MEN September 09 by Eastern Trade Media

Wire/Tube Southeast Asia 2009, BITEC, Bangkok September 2009

www.equipment-news.com

M.I.C.A. (P) No. 233/06/2009

P M K N S H 3 3

P M K N S H 3 3 3 3 3

A very hard substrate with a cobalt enriched layer, improved MTCVD TiCN and a thick alpha Al2o3 CVD coating. Features excellent thermal stability, resistance to chipping and plastic deformation. recommended for high speed machining of steel at stable or slightly unstable conditions.

A tough submicron substrate, improved TiAlN pVD coated grade for better chip flow. Suitable for turning heat resistant alloys, austenitic stainless steel and hard steel at low to medium cutting speeds.

P M K N S H 3 3 3 3

P M K N S H 3 3 A tough substrate with a cobalt enriched layer combined with improved MTCVD TiCN and a thick alpha Al2o3 CVD coating. recommended for general use machining of steel in a wide range of conditions, featuring high toughness and resistance to chipping and plastic deformation.

A tough submicron substrate, improved TiAlN pVD coated grade for better chip flow. Designed for machining heat resistant alloys, austenitic stainless steel, hard alloys and carbon steel at medium to high cutting speeds, interrupted cut and unfavorable conditions. Excellent notch wear and built-up edge resistance.

P M K N S H 3 3

P M K N S H 3 3 3

A very tough substrate with a cobalt enriched layer combined with an improved MTCVD TiCN and alpha Al2o3 CVD coating. provides excellent toughness and chipping resistance on steel for interrupted and unstable cutting conditions.

A tough substrate combined with an improved AlTiN pVD coating that provides high oxidation resistance. recommended for milling nodular cast iron at high speeds and grey cast iron at low to medium cutting speeds under unstable conditions.

P M K N S H 3

P M K N S H 3 3 3 3

A very hard substrate, improved MTCVD TiCN and a thick alpha Al2o3 CVD coating. Features excellent thermal stability and resistance to chipping and plastic deformation. Improved wear resistance. recommended mainly for nodular cast iron at stable or slightly unstable conditions. Can also be used successfully on grey cast iron.

An improved pVD TiAlN coated tough grade with better chip flow. Suitable for milling stainless steel, high temperature alloys and other alloy steels. recommended for interrupted cut and heavy operations.

P M K N S H 3 3

ENQUIRY NO 118

A tough substrate with a new MTCVD and alpha Al2o3 coating. recommended for milling grey cast iron at high cutting speeds, providing excellent tool life.

P M K N S H 3

A hard substrate, improved MTCVD TiCN and a thick alpha Al2o3 CVD coating. Features excellent thermal stability and improved toughness. recommended mainly for grey cast iron at stable or slightly unstable conditions. Can be used successfully also on nodular cast iron.

A hard fine grain substrate with MTCVD and alpha Al2o3 coating. Features excellent chipping and wear resistance. recommended for high speed drilling of cast iron and steel, to be used for the peripheral insert on Dr drills.

ISCAR JAPAN Tel + 81 6 835 5471 iscar@iscar.co.jp

ISCAR THAILAND Tel + 66 (2) 7136633 iscar@iscarthailand.com

CV MULTI TEKNIK Tel + 62 21 6307303 multi@centrin.net.id

ISCAR TAIWAN Tel +886 (0)4 247 31573 iscar.taiwan@msa.hinet.net

ISCAR VIETNAM Tel + 84 8 8123 519/20 iscarvn@hcm.fpt.vn

SINO TOOLING SYSTEM Tel + 65 6566 7668 sinotool@singnet.com.sg

WWW.ISCAr.CoM

MESCO Tel + 63 2631 1775 mesco@mesco.com.ph

ENQUIRY NO 110

Contents September 2009

22 FIRST CUT When Machine Meets CNC

CNC has taken machine control and machining operations to higher grounds of efficiency. By Thomas Lee, deputy GM, engineering division, Yamazaki Mazak Singapore

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. 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 SHOULD PLACE THEIR ADVERTISEMENTS ONLY IN AUDITED PUBLICATIONS

A Balancing Act

High-speed and high-rigidity must complement each other in order to construct an efficient five-face milling machine. By Hiroyuki Yamamura, Mutsumi Yoshikawa, Takayuki Kume, Hiroyuki Tauchi and Yoshifumi Tanigawa, Mitsubishi Heavy Industries

Made to Print

The machining accuracy and process integration ability of a turning machine allow the manufacture of a high-end web offset press. Contributed by Masaki Momiki, regional manager, Mori Seiki Singapore

32 TECHNOLOGY UPDATE Metalwork That Composite!

As far as machining aerospace and medical parts are concerned, tool construction, geometry, and coating can make a significant difference. By Karthik Sampath and Wang Yang Ni, senior engineers, Kennametal.

Drilling: Leaving A Deep Impression

Deep hole drilling were besieged by difficulties but things are slowly changing now. Contributed by Kobi Kisos, hole making products manager and Zeev Fisher, deep drilling products manager, Iscar.

Drill To The Core

Understanding the rationale behind tool selections and the process mechanisms are important part of the drilling process. By Adeline Riou, general secretary, HSS Forum and marketing manager of Erasteel and Olivier Verot, UF1

JOINT ADVERTISING DISCOUNT WMEM, 30,000 copies circulated quarterly in China combines with M.E.N, 10,000 copies circulated bi-monthly in ASEAN in joint advertising. Ask for more details now.

INDUSTRY

Endorsements

SPETA

Singapore Precision Engineering and Tooling Association (SPETA) Federation of Asian Die & Mould Associations (FADMA) Federation of Malaysian Foundry & Engineering Industry Associations Indian Machine Tool Manufacturing Association (IMTMA)

China Machine Tool & Tool Builders' Association (CMTBA)

Machine Tool Club (MTC)

46 SOFTWARE & MEASUREMENT Accurate Measurement: Itâ&#x20AC;&#x2122;s Complicated

Quantifying precision is a tricky business especially in metrology where the demands of accuracy is at its highest. Contributed by Yoshikazu Muraoka, senior manager, Mitutoyo Corp 2

metalworking equipment news September 2009

Taiwan Association of Machinery Industry (TAMI)

dmg dmg dmg – –technologies –technologies technologies for for for tomorrow tomorrow tomorrow dmg – technologies for tomorrow

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turing turing turing technology, technology, technology, DMG DMG DMG offers offers offers a aunique aunique unique product product product range range range ofofof highhighhighturing technology, DMG offers a unique product range of high-

tech tech tech metal metal metal cutting cutting cutting machine machine machine tools tools tools for for for workpiece workpiece workpiece manufacturing manufacturing manufacturing tech metal cutting machine tools for workpiece manufacturing

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| Structural wing component |

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| Structural | Structural | Structural fuselage fuselage fuselage component component component |||

| High pressure compressor casing |

| High | High | High pressure pressure pressure compressor compressor compressor casing casing casing |||

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| Impeller | Impeller | Impeller disk disk disk |||

DMG - Your partner in the aerospace

DMG DMG DMG--Your -Your Yourpartner partner partnerin in inthe the theaerospace aerospace aerospace industry for machine tools. industry industry industryfor for formachine machine machinetools. tools. tools. _ _ _ _ _ _ _ _ DMG is the world market leader

_in___CNC ________machine ___________DMG _DMG DMG isis is the the the world world world market market market leader leader leader tools but also a specialist in the in inin CNC CNC CNC machine machine machine tools tools tools but but but also also also aaspecialist agas specialist specialist ininin the the the area of aero engines and industrial turbines. area area area of of of aero aero aero engines engines engines and and and industrial industrial industrial gas gas gas turbines. turbines. turbines. This knowledge has been gained over 138 years This This This knowledge knowledge knowledge has has has been been been gained gained gained over over over 138 138 138 years years years by working with our customers to develope highby by by working working working with with with our our our customers customers customers tototo develope develope develope highhighhightech metal cutting solutions for milling, turning and laser machines. tech tech tech metal metal metal cutting cutting cutting solutions solutions solutions for for for milling, milling, milling, turning turning turning For inquiries call us directly: +65-6660-6688 and and and laser laser laser machines. machines. machines. For For For inquiries inquiries inquiries call call call us us us directly: directly: directly: +65-6660-6688 +65-6660-6688 +65-6660-6688

www.dmgasiapacific.com DMG Asia Pacific Pte Ltd.: No. 3 Tuas Link 1，Singapore 638584, www.dmgasiapacific.com www.dmgasiapacific.com www.dmgasiapacific.com Tel.: +65 66 60 66 88, Fax: +65 66 60 66 99, E-Mail: info@dmgasiapacific.com, Website: www.dmgasiapacific.com DMG DMG DMG Asia Asia Asia Pacific Pacific Pacific Pte Pte Pte Ltd.: Ltd.: Ltd.: No. No. No. 3 3Tuas 3Tuas Tuas Link Link Link 1，Singapore 1，Singapore 1，Singapore 638584, 638584, 638584, Tel.: Tel.: Tel.: +65 +65 +65 666666 606060 666666 88, 88, 88, Fax: Fax: Fax: +65 +65 +65 666666 606060 666666 99, 99, 99, E-Mail: E-Mail: E-Mail: info@dmgasiapacific.com, info@dmgasiapacific.com, info@dmgasiapacific.com,

ENQUIRY NO 127

Wire/Tube Southeast Asia 2009, BITEC, Bangkok

Contents

Regulars

September 2009

www.equipment-news.com M.I.C.A. (P) No. 233/06/2009

• 10 Business News • 20 Business Statistics • 74 Product Finder • 79 Exhibition Programmes • 80A Product Enquiry Card

50 FAB & FORM The Big Bend

An aircraft component maker uses an all-electric tubebending machine to increase productivity and quality. By Alan Pickering, MD, Unison.

P M K N S H

333

ASIA PACIFIC AD 584x275.indd 1

Vacuum Chuck: Holding It In Place

Vacuum systems are putting the squeeze on conventional clamping methods by providing safe and simple solutions. By Maren Roeding, PR manager, Witte Far East

54 INDUSTRY SPOTLIGHT Bite-Sized Solutions For The Medical Industry Miniature parts play a big role in today’s medical industry giving the machining process a whole new complexion. Contributed by Yair Selek, project manager, Iscar Miniature Industries.

Production Machinery Automation Market To Reach US $21.2 Billion

With higher speed in machinery operations comes a greater need for process control in automated machineries. By Sal Spada, research director, ARC Advisory Group

56 FEATURES Full Throttle Ahead

Challenges are aplenty when machining aero parts but there are opportunities as well. By K S Sankaran, chief operating officer, Makino Asia.

Whether in automation, power supply box on machines or food packaging, stainless steel is used to construct corrosion resistant enclosures. By Nathan Xavier, applications engineer, Rittal Corp.

Indian Airport Infrastructure Market: Taking Off

Growth in aircraft, passenger and cargo movement in India is driving the government and private sectors to improve airport infrastructure. By Chethan Kambi, senior research analyst, Frost & Sullivan.

Stainless Steel Enclosures: Protecting What’s Inside

EVENTS & EXHIBITION

Swiss Made Precision Grinding Technology Seminar Event Review: MTA Vietnam 2009 Event Preview: Wire/Tube South East Asia 2009 Event Preview: EPM Linkage Vietnam 2009

• Refer to Advertising Index...

Pg 80

for Advertisers' Enquiry numbers

P M K N S H

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:

Trends Spotting

Eastern Trade Media Pte Ltd (a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

managing director Kenneth Tan assistant editor Joson Ng

josonng@epl.com.sg

advertising sales manager Derick Chia

derickchia@epl.com.sg

assistant sales manager Yessica

yessica@epl.com.sg

editorial assistant Sharifah Zainon sharifah@epl.com.sg senior art director / studio manager Lawrence Lee lawrencelee@epl.com.sg

The first few things that come to mind in metalworking are probably the machine tools, cutting tools and metrolog y products. In a typical machine shop, the lathe is probably one of the most commonly used machine. There are new improvements even for this traditional and simple work horse. Although CNC is by no means a recent invention, it has taken machine controls and machining operations to higher grounds of efficiency, maintaining its applicability in the ever-changing world. Moving away from machine tools, this trend of re-inventing established favourites are already underway. Take drilling for example, improvements have been made in order to tackle materials that were not so commonly used in the past. For instance, materials like titanium and composite having higher usage in the manufacturing and medical industries today, demand specialised drills with specific applications. In deep oil hole drilling on engine crankshafts, lowhelix solid carbide drills can penetrate 10 percent faster than brazed gundrills and six times faster than HSS, while outlasting both types.

Improvements made to existing tools and machines are not the only way for wa rd. New industrie s a nd government policies have opened the door to new markets. The wind energy industry, driven by the impending depletion of crude oil and higher awareness in clean energy have experienced growing demand for wind turbines. This is a timely shot in the arm for the metalworking fraternity, as gearbox manufacturing in generators requires substantial metalworking processes and machines. Expected to take up 12 percent in the global energy demand in 2020, the wind power generator market is estimated to be worth some US$74 billion, giving incentives for many to try and gain a slice of the market share. A s t he meta lwork ing indu st r y continues to evolve and find relevance in new areas, the message is clear. Be it new designs, techniques or market, spotting new trends may be the key to unlocking the door to a new frontier.

Joson Ng Assistant Editor

metalworking equipment news September 2009

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

irenetow@epl.com.sg

contributors Thomas Lee, Hiroyuki Yamamura Mutsumi Yoshikawa, Takayuki Kume Hiroyuki Tauchi, Yoshifumi Tanigawa Karthik Sampath, Wang Yang Ni Kobi Kisos, Zeev Fisher, Adeline Riou Olivier Verot, Yoshikazu Muraoka Alan Pickering, Yair Selek K S Sankaran, Chethan Kambi Nathan Xavier, Sal Spada Masaki Momiki, Maren Roeding 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. 233/06/2009 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

Head Office & Mailing Address: 1100 Lower Delta Road, EPL Building #04-02, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806 Thailand Office: Thai Trade and 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

ENQUIRY NO 109

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Vietnam Vietnam Malaysia Malaysia ThailandPhilippines Malaysia Malaysia Vietnam DIETHELM DIETHELM ANDAND CO.CLOTD . L. Vietnam TD. Philippines A DAIVISION DIVISION OF OF D IETHELM AND CO. LTD. DIETHELM AND CO A DM IVISION OFTECH A DIVISION OFA Philippines Philippines A DSPC IVISION OF DHD IVISION OF TECHNOLOGY TECHNOLOGY Singapore Singapore MACHINE ACHINE TECH CO CLTD O LTD DAIVISION DIVISION OF OF SPC MACHINERY MACHINERY SDNSDN BAHDB ECHNOLOGY ECHNOLOGY TDN Singapore M ACHINE TECH CO7267-1915 LTD MACHINE TECH CGIVISION OAYLAN LTD A D OF A DIVISION OF MLumpur, ACHINERY SDN BSPC HD MACHINERY SHanoi, BHD+84-4 Hanoi, +84-4 9424 9424 725T725 DKSH DKSH TECHNOLOGY TECHNOLOGY Singapore SPC Bangkok, Bangkok, +662 +662 7267-1915 GAYLAN TECHNOLOGIES TECHNOLOGIES Kuala Kuala Lumpur, +603 +603 5569-5901 5569-5901 Thailand Thailand Thailand A DAIVISION DIVISION OF OF

Hanoi, +84-4 9424 725 Hanoi, DKSH TECHNOLOGY DKSH TECHNOLOGY Bangkok, +662 7267-1915 Bangkok, +662 7267-1915 G AYLAN T+632 ECHNOLOGIES GAYLAN TECHNOLOGIES Kuala Lumpur, +603 5569-5901 Kuala Lumpur, +603 5569-5901 HCMC, HCMC, +84-8 +84-8 5121 5121 334 334 +84-4 94 Harbour Harbour Front, Front, +65+65 6471-9263 6471-9263 Chonburi, Chonburi, +66+66 3811-2700 3811-2700 Manila, Manila, +632 915-8725 915-8725 Penang, Penang, +604 +604 3801581 3801581 HCMC, +84-8 5121 334 HCMC, +84-8 5 Harbour Front, +65 6471-9263 Harbour Front, +65 6471-9263 Chonburi, +66 3811-2700 Chonburi, +66 3811-2700 Manila, +632 915-8725Manila, +632 915-8725 Penang, +604 3801581 Penang, +604 3801581

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Victory Top Drill M1™ Our new WIDIA Victory Top Drill M1™ delivers the overall advantages of a replaceable-tip system — with the SAME high performance and hole quality as costly solid-carbide styles! Get 50% better tool life — with greatly reduced cycle times — versus competitive offerings! Ideal for even the most challenging steel and cast-iron applications! No reconditioning costs — simply change out inserts! Drill at exceptionally high feeds and speeds! Clampless pockets — no screws required! To learn more about our innovations: > 65 6 265-9222 > ap-widia.techsupport@kennametal.com > www.widia.com

ENQUIRY NO 126

Businessnews APMEN Receives TAMI’s Endorsement

Singapore: Asia Pacific Metalworking Equipment News (APMEN) is pleased to announce the addition of Taiwan Association of Machinery Industry (TAMI) to our list of industry supporter. TAMI is a new addition to a growing list of industry partners that includes Singapore Precision Engineering and Tooling Association (SPETA), Federation of Asian Die and Mould Associations (FADMA), Federation of Malaysian Foundry and Engineering Industry Associations (FOMFEIA), Indian Machine Tool Manufacturing Association (IMTMA), China Machine Tool and Tool Builders’ Association (CMTBA), and Machine Tool Club (MTC). The latest endorsement is a sign of growing support from East Asia, which APMEN is very proud to be associated with. We at Asia Pacific Metalworking Equipment News would like to extend our appreciation to all industry partners for their continued support.

www.equipment-news.com

GE Energy & MHI To CoDevelop World’s Most Advanced Steam Turbine New York, USA: GE Energy and Mitsubishi Heavy Industries (MHI) have signed final agreements to co-develop a ‘next generation’ steam turbine for use in gas turbine combined-cycle power plants. The codevelopment effort will focus on the design of a new, advanced steam turbine, leaving each of the parties to separately manufacture and sell the co-developed steam turbine in support of its natural gas-fired, combined-cycle power generation products. Much of the current demand for steam turbines is driven by the strong global interest in natural gasfired, combined-cycle power generation. Although a full range of technology options is required to meet the world’s growing energy needs, steam turbines remain a backbone of the power generation industry, playing a part in generating more than 80 percent of the world’s electricity. The new steam turbine will enter commercial service coupled with the GE frame FB and the MHI G-class gas turbine products in the 50 Hz segment of the global power generation market. These gas turbine models are typically used for combined-cycle power plants in the range of 850 - 1,000 MW.

