Canadian Metalworking by Annex Business Media

Performance

Steels

30 MACHINING: Solutions from A to Z.

Productivity

IMTSQuality

Controls Growth

Multi-tasking

2010

45 CUTTING TOOLS: Extending tool life in the hot zone.

Turning

51 FABRICATING: Cutting costs with waterjet.

Laser

Improvement Lathes Grinding Job Shops Machinery Cutting tools

Metal

August 2010 â&#x20AC;˘ www.canadianmetalworking.com

Machine Tools

61 WELDING: 5 factors to

consider for automation.

Very BIG and beautifully engineered

Hurco’s NEW DCX Series. High Capacity, Dual Column Machining Centers.

Because SIZE is important... CANADA

www.hurco.ca

VMX Series High Performance Mills

800.992.7314

Travels Spindle Tools

VM Series U Series (5-Axis) SR Series (5-Axis) General Purpose Trunnion Table Swivel Head, Rotary Table Mills Mills Mills

DCX22 - 40T 86.5″ x 66.9″ x 29.5″ 8k, 10k or 15k 40 CAT (BT) 40

DCX Series Dual Column Mills

Z Series Zone Mills

DCX22 - 50T 86.5″ x 66.9″ x 29.5″ 6k 40 CAT (BT) 50

HTX Series Horizontal Mills

Machines shown with options. Information may change without notice.

DCX32 - 50T 126″ x 82.7″ x 36.2″ 6k or 10k 40 CAT (BT) 50

TMX Series High Performance Lathes

TM / TMM Series General Purpose Lathes

See us at IMTS Booth S-8336

Inside this issue... Volume 105 | No.6 | August 2010 | www.canadianmetalworking.com

INDUSTRY REPORT

WELDING

SHOW PREVIEW

AUTOMATION

MANUFACTURING SUCCESS ... 16

IS IT TIME TO AUTOMATE?........61

Following on the heels of a tough economic period, North America’s biggest event for manufacturers holds the promise of success.

IMTS At-A-Glance.......................... 18 Exhibitor Spotlights........................ 19 What to do Guide......................... 27

MACHINE TOOLS

Five factors to consider before making the decision.

PRODUCT REPORT TOOLS OF THE TRADE..............56 Our periodic look at the latest developments for machining, fabricating and welding.

CASE STUDY

QUALITY CANADA

FROM A TO Z ......................... 29

MEASUREMENT

An Ontario job shop aims to help manufacturers from start to finish.

(between pgs 32-33)

HANDHELD GAUGES .................3

An expert’s outlook on where developments for handheld gauges are heading.

BUSINESS REPORT MACHINE VISION

ENERGY REDUCTION

ENERGY TO SAVE.................... 39

Cut energy consumption and costs without compromising your operation.

CUTTING TOOLS

BETTER VISION ..7 A new technology to verify manufactured parts.

SOFTWARE

TURNING

HARD WORK .......................... 43 Extending tool life in the hot zone.

SPC SOFTWARE.......................10 8 Do’s and Don’ts.

DEPARTMENTS

FABRICATING WATERJET CUTTING

CUTTING COSTS ..................... 51 Ontario fabricating shop cuts costs, improves turnaround time with new waterjet cutting system.

Upfront .......................................... 6 News ............................................ 8 Calendar ..................................... 10 Shop Talk..................................... 12 Metal...Works .............................. 64

Instant access online

ONLINE SUBSCRIPTION SERVICES

In addition to the valuable and insightful information already available on our Website, you can now interact with CANADIAN METALWORKING to get the most up-to-date information about your subscription.

Online Subscription Services

This is a secure site. It’s easy to use and most of all convenient. You can renew your current subscription or apply for a new subscription, change your mailing address, report missing issues and check the status of your account.

Subscribe to CANADIAN METALWORKING Sign up for our FREE e-newsletter Verify your account status Change your mailing address

