dmgasiapacific.com
ENQUIRY NO 095
No vibration or tilt effect in Y due to the complete control stand
Consumer Electronics:
Regulars
44 FAB & FORM HMCs are proving to be a firm favourite that will never go out of fashion. By Augustine Quek
58 FEATURES
www.equipment-news.com M.I.C.A. (P) No. 119/12/2008
Precision Technology:
Versatile Measurement HMC:
New Horizons In Machining M.I.C.A. (P) No. 119/12/2008 • PPS 840/10/2009(028102) • ISSN 0129 5519
New Horizons
Software:
THE PRODUCTIVITY MULTIPLIER July-August 2009
VOL. 23 NO. 5 JULY/AUGUST 2009
• 8 Business News • 18 Business Statistics • 74 Product Finder • 79 Exhibition Programmes • 80A Product Enquiry Card
ASIA PACIFIC METALWORKING EQUIPMENT NEWS
Contents
GOOD NEWS FOR METALWORKING
Cover Jul-Aug09.indd 2
Plasma & Laser Cutting:
Making The Precise Cover credit: LVD
6/23/09 8:45 AM
Malaysia Mould and Die Association: Propelling Forward
Making rational decisions, focussing on development and technology are all part of the masterplan to make the big stride forward. By Joson Ng
60
No Fixed Rules
Fluidity in fixturing was unthinkable in the past but not anymore with the combination of modular fixturing and CAD coming to the fore. By Maren Roeding, PR manager, Witte Far East
50 INDUSTRY SPOTLIGHT Consumer Electronics: Innovation In Difficult Economic Times
Creative solutions are the perfect antiviral drugs for those in the consumer electronic sector who are suffering from the latest bout of economic influenza. By Thomas W Maurer and Daniel J Staresinic, worldwide director, Siemens PLM
52
Consumer Electronics: Cosy Comfort
The consumer electronics industry may not have been spared from the dreaded downturn but there are signs that bode well for the metalworking industry. By Joson Ng
62
Synergy In Action
Co-operation on an organisational level is a philosophy that is creating much sucess in one tool-making unit. By Ralph Schiffler, for DMG
66
Take The Heat Off
56 COUNTRY FOCUS Taiwan Focus: Island Of Steel
Like the Taipei 101, the Taiwanese machinery industry is standing tall and firm. By Joson Ng
67
It is always important to stay cool under high pressure and heat, this is all the more true in drilling. By Gregory S Antoun, president, ChipBlaster Inc, USA
78 PARTING SHOT Tata Nano: Pint Size Giant
What Tata Nano lacks in size, it makes up in its competitive price.
EVENTS & EXHIBITION
Aerospace Supplier eXchange: Planting The Seed
The economic situation may not be all that rosy at the moment but it does not mean it is time to head for the hills. By Joson Ng
MTA Malaysia 2009 • Metaltech 2009 • Metalex Vietnam • Eastpo 2009 • EMO Milano 2009
• Refer to Advertising Index...
Pg 80
for Advertisers' Enquiry numbers
ENQUIRY NO 090 add-resize.indd add-resize.indd 1 1 add-resize.indd add-resize.indd 1 1
12/06/2009 12/06/2009 08:59:0308:59:03 12/06/2009 12/06/2009 08:59:0308:59:03
editor’s note
Published by:
Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)
A Welcomed
Lift Man has always been fascinated by flight, which operates on the basis of lift. Without it there can be no flight. Lift is generated from the wings of the plane, which obeys Bernoulli’s principle. Fast forward to present day, the situation the world is in now can be likened to a bumpy flight. As the plane flies through the turbulent sky, it is bound to lose altitude, which of course can be a harrowing experience. As fear is one of man’s innate emotions, it is natural to feel fearful in response to danger and threats. Losing altitude however, does not equate imminent disaster. Casting fears aside, it is important to k now t he ‘pla ne’ t he world i s traveling in now still has its wings intact and able pilots in command. With wings, there will be lift. As such, the plane will not fall from the sky like dead weight. All there is to do now is to wait for the pilot to ‘pull up’ and eventually the plane will regain normal cruising altitude. In
the metalworking world, the process of ‘pulling up’ has begun in earnest. In the recently concluded MTA 2009 in Malaysia, the floor area may have gone down but the cash registers are ringing with the sale of machines during the show. Elsewhere in Singapore, plenty of effort is being made by authorities to make sure people are ready for the up-turn. Take the Aerospace Supplier Exchange for example, the show aims to showcase the country’s MRO cluster to the rest of the world. Despite the current situation in aviation, the turn-out was promising. Incorporating events like Global Asia Trade Exchange (GATE 09) that match make buyers with suppliers are just one of the examples of the corrective action taken by the ‘pilot’. Air turbulence does not last forever so as the seat belt sign is on now, fasten all seatbelts and remain seated. Before long, we can expect to be gaining altitude again.
Reg No: 199908196C
managing director Kenneth Tan managing editor Eileen Chan
eileenchan@epl.com.sg
assistant editor Joson Ng
josonng@epl.com.sg
advertising sales manager Derick Chia
derickchia@epl.com.sg
editorial assistant Sharifah Zainon sharifah@epl.com.sg senior art director / studio manager Lawrence Lee lawrencelee@epl.com.sg graphic designer Jef Pimentel jeffreypimentel@epl.com.sg circulation executive Irene Tow
irenetow@epl.com.sg
contributors Matthew Fowles, Kelly Ho Soafara Menke, Peter Dickin Augustine Quek, Thomas W Maurer Daniel J Staresinic, Maren Roeding Ralph Schiffler, Gregory S Antoun Mandy Wong, Derek Rodriguez 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. 119/12/2008 PPS 840/10/2009 (028102) ISSN 0129/5519
Eastern HOLDINGS Ltd Executive Board
chairman Stephen Tay group executive director Kenneth Tan financial controller Robbin Lim
etm
Eastern
Trade Media Pte Ltd an Eastern Holdings Ltd company
Joson Ng Assistant Editor
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metalworking equipment news Jul-Aug 2009
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ENQUIRY NO 087
The Haas SL-20 Turning Center Includes a Special Feature You May Not Notice Right Away...
a Lot of Machine for the Price.
Machines shown with optional equipment.
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Businessnews
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Renault-Nissan For Zero-Emission
8
Singapore: The Renault-Nissan Alliance has formed a partnership with the Energy Market Authority (EMA), the Land Transport Authority (LTA) and the Economic Development Board (EDB) of Singapore to explore the development of Zero Emission Vehicles Programme. Under a memorandum of understanding signed, the organisations have agreed to set up working team of representatives and promote introduction and expansion of Electric Vehicles (EVs) in Singapore. “Renault and Nissan aim to become leading brands in zero emission vehicles. Singapore is for us a key priority, as the geography of the country and the focus on environment issues make fast and strong development of electric cars,� said Thierry Koskas, Renault electric vehicles programme director. The Alliance has formed partnerships with 26 governments, cities and other organisations to advance the deployment of EVs worldwide. To spearhead EV test-bedding and infrastructure development in Singapore, a multi-agency taskforce
chaired by EMA and LTA has been set up with members comprising the Agency for Science, Technology and Research, EDB, National Environment Agency, Ministry of the Environment and Water Resources and Ministry of Trade and Industry. The EV taskforce was set up to assess the benefits and applicability of adopting EVs in Singapore. It will draw up the overall plan of EV test-bedding and evaluation of the environmental and economic benefits, with a view of a potential larger scale adoption of EVs in the future. The taskforce will work with key industry players to examine infrastructural requirements, policy requirements and new business models arising from EVs, as well as identify industry development and R&D opportunities. It will also look into educating the public on EV technology through a nationwide EV sharing programme or through corporate fleets. The taskforce will set aside funding for interested parties to develop infrastructure and buy EV during the test-bedding process.
ExxonMobil Breaks Ground In China
Mori Seiki Establishes Micro Machining Society
Beijing, China: ExxonMobil Chemical broke ground on its technology centre in Shanghai, China. The groundbreaking ceremony was held on its site at Shanghai Zizhu science-based industrial park. The 27,000 sq m facility will be built and operated by ExxonMobil Asia Pacific R&D company. The initial investment in the technolog y centre and related equipment is US$70 million. It will house laboratories and product demonstration facilities, providing applications technical service and a range of application development capabilities for the company’s polymer products and plasticisers. Initial employment will be approximately 200 people. The facility is expected to be operational in 2010. The centre in Sha nghai will prov ide product applications support.
Nagoya, Japan: Mori Seiki and Iriso Seimitsu have jointly established the Micro Machining Society. Recently, large machine tools have been drawing attention in the aircraft and energy industries. Meanwhile, with an increase in demand for highaccuracy machining of complex-shaped workpieces in the medical, precision parts and precision dies/moulds fields, the need for research on machining methods for those workpieces and for precision machines have also been growing. In order to accumulate know-hows for micro machining and free form machining, the two companies reached an agreement on jointly estabishing one research organisation. The aim of this organisation is to conduct research on technologies, and to develop markets and new models, specifically for the micro machining and freeform machining fields. The activities will focus on micro machining/free-form machining using a CAM system or scanner, and test machining of parts with Mori Seiki NVD1500 DCG or precision machines, which are under development. The results will be reported at a quarterly meeting.
metalworking equipment news Jul-Aug 2009
businessnews
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Kennametal Completes Acquisition Of Romicron
Moog Expands Wind Power Business
Latrobe, USA: Kennametal has completed the acquisition of Romicron from Indústrias Romi SA. The acquired technology and manufacturing will be integrated into the company’s Brazil location in Indaiatuba and will help to strengthen the company’s holemaking and precision hole finishing portfolio. With the addition of Romicron’s precision boring systems, the company’s capabilities to offer holemaking solutions from roughing to fine finishing will be expanded, according to Paul DeMand, Kennametal VP and president of the company’s metalworking solutions and services group.
Singapore: Moog Asia Pacific will expand its wind power business by offering fibre optic load measurement systems for wind turbines. The move follows the acquisition by parent company Moog of 70 percent of Insensys for £11 million (US$17.3 million), with an option to purchase the remaining 30 percent within one year. In the past year, the company has expanded its wind power capabilities with the acquisition of 40 percent of LTi REEnergy, which designs and manufactures servo controllers and complete drive systems for electric pitch control of wind turbines. With the acquisition of Insensys, the company possesses all the components for electric and hydraulic pitch control solutions in-house. These core components include sensors, servomotors, servovalves, electro-mechanical and electro-hydraulic actuators, rotating connectors (slip rings and fibre optical rotary joints), controllers, and drives.
Doosan’s Vietnam Plant Seoul, S Korea: Doosan has inaugurated a production plant in Vietnam at the Dung Quat industrial complex. Costing some KRW300 billion (US$239 million), the 330,000 sq m site consists of five plants, including a boiler production plant and a chemical process equipment plant, as well as the main office building, an in-house pier and various port facilities.
TYROLIT Thailand Co., Ltd. (Sales office) TYROLIT Asia Pacific | 20th Fl. Thanapoom Tw. TYROLIT Ltd. (China) 1550 New Petchburi Rd. | Bangkok 10400 Hong Kong T: +852-275 751 28 | Beijing T: +86-10-822 509 91 T: +662 7036672-5 | F: +662 703-6676 T: +662 251 7861 | E-mail: tyrolit-thailand@tyrolit.com Shanghai T: +86-21-525 855 00 | E-mail: tyrolit@tyrolit.cn E-mail: tyrolit@loxinfo.co.th
A Company within the SWAROVSKI Group www.tyrolit.com
ENQUIRY NO 107
TYROLIT – YOUR PARTNER IN GRINDING DIAMOND AND CBN PRECISION GRINDING TOOLS
Jul-Aug 2009 metalworking equipment news
9
businessnews
Notice Of Postponement Johor Bahru, Malaysia: MYMEX Johor Bahru 2009, scheduled to be held from July 22 - 25, 2009 at the Persada Johor International Convention Centre is postponed. The decision was made on the request of the majority of exhibitors due to the prevailing economic climate. Currently there is no fixed date for the return of MYMEX in Johor Bahru. The organiser will continue to engage the industry to ascertain the best possible date of return.
Aconex Selected For Rail Station Project In Singapore
Singapore: Technology firm Aconex has been selected by engineering and construction firm McConnell Dowell to provide its online collaboration solution to the S$340 million (US$224 million) Beauty World Mass Rapid Transit (MRT) station development in Singapore. The company will manage information and link organisations involved in the project. Due for completion in 2015, the project includes the design and construction of the Beauty World MRT underground station, as well as station entrances, subway links, architectural finishes and external landscaping. It also includes the development of two underground 1.1 km rail tunnels, two cross passages, and 135 m of cut and cover tunnels.
SKF India Starts Constructing Manufacturing Site Uttarakhand, India: SKF India has begun work for the manufacturing site in Haridwar. It will be operational by January 2010. The company will be investing Rs 1,500 million (US$33.6 million) in this project and plans to employ more than 200 people. This plant will specifically cater to the automotive market segment in India. Situated over an area of 10 acres (40,468 sq m), the new bearing factory will have a production capacity of 40 million bearings. 10
metalworking equipment news Jul-Aug 2009
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Sumitomo Metals Expands Into India Tokyo, Japan: Sumitomo Metals has established a Joint Venture (J V ) with Amtek, a manufacturer of automobile parts in India, in order to enter the Indian market where high growth is anticipated. This is in line with the company’s strategy to expand its forged crankshaft business. With this entry to India, the company will have a global ‘tetrapolar’ production system (Japan, US, China and India) and cement their global share in forged crankshafts to over 10 percent. A JV is to be formed with investment of 40 percent by Sumitomo Metals, 10 percent by Sumitomo Corp, and 50 percent by Amtek. The JV Company will acquire Amtek’s Dharuhera plant near New Delhi. The plant is equipped with a 4,000 ton pressing machine and will produce and sell small-size forged crankshafts and other forged products. The planned start of operation is in late July 2009. Production capacity is 800,000 crankshafts pa (in full production).
Usage Of Automotive Aluminium At All-Time High Atlanta, USA: Novelis, the producer of aluminium sheet for automobiles, has seen an increase of more than 20 percent in the number of automotive applications of its lightweight material compared to a year ago. The most popular automotive application for aluminium sheet is the hood or bonnet. Other applications include fenders, deck lids, doors, roofs, liftgates and structural components. The company recently expanded its service into Asia and is supplying aluminium to South Korean car makers for the manufacture of car hoods. In March, the Aluminium Association released the results of a study that shows the use of automotive aluminium globally is at an all-time high, averaging 7.8 percent of the average worldwide light-vehicle curb weight in 2009. The study covered all forms of the metal – rolled products, castings, extrusions and forgings. The study predicts that growth will continue at a rate of fourto-five pounds (2 kg) per vehicle, per year, and approach 300 pounds (136 kg) per vehicle worldwide in 2020. The study also indicates a growing penetration of aluminium in high-volume, mid-size vehicles, suggesting the lightweight metal is no longer used exclusively on luxury or high-performance models, but is moving into mainstream applications.
businessnews
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Samsung Heavy Industries Advances Into Wind Power
C
M
Y
CM
MY
CY CMY
K
ENQUIRY NO 083
Seoul, S Korea: Samsung Heavy Industries has entered into the US wind power generator market, which it achieved by concluding an LOI with Cielo, a US-based firm, for the installation of three 2.5 MW wind power generators by 2011 in Texas. As the US government has announced its intention to increase the portion of wind-generated power from its current level of one percent to over 20 percent of the power used in the US by 2030, the company decided to
advance into the US market, recognising its high growth potential. These efforts have now borne fruit, with the company signalling its US market entry just nine months after launching the business. The 2.5 MW wind power generator developed by the company has a 10 percent higher power generation efficiency, a lifecycle of 25 years, which is five years longer than existing products. In addition, the company unveiled its mid-term targets, which include investments of KRW 600 billion (US$481 million) and annual production of 200 units of 2.5 MW inland power generators and 5 MW offshore power generators by 2010. Furthermore, they are targeting revenues of KRW 3 trillion through the production of 800 units of wind power generators in 2015 and the world’s seventh largest market share (10 percent). The company aims to operate in the US, Chinese and Indian markets with large territories through its 2.5 MW in-land wind power generators in the initial stage, and then increase its Asian and EU market shares with offshore generators that boast high efficiency and lower noise from 2015.
Jul-Aug 2009 metalworking equipment news
11
businessnews
www.equipment-news.com
OIL & GAS
Saipem Wins US$280 Million Offshore Contract
China North East Petroleum Completes Additional Wells Harbin, China: China North East Petroleum has drilled and completed three additional oil producing wells. During the first quarter of 2009, there were seven wells under construction, none of which were placed into production due to relatively weak oil prices. As of May, the company successfully completed fracturing and cementing three of these wells and brought them into production. Additionally, the initial productivity of the new wells has exceeded the engineers’ original expectations. As previously announced, the company intends to place approximately 35 more new wells into production for the remainder of 2009.
PetroChina Acquires Keppel’s Entire Stake In SPC Milan, Italy: Saipem has been awarded an offshore contract for the development of the Gajah Baru field located in the Natuna block ‘A’ in the West Natuna sea, off the coast of Indonesia. T h e c o m p a n y ’s c o n t r a c t p o r t i o n i s w o r t h a p p r o x i m a te l y U S $ 2 8 0 m i l l i o n , a n d i n c l u d e s engineering, procurement, transport and installation of the platforms and pipeline. Saipem, in a consortium with PT SMOE Indonesia, has been awarded by Premier Oil Natuna Sea BV the EPCI contract (engineering, procurement, construction and installation) for the central processing platform (weighing a total of 12,900 tonnes), the Wellhead platform, a connecting bridge and a 16” gas export pipeline 3 km long.
CNOOC Start-Up Oil Field Hong Kong, China: CNOOC start-up its independent oil field Qinhuangdao (QHD) 33-1. The company holds 100 percent interest of the oil field and acts as the operator. Currently, it is producing approximately 2,000 barrels of oil per day via two wells. QHD33-1 is located in the central to western Bohai Bay with a water depth of about 21 m. The development and production of QHD33 -1 mainly rely on the facilities of the adjacent producing field QHD 32-6. The oil produced will be transferred to QHD32-6 via subsea pipeline for processing, storage and transportation. 12
metalworking equipment news Jul-Aug 2009
Beijing, China: PetroChina has entered into a conditional agreement with Keppel Oil and Gas Services, to acquire its entire shareholding in Singapore Petroleum Company (SPC) representing approximately 45.51 percent of the total issued share capital of SPC (excluding treasury shares) for cash consideration of S$6.25 per share, equivalent to approximately S$1.47 billion (US$1.02 billion) to be paid in full on completion. SPC is a regional energy company with interests in petroleum refining and marketing, in oil and gas exploration and production. The company has a 50 percent interest in Singapore Refining Company, one of the three major petroleum refiners in Singapore. The company also conducts terminalling and distribution, and trading of crude and refined petroleum products.