Gildemeister & Mori Seiki (Japan) In Joint Sales & Services

Bielefeld, Germany: DMG Vertriebs und Service, a 100 percent subsidiary of the Gildemeister group, will commence joint sales and services with the Japanese machine tool manufacturer, Mori Seiki (Nagoya). This strategic cooperation will start in four markets in Taiwan, Thailand, Indonesia and Turkey. Moreover, the cooperation also covers R&D, purchasing and the worldwide provision of customer financing. The two companies will be present on four markets under the brand DMG/Mori Seiki. All four sales and 10

metalworking equipment news September 2009

service companies will market the complementary product range of both manufacturers. The joint technology centres ensure a strong product presence, better local service and support, and fast response times for the customer. The alliance between the two companies opens up synergies in production as well as in R&D. The aim of this ‘win-win’ partnership is the same for both sides, that is, to achieve synergies of about €15 million (US$21 million) per year.

businessnews

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Phoenix Solar To Build Photovoltaic Power Plant

Special HSGT Taps

Patrick Moore, Oklahoma, United States

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Supa FaST Sutton Tools is a leading international Manufacturer of specialist cutting tools and is renowned for producing high performance, precision cutting tools specifically designed to individual customer requirements. With comprehensive customer service and warehouse facilities, our Express Delivery Service enables us to meet your requirements more efficiently than ever before. With our state of the art CNC grinding equipment almost any profile can be achieved. Feel free to discuss these with our Tech team. Within 24 hours • Straight Flute Taps M3 to M127 • Spiral Taps M3 to M36 Within 48 Hours • Gun Taps M3 to M36 Within 5 Working Days Tool Coatings and Surface Finishes: • TiN • TiCN • TiAlN • CrN • AlCrN • Steam Oxide • Gas Nitride

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ENQUIRY NO 117

Sulzemoos, Germany: The Singapore branch of Phoenix Solar has won a tender to install a 250 kWp photovoltaic power plant at Changi Airport’s Budget Terminal. The project is supported by the Clean Energy Re se a rch a nd Te st- bedding (CE RT ) prog ra mme lau nched by t he E conomic D evelopment Boa rd and Clean Energy Programme Office. CERT aims to provide opportunities for companies to develop and testbed clean energy applications and solutions using government buildings and facilities in Singapore. The company will use 127 kWp of First Solar’s thin film solar modules and 123 kWp of REC’s polycrystalline sola r modules, together with SM A inver ters for this installation. This will be South-east Asia’s first commercial airport with a photovoltaic power plant, as well as the first commercial application of First Solar modules in Singapore. REC is constructing a fully integrated wafer, cell and module manufacturing plant in Singapore. Almost 200 kWp of those modules have already been installed locally, with another 300 kWp project under way. The modules will be installed on the north and south face of the Budget Terminal using Phoenix Solar’s Tecto-Sun mounting system, and will cover a rooftop area of about 2,500 sq m. The solar power plant is expected to generate over 280,000 kW hours per year. The company will also install various sensors to capture environmental data such as ambient temperature, module temperature and insolation – all of which will be fed into the National Solar Data Repository.

September 2009 metalworking equipment news

businessnews

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Delcam Launches Online TV Channel

Birmingham, UK: Delcam has launched its own online TV channel, Delcam TV. The company is believed to be the first CADCAM company to invest in this new marketing medium. It garnered some 100 visits in its beta test phase when there was no formal publicity.

The company expects the number to go up with the official launch. Customer testimonials are featured in the channel. It also covers design, manufacturing and inspection across a range of industries such as aerospace, automotive, orthotics, dental, robotics, sculpting, jewellery, coin making and signmaking. Existing users can benefit from product videos showing the latest developments in the software and highlighting tips and tricks to further improve their productivity. Content can be viewed online or downloaded to be played on a range of media players. Viewers can share videos with friends and colleagues directly from Delcam TV. The channel also supports mobile phone platforms. “More and more of our prospective customers are using the internet to gather information on different CADCAM systems,” explains the company’s multimedia manager, Fabio De Rosa. “We believe that our new TV channel will provide even more evidence of the need for companies to consider our software when they are looking at improving their CADCAM system,” he adds.

ABB Wins US$52 Million Power Orders In India

BHEL Bags US$143.5 Million Contract For Power Plant

Zurich, Switzerland: ABB has won orders worth US$52 million to provide power products and solutions for a super-critical coal-fired power plant in the southern Indian state of Andhra Pradesh. The contract was awarded by Tata Projects, the engineering, procurement and construction contractor to the 2x800 MW Krishnapatnam thermal power plant. The plant will be the first in India to deploy supercritical technology on such a large scale. This technology achieves more efficient power generation, and therefore lowers CO2 emissions, by using higher steam temperatures and pressures than conventional plants. Under the terms of the contract, the company will provide an integrated electrical balance of plant solution. They include transformers, switchgear and protection equipment, as well as a 400 kV turnkey substation to facilitate power transmission from the plant. The company will also provide system engineering, installation, testing, commissioning and overall project management. The project is scheduled for completion in 2012.

New Delhi, India: Bharat Heavy Electricals Limited (BHEL) has an order for the main plant package for an upcoming thermal power project in Jharkhand, involving one new-rating unit of 270 MW. Valued at nearly Rs 6,400 million (US$143.5 million), the order for the greenfield power project, located in Jamshedpur district, has been placed on BHEL by Adhunik Power and Natural Resources. Significantly, private sector customers have been reposing confidence in the company. In fiscal 2008-09 itself, orders were worth over Rs 130,000 million. Even in the current fiscal, around 80 percent of the orders booked so far in the power sector are from private sector customers. The compa ny’s scope of work in the present contract envisages design, engineering, manufacture, supply, erection and commissioning of steam turbine, generator and boiler, along with associated auxiliaries and electricals. In fiscal 2008-09, the installed capacity of BHELsupplied utility sets went up to 87,646 MW and the company maintained its share of 64 percent in the country’s total installed capacity of 1,38,175 MW.

metalworking equipment news September 2009

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businessnews

Griszka Niewiadomski, Poland

Toshiba Corp To Enter Indian Thermal Power Industry

Identify trends. Seize opportunities. Shape the future. 21st International Sheet Metal Working Technology Exhibition

26 - 30 October 2010

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For further information on how to book your stand space: Mack Brooks Exhibitions Limited T: +44 (0)1727 814 400 E: info@euroblech.com

ENQUIRY NO 128

Tokyo, Japan: Toshiba JSW Turbine and Generator (Toshiba JSW), a joint venture with JSW will manufacture and market steam turbines and generators in India. They signed a Memorandum of Understanding (MOU) with the government of Tamil Nadu. The MOU allows the company to lease land for the construction of manufacturing facilities on a site in Chennai, the capital of Tamil Nadu state. The JV will manufacture and market mid- to largesized steam turbines and generators, ranging in size from 500 to 1,000 MW, for thermal power plants in India. Located about 18 km north of downtown Chennai, the site has a ground area of some 400,000 sq m, and the company expects to invest some US$160 million in plant and manufacturing equipment over five years from fiscal year 2009. Manufacturing is expected to start in January 2011. Keihin Operations, Toshibaâ&#x20AC;&#x2122;s power equipment production facility in Yokohama, Japan, will support the company in ramping up manufacturing, and in working toward establishing an independent production scale of 3,000 MW a year. The company anticipates sales of US$400 million by the end of fiscal year 2015. With support from the government of Tamil Nadu, Toshiba will build a heavy equipment manufacturing facility in Chennai, and hopes to contribute to the further development of local industry and to help India in its efforts to promote stable electricity supply. Driven by strong economic growth, the Indian power generation equipment market is expected to see demand growth of 15,000-16,000 MW a year for the next decade, according to the Eleventh (2007-2012) and Twelfth (20122017) Five-Year National Electricity Plans published by the Indian government. Coal-fired thermal power stations will account for over 60 percent of the capacity growth, far surpassing other energy sources, and 80 percent of those power stations will be efficient super-critical thermal power plants.

September 2009 metalworking equipment news

businessnews

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Jelle Weidema, United States

Jeju Air Selects ST Aerospace Essar Steel To Set Up Service For Component Support Centre In India

S i n gap or e: ST Aerospace sig ne d a comp onent Maintenance-By-the-Hour (MBH) support agreement with Jeju Air. The agreement is worth US$45 million. Under the agreement, ST Aerospace will provide component maintenance works on an MBH basis to support Jeju Air’s fleet of Boeing 737 aircraft over 10 years. The company has added Shanghai Airlines and Primera Air as its customers for its component MBH programme. The MBH solution was initially tailored for start-up airlines and low cost carriers but it has also achieved initial successes with some traditional airlines.

Posco-CWPC Completed In China Seoul, S Korea: Posco completes an automotive steelprocessing centre, Posco-CWPC (Posco China Wuhu Automotive Processing Center), which is capable of producing 180,000 tonnes of steel a year, in Wuhu, China. The processing centre in Wuhu is the company’s 39th overseas steel processing centre and follows the second plant at Posco-MKPC in Malaysia. The processing centre will import automobile sheets from Gwangyang works, and it is expected that it will contribute to increasing automobile sheet exports to more than 100,000 tonnes a year after 2010. It is expected to be a steppingstone for the company to increase its share of the Chinese automobile steel market which has been quickly growing on the back of the government’s recent stimulus packages. The combined car production of China reached 9.36 million units, the third largest number after the United States and Japan, last year. This year, the number is expected to go up to 10 million, and it will increase to 13.45 million in 2012. 14

metalworking equipment news September 2009

Bhuj, India: Essar Steel will be setting up its fifth service centre in India at Bhuj, which will make it the second such centre in Gujarat state. The service centre will be the first centre of its kind to be set up by any steel company in a town that is a growing steel consumer with current consumption levels at 1.5 MTPA (million tonnes per annum). The service centre will have an annual capacity of 200,000 tonnes. Slated for commissioning by March 2010, it will primarily cater to the requirements of clients in the auto and general engineering sectors. It will also service the Essar Hypermarts located in northern Gujarat. This centre is backed by the company’s 4.6 MTPA Hazira steel plant, which ensures steady supplies. The facility will take the total aggregated capacity of the five centres to 2.7 MTPA. With another centre already operational at Hazira, Gujarat, the company has three more centres at Bahadurgarh, Chennai and Pune.

Siemens To Supply Compressor Trains To China Erlangen, Germany: Siemens has received an order from China for the supply of key components for a petrochemical plant, in which methanol will be produced from natural gas. Purchaser is Chongqing Carbinol Chemical Industrial (CCCI), a subsidiary of Chongqing Chemical and Pharmaceutical Holding Company (CCPHC). The compressor trains consist of compressors and a steam turbine, and will be deployed in China’s largest methanol production plant. The order volume is over €10 million (US$14 million). This order from China is divided into two parts. The Siemens scope of supply encompasses a two-casing syngas compressor train, which will be driven by a double-end-drive SST-600 steam turbine. The company will also supply together with its Chinese joint venture Siemens Industrial Turbomachinery Huludao, a CO2 compressor driven by a steam turbine SST-150. In addition, the order also includes supply of the auxiliary systems, local packaging and services for the two trains. The compressor trains are slated for ex works dispatch in the fall of 2010. The methanol production plant will be erected in Chongqing, China’s largest megacity. With a capacity of 850,000 mtpy of methanol the plant will be the largest of its kind in China. Methanol is an essential raw material for a wide variety of processes in the chemical industry. The customer CCCI intends to use approximately one-third of the high-grade methanol for petrochemical processes, some 30 percent will be used within CCPHC and the remaining methanol is intended for sale to companies within a radius of 500 km.

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Munger Machine Tool Pte Ltd. Tel: +65 6764 63 88 Fax: +65 6764 33 18 E-mail: mungermachine@pacific.net.sg MMT Thailand Tel: +66 2 391 9953 Fax: +66 2 712 3973 MMT Malaysia Tel: +60 12 326 6309 Fax: +60 3 7980 4744

Fritz Studer AG CH-3602 Thun (Switzerland) Telephone +41-33-439 11 11 Âˇ Telefax +41-33-439 11 12 www.studer.com

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Bumi Armada’s Second FPSO Completed

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ExxonMobil To Launch Biofuels Programme Texas, USA: Exxon Mobil Corp formed an alliance with Synthetic Genomics Inc (SGI), a biotech company, to research and develop next generation biofuels from photosynthetic algae. Under the programme, if R&D milestones are successfully met, the company expects to spend more than US$600 million, which includes US$300 million in internal costs and potentially more than US$300 million to SGI. “After considerable study, we have determined that the potential advantages and benefits of biofuel from algae could be significant. Among other advantages, readily available sunlight and carbon dioxide used to grow the photosynthetic algae could provide greenhouse gas mitigation benefits. Growing algae does not rely on fresh water and arable land otherwise used for food production. And lastly, algae have the potential to produce large volumes of oils that can be processed in existing refineries to manufacture fuels that are compatible with existing transportation technology and infrastructure,” said Dr Emil Jacobs, VP of R&D at ExxonMobil research and engineering company. The company has invested more than US$1.5 billion over the past five years on activities that improve energy efficiency and reduce greenhouse gas emissions. Initiatives include technologies to improve automobile efficiency, such as tire liners that keep tires inflated longer, advanced fueleconomy engine oil and light-weight automobile plastics. Furthermore, the company is researching enhanced engine efficiency and has developed an improved lithium battery separator film for hybrid electric cars. It also sponsors research into ways to improve solar energy, biofuels and carbon capture and storage.

HHI Completes Delivery of Iraqi Diesel Power Plants Kuala Lumpur, Malaysia: Bumi Armada Berhad’s second F PSO (f loating production, stora ge a nd offloading) vessel is almost ready to leave for Nigeria to work for Nigerian Agip Exploration, a subsidiary of Italian oil major, Eni SpA, following a naming ceremony at Keppel Shipyard. A 1988 converted vessel, the FPSO was named ‘A r m ada Pe rda na’. T he F P S O ha s 4 5,0 0 0 B L PD processing capacity and storage capacity of 1,000,000 barrels of processed oil with water and gas injection capabilities included in its topside. It is expected to arrive in the Oyo field (OML 120), 70 km off the coast of Nigeria in August 2009 and deliver first oil in the fourth quarter of 2009. 16

metalworking equipment news September 2009

Seoul, S Korea: Hyundai Heav y Industries ( HHI ) completed 144 units of Diesel Power Plant (DPP) delivery to Iraq. The DPPs are worth US$380 million. The DPPs, ordered by the Iraqi government in June 2008, have a total capacity of 360MW and can provide electricity to 120,000 households. They will be installed in 12 regions, including Baghdad, and supply electricity to households and industry. It is one of Iraqi restoration work after war. HHI has exported more than a thousand packaged diesel power facilities to 23 countries throughout South Asia, the Middle East, South America, Europe, and Africa. The company has so far been contracted to supply a total of 180 DPPs worth US$420 million to Iraq.

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FOUNDRY

World Steel Figures 2009 Br us sels, Belgium: The World Steel A ssociation (worldsteel) lists the top steel-producing countries and companies around the world. In 2008, the five major steel producing countries were: 1. China 500.5 mmt 2. Japan 118.7 mmt 3. United States 91.4 mmt 4. Russia 68.5 mmt 5. India 55.2 mmt Total world production was 1,326.5 mmt in 2008, down from 1,351.3 mmt in 2007. The largest five steel-producing companies in 2008 were: 1. ArcelorMittal 101.6 mmt 2. Nippon Steel 37.5 mmt 3. Baosteel Group 35.4 mmt 4. Hebei Steel Group 33.3 mmt 5. JFE 32.4 mmt

Kobe Steel Opens Sales Unit In Kolkata Tokyo, Japan: Kobe Steel has opened a subsidiary company in Kolkata, West Bengal, to market its steel production machinery in India. Called Kobelco Machinery India (KMI), the marketing company will sell steel rolling mills, continuous casters, nonferrous rolling mills and presses. The company holds a 90 percent equity share in KMI, while trading firm Shinsho Corp, a Kobe Steel affiliate, has a 10 percent share. Realising the potential of India’s growing market, The company decided to establish a marketing office in Kolkata. “New steel plant projects are concentrated in the eastern part of India along the Bay of Bengal. We selected Kolkata because of its location,” said MD Yutaka Nakamoto. India’s steel production has risen in recent years. Due to the worldwide economic crisis, Indian steel production has slowed but continues to grow. India’s apparent steel use reached 52.6 million metric tonnes in 2008 and is estimated to rise to 53.5 million metric tonnes, according to the World Steel Association. India’s Ministry of Steel anticipates crude steel capacity of 200 million metric tonnes in 2020.

grinding Wheels from Winterthur: passionately precise Thailand Winterthur Technology Co., Ltd. 947/37, 8th Floor Thosapol Land, Building 4, Bangna 10260 Bangkok Phone: +66 27 441 5779 nattana@winterthurtechnology.co.th Malaysia Rappold Winterthur Technologie GmbH No. 22, 1st Floor, Jalan Putra Mahkota 7/6A Putra Heights 47650 Subang Jaya Selangor Darul Ehsan Phone: +60 35 191 0534 sharudin@winterthurtechnology.com.my

China WENDT Precision Co. Ltd. No. 8 Loujiang Road North 215400 Taicang Phone: +86 512 8161 6801 sales@wendtgroup.com.cn

www.winterthurtechnology.com

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South Korea Winterthur Technology Ltd. 304-704 Bucheon Technopark 3 365 Samjeong-Dong Ohjeong-Gu, Kyungki-Do Phone: +82 32 310 1000 lee@winterthurtechnology.com

1.7.2009 10:12:56 Uhr

September 2009 metalworking equipment news

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OIL & GAS

Stefanie L, Meppen, Germany

Premier Strikes Oil In Vietnam

Ho Chi Minh City, Vietnam: Premier has completed drill stem testing of the Ca Rong Do discovery well on Block 07/03, offshore Vietnam. The well was drilled to a total depth of 3,810 m BRT and has intersected approximately 90 m net oil and gas pay within multiple stacked reservoir layers. Two of these reservoir zones have now been tested. The zones tested flowed oil at a combined rate of 3,265 barrels of oil per day plus 8.1 million standard cubic feet of gas per day, through a 48/64” choke. No water was produced from either zone. The company plans to conduct a 3D survey to define the resource potential of the Ca Rong Do discovery and adjacent structures and to determine future exploration and appraisal activity. It currently plans to drill a second exploration well elsewhere on Block 07/03 in Q4 2009.

Technip Awarded Contract For LNG Plant In China Paris, France: Technip has been awarded by Ningxia Hanas Natural Gas Company, a lump sum contract for a mid-scale liquefied natural gas (LNG) plant to be built in Yinchuan, China. The contract covers the engineering, supply of main equipment, procurement and construction management services for facilities for natural gas pre-treatment, liquefaction, LNG storage and loading, utilities, offsites, buildings and other infrastructure. This LNG plant will be the largest facility of its kind in China. It will have two trains* with a capacity of 400,000 tonnes per year each, based on an air products liquefaction process. The LNG will be distributed to the Chinese market to help meet the growing demand for clean energy. The company’s operating centres in Kuala Lumpur, Malaysia and Shanghai, China will execute the contract, which is scheduled to be completed in the second half of 2011. *LNG Train: unit that transforms natural gas into liquefied natural gas by cooling it to a temperature of – 162 deg C.

Gazprom Commences Drilling In Offshore Sakhalin

ConocoPhillips In Joint Venture Houston, USA: ConocoPhillips and Abu Dhabi National Oil Company (ADNOC) signed the Shah Gas Field Joint Venture and Field Entry agreements to develop the Shah Gas field in Abu Dhabi. ADNOC owns 60 percent interest and ConocoPhillips owns the remaining 40 percent interest in the project. Upon receipt of the Emiri Decree, a new operating company will be formed to manage and operate the project. This large-scale project involves the development of sour natural gas and condensate reservoirs within the Shah Gas field located onshore approximately 180 km South-west of the city of Abu Dhabi. The project requires the construction of facilities including gas gathering systems, gas processing trains and product pipelines designed to process and transport one billion cubic feet per day of gas, associated liquids and sulphur. The Shah Project will include one of the largest sulphur removal plants in the world and will also include a sulphur processing and exporting facility, which will be located in Ruwais Industrial City, UAE. 18

metalworking equipment news September 2009

Moscow, Russia: Gazprom has started exploration drilling in the Kirinskoye field, offshore on the Sakhalin Peninsula. This will be the first project in offshore Sakhalin carried out solely by Russian companies. To develop Sakhalin’s potential hydrocarbon resources, the company will make maximum use of the capabilities of domestic shipbuilding and machine-building companies. Starting from 2014, the Kirinskoye field will turn into a gas source for the Sakhalin – Khabarovsk – Vladivostok gas transmission system being constructed to ensure reliable gas supplies to consumers of the Khabarovsk and Primorsky Krais and the Sakhalin Oblast.

ENQUIRY NO 114

Business

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statistics

Metal Powder Industry Surviving Recession Las Vegas, US: The Powder Metallurgy (PM) industry in 2008 weakened in the second half, especially in the final quarter mainly due to a sharp decrease in auto production in November and December. Iron powder production declined 19 percent to 327,272 short tonnes. Copper and copper-based powder shipments declined 13 percent to 17,400 short tonnes, and stainless steel powder shipments declined about 20 percent to an estimated 7,750 short tonnes. Reflecting the continuing decrease in auto production, metal powder production declined further during the first half of 2009. “We can view the current state of the PM industry through short-term fear-tinted glasses or as long-range opportunities,” said Mark C Paullin, president of the Metal Powder Industries Federation (MPIF). “Just like US manufacturing in general, the PM industry has been impacted negatively by the current recession and plunging automotive production,” he added.