Foster Wheeler To Supply CO Boiler To Refinery Zug, Switzerland: Foster Wheeler Energy and Foster Wheeler have been awarded contracts by CTCI for the supply of a carbon monoxide boiler for CPC’s Residue Fluidised Catalytic Cracker (RFCC) at the company’s Talin refinery, Kaohsiung, Taiwan. CTCI is the prime contractor for the engineering, procurement and construction of CPC’s RFCC project. Foster Wheeler’s scope includes supplying an incinerator to destroy carbon monoxide in the waste gas stream from the RFCC, a boiler section to recover heat from the resulting flue gas, and a selective catalytic reduction flue gas treating system to minimise emissions of nitrogen oxides to the atmosphere.
ENQUIRY NO 091
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AEROSPACE
Honeywell Opens Engineering Centre In Bangalore
Bangalore, India: Honeywell inaugurated a US$50 million re se a rch, development & engineering facility at Orion, Bangalore. It is the company’s second R& D centre in the cit y. T he facilit y w ill accommodate 3,000 people a n d f e a t u r e s l a b o r a to r y facilities, simulators, and a training centre. The company is looking Ben Spear, London, UK into aerospace and defence, public safety and security and infrastructure development. It is collaborating with Hindustan Aeronautics to produce TPE331 aircraft engines in India. The company is also pursuing a programme to re-engine the IAF’s strike aircraft Jaguar with its F125IN turbofan engine.
ST Aerospace Acquires PPS Singapore: Singapore Technologies Aerospace (ST Aerospace) has acquired all the shares of Precision Products Singapore ( PPS) from Nippon Precision Casting Corp, Renaissance Capital Management and Singapore Technologies Industrial Corp respectively. The acquisition was for a cash consideration of S$7.65 million (US$5.3 million). With this purchase, PPS becomes a wholly-owned subsidiary of ST Aerospace. PPS manufactures casting and mould toolings for customers in the aerospace, defence, commercial, and oil and gas industries. The acquisition will support the company’s commercial and defence business.
Rolls-Royce To Support Malaysian Fleet London, UK: Rolls-Royce has signed a £75 million (US$116 million) MissionCare contract with the Royal Malaysian Air Force (RMAF) to support the Adour engines which power its fleet of Hawk aircraft. The five-year contract covers the overhaul of the fleet of 26 Adour Mk871 engines, an annual training programme for RMAF engineers and the calibration, maintenance and re-certification of the Adour test bed located at the Kuantan Air Base. RMAF will also be supported by an in-country technical representative and have access to the RollsRoyce operations centre for 24/7 technical support. 14
metalworking equipment news Jul-Aug 2009
BAE Systems & L-3 MAS To Maintain F/A-18
Dave Kendall, CA, United States
NSW, Australia: BAE Systems Australia and L-3 MAS Canada have confirmed their selection to provide long term maintenance and modification support for the F/A-18 Hornet fighter in Australia. The four-year initial contract period (2009 –2012) has extension options until 2018 and has a potential total value of approximately AUD $150 million (US$117 million). BAE Systems Australia’s MD Jim McDowell said the contract was a key element in sustaining the jet support capability that BAE Systems and L-3 MAS have established in support of the air combat capabilities of the Royal Australian Air Force.
Chinese Assembled A320 Performs Maiden Flight Tianjin, China: The first A320 aircraft assembled outside Europe in the Airbus Final Assembly Line China (FALC) successfully completed its first flight. This first aircraft will be delivered to Dragon Aviation Leasing in June from the Airbus delivery centre in Tianjin and will be operated by Sichuan Airlines. Eleven A319/A320 aircraft are scheduled for delivery in Tianjin in 2009 and the FALC production rate will be ramped up to four aircrafts per month by the end of 2011. The A320 FALC is a joint venture between Airbus and a Chinese consortium comprising Tianjin free trade zone and China Aviation Industry Corp. Airbus China holds 51 percent of the shares, while the Chinese consortium holds 49 percent. The FALC in Tianjin is based on the Airbus single-aisle final assembly line in Hamburg, Germany.
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AUTOMOTIVE
Blue Energy Constructs New Plant Kyoto, Japan: Blue Energy, a joint venture company between GS Yuasa and Honda for the manufacturing, sales and R& D of lithium-ion batteries for hybrid vehicles, held a groundbreaking ceremony to mark the start of construction of its Osadano plant in Fukuchiyama, Kyoto. The 16,000 sq m plant is scheduled to begin production sometime around fall 2010 and it comes with a price tag of approximately 25 billion yen (US$261 million).
APPOINTMENTS
Delcam Gets New MD
Clive Martell
Birmingham, UK: Clive Martell will replace Hugh Humphreys as MD who will be stepping down from the role on August 1. Mr Mar tell, aged 47 years, is currently operations director and responsible for the day-to-day management of the group’s operations worldwide.
Toyota To Produce In China Tokyo, Japan: Toyota Motor Corp held a line-off ceremony for the ‘Highlander’ SUV, at its plant in Nansha district, Guangzhou, China. The China-produced Highlander, with a 2009 sales target of 20,000 vehicles, will be priced between RMB 248,800 and 429,800 (US$36,437 and 62,937).
Suzuki End Financial Year In The Black
Bosch Inaugurates Plant In India Bangalore, India: Bosch Automotive Electronics India, a 100 percent subsidiary of the Bosch group, inaugurated its manufacturing plant at Naganathapura, Bangalore. The company will manufacture Electronic Control Units (ECU) for diesel and gasoline fuel injection systems. In India, the company has invested over Rs 60 crores (US$13.4 million) in this facility during 2008 and 2009 and plans an additional investment of Rs 68 crores by 2010. The first batch of ECUs produced at Naganathapura will be supplied for Tata’s Nano model.
Volkswagen To Grow In SEA Bentley Smith, Australia
Shizuoka, Japan: A market slowdown in Europe and North America and the effects of a strong yen amid the global financial crisis did not stop Suzuki to post an operating profit (FY ending March 2009) of ¥76.93 billion (US$787 million). In North America, the credit crunch and general economic weakness dragged sales amount down by 44.4 percent on the year. In Europe, the recession and the effects of a strong yen pulled sales amount down by 20.4 percent on the year. The strong yen also impacted sales amount in the company’s export markets in Asia, dragging it down by 11.1 percent on the year. Sales amount in Japan was down 16.9 percent on the year. Two key factors enabled the company to remain in the black at the consolidated level despite the fall in sales and earnings in major markets. One was solid domestic sales of minivehicles. The other was stability in the Indian market. 16
metalworking equipment news Jul-Aug 2009
Wolfsburg, Germany: Volkswagen is expanding its commitment in South-east Asia as part of its 2018 growth strategy. In cooperation with the Indonesian partner company Indomobil, local vehicle assembly op erat ion s a re to b e set up. A n a g re eme nt on assembling selected models in the capital city of Jakarta has already been signed. The goal of the partnership with Indomobil is to develop the Indonesian automobile market with locally built vehicles. Production of partly assembled models will commence this year. Initial production capacity from mid 2009 will be several hundred Touran (a MPV) and will subsequently be increased. In a further step, CKD production of group vehicles from 2012 is conceivable. The plans envisage expanding market share in the ASEAN region beyond Indonesia so as to establish the company throughout the region. It is intended to broaden the product offering to include further vehicles from the Volkswagen, Skoda, Audi and Volkswagen commercial vehicles brands.
ENQUIRY NO 019
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FOUNDRY
Posco-JKPC’s Second Plant Opens
Siemens To Supply Casters
Kyushu, Japan: The second Posco-JKPC (Japan Kyushu Processing Center) plant has opened. With an annual processing capacity of 150,000 tonnes of automotive steel plates, the plant is expected to offer logistics services for a maximum of 400,000 tonnes of steel products every year. The company also signed a contract to provide steel for Toyota’s main plant in Japan in January to consolidate its position as one of the world’s leading steelmakers.
Linz, Austria: Siemens VAI Metals Technologies received an order from SAIL (Steel Authority of India Limited) for the supply of four long-product casters to be installed at its Bhilai steel plant. The project includes basic and detail engineering as well as the equipment for two 6-strand billet casters, one 6-strand billet/bloom combi-caster and one 3-strand beam-blank caster. With an order volume in the three-digit-million-euro range, the project is scheduled for completion in the last quarter of 2011. The casters are part of a modernisation and 7 million tonnes per year steel-capacity expansion project underway at the steel plant. Siemens VAI will provide level one and two automation, electrical equipment, the complete coolant and hydraulics systems. In addition, they will also provide advisory services for erection, commissioning as well as training for all four casters.
businessStatistics
Worldsteel Short Range Outlook London, UK: The World Steel Association (worldsteel) forecasts that worldwide apparent steel use is expected to decline by -14.9 percent to 1,018.6 million metric tonnes (mmt) in 2009 after declining by -1.4 percent (1,197 mmt) in 2008. However, steel demand is expected to stabilise in the latter part of 2009 leading to a mild recovery in 2010. China is expected to witness negative growth of –5 percent in apparent steel use in 2009 as the ongoing global economic crisis hits China’s exports in addition to the effects of a slowing domestic economy. The last time that China’s apparent steel use recorded negative growth was in 1995 when apparent steel use fell by -17.2 percent following the real estate bubble burst. Apparent steel use for the world excluding China is expected to decline by -20.4 percent in 2009. Japan has also been affected by a sharp decline in the
exports of its steel-using industries, especially automotive and machinery. Apparent steel use is expected to fall by -20.4 percent in 2009. Emerging economies are being affected by the economic crisis as well, but to a lesser degree. India is projected to have a positive growth of 2 percent for apparent steel use in 2009 and BRIC countries as a whole are forecasted to contract by only -5.9 percent. Projected apparent steel use for the world, excluding BRIC, is down -22.3 percent in 2009. Within the NAFTA region, the US is expected to show the largest decline in steel demand in the post-war period. In 2009, apparent steel use is expected to fall by -36.6 percent. Europe will be the most affected region outside NAFTA. The EU 27, other Europe, and CIS regions are expected to show a decline of more than 25 percent in their apparent steel use in 2009.
Short Range Outlook For Apparent Steel Use (2008-2009) In mmt Regions EU (27) Other Europe CIS NAFTA Central and South America Africa Middle East Asia and Oceania World BRIC World (excl. BRIC) World (excl. China) 18
metalworking equipment news Jul-Aug 2009
2008
2009
2008 (Percent)
2009 (Percent)
181.5 28.9 50.0 129.7 43.6 25.3 42.8 693.8 1,197.4 537.6 659.8 771.8
129.2 21.5 38.4 88.0 37.6 25.2 39.0 637.4 1,018.6 505.9 512.7 614.2
-8.4 -8.3 -11.8 -8.2 5.7 0.2 -0.9 2.0 -1.4 2.3 -4.2 -3.6
-28.8 -25.7 -23.1 -32.2 -13.9 -0.5 -8.9 -8.1 -14.9 -5.9 -22.3 -20.4
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ISCAR’s
PRODUCTIVE TURNING SOLUTIONS
Fig. 1
Fig. 2
Fig. 3
The advance of technology influences the development of cutting tools and cutting tools in turn influence the development of technology and methods for metal cutting removal processes. The link between them leads to solutions that change and improve machining processes. These developments bring many benefits to the enduser – particularly savings in cost reduction and machining time, which translates to increased productivity levels. The cost of the tool comprises only 3% and therefore the focal point should be to search for improved productivity in order to gain added value and benefits. ISCAR, as a conceptual pioneer in metalworking tools was the first company to change the traditional method of turning and grooving. Its revolutionary concepts and dedicated efforts have set the path to decrease production time, thus lowering production costs. ISCAR’s creative innovations emanate from the development of SELF-GRIP and CUTGRIP. (see fig.1) Today, TANG - GRIP tangential inserts operate at much faster speeds and feeds with ISCAR’s advanced grade IC808 for hard machining conditions, and IC830 for tough conditions. The recently introduced SUMO TEC carbide grades enable ISCAR to cope better with heavy duty turning. The new Fig. 4
tools expand the range of ISCAR tools for rough turning applications. Lever lock tools are recommended for large depth of cut and interrupted cut applications. The HELITURN family consists of WNMX, CNMX and DNMX inserts that are produced from the most advanced SUMO TEC grades. HELITURN LD inserts were designed for heavy machining applications. Their unique design ensures reliable, Fast Metal Removal with ISCAR’s SUMO TEC IC8150, IC8250 and for interrupted cut and unstable conditions, IC8350. (fig.2) ISCAR has developed heavy duty turning tools and inserts, as a result of increased turning production volumes. Industries such as power generation machine large workpieces with high metal removal rates demand new chipbreakers for larger depths of cut and higher feed rates. (see fig.3) Additionally, ISCAR has specially developed tools for the miniature industry enabling small size diameter turning – featuring complicated application shapes and profile. A derivative of this industry is medical parts manufacturing, featuring complicated shapes and profiles made out of titanium or other types of difficult to machine materials such as stainless steel. (see fig.4) This type of machining required the development of a special chipbreaker that can handle shallow depths of cut, grooves or threads, good control of chip breaking and evacuation. They are characterized by their positive geometry for power and load reduction, which improves surface finish. Groove-turn ISCAR’s unique patented groove-turn method enables machining between shoulders, which subsequently improves the conventional turning process. A turning application that called for two or three ISO tools for completion, can today be machined by using only one tool. The groove-turn technique not only saves 30% in machining time, but also saves on tooling and additional costs. Changing turning concepts towards the use of multifunction tools or multidirectional tools will deliver more productivity.
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Fig. 5
ISCAR’s SUMO -GRIP family was designed in answer to the growing demand for a dedicated tool for heav y-dut y applications. (see fig.5) SUMO-GRIP’s unique tooling concept is comprised of a non-screwed clamping insert, with a userfriendly mounting mechanism and requires no spare parts. The cutting edge faces no obstructions in terms of chip flow, which dramatically reduces the risk of rubbing the tool body. The inserts are very durable and feature less generated heat. In addition to the external coolant – the stream of coolant fluids streams directly to the chip-tool contact area, providing better cooling media for chip control and evacuation. ISCAR’s highly advanced grade IC808 and IC8250 sustain heavy duty groove-turn applications. The advantage of a dual coolant stream from both the top and bottom allows for increased machining conditions and thus productivity output. The cooling effect is due to controlling the temperature at the cutting zone and therefore prolonging tool life. This ensures less idle machine time and higher productivity. Parting ISCAR has developed a new line of inserts designed with a tangential clamping mechanism which does not use screws for locking or any upper jaw. (see fig.6) This design contributes immensely to the pocket strength. In addition, ISCAR’s unique patented DO-GRIP with the twisted design allows deep groove or parting without rubbing the back of the insert with one of the walls. (see fig.7) The unbeatable grade IC808 is ideal for prolonged insert life. JETCUT is designed with a coolant feature which streams from the chipbreaker towards the bottom side of the removed material. This feature is exceptionally imp o r t a nt a nd adva nt ag e ou s w he n machining exotic materials as well as stainless steel. Another of ISCAR’s unique patented solutions for grooving and parting is the PENTACUT 34, with its robust design. (see fig.8) This tool, compared to the existing PENTACUT 24 can per form grooving
and parting of components to a 10 mm maximum depth of cut. Grades IC1008 and IC908is most ideal for optimal groove-turn machining conditions. The inser t has 5 cut ting e dges, contributing to its economical advantages, with an effective chipbreaker embedded into each of the cutting edges. These chipbreakers can navigate all type of materials including stainless steel and high temperature alloys. With a selection of the right chipbreaker and ISCAR’s carbide grade, you can cover a wide range of materials. That means less tool stock. The advancement in powder metallurgy and pressing techniques brought about the development of such a sophisticated shape. The outstanding performance attributed to this tool positioned ISCAR as a leading manufacturer of revolutionary products for turning and grooving solutions, with an emphasis on productivity and cost reduction.
Fig. 6
Fig. 7
Fig. 8
Multifunction Tools In recent years we have been witnessing the growing popularit y of multitask machines in the form of Mill-Turn centers. For that purpose, ISCAR developed a line of tools specifically designed for these new class machines, to finish a part with a single clamping and with minimum chipto-chip time. Mini-Turret One example of a multitask tool is the ISCAR MINITURRET, which fully utilizes the B-axis of the Mill-Turn machine. The MINITURRET features four pockets that can accommodate adapters, holding various types of groove-turn and ISO standard inserts. (see fig.9) This modular tool offers flexibility in configurations, which minimizes tool changing. The MINITURRET improves precision, increases productivity and offers performance advantages when using multitask machines. The MINITURRET tool can operate roughing, finishing, grooving and threading operations in one sequence. Other multifunction tools designed by ISCAR can perform turning, milling, grooving and threading operations using a single clamping mechanism.
Fig. 9
ENQUIRY NO 104 Jul-Aug 2009 metalworking equipment news
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cut
Plasma Cutting:
Unveiling The
The mask is off the reclusive fourth state of matter as plasma makes its presence felt in cutting. By Joson Ng
F
or a relatively unknown state, plasmas are the most common form of matter. Accordingly to Pla sma s International, it comprises more tha n 99 percent of the v isible universe, and permeates the solar system, interstellar and intergalactic environments. Exhibiting collective effects, plasmas are known as conductive assemblies of charged particles, neutrals and fields. They carry electrical currents and generate magnetic fields.
Cutting With Gas Plasma cutting was developed in the 1950s. Before that, flame cutting was the method of choice. With the increasing usage of metal that could not be flame cut like aluminium and copper, a new type of cutting was required and that heralded the era of plasma cutting. The process uses a hot plasma stream that can be used to cut materials such as plastics. Focussed by a special design, the plasma gas is ionised in the nozzle. In metal cutting, an electrical arc is ignited 22
metalworking equipment news Jul-Aug 2009
between the electrode and the workpiece to increase the energy transfer. The plasma heats the workpiece, melting the material. High velocity stream of ionised gas mechanically blows the molten metal away, severing the material. Va r i o u s g a s e s l i k e a r g o n , hydrogen, nitrogen and mixtures are used for plasma cutting, which is of ten done, u nder water for environmental reasons. Plasma cutters come in all shapes and sizes. They can be used for robotic arms to make precision cuts. They also come in the form of compact, handheld units that you might find in a handyman’s shop. Regardless of size, all plasma cutters function on the same principle and are constructed around roughly the same design.
Making The Right Cut It is impor ta nt to think about picking the right machine for certain operations as there are many factors in question. Most plasma cutting power sources are rated on their cut t ing abilit y a nd a mp era ge. According to Lincoln Electric, you
Nick Winterhalter
State
should consider a lower amperage plasma cutter if you frequently cut ¼” thick material. A higher amperage machine is more suitable if you regularly cut metal that is ½” in thickness. Getting the amperage and the required thickness of cut right is crucial for the cutting process. Even though a smaller machine may be able to cut through a given thickness of metal, it may not produce a quality cut. Instead, you may get a sever cut which barely makes it through the plate and leaves behind dross or slag. The Cleveland headquartered manufacturer also brought up the importance of cutting speed. For production cutting, a good rule of thumb is to choose a machine, which can handle approximately twice your normal cutting thickness. For example, to perform long, fast, quality production cuts on ¼” steel, choose a ½” class (60 amp) machine. The world of plasma may be shrouded in mystery to the general public but plasma cutting is a clear and simple way to cut metal. MEN Enquiry No. 5001
THEY’RE HERE ! . . .
NEW SOLUTIONS FOR STEEL TURNING !!
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ENQUIRY NO 053
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UppingThe Ante
Investing in right machineries can rapidly transport a company to a whole new playing field. By Matthew Fowles, marketing manager, LVD Group
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olden Seal Singapore, a fabricator of conveyors, material handling systems, ra c k i n g s y s te m s, a n d machine structures, primarily deals with sheet metal fabrication. With a simple vision of: We can do it better, they invest in technology to change their manufacturing process around. The company partners LVD as its solution provider of sheet metal fabrication equipment. Siow Siok Hwa and Soh Chai Seng, founders of the company initially turned to the machine maker to achieve better bending accuracy when forming sta inle ss steel, mild steel a nd aluminium parts for railway platform screen doors ranging from 1 to 3 mm in thicknesses and in quantities of a few hundred to a few thousand.
pre s s w it h pic k- sor t mate r ia l handling system. With it, the compa ny ha s expanded its capabilities, streamlined production, reduced its need for skilled labour, and decreased scrap – all contributors to the company’s steady growth. The company’s early products included safety grills for windows and chain link fencing. After observing conveyor components and realising they could produce a better product,
they began building conveyors for the consumer electronic market. That is a lso how the compa ny started retrofitting hospital beds from manual to motorised units, and it brought them to the three primary markets it now serves from its 30,000 sq ft (2,787 sq m) facility. “Investing in machiner y has helped us secure more work,” says Mr Siow. Recognising the importance of machines, he adds: “We have understood from day one that
Past & New Acquisitions That initial purchase allowed the company to secure larger, more diversified projects. Most recently, the company invested in a LVD Strippit V20-1525 CNC turret punch 24
metalworking equipment news Jul-Aug 2009
Mr Siow (right): Investing in machinery has helped us secure more work
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while reducing set-up time. “The autoload is compact and it provides a level of automation that is affordable for a shop our size,” says Mr Siow.
Completing The Jigsaw
The pick-sort system reduces the company’s manual worksheet handling time
without the right equipment, you will not get the right jobs, LVD has a range of machines from entry level to high performance. It’s a concept that has helped us balance our application needs with our budget.”
Smoothing Out The Edges As the company broadens its market scope, they have had to sharpen their competitiveness. One of the ways they have become more competitive is through the use of automation; first with the purchase of Orion Plus laser cutting system with autoload, and later with the installation of V-Series CNC turret punch press with pick-sort. The pick-sort system reduces the company’s manual wo rk she e t h a n d l i n g t i m e a n d p rov i d e s f l e x ib i l i t y fo r sm a l l batch production. The company purchased the system to fulfill large contracts to manufacture airport baggage handling conveyor s y s te m s , e l e c t r i c a l c a b i n e t s , ra ilway screen door a nd other sheet-metal production. It converts the punch press into a freestanding production cell. The 20-tonnes turret punch press is equipped with a Kuka robot for automatic material handling. Machine and robot are integrated to maximise punch press productivity. Integrating a robotic system allows loading of full size sheets and retrieval and stacking of individual
punched parts with dimensions up to 1,524 x 3,048 mm. The punch press comes with extended X-axis for handling the long parts required to produce conveyor systems up to tens of kilometres long. Capacity and flexibility is resulted from the machine’s mix of 34 turret stations with four indexable stations. Auto -indexing stations accept a variety of indexable multi-tools to enhance capability and flexibility
Punched pa r ts move from the robotic cell unload station to the next operation, forming. The three press brakes are used to bend the three metres long parts that are part of the conveyor systems the company manufactures. The PPEB press brake using the CADMAN control is able to form parts accurately. Prior to the bending equipment, Golden Seal was forced to outsource most of its components. The equipment has provided overall manufacturing cost savings. On some operations, the company has reduced months of lead time. “The machines give us speed, efficiency and control. We used to rely heavily on subcontractors, now everything is within our control,” says Mr Siow. MEN Enquiry No. 5002
LVD:
Automatic Loading Laser Cutting System
The Axel 4020 laser cutting system by LVD now features an optional load/ unload system providing continuous, uninterrupted processing of sheets up to 4 x 2 m with automated material handling. Combining linear drive technology with laser power, the system is suitable for large sheet processing. Machine flexibility and productivity is enhanced with the addition of the load/unload system, which can be retrofitted. Automated load/unload unit handles sheets up to 1,000 kg and is fully integrated and programmable. Plate-to-plate changeover time is 29 s. Thin materials are processed at speeds up to 40 m/min. Featuring a modular design, the machine provides maximum efficiency in material handling, while minimising the required floor space.
Enquiry No. 5003 Jul-Aug 2009 metalworking equipment news
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More Variety with the
Universal Model Ditzingen, April 23, 2009. TRUMPF’s universal laser cutting machine is now available with 3,200 and 4,000 watts of laser output. We spoke to Andreas Kettner-Reich, TRUMPF development manager of 2D laser cutting machines, about customer-specific retrofit options and other features of the TruLaser 3030 NEW.
sheet thickness range and processing speed. The maximum thickness for mild steel is 20 instead of 25 mm, for stainless steel, 12 or 15 mm instead of 20 mm, and for aluminum, the range is 8 and 10 mm – while for the 5 kilowatt laser, it is 12 mm.
Mr. Kettner-Reich, the TruLaser 3030 NEW was designed with what industries and users in mind? The user group is broadly diversified. The machines are typically purchased by job shops, but they are also used by major product manufacturers, small metalworking operations and everything in between. The TruLaser 3030 NEW is geared toward all operations that call for a tough, productive all-around machine for the widest variety of laser cutting applications.
What were the challenges and goals in the development of the TruLaser 3030 NEW? TRUMPF set the market standard with the TruLaser 3030 and it must be continually enhanced and improved. The art is also putting a new, innovative machine on the market without throwing the old one overboard. In this context, one major challenge was the new materials handling concept with a pallet changer that can be set up in the traditional inline position or parallel to the machine. This flexibility is unique – other machines can do one or the other, but not both.
Most recently, the machine has come with 3.2- and 4-kilowatt lasers. Why and what is the payback? We first launched this machine only with the 5 kilowatt laser because that’s what a lot of customers wanted. The lower output levels are now comparable with those from the predecessor model – and for many applications, it is completely sufficient. The 3.2- and 4-kilowatt versions of the TruLaser 3030 NEW can be distinguished from the 5 kilowatt model exclusively by the laser output and the related results, specifically in the
Were you able to achieve your development goals? We simultaneously increased the dynamics and reduced the machine body to facilitate parallel setup, while successfully achieving the new concept for material handling. What helped us during this process was the developer’s complete “modular concept”: FEM (Finite Element Method) calculations, computer simulations of the dynamic behavior, and virtual reality tests. An additional development goal was a new operating concept. We implemented it in the form of an ergonomic operating panel,
Andreas Kettner-Reich, TRUMPF development manager of 2D laser cutting machines explains: “The TruLaser 3030 NEW is geared toward all operations that call for a tough, productive all-around machine for the widest variety of laser cutting applications.”
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an optimized maintenance concept with a clearly laid out service area, a larger horizontal conveyor belt for easier cleaning and last, but not least, a wider door that improves the machine’s accessibility. In your opinion, what is unique about the machine’s concept? The special thing about it is that TRUMPF once again thoroughly addressed the needs of the users. We listen to our customers. The operating panel, the conveyor belt, the wider doors and the lateral changes are the best examples of that. And not only that: The use of a 5 kilowatt laser for higher cutting speeds and thicker sheets in the TruLaser Series 3000 has been on our customers’ wish list for a long time. Also, the newly designed automated nozzle changer with 18 nozzles, which only needs 20 seconds for a nozzle change, is a result of requirements “from the field.” The same is true of why we adapted our single cutting head strategy, which is well-known in the high-end range, to the TruLaser 3030 universal machine. And last but not least, there are other details, like a considerably larger control cabinet under the laser unit, that show our customers that we take their ideas and suggestions seriously.
than 30 percent. In addition to faster parts processing, an important contribution is also a strong reduction in auxiliary processing times. With regard to power consumption, the machine has a new cooling unit that can be more precisely controlled and ensures that only as much power as needed is used. In addition, the laser unit automatically goes into stand-by mode when not in use, which lowers the power consumption by over 40 percent compared to conventional machines. And last but not least, the automatic shut-off feature reduces the power consumption down to below 1 kilowatt if the machine is not going to be used for a longer period of time – ideal for unmanned operation during the last shift. Which automation options does the new laser cutting machine offer? The same as the previous TruLaser 3030. These range from automated loading with the LoadMaster to the fully automated production cell with store connection, such as the TruStore compact store. A new feature is the LiftMaster Compact that fits the TruLaser 3030 NEW perfectly due to its compact, space-saving design.
Why should someone buy this machine in particular? The TruLaser 3030 is the most successful 2D laser in the world. Thousands of customers trust its absolutely reliable processing. The TruLaser 3030 NEW continues to raise the bar and is even more efficient thanks to its high processing speeds, shorter auxiliary times and a more compact use of space.
When was the first TruLaser 3030 NEW delivered? Newly developed machines have to be sufficiently tested and be mature enough to be launched on the market. This is a very important requirement, especially with a machine that stands for reliability and was developed with this focus in mind. Therefore, in the first six months of 2008, test machines were delivered and installed at different customers.
Compared with the predecessor model, how much faster and more energy efficient is the TruLaser 3030 NEW? For all TRUMPF machines, energy efficiency is an important area that is not limited just to the TruLaser 3030 NEW. Energy efficiency describes the ratio of the energy absorbed to productivity, or to the number of parts of defined quality per time period. Through various measures, we were able to increase the productivity of the TruLaser 3030 NEW by more
How many of these machines do you want to sell per year in the future? Our clearly formulated goal with the new machine is to by far exceed the sales figures of the last generation. And, the predecessor model is after all, already the biggest-selling flatbed laser machine worldwide.
The TruLaser 3030 NEW is even more user efficient thanks to its high processing speeds, shorter auxiliary times and a more compact use of space.
Also, the newly designed automated nozzle changer with 18 nozzles, which only needs 20 seconds for a nozzle change, is a result of customer requirements.
About TRUMPF With sales totaling € 2.14 billion for the 2007/08 fiscal year and about 8,000 employees, the TRUMPF Group ranks among the leading manufacturing companies worldwide. The three following business divisions are combined under the umbrella of a holding company: Machine Tools/Power Tools, Laser Technology/Electronics and Medical Technology. Its core business are machine tools for flexible sheet metal processing for punching and forming, laser processing and bending. In the field of industrial lasers and laser systems, the company is the technological leader on the world market. With about 50 subsidiaries and branch offices, the Group is represented in almost every European country, in North and South America as well as in Asia. Production locations can be found in Germany, Austria, China, Czech Republic, France, Great Britain, Japan, Mexico, Poland, Switzerland and the USA. For further information about the company, please visit www.trumpf.com
Photos: TRUMPF GmbH + Co. KG
The use of a 5 kilowatt laser for higher cutting speeds and thicker sheets in the TruLaser Series 3000 was long requested by our customers.
ENQUIRY NO 093 Jul-Aug 2009 metalworking equipment news
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Precision Technology:
Versatility
Personified
Parts of different shapes and sizes require a more multi-functional approach to measurement. By Kelly Ho, GM, Optical Gaging, Singapore
M
ost ma nufacturing companies have some number of measuring dev ices available from the day they start operation. They ra nge from ha nd gauges, micrometers, a nd ca lipers, up to a CMM and maybe an optical co m p a r a to r. T h o s e to o l s a r e purchased to support a particular level of manufacturing with its associated tolerance and accuracy requirements. Over time, new manufacturing equipment may be purchased to machine more complex parts that need to meet tighter tolera nce requirements. It can be tempting to do all the new measurements with the available tools already on hand. However, it is easy to reach a point where the measuring capabilities simply cannot keep up with the latest requirements. Even if the existing measuring tools are determined to be capable of the new measurements, there can be cost implications. Certain measuring devices are good at particular measurements. Verifying
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all the necessary dimensions may require using several measuring devices that may be located in different parts of a shop, or in use for other parts, or that require a particular skilled operator who may not be available. Shops striving for lean operations can encounter bottlenecks in any of those places. Time wasted in moving a part to different measuring machines or waiting in a queue until a machine is available contribute to the total cost of that part. In addition, the delay in getting the measurements may increase scrap if the process continued and the delayed measurements determine that the process was out of control.
All In One The true value of multisensing (dimensional measurement that utilises two or more sensors to measure features and surfaces of a part) can be explained by using a golf analogy. A round of golf requires the use of a variety of clubs, each capable of hitting the ball different distances. Although it is possible
to play a round of golf with a single club, the score would probably not be very good. The same concept applies to measuring devices. Think about a CM M . A lt hou g h it u se s one measurement technique (touch triggering), it supports probes of different lengths and tips of different sizes. Such a CMM can be considered a golf bag with a set of clubs. And that may be all you need – until the rules change. Introduce parts with increased complexity, tighter tolerances, critical depths, edge positions, and angular relationships and that set of clubs (probes) may no longer be adequate. Instead of a CMM, consider a video measuring machine. Video excels at measuring edges it images with its magnifying optics. A zoom le n s a l low s me a su re m e nt s a t different magnifications. Software tools can measure single points, edges, arcs, diameters and more. These capabilities are the set of clubs in the video golf bag. A limitation of video is that it can only measure what it ‘sees’.
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A critical bore perpendicular to another surface may be inaccessible for video measurement. However, a multisensor video system can use the touch probe to probe the perpendicular bore while using video on the top surfaces and get data from the part for all the necessary measurements.
The motivation behind multisensor measuring machines is cost reduction for the people who use them. Doing all the necessary measurements in one setup on one machine cuts total costs in many ways: the part is handled less so risk of damage o r l o s s i s re du ce d ; p o te nt i a l bottlenecks while queuing at several machines are eliminated; fewer fixtures are required; utility costs for one machine can be less than for two or three separate machines; personnel costs are reduced with training for one machine versus the knowledge needed to operate different machines; and service and calibration costs are lower and spares for one system cost less than what might be needed to support several systems. Measurements performed on a calibrated multisensor measuring system a re more reliable tha n cobbling together diverse sets of measurements done on several different machines. A typical multisensor configuration includes a touch trigger probe, video/ vision measurement, and possibly a laser. Referred to as sensors for simplification, the former requires contact with the part while the others are non- contact. Other sensors can also be integrated into some multisensor measuring systems. Some micro-probing technologies provide access to intricate features or details that are simply too small for touch trigger probes. White light scanning probes provide an alternative to lasers with small spot sizes and very high resolution. And to make it interesting, some sensors can be used in different ways.
Left: Other sensors can also be integrated AD130-WFE:111x183 02.06.09 08:52 Seite into 1 some multisensory measuring systems.
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Measure All At Once
Top: Multisensing can help cut down time wastage in measuring parts.
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Some micro-probing technologies provide access to intricate features that are too small for touch trigger probes.
Fo r e x a mp l e , u n l i ke to u c h trigger probes which acquire a point at a time, there are scanning touch probes that acquire data points from surfaces continuously a s they a re sca nned across. Typically, lasers and white light probes can also be scanned, or provide single points from surfaces. Good metrology software products handle the deployment and use of all the sensors, and use their data equally for measuring the most complex feature relationships, distances, and angles. MEN Enquiry No. 5101
Multisensor Metrology:
Measuring What’s Important Multisensor metrology are pushed into the lime light with the arrival of more intricate parts
Figure 1a
Multisensor metrology is a dimensional measurement on a measuring machine that utilises two or more different sensor technologies to acquire data points from features and surfaces of a part to perform more measurements than would be possible on a machine using a single sensor. Figures 1a and b show a complex machined part and its corresponding CAD model. Selection of sensors depends on the features to be measured. The design drawing shows what needs to be measured. The following series of illustrations show areas on a single part
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Figure 1b
best measured by each sensor technology. Note that the part has an assortment of holes and slots, surfaces at different depths, and some intricate detail.
Probe.Scan.Laser.Result Selection of the sensor depends on the characteristics of the feature to be measured. Remember that data points about the part are used for measurements regardless of the sensors used to derive them. Let’s consider features of this part to measure with each available sensor.
Features • Speedy measurement: 2mm spindle feed per r evolution • Patented ratchet thimble mechanism helps ensure repeatable measurement. • Function lock helps prevent error
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Figure 2: Certain video tools can automatically follow an edge, collecting points even if it has changes in direction.
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Figure 3: The best sensor for this is a laser as its focus point can be scanned across each plane.
Figure 4: A touch probe is the best tool for the job when measuring the perpendicularity of the cylindrical axis.
Figure 3a
Figure 2a
Figure 2b
Figure 3b
Assume the blue-highlighted edges in the CAD model in Figure 2b need to be measured to determine the relationship (distances) between them. Either of those edges can be assumed to be the intersection where perpendicular surfaces meet. In such a case, a touch probe can collect data points on each of those perpendicular surfaces. The software then fits those sets of points to planes and intersects the planes. Those intersections represent those edges. That through-hole and the edge radius complicate this otherwise straightforward process. Fortunately, it is possible to measure those edges directly with video. The edges appear to be parallel to the worktable and thus perpendicular to the optical axis of the video sensor.
Capturing Data Figure 2a shows a video measurement of an arc segment on the actual part. Certain video tools can automatically follow an edge, collecting points even if it has changes in direction. This example also shows that each edge lies in a different plane yet they still can be measured with video. On the same part, Figure 3b shows two areas in blue that form planes which must be parallel to each other. In addition, it is necessary to know how far each surface deviates from a plane (its flatness). The best sensor for this is a laser. Its focus point can be scanned across each plane acquiring point clouds of data. Each set of data can be fit to a plane. Deviations from each plane can be measured. In addition, the relationship between
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the planes can be compared to determine their degree of parallelism. Not all lasers are created equal and this part has characteristics that make laser selection important. Note the perpendicular surface between the two planes. Measuring the larger plane requires adequate working distance to avoid collisions with the higher surface. (See the laser spot and its path in the photograph of Figure 3a) Measuring that plane close to the perpendicular surface may be a problem for some triangulation lasers since that surface may block either the incident or reflected light. Some Through-The-Lens (TTL) lasers can measure up to the base of the perpendicular plane. This part also has some holes that are perpendicular to the top surface when the part is in this position. If we want to measure the perpendicularity of the cylindrical axis of one of these holes to the surface the hole is drilled into, a touch probe is the best tool for the job. As shown in Figure 4, points on the plane can be probed. Then a star probe can collect points along the cylinder walls. Those sets of points are fit to a plane and cylinder, respectively and their angular relationship measured.