Mr Paullin also stressed that the PM industry still has much to offer car makers in conventional power trains, in diesel engines, a nd in hybrid vehicles. He said: “We can offer engineering/materials solutions, cost savings, and a technology that is environmentally safe.” Future PM pa r t s usa ge in light vehicle s is projected to grow from between 590,000 to 900,000 tonnes globally by 2015, based on an estimated global market of almost 77 million vehicles. Potential new applications include connecting rods for diesel engines and electric traction drives and electric motor gears in hybrid vehicles. He reported that the MPIF technical board had just released the results of the PM parts catalogue study that has identified more than 300 PM automotive applications representing more than 750 total parts. Renewable ‘green’ energy, particularly in wind

NORTH AMERICAN IRON POWDER NORTH AMERICAN IRON POWDER SHIPMENTS 500,000 Short Tonnes Short Tons 450,000 SHIPMENTS 400,000 500,000 Short Tons

350,000 450,000 300,000 400,000 350,000 250,000 300,000 200,000 250,000 150,000 200,000 100,000 50,000 150,000 0 100,000 50,000 1998 1999 0 1998 1999

2000 2001

PM Parts

2000 2001

2002 2002

PM Parts

2003

2004

Welding 2003

2004

2005 2005

Welding

2006

2007

Other Uses 2006

2007

Other Uses

Total 327,272 Total 327,272 PM Parts Total 284,957 PM Parts Total 284,957

2008 2008 Copyright MPIF 2009 Copyright MPIF 2009

NORTH AMERICAN SHIPMENTS OF COPPER COPPERSHIPMENTS BASE POWDERS NORTHAND AMERICAN OF Short Short Tons Tonnes COPPER AND COPPER BASE POWDERS Short Tons 30,000 25,000 30,000 20,000 25,000 15,000 20,000 10,000 15,000 5,000 10,000 0 5,000 0

17,400 17,400

1998

1999

2000

1998

1999

2001

2002

2003

2004

2005

2006

2007

2008

PM Parts 2000 2001 2002

Other Uses 2003 2004 2005

2006

PM Parts

Other Uses

2007 2008 Copyright MPIF 2009

metalworking equipment news September 2009

North American Metal Powder Shipments

500,000 450,000 Short Tons 400,000 www.equipment-news.com 350,000 30,000 300,000 25,000 250,000 20,000 200,000 150,000 turbines and solar 15,000 panels, presents opportunities 100,000 10,000meta l injection moulding, for conventiona l50,000 PM, a nd na note ch nolog5,000 y. 0 PM is a su sta inable, net1998 1999 2000 2001 2002 2003

327,272

17,400

businessStatistics

PM Parts Total 284,957

for PM as well. “While the PM industry faces many challenges, it will still be an important materials technology and 2004 2005 2006 2007 2008 manufacturing process. As the current recession shape manufacturing process that has long been 0 1998 1999 PM 2000 2001 2002 Welding 2003 2004 2005 2006 2007 2008 Parts Uses subsides, Other the PM market will return and grow. The recognised as a green technology for minimising energy PM Parts Other Uses Copyright MPIF 2009 US automotive and industrial markets will still need consumption and for recyclability. Copyright MPIF 2009 innovative suppliers that offer precision productions Although still in their infancy, rapid prototyping and cost savings,” he concluded. and rapid manufacturing offer exciting opportunities

NORTH AMERICAN SHIPMENTS OF North American Metal Powder Shipments 2007 2008 COPPER AND COPPER BASE POWDERS Iron Short Tons

& Steel Steel

404,650

Stainless Steel 30,000Copper &

327,272

9,676 (E)

Copper Base

25,000Aluminium Aluminum

7,750 (E)

19,992

17,400

50,000 (E)

42,500 (E)

20,000Molybdenum Molybdenum

2,800 (E)

2,000 (E)

15,000Tungsten

4,650 (E)

4,000 (F)

10,000Tungsten Carbide Carbide

7,394

5,103

9,190 (E)

8,650 (E)

5,000Nickel 0Tin 1998

1999

2000

(E) estimate

2001

785

2002

2003

2004

2005

752

2006

17,400

2007

2008

Other PM Parts 509,137 short tonnes tonsUses415.427 short tonnes tons

North American Metal Powder Shipments Iron & Steel Stainless Steel

2007

2008

404,650

327,272

9,676 (E)

7,750 (E)

WithCopper the TORNOS range of solutions you can benefit from a & Copper Base 19,992 17,400 ONEAluminum STOP SHOP provider for(E)all your high precision machining 50,000 42,500 (E) Molybdenum 2,800 (E) applications! 2,000 (E) needs in MEDICAL and DENTAL Tungsten

4,650 (E)

4,000 (F)

Tungsten Carbide

7,394

5,103

Nickel

13a/e (E) 9,190 (E)TORNOS DECO 8,650

TORNOS Sigma 20 II Accessibility, Simplicity

Tin

(E) estimate

785

High Productivity, 752 Very Complex Parts

509,137 short tons

415.427 short tons

TORNOS TECHNOLOGIES ASIA LTD Unit 4, G/F, Transport City Building 1-7 Shing Wan Road, Tai Wai Shatin, N.T., HONG KONG Tel. +852 2691 2633 / Fax +852 2691 2133 asiapacific.contact@tornos.ch TORNOS S.A. THAILAND REPRESENTATIVE OFFICE Tel. +66 2 662 3908 / Fax +66 2 662 3910 thailand.contact@tornos.com TORNOS TECHNOLOGIES ASIA LTD MALAYSIA REPRESENTATIVE OFFICE Tel. +60 4 263 0118 / Fax +60 4 262 4118 malaysia.contact@tornos.com

www. tornos.com

ENQUIRY NO 113

Almac FB1005 Versatility, Modularity

September 2009 metalworking equipment news

FIRST

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cut

M When

Machine Meets

CNC

CNC has taken machine controls and machining operations to higher grounds of efficiency. By Thomas Lee, deputy GM, engineering division, Yamazaki Mazak Singapore 22

metalworking equipment news September 2009

anufacturers in todayâ&#x20AC;&#x2122;s metalworking industries face growing challenges associated with high-speed machining, complex machining and reliable operability on a machine tool. A simple turning or milling operation performed on a traditional machine tool a few decades ago is today made complicated by the demands coming from the consumer market place. Tr a d i t i o n a l l y, a l a t h e i s a mach ine to ol where a tu r n ing operation is performed to produce cylindrical parts. Generically, a work piece is held in a work-holding device and rotated while a cutting tool is moved linearly accordingly to generate the desired shape. The operator of the lathe manually controls the speeds a nd feeds of the cutting tool. Inev itably, the quality of the part produced depends directly on the skills of the operator.

firstcut

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To d a y, w i t h t h e g r o w i n g sophistication of parts, the term ‘turning centre’ has evolved in order to meet higher performance expectations. Technically speaking, a turning centre is a machine where secondary capabilities are involved in addition to the primary turning operation. Typical examples include the inclusion of a secondary spindle, rotating tools for drilling and milling operations, and auxiliary axes of movements a nd control. Rapid developments in recent years have brought the introduction of multitasking machines whereby complex work pieces may be completed in a single set-up.

The Computer Revolution W hen Computer Numerica l C o n t r o l (C N C ) s y s te m s w e r e f i r st appl ie d o n lat he s i n t he 1960s, tremendous benefits were realised. They improved operation repetitiveness and productivity, accuracy and consistency. There were advancements in the overall ease of set-up, programming and operation. S ome limitations were a lso understood. Examples included high cost of CNC equipment, need for skilled machine programmer, need for preventative maintenance skills, etc. From that time onwards, the CNC window opened itself to many opportunities and challenges. Differences and similarities exist between different controllers in the market today. Differences can result from different manufacturers and different machine tools, and the applications they are used for. In the area of programming, two main standards have been accepted globally as industrial standard – the ISO 6983 and the EIA RS274. ISO (International Standardisation Organisation) and EIA (Electronic Industries Association) developed the ma in sta nda rd for CNC, which uses simple programming instructions or codes. A not he r i s a non - st a nda rd

format that is mainly proprietary to the manufacturer. Instead of u si n g prog ra m m ing co de s (a s defined in EIA and ISO standards), the controller provides a manmachine-interface where the user or programmer makes inputs as part of the programming process. This conversational or interactive method makes machine programming and set-up a lot more user-friendly. Since then, much has evolved and manufacturers of CNC systems as well as machine tool manufacturers have focussed efforts in the development of user interface in addition to the programming interface. The ultimate aim is to make the machine easy to use and operate, and to derive maximum productivity. Whether a person is an entry l e v e l o r a d v a n c e d u s e r, t h e performance of the CNC system directly influences the efficiency of the machining operation. In general, the objective of any CNC system must be to ensure that the machine is able to operate or perform to its full potential and realise the maximum level of productivity.

New-Age Thinking Machine NC machines introduced in the 19 4 0 s had si mple ( but ye t inflexible) hardware configuration. Communication link between the controller and an external device such as a computer was scarcely limited, if not non-existent. Today,

we have CNC machines that are sophisticated and powerful. Direct communication between the controller and a built-in computer provides a new dimension in dataprocessing capabilities. The modern CNC system needs to incorporate high-speed dataprocessing instruction set on its CPU in order to handle all the high volume of data as well as complex algorithmic computations. CNC systems, together with control and software technologies, need to catch up with advances in hardware innovation in order to realise the quantum leap in productivity and quality gains. Let us look at some of the areas where intelligent functions can be applied to take machine control and machining operation to higher efficiency levels. • Heat Displacement Control This has the objective of achieving and maintaining temperature s t a b i l i t y fo r h i g h - p r e c i s i o n machining. Heat build-up within the machine during the machining operation, as well as ambient te mp e ratu re c ha n ge s i n t he surroundings can have direct effect on the continuous machining accuracy. Automatic compensation can be based on data obtained during tests in a temperaturecontrolled room.

The objective of any CNC system is to ensure that the machine is able to operate or perform to its full potential

September 2009 metalworking equipment news

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The modern CNC system incorporates highspeed data-processing instruction in order to handle all the high volume of data as well as complex algorithmic computations

• Machine Interference Prevention This provides the user with active collision monitoring, in manual mode or full automatic mode. The CNC system uses 3D solid model of the machine and its other elements to generate interference zones that might be breached. In the event of any interference, the machine movements are stopped immediately.

safety issues. Poor machining accuracy will also result. This function serves to detect the outof-balance and even display the counter-balance to be set in place. In addition, if excessive vibration is detected during automatic operation for whatever reasons, the system w ill stop spindle rotation automatically.

A Sneak Peek Into The Future • Spindle Monitoring Sensors housed in the spindle assembly provide useful feedback on parameters such as temperature, vibration and displacement. With this data, potential machine problems may be prevented and preventative maintenance can be organised. All these result in decrease in machine downtime. • Maintenance Monitor Perishable or consumable items such as wipers, filters, etc are u n d e r co n s t a nt m o n ito r i n g. Operation history of machine units is also monitored. This information is useful for preventative maintenance to avoid unexpected machine downtime. • Out-Of-Balance Analysis On a lathe or turning centre, especially in the case of large-size machine, the work piece or fixture mounted on a table that are being made to rotate, can generate outof-balance forces that could pose 24

metalworking equipment news September 2009

For many years, researchers and a c a d e m ic s h av e b e e n t a l k i n g about future CNC systems that could incorporate fuzzy logic and/

or knowledge engine as part of intelligent processing. Manufacturers or users of machine tools worldwide have observed the increasing trend of lesser skilled operators, increased complexity of manufacturing parts, increased sophistication of machine operation and increased demand on part quality. To address these issues, some machine tool manufacturers are working towards the realisation of intelligent machines. They are built with artificial intelligence systems that help the machines ‘think’ and operate accordingly in order to deliver optimum operating efficiency. Smart sensors or transducer systems may be incorporated onto machine ha rdwa re to prov ide essential feedback in real-time. An intelligent knowledge engine can serve to monitor key elements and provide appropriate and timely advice and warning. The end result is an intelligent system where the machine is capable of monitoring its own operation. MEN Enquiry No. 6001

Yamazaki Mazak:

Heavy Duty Vertical Turning Centre The Megaturn Nexus 900 is a vertical turning centre designed by Yamazaki Mazak to machine large workpieces such as those found in the construction machinery, industrial machinery and jet engine industries. T his machine is e quipp e d with the 6th generation CNC system, the Matatrol Matrix Nexus. Conversational programming provides easy operation even for inexperienced operators. The CNC system comes equipped with a variety of functions, making it possible to shorten the time required from programming to completion of the first workpiece to a third of that of conventional systems. This ability is effective for the machining of prototype components and small lot sizes.

Enquiry No. 6002

look

closer

Do you think all measuring systems are identical? That is not true. Look closer at SmartScope速 dimensional measuring systems form Optical Gaging Products (OGP速), and you will see the difference. OGP is the world leader in video and multisensory metrology, and our machines can measure a variety of parts with optical, laser, touch probe, and micro-sensor technology. With tens of thousands of OGP systems installed in more than 65 countries, manufacturers everywhere rely in OGP systems and trust us for expert advice and service, for innovation, for productivity, and for reliability. See for yourself how OGP can help you solve your measurement challenges. ShapeGrabber a fully automated industrial 3D scanners that inspect whole part in minutes. It is ideal for rigorous, full surface 3D quality control and is easy to use even without CAD training.

Optical Gaging (S) Pte Ltd www.smartscope.com.sg

21 Tannery Road, Singapore 347733 Tel: (65) 6741 8880 Fax: (65) 6741 8998

Email: sales_epl@smartscope.com.sg

Singapore . Malaysia . Thailand . Indonesia . Philippines . Vietnam . Hong Kong . Taiwan . South China . India . Australia . New Zealand

ENQUIRY NO 112

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Balancing Act

n recent years, in the field of large part machining, there has been an increasing need for versatile machines which allow the user to use both high-feed rate tools, as well as small-diameter drills and taps in machining. These are in addition to those designed for more efficient machining, and those with higher heavy cutting capabilities. To address this need with a portal five-face milling machine, machine manufacturers must satisfy conflicting requirements. In order to meet this challenge, large machining centres, which offers more machining capabilities tha n conventiona l machines are developed. Obviously, it is also essential to further improve the rapid traverse rate in milling machines to reduce the non-cutting time. To realise this, a high rigidity and lightweight structure must be built. Rigidity must also be present in the spindle for low and high-speeds. A feed system with high thrust must be available to support high-speed feeds.

(MHI ) as an example, the table moves inside the portal structure in a longitudinal direction (X-axis). The portal structure consists of the column bridge and the crossrail. In front of the crossrail, the ram saddle with the spindle is located. The ver tica l movement of the spindle is generated by the vertical movement of the entire crossrail (W-axis) and the vertical movement of t he ra m ( Z - a x is) that runs through the saddle. The horizontal movement of the spindle (Y-axis) is generated by the saddle that moves in front of the crossrail in a horizontal direction. A workpiece is located on the table that moves along the X-axis. Each axis is driven accurately by the combination of a ball screw mechanism and a linear scale. The spindle is rotated via the gearbox located in the upper portion of the ram to cut the workpiece loaded on the table.

Recipe For High Rigidity Machine Construction As shown in figure one, using the MVR-Dx, a five face milling machine by Mitsubishi Heav y Industries 26

metalworking equipment news September 2009

A machine requires robust structures with high rigidity to exhibit high cutting performance. To design a vibration-resistant

Kostya Kisleyko, Russia

High-speed and highrigidity must complement each other in order to construct an efficient fiveface milling machine. By Hiroyuki Yamamura, Mutsumi Yoshikawa, Takayuki Kume, Hiroyuki Tauchi and Yoshifumi Tanigawa, Mitsubishi Heavy Industries structure, the three factors that govern vibration, ‘spring constant’, ‘damping coefficient’, and ‘mass’, must be well balanced. Conventiona l machine s use welded structures made of steel with a high elastic coefficient. Through the use of FEM analysis, it has become possible to minimise the increase in mass and provide static rigidity equivalent to that of a welded structure even with a cast structure. • Material Selection For structures such as the ram, saddle and table, we used cast materials as before and made them as light as possible while ma inta ining their r ig idit y to support higher spindle speeds. However, for the crossrail, columns and bridge bed, we change from conventional welded structures to cast materials and utilised all our analysis technologies to improve the dynamic rigidity. • Determining Rigidity Values T he re lat io n sh ip b e t we e n a machine’s cutting capacity and the static and dynamic rigidity values is still unsolved. Therefore,

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we collected the cutting capacity and static/dynamic rigidity data from the various types of machine we manufactured. They were then organised into a database so that the target static and dynamic rigidity can be determined based on the target cutting capacity.

Figure 1: Machine construction must satisfy high rigidity

Ram, vertical (Z)

Saddle, horizontal (Y)

Crossrail, vertical (W)

â&#x20AC;˘ Getting The Right Shape In the past, the shape of each machine structure is first determined by seasoned engineers. It is then verified through FEM analysis that it has the target rigidity. However, using this method, it had often been impossible to attain the target rigidity in a single attempt, which prolonged the determination of structure shapes. We considered that this is due to the difficulty in simultaneously ta k ing into accou nt ma ny conditions that determine the rigidity. As a solution, we adopted the method of determining the basic machine dimensions based on quality engineering. The use of quality engineering enabled us to cover all dimensional pattern that can be designed. It also minimises the rigidity variation caused by changes in the cutting direction or position, and derive the basic dimensions that provide lightweight structures with high rigidity. Next, based on these basic dimensions, we prepared models of each structure and conducted FEM analysis on all structure

Table, longitudinal (X)

members. We increased the well thickness, added rids, or used other reinforcing measures for members subjected to low stress. Implementing this process for all the structures allow us to minimise the increase in the mass and derive shapes that provide high rigidity. F ina lly, we combine d t he determined structures, analysed the entire machine to check e ach por tion wa s connected appropriately, and fine -tuned e ach str ucture to the ta rget specifications to accomplish the final shapes. Using this method, although the main structures were changed from a sheet metal construction to a casting, which has a disadvantage in rigidity, we could minimise the increase in mass and achieve the static and dynamic rigidity

equivalent to, or, exceeding that of conventional machines. â&#x20AC;˘ Final Analysis Figure two shows a comparison of the actual dynamic rigidity with the value from FEM analysis. The graph shows that both the actual and analysis values attained the target dynamic rigidity, with the frequency and the peak height at the proper value matched to a satisfactory degree. In the analysis of dynamic rigidity, because it is essential to consider various boundary conditions, estimating the dynamic rigidity with high accuracy has been difficult. However, the accumulation of a substantial amount of knowhow enables us to improve the calculation accuracy and, as a result, analysed dynamic rigidity with accuracy in the calculation stage. The synergistic effects of this high calculation accuracy and the engineering process that realised high rigidity have made the MVR-Dx with rigidity balance.

Achieving High Spindle Speed

Figure 2: In the analysis of dynamic rigidity of the five-face milling machine, it is essential to consider various boundary conditions

A machine used for heavy cutting applications requires a high-rigidity spindle that withstands large cutting loads generated during machining. Although setting a large preload on bearing improves the rigidity of a spindle, this is not a straightforward way to achieve high spindle speeds September 2009 metalworking equipment news

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Temperature rise in ram body is minimised

Heat generated from bearings is quickly cooled

Figure 3: It is important to study the heat generated from the bearings in order to introduce a better cooling method

because setting an excessive preload substantially increases the heat generated from the bearings. To solve this problem, it is necessary to conduct an accurate therma l a na lysis a nd consider introducing a better cooling method. Doing this is not so easy because of the difficulty in accurately estimating the heat generated from bearings and the coefficient of heat transfer between parts. However with the know-how of accurate thermal analysis developed through experience in va rious products, as shown in figure three, we minimised the temperature rise in bearing by efficiently cooling the bearings and also reduced the temperature rise in the ram body, which is a major cause of thermal displacement. Using t his te chnique, we successfully developed a highprecision and high-efficiency spindle capable of cutting at any speed in the range of 7 to 4,000 min-1. â&#x20AC;˘ Increasing Y-axis Traverse Rate For the Y-axis guide, the milling machine uses a roller type linear guide with high rigidity, which is suitable for high feedrate and can suppress yawing the ram and saddle when the Y-axis is traveling. In addition, the capacity of the Y-axis feed motor was expanded to improve the conventional Y-axis traverse rate from 24 to 30m/min 28

metalworking equipment news September 2009

while maintaining the feed thrust. T his cont r ibute s to t he reduction of the non - cutting time w ithout impa iring the advantages of high-rigidity and high accuracy. â&#x20AC;˘ Z Axis Feed We redesigned the Z-axis to use a twin feed motor/ball screw system by eliminating the hydrauliccylinder based ram balancing s y s te m , a lt h o u g h t h e r a p i d traverse rate of the Z-axis is kept at 15 m/min.