Choose Wisely All the measurements described can be performed on one multisensor measurement machine with the part in a single location. None of the sensors is best for doing all these measurements. Selecting the best sensor for each aspect of the total job depends on understanding what each does best.
Enquiry No. 5102
ENQUIRY NO 089
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R
Working
Backwards
High tech metrology products and reverse engineering are generally deployed in a traditional industrial setting like in metalworking but that is no longer the case. By Soafara Menke, regional marketing coordinator, Faro. Reverse engineering is often used to carry out inspection and improve the part
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everse engineering allows transforming reality into a virtual representation. The technique is widely used in modelling ancient buildings, automotive industry and even crime scene investigations. With no design data, the technique enables us to create virtually anything we can touch. FaroArms and laser trackers are used to reverse engineer geometric objects while more complex shapes are better captured using a noncontact device. The digitalised version of a part is usually in a form of a CAD model making recording and recreation possible. Metal parts, some with complex structures are often made for the automot i ve i ndu st r y. Re ve r se engineering is often used in tandem with metrology equipment to carry out inspection in order to improve the part. Carr ying out product analysis will allow designers to examine how a product works and estimate costs.
Stepping Away From Convention A p a r t f rom pro duc t a na l y si s, reverse engineering and metrology equipment are used for major events such as air crashes or large-scale traffic accidents. Geographical information can be integrated with the models of the object under investigation. This type of presentation means that missing elements can be restored or re co n st r u c te d i n a n e x ac t representation of reality. Although these are undesirable results for the automotive a nd aerospace industries, valuable insight are gathered to find out what actually happened. As far as the search for truth goes, the Forensic Research Institute of t he G enda r mer ie Nat iona le (IRCGN), a division of the French Police uses laser scanner to create high-resolution, accurate 3D images of crime scenes. By doing so the scene can be preserved in its original
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In large-scale traffic accidents, geographic information can be integrated with the models of the object under investigation
state so that investigators can go through various scenarios, explore different hypotheses or use it as hard evidence in court.
Analysing All Possibilities Specialists are often involved in cr im ina l inve st igat ion s where ‘scientific evidence’ has become indispensable in. Forensic scientists a re re sponsible for orga nising investigations at crime scenes and for identifying and collecting material evidence. The principal role of other units like the IRCGN is to analyse samples of this type with the aid of specialist equipment. For example, the authorities used a digital equipment to conduct a computerised survey of the entire site of the Saint-BrĂŠvins les-Pins holiday centre, a crime scene, and used the digitised data to create a 3D model of the site. This way, they ca n work with 3D models of ev idence, crime scene s a nd accident scenes. This type of application means that the scene of a crime can be preserved in its original state by modelling it, so that investigators can go through various scenarios in order to understand the sequence of events, or to explore different hypotheses, analysing the scene of a crime and forensic evidence from different perspectives. The aim of modelling based on
The scene of a crime can be preserved in its original state by modelling it
data captured by laser scan is to recreate the setting of the events as realistically as possible. The concept involves creating a model of the crime scene by a scatter plot collected by laser scans.
Plotting Against Criminals This scatter plot is integ rated with photographic images to make t he mo del more re a list ic. T he adva ntage of this technique is the perfect precision with which the various components of the cr ime scene ca n be pre sented as well as the opportunity to go beyond mere replication and into an interpretative stage. It is even possible, for example,
It is now possible to use models to analyse ballistic patterns
to a nalyse bloodstain patterns in the same way as for ballistic patterns. Laser digitisation enables the scene of a crime or accident to be captured digitally in next to no time, and generate both realistic a nd deta iled sca ns before t he scene becomes contaminated or otherwise changed. The information can be processed, and the user can return at any stage to the initial scans to recalculate the components or to try out new hypotheses. The information collected by the laser scanner can then be served as hard evidence in court. MEN Enquiry No. 5103
Faro: Phase Shifting
Laser Scanner
Th e L aser Scanner Photon 120/20 combined with the Faro Scene 4.6 software offers fast and long-range phase shift laser scanning solution. Photon models capture and analyse 3D images of large objects by reducing scan time and post processing work. Key features include automatic registration and colour adjustment, up to 976,000 points/s compared to 120,000 points/s of Photon 80 and unambiguity interval of 153.49 m.
Enquiry No. 5104
Jul-Aug 2009 metalworking equipment news
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Applications & Software:
Putting The P In Productivity
Application software packages catalyse the reaction commonly known as productivity. By Peter Dickin, marketing manager, Delcam.
C
A DCA M softwa re ha s helped the Nor thbend Patter n Work s, a mould ma nufacturer from Indiana, USA, to streamline its ma nufacturing process a nd accelerate the turnaround of every mould. Delivery time has been cut by up to 75 percent. The company uses the PowerShape CAD software to convert customers’ part designs into tooling designs and the PowerInspect inspection system to check both the moulds and the initial sample parts. Over 90 percent of the moulds made by the company are highvolume automotive parts, such as brake callipers. The shop produces some 100 to 150 new moulds and patterns each year and can be working on between 20 to 50 projects at any one time.
Greater Expectations With growing expectations, their customers must now deliver tolerances
in their castings once expected of machined parts. As a result, they have tightened the requirements on their mould suppliers. This increased level of precision is expected on top of the ability to deliver on time and to accommodate design changes almost overnight. “The software allows us not only to produce moulds directly from CAD data, but also to make changes to the designs very quickly and produce a new model to return to the customer,” says Neil Rullma n, production coordinator at Northbend. With the software, the company’s designers typically import a CAD model from the customer, analyse the model for damaged, duplicated or missing surfaces, and identify difficult areas like thin walls and ribs, and undercut areas. They can then correct any problems in the file and extract mould features from the imported geometry. When the model comes back from the
customer, they can easily identify any changes, replace or modify surfaces as required and generate a new model.
Taking A Closer Look To inspect moulds and sample parts, Mr Rullman checks key points and features with a Faro inspection arm and compare the results to the CAD data with an inspection software. The system verifies all of the part’s 3D measurements against the original PowerShape file to see if it was made correctly and, if not, where it needs to be corrected. M r Ru llma n ca n generate inspection repor ts in a format built specifically for each of his customers. D e sig ne d to work together, this is a positive demonstration how sof twa re programmes can push the whole production process up a notch. MEN Enquiry No. 5201
The shop produces some 100 to 150 new moulds and patterns each year
Neil Rullman, production coordinator at Northbend
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metalworking equipment news Jul-Aug 2009
An increased level of precision can be expected as well as the ability to deliver on time and to accommodate design changes
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Metrology:
Making The
Right Choice Material selection is the first and arguably the most important choice in constructing a reliable CMM. Contributed By Mandy Wong, regional MarComms and PR manager, Carl Zeiss
M
oder n metrolog y is a complex a ffa ir. In ter ms of ha rdwa re, t he mate r ia l s u se d must measure up every time. Some manufacturers use granite for all purposes. This is their attempt to ensure stabilit y a nd a lso a uniform reaction of the individual components in operating conditions. When the material is no longer able to cope with metrological requirements, subsequent mathematical correction methods (using computer software) are used to smooth the results according to basic physical principles. Another drawback to using heavy material like granite is it makes the measuring machines heav y, that subsequently calls for the construction of foundations. As a result, considerable time and costs are involved if a machine needs to be relocated.
CMM: Material & Design When it comes to CMMs, the bridge is the machine component that is exposed to the most pressure. Its rigidity is vital for the machine’s accuracy. As such, new materials like carbon fibre are used in the construction of higher end CMM systems. As these materials offer 38
metalworking equipment news Jul-Aug 2009
better dynamic rigidity, it enables short settling process and reduces measuring times. In terms of design, Carl Zeiss, a m a nu fa c t u re r o f m e a su r i n g syste m s ha s develop e d CM M s such as the Duramax machine with the raised Y-guideway that gives optimum torsional rigidity. The bridge construction remains stable even with a Z-measuring height of up to 1,000 mm.
Material Selection During Scale Construction S ome ma nu factu rers use ste el sca les to ensure uniform, qu a nt i f iable e x p a n sion of t he scales. The advantage of using this material is that it is corrosion-free, hard-wearing, stable and has a high load capacity. Its expansion, however, must be measured and corrected on an ongoing basis as a function of the temperature fluctuations. These scales are therefore equipped with numerous temperature sensors for the calculation of the scale expansion. This however results in uncertainty. First, a measurement is performed which itself has an inherent uncertainty that is basic error present in all measurement. Second, the measurement result is inaccurate if
one sensor fails without being noticed. In addition, it is almost impossible to record partial temperature influences. If these inaccurate results are used as the basis for production, rejects are inevitable.
Controlling Distortion Some manufacturers use compressed air for controlling the temperature to avoid scale distortion. These refrigerating type air dryers need to be purchased additionally and maintained. However, this method is also error-prone. M o re a d v a n ce d m e a su r i n g machines are equipped with scales made of zerodur. This material has virtually no expansion coefficient and therefore requires no mathematical or mechanical correction. As the cross beam of the bridge is likely to be deformed, we take the additional measure of floating the scales on an oil film and using ball bearing supports. Be it temperature, stress and vibration, they point to one thing, ie: material selection. Although measuring accuracy is tied to other factors but with the correct choice of material, you are half way to making an accurate measuring machine. Enquiry No. 5202
ENQUIRY NO 103
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Soft On
Applications Placing increasing emphasis on software applications can reap healthy rewards in machining, metrology and manufacturing. By Derek Rodriguez
T
here are many types of sof t wa re pro duc t s a nd perhaps the most interesting are application software solutions. They allow users to complete one or more tasks. From industrial automation all the way to computer games, application software products are everywhere, impacting our lives for better or worse. In the world of metalworking, the introduction of application software products has resulted in higher productivity and the ability to produce complex parts with tight tolerances.
Hands Off Process In modern machining, computers have taken over in a big way. With t he advent of CNC machining, t he play ing field ha s cha nge d d r a s t i c a l l y. C o m p u t e r a i d e d machining however has evolved massively from the 1960s to present day. Today’s CNC machines are arguably more reliant on software compared to their predecessors. Though there are pros and cons about the ‘new age’ machines, even the staunchest supporters of manual machines cannot deny that they have pushed the envelope well into the micron level. The success of modern machines can partly be attributed to the proficiency of CAD/ CAM and their integration to the manufacturing process. Computer aided design allows si mu lat ion t hat i s c r uc ia l for engineers in selecting the right 40
metalworking equipment news Jul-Aug 2009
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processes and anticipating any potential hiccups along the way. Changes can also be made easily follow ing discussions between designers and engineers, making it an important tool prior to the prototype phase. Computer aided manufacturing on the other hand is a tool used by engineers and machinists in ma nu fac tu r ing or protot y ping product components. It uses designs from CAD programmes and turns them into CNC code to drive the machine tools to manufacture the actual physical parts.
Human Judgement Out Application software solutions in addition to making a big splash in the field of machining have also made considerable in-roads into the realms of metrology. When parts become more accurate, measuring devices have to be one notch higher in terms of accuracy. In order to stay a he ad of t heir machining counterparts, software solutions are used to ensure metrology keeps pace with machining. As such, to accommodate the rapidly changing scene, application software products are programmed to define the different types of features they measure. For instance in CMM, emerging technologies in probing are changing the way customers measure their parts. Software solutions are adapted to process tens of thousands of points to give a better representation of the actual part compared to probing a few points in the past. It is used to calibrate the probing system, control its motion and handle large amounts of data. The PC-DMIS CAD++ from Wilcox A ssociate is a typical software that aids measurement. Makers of sheet metal parts, in particular automotive manufacturers, face a set of measurement requirements and difficulties. Their parts are hard to measure and they have to deal with rare types of features a nd dime n sion s. I n t his ca se ,
In modern machining, computers have taken over in a big way.
software applications are used to aid measurements. Usage of softwa re products opens the door to manual CMMs in some of the most demanding applications. Ma nua l CMMs, particularly articulated arms, though mechanically simpler and oftentimes portable, face a criticism of being limited in terms of capabilities. With application software solutions, they are enhanced, increasing their operating range.
Process Parameters Application software solutions can be deployed to plan and maintain the whole production cycle. This holistic approach manifests itself as Product Lifecycle Management ( PL M ). From pla nning, de sig n, realisation and service, software products are used extensively.
Defining the needs of the customer is a lways a good starting point. From this, major understanding in terms of process parameters can be formulated. This stage is necessary to give designers and engineers alike a brief idea about the product. W he n t h a t i s do ne , ac t u a l de sig ning, tolera ncing a nd prototyping of the product starts. The main tool used for design and development is CAD programmes where simulation, validation and optimisation ta sk s a re ca rried out. Various tasks like geometric tolerancing analysis and stress simulation are done using computer programmes. Once the design of the product’s components is completed, the next step will see the method of manufacturing defined. Process May-Jun 2009 metalworking equipment news
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software&measurement
Kalyana Sundaram, Tamilnadu, India
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Application software products have extended their reach into the world of machining.
plans are formulated and toolings are designed using integrated or separate CAM software. The final phase of the lifecycle involves managing of in service information. It includes providing repair and maintenance support. Although PLM runs in phases, they are closely related and cannot be viewed in isolation. A major part of PLM is the co-ordination of and management of product definition data. Application software products has stretched its considerable muscle and imposed itself in many aspect of the metalworking industry. From the looks of it, the industry has a soft spot for this particular approach. MEN Enquiry No. 5203
Business Process Management:
Optimisation = Savings
Business Process Management (BPM) investments can provide cost savings of as much as 20 percent within the first year of implementation. Enterprises can achieve the payback from their investments within a year according to Gartner, an information technology research and advisory company headquartered in the USA. “Economic woes are driving increased usage of the system as a cost-cutting mechanism for survival. We are seeing onethird of companies increasing their investments in this software solution,” said Michele Cantara, research VP at Gartner. “It makes business processes visible to both business managers and IT, allowing them to work together and change processes more quickly and effectively. In today’s troubled economy, companies need to continually reduce costs and rapidly react to market changes.” At a London event, attendees were asked about the impact the economy was having on their business. The company estimates that 70 percent of attendees were from companies that are in ‘survival’ mode, and their organisations view the programme as a lifeline keeping them above water in the economic crisis. Approximately 20 percent of attendees said they were ‘thriving with BPM’. These were typically organisations that had successfully implemented the system in the past. Some were moving resulting cost savings into other similar projects
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metalworking equipment news Jul-Aug 2009
for ongoing business process improvement, rather than survival. Approximately 10 percent of attendees were from organisations that viewed the software as a weapon for capitalising on transformational oppor tunities unavailable to beleaguered competitors in this recessionary environment. Analysts said that in some ways, the programme is no different from any other management effort. Technology is only a small part of the problem. Changing the behaviour of process participants is the bigger challenge. Projects can get bogged down in organisational politics and can lose the way amid a swamp of change management and communication techniques. “Some organisations get mired in debates about who should drive the effort, who should own the end-to-end process, how to define processes, and how to prioritise which process improvement efforts to tackle first,” said Ms Cantara. “Yet, there are some organisations that understand the system and can sustain continuous process improvement. These organisations are able to cope with the thorny problems of getting started, affecting organisational change, using appropriate technologies, as well as staffing and maturing BPM efforts.”
Enquiry No. 5204
Industrial Metrology From Carl Zeiss
ACCURA II The new ACCURA provides outstanding performance and flexibility where high accuracies and high measuring speeds are demanded - even in fluctuating temperatures.
CONTURA G2
ENQUIRY NO 105
The CMM that brought Active Scanning to small and midsize manufacturers has been redesigned from the ground up to offer flexibility and better accuracy.
O-INSPECT
DuraMax A universal CNC coordinate measuring machine with VAST XXT scanning probe from ZEISS. For shopfloor use as universal measuring machine and flexible gage.
A CNC coordinate measuring machine equipped with optical and contact measuring technology from Carl Zeiss.
Carl Zeiss S.E.Asia Industrial Metrology Group imt@zeiss.com.sg www.zeiss.com.sg/imt Singapore HQ Tel: (65) 6741 9600
Malaysia Tel: (60) 3 7877 5058
Thailand Tel: (66) 2 274 0643
Vietnam - Ho Chi Minh Tel: (84) 8 3911 8670
Fab&
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Form
New
Horizons HMCs are proving to be a firm favourite that will never go out of fashion. By Augustine Quek
T
y pica l HMCs today ca n achieve spindle speeds of 18,000 revolutions per minute (rpm), with torques reaching over 80 ft/lbs. For example, Deckel Maho DMC 50 H horizontal machining centre has a motor spindle with 18,000 rpm, rapid traverses of 1,968 inches per minute (in/min) and acceleration rates of 7 m/s2 in all axes. The unit comes equipped with a NC rotary positioning table and can be positioned in increments of one degree. As an additional option, a continuously positioning NC rotary table as ‘real’ B-axis is also available. Its DMC 65 H duoBLOCK has a machine design built with a large static base with smaller moveable axes with a rapid traverse and feed rate of 2,362 in/min. Similarly, the Niigata HN80D HMC from SNK America features traverse rates of 1,181 in/min and feed rates of 592 in/min on heavy-duty box ways. The spindles are powered through an advanced-range geared 44
metalworking equipment news Jul-Aug 2009
headstock. It has only three rotating components, with large-diameter ball screws, coupled directly to AC digital servo motors. A large spindle diameter and a single-piece snout-type head design is said to provide heavier milling capability and greater accuracy, as compared to traditional bolttogether-type spindle-head designs. The bed-type design provides suppor t over the entire X- a x is travel, eliminating the possibility of overhang weakness. The Y-axis double - guide system results in stability and ensures rigidity and improved contouring capabilities.
Two In One Several HMCs are also built from c o m b i n a t i o n o f t wo o r m o r e machine s. The two - spindle BA 321 HMC from German company SW combines design elements of machining centres with those of rotary index machines. It is designed for 3- and 4-axis production work of
steel and cast iron workpieces. The two synchronous motor spindles have power rating of 32 kW, a torque of 72 Nm and can reach 17,500 rpm. The workpiece carrier is a rotary axis in a form of a horizontal beam, with four clamping stations, each accommodating two or four workholding fixtures. Each station also features up to seven distributor ports for the hydraulics and pneumatics needed to cla mp t he work piece s. T he workpiece carrier arrangement allows the two main spindles to machine the workpieces on each of the three cla mping stations within the machining area, while the operator loads and unloads workpieces from the fourth station in the loading station. M o r i S e i k i’s N T S e r i e s o f inte g rate d m ill - tu r n ce nt re s combines a lathe with a machining centre. They contain a B-axis that uses a direct drive motor, achieving a maximum spindle speed of 5,000
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rpm with a maximum tool spindle speed of 12,000 rpm. The machine also uses DCG (Driven at the Centre of Gravity) technology, which controls vibration by driving structural parts at their centre of gravity using twin drives with two ball screws. Its box-in-box construction with a built-in milling motor effectively combines the turning ability of a lathe and the cutting ability of a machining centre.
Axis Of Technology The more advanced HMCs, the 5-axis machines, has two more axes, a C or Q axis and a B axis, in addition to the three normal axes (XYZ). The C or Q axis allows the horizontally mounted workpiece to be rotated, essentially allowing asymmetric and eccentric turning, while the B axis controls the tilt of the tool itself. For example, Cincinnati’s Mega Series 5 -a xis HMCs utilise twin ballscrew-driven axes configuration in XYZ and the basic B-axis table to provide a compact tilt-spindle with 180 deg sweep. It also allows tuning and coolant delivery options to improve throughput, at feed rates of 60 m/min (2,362 in/min) and acceleration rates of 1 g. T he se computer- cont rol le d machines also have the ability to move the spindle vertically along the Z-axis. This extra degree of freedom
is what gives HMCs their varied functionality, such as diesinking, engraving applications and relief sculptures. When combined with the use of conical tools or a ball nose cutter, it also improves machining precision without a decrease in speed. This means HMCs can be used in the machining of delicate components or very small parts, such as those in the medical, dental, micro and optical sectors as well as the production of small aerospace and automotive components. For example, a custom built Mitsui Seiki HMC has been used to machine the largest lightweight beryllium optic ever made. One of eight installed in a climate-controlled factory at Axsys Technologies, the HMCs have micronlevel precision in positioning the beryllium segments. The machining and milling form part of a year-long sequence in processing the segments. The beryllium component is a central element in the James Webb infrared optimised space telescope, to be launched in 2013.
Pushing The Envelope The deployment of HMC in the machining of medica l pa r ts is a testament to its high degree of precision. Clada Medical and Alta Science are using Schaublin’s 102 TM CNC machine for intricate micro machining. It has a +/- three micron accuracy level with C-axis machining
programmable increment of 0.001 deg. When all of these axes are used in conjunction with each other, complicated geometries can be made with these machines. But the skill to programme such geometries is beyond that of most operators. Therefore, 5-axis milling machines are almost always programmed with CAM. A recent addition to HMC CAM is SmartcamCNC’s Smartcam version 16.0. It features automated toolpath generation directly from a solid model and improvements to visualisation, verification and usability. Another major component is an integrated data translator that allows import and export of solid or wireframe models in the step format. Fully integ rated, nat ive - file format translators for Autodesk I n v e n to r a n d S o l i d w o r k s a r e optionally available. HMCs offer numerous capabilities for the end-user, such as roughing, g un dr illing, ha rd milling a nd finishing operations. It incorporates the same technology as those in a vertical machine but has many inherent advantages. The se adva ntage s include versatility, flexibility in automation and accessibility to the workpiece or fixture while the machine is running. Today’s HMCs have taken technology to the next level. MEN Enquiry No. 5301
The deployment of HMC in the machining of medical parts is a testament to its precision Jul-Aug 2009 metalworking equipment news
45
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Product Highlights Chi-Fa: High-Tech HMC
Haas Automation: High-Productivity HMC
The HT-500A by Taiwanese machine tool maker Chi-Fa offers a strong machine structure that provides cutting rigidity and moving stability. Featuring a high-speed feedrate of 60 M/min in three axes, the HMC also has an angular positioning of rotary working table. Working in tandem with the APC and ATC system, these features bring users into high production.
EC-550 features a 30” x 34” x 32” work envelope, 50-taper spindle, dual pallet changer with 550 mm pallets and a built-in one-degree pallet indexer. The Haas H M C ’s s t a n d a r d 6,000 rpm spindle uses an inline direct-drive system that couples the motor directly to the spindle to provide fine surface finishes, thermal stability and quiet operation. For high-speed work, an optional 10,000 rpm inline directdrive spindle is available. Driven by a 45 hp vector drive system, this spindle yields 170 ft-lb of torque at 1,400 rpm, and a power rating of 60 hp at 7,000 rpm.
Enquiry No. 5304
Enquiry No. 5302
46
DMG: HMC For Special Alloys
Kitamura: Tool Life Extension
DMC 75 H duoBlock provides motor spindles up to 52 kW and 430 Nm. With a work area (in X, Y and Z) of 750 mm x 800 mm x 800 mm, the standard version HMC already provides a 44 kW motor spindle with slender spindle nose and SK50 tool holder. This cooled standard motor spindle with speed range up to 10,000 rpm develops 288 Nm torque. DMG optionally offers another motor spindle with 12,000 rpm, which has a capacity of 52 kW and a torque of 430 Nm. This, together with the feed force of up to 12 kN, should be enough to even machine special aluminium alloys like those in the aerospace industry, with very high cutting speeds.
Mycenter-HX800i HMC delivers the precision, accuracy and repeatability required to produce close tolerance parts. With the versatility for roughing and fine finish capabilities in a single set-up, the Kitamura produced machine is designed for the automotive, oil and gas machinery, aerospace and heavy machinery industries. Net weight of the machine is 45,100 lbs (20,457 kg). The machine comes with a 35 hp, 12,000 rpm two-step geared spindle. An optional 8,000 rpm high torque spindle is an available option with output max torque of 699.3 ft/lbs. The combination of spindle gear system with a dual contact spindle design offers higher cutting accuracy and extended cutting tool life.
Enquiry No. 5303
Enquiry No. 5305
metalworking equipment news Jul-Aug 2009
ENQUIRY NO 079
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Matsuura Machinery: Upgraded HMC
Victor Taichung: Versatile Solution
Matsuura has upgraded its H Plus-405. It uses 500 mm x 500 mm pallets in spite of its compact machine size. The results are improved mechanical functionality and aesthetics. In terms of functions, all the axis-strokes in the HMC have been increased to 660 mm (+ 60 mm). In additiion, the max work piece envelope has increased to D700 mm (+ 50 mm) x H 850 mm (+ 100 mm). Together, the enhancements have enabled the use of larger fixing jigs. To add to that, all the X/Y/Z-axis feedrates have been increased to 60 m/min (+ 1.2 times). Furthermore, simultaneous operation of the ATC (tool change) and the APC (pallet change) has been achieved to facilitate a reduction of non-cutting hours. Though all-axis strokes have been increased, the floor space has been reduced by 12 percent.
With the rotary table embedded inside the 3.5 m long fixed table, Victor Taichung Machinery has its Vcenter-X300 machining centre equipped with an swivel head on the travelling column to implement the 5-axis simultaneous machining at an arbitrary angle for part diameter of 1,100 mm. The central partition guarding the machine not only does the multi-face machining on 3 m long parts but also transforms into two smaller vertical machining centres for pendulum machining at different set-ups for 4-axis and 5-axis machining.
Enquiry No. 5308
Yida: Heavy Duty Machining Centre
Enquiry No. 5306
Milltronics: Flexibility On Rigid Frame
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The flexibility of HM20 HMC provides a cost effective alternative to other high priced machines on the market. Large travels and a rigid frame design make this Milltronics machine suitable for a mould shop or a production environment. Features include 40 taper spindle options up to 15,000 rpm and 70 mm spindle design with air purged labyrinth seal. The automatic metered lubrication with low lube fault and six nozzle high volume flood coolant system can be found on this machine.
The MH-500 plus by Yida is a solid HMC with its base manufactured from high tensile Meehanite cast iron. Highhardness sliding tracks and the square shape column facilitate heavy milling task. Driven by a servomotor, the pallet change time is 6.8 s. In addition, Heidenhain absolute optical linear scale is available, the resolution is down to 0.05 Âľm. Including a high-pressure coolant delivery system, the CTS could work with 70 bar and high volume coolant delivery system but maintains the filtration down to five microns to protect machine and tooling. Oil cooling for ball screw takes away rotating heat quickly. Tool changing and door opening can be done at the same time to reduce total tool change time to 1.9 s.
Enquiry No. 5307
Enquiry No. 5309
metalworking equipment news Jul-Aug 2009
Crysta-Plus M 3D COORDINATE MEASURING MACHINE
MANUAL-FLOATING TYPE CMM FEATURES l High-precision air bearings and lightweight moving members. l Continuous fine feed over the entire measuring range. l One-touch air clamp for each axis.
An intelligent alternative to complex and cost-intensive measuring machines.
T
he Crysta-Plus M is a high-performance manual 3D CMM. Cryta-Plus M is well designed to meet the constant changing measuring tasks, different types of workpiece and random sampling. With its enhanced features, the Crysta-Plus M combines the capabilities of many individual measuring and testing instruments in a single, economical, allround system, making enormous savings and long-term maintenance. Look no further, the Crysta-Plus M is your choice where precise measurement is concerned.
SPECIFICATIONS Measuring range M443 X axis 400 mm Y axis 400 mm Z axis 300 mm Machine accuracy E=(3.0+4.0L/1000)µm ISO 10360-2(20ºC±1ºC) R= 4.0µm Resolution
M544 M574 M776 M7106 500 mm 500 mm 700 mm 700 mm 400 mm 700 mm 700 mm 1000 mm 400 mm 400 mm 600 mm 600 mm E=(3.5+4.5L/1000)µm E=(4.5+4.5L/1000)µm R= 4.0µm R= 5.0µm 0.5 µm
Mitutoyo Asia Pacific Pte. Ltd. Company Reg No. 892/1978-N
Mitutoyo (Malaysia) Sdn. Bhd.
Tel: (60)3-7845 9318 Fax: (60)3-7845 9346 E-mail: mmsb@mitutoyo.com.my M(M)S.B. - Penang Branch Tel: (60)4-641 1998 Fax: (60)4-641 2998 E-mail: mmsbpen@mitutoyo.com.my M(M)S.B. - Johor Branch Tel: (60)7-352 1626 Fax: (60)7-352 1628 E-mail: mmsbjhr@mitutoyo.com.my
Mitutoyo (Thailand) Co., Ltd.
Tel: (66)2-521 6130 Fax: (66)2-521 6136 E-mail: office@mitutoyo.co.th MTC - Cholburi Branch Tel: (66)3-834 5783 Fax: (66)3-834 5788 MTC - Amata Nakorn Branch Tel: (66)3-846 8976 Fax: (66)3-846 8978
PT. Mitutoyo Indonesia
Ho Chi Minh City Rep. Office
Tel: (62)21-898 0841 Fax: (62)21-898 0842
Tel: (84)8-3517 4561 Fax: (84)8-3517 4582
E-mail: ptmi@mitutoyo.co.id
E-mail: mitutoyo@mitutoyo.com.vn
Philippine Representative Office
Hanoi Representative Office
Tel: (63)2-842 9305/6 Fax: (63)2-842 9307
Tel: (84)4-3768 8963 Fax: (84)4-3768 8960
E-mail: mph@mitutoyo.com.ph
E-mail: mitutoyo-hn@mitutoyo.com.vn
ENQUIRY NO 098
24 Kallang Avenue, Mitutoyo Building, Singapore 339415 Tel: (65) 6294 2211 Fax: (65) 6299 6666 E-mail: mapsg@mitutoyo.com.sg http://www.mitutoyo.com.sg
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spotlight
Consumer Electronics:
Inn vation
In Difficult Economic Times
Creative solutions are the perfect antiviral drugs for those in the consumer electronic sector who are suffering from the latest bout of economic influenza. By Thomas W Maurer and Daniel J Staresinic, worldwide director, Siemens PLM.
C
onsumer electronic comp a n ie s a re u nde r co n s t a nt p re s su re to i n c r e a s e t h e nu m b e r of new products they bring into the market while minimising their development costs. Lean times force a re-evaluation of product portfolios and R&D allocations. Analysts and consultants agree that innovation is the key to creating sustainable growth. And with what is at stake, it is obvious why these companies spend so much on R&D. Being the first to market a new product can mean a huge market share advantage and higher gross margins of up to as much as 20 percent. In short, this is not the time to cut back on new product development. Efficient and cost-effective innovation is now more important than ever, and here are some of the key things that consumer product manufacturers, including consu mer ele ct ronic companies, should consider under such circumstances.
Making Adjustments When the economy is strong, the i n n ov a t i v e co n su m e r p ro du c t manufacturer enjoys the luxury of 50
metalworking equipment news Jul-Aug 2009
focusing on margin growth. A relative high percentage of the product and brand focus is ‘up -market,’ with the goal of providing superior performance at a premium price. In a down economy the consumer is more willing to step past superior performance, at least for a while. The leaders in consumer products shift their focus correspondingly to the promotion of midrange and value brands. And while the margin game is temporarily delayed, the market share game begins in earnest.
Innovation & Development The new product development engine will be asked to crank out a higher percentage of cost reductions and low-cost upgrades that can provide ‘new news’ without requiring price hikes at the shelf. Some larger efforts may be put on hold in favour of these share-building effor t s. I n addition, some new projects established may deliver no consumer-noticeable benefits at all, but instead allow the manufacturer to switch to a less expensive ingredient or component. With more projects now in the pipeline and with cost control at a
super-premium, it is more important than ever to identify and accelerate the best ideas, and to identify and eliminate the bad ones early in the process. A purposeful and well-managed ideation/selection process is a must, as is rigorous portfolio management. Particularly helpful are portfolio ma nagement tools that ca n re evaluate projects quickly against the heightened priority on cost reduction and share growth. In addition, if consumer product companies are not already doing so, t hey shou ld broade n t heir definition of innovation so that it begins at the idea and continues through to the shelf. There are ample opportunities for innovation at every stage of the lifecycle, and a holistic view is always important to getting new products to market faster and more cost-effectively.
PLM Technology The University of Michigan PLM development consortium defines PLM as an integrated, informationdriven approach to all aspects of a product’s life – from its design inception through its manufacture,
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Done properly, portfolio planning can help companies focus their resources on the products that will provide the highest value while accounting for the risk and uncertainty inherent in bringing new products to market.
compa nie s a re utilising be st practices, such as PLM technology in the strategic planning process to ensure that they build the right products. The technology also provides the necessa r y infra structure for effective management of the innovation process and addresses all of the requirements for building the product right, using virtual product development best practices.
Tuning Up Portfolio optimisation or portfolio tuning is a very powerful strategic planning tool. Done properly, portfolio planning can help companies focus their resources on the products that will provide the highest value
Enquiry No. 5401 Nintaro, Shizuoka, Japan
deploy me nt a nd ma i nte na nce , culminating in its removal from service and final disposal. It is the single source of truth about product, production, and process information, as well as the infrastructure necessary to enforce best business practices throughout the lifecycle. PLM enables an organisation to rally around its true source of value (its products) and to digitally supply information about these products to all other enterprise systems. This, along with well-structured security and change management capabilities, provides an effective collaboration environment. And in a large consumer product orga nisation, effective collaboration is the foundation of effective innovation. This aspect of the tool – that it can link product team members no matter where they are located – is particularly important today with project team members distributed around the globe and with cost pressures creating a revolving door of material and contract manufacturing vendors. It is worth noting that bestpractice companies spend sig nifica ntly le ss re source s on project fa ilures tha n ty pica l companies. In other words, leading
while accounting for the risk and uncertainty inherent in bringing new products to market. It requires the ability to define strategy through weighting, modelling and performance measurements, and to perform what-if analyses of multiple scenarios with current and future products. Additionally, a good platform strategy leverages approved and tested products to make incremental c ha n ge s t hat re f re sh e x i st i n g products with new technologies or fe ature s, while ma inta ining product uniformity and identity in the marketplace. With the most successful products (a popular MP3 player comes to mind), subsequent variations of a platform sell better than previous models. The idea here is to enable the reuse of common components as early as possible in the product lifecycle and schedule the introduction of new technology components when they become available. The critical capabilities include being able to manage product information at the platform a rchitecture level and being able to connect concept management and strategic sourcing with engineering bill of material management. Now is the time to start executing on innovation plans. Our shorthand for the two-part challenge is ‘build the right product/build the product right.’ PLM provides the platform to support this process. MEN
There are opportunities for innovation at every stage of the product lifecycle in order to get new products to market faster and more cost-effectively. Jul-Aug 2009 metalworking equipment news
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Cosy
Consumer Electronics:
Comfort
Craig Jewell, Brisbane, Australia
The consumer electronics industry may not have been spared from the dreaded downturn but there are signs that bode well for the metalworking industry. By Joson Ng
52
I
t may seem impossible to link the metalworking world to consumer electronics at first, but upon taking a closer look that has proved to be untrue. Metalworking pro ce sse s a re re sp on sible for several consumer electronic goods like mobile phone, television and personal computer parts. It is therefore good news for the metalworking fraternity when consumer electronics manufacturing is on the up. This industry has suffered in this worldwide recession. According to IDC, a provider of market intelligence, worldwide semiconductor market for portable media players (PMPs) is poised to drop from US$7.5 billion in 2008 to US$4.6 billion in 2013, representing a Compound Annual Growth Rate (CAGR) of –9 percent, according to a forecast from the firm. A mature market coupled with the economic downturn and growing similarity with mobile phones and mobile Internet devices (MIDs), a ll contribute to the shrink ing semiconductor opportunity in PMPs. They will cease to be the largest market for NAND flash memory. The decline in PMP unit shipments is offset by modest growth in wireless connectivity semiconductors, driven by the increase in attach rate for FM, WLAN, and Bluetooth radios. metalworking equipment news Jul-Aug 2009
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Things may not be rosy on the PMPs front but electronic manufacturing on the whole is showing some encouraging signs. According to a market research report available on Electronics.ca Publications, the global market for electronics contract manufacturing (ECM) technology was worth US$321.0 billion in 2008. This is expected to increase to over US$345.0 billion in 2009 and US$519.0 billion in 2014, in a CAGR of 8.5 percent. The market is broken down into the application segments of computers and telecommunication, consumer and industrial electronics, and others. Consumer and industrial electronics were worth US$92.0 billion in 2008 and an estimated US$96.5 billion in 2009. This segment is expected to increase at a CAGR of 7.2 percent to reach US$136.7 billion in 2014. O ther application seg ments generated US$22.0 billion in 2008. This should increase to US$23.5 billion in 2009 and US$30.3 billion in 2014, for a CAGR of 5.2 percent.
Trickle Effect This positive showing is good news for metalworking job shops dealing in die and mould and machining in particular where zinc alloy, aluminium alloy die casting components are used to make automobile, motorcycle, DVD and
computer parts, household appliances, hard disk components and so on.