In addition to doing this to improve the axis rigidity during travel, we also paid attention to the layout of the ball screw so that the axis is driven at the centre of gravity. This theoretically eliminates the moment caused by the unevenness of the force generated by the balancing system. This contributes to the development of a highprecision drive. Moreover, the elimination of power consumption allows the use of a smaller hydraulic unit, which is one of the heav ie st consumers of electricity in a machine tool.

Conclusion Using a modular design approach to support a wide range of machine specifications, it is possible to create a machine that satisfies both high-speed and high-rigidity requirements. Coupling that with analysis knowhow and technologies, it allows us to support more diverse machining applications than ever. MEN Enquiry No. 6003

Mitsubishi Heavy Industries:

High Precision Machining Developed for high precision parts, die and mould and electrode high speed machining, the Âľmicro V1 is suitable for accurate and long machining operations. The micro-milling machine from Mitsubishi Heavy Industries features a cooling and lubrication system that utilises cooling oil for lubrication of bearing. In addition, spindle thermal displacement during long machining operation is stable due to cooling system. Furthermore, repeatability of Z-axis position when restarting rotation after stopping is higher. As a result, this higher repeatability lead tools are used on the same surface.

Enquiry No. 6004

(Full-scale)

Compared with competitor's cutter

C-cutter mini

Small cutting diameter and 4 Inserts!!

World's smallest 5mm square insert is used. World's smallest 5mm square insert with 4 cutting edges.

World's smallest

Competitor's cutter

Large cutting diameter with only 1 or 2 Inserts.

High speed back-chamfering!! High speed back-chamfering reducecs hand de-burring!!

Competitor's Tool Chamfering dia.

Ă¸29

Number of teeth

Cutting speed (m/min)

150

Spindle speed (min-1)

1,646

Feed

(mm/min)

329

C-cutter mini

(ST12-C1116-45B-25)

Ă¸13.5

Small dia.

4 300

7,040

2,820

Face milling is possible even with this chamfering cutter.

(Possible only with 45 degree chamfering type with 10mm square insert)

Minor cutting edge allows light face milling.

5mm

Bolt hole & starting hole for tapping Type New series for starting hole for tapping are available from M8 to M20 range.

ENQUIRY NO 123

www.big-daishowa.com

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o k y o K i k a i S e i s a k u sh o is a printing system manufacturer who p r o d u c e d J a p a n’s f i r s t n e w sp a p e r ro t a r y p r e s s . T h e company has conducted integrated manufacturing from development to production for more than 30 various types of rotary presses and peripheral equipment. A rotary press performs printing by transferring colour inks (Cyan, Magenta, Yellow and Black) on plate cylinders, which are wrapped with aluminium plates, onto a blanket cylinder. Fo r h i g h - q u a l i t y p r i n t i n g , it is ver y important to prevent displacement and deformation of four colour inks printed on the paper, which is fed at a maximum speed of 15.2 m/s. With accuracy an important consideration, the pr i nt i n g s y ste m ma nu fac tu re r makes machines capable of achieving a positioning error of less than 2 μm. The company has used several Mori Seiki machines to help them ma nufacture their machines. Cu r re nt ly, t hey a re u si n g t wo integrated mill turn centres in order to achieve fur ther high precision machining.

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Made To Print The machining accuracy and process integration ability of a turning machine allow the manufacture of a high-end web offset press. Contributed by Masaki Momiki, regional manager, Mori Seiki Singapore

Yamashita Hiroyuki, chief of the centre says: “At first, we considered Mori Seiki and other companies’ machines, but we found that only NT6600 DCG could achieve the required accuracy. It is suitable for us because we produce a large number of products with different sizes and shapes, and we do not want to make a compromise for small or large workpieces.”

Productivity Multiplier I n a d d i t i o n to t h e m a c h i n i n g

accuracy, the machine also offers sh o r te r m a c h i n i n g t i m e s a n d labour- sav ing. For exa mple, to make a special steel plate cylinder with a length of 2,500 mm and a dia meter of 34 8 mm, severa l processes including roughing, hole machining, surface machining and grooving are required. In the past, it took 20 hours to complete one component because setup change

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Mr Yamashita (right) and Mr Yanagi insist on both quality and productivity

was necessary for each process. However, the mill turn centre require s no setup cha nge a nd completes machining in less than ha l f t he t i me o f conve nt iona l machines. Yanagi Katsutoshi, GM of the parts department where 24-hour operations are conducted, says: â&#x20AC;&#x153;If we set up parts in the morning, they will be finished by the evening, and if we set up parts before we leave the factory, they will be finished by the next morning. In the past, we assigned one operator to one machine, but now we can leave multiple machines to one operator.â&#x20AC;?

Looking Ahead

The recent acquisitions require no setup change and complete machining of a special steel plate cylinder in less than half the time of conventional machines

In the future, the printing industry will shift its emphasis to much higher quality and multiple-item, small-lot printing. The company responded by improving the production system. For e x a mple , t he comp a ny established a temperature-controlled machining area at a constant 22 Âą 2 deg C in the Iga Techno Centre in 2004 to better serve their customers all over the world. MEN Enquiry No. 6005

Mori Seiki:

Integrated Mill Turn Centre

In the field of small precision parts manufacturing including medical equipment, watches and measuring instruments, there is a growing demand for machine tools that are capable of high-precision machining of complexshaped workpieces. Responding to this demand, Mori Seiki has developed the NT1000, an addition to the NT series of integrated mill turn centres. The machine with a maximum turning diameter of 370 mm and maximum turning length of 400 mm offers high-precision machining. In addition, it improves productivity per unit area as it has approximately 40 percent smaller floor space compared to the previous models.

Enquiry No. 6006

September 2009 metalworking equipment news

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update

Metalwork That Composite! As far as machining aerospace and medical parts are concerned, tool construction, geometry, and coating can make a significant difference. By Karthik Sampath and Wang Yang Ni, senior engineers, Kennametal.

n the aerospace and medical industry, strength-to -weight ratio and corrosion resistance are only some of the many material properties placed under consideration. Tool manufacturers have to take heed of this trend and develop products that cross the traditional boundaries. As such, many tools can be used in metalworking and composite materials. Carbon- Fibre - Reinforced Polymers (CFRP) has been with us for decades as engineers continue to use them in the aerospace and medical industry. Their structures, however, have proven difficult to machine cleanly and precisely. At the same time, seeking ever-higher performance from CFRPs has meant introducing new materials to the composite makeup, expanding the challenges for manufacturers, cutting tool, and machine tool suppliers alike.

metalworking equipment news September 2009

Tool Design Given the abrasiveness, hardness, and crumbling cutting action, the search for productive cutting must encompass not only tool geometry, but the base and coating material of the tool itself, and the appropriate speeds and feeds to maximise hole quality and tool longevity. Objectives of geometry design include minimising stresses leading to dela mination, maintaining a

sharp edge to cut fibres cleanly, and evacuating the dust created by the cutting action. Tests prove that these conditions dictate a high helix angle, a severe clearance angle, and a highrake gash angle for easier entry into the material. Particular attention must be paid to the clearance angle behind the cutting edge. In one application, clearances of 10, 20, and 36 degrees were te sted. A s the cle a ra nce

A Speed Bump Named Delamination Delamination is one of the most serious quality issues when machining holes in composites. Typically, it occurs on the tool breakout at completion of the drilling cycle as the axial thrust force puts pressure on the lower surface laminations. It also happens at the part surface as the rotating drill torque is applied to the workpiece during entry. While there is a strong correlation between thrust and breakout delamination, variation in fibre position, voids, and other material variances are also contributors to this problem.

Enquiry No. 6101

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The Orbital Alternative Orbital drilling is a relatively new concept in holemaking in CFR P materials. Developed and patented by Novator, AB, Sweden, the orbital drill unit is a self-contained spindle that spins the drill on its own axis

Varying point angles produce different results, affecting hole quality AD130-WFE:111x183 02.06.09 08:52 Seite 1

ALUFIX

the workholding system for quality control Modular

High precision

Reusable

Alufix is a modular, highly accurate and reusable workholding system made of high-tensile Aerospace Aluminium. It is used for assembling all kinds measuring fixtures, chekking gauges, assembly fixtures, cubings, basic frames etc.

Comprehensive Measuring Service for big and small workpieces! • Measurement from parts up to 6.3 m of length • Single part and series measurements • Third party verification/certification process • First article inspection • Reverse engineering processes • Profile scanning

Witte Far East Pte Ltd 1st Level •13 Joo Koon Crescent•SGP-629021 Singapore Tel.: +65-6248 5961 • Fax: +65-6898 4542 Email: info@witteasia.com • www.witteasia.com

Cert No: LA-2007-0394C

ENQUIRY NO 094

increases, hole quality improves dramatically. This is attributed to a much smaller wear land created by the additional clearance and limiting the build-up of torque and thrust from tool wear. Less thrust ensures cleaner cutting. In keeping with low-thrust cutting in CFRP, initial edge preparation also plays a key role. A sharp edge (≤ 10 µm radius) before applying a coating material works best. A diamond coating thickness of 12 µm for maximum wear resistance and good cutting properties is recommended. Thinner coating ca n lead to edge chipping a nd thicker coating does not improve the performance relative to its extra cost. Selection of the point angle for the cutting tool is dependent on the problem one needs to control. A lower point angle (less than 90 degree included angle) delivers much better exit (breakout) hole quality, while a higher angle (above 90 degrees) leads to much higher edge strength. The edge strength is needed to control chipping of the cutting edge, resulting in premature tool failure. A mong conventional tooling choices, Polycrystalline Diamond (PCD) veined drills and diamond coating of low-cobalt carbide drills are the only practical choice for holemaking in composites. Diamond-coated drills deliver a 10-to-1 improvement in tool life over uncoated carbide and a 50 percent longevity increase over PCD drill technology. Based on a practical balance of hole entry and exit quality plus throughput, we suggest 400 surface feet per minute and 0.0015 inch per minute feedrate as starting process parameters.

September 2009 metalworking equipment news

technologyupdate

while rotating (orbiting) around its central axis. A range of hole sizes and fine adjustment is possible by utilising an adjustable offset feature that covers a range of 6 mm. It also contains its own precision feed mechanism. As discussed, tool thrust and friction are the enemies when it comes to avoiding delamination in CFRP drilling. Orbital drilling uses a multi-tooth cutter with a high helix angle (somewhat resembling an end mill) simultaneously rotated and fed into the composite material. The tool diameter is always smaller than the finished hole, so one tool can machine many finished diameters, providing inventory savings. The smaller tool size also promotes chip and fibre removal, which is performed by the spindle unit. Cutting is performed without coolant. Apply ing the se spindle a nd cutter technologies, the cutting tool edges only contact the inside diameter of the hole intermittently. This prov ide s g re atly reduced rotating friction compared to a conventional drill. That in turn also controls cutting temperature that can lead to melting of the matrix material. I n add it ion, t he mu lt i - f lute design applies much less thrust pressure along the drilling axis than does a twist drill point. This feature allows delamination to be controlled during both entry and exit from the workpiece. Further control over hole quality is accomplished by the orbital drill’s electric axial feed, adjustable through a range of 10 to 600 mm/min, rather than the variable process of drilling by hand. Orbital drilling also addresses applications in which various materials are stacked together for drilling. A typical example of this might include a composite material combined with aluminium and titanium.

Drilling The Perfect Hole In addition to effectively machining the composite layer, the multi34

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The CFRP Exposé Understanding the nature of the material makes machining it a whole lot easier. G e ne r a lly, c omp o site s tr u c ture s consist of a relatively soft, tough matrix Breakout/ material layered with stronger, stiffer Delamination reinforcement fibres cured under heat Uncut resin and pressure. The base polymer matrix can be epoxy, phenolic, polymide, or polyetheretheketone. Reinforcement Holemaking issues in CFRPs fibres used include carbon, graphite, include spalling, delamination, and uncut reinforcing fibres, glass, ceramic, kevlar, polyethylene, and which can shorten tool life even tungsten. The most common method of fabricating Carbon-Fibre-Reinforced Polymers (CFRPs) is to build up layers of fibre-resin ‘prepregs’ to achieve proper thickness and form. This fibre-resin is commonly applied from tape-like rolls, which may orientate the fibres in either a uni-directional or a fabric-like weave pattern. The tape is laid in selected layers and orientations to achieve the desired strength and stiffness. Typically, this lay-up is then vacuum/bag-moulded to create a laminate. Bulk resin impregnation, compression moulding, filament winding, and pultrusion are other processes that may be used to complete a laminate structure. Spalling

Uncut fibre

Challenges In Machining Composites The expanding multitude of possible combinations of tough core materials with a variety of hard reinforcing materials makes choosing effective cutting tools difficult. Many other variables also affect mechanical performance of the composite and its machining properties. For example, using larger-diameter and a relatively higher volume of reinforcement fibres offer mechanical benefits in the final part, but they increase abrasiveness and greatly reduce tool life. Also, short fibre pieces contribute heavily to delaminating problems as do single-direction orientation of the reinforcing fibres. While machining ductile materials, like steel or aluminium, is based on shearing and consistent chip formation, machining composites is a more complex mechanism. It involves the fracture of fibres by compression or bending forces along with shearing and cracking the matrix material. As cutting tools wear, the appearance of spalling (surface chipping), uncut fibres or resin (bending but not fracturing), and delamination at the surface or internal wall of the hole, all occur at an increasing rate. This causes costly inspection and repair delays.

Enquiry No. 6102 Orbital drilling • Rotating the tool around its own axis • Revolving (orbiting) the tool around hole centre • Feeding the tool through the material

Tool spin Hole centre

Tool centre

Orbital cutter hole orbital revolution

Helical path of tool centre

Orbital cutter

Orbital drilling uses a multi-tooth cutter with a high helix angle simultaneously rotated and fed into the composite material

workpiece

offset

Feed in axial direction

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Tool geometry and material selection in the drilling of composites are important points to consider

Hole diameter (mm) is maximised at the shortest drilling distance

tooth cutter generates small, easy to handle chips because of the intermittent contact of cutting edge and material. The positive tool geometry also controls burrs that typically occur when drilling in aluminium. The cutters can be constructed to provide either through holes only, or incorporate a countersink operation in one drill cycle. Orbital dr il ling is e f fe c t ive for repa ir operations including re - drilling misaligned holes in material stacks. In one study, the nominal hole diameter was measured over 1,200 mm of CFRP drilling penetration. The variation of hole size covered a range of only 25 Âľm. Other tests focused on unidirectional and woven fibre patterns, with countersunk as well as plain holes, in composites averaging 5 mm thick. More than 200 holes were machined before evidence of delamination or uncut fibres appeared. The orbital drilling spindle unit may be mounted on machining centres for pre - progra mmed cycles when drilling composites and stacked materials. For semiautomatic drilling on the factory f lo or, t he u n it i s mou nte d o n templates to ensure accurate hole locations and to provide a stable platform for machining.

Future Challenges

selection in the drilling function on composites are important points to consider. PCD and diamond coated conventional drills are effective choices for drilling composites, while orbital drilling offers technology solutions for manufacturers in the aerospace, automotive and medical industry segments. Recognising that not every plant either has or will adopt orbital machining of CFRPs, additional

research for drilling stacks of dissimilar materials using conventional drilling tools is underway. Issues involving burrs, stringy chips, and smearing of aluminium remain under study, as do considerations unique to titanium including chip control, heat buildup, cutting edge strength, and the difficulty of using diamond tools on this material. MEN Enquiry No. 6103

Kennametal:

High-Performance Aluminium Machining MaxiMet end mills from Kennametal are suitable for aerospace and general engineering shops seeking to improve performance in machining high volumes of aluminium from parts. The end mills are appropriate where both maximum metal removal rates and good wall and floor finishes are required. One reason is the flute design that results in rigidity behind the cutting edges enabling high feed rates. The results are more metal removed in fewer passes, lowering costs per part. Additionally, an edge condition and wiper facets on the tool corner g e o m e tr y p r ov i d e g o o d s u r f a c e finishes. The end mills can be used for roughing, semi-finishing, finishing and super-finishing operations.

Enquiry No. 6104

Tool geometry and tool material September 2009 metalworking equipment news

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Drilling:

Leaving a

Impression

Deep hole drilling were besieged by difficulties but things are slowly changing now. Contributed by Kobi Kisos, hole making products manager and Zeev Fisher, deep drilling products manager, Iscar.

hether it is for coolant p a t h s i n a p l a s t ic mould, the bore of a gun barrel, a hydraulic cylinder or the hollowed-out main shaft of a jet engine or ship’s propeller, deep hole drilling often remains a serious bottleneck on many machineshop floors. This is especially the case when trying to gundrill a higha spect hole. W hen penetrating beyond 4x diameter, chips start to jam up. The drill head, on the end of a slender shaft, advances slowly and wanders, leaving a hole both out in terms of roundness and location. Recent developments in two classes of deep hole drills have alleviated the problem. Today’s tubular drilling systems tackle larger diameters and depths (up to 300 x diameter), typically outpacing

metalworking equipment news September 2009

gundrills by five to one or better. Low-helix solid carbide drills effectively cover smaller diameters and aspect ratios up to 22 to 1 ( Figure 1). In deep oil holes on engine crankshafts, they penetrate 10 p e rce nt fa ste r t ha n bra ze d gundrills and six times faster than HSS, while outlasting both types. Applications include automotive, turbomachinery, aircraft landing gear, defence and general machinery as well as oil-patch, mining and agricultural equipment.

Two Kinds Of Solutions Let’s look at the two classes of deep-hole drills. In a tubular drill, the cutting head mounts on a thinwall tube just slightly smaller than the hole diameter. Cutting fluid is pumped into the space between the

Figure 1: Low-helix solid carbide drills effectively cover smaller diameters and aspect ratios up to 22 to 1

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tube and the hole wall, flushing chips out through the tube interior. Compared with the small solid shaft of a gundrill, this makes for a stronger platform for the cutting head, enabling it to deliver more torque and thrust to the cutting face, while expanding the channel for chip evacuation. The result is faster, truer penetration and reliable chip evacuation. For drilling a 40 mm hole 660 mm deep through a type 6AL-4V titanium billets with gundrilling, a typical shop can manage 12.7 mm a minute at 300 rpm, which works out to 52 minutes per billet. Improvements are seen in conventional solid carbide drill but the cutting edges began to chip while working on the second billet, causing the clutch to slip. However, with a single tube drill on the same machine, the holes were opened five times faster and the drill head lasted more than a full shift.

Anatomy Of A Tubular Drill Like a gundrill, this single tube system re qu ire s a de dicate d machine, with a pressure seal at the top of the hole to contain the cutting fluid in its allotted space. Dedicated machines are equipped with a guide bush so no pre-drilled hole should be necessary. It is only necessary to use a pre-drilled hole with a conventional machine. A conventional machine can be retro-fitted to adapt to the double tube system, eliminating the dedicatedmachine requirement. Over the past

Todayâ&#x20AC;&#x2122;s tubular drilling systems tackle larger diameters and depths, outpacing gundrills by five to one or better

few years there have been several improvements in tubular drilling systems. First, the current selection covers a wider range of sizes and hole types, especially at the low end. Today, tubular deep hole drilling is available for diameters down to 8 mm for the single tube system with brazed inserts and 16 mm with indexable inserts. For a double tube system, the respective minimums are 18 mm and 18 mm. The inserts for tubula r drills a re ava ilable in PV D coate d g rade s, le ading to longer lasting edges at higher cutting rates, even on difficultchipping materials. However, as with any drilling operation, tubular drills require adequate spindle power and rigidity to achieve optimum cutting action down deep, especially when drilling solid material. Hole making involves more friction and dissipates more energy in coolant delivery and chip extraction in per unit volume of metal removed, compared to milling and turning.

Deep drilling has applications in automotive, turbomachinery and aircraft landing gear

Solid Carbide Drills For lower-aspect deep holes and diameters too small for tubular drills, the current solution is the solid carbide deep hole drill. They are suitable for high-volume automotive powertrain applications including crankshaft oil holes. Other target applications include deep holes in camshafts, connecting rods, cylinder heads, cylinder blocks, hydraulic blocks and die and mould work. The recommended depth-to-diameter limit for this drill is 22 to 1. A combination of feature s help the twist drills cut fa ster, straighter and deeper, last longer and expel chips more effectively. The high-strength core creates a more durable drill point and allows for deeper flutes, enlarging the exit path for chips. Chip clearance is facilitated by a helix angle of 30 deg. The typical tip of a deep hole drill has a 140 deg positive-point, four-margin design to preserve the edge, reduce thrust forces and aid in centring and tracking. A post-coat polishing step on the flutes, margins and cutting edges reduces friction and torque that can snap a drill very quickly. To further reduce friction, flutes are radially relieved, which reduces the diameter behind the tip and rubbing with the walls. The advent of new tools ha s mitigated the risks in deep hole drilling making it suitable to an ever-widening range of applications. MEN Enquiry No. 6105 September 2009 metalworking equipment news

Dr ll

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Core To The

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rilling involves the usage of drill bits to cut or enlarge holes. As the drill advances into the part, the fluted shank of the drill facilitates material removal leaving them as chips. Different tools and methods are used for drilling. Much is dependant on the size of the hole, the number of holes and the type of material.

Pre-Operation

Tool substrate dictates the performance of the drill and where it should be deployed. HSS

HSS-E

HSS-PM

(5 Percent Cobalt)

(8 Percent Cobalt)

(Powder Metallurgy) For high performance machining

For conventional use

Basic choice for industrial applications

For drilling of difficult-to- machine materials

Combines the performance of carbide with the toughness of HSS

Maximum tool efficiency is affected by the tool substrate. Surface treatments are important to drills as they affect cutting performance and contribute to the properties of the drill. Steam Oxide

Nitride

TiN

TiCN

TiALN or TiALCN

MoS2 or WC-C

(Gold)

(Grey-Violet)

(Black-Violet)

(Grey-Black)

High performance Conventional

High wear resistance

Popular surface treatment

Seldom used

multi-purpose coating

For steels

For ferrous materials only

For cast iron and aluminium

Cost efficient

For interrupted cuts in

Medium performance

difficult-to-machine materials

multi-purpose coating, for

Good anti-welding

higher cutting speeds

properties, reduces friction

For ferrous alloys

Used in combination with

(steels, cast iron), hard or

other coatings

abrasive materials Suitable for dry machining

metalworking equipment news September 2009

Suitable for dry machining

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Flute length is one of the most critical determinants of tool life: for longer tool life, the flute length should be as short as possible. Longer flute length results in a lower rigidity of the drill, which causes unstable drilling

Flute length (of new drill) Length of point

Penetration length

Thickness of workpiece

Clearance for chip ejection (2.0 x D)

Resharpening length

In most operations, the flute length can be calculated as follows: • Depth of hole • Bush length • Distance between bush and workpiece • 2x diameter (clearance for chip ejection) • Resharpening length • Penetration length

Bush Bush plate

Solid Twist Drill

Drill With HSS Indexable Inserts For drilling large holes, especially above 20 mm, or for combined operations + No Resharpening needed (throw-away inserts)

+ Multi-purpose tools

+ Multi-purpose tool holder, for several insert diameters

+ The widest range of diameters (from 0.05 up to 80mm or more) + Auto-centering point and sharp edges for lower cutting forces, compared

+ Available in four lengths

with carbide inserts

+ The longest tools (for instance 1000 mm, in diameter 10 mm)

+ Can be used in stacked plates and holes > 50mm - More fragile and not cost efficient in small diameters

This table shows the different type of drill available and the pertinent points of each individual drill like helix angle and point angle. Type N

Web Standard Web

Helix Angle 30º

Point Angle 118 or 120º

Use Ferrous materials Cast iron Short chip materials

Small Web

12 or 16º

118 or 120 or 130º

Bronze Brass Long chip materials

Small Web

35-40º

130º

Aluminium alloys Copper

Parabolic

Large Or Small Web

35-40º

118 or 120 or 130º

Easy-to-machine materials Long chip materials Difficult-to-machine materials

Highly Rigid

Large Web

20-35º

130º

(stainless steels, heat resistant steels, spring steels)

September 2009 metalworking equipment news

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During Operation The Basics Of Drilling Drilling is a machining operation in which the tool rotates with an axial displacement, except when mounted on lathes, where the drill is fixed and the drilled bars rotate. In drilling, the cutting speed varies along the cutting edge. At the drill point, the cutting speed is zero. The point does not cut, but pushes the metal.

Cooling & Chip Removal • Cutting fluids are essential for heat evacuation, chip removal and for lubrication, to prevent adhesive wear at the drill point (where the cutting speed is zero). • In drilling, soluble oils are usually preferred but oil can also be used • Soluble oils with additives significantly prolong the tool life of HSS drills. • The cutting fluid must be supplied directly to the cutting edge • The amount of lubricant required depends on drill diameter, hole depth and cutting data.

Benefits Of Oil-Hole Drills & High Pressure Coolant + Prevent chip welding + Prevent damaging chemical reactions that occur at high temperatures + Prolong tool life (up to 300 percent) + Allow an increase of cutting speeds by more than 30 percent + Improve surface finish

Chips’ Tale • Long curly chips stick to the flute and prevent the coolant from going through the hole. The result is tool melting or breakage. • When too short, chips are difficult to evacuate and sometimes pack in the flute. This worsens the quality of the drilled hole and shortens tool life.

Drilling chip shapes

Oil hole

metalworking equipment news September 2009

Chip form at each stage of the drilling process when a drill with point thinning is used.

ENQUIRY NO 115

Exotic? Not for Malcolm M. who has been a zookeeper for 40 years. The same goes for materials such as titanium, super alloys and stainless steels â&#x20AC;&#x201C; certainly not exotic for companies trusting the cutting tools from CERATIZIT. www.ceratizit.com

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Post Operation After Action Review

Benefits Of Point Thinning

Problem

Causes

Oversize hole

Unequal point angle

Solutions

Loose hold

Check holder and run-out Regrind and check precision

Varying length of lip Loose hold

Check holder and run-out

Unequal point angle

Regrind and check precision

Large length of lip

Irregular hole size

Standard drill geometry (without point thinning)

Decrease feedrate

Excessive feed rate

Use an oil-hole drill

Poor lubrication

Check holder and run-out

Low position accuracy

Spindle run out

Check alignment

Low alignment accuracy

Select a low cutting resistance thinning

Run out when cutting

Use a drill bush Use centering

Excessive tool wear Poor hole perpendicularity

Regrind and check precision

Unequal point angle

Check the workpiece position

Drilling surface not horizontal

Make a centre hole

Poor alignment (on lathes) Loose hold

Check holder and run-out

Unequal point angle

Bad cylindrical accuracy

Regrind and check precision

Relief angle too wide

Use a large web drill

Low drill rigidity

Poor surface finish

Poor regrinding

Regrind correctly, increase coolant

Cooling problem

volume and improve quality

Loose hold

Reduce feed rate

Excessive feed rate

Select a wide flute, high helix oilhole drill

Chip packing

Drill breakage

Low rigidity

Increase rigidity

Excessive feed rate

Reduce feedrate

Tool wear

Select a wide flute

Chip packing

High helix oil-hole drill

Difficult entering

Use a drill bush or centering

Advanced drill geometry (with point thinning)

Slipping chuck Tang breakage

Defect (damage, swarf) of the inner surface of morse taper

Modify the surface of the holder or change the holder

Tips For Special Drilling Conditions Drilling Of

Cross-Hole And

Inclined Surface

Non-Symmetric Hole

Mill a flat surface before drilling

To be avoided

Make a pre hole with a centre or starting drill

Use a highly rigid drill or a double margin drill

Use the back-up plate

Reduce the feed rate

Use a brad point or a step drill

Fill the hole with the same material in order to balance the cutting

Reduce the feedrate

Use a guide bush Use a highly rigid drill Decrease the feed rate

Drilling Sheets

Drilling Stacked Plates

Pipe Drilling

Use a bradpoint or a step drill

Reduce the feedrate

Use an end mill instead of a drill

Enquiry No. 6106 42

metalworking equipment news September 2009

Complete solution for all your measuring needs

Hardness Tester

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* Terms and conditions apply. Please contact your nearest Mitutoyo Office or Representative for more details.

Mitutoyo Asia Pacific Pte. Ltd.

ENQUIRY NO 121

Company Reg No. 892/1978-N

24 Kallang Avenue, Mitutoyo Building, Singapore 339415 Tel: (65)6294 2211 Fax: (65)6299 6666 E-mail: mapsg@mitutoyo.com.sg Website: http://www.mitutoyo.com.sg 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

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Product Highlights Dormer: High Performance Solid Carbide Drills

Komet: Continuous Insert Drilling

Dormer has developed solid carbide drills for machining composite materials. Although they are designed for use in polymer matrix composites, which are also known as fibre reinforced polymers, the drills work equally well in carbon fibre reinforced polymers and glass fibre reinforced polymers. The range features a point design that reduces thrust and torque requirements. This improves cutting efficiency and reduces splintering and delamination at exit. There is an internal coolant option for wet machining and a diamond coated option to further enhance tool life. The range is available from 2.38 to 20 mm diameter and with overall lengths up to 310 mm.

KUB Pentron by Komet offers continuous drilling up to 5 x D. The insert drill permits up to 20 percent higher cut and feed rate values than insert drills currently on the market according to the company. The tool is equipped with two square inserts that each have four effective cutting edges. The internal and external inserts have exactly the same shape. From all-round geometry to soft cutting and what is known as chip breaker geometry, inserts with high performance substrates and coatings are available for a wide variety of materials. There are three basic holder variants for 3 x D, 4 x D and 5 x D with parallel shank and ABS connection.

Enquiry No. 6107

Enquiry No. 6109

Heule: Combination Drill

Walter: Spiral Drill For Composites

The VE X-S tool combines solid carbide drill with Heuleâ&#x20AC;&#x2122;s snap chamfering system to drill and chamfer through holes in a single operation. Combining common operations increase the userâ&#x20AC;&#x2122;s productivity and efficiency while maintaining quality. The connecting system ensures accurate connection with the tool body and facilitates good transmission of power. It also allows quick and easy replacement of the twist drill. Suitable for drilling smaller diameters, it is appropriate for the automotive industry and other high production environments. Applications include brake discs, various tube applications and wheel hubs.

The machining of CFRP or GFRP is difficult and can mostly only be achieved economically using PCD-coated tools. Walter has now developed a PCD drill that is suitable for fibre-reinforced plastics. It can be reground and reconditioned several times so that tool costs can be reduced. The drill developed specifically for composite materials has a geometry that reduces cutting forces and therefore minimises the risk of delamination. During the machining of an 11.4 mm thick CFRP workpiece with fibres laid in various directions, the drill achieved a tool edge life of 600 holes, with negligible delamination.

Enquiry No. 6108

Enquiry No. 6110

metalworking equipment news September 2009

28. – 31. March 2007 · Hall 6/Booth 6H1-01

NE W

BSTA 500

BSTA 200 BSTA 250

The biggest obstacle in the production of Lead Frames and other sensitive electronic parts lies in maintaining the exact punch position during the cutting and coining process. Only BRUDERER can assure a prolonged tool life due to the unique ram guiding technology and the dynamic ram BDC adjustment.

Small in size but huge in precision and performance! The compact machine design of the new BSTA series guarantees the best possible cost /benefit ratio and is the perfect choice for small but precise stamped parts like connectors, contacts, watch parts or razor blades.

Different parts used in the communication industry require an extremely high level of accuracy arising from complex bending and coining stages. The BSTA series offer not only accuracy but also unsurpassed repeatability and high performance for increased output and reduced manufacturing costs.

Welcome to the world of high performance stamping.

Welcome to BRUDERER. from the unequalled durability of the stamping machines. The proof of this is a large number of satisfied customers – who have been using our products for decades – from diversified fields, including the connector industry, watchmaking,

BRUDERER PRESSES (Far East) Pte Ltd. 65 Loyang Way · Singapore 508 755 Tel.+65 65 46 81 21 · Fax:+65 65 46 81 31 info@sg.bruderer-presses.com

Headquarters BRUDERER AG CH-9320 Frasnacht · Switzerland Tel. +41 71 447 75 00 · Fax +41 71 447 77 80 info@ch.bruderer-presses.com

automotive and lamination industries. No matter how complex your application is, the worldwide BRUDERER team will find a solution that serves your needs efficiently and effectively.

www.bruderer-presses.com

ENQUIRY NO 197

“Made by BRUDERER” is a guarantee that has, over the past six decades, become a worldwide synonym for outstanding precision, performance, reliability and highly efficient stamping technology. BRUDERER customers also profit

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measurement

Accurate Measurement:

It’s Complicated Quantifying precision is a tricky business especially in metrology where the demands of accuracy is at its highest. Contributed by Yoshikazu Muraoka, senior manager, Mitutoyo Corp

he body is the part of each automobile that receives the greatest emphasis from manufacturers, in terms of both interior and exterior elements. This is because consumers look to the vehicle’s body not only for aesthetic appeal but also for crash sa fety, fuel economy, comfor t, low-noise operation, a sense of security, and many other factors, all of which affect the body’s overall completeness and quality.

metalworking equipment news September 2009

ENQUIRY NO 089

software&measurement

Since auto body manufacturing necessarily involves large workpieces and plastic working of thin plate materials, maintaining strict error tolera nce s for component dimensions to ensure quality is more difficult than when manufacturing smaller components such as engine parts. Due to differences in gravity effects and Coordinate Measuring Machine (CMM) structure, accuracy decreases from the vertical type to the horizontal type and multi-axis type in that order, although all three types use the same skills for manufacturing. C o n s e qu e nt l y, t he v e r t ic a l type is mainly used for moulds, inspection jigs and others, while the horizontal type is often used for moulded components. The multi-axis type is typically used for parts (such as reinforcement pa r ts a nd pa r ts used in collision tests) that do not require such a high level of accuracy, or in cases where the installation site must be moveable. In addition, a type of non-contact sensor called a line laser has been attached to the end of a CMM, and non-contact sensors are used alternately with contact sensors. They are increasingly applied to measure moulds and panels.

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A vertical type CMM is mainly used for mounds and inspection jigs

The Visionary Meanwhile, camera type (vision t y pe) mea suring systems have also been coming into wider use, often as add-ons to CMMs, where they are considered useful for the following reasons. • Measurement results from nonco n t a c t s e n s o r s a r e a l w ay s calibrated and can be compared with results from contact-type sensors. • Measurements can be performed automatically, thereby enabling unmanned operation (at night).

• The sensor angles that are set for e a c h wo r k p i e c e c a n b e s e t repeatedly by re -running the program. (The same laser angles are used for each workpiece. This helps to maintain precision during repeated operations.) • Non - contac t sensors ca n b e swapped w ith contact- t y pe sensors to enable measurement of workpieces or sites that are difficult for non-contact sensors (s u c h a s m i r r o r s u r f a c e s , transparent surfaces, or deep recesses). • The offline programming system enable s off line te aching a nd preliminary interference checks. • There is no need to attach a target for positioning workpieces before measuring, nor is there any need to place a target bar near the workpiece.

Shape evaluation is possible using non-contact sensors

metalworking equipment news September 2009

When measuring geometric elements, contact-type sensors are still widely used due to their high precision and the fact that operators are accustomed to them. As new types of non-contact sensors are developed, they are gradually being applied to a broader range of measurement applications.

software&measurement

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There is no standard universally accepted by both manufacturers and users to indicate the overall precision of non-contact sensors and their corresponding machinery

A Touchy Subject

Quantifying Measurements

Non - contact sensors have t he ability to obtain measurements from literally millions of measurement points, which are very useful when evaluating multiple curved surfaces, when measuring the thickness of materials, or for reverse engineering. Already, non-contact sensors are widely used to evaluate overall shapes, such as when maintaining the shape of moulded surfaces after insertions or when evaluating the shapes of resin parts, stamped parts, or castings (including comparisons with 3D CAD data). They are also widely used for partial assembly of auto body parts. W he n no n - co nt a c t s e n s o r s are used, large numbers of mea surement points ca n be m e a s u r e d q u i c k l y, a n d C A D comparisons can be displayed. In some ca se s, non - contact sensors are simply installed on their own stand, while in many other cases they are attached to industria l robots. Today, some CMMs equipped with contact-type sensors may come close to the precision of machines equipped with non-contact sensors, but they are no longer likely to exceed that level of precision. The post-processing ta sk of connecting measurement sites for each shot is performed using either a stand-based system or robotbased system.

Due to noise-related factors such a s mea surement points that a re re f le c te d ir re g u la rly f rom t he work pie ce sur face (due to different positions and different measurement point thicknesses even when the workpiece surface ha s zero thick ness), refraction that occurs in ambient air or lens aberrations, cause a cumulative error to occur. Given the fact that the more complicated a workpieceâ&#x20AC;&#x2122;s shape is, the more times the non-contact sensors must be realigned, it would be very convenient to have a CMM system that is prog ra mmed to automatically adjust them with a

high degree of precision. At present, there is no sta nda rd universa lly accepted by both manufacturers and users concerning how to indicate the overall precision of non-contact sensors and their corresponding machinery (CMMs, robots, etc), so each manufacturer has its own precision display method. Currently, Mitutoyo ensures traceability for equipment with noncontact sensors by comparing its measurement results with results from CMM/contact-type sensor combinations for which official standards exist. MEN Enquiry No. 6201

Mitutoyo:

Surface Measuring Instrument The SJ-500 by Mitutoyo is a form measuring machine system. The machine comes with a display panel with a 7.5 inch colour TFT LCD icon display and built-in printer. It has capabilities in levelling adjustment function and fine contour analysis supporting 43 types of analysis parameters, complying with surface roughness standards such as ISO 1997 and JIS 2001. The durable ceramic guide way that is free from wear and deterioration with age, is used to maintain the traversing straightness of the unit drive (x-axis).

Enquiry No. 6202

September 2009 metalworking equipment news

Fab&

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Form

The Big

Bend An aircraft component maker uses an all-electric tube-bending machine to increase productivity and quality. By Alan Pickering, MD, Unison

K N Aerospace has improved the efficiency and speed of tube bending operations at its wing component operation in Filton, UK, despite using demanding tubing materials and fabricating complex part shapes. Successive installations of allelectric tube bending machinery from Unison, culminating in the recent installation of combined leftand right-hand bending machines, underpin a fabrication process that now manufactures ultra-precise parts in very small batches. Among the challenges the tube bending team face every day are tubular parts with as many as 19 bends, complex shapes with multiradius coils, and bending titanium tubing with wall thicknesses up to 2.6 mm. These requirements are necessary in order to cope with the high-pressure systems on its customer Airbus’ double-deck A380 aircraft.