• Metrology Many of today’s metalworking processes involve software design suites and metrology systems, which can benefit from this trickling effect. In metrology, there are various arms, gauges and software to help in part alignment, system calibration, and part inspection. “Metrology software products h e l p to m e a s u r e c o n s u m e r electronics goods in different stages of product life cycle,” says Anthony Lur, senior applications engineer, Faro. “A s the product goes into product ion, common qua lit y checks with metrology dimensional software involves checking the structural dimension in order to comply w ith the de sig ner information. I have experience using Faro dimensional software to check the structure of printers and third party dimensional software for the ca sing of automotive speedometer,” he elaborates.
• Savings Metrology solutions like laser t rackers ca n be deployed to measure the position of a part on a machine tool depending upon
Encouraging signs in the consumer electronic market are good news for the metalworking industry
Sanja Gjenero, Zagreb, Croatia
Sliver Lining
the size of the part in question. The larger the machine tool the more difficult and time-consuming evaluation can become. “Time can be a major factor to hinder production if a mass volume of the product especially electronic goods do not comply to quality. The faster way is to use a metrology software routine to re a lise such applic at ion s nowadays,” says Mr Lur. “My opinion of time based saving in the case of checking simple perpendicularity of a structure can be up to 70 percent. Some in the market prefer traditional methods and have standard hand tools to perform the job. To be frank, some old methodologies are more effective than computational software, however in this case I am refering to a more complex measurement,” he adds. Mr Lur prefers to see both methods as complementary, rather than in opposition. “It is important for users to rely on traditional methods or even the least accurate way to quantify the quality of the product when using metrology software. In the long run, cost can be brought dow n significa ntly, va riables include geographical location where production is setup, types of electronics goods, scrap rate, labour cost (man hours) to inspect the product affect the preference of cost savings. But generally speaking if there is no minimum of 30 percent on cost savings of returns of investment using a metrology software, most businesses will not consider acquiring it,” he concludes.
• Software Design Visualisation and 3D modelling a re i mp o r t a nt s te p s b e fo re manufacturing of complex consumer electronic parts. The electronic aspect demands accuracy, as this is where nanotechnology comes into play. The consumer aspect weighs heavily on aesthetics. The combination of the two opens Jul-Aug 2009 metalworking equipment news
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the door for design software applications. Today’s electronics/electrical product manufacturers use analysis software to simulate and assess the performance of a variety of product designs, including consumer electronics. Analysis software enable engineers to simulate design performance, identify and address potential design problems before prototyping and production. T he i r p opu la r it y c a n b e attributed to a few points as Rajagopalan Varadarajan, product manager, SolidWorks Simulation Solutions explains: “The software is customisable to suit consumer electronic goods. This organises all the software tools which are relevant to this industry.” In addition, software programmes can resize automatically, making it a useful proposition. “They have the ability to create top down assemblies and, when the size of one part changes, all the parts and assemblies can change. For example, when the outer dimension of a microwave oven changes, all the internal parts – which depend on the outer size can automatically resize,” he adds. In the competitive market of consumer electronics, the design phase is of utmost importance. With added requirements like thermal management, product abuse test (drop test), warranty prediction, vibration testing, hot and cold chamber testing, software products are used more than ever.
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“In all these cases, if the heat dissipation as well as location of the critical components and cooling systems are not designed properly, it will lead to failure,” he muses. According to Mr Varadarajan, product abuse is another issue where users can accidentally drop products and claim warranty. Long design lead-time is also another factor in market leadership. One of the reasons for this is the prototype testing on a vibration shaker, hot/ cold chamber testing and drop tests. They consume a lot of time, money and effort. These tests can be done using simulation products, right at the design stage, using tools within SolidWorks integrated platform. He mentions: “Software products help in design optimisation and material selection. It also helps to conduct tests, which you can never do physically in a shortest possible time and as a result, the designs are optimised. Our customers say there is about 50 to 80 percent on time savings in prototype testing.”
Consuming The Future With more than 30 percent drop per annum in the prices of LCD, Plasma, and DLP televisions, large
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Enquiry No. 5402
Metalworking has a hand in the manufacture of refrigerator coils
Oleksiy Petrenko, Kyiv, Ukraine
• Challenges In Designs “The biggest challenge today in electronics design is thermal management. Products sizes are becoming smaller and smaller with every new design. At the same time, they are denser inside (eg: digital camera inside a phone) and are built with more powerful processors. Non-serviceable products (they are built with no fans) are also getting popular,” says Mr Varadarajan
screen HDTVs have found their way to more homes. This is according to Altera Corp, a programmable logic solutions provider. With homes equipped with HDTVs, and highdefinition content available through broadband, terrestrial, cable, and satellite, the good run looks set to continue. Consumers generally want to stay connected these days. In the pa st, laptops for were used to access emails and the Internet. However, w it h ter re st r ia l a nd mobile broadca st ser v ice s for ha ndheld dev ices becoming common and broadband wireless connectiv ity ava ilable in more areas, mobile devices such as cell phones and portable media players are being used to access audio, video, and data. These trends indicate that the consumer electronics market is in a rapid evolution phase and the manufacturers are under tremendous competitive pressure to be the first-tomarket with unique and differentiated products. Great challenge this may be, but this piece of news has given the metalworking industry a welcome shot in the arm. MEN
ENQUIRY NO 088
www.epmlinkage.com
Akai Lin
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Focus
Taiwan Focus:
Island Of Like the Taipei 101, the Taiwanese machinery industry is standing tall and firm. By Joson Ng
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aiwan is one of the leading machine tool manufacturers. In 2008, the export value registered a 5.9 percent i nc re a s e f ro m 2 0 07, re ac h i n g US$3.72 billion, according to figures supplied by Taiwan External Trade Development Council ( TAITR A). Items exported include machining centres, metal cutting machine tools, lathes, presses and shearing machines. The top two exported items were machining centres and lathes worth US$1.2 billion and US$856 million respectively. The ‘made in Taiwan’ machines were exported all over the world in 2008 with China (US$1.1 billion), USA (US$338 million), Germany (US$224 million), Turkey (US$161 million) and Brazil (US$157 million) making up the top five destinations. Although not spared from the worldwide economic downturn, the island’s machinery industry 56
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is in good hands with the Taiwan Association of Machinery Industry ( TAMI) and TAITR A doing their upmost to guide the industry through this storm. To better understand the current policies, strategies and future trends, Asia Pacific Metalworking Equipment News speaks to CC Wang, president, TAMI, to get his expert opinion.
Battle Plan TAMI has already formulated some strategies for this year all the way to 2010 to keep the island ahead of t he g loba l comp et it ion. M r Wang says: “The global financial crisis has brought tremendous changes to world trade and the e co n o m y, a n d o u r m a c h i n e r y industry is no exception. As such, we have recommended government financial authorities to convince domestic banks to provide ‘short to mid-term working capital loans’
in order to help companies weather the storm.” Tackling the current slump from another angle, the association hopes to see a reduction in production cost for the machine manufacturers. “We have also been urging the authorities to negotiate with China Steel to lower the steel price, so that our machinery industry can reduce cost and enhance its competitiveness in the global market in order to cope with changes due to recession and deflation better,” he adds. Apart from reducing cost and providing loans, the organisation is also looking into means to make the island more attractive to potential investors as Mr Wang comments: “Our machiner y industr y must speed up the process of market diversification. We recommend that the authorities streamline the visa application process for businessmen from the Middle East and South-West
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Asia. We also hope that visas can be issued in one day. It would attract more businessmen to Taiwan for potential trade.”
Sizing Up The Competition With the rise of China and stern challenges offered by the South Koreans, there are challenges aplenty for the Taiwanese makers, as they have to compete in close quarters with formidable rivals including A sia n m ac h i ne r y p owe rhou se Japan. Mr Wang however is staying optimistic. He ex pla ins: “Japa n, China , Taiwan, South Korea as well as other South-east Asian machine tool manufacturers possess better opportunities because they are closer to countries with higher economic grow th rate, such as China (5.9 percent in 2009), India (4.3 percent), Vietnam (3.7 percent) and Indonesia (2.2 percent).” Although viewing the rivalry between the four competing nations as healthy, he admitted competition between the four is intense. “Our main competitors are China and S out h Kore a ,” he de cla re s. I n order to give his countryman the edge, the association will assist the Taiwan machine tool industry
“Our machinery industry must speed up the process of market diversification. We recommend that the authorities streamline the visa application process for businessmen from the Middle East and South-west Asia.” – CC Wang to become more competitive in the global market by arranging ECFA negotiation with China and requesting government authorities to conduct FTA negotiations with the US, EU and ASEAN. With quiet confidence, Mr Wang says: “Our machine tool products are very competitive in terms of price and delivery time.”
Ask The Magic 8 Ball In a ny unavoidable slide, it is impor ta nt to rema in ca lm a nd stay optimistic, as panic will only exacerbate a bad situation. Though the output value of the island’s machinery products is expected to fall, Mr Wang is looking beyond
High speed, high precision and automation are the future technical developments of Taiwanese machine tool products
that and taking an optimistic view of things. “The output value of Taiwan machinery products is expected to decline 20 to 25 percent in 2009. However, it should be able to come back to the same level of 2008 in 2010. We are committed to help companies in R&D and global marketing to meet the target,” he says. More R&D will invariantly lead to more technological advances and Mr Wang is quick to add that high speed, high precision, high level of integration and automation are the future trends of technical development in Taiwanese machine tool products. Other determinant factors also include the R&D of compact machine structure and key components, such as hardware and software of NC controller, ball screws, linear guide ways, 5-axis rotary tables, 5-axis milling and cutting spindles. In a highly globalised world where the economic situation is as fluid as it can ever get, competition is inevitable and instead of shunning them, facing them head on with optimism is perhaps the best weapon as Mr Wang concludes: “Taiwanese machine to ols a nd machiner y products are bound to compete with products from Japan, the US and EU in the future. However, we are confident because of our competitiveness in terms of price and delivery time.” MEN Enquiry No. 5501 Jul-Aug 2009 metalworking equipment news
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Malaysia Mould and Die Association:
Propelling
Forward
Making rational decisions, focussing on development and technology are all part of the masterplan to make the big stride forward. By Joson Ng
Mr Cheng remains confident as the country has invested much in technology
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he Ma laysia Mould a nd Die Association (MMADA) aims to promote and protect the general interest of all its members by exchanging and using technical knowledge in and out of Malaysia. This noble aim is very much in the spotlight as the world’s economy is currently in the doldrums. Asia Pacific Metalworkin g Equipment News speaks to Albert Cheng, president, MMADA to find out how the association plans to carry out its vision of promoting and protecting its members. Mr Cheng admits that it is an uphill task given the present situation. He says: “Generally the domestic market for the mould and dies is badly affected by the current global economic downturn. No one can be spared from this. Most projects have been delayed until further notice.” As the mould and die industry is generally viewed as a support industry, the effect can be significant
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as the other industries slow down. “The automotive industry, the main consumer for tooling, is so badly affected that every maker is just thinking of how to minimise tooling costs on every new model by communising the parts on many of their models to keep tooling costs down. Also, the automotive makers are slowing down on model change and this generally affects the tooling industry, in particularly the mould and die industry. We are also facing very stiff competition in the electronic and machinery tooling sector, mainly from China as their products come with lower price tags,” he adds.
The Rescue Act Looking at his own backyard and assessing the situation, Mr Cheng takes a pragmatic view and has no illusion where the problem lies. He is however, unfazed with the scale of challenge ahead as he has plans in place to tackle them.
“Majority of our members, about 80 percent of them are small and medium size companies. Although m o s t o f t he m a re c a p a b l e o f producing quality mould and dies, only a very small percentage are able to penetrate the export market due to various reasons,” he offers. One weakness he identifies is the lack of marketing capability and quality management for smaller companies. Help is at hand as Mr Cheng says: “All this while our association have been educating its members to re-engineer their business for better competitiveness by adopting ICT tools for manufacturing – such as CAD/CAM and CAE. Last year, we set up a web portal for our members with a free listing for all the members.” A p a r t f ro m e du c at io n , t he association has been working hard, forming alliances in order to give its members more exposure. “ Wit h M M A DA a f f il iate d to
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two global tooling associations, namely Federation of Asian Die & Mould Associations (FADMA) and International Special Tooling and Machining Associations (ISTMA), we have expanded our members’ network. We encourage our members to improve market exposure through p a r t ic ip at io n i n t rade shows, dialogue exchanges and business network seminars,” he adds.
Hot Spots Digging deep into his industrial k nowledge, Mr Cheng attempts to analyse where the hot spots are and predict future trends. He says: “Medical and biotechnology have been a focus industry by the Malaysian government for the last two years. Huge grants have been allocated by our government as an incentive for the tooling industry to diversify into the medical & biotechnology field.” The results have been mixed as Mr Cheng elaborates: “Within t h i s sho r t du r a t io n , we h av e seen significant surge in medical parts manufacturing, aerospace components making as well as oil and gas industries manufacturing activities. This speciality area of manufacturing requires different technology and equipment and we foresee only a small portion of our more established mould and die
makers have benefited.” I n te r m s o f te c h n o l o g i c a l advances in the industry, Mr Cheng feels more can be done to improve and they are now well on their way. “Ou r gover n ment ha s b e en pushing for machineries invention, manufacturing and biotechnology. However we believe that there is still room for improvements in terms of usage of ICT in manufacturing. We hope to make our mould and die makers more productive and be able to develop their own product, with innovations and creativity built into it,” he muses. Embracing technology is the way forward for Malaysia as Mr Cheng says: “Today, we see the wide use of ICT technology in the mould and die design and manufacturing process. This include use of plastic injection mould flow analysis, for producing quality plastic parts, use of stamping and forming analysis tools, to produce quality stamping components, use of metal flow simulations tools to improve metal die casting mould making, use of FEA (finite element analysis) to validate design and optimised design, before proceeding to produce tooling or moulds for the products.”
Focussing On The Positives Mr Cheng feels that in this env ironment, the mould a nd
The mould and die industry has taken a hit recently when the automotive industry slowed
die industry is in no position to expect a growth. He hopes that each member does their best to maintain their relationship with their customers and at the same time spare some time to upgrade the design and manufacturing skills of their engineers and technicians so that they are ready for the market recovery. Refusing to wallow in sadness, Mr Cheng chooses to remind everyone the strengths of the Malaysian mould and die industry and why they will come out of this situation stronger. “The Malaysian mould and die industry in general has good skill and possess innovation in order to meet technological requirement. In addition, we are support oriented and are able to deliver fast. As such we produce better products, in term of accuracy, reliability and consistency. By doing so, our products usually sell at a higher price. We are competitive, if potential customers consider quality and reliability as their key selection factor, instead of just low price,” he says. Language skills and the availability of training institutes in Malaysia are also the main driving force behind this industry as Mr Cheng explains: “Due to our multilanguage capability, we have better and more effective adoption of new technology. IT has given Malaysia an upper hand in enhancing our mould and die making technology and skills as compare to most of the other countries in South-east Asia.” As far as Mr Cheng is concerned, the future of the industry is bright as new talents are being produced in the local universities. “The Ma laysia n Institutions of higher learning have already implemented all these ICT solutions for manufacturing – we are well ahead of many neighbours in taking the proactive approach to prepare our young generations in meeting the challenges in mould and die industry in the near future,” he concludes. MEN Enquiry No. 5601 Jul-Aug 2009 metalworking equipment news
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No
Fixed
Rules
Fluidity in fixturing was unthinkable in the past but not anymore with the combination of modular fixturing and CAD coming to the fore. By Maren Roeding, PR manager, Witte Far East.
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a rious methods have become generally accepted for the ma nufacture of measuring fixtures, gauges and cubing. However, the use of modular systems is on the increase. T hey have a n adva nta ge in that they can be adapted to any subsequent changes made in the part to be measured. And of course the indiv idua l components a re available again for later projects. Despite modern developments like optical measuring systems, many users still prefer gauges with flush and gap contours for examining plastic and sheet metal parts, the so-
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called ‘go’, ‘no go’ fixtures.
The Good Old Days Normally steel or aluminium base frames mounted with cast aluminium or polymer blocks are used for this type of fixture. The complete unit comprising of frame and blocks is then milled into a 3D contour shape in a correspondingly large CNC machining centre. The 3D geometry of the contour parts corresponds to the outline or surface of its neighbouring parts (eg: fenders to hood). This approach, which is called traditional fixture building, is very time
and cost-intensive. First, casts must be designed and moulds manufactured. Subsequently, the form is cast. After that several machining steps are required to achieve the finished form. If there are any changes to the part then both design and model have to be reworked. The worst case may even be that the whole fixture has to be remade.
Moving On A considerably faster, simpler and at the same time more economical approach is possible when using modular fixturing system. The base frame is assembled
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using standard components of the modular system. Only the workpiecespecific adapters a re specia lly machined. To do this, first of all the rough block s have nubs according to special grid milled on the underside. The blocks are then mounted to the machine table using the premachined nubs and the surface is machined into 3D contours. Due to the grid accuracy of the fixture profiles, contour parts, which have been prepared with the typical nubs can be mounted directly onto the fixture frame. It is irrelevant whether the outline parts are aluminium, uriol or other materials. Interaction between the design software Expert and modular fixtures offers an advantage. Individual fixtures are designed, parts lists issued and fixtures assembled using standard components. This can often reduce the time from design to finished fixture to only a few hours. The connecting contours are designed to fit into the fixturing grid using CAD. Manufacture of relatively sma ll contour pa r ts requires considerably less time compared to conventional methods. But recently even this approach has been simplified further.
Modular Fixtures Witte Far East, manufacturer of
Changes in the part mean only that particular contour needs to be exchanged
modular fixturing system, is giving modern fix ture building a new direction with a partnership with rapid-prototyping specialists. The process, normally used for preparing prototypes, is now being used to provide individual contact points. Prototyping technolog y involves a process, with which parts in neutral material are made directly under the influence of physical and/ or chemical effects on the basis of CAD data. These prototypes enable optical/ visual analysis of the design. The company is now using this process for gauge and fixture building for certain applications. First the design of the base as far as the contour connecting points is done in software on which RapidFit prototy ping process is implemented.
Top: Manufacture of relatively small contour parts requires less time compared to conventional methods Right: A faster, simpler and more economical approach is possible when using modular fixturing system
T he dat a i s t ra n sfe r re d to RapidFit software, the geometry of the contours is calculated, then a preselected manufacturing method such as stereo lithography or selective laser-sintering actually manufactures them growing layer by layer. Also for these applications the contours are equipped with the typical grid nubs so they can be mounted directly onto frames. As a result of this method, new possibilities are unfolding with regard to part shapes. Technical limitations due to traverse paths or axis layout common to CNC manufacturing do not exist with rapid-prototyping. Any 3D shape, which often cannot be manufactured with conventional mechanical machining methods, can be manufactured. Several contours can be made simultaneously, speeding up the entire fixture building process. Changes in the part mean only that particular contour need to be exchanged and it can be designed and made very quickly. “In the past, rapid-prototype parts were not suitable for long-term use due to relatively low surface hardness. Now more and more new materials ensure stability and long life in use. Meanwhile several rapid-prototyping materials are available, which compare admirably with simple aluminium alloys,� says Stefan Roeding, MD, Witte Far East. MEN Enquiry No. 5602 Jul-Aug 2009 metalworking equipment news
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Synergy
In Action
Co-operation on an organisational level is a philosophy that is creating much success in one tool-making unit. By Ralph Schiffler, for DMG
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olkswagen Group defines tool making as a key technology. Its component tool-making department acts as an autonomous business unit and a service provider for the component works of the group. It comprises the development and fabrication of moulds for large plastic components, (eg: for instrument panels or bumpers) heavy die casting moulds, (eg: for gearbox casings and crankcases) and ingot and sand moulds, as well as tools used in sheet-forming processes such as hydroforming. Components produced also include plant-engineering components, (eg: components used in welding cells for assembling undercarriages and exhaust systems) or in assembly machinery for manufacturing steering systems. The group’s product portfolio helps ensure process reliability through its range of operating materials and equipment designed according to process-based specifications.
Tool Making Another important field of activity under the scope of tool making is prototype fabrication for undercarriages. From the fabrication of simple sheet metal parts right through to the assembly of complex undercarriage modules, expertise are required to perform the range of functions all along the process chain.Together with the testing of manufacturing processes (such as electron beam welding), the use of lightweight materials – aluminium and magnesium, is playing an increasingly important role. In order to realise even greater synergies and develop reserves of efficiency in a sustainable manner, technology and process standards have been standardised. One element of this move was also the concentration of
selected partners with respect to machinery suppliers. Today, Volkswagen’s Braunschweig works, which is responsible for its own financial results, serves as the supplier of steering components and systems – with a clear focus on chassis technology. Its product range includes, among other things, front and rear axles as well as shock absorbers and steering systems. The recent past has been a period for tool making with its strategic revaluation as a key technology, according to Dirk Strümpfler, manager of component tool making at Braunschweig: “We used to have to think from one tool to the next within the framework of a primarily procurement-oriented strategy. Now we’re in a position to develop and implement long-term and above all sustainable strategies consistently.” In this context, those responsible for tool making are also aware, of course, of the greater individual responsibility that comes with this strategic realignment towards tool making. Above all, there are very clear targets that have to be met in terms of financial results. “The only viable path to success is one that involves improvement that is every bit as consistent as it is sustainable – and improvement that is, above all, continuous – along the entire process chain. That improvement starts from the input of CAD system geometries and extends to the preparation of the work and the mechanical processing right through to the assembly of the tooling and its provision for subsequent serial production,” Mr Strümpfler explains.
Hand-In-Hand During the process, the toolmakers in Braunschweig do not work alone, but instead they form alliances with other locations within the group. This network includes
Synergetic approach is used for tool component manufacturing Jul-Aug 2009 metalworking equipment news
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the company’s tool making services in Wolfsburg and in Brazil, as well as Skoda’s tool making services and the toolmakers at Audi. The goal of this concerted action, according to Mr Strümpfler, is to use jointly developed best-practice solutions to implement uniform standards for workflows, processes and technologies at all works, and ultimately to realise a standardised methodology for the construction of vehicles. He then emphasises: “Essentially it’s always been, and continues to be, all about reducing complexities, maximising synergies and thus ultimately establishing a t ra n spa re nt fou ndat ion for k nowle dge - ba se d production, and promoting innovations in processes and products.” “With this in mind, for instance, we no longer think in terms of individual tools, but rather we act in a consistently process-oriented manner,” continues the manager. By way of example he points to the machining operation in Braunschweig, which, with about 200 employees and currently around 100 machines, serves in organisational terms as an in-house service provider for all areas of component tool making.
Picking The Right Machine When the need to prepare technical specifications for the future procurement of 5-axis milling machines arose recently, it was no longer handled in isolation. It was addressed on the basis of common interests through a group-wide, committee-based process in which the initial discussions were expanded to include the technical specifications provided by each location. “In so doing, many common points were identified, but some serious differences also arose among the
specific requirements of the individual group locations,” recalls Oliver Schütze, manager of central machining of component tool making. The next step, therefore, was to find a common denominator and to define the higher-level selection criteria. In the second step, the machine suppliers concerned were then brought on board in an initial round of discussions. The intention here was not to come up with the best offer, but primarily to examine general questions of coordination in a technical context. Because even the revised Volkswagen specifications differed to some degree from what the machine tool manufacturers define as standard for their product range. The result was a series of meetings in which both sides discussed the issues ‘out in the open’, as Mr Strümpfler describes it. In this way the selection criteria were successively formulated. Meanwhile machining trials were carried out in parallel with representative components and the results were used to shorten the list of potential suppliers incrementally until only a few suppliers remained. Mr Schütze recalls the results for the medium-sized 5-axis machines, he says: “We were happy with the universality and stability of these DMU machines with their performance spectrum ranging from hard rough machining to fine surface finishing.” He adds: “This higher degree of standardisation in all areas improves quality, as it increases process stability and transparency and enables the continuous development and implementation of optimisation processes on a timely basis.” MEN Enquiry No. 5603
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Organized by :
ENQUIRY NO 108
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Tanaka, Tokyo, Japan
Drilling:
Take The Heat Off It is always important to stay cool under high pressure and heat, this is all the more true in drilling. By Gregory S Antoun, president, ChipBlaster Inc, USA
H
igh - pre ssure coola nt keeps the temperature low, changing the way metal is cut, as damaging chemical reactions do not occur at low temperatures. With a properly designed high pressure and high volume coolant and the appropriate tooling system, surface speed can be increased a minimum of 30 percent, with some operations improving by 300 percent. It also provides lubricity by bla sting lubricating fluid between the chip and the cutting edge at hundreds of miles per hour. Combined with lower temperature, this increased lubricity often causes surface finishes to be twice as good. With conventional coolant the cutting edge comes up to a very high temperature as it enters the cut, and stays hot until it finishes the cut and is subsequently exposed to an extreme thermal shock as the coolant quenches the exposed tool.
Do It Right Tooling manufacturers recommend dry milling because they believe that the continual heat and chip da mage is better tha n therma l shock damage. You do not have to make this tradeoff with a better engineered system. Let’s also answer a frequently asked question, yes you do have to
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have a drill with coolant holes (oil hole drill). Without coolant holes in the drill, the application of coolant is difficult to control. The operators’ individual preference, experience or mood is completely responsible for the process. As a result the coolant is often poorly applied. This hapha za rd system i nt ro du ce s a hu g e a m o u nt o f process variation. High-pressure coolant is only part of the process. In fact if you aim high-pressure coolant down the flute of a drill the way you would with low-pressure coolant you can force the chips back into the bottom of the hole and cause premature drill breakage.
The pressure that really matters is the back pressure. Take two 0.375” drills as an example, a high speed drill typically has much larger coolant holes than some (but not all) solid carbide drills. Much more coolant will pass through the drill with large coolant holes and cause much more flow, chip removal and pressure in the hole. Ch ip s c au se u npre d ic t able damage, in general the longer the chips the harder it is to control and the more damage they cause. Long stringy chips wrap around drills, fill the bottoms of holes, catch on the chucks, cause mechanical problems with loaders and in many cases require manual removal. MEN
Controlled Agression Drilling fits into the category of ‘contained coolant’ where you are machining in a confined area like a drilled hole, or tapping a blind hole. Here your intention is to pump enough coolant through the tool to completely fill and pressurise the hole. The point of this is to eliminate any possibility of vapour forming so you never get the high temperatures normally associated with metal cutting. This is the same principle that is used in gun drilling and the pressure required is essentially the same. Pressures in the 1,000 psi range are generally adequate, but higher pressures may be needed for particularly difficult applications.
Enquiry No. 5604
Without coolant holes in the drill, the application of coolant is difficult to control.
EVENTs&
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exhibitions
MetalTech 2009
M
etalTech 2009 was a sourcing ground for specialised machineries, equipment and tools. With an estimated value of exhibits totalling some R M200 million ( US$57 million), the total estimated sales (on-the-spot and followup) were RM650 million. The sales figures were a real shot in the arm for many including the organiser. Albert Lai, MD of Trade-Link Exhibition Services said: “In view of the pessimistic market economy, many exhibitors were planning to use the event as a platform to network. However, exhibitors were making unexpected sales.” Director of Robo Machine Tools, Teo Cheng Chuan has the figures to back Mr Lai up. He said: “Despite the current economic recession, 22 units of the Robodrill were sold during the show pushing our total sales over RM4 million.”
Facing Challenges Making its 15th presentation from 6 - 10 May 2009 at the Putra World Trade Centre, Kuala Lumpur, Malaysia, the event attracted over 17,371 trade visitors from 53 countries. Covering 25,000 sq m of exhibition space, the event has drawn the participation of over 900 exhibiting companies including six national groups from Singapore, China, Taiwan, South Korea, Austria, and Germany. The deputy minister of International Trade and Industry, Dato’ Mukhriz bin Tun Dr Mahathir who officiated the opening ceremony of the event commented: “Even during these harsh economic times, the organisers have been successful in ensuring the participation of foreign companies. This showing of precision engineering
Deputy minister of International Trade and Industry, Dato’ Mukhriz bin Tun Dr Mahathir, who officiated the opening ceremony, felt that the event has stood up to the test
and manufacturing machines will help the established and budding entrepreneur tool up and hone the necessary skills to successfully round off their business.”
Cosmopolitan Affair The presence of five national pavilions gave the event an international flavour. Austria, Busan (South Korea), China, Singapore and Taiwan were the countries that were featured. During MetalTech 2009, Taiwan had the most number of foreign participating companies with a total of 74 companies. Singapore came in second with a total of 51 companies.
The Numbers Game Of the 17,371 visitors, 13,843 were walk-in trade visitors and 800 were pre-registered visitor. There were also 1,131 VIPs and 1,597 students. Some 89.91 percent of visitors were from Malaysia and visitors from Thailand were the highest amongst foreign visitors. In terms of equipment, tools and tooling were the most popular as some 4,089 visitors (25.92 percent) indicated that it was their product of interest. Other products like turning centres and lathes and machining centres garnered 15.50 and 15.66 percent respectively. Putra World Trade Centre Kuala Lumpur, Malaysia May 6 - 10, 2009 Enquiry No. 5701
The presence of five national pavilions gave the event an international flavour
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Aerospace Supplier eXchange:
Marja Flick-Buijs, Netherlands
Planting The Seed
The economic situation may not be all that rosy at the moment but it does not mean it is time to head for the hills. By Joson Ng
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e spite the current economic situation, aerospace manufacturing continues to see positive indicators of growth and development through the emergence of new aerospace manufacturing plants in 2009. In terms of commercial aerospace manufacturing, analysts predict the Compounded Annual Growth Rate (CAGR) from 2008 to 2030 will be at 4.01 percent globally, whereas Asia-Pacific’s CAGR is significantly higher at 7.7 percent. It is clear that the Asia-Pacific will be a hotbed of aerospace opportunities and activities, and Singapore is well-positioned and primed to capitalise on this. The inaugural Aerospace Supplier eXchange (ASX) was held at the Singapore Expo from May 27 – 29, 2009 where exhibitors were mainly made up of tier three and four suppliers. Some 2,624 visitors attended the event. One of the highlights was the opening ceremony, which was officiated by Lim Hng Kiang, minister for trade and industry where he witnessed the signing of a number of MOUs, cementing new busine ss a rra ngements in the industr y. They include the signing of an agreement for a local aerospace training organisation to export their training programmes to Jamaica, as well as a consortium formation to facilitate the export of four local aerospace companies. Asia Pacific Metalworking Equipment News speaks to Gary Nutter second VP, Association of Aerospace Industries (Singapore) on his thoughts on the event. “I think it is very heart warming for us the organiser to see the number of exhibitors and international buyers
we attracted. I thought that the turnout for the opening ceremony was fantastic,” he says.
Gearing Up Staring straight at the economic downturn, Mr Nutter maintains his optimism as he explains: “The whole event aims to showcase the capabilities of the aerospace suppliers in tier three and four. So this is really about how you raise the profile and capabilities they have and facilitate meetings between them and the international buyers. The downturn probably gave us the added incentive to invest and get ready for the upturn.” In line with the focus of ASX, the Global Asia Trade Exchange (GATE) 09 aerospace, a platform that enables the interaction between the suppliers and the buyers was held in conjunction with the main event. “It is about giving people the opportunity to meet and talk about what they can offer. The success of GATE depends on the forces of supply and demand. Hopefully some deals will come out of these meetings, maybe not today but somewhere down the road,” says Mr Nutter. From the organiser’s point of view, Mr Nutter feels that it is important to get the right exhibitors and buyers. Organising the event around conferences is also part of the plan to help attract a wider group of audience. Lastly, he hopes to see improving economic situation by the back end of this year or early next year. As such, he hopes that the next ASX will be bigger to showcase more companies. Enquiry No. 5702 Mr Nutter feels an event like ASX is a platform to showcase technical capabilities
One of the highlights of ASX was the opening ceremony.
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Matchmaking Success With many choices out there, the task of sourcing for the right supplier is made easier with events like GATE. GATE 09 Aerospace is coorganised by IE Singapore, a n a genc y in - cha rge of the development of Si n gap ore’s e x ter na l economic wing. The GATE concept was implemented for the first time in 2004 and made its aerospace Mr Thian: One thing is for sure, this debut i n A S X a s we group of suppliers have the potential speak to Thian Tai Chew, to grow. dire c tor, te ch nolog y business division, IE Singapore, to find out more. “By inviting buyers to come down rather than sending our companies overseas enable the potential buyers to meet a lot more suppliers. They can also see for themselves the manufacturing scene in Singapore. We feel this is a successful programme so we will continue to take this approach,” he says.
Speed Dating Process The pertinent point in the concept of GATE is the prequalifying process, which allows the moderators to match buyers to suppliers in terms of needs and capabilities. Mr Thian illustrates: “In the registration phase, we send various information to the foreign buyers. They have to tell us in detail what they are looking for in Singapore.
Based on that information, our officers will decide which company suits the buyers and contact them to see if they are interested to meet the buyers.” Details are key to the pre-qualifying process. “We will try to get them to be specific. We are looking for specific information, for example, engine types and methods of treatment,” he adds.
Eye On The Horizon The aerospace industry has suffered a turbulent year and looking towards the future, Mr Thian is focussed on the buzzword ‘certification’. “We must make sure that our suppliers are equipped with right capabilities and we are pushing hard for them to get certified because more often than not, this is the first question a potential buyer asks,” he muses. Through frequent dialogues with international buyers, the agency is able to identify ‘capability gaps’. They will then relate the information to agencies like Spring Singapore and A*Star to address the issues. The aerospace sector may be shrouded with uncertainties at the moment but Mr Thian has no doubts about the industry. He concludes:” One thing is for sure, this group of suppliers have the potential to grow.” Enquiry No. 5703
Widening The Scope Training support provides the ammunition for MRO providers to fight the battles. In these days of global e conom ic dow ntu r n, Mil-Com, a provider of aerospace engineering support services, aviation training and consultancy services has to find new markets for its services. The company Mr Chua Keng Ann, senior manager, is constantly seeking Mil-Com (Right) opportunity in forming alliances with established partners to offer its services. “We try to form alliances with as many companies as possible,” says Chua Keng Ann, senior manager of MilCom. In this respect, the company has many strategic partners including Boeing, Alteon, Jeppesen and Avisa (Aviation Safety Systems). In addition to the tie-ups with industry players, the company has also joined forces with educational institutes in Singapore and China. “Besides our tie-up
with the Civil Aviation University of China and Xian Aeronautical Polytechnic Institute, we are also offering specialised diploma courses this year to Republic Polytechnic, Singapore,” he adds.
Casting The Net Although the main focus of the company is on engineering support and training, it is also branching out to other area of services such as consultancy. The company is always looking out for new opportunity. In this area, it has entered into agreement with Boeing to set up a facility for composite repair and training to cater to the requirements of Boeing 787s (Dreamliner). ASX 2009 Singapore Expo Singapore 27 – 29 May 2009 Enquiry No. 5704 Jul-Aug 2009 metalworking equipment news
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MTA Malaysia 2009
All Smiles - Yang Berbahagia Dato’ Mukhriz Bin Tun Dr Mahathir (centre), deputy minister of international trade & industry, opens MTA Malaysia 2009 and Metaltech 2009
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ith a total of 900 exhibiting companies from 30 different countries and six national pavilions participating at this year’s show, MTA Malaysia 2009, which took place from May 6 – 10, 2009 at the Putra World Trade Centre in Kuala Lumpur, Malaysia, attracted some 17,371 trade visitors. They come from various industries namely the aerospace manufacturing, automotive manufacturing, electronics and electrical manufacturing, machinery and equipment manufacturing and mould and die. The total exhibiting area of both shows, MTA Malaysia 2009 and Metaltech 2009, measured at 25,000 sq m (gross). Despite having to run on a relatively smaller scale in terms of total floor space this year as compared to the previous year, sales of machineries were recorded at the show. Day one witnessed a German based exhibitor selling two units of its grinding machines. Following suit was another sale recorded by Tornos Technologies Asia.
spearheaded the Taiwan national group pavilion that showcased technology by Taiwanese companies. T he ( V DW ) G er ma n Machine Tool Bu ilders’ Association brought the latest German technology to the event. According to the spokesperson for the German machine tool industry, VDW has been successful so far in gathering small and medium sized German companies and promoting them abroad, with the support of the German government. Over at the Singapore pavilion, the group was coordinated by the Singapore Precision Engineering and Tooling Association (SPETA) – a non-profit trade association and a representative for locally registered companies engaging in the manufacturing of mould and dies, jigs and fixtures, metal stamping, metal precision machining, photonic and semi-conductor equipment, aerospace and automotive parts, as well as in providing services related to the precision engineering industry in Singapore.
International Pavilions
Encouraging Signs
Technologies, machinery and equipment on display in the international pavilions were worth an estimated value of RM200 million (US$57.3 million). The six national group pavilions were from Austria, China, Germany, South Korea, Singapore and Taiwan. Taiwan Association of Machinery Industry (TAMI) and their Tool & Accessory Builder’s Association (TMBA)
Malaysian Exhibition Services, organiser of the event was proud to have the pleasure of Yang Berbahagia Dato’ Mukhriz bin Tun Dr Mahathir, deputy minister of International Trade and Industry, to officially launch the trade exhibition followed by a guided tour to all the exhibition halls after the opening ceremony on day two. Having witnessed the support shown by trade
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Visitors getting ready to visit the MTA exhibition halls
visitors who turned up for the exhibition, Dato’ Mukhriz commented: “Although the floor space at Metaltech 2009 and MTA Malaysia 2009 is smaller than previously, the number of industry visitors is encouraging.” In his opening speech, Dato’ Mukhriz shared his ministry’s plans and aspirations on the Malaysian economy this year. He said: “This year the Malaysian economy is forecasted between -1 to 1 percent in comparison to 4.8 percent in 2008. I want to assure you that the Malaysian government is not in any way distracted from the heavy responsibility and tasks at hand. The government has also introduced a number of measures to stimulate and fortify the manufacturing and service sector as you may well know.” He also said that the machinery and equipment industry under the third industrial master plan 20062020, is projected to further expand in tandem with the continued growth of major economic sectors – in particular the manufacturing and agriculture sectors. As such, there should be greater emphasis on technology and specialised machineries. The event was supported by the Federation of Malaysian Foundry and Engineering Industries Association, the Malaysian Industrial Development Authority, VDW, SPETA and Malaysia Mould and Die Association.