Kok Leng Yeo, Singapore

Right For The Job

metalworking equipment news September 2009

T h e co mp a n y ’s t ub e b e n d i n g facility fabricates around 3,000 to 4,000 parts per week, using tubing ranging from a few millimetres in diameter to over 100 mm. Aircraft applications are its main market, and the materials used include titanium, aircraft-grade aluminium and corrosion-resistant steels. Intere st in a ll - electric tube benders arose when there was a need to cope more efficiently with small batch sizes – which are typically less than 20 parts. Until some seven years ago, the workshop used hydraulically actuated bending machines, and the skilled attention required to reconfigure a machine for a new batch meant that scrap was almost invariably produced at each batch changeover – sometimes several pieces. For materials such as titanium this was extremely expensive, and they initiated a search for machines offering higher levels of accuracy and repeatability.

fab&form

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Fabricating complex tubular part shapes are part of the daily workload at the wing component facility

The company picked a 65mm diameter all-electric tube bender. Bends are typically made to 1 mm 3D envelope accuracy and sometimes as tight as 0.3 mm for the workshop’s military aircraft output. This ability to meet specifications reliably has allowed the workshop to eliminate a lot of the jig-based inspection processes previously favoured. Improvements in this process have helped achieve cost reductions on the component parts. Instead of inspection jigs, a coordinate measuring machine is now usually employed for post-bending inspection. Unison also wrote an interface utility to this to speed the development of new bending prog ra m me s by automat ic a l ly compensat ing for tolera nce variations in the first prototype component. Precision and repeatability of bending also allowed the component maker to eliminate any need for sawing operations following bending to meet the target length, yielding yet more savings. The workshop further capitalised on this attribute by purchasing many of its steel tubes pre-sawn to the exact lengths required. The intrinsic qua lity of the bend is another area where allelectric operation has supported improvements. The ductility of titanium in particular mean that slowing the bending process down improves forming. This can be a particular issue with some of the material that the company has to

process, such as thin-wall titanium tubing. Servomotor-controlled bending a xe s on the machine s a llow the company to create bending programmes that exercise precise control over all aspects of the tooling’s speed and force applied during fabrication. They are available at very low speeds, something that is impossible with hydraulic technology.

Ambidextrous Bending Machine The latest machinery installations (the two combined left and rightha nd bending machine s) were a c q u i r e d b y t h e co m p a n y to overcome a long-standing problem w ith some specific component shapes. These include tubular parts with lots of closely-spaced bends,

and tubes with coil structures that provide the mechanical flexibility to accommodate flexing movement during the operation of wing flaps. One part has so many bends that the company used to make it on two machines, to avoid collisions. The operator skill required was very high. Other coiled parts posed further problems, in that the need for variable radii necessitated an individual hand-crafted approach. GKN approached Unison with the problem, and a solution was devised in the form of combined left and right-hand bending machines – the first all-electric version of this automation. Workpieces can now be transferred automatically from left to right hand tool heads as many times as required to bend the required shape in a single stage. As a result, batch fabrication times have come down from three days to one and a half hours for one of the coiled parts, and from two and half hours to 30 minutes for a batch of the multi-bend part that used to involve switching machines. MEN Enquiry No. 6301

Some of the challenges include bending titanium tubing with wall thicknesses up to 2.6mm – to cope with the high-pressure systems on the double-deck A380 aircraft

September 2009 metalworking equipment news

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makers in the industry • Increase in circulation for the China market by 53.3%

• And, in India by 31.5% • Official publication for major trade events in the region, and the only magazine that is fully endorsed by 7 leading industry organisation and associations. • The most established metalworking journal in the region and the only publication in Asia that is BPA audited.

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The Engineering Journal For Manufacturing, Automation & Quality Control

ENQUIRY NO 130

industry

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spotlight

here was a time when the term ‘miniature-part machining’ or ‘Swiss automatic work’ mainly meant turning tiny parts in long runs on dedicated mac h i ne s. Ty pic a l work pie ce s needed turning only because, for the most part, they went into miniature rotating machinery. Their functions were mainly mechanical. Worn-tool replacement and jobto-job changeovers were tedious and time-consuming. Set screws and other clamp parts on the tooling were usually difficult to access and handle. Half the setup, or tool-replacement time was often wasted fixing a tiny clamp part or insert back into place, or trying to trace where it went when you dropped it. Not so anymore. Increasingly, today’s typical miniature part is as likely to be electronic or biomedical as mechanical, with more asymmetric features like flats and transverse holes. As a result, they require milling and C or X-axis drilling as well as turning. Repeat orders are involved more frequently with running design changes in the part, forcing changes in how they are manufactured in the first place. In miniature part m a nu fac t u r i n g e sp e c ia l l y, b i g changes are developing.

Bite-Sized Solutions For The

Medical Industry

Miniature parts play a big role in today’s medical industry giving the machining process a whole new complexion. Contributed by Yair Selek, project manager, Iscar Miniature Industries

Big Change In Small Parts To address these changes, many new ‘Swiss automatics’ are essentially miniature CNC mill/turn centres. Their tooling borrows some of the best ideas from mainstream CNC tooling to speed metal removal and reduce cutting forces while simplifying tool replacement and changeout. For example, some new tooling for miniature work ‘multi-tasks’ to reduce dead cycle time, free up turret space and reduce tool inventories. Other new replaceable-tip tools permit insitu insert changing for immediate re-starting with no offsetting. Virtually all new generation miniature tooling features highpositive presentation geometries for faster metal removal, together with lower cutting forces. In addition, most 54

metalworking equipment news September 2009

Today’s typical miniature part is likely to be electronic or biomedical as mechanical, with more asymmetric features like flats and transverse holes

industryspotlight

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new tooling for cam-type miniature Swiss automatics enables retooling or worn-tool replacement without having to remove the gang plate. (Figure 1) To handle the growing demand for asymmetric electronic and biomedical parts, more and more milling is needed. We expect this trend to continue. This is why so many miniature machine tool builders have added a milling axis to their products or even offered fully equipped CNC mill-turn centres in miniature sizes. Not surprisingly, replaceable tipmilling tools in miniature sizes are being introduced. The latest example is the Multi-Master replaceable-tip milling tool. While still chucked in the spindle, a single shaft of the milling tool can accommodate tips for shoulder milling, slotting, small-area face milling, profiling, drilling, chamfering and a variety of rampdown operations. (Figure 2)

Figure 1: New tooling for cam-type miniature Swiss automatics enables retooling or worn-tool replacement without having to remove the gang plate Figure 2: While still chucked in the spindle, a single shaft of the milling tool can accommodate tips for a variety of operations

Fig. 1

nearly triple by the year 2050. A l e r t Sw i s s a u to m a t i c a n d miniature machine shops have begun to prepare for this impending jump. The main differentiating feature in medical part manufacturing is that 90 percent of the implant components are made of titanium alloy Ti6Al4V, an unfamiliar metal in this industry. Some stainless steel are used as well, but surgeons prefer titanium because of its strength-to-weight ratio and the fact that human tissue adheres to it better. Compared with the more familiar fer rou s a nd a lu m iniu m a lloys, titanium is more difficult to machine. Think of it as stainless steel but with

Fig. 2

a tougher, stringier chip, plus a strong tendency for break-out at tool entry and exit points.

Tools For Ti Parts

Mincut MIFR, inserts and tools for small face grooving and turning by Iscar incorporate a design and clamping system that prolong tool life. The inserts and toolbars cover the diameter range from 8 to 17 mm and grooving depths up to 5.5 mm. As a result of its geometry and internal coolant delivery, the g ro oving to ol de live r s uninterrupted chip flow that can be safely used for grooving in deep holes. It can also handle rotating applications, functioning like a single point trepanning tool. Inserts, in hard, fine-grain grade IC 908 for high chipping resistance, are available in widths from 1.5 to 2.2 mm.

Iscar has a line of miniature inserts designed for titanium work. Their main characteristics are very sharp edges, and honed or ground surfaces to produce a fine finish and deny a foothold for built-up edge. Virtually all are available in carbide grade 908. As of today, the companyâ&#x20AC;&#x2122;s lineup of miniature titanium tooling includes solid carbide drills as small as 0.8 mm with P geometry and reamers with S geometry. In addition, there are four types of turning inserts with WF or MD chipbreakers and titanium versions of Jetcut parting tools. In the pipeline is a titanium version of the Tang-grip heavy-duty tangential parting tool. Carbide tools do not need to be coated because they do not react chemically with titanium as they do with steel, but do need to be very sharp. Also, to protect a ga i n st ove rhe at i n g at h ig he r machining rates, a PVD coated grades such as IC908 -IC907- IC1008 are recommended. The bottom line is, given all the new challenges and opportunities facing the miniature parts manufacturers, todayâ&#x20AC;&#x2122;s tooling will not hold businesses back. In fact it will help them move ahead. MEN

Enquiry No. 6401

Enquiry No. 6402

Innovations In Medical Parts Manufacturing One of the fastest growing segments of the miniature machining industry is medical parts, especially orthopedic implants and prostheses. The reason is the worldwide population of people over the age of 65, the biggest market sector for implants, is expected to

Iscar: Tools For Face Grooving & Turning

September 2009 metalworking equipment news

features

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Full Throttle

Ahead

Challenges are aplenty when machining aero parts but there are opportunities as well. By K S Sankaran, chief operating officer, Makino Asia.

and how we manage the process efficiently. Aerospace industries exercise strict control on material science and how the process and procedures are followed throughout the value chain. There are several auditing and inspection processes on infrastructure, systems and organisation before the vendor is qualified to supply parts. Every new initiative needs to be validated and certified.

Structural Parts

here has been a lot of debate and discussions about the current economic crisis and it is time we take a prudent view of the options and resources available to rebuild an organisation. Actions taken should wither the negative sentiments of market as companies prepare themselves for the industry to pick up steam in the coming months. The aerospace industr y has caught a lot of attention in the last 10 years as the Asian economy grew at an accelerated pace. The growth was both in business and leisure travel segments. Opportunities will be more apparent once the current economy gets corrected. If we take the ratio between aircrafts and human population of USA, both China and India trail by six and ten times respectively in terms of commercial aircraft population. It is an opportunity index but we have to admit that success of penetration purely lies in competitive advantage. While

metalworking equipment news September 2009

this is the case with every business, protective shield does not work in the current globalisation efforts.

Focus On Opportunities There a re oppor tunities for supporting industries. We can divide the opportunities into a few areas, like MRO (Maintenance, Repair and Overhaul), surface treatment, and parts machining. Makinoâ&#x20AC;&#x2122;s focus is on machining that fits well within the precision engineering environment. In the conte x t of mac h i n i n g, we c a n identify two segments that cover a wide range of parts. One segment is st r uc tu ra l pa r t s, which a re basically made from aluminium and more recently, composites have gained entry. The other segment is engine components, which are further divided into cold and hot section parts. While these two segments are worlds apart in the way the process is designed, we will address the critical challenges in each of them

Though aluminium parts appear simple to handle, we have to make good judgment on process to make it simple and cost effective. Many job shops tend to compete on low cost capital investments but later realise the complexities of handling large volumes of chips and process initiatives. We have come across structural parts in the section of 3x1.5 x 0.05m which run for couple of shifts. Components of that nature shed 90 percent of their weight from raw to finish. Traditional machining is slow and leaves most of the heat on the part and that slows down the Metal Removal Rate (MRR), otherwise the thin sections will warp and distort. When High Speed Machining ( H SM ) te c h nolog y i s appl ie d, the chip carries most of the heat and one can even touch the part immediately after machining. HSM is not about speed but encompasses numerous factors that influence HSM technology. Imagine MRR of 3 to 4 ltr of chips a minute as the capability of a machine but in actual machining, the chip volume is not just 4 ltr. It is about 20 to 30 times the volume of a billet. We need to have a holistic view of what it means to run programmes of large aluminium parts. The subjects in question are how such large volume of chips inside and outside the machine can be handled and how tool design can be optimised. There are tools that come with

features

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Though aluminium parts appear simple to handle, we have to make good judgment on process to make it simple and cost effective.

Metal removal is approximately 85 percent from solid for this part

shallow gash of flutes to provide higher st iffne ss a nd st reng t h, higher number of flutes to realise higher feed per rotation and above all, ability to evacuate chips from cutting zone. The other tricky part is to recover the coolant from chips, where the best way is to compact the chips into billet form that makes it dry and easy to transport.

Engine Parts They pose challenges quite the other way. Cold and hot sections have different material content and the latter uses exotic super a l loy s. I n m ac h i n i n g ra n k i n g, this may be the most demanding compared to other parts. These super alloys contain Nickel, Cobalt, (eg: Inconel 718, Hastelloy, Waspaloy) with metallurgical properties to withstand high temperature and are corrosion resistant. Currently, over 60 percent of such alloys are consumed by aerospace industries alone, providing great opportunity for supporting industrie s. The ma nufacturing strategy is quite different compared to aluminium structural parts. Super alloys are ver y tough and poor conductors of heat with machining index of approximately 30 percent of medium alloyed steel.

The machines must have high torque spindle and should be able to deliver full power at low base speeds. Spindle specification varies among numerous machine tools but we can see torque in the range of 300 to 1,000 Nm depending on 40 or 100 taper machines and spindles that can deliver 20 to 50 kW power. Here the chips are harder and due to poor conductivity of heat, the tool takes the brunt of machining heat. There are several inserts and hole making tools with special coatings for such applications. One must pay attention to tooling cost, which can be as high as 15 percent

of machining cost, versus in auto industry where the tooling cost is under six percent. Tool management is very demanding due to short tool life and long cycle time. Take the case of engine casings, which is a very typical part that runs anywhere between 50 and 100 hrs, depending on size or alloy type. Some companies recognise this phenomenon and deploy spare tool management, ID chips to monitor tool life and integrating them with tool management system.

Using CAD/CAM Another area of consideration is how we can minimise the time for first article approval with very limited use of expensive material, which may cost up to several thousands of dollars. One way is to use simpleto -machine material to tr y out programming tool path and establish quality parameters. In this ca se, the debugg ing time is short. An important factor is the programming technique.

Structural wings are made of Ti6Al4V

September 2009 metalworking equipment news

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Most of us simply group CAD/CAM as one system, but in reality, they are different in the way in which we manage each with specialised skill sets. CA D model comes from the design after series of validation for the functional requirement. Part manufacturers have no control over the model design. However, the trend among consumer industry is gradually shifting to combine CAD and CAM under one entity for concurrent engineering. Aerospace industry adopts a common brand of CAD software for most applications but there are many CAM packages in the market for manufacturers. The tool path a lgorithm differentiates one product from the other. Apart from the choice of CAM, the tool path programmer must be well versed in tool path management. The process should b e l a i d o u t f ro m ro u g h i n g to finishing, using wide range of tool dia meters w ith optimum stock removal for each tool. Here we have to consider heat distribution and wall thickness. S ome prog ra m mers tend to select a few tools and jump to final process, sk ipping few steps. It may appear simple and quick but it is inefficient, slow and leads to shortened tool life. A tool that is twice as long as the other one of same diameter will deflect eight times more than a short tool. It is like pumping the mechanical pencil

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Impellers are often made by 5-axis machining

It is possible to complete three processes on one machine

a few times more than necessary and the result is predictable.

Automation & Machining There is an increment in the entry of five-axis CNC machines as part of upgrading programme in many small job shops. Simply adding a fifth axis does not qualify the user to handle complex parts or reduce the number of set ups to become more efficient. Handling of five axis machines certainly benefited those in turbine business. There are other business opportunities for those who are familiar with running a business on aerospace parts like setting a system on traceability, process auditing, process planning, material

CAD/CAM facilitates the integration of processes 58

metalworking equipment news September 2009

management and more. The costs a s s o c i a te d w i t h c o m p l i a n c e , auditing, validation traceability and others need to be factored in the business if one intends to be a part of the supporting industry. One way to simplify is to get a robust ERP system and deploy automation to minimise human error and be compliant with the quality standards of aerospace industries. An extension of business that share similar organisation attributes is the medical engineering industry. Com me rc ia l a i rc ra f t i s not just about structural and engine pa r ts. The nature of travel ha s cha nged over the yea rs, br i n g i n g ne w e x p e r ie nce s for passengers. Reclined beds, in-flight entertainment and communication systems and interior furnishings of business jets offer tremendous opportunities. We also need to study the trend in materia l science whether in aerospace, oil and gas or medical and one example is the evolution of composite materials like carbon fibre reinforced plastics, glass fibre reinforced plastics and titanium matrix composites. New aircraft programmes may reduce the use of aluminium by as much as half. MEN Enquiry No. 6501

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Off

Indian Airport Infrastructure Market:

Carolin Chan, Singapore

Taking

Growth in aircraft, passenger and cargo movement in India is driving the government and private sectors to improve airport infrastructure. By Chethan Kambi, senior research analyst, South Asia and Middle East, aerospace and defense, Frost & Sullivan. Nina Chantrasmi, Bangkok, Thailand

arge-scale improvisation and expansion in the Indian airport infrastructure market coupled w ith active gover nment support for private participants, particularly in Greenfield projects, has enabled the sector to take huge strides forward. Observations indicate that long-term prospects for both private participants and the country look promising. An analytical report from Frost & Sullivan finds that investment in airport infrastructure was over US$5 billion in 2008. It is estimated to reach US$9 billion by 2013, of which close to US$6.8 billion is expected to come through Public Private Partnerships (PPPs). The addressed market includes both the Greenfield and Brownfield opportunities.

Growth Drivers The drivers for the a irpor t infrastructure development in India have been emerging business places, increased scope for connectivity, op e rat i n g mo de l s o f a i rl i ne s, government initiatives, and the dynamic growth of tourism. Growth forecast for the period 2009 - 2013 for international and domestic aircraft movement is 13 and 14 percent respectively. Domestic passenger growth is expected to be 20 percent while international is poised to be at 16 percent. The cargo growth is expected at 12 percent and 10 percent for domestic a nd internationa l respectively.

Inter nationa l inve stors a nd airport companies have evinced interest in the past during the bidding for Greenfield airports a nd ma ny such compa nies a re consortium partners in current a ir por t development projects. The government aims to bring in international players to incorporate operating efficiency and global standards.

There are immense opportunities in the next five years for all the vendors and stakeholders in the Indian airport infrastructure markets across all segments A not her key dr iver for t he airport infrastructure market is the upgradation of 35 non-metro airports identified by the Airport Authority of India (AAI).

Airport Projects These airports are planned to be upgraded in three phases. All these Brownfield airports can have private participants pitching in for the landside development and some of the areas on the airside development. The primary

challenges that face the market are financing and the identification of key geographical areas. Funding for the airport development projects encompasses equity from loans, government grants, investors, AAI, and consortium partners, all of which will be invested in the project in a phased manner to accommodate planned expansions. Funding can be purely public or public private. But Greenfield projects have remained public private alliances. No airport infrastructure has been developed using private funding. The primary infrastructure development model in India in the recent past has been PPPs. “The gap between developmental needs and funding is wide, posing limitations on the ability of the government to satisfy growth and opportunities for private players,” says Ratan Shrivastava, director of aerospace & defence practice at Frost & Sullivan. “Long-term sustainability of the airports in terms of funding is an issue for the government. Factors including the lack of indigenous technical and administrative expertise are perceived as prime reasons for poor planning and management, according to our recent research,” he adds. Nonetheless, there are immense opportunities in the next five years for all the vendors and stakeholders in the Indian airport infrastructure markets across all segments. MEN Enquiry No. 6502 September 2009 metalworking equipment news

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Vacuum Chuck:

Holding It In

Place

Vacuum systems are putting the squeeze on conventional clamping methods by providing safe and simple solutions. By Maren Roeding, PR manager, Witte Far East.

Using O-shaped seal, the clamping area (to which vacuum is applied) is limited according to the workpiece outline 60

metalworking equipment news September 2009

o fix and hold a part for CNC machining processes is not a problem. There are a variety of different clamping means available for todayâ&#x20AC;&#x2122;s users. These range from numerous variations of vices, to different kinds of threejaw chucks to magnetic clamping fixtures. That is assuming the work piece or material to be machined is suitable for these conventional clamping methods. However if ver y fragile materials, ex tremely thin work p i e c e s o r sp e c i f i c m a c h i n i n g requirements are involved, special clamping methods are essential. Many materials require particularly careful handling and can be warped or damaged by using jaws or vices. One possibility to hold sensitive

parts securely and safely without applying force is vacuum clamping technology. This is applicable on almost all established CNC machines and is also increasingly in use for measuring processes. Only a vacuum chuck and a pump are required. The pump evacuates air between clamping plate and work piece undersurface and allows a vacuum to develop. Depending on applications, systems ca n be ex tended with further accessories such as liquid separators for draining off coolant and lubricants, safety switches and manifold distributors.