Putra World Trade Centre Kuala Lumpur, Malaysia May 6 - 10, 2009 Two grinding machines were sold on the first day
Enquiry No. 5705
Dato’ Mukhriz Bin Tan Dr Mahathir toured all exhibition halls Jul-Aug 2009 metalworking equipment news
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Eastpo2009
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he 11th edition of Shanghai international machine tool fair (Eastpo 2009) scheduled from July 15 - 18, 2009, is to be held at the Shanghai New International Expo Center (SNIEC) with 1,000 expected exhibitors and 100,000 expected visitors. During the fair, more than 40 professional events will be held contemporaneously, including the 5th seminar on tooling technology and its application in automotive industry. Other seminars at the event are national automotive powertrain technology and its development, 2009 seminar of manufacturing technology and process innovation in national defence industry, Yangtze River Delta 2009 forum of independent innovation in equipment manufacturing, national seminar of research and innovation in automotive industry and more. Playing the role of a matchmaker, the organisers of the event aim to provide a platform for the trade professionals to communicate with counterparts to reach a deal. German, Japanese and South Korean pavilions will be featured. This year’s event will see an active participation by South Korean companies. The Korean Association of Machinery Industry mobilised more than 70 enterprises to Eastpo 2008. They will again organise more than 70 South Korean companies to the event this year. Products to be demonstrated at the event include machine tools, tools and accessories, automatic devices, power transmission, thermal processing technology and equipments and other related manufacturing technology and equipments. During the exhibition, the organising committee will provide both exhibitors and visitors a chance to visit industrial parks in Shanghai and surrounding cities. The industrial parks include new energy vehicles, power plan equipment, marine engineering and ship facilities, civil aviation manufacturing and others. Shanghai New International Expo Center (SNIEC) Shanghai, China July 15 - 18, 2009 Enquiry No. 5706
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Metalex Vietnam 2009
There will be 20 technical conferences by overseas industry experts in this year’s show
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ome 7,000 buyers are expected to attend Metalex Vietnam from October 8 – 10, 2009 at Saigon Exhibition & Convention Center (SECC) in Ho Chi Minh City. Over 500 global brands from 25 countries, will take part in the event. Exhibitors will showcase machine tools and machining centres, welding technology, factory automation, mould and die, wire and tube technology, control measurement, tools and tooling, and many more. So far, eight international pavilions from China, Germany, India, Japan, Singapore, Taiwan, Thailand, and the UK, have confirmed to participate.
Special Features Metalex Vietnam will provide participants with a range of opportunities with special features and activities like robot demonstration zone, which will highlight
the capacity of industrial robots for manufacturing. In addition, there will be 20 technical conferences by overseas industry experts. From the business point of view, there will be an ‘agent wanted’ programme for international technology providers to find agents for their brands in Vietnam. Furthermore, in the interest of stimulating more business, a matchmaking programme to match the industrialists and overseas trade missions with their future business partners will be organised. Saigon Exhibition & Convention Center (SECC) Ho Chi Minh City, Vietnam October 8 – 10, 2009 Enquiry No. 5707
EMO Milano 2009
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eaturing some 1,250 companies, the exhibition dedicated to the world of metalworking is scheduled from October 5 – 10, 2009. Promoted by CECIMO and organised by EFIM, the event will provide a net area of about 100,000 sq m, fully summarising the international production system offering. To be held in Fieramilano, Italy, some 70 percent of total exhibitors hail from 34 different countries. Visitors will travel to the capital of Lombardy come October to experience all segments of the sector: from metalforming to metalcutting, from components to tools, from robotics to automation. “If the third quarter of the year coincides with an inversion of trends, as several international economic analysis institutes suggest, the event will be the right moment to plan investments,” says Alfredo Mariotti, director of the event. Pier Luigi Streparava, commissioner general of EMO
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Milano 2009, says: “The nature of the event, hosted in Italy every six years, means that it is a not to be missed occasion for Italian constructors to present their offerings to an international audience. Special finance tools, some now ready and others being defined, includes a package named ‘EMO all inclusive’ which will provide companies with a set-up stand, handling, services and other benefits at a particularly advantageous price.”
Fieramilano Milan, Italy October 5 – 10, 2009 Enquiry No. 5708 Jul-Aug 2009 metalworking equipment news
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product finder
Iscar: Reinforced Blades
Kennametal: High Metal Removal
Iscar has developed a family of reinforced Tang-Grip blades for the index turn/mill machines. These blades, due to their reinforced construction, can be used in long overhang. Only the part of the blade required for penetration (cutting depth) has a reduced width. The rest is thick, which provides improved rigidity and stiffness. Designed for parting and grooving between the main and sub-spindle of turn/mill machines, the single-ended insert has a rigid clamping and therefore provides an advantage over other systems. Enquiry No. 5801
Kennametal: Indexable Milling Inserts
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KenFeed end mills from Kennametal are designed to machine materials with hardness ratings up to 67 HRc. With end geometr y de si g ne d fo r h i g h fe e d processes, the end mills have six flutes and AlTiN coating, enabling feed and speed rates of 0.6 mm per tooth on a 20 mm tool. Designed for 3D (Z-axis) machining in die and mould shops, 55 percent of the tool’s cutting edge is engaged in the cut as compared to 10 percent in typical ball-nose end mill. By taking light depth of cuts and using high speed and feed rates, parts can be finished faster compared to conventional tools and processes. Enquiry No. 5803
Sandvik Coromant: Multi-Edge Face Milling
B eyond l i ne of tu r n i n g products from Ke n n a me t a l i s now b eing e x te nde d to indexable milling inser ts. Two g rade s are now available for machining steel, cast iron, and stainless steel workpiece materials. KC915M (KCK15) is a dry-milling grade suitable for applications in grey cast iron and grey cast iron with nodular graphite. It can also be used to finish-mill low-alloyed steel. KC935M (KCPK30), a dry milling grade, is suitable for applications in plain and alloyed steel, stainless steel and certain high-temperature alloys. All the milling insert grades have micro-polished edges that improve edge toughness and post-coat treatment that reduces depth-of-cut notching.
Sa ndv ik Coroma nt ha s developed the CoroMill 345 for both small-batch, mixed machining and high-volume machining. The tool is designed to mill with smaller depth of cut in steel and stainless steel. I t s ve r s at i l it y makes it suitable for roughing and smooth operations. It is also able to produce mirror-finishing with wiper inserts. With the additional pitch alternative, the tool will increase metal removal capacity. Finally, the 45-degree facemills are equipped with double-sided inserts having four edges on each side.
Enquiry No. 5802
Enquiry No. 5804
metalworking equipment news Jul-Aug 2009
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Walter: Grooving Tool Holder
Trumpf: Sheet Metal Cutting Machine
With the G1011, Walter is bringing out a tool for the GX24 grooving insert. The insert seat has been improved and the screw clamp optimised. A reduced tool head height eases the flow of chips. Screw clamp on the grooving tool holder can now be released and clamped from above or below. As a result it is easier to replace the grooving inserts particularly in case of inverted use. An optimal screw position and extra large head diameter provide the clamping force. This design makes it impossible to tear out the grooving insert. The tool holder is available for insert widths between 3 and 6 mm at depths of 12 and 21 mm. Enquiry No. 5805
The TruLaser 3030 is a sheet metal cutting machine equipped with a 5 kW CO2 laser, which can be used to cut sheet thicknesses up to 25 mm. Instead of a threephase servo motor, the long X axis works with a gearless motor that distinguishes itself by its torque. Y and Z axes are driven by wear-free and oil-free linear motors. This solution by Trumpf increases the simultaneous axis speeds, from 85 m/min to 140 m/min. To add to that, the FastLine process, generates a flow transition between the piercing and cutting processes which reduces processing times by an average of 20 percent in thin sheet. When the machine is not cutting, the turbo radial fan goes into standby mode until it is needed again to get energy savings of more than 10 kW. Enquiry No. 5807
The VL - 553 II and VL -553MC II by Mori Seik i have improved operability compared to the previous model. The distance between the operator and the spindle has been shortened, and also the spindle height has been reduced by 120 mm to improve operability for setup. Distance from the front part of the machine to the spindle centre has been shortened along with the height of the spindle large nose by 84 and 120 mm respectively. Machining area has been extended. By increasing the X-axis stroke, the maximum turning diameter has been expanded by 130 mm compared to the previous model, which has enabled machining of larger workpieces. Enquiry No. 5806
ENQUIRY NO 190
Mori Seiki: Heavy-Duty CNC Lathe
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productfinder
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ISA Technology: Video Measurement System
The MS4502-220 2D video measurement system adds to ISA Technology’s range of viewing and measurement solutions. This low investment system comes in a sturdy and compact design. It is equipped with a 50 x 50 mm travel range manual X Y stage a nd a pa ir of Digimatic micrometer head. High-resolution digita l ca mera ensures quality image during any measuring applications. Accessories are also available to enhance the measuring system. Enquiry No. 5808
Mitutoyo: Quick Measure Micrometer
The QuantuMike by Mitutoyo is a coolant proof micrometer. Faster measurement is achieved by using a coarser thread, which feeds the spindle by 2 mm per revolution of the thimble instead of the standard 0.5 mm. Trials by the company show that there is a reduction in positioning times of 60 percent and measuring times of 35 percent, compared with a conventional micrometer. Repeatable results are achieved by the ratchet thimble mechanism, which helps by transmitting microvibrations along the spindle to the contact face to provide a constant measuring force and encourage good contact with the workpiece. Enquiry No. 5810
Micro-Vu: Multisensor Measurement Machines OGP: Video-Based Inspection
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Excel 650 series of multisensor measurement machines by Micro-Vu accommodate large parts or multiple smaller parts for 3D measurement. The systems feature measurement using optics, laser capabilities, a granite base, closed loop motion control, and high-resolution encoders. With a capacity of 650x650 mm (XY), the machines can accommodate large parts up to 100 kg on the glass. Featuring larger Z capacities of 160 mm, 250 mm, and 400 mm, the gantry style machine design allows parts to remain stationary while the XYZ movement of sensors takes place above the parts.
SmartScope MVP is the cost-effective way to get the benefits of video-based inspection and measurement. The machine from Optical Gaging Products has a granite base and column, 6.5:1 zoom lens, and mechanical bearing translation stages for positioning in every axis. Measure-X software enables creation of part routines using video and multisensor metrology. The touch probe option adds multisensor functionality, extending the versatility of the measurement system.
Enquiry No. 5809
Enquiry No. 5811
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Showcase
The Lynx Stereo Microscope • Patented Eye-Pieceless technology • Advanced ergonomics • High Res Magnification up to 120X
Bi/Trinocular Stereo Zoom Microscope • Economical and high performance • Versatile setup for different applications • Long working distance
2D Video Measurement System • Low investment high value • High resolution video images • Equipped with Digital Micrometer • XY travel range 50 x 50mm
ENQUIRY NO 099
Offering a wide variety of other products: Viewing Systems • Manual and Motorized Positioning Stages • Laser and Optical Products Uhing Traversal Units for wire winding • Zaytran Grippers
ISA Technology Pte Ltd Tel: 65 6747 8946 • Fax: 65 6744 6687 Email: info@isatech.com.sg • Website: www.isatech.com.sg
The difference between a good machining center and a GREAT machining center. The way a machining center is built affects the way it performs. We use premium quality components throughout to assure long term reliability and peak performance. And we don’t take manufacturing short cuts. Our castings are hand scraped and pains takingly fit to deliver consistent”out-of- the- box” accuracies upto 0.002mm/full stroke. Our machining centers with two step geared spindle and twin ballscrew on all axes is long term investment. See what true quality can do for you. Call us today. SMG Technologies Pte Ltd No. 7 Toh Guan Road East #08-01/17, Alpha Industrial Building Singapore 608599 Ph: (65)-65622093 www.smgtech.com.sg
Precision Measurement Equipment Since 1959 Micro-Vu Corporation designs and manufactures a broad line of measuring machines including Automated Vision Systems, Manual Video Systems, and Optical Comparators. These non-contact and contact measurement system use video and touch probe inputs to perform high precision 2D and 3D measurements. Excel Spectra
Matrix Vertex Vector Henko Machine Tools Pte Ltd No.23 Kaki Bukit Industrial Terrace, Singapore 416103 Tel: +65 6846 4666 • Fax: +65 6846 4555
MACHINERY Co Ltd
1870-Toide, Takaoka-City Toyama Pref Japan 9391192 Ph: (81)766-63-1100 www.kitamura-machinery.co.jp
BME Industries (M) Sdn Bhd D-G-2 & D-1-2 Persiaran Relau Sungai Ara, 11900 Bayan Lepas Penang Tel: +604 640 8686 Mobile: +6016 440 0618
Henko Machine Tools (Thailand) Co Ltd 26/357 Moo 18, Tumbol Klongnuang Amper Klongnuang Pathumthani Province Thailand 12120 Tel: +66 2908 1131 Mobile: +66 860 423 383
恒科商贸（上海）有限公司 上海市徐汇区沪闵路8075 号红梅商务大厦613 室邮编200233 电话: +86 21 5418 4811 手机：+86 1360 164 1618
For enquiries, please email: info@henko.com • Website: www.henko.com
ENQUIRY NO 096
ENQUIRY NO 101
The Mantis Optical System • Superior ergonomics, improved productivity • Long working distance, easy manipulation • Superb hand-eye co-ordination
ENQUIRY NO 102
High Performance Viewing & Measuring Systems
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PARTING
Daniel Gasienica, Zurich, Switzerland
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shot
Tata Nano:
Pint Size
Giant T
What Tata Nano lacks in size, it makes up in its competitive price.
he setting is the year 2009 where the world is in recession. When major carmakers in the US are running into financial woes, Tata motors launches the Tata Nano. Dubbed ‘the cheapest car in the world,’ and the ‘people’s car,’ by many, the two-cylinder, 623 cc car is making headlines. Available in three variants, the automobile is currently being manufactured at the company’s Pantnagar plant in Uttarakhand in limited numbers. The new dedicated plant, at Sanand in Gujarat, will be ready in 2010 with an annualised capacity of 350,000 cars. Costing about US$2,000, many have wondered how the makers managed to keep the price so low. In a report by The Times, Tata cut costs by minimising components, particularly steel, and took advantage of India’s low production costs.
Engineering The Nano The company has applied for 34 patents to cover its innovations. “We shrunk it, made the engine smaller and used fewer materials but we haven’t taken any shortcuts in term of safety or emissions,” Ratan Tata, chairman of the Tata Group and Tata Motors said. 78
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Because of its size, it uses less sheet metal, has a smaller and lighter engine than other cars, smaller tubeless tyres and a no-frills interior. The engineering work behind the Nano is very much in the spotlight as engineers from other manufacturers are rushing in like bee to honey to study the car. Business Today said while the design phase was tough and long, they decided on a rear engine four years ago, with the objective of getting the best, optimal layout.
Keep It Down Moving away from the engineering aspect, the cost of manufacturing is also of interest to many. In the business climate of today, flexibility is perhaps the key. According to Business Today, Girish A Wagh, chief engineer said that when the steel prices went up, they had no choice but to reduce the amount of steel in the car. He is however also quick to add that the performance of the car is what matters in the end. To that end, every component in the Nano has been studied from a functionality, cost and performance point of view. MEN Enquiry No. 5901
Exhibition Programmes
2009
July 8 – 11 MTA Vietnam 2009 HCMC Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam Singapore Exhibitions Services events@sesallworld.com www.sesallworld.com
15 – 18 Eastpo 2009
Shanghai New International Expo Center (SNIEC) Shanghai, China Eastpo International Expo eastpo@eastpo.net en.eastpo.net
16 – 19 MachinExpo Bangladesh 2009
Bangladesh - China Friendship Conference Centre Dhaka, Bangladesh CEMS cems@cemsonline.com www.machinexpoonline.org
24 – 27 India Machine Tools Show 2009 Pragati Maidan New Delhi, India K & D Communication imtos@imtos.com www.imtos.com
August 5–8 2009 Taipei International Mold & Die Industry Fair
Taipei World Trade Centre Nangang Exhibition Hall Taipei, Taiwan Chan Chao International ken@chanchao.com.tw www.odm-dmi.com/tw
11 – 13 MTT Expo 2009
8 - 10 Metalex Vietnam HCMC 2009
Jakarta International Expo Jakarta, Indonesia ECMI mtt@ecmi.cc mtt-indonesia.com
Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam Reed Tradex metalexvietnam@reedtradex.co.th www.metalexvietnam.com
13 – 16 2009 Taipei Aerospace & Defense Technology Exhibition
13 – 15 Wire South-East Asia
Taipei World Trade Center Exhibition Hall 1 Taipei, Taiwan Taiwan External Trade Development Council (TAITRA) tadte@taitra.org.tw www.tadte.com.tw
September 1–5 China Int’l Equipment Manufacturing Expo
Shenyang Int’l Exhibition Centre Shenyang, China Shenyang Renaissance International Exhibitions cieme@zxexpo.com www.zxexpo.com
October 5 – 10 EMO Milano
Fieramilano Milan, Italy EFIM press@emo-milan.com www.emo-milan.com
BITEC Bangkok, Thailand Messe Düsseldorf Asia wire@mda.com.sg www.wire-southeastasia.com
13 – 15 Tube South-East Asia BITEC Bangkok, Thailand Messe Düsseldorf Asia tube@mda.com.sg www.tube-southeastasia.com
15 – 17 EPM Linkage Vietnam
Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam Chan Chao International machine@chanchao.com.tw www.epmlinkage.com
November 3–7 Metalworking & CNC Machine Tool Show 2009 Shanghai New Int’l Expo Centre Shanghai, China Hannover Fairs Shanghai mwcs@hfchina.com www.metalworkingchina.com
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ASIA PACIFIC METALWORKING
The Engineering Journal For Manufacturing,Automation & Quality Control
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ASIA PACIFIC METALWORKING
No. 5 2009
The Engineering Journal For Manufacturing,Automation & Quality Control
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Turning l Threading l Grooving l Cut-Off l Holemaking l Indexable Milling l Solid-Carbide End Milling l Tooling Systems l Services ©2009 Kennametal Inc. l All rights reserved. l A-09-02006
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