Air Tight Chucks Clamping with vacuum constitutes a safe and simple method, which is used

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It is possible to hold extremely thin parts on chuck with completely porous surface

Vacuum grid chucks are suitable for many kinds of machining like grinding and light machining

for both light machining processes such as grinding and also for heavy cutting jobs. For different clamping or machining tasks there are different kinds of vacuum systems available. A further advantage of vacuum clamping is that up to five sides can be machined in one single clamping process. As there is only the need to align and fix the part only once, it leads to substantial timesavings. Certain factors such as size, weight, material and material thickness of the part as well as the type of machining involved have to be taken into account when choosing a clamping system. According to vacuum chuck m a n u f a c t u r e r W i t te Fa r E a s t (Singapore), grid type chucks are the most widely accepted. They can be used for both light and heavy cutting processes of almost all materials. Grid chucks are suitable for parts of different shapes and sizes. Standard modular chucks, which measure 200 x 300 mm, can be assembled to make a larger clamping surface. In addition, special contour chucks are possible. Using O-shaped seal, the clamping area (to which vacuu m is appl ie d ) is l im ite d according to the workpiece outline. The area outside that limited area is not affected by vacuum. For the next workpiece, only the O-shaped seal must be rearranged. The elastic seal offers a further advantage of being able to compensate unevenness on the part clamping surface. Depending on the seal diameter, unevenness and/or curvature of up to 1 mm can be evened out. This type

of vacuum chuck is versatile and covers many applications. However, there are limits when milling cutouts or contours or when machining fine, thin materials. Machining cutouts require s special attention. With conventional clamping methods, cutting through workpieces is a difficult process. Cut parts can fly off and cause accidents. That is why such parts are usually only surface-milled to a certain thickness, which leads to time consuming finishing work. The remaining material must be separated and deburred by hand.

Fine Applications Vacuum clamping technology is not only applicable for milling and turning, but also for other machining methods.

The full ra nge of applicability become s appa rent when using chucks with a universal porous and air-permeable surface. This type of vacuum chuck is frequently used for holding thin foils or rubber products. A preferred application is also in measuring and inspection. Parts such as circuit boards, circuit foils and electronic chips a re se cu re d a nd a re rendere d damage and deformation free by the porosity and evenness of the chuck over the whole surface. In order to reach an accuracy of 5 Âľm, the surfaces are generally diamond-milled. The chucks are equipped with fitted bushes around the edge to facilitate repeatable positioning using stops. These chucks also have the advantage that unused clamping surfaces do not need to be covered. D i f fere nt v acuu m cla mpi n g systems are available in standard dimensions of 200 x 300 mm since applications, which require the use of vacuum clamping technology, frequently prove to be difficult. Therefore design and manufacture of special solutions from chucks to complete engineering projects are often the case. MEN Enquiry No. 6503

Witte: Vacuum Clamping System The Vac Mat vacuum clamping system by Witte enables the clamping process to be simplified and sped up. This system comprises of a vacuum chuck on which flexible rubber mats are laid. The thin, soft mats have vacuum suction holes through which air is conveyed between part and mat clamping surface. Underneath the mats, plastic lugs serve to position them on the chuck. Adopting this system allows the milling of cutouts and slots. In addition, machining of outlines and chamfers, which would normally only be possible with special adapter plates, is feasible with this method. The system is capable of completing part machining in one clamping process.

Enquiry No. 6504

September 2009 metalworking equipment news

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Production Machinery Automation Market To Reach

US $21.2 Billion

With higher speed in machinery operations comes a greater need for process control in automated machineries. By Sal Spada, research director, ARC Advisory Group

ow power AC dr ive s, programmable logic controllers, general motion controls, computer numerical controls, and machine safeguarding represent the core automation for production machinery. The shipments of automation components to the OEM machine builder and system integrator market rely upon increasingly more advanced automation to remain competitive. T h e wo r l d w i d e m a r k e t f o r production machinery automation is expected to grow at a CAGR (compounded annual growth rate) of 3.4 percent over the next five years. The market was US$18.0 billion in 2008 and is forecasted to be over US$21.2 billion in 2013, according to a n A RC Adv isor y Group study. “More machinery applications a r e m ov i n g to h i g h e r sp e e d s o f op e r a t io n . P ro du c t io n r aw m a te r i a l s a r e b e c o m i n g l e s s consistent as recycled materials enter the market. The result is that machine builders need to consider a wider range of operation in the original design to accommodate changes,” says research director Sal Spada, the principal author of ‘Production Machinery Automation Worldwide Outlook’. 62

metalworking equipment news September 2009

Machine Builders In Emerging Markets Developing economies all over the world are increasing the demand for industrial production machinery at high rates. Feeding this demand has been a surge of regional machine builders in emerg ing ma rkets.

The worldwide market for production machinery automation is expected to grow at a CAGR of 3.4 percent over the next five years Domestic machine builders with a vertical specialisation have an advantage that goes beyond machine performance issues. It is the greater understanding of the technical and cultural needs of the end user customer that are now emerging as competitive advantages to machine builders in these markets. Regional OEMs, including both domestic and foreign

transplants, have leveraged their close proximity to the customer to create an understanding of the particular niche their customers operate in and are able to build machines, which are more suitable for regional issues. The growth of OEMs in emerging markets has enabled manufacturers who once relied on a comparative labour advantage to produce low valued products to become confident with employing machinery in their facilities that will enable production of higher valued finished goods. Because of this, industrial automation suppliers are also experiencing a tremendous growth in these emerging markets in both unit volume and unit value.

China & India Offer The Next Opportunity In many developing regions, such as China and India, the final goods exports are beginning to appear far more high-tech than the economics of comparative advantage would predict. Developing regions have realised that they can improve vertical specialisation by employing machinery with greater intelligence even if it me a n s t hat some of their workers may lose their jobs initially. MEN Enquiry No. 6505

ENQUIRY NO 129

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Stainless Steel Enclosures:

Protecting What’s Inside

ta inless Steel (SS) is a versatile material known primarily for its strength and corrosion resistant properties. They are utilised in the construction of enclosure solutions that satisfy applications across a broad spectrum of industries. W hile a wide a ssor tment of different components are housed within these enclosures and placed in disparate environments, there are common criteria that must be considered to ensure that the proper SS enclosure is chosen for a given application.

Grades Of SS Society of Automotive Engineers International (SAE) grade 304 SS is comprised of 18 – 20 percent chromium and 8 – 10.5 percent nickel. This is the standard type of SS used in the enclosure industry. Limitations of type 304 SS include use in outdoor applications near large bodies of saltwater where airborne salt can come into contact with the surface of the enclosure. A rule of thumb is that type 64

metalworking equipment news September 2009

304 SS should not be used within five miles of the coast, but the true distance at which corrosion can occur is dependent upon local weather patterns. Cold climate regions where chlorides are used as de-icing agents may also cause sig nifica nt pitt ing in t y pe 3 0 4 SS. For these reasons, it is not recommended in these situations without a regular cleaning regimen. F o r t u n a t e l y, m a n y o f t h e limitations of 304 SS are not apparent with the second most common SS, SAE grade 316. Generally 25 – 35 percent costlier than type 304, it has a higher percentage of nickel and an alloy addition of molybdenum (2 – 3 percent). The molybdenum provides better resistance to pitting and crevice corrosion, particularly in chloride-rich environments. The 316L SS commonly found in many enclosures has a lower carbon content (< 0.03 percent) than 304 or 316 making it more resistant to sensitisation (grain boundary carbide precipitation), a by-product of welding. Due to the ex treme heat in

Edmondo Dantes, Torino, Italy

Whether in automation, power supply box on machines or food packaging, stainless steel is used to construct corrosion resistant enclosures. By Nathan Xavier, applications engineer, Rittal Corp.

welding, localised corrosion can occur in SS in areas where the material has been welded, but the lower carbon content of type 316L prevents the carbide precipitation that can lead to weld decay and possible structural failure.

Finishing Touches Metals are finished not only for aesthetic purposes, but also to improve their corrosion resistant properties. Metal finishes are often designated by a system of numbers ranging from a No 0 finish (scaled black finish; not suitable for end-use) to a No 8 finish (highly polished, mirror-like finish). The No 4 finish used for most SS enclosures is a unidirectional finish with a maximum average surface roughness (Ra) of 0.64 micrometers. It is considered a general-purpose finish with a visible grain that helps to minimise the reflection of light. In addition to surface finish quality, the grain orientation of a SS enclosure can have a significant impact on corrosion resistance. A vertical grain orientation can help

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to provide an easier, more thorough cleaning since rainwater and gravity fed hose water will run parallel to the grains. By contrast, horizontal grain lines may retain corrosive contaminates, thereby expediting the corrosion process.

One of the most common applications for type 304 SS enclosures are for Industries Using Stainless Steel Enclosures housing controls used to operate General Food Processing 304 or 316 SS the machinery found in food and Milk & Dairy 304 or 316 SS beverage processing plants. Brewery and Wine 304 or 316 SS As a general rule, type 316 SS Bottling 304 or 316 SS SS can be susceptible to localised corrosion when enclosures are more reliable in& Beverage Food Bakeries 304 or 316 SS subjected to extreme heat during welding harsh chemical environments than Pharmaceutical 316 SS Chemical Petrochemical 316 SS other grades. The primary exception Offshore Drilling 316SAE SS 304 to this rule is exposure to nitric nitric acids are prevalent, applicat ions such a s shipping Marine Shipping 316 SS acids, which are principally used enclosures are usually preferred a nd offshore dr illing a nd, not Waste Water Treatment 304 or 316 SS in the production of fertiliser and because of their superior resistance surprisingly, in salt mines. Basically, Potable Water Treatment 304 or 316 SS explosives. to this specific substance. any application where high chloride Desalination 316 SS Distribution All SS has some resistance toWater Ty p e 3 1 6 S S e n c304 l o or s u316 r eSS s levels are present, type 316 SS is the nitric acids, but in industries where a re Pulp re co m me nde d for316mSS a r i ne metal of choice. Paper 304 or 316 SS It is impor ta nt to note that Rubber 316 SS neither 304 nor 316 SS will resist Materials Plastic 304 or 316 SS Ore 304 or 316 SS the chemical corrosion caused by Salt 316 SS hydrochloric acid. The acid will Mining Coal 304 or 316 SS destroy the passivity, leaving the surface of the metal defenceless.

Kalyana Sundaram, Chennai, India

Common Applications

Bjarne Henning Kvaale, Oslo, Norway

Variables Affecting Corrosion

It is important to note that neither 304 nor 316 stainless steel will resist the chemical corrosion caused by hydrochloric acid. The acid will destroy the passivity, leaving the surface of the metal defenseless. The following chart shows how 304 and 316 stainless steels react withFurther some of theBenefits chemicals present in common application environments.

Chemical Resistance Table

It is important to study the ability of a material to resist corrosion

Chemical Acetic acid (20%) Citric acid Fatty acids Fresh water Hydrochloric acid Nitric acid Phosphoric acid Sea water Sodium hydroxide Sodium hypochlorite (<20%) Sulfur dioxide Sulfuric acid (<10%)

304 SS Good Good Good Excellent Poor Excellent Poor Poor Good Fair Poor Poor

316 SS Excellent Excellent Excellent Excellent Poor Good Fair Fair Good Fair Excellent Good

Exactly how a metal will corrode in a given environment is often difficult to predict. Variables that can affect corrosion include the concentration and pH 5 of the corrosive material and the temperature of the environment. Generally speaking, stainless steel will corrode when exposed to strong acids or alkalis but the overall effect of this corrosion is dependent upon the temperature at which the corrosive attack takes place. It is important to differentiate the ability of a material to resist corrosion following prolonged contact and the ability of a material to resist corrosion resulting from occasional or possible accidental contact.

Enquiry No. 6506

Other material properties of SS enclosures offer advantages when compared to carbon steel models. A greater strength-to-weight ratio results in increased rigidity in larger enclosures, plus, stainless steelâ&#x20AC;&#x2122;s superior hardness provides an increased ability to withstand damage. W hen tota l life c ycle costs are taken into consideration, SS enclosure costs may be equal to, or in some cases, less than that of carbon steel. Although the acquisition cost of SS is greater than that of carbon steel, this is often offset by lower maintenance costs and a greater life expectancy. Once the serviceable life of the enclosure is over, SS also delivers yet another benefit versus carbon steel â&#x20AC;&#x201C; a better return on scrap metal. MEN Enquiry No. 6507 September 2009 metalworking equipment news

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exhibitions

Swiss-Made Precision Grinding Technology Seminar

eld at the Grand Copthorne Wa t e r f r o n t H o t e l o n May 29, 2009, the Swissmade Precision Grinding Technology Seminar showcased grinding, machining, measuring and other technologies from Switzerland. A s i a Pa c i f i c M e t a l wo r k i n g Equipment News was there and we spoke to the speakers involved in the seminar about their strategies in marketing and R&D.

Covering All Angles Balancing product innovation with customer service, Blaser Swisslube looks at providing complete solutions. well as new requirements from customers demand constant R&D. T he comp a ny a l so prov ide qualified on-site sales specialists and customer service laboratories to their customers in the automotive, aerosp ace a nd se m iconduc tor industry. Hans Niederhäuser, VP, Blaser Swisslube SEA.

Fa r f ro m ju s t fo c u s si n g o n performance and the economical aspects of the products, Blaser Swisslube pays attention to health, safety and the environment during development. New possibilities f rom raw mate r ia l sou rce s a s

Training & Know-How With uncertainties all around, the company has decided to focus on a sure bet, ie: training. “We have a company owned college where we train our field staff. We are convinced they can transfer their know-how in technology and

metalworking to our customers whom they have frequent contact with. Our policy involves more than bringing a drum of oil to our customers. We endeavour to find together with our customer the best solution for them through the quality of our products and customised services,” says Hans Niederhäuser, VP, Blaser Swisslube SEA. From the looks of things, they are applying that concept in Asia as well as they recently conducted their first training session in Singapore for their South-east Asian distributors. Enquiry No. 6601

Techno Savvy

Building a company based on technology can do no wrong especially in trying times.

Michael E Berne, MD, Hommel-Movomatic Suisse SA

Proud of the technology developed over the years, Michael E Berne, 66

metalworking equipment news September 2009

MD, Hommel-Movomatic Suisse SA, a branch of the industrial metrology division of Jenoptik is staying true to the tried and tested formula, which has served the company well. “For us, the main thing is to develop new technology. Our measuring devices boast a repeatability of 0.2 microns,” he says. For a company that prides itself in developing new technology, their commitment to R&D is evident as about 10 percent of their annual

turnover goes into R&D according to Mr Berne. It is perhaps not surprising that they managed to produce some exciting products over the years. Mr Berne explains: “We developed digital gauge heads and so far, we are the only one in the world who possesses this capability. As such, we are the only supplier of digital gauge heads.” With such advantage over its competitors, the company posted

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sales of €87 million in 2008 (US$122 million). They are however, not resting on their laurels. “We are

focussing on the US and also the East Asian market. Furthermore, we have launched a sales department

in Bangalore, India,” he concludes. Enquiry No. 6602

Meeting The Challenge

The gloves are off as the company aims to take on their competitors and match them stride-by-stride. H owe ve r t he si mpl i f ic at ion of the machine specification does not mean sacrificing accuracy,” says Roberto Alfonsi, area sales manager, Studer.

Future Trends Roberto Alfonsi, area sales manager, Studer.

Studer ma nufactures precision cylindrical grinding machines and is used to reacting to the market demands. In order to compete in the market today, the company is making changes to their machines. “The increasing demand for simplified CNC grinding machines in a lower price range is a challenge that the company has accepted.

Although the company is trying to compete on a more level playing field, they are under no illusions and taking the pragmatic approach is the order of the day. C o m p e t i t i v e n e s s h o w e v e r, requires R& D. Mr A lfonsi says: “Over 80 engineers working in our R&D department are analysing new trends and long term developments. The company invests some five percent of its annual turnover into this segment.”

Look ing a head he says: “Increa sed accuracy combined w it h incre a se d ma nu fac tu r ing flexibility and smaller batch sizes is a trend in the market today. Due to this, solutions like the complete machining of a component in one clamping, simplified part set-up or the combination of grinding with hard turning are some of the focal points for the future development of products.” According to Mr Alfonsi, some two-third of the machines delivered worldwide are machines tailored to a customer specific process, adding an additional capability to their arsenal of services. Enquiry No. 6603

Taking A Break From The Grind The availability of time brought about by the current downturn must be put into good use. in 20 08. This is a n increa se of 39 percent compa red w ith the previous year.

Technical Discussions

Walter Graf, marketing director, Winterthur Technology Group

De spite t he obv ious economic downturn, Walter Graf, marketing director, Winterthur Technology Group (WTG) is staying cool. “ We have double d ou r sales efforts in spite of the bad situation. In addition, we do a lot of research and conduct tests for our customers.” Net sales of W TG amounted to €219 million (US$303 million)

For better or worse, the downturn has given the company time to run seminars and build relationships with its customers. “In terms of technical advances and trends, it is different in grinding compa red to other industr ie s. You do not have this big jump or pa radig m shif t a s they ca ll it. But there is always a gradual improvement. For instance, there are always new abrasives coming out and we are testing them now in the industry. In super abrasives, there will be a shift I think towards peel grinding, replacing standard cylindrical grinding,” he says. T h i s g r a du a l i mp rov e m e nt

in g rinding technolog y w ill no doubt op en t he door to ot her opportunities like wind power. Mr Graf explains: “A growth area for us is in wind power. A lot of grinding is happening in gearboxes. They a re ver y complex because the rpm on the propeller is low and the generator works best around 1,500 rpm so you have to have an inverse reduction gearbox to get that speed.” Although there are major growth areas to go into, Mr Graf states that the company is concentrating on their core competency that is in the field of grinding. Grand Copthrone Waterfront Hotel Singapore May 29, 2009 Enquiry No. 6604 September 2009 metalworking equipment news

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Event Review:

MTA Vietnam 2009

he mood was buoyant after four days of brisk business as MTA Vietnam 2009 drew to a close on July 11, 2009. Some 7,270 trade visitors turned up at Vietnam’s manufacturing solutions trade event to check out first-hand the technologies showcased by more than 234 exhibiting companies. A b out 81 p e rce nt o f t he exhibiting companies hailed from 20 countries/regions. They included nine international group pavilions from Germany, South Korea, Japan, Singapore, Taiwan and Thailand. The opening of the show w i t n e s s e d t h e a t te n d a n c e o f many officials, including Hoang Van Dung, first vice chairman of Vietnam Chamber of Commerce a n d I n du s t r y ; Ph a n T h e H a o, repre sentative of the Ministr y of Industry and Trade in Ho Chi Minh City; Pham Thien Nghe, vice chairman of Vietnam Electronic Industries A ssociation; Nguyen M on g Hu n g, v ice c ha i r ma n of Vietnam Automation Association. T he e ve nt i s supp or te d by

metalworking equipment news September 2009

Vietna m’s Ministr y of Industr y and Trade, the Vietnam Chamber of Commerce and Industry, the People’s Committee of HCMC, the Vietnam Automation Association, the Vietnam Automobile Manufacturers’ Association, the Vietnam Association of Mechanical Industry, the Vietnam Electronic Industries Association, the Vietnam

Steel Association, and the Vietnam Society of Automotive Engineers. MTA Vietnam will return to Ho Chi Minh City for its seventh edition, from July 7 – 10, 2010.

Having The Desired Effect Local enterprises were out in force with 75 group delegations attending the show to learn about machine tools

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Big crowds were drawn to the live demonstrations

and catch live product demonstrations from manufacturing players from Vietnam and overseas. Exhibitors were happy with quality of visitors, and visitors were similarly impressed with the innovative range of machine tools and solutions showcased by global manufacturing companies. “I’ve witnessed a significant improvement in the quality of the show with many relevant trade visitors at our booth. MTA Vietnam continues to be the only manufacturing show in Vietnam that Nikon will continue to support and participate in,” said M Tsuji, GM of instruments department, Nikon Singapore. This year’s event saw the sales of some machines. One of them is the TruBend5130 by Trumpf. Occupy ing some 105 sq m, the company’s booth was visited by an estimated 400 visitors making MTA Vietnam a successful exhibition for the company.

A TruBend5130 was sold in MTA Vietnam this year bringing smiles all round

An estimated 400 visitors called on Trumpf at MTA Vietnam

Saigon Exhibition and Convention Center Ho Chi Minh City, Vietnam July 8 – 11, 2009 Enquiry No. 6605 September 2009 metalworking equipment news

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Wire/Tube South East Asia 2009

ith the recover y of the global economy in sight, the role that A si a p l ay s i n t h i s impending recovery is becoming increasingly apparent by the day. Put simply, Asian countries such as Thailand, will be responsible for the major proportion of global growth in the immediate and longterm future as the world rises up from recession. Countries that have strong manufacturing bases will continue to attract investments and grow stronger. This underlying trend highlights the relevance and timely convening of wire/Tube South-east Asia 2009 at BITEC, Bangkok, October 13 – 15, 2009. The total floor area for this year’s show is 15,000 sq m. The previous edition in October 2007 proved to be a successful debut, with the three-day event welcoming a total of 7,038 visitors. The international nature of the show was also reflected in the presence of visitors from 65 countries, with a good number from China, India, Malaysia, Singapore, Vietnam, Indonesia, S Korea and the Middle East.

Manufacturing Sector Of Thailand In Thailand, manufacturing’s share of GDP is at around 40 percent, compared with 25 percent in emerging Vietnam, and approximately 28 percent in neighbouring Malaysia. Forecasts point to a 42 percent contribution in Thailand by 2012, while economist expects growth in manufacturing to return in the second half of 2009 and continue through 2010. Thailand’s manufacturing sector 70

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production must also be approved by the BOI. Privileges include exemption of import duties on machiner y regardless of plant location and corporate tax exemptions. With the global automotive industry in the midst of a phase of restructuring that prioritises increased market competitiveness, global automakers are looking to consolidate their operations with Thailand certain to be high on the list of beneficiaries.

Exhibition Highlights

Participating companies from Germany and other parts of Europe highlight the internationality of the event

is anticipated to do particularly well in 2011 and 2012, when growth in output is forecast to reach and then exceed the long-term average. The smart operators will then be looking to invest in new capital equipment and machinery sooner rather than later. They will do so in anticipation of a firm recovery in 2010 led by exports. Long-term forecasts, meanwhile, continue to point to Tha ila nd, expanding its role as a key base for global vehicle manufacture and supply. They are backed up by an increasingly diverse and competent multi- tiered component supply segment and the government is doing its utmost to facilitate this. The Board of Investment (BOI), for example, is expanding its incentives scheme to cover automobiles that employ advanced new technologies such as hybrid drive, brake energy regeneration, and electronic stability control in order to attract further foreign direct investment in automobile sector. Investments in new assembly lines with the capability of manufacturing a minimum of 100,000 vehicles per year in any year within the first five years of operations would qualify, while plans for parts

Some 300 exhibiting companies from 30 countries including Austria, China, France, Germany, Italy, Russia, United Kingdom and USA amongst others will be making their presence felt at the event. E x hibitors at the event a re encouraged to maximise the use of the trade fairs’ business matching ser v ice. Simply put, exhibitors submit their target customer profiles to the organiser prior to the show, and these profiles are matched with the list of pre-registered visitors to arrange for one-on-one meetings at the exhibition. Both exhibitors and visitors, meanwhile, can take advantage of the Institute of Spring Technology one - day tra ining course on ‘Compression Springs – Material Selection, Manufacture and Design’. This course, sponsored by the IWMA Education Trust Fund, will take place on October 13. Exhibition hours are from 1030 to 1800 hrs on the first two days and 1030 to 1700hrs on the final day.

BITEC Bangkok, Thailand October 13 – 15, 2009 Enquiry No. 6606 September 2009 metalworking equipment news

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Event Preview:

EPM Linkage Vietnam 2009

aking place from October 15 – 17, 2009 at the Saigon Exhibition & Convention Center in Ho Chi Minh City is EPM Linkage Vietnam. The event will focus on industrial capital goods and technologies from the areas of automation, electricity and energy, environmental protection and water management, machine tools, as well as power transmission and control technology. There are in total five trade shows at the event this year, of which two are new. Returning this year are Machine Tool, Energy and Electricity and H2O and Environmental Protection. New shows this year will be Industrial Automation a nd Motion, Drive, Automation. By offering five trade shows, the exhibition networks related technology sectors meaningfully, enabling trade visitors to gain an overview of the various sectors at the same time within a compact display area. This interaction aids interdisciplinary ‘thinking outside the box’ and paves the way for making valuable contacts and furthering global progress. T he e ve nt i s supp or te d by industrial associations such as the German Engineering Federation,

the Singapore Precision Engineering & Tools Association, the Overseas Market Development Association Singapore, the Taiwan Mold & Die Industry Association as well as the Taiwan External Trade Development Council and the Vietnamese Ministry of Industry and Trade.

Gateway To SEA The show provides the platform for entry into the dynamic markets of South-east Asia and Vietnam in particular. The country’s economy is enjoying success, with GDP rising by 8.5 percent in 2007. After several record years in succession and overheating of the national economy in early 2008, the economic situation has now stabilised and growth in 2008 was as high as six percent. T he fa c t t h a t i n f l a t io n h a s dropped noticeably may be even more important. During that period, foreign direct investment rose to an all-time high in 2008. Vietnam is now among the ten most attractive countries worldwide for investment. Low wage levels naturally play a role as well. Moreover, a young, educated population and demographic growth of one percent in a country with 86 million inhabitants make Vietnam

The show paves the way for making valuable contacts

metalworking equipment news September 2009

increasingly attractive as a sales market. Of the 10 ASEAN members, Vietnam is already second in the list of ranked investment locations. T h e p o te n t i a l r e w a r d s f o r investors and overseas suppliers a re si g n i f ic a nt a s V ie t n a me se companies lag behind in terms of production methods. Given that many profitable largescale enterprises are to be privatised, it is anticipated that this lag will translate into concrete demand. The measures taken so far by the Vietnamese government to transform t he co u nt r y a n d it s e co n o m y into an industrial nation capable of competing on an international level are already having a positive effect. As a result, it is expected that Vietnam will enjoy stable and sustained economic growth in the medium to long term.

Saigon Exhibition & Convention Center Ho Chi Minh City, Vietnam October 15 – 17, 2009 Enquiry No. 6607

The event provides the platform for entry into the dynamic markets of South-east Asia and Vietnam in particular

ENQUIRY NO 088

www.epmlinkage.com

Akai Lin

176

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product finder

MMC: Indexable Ball End Mill

Sumitomo Electric Hardmetal: CVD-Coated Carbide Grade

A ra nge of index able ball end mills, the SR B series, ha s been developed by MMC. Inserts for the tool use grinding technologies that can provide both ground radius form and a co mp e t it i ve pr ice , therefore ma k ing the tool suitable for semif i n i sh i n g t h ro u g h to finishing applications for the die and mould industry. The inserts for the SRB series cover the diameter range required for mould and die applications. The series includes diameters 10 mm, 12 mm, 16 mm, 20 mm, 25 mm, 30 mm and 32 mm. Additionally the inserts have a chip breaker on the periphery to reduce cutting resistance when machining angled faces.

Acecoat AC820P is a carbide grade that has a stable and long tool life â&#x20AC;&#x201C; more than twice that of conventional tools. In the fields of parts machining for the automobile and heavy electric machinery, demand is growing each year for high-efficiency and long-life cutting tools. Sumitomo Electric Hardmetal developed the product with features like enhanced wear resistance and improved chipping resistance on edges. By obtaining the maximum film thickness, at least twice as much wear resistance as that of conventional grades is provided. Strength at cutting edges has improved by at least 1.5 times compared to existing grade.

Enquiry No. 6701

Enquiry No. 6703

Sandvik Coromant: Rigid Performance To General Threading

Sutton Tools: Faster & Longer Tapping

CoroThread 266, the size 16 insert complements the existing size 22 and 27 inserts and benefits from the iLock interface. Here, slots on the insert connect to the guide rail on the shim in the tool holder to provide secure insert clamping a nd comb at cut t i n g forces, improving thread precision and tool life. This stability on the Sandvik Coromant tool enables a wide range of thread forms to be completed in fewer passes, and with greater accuracy. Tool handling is made easier and correct insert mounting is achieved repeatedly, reducing time spent changing tools.

The Synchro Tap series is designed for machines, where the spindle revolution (A- axis) and feed movement (Z-Axis) are synchronously controlled. The series by Sutton Tools work in unison with the pitch controlling capabilities of the machine tool. This will not only reduce cycle time but also extend tool life. Key feature includes smooth flute and thread surface finish with post grinding surface treatment to further aid in reducing friction. In addition, the PM-HSSE material grade provides a combination of toughness, wear resistance and hot hardness for extended tool life on tools exposed to high cutting temperatures.

Enquiry No. 6702

Enquiry No. 6704

metalworking equipment news September 2009

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Widia: Productive Aluminium Milling

Prima: Five-Axis Laser System

The additions to the M6800 series of milling tools from Widia are aimed at increasing the productivity of aluminium milling for users and expanding the company’s shell mill body line with new metric sizes. The M6800 product line is engineered for high cutting speeds and feed rates with reduced cutting forces, and offers productivity in 90 deg shoulder-milling applications. They are applicable over a range of ramping, slotting, square shoulder, and face-milling operations in the general engineering, aerospace, die/mould, and power-generation industries.

The Laserdyne model 450 five-axis laser system is designed by Prima for percussion and trepan drilling of turbine engine blades, nozzle guide vanes, shrouds, and similar size components. Feature includes the Optical Focus Control (OFC). OFC provides focus control for ceramic coated as well as metal surfaces along with probing of the surface prior to and during laser drilling. Another feature is Active Optical Sensing (AOS). AOS is a combination of hardware and software, which monitors the state of optics during the drilling process. AOS warns the operator or will actually stop the process when the optics have been compromised.

Enquiry No. 6705

Enquiry No. 6707

Haas Automation: High-Performance Turning Centres

Do You know

No.1 the

Supplier for

Haas Automation has created a pair of turning centres, the SS-30 and ST-30. All castings were optimised using finite element analysis to produce rigid designs, while improving chip and coolant flow, and simplifying maintenance and service. The spindle heads feature a compact, symmetric design for thermal stability and rigidity, and the 45 deg wedge design increases the tool-mounting envelope and improves chip flow. Both machines feature an A2-6 spindle nose with a 3.5” bore, and a 10” hydraulic chucking system. Standard equipment on both the SS-30 and ST-30 includes a 15” colour LCD monitor and a USB port. Enquiry No. 6706

Distributed by

ow Order N

Phone +65 6569 1110 Fax +65 6569 2220 sales@sm-component.com

ENQUIRY NO 031

Standard Machine Elements…

September 2009 metalworking equipment news

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Walter Maschinenbau: Face & Contour Measuring Machine

With the rounding sensor (SKV ), Walter Maschinenbau has made it possible to measure µm-precise face a nd contour cutting edge rounding on cutting tools precisely. The measurement of edge rounding is a starting point for further optimisation of the tools with regard to their service life and cutting ability. The edge roundings are designed to be smaller and, in part, also asymmetrical. Up to now, the cutting edge radius is difficult to be measured precisely. The rounding sensor from Walter makes this possible. The cutting edge rounding sensor is available as an option for the Helicheck Pro/Plus measuring machines. Enquiry No. 6708

Ametek: Alloys For Engineered Shapes

The combination of strength, formability, non-sparking and anti-galling characteristics of Ametek’s Pfinodal alloys make them a choice for a range of land-based or off-shore oil and gas applications, especially as a suitable replacement for beryllium copper components. The alloy consists of copper, nickel (15 percent) and tin (8 percent). They are made using powder metallurgy technology. The homogeneous single-phase structure of the alloy achieves uniformity, formability, strength and ensures reproducible properties. They are available in a variety of forms, including rod/bar, plate, tube and as custom engineered shapes and finished parts. Enquiry No. 6710

ISA Technology: Laser System

YCM: High Performance VMC

The NSV156A by YCM combines high-speed cutting, chip dispensing and performance. Features include a 15,000 rpm high-speed IDD spindle, 22 kW high performance spindle power, maximum 0.9 g axial acceleration and feedrate of 48 m/min. The VMC consists a reinforced body structure through FEM analysis. The structure is strengthened while its weight is reduced to provide best possible cutting performance and rigidity. In addition, there are four high rigidity roller type guideways on Y-axis to ensure levelling precision.

With the Teleos laser system, Diode Laser Concepts has a laser diode with good optical stability and performance. The company’s optical stability specification communicates with the electronic, therma l a nd me c h a n ic a l s t a b i l it y de si g n fe at u re s t h at a re incorporated into the laser system. In addition, the system offers the highest output power at 643 nm and 405 nm, up to 60mW at the fibre output. Customisable areas include the fibre type, length and termination. For customers needing more than 60mW or more than one wavelength, the company offers custom systems that incorporate multiple fibre pigtailed laser diodes into a single mechanical housing.

Enquiry No. 6709

Enquiry No. 6711

metalworking equipment news September 2009

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Showcase

High Performance Viewing & Measuring Systems The Mantis Optical System • Superior ergonomics, improved productivity • Long working distance, easy manipulation • Superb hand-eye co-ordination

Linear Stages with Positioning Feedback • Resolution of choice: 1µm or 5 µm • Customizable travel length • Manual and motorized versions available • Low profile design

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 • Spooling Machines for Optical Fiber

ENQUIRY NO 124

ENQUIRY NO 122

2D Video Measurement System • Low investment high value • High resolution video images • Equipped with Digital Micrometer • XY travel range 50 x 50mm

Bi/Trinocular Stereo Zoom Microscope • Economical and high performance • Versatile setup for different applications • Long working distance

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.

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

Henko Machine Tools Pte Ltd is the authorised Distributor for LEISTRITZ, distributing the Profile and Keyseating Machine. Together with LEISTRITZ unique toolings, the Profile & Keyseating machine is able to manufacture part/components with either taper or parallel keyways. With the use of this machine, it offers you the Flexibility, Productivity & Quick Service.

MACHINERY Co Ltd

1870-Toide, Takaoka-City Toyama Pref Japan 9391192 Ph: (81)766-63-1100 www.kitamura-machinery.co.jp

Henko Machine Tools Pte Ltd No.23 Kaki Bukit Industrial Terrace Singapore 416103 Tel: +65 6846 4666 Fax: +65 6846 4555 For enquiries, please email: info@henko.com Website: www.henko.com

ENQUIRY NO 120

ENQUIRY NO 101

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.

September 2009 metalworking equipment news

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OGP: Benchtop Multisensor Measurement System

Witte: Sandwich Plates

SmartScope Vantage 300 by OGP offers the measurement versatility and accuracy needed for demanding parts. With 300x300x250 mm XYZ measurement volume to acco m mo date la rge p a r t s, t he multisensor combines video and autofocus to deliver productivity. Features include an elevating bridge design that yields large XYZ travel with compact machine size and a telecentric TeleStar 10:1 metrology zoom lens that provides the optical performance over its entire range. The system comes standard with MeasureMind 3D multisensor metrology software that accepts data points from all sensors and builds a model in 3D space. Optional add-ons include through-the-lens laser, touch probe or micro-probe. Enquiry No. 6712

Renishaw: On-Machine Geometric Measurement

Sandwich plates are often used as a base for measuring fixtures and structures. However they are increasingly being used as a means of transport between measuring centre and assembly area. Witte Far East has developed a multi direction drive sandwich plate that is easy to move and steer. The character of the rollers enables simple movement and positioning, which is remote controlled with the help of a joystick. It is easy to rotate the sandwich plates on the spot or drive sideways. The rollers have a outer surface, which ensures careful treatment of the floor. Enquiry No. 6714

Z Corp: Material For Tougher 3D Printed Parts

Renishaw has released a version of its OMV Pro software. It works with touch probes to give on-machine part verification and machine simulation capabilities. Now supporting Microsoft Windows Vista, the OMV Pro 2.02 adds co-ordinate measuring machine style capability with an extended range of geometric dimensioning and tolerancing functionality. The product also allows users of machine tool touch probes to verify the accuracy of free-form and prismatic parts, without ever moving the part from the machine-bed. In addition, it allows the use of two or more alignments in a program, which is a benefit to users working with components on multi-axis machines or with large or flexible components.

Z Corp has developed the zp150, a composite build material for its 3D printers, the ZPrinter 450 and 650. The material improves the streng th and colour of 3D printed models for 3D CAD while producing whiter whites for applications such as architectural modelling where true white is the traditional standard. When using the material, water can be used as the curing agent in finishing multicolour models, making it suitable for early prototypes and education environments. In addition, the product enables some 40 percent increase in â&#x20AC;&#x2DC;greenâ&#x20AC;&#x2122; and final strength of parts.

Enquiry No. 6713

Enquiry No. 6715

metalworking equipment news September 2009

Exhibition Programmes

2009

SeptEMBER 1-5 China International Equipment Manufacturing Expo

Shenyang International Exhibition Center 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

8 - 10 Metalex Vietnam HCMC 2009 Saigon Exhibition and Convention Center (SECC) Ho Chi Minh City, Vietnam Reed Tradex metalexvietnam@reedtradex.co.th www.metalexvietnam.com

13 – 15 Wire South-East Asia 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

14 – 16 China Steel Tube Expo 2009 Tianjin Binhai International Convention & Exhibition Centre Tianjin, China Shanghai Shenshi Exhibition Service tubeexpo@gmail.com tj.gangguan-expo.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

20 – 24 Vietnam International Industrial Fair Vietnam Exhibition Fair Centre Hanoi, Vietnam VEFAC vefac@netnam.vn www.vietnamindustrialfair.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

19 – 22 Metalex 2009

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

December 2-5 Manufacturing Indonesia 2009 Jakarta International Expo Kemayoran Jakarta, Indonesia PT Pamerindo Buana Abadi info@pamerindo.com www.pamerindo.com

27 - 31 Korea Metal Week 2009 Korea International Exhibition Center Seoul, S Korea Korea Trade Fairs master1@ktfairs.com korea-metal.com

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ENQUIRY NO 106

Precise solutions lead to quality results every time. Whether drilling, tapping, boring, or reaming, trust Kennametal, the world’s leading tooling provider, to deliver the most complete portfolio of holemaking and finishing products. From solid-carbide to modular to indexable and more, Kennametal’s precision tools are built for performance, accuracy, and speed.

So lid -C ar bi de

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We set out to create the most productive tools in your arsenal — and did not stop until we reached perfection. To discover the best tool for any demanding job, call (65) 6255.9222 or visit www.kennametal.com.

DRILLING/TAPPING

Y-TECHTM Drills Unmatched performance in stainless steel and other challenging materials. KenTIPTM Modular Drills No regrinds, no reconditioning costs. SPFTM Drills Reduce composite hole expenses by up to 70%. Solid-Carbide Drills Produce superior holes in stainless steel, steel, and cast iron. KSEMTM Plus Modular Drills Increase metal-removal rates by up to 100% — with 200% better tool life and 10xD L/D capability.

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We went searching for productivity — and found perfection.

BORING

DFSTM Indexable Drills For unparalleled short-hole quality and size control — in any workpiece. Solid-Carbide Taps Cut operating costs by as much as 65%.

RomicronTM System Unsurpassed speed and accuracy in exceptionally precise applications. You can actually see, feel, and hear each 2-micron diameter adaptation.

REAMING

RIQTM Padded Reamers Blade easily adjusts — with four cutting edges per insert. RIRTM Reamers Specifically for exacting, small-diameter work — just one screw to set.

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Australia 7 800-666-667 • India 91-80-2219 8341 • Japan 81-3-3820 2855 • Malaysia 60-3-5569 9080 • Singapore (65) 6255.9222

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