Check our publishing schedule Tell us you’ve missed an issue Ask us a question Renew your subscription

www.rogersb2bmedia.com/cmm www.canadianmetalworking.com | AUGUST 2010 | 5

SENIOR PUBLISHER Larry Bonikowsky 416-764-1489 | larry.bonikowsky@rci.rogers.com EDITOR Mary Scianna 416-764-1540 | mary.scianna@rci.rogers.com ART DIRECTOR Jill Nelson 416-764-1518 | jill.nelson@rci.rogers.com SALES MANAGER Steve Devonport 416-764-1498 | steve.devonport@rci.rogers.com CIRCULATION MANAGER Bibi Khan 416-764-1450 | bibi.khan@rci.rogers.com JUNIOR WEB PRODUCER Jessica Mirabelli 416-764-1316 | jessica.mirabelli@rci.rogers.com PRODUCTION MANAGER Kristen Hrdlicka 416-764-1692 | kristen.hrdlicka@rci.rogers.com ROGERS PUBLISHING LIMITED .............................................................. PRESIDENT AND CEO Brian Segal ROGERS BUSINESS & PROFESSIONAL PUBLISHING ........................ SENIOR VICE-PRESIDENT John Milne VICE-PRESIDENT, FINANCIAL PUBLISHING, BRAND EXTENSIONS & ONLINE SERVICES Paul Williams DIRECTOR OF AUDIENCE DEVELOPMENT Keith Fulford 416-764-3878 | keith.fulford@rci.rogers.com EXECUTIVE PUBLISHER, INDUSTRIAL GROUP. Tim Dimopoulos 416-764-1499 | tim.dimopoulos@rci.rogers.com CORPORATE SALES....................................................................... Sandra Parente, GENERAL MANAGER, CORPORATE SALES

416-764-3818 | sandra.parente@rci.rogers.com

WEB ............................................................................................ GENERAL MANAGER, ONLINE OPERATIONS David Carmichael

416-764-3820 | david.carmichael@rci.rogers.com

RESEARCH ................................................................................... SENIOR DIRECTOR, ROGERS CONNECT MARKET RESEARCH Tricia Benn

416-764-3856 | tricia.benn@rci.rogers.com

EVENTS ....................................................................................... GENERAL MANAGER, CONFERENCES & EVENTS Stephen T. Dempsey

416-764-1635 | steve.dempsey@mtg.rogers.com

HOW TO REACH US...................................................................... TORONTO OFFICE One Mount Pleasant Road, Toronto, ON M4Y 2Y5

Tel: 416-764-2000 Fax: 416-764-1735

SUBSCRIPTION RATES Canada $55.00 per year, Outside Canada $90.00 US

per year, Single Copy Canada $8.00. Canadian Metalworking is published 9 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. SUBSCRIBER SERVICES To subscribe, renew your subscription or to change your address or information… please visit us at www.rogersb2bmedia.com/cmm Canadian Publications Mail Agreement No. 40070230 US POSTMASTER Periodicals postage paid at Lewiston, NY, 14092 as well as US office of publication Lewiston NY. Send address corrections to Box 4541, Buffalo, NY 14240 Taiwan: Worldwide Services Co. Ltd., P.O. Box 44-100 Taichung, Taiwan, R.O.C. Tel: 886-4-3251784 Fax: 886-4-3252967 Email: sales@wwstaiwan.com MAIL PREFERENCE Occasionally we make our subscriber list available to reputable companies whose products or services may be of interest to you. If you do not want your name to be made available please contact us at rogers@ cstonecanada.com or update your profile at www.rogersb2bmedia.com/cmm. CM receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. CM, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. CM accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. CM, established: 1905 is published 9 times per year by Rogers Publishing Limited, (www.rogerspublishing.ca), a division of Rogers Media Inc. ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities. Our environmental policy is available at www.rogerspublishing.ca/environment. Content copyright ©2010 by Rogers Publishing Limited, may not be reprinted without permission.

6 | AUGUST 2010 | www.canadianmetalworking.com

Upfront Me Too or Go To? Where do you think manufacturers can make more money: selling popular me-too products or novel ones? In the short term, selling popular me-too products will likely help a company make more money. I don’t think this approach is sustainable though and in the long run, carving a niche as a manufacturer of an innovative product that fits a need and no one else has thought about is more likely to garner higher profit margins. How one goes about creating one-of-a-kind innovative products that meet a market need is easier said than done. Monetary investment in research and development is one obvious approach, but more importantly, a keen eye and an ability to think outside the box—some might call this having a vision—are two other critical tools to help you gain a competitive edge. Take the environment as an example. Everyone seems to be jumping on the green bandwagon. Just look at these recent headlines: •Solar-powered plane makes successful maiden ﬂight without use of fuel (April, 2010) •Study on aluminum shows better energy savings over steel (April, 2010) •All-composite seaplane from Dornier Seaplane Co. (May, 2010) •Linamar to make wind turbine components (May, 2010) As a visionary, think-outside-the-box kind of manufacturer, what opportunities does this type of activity present for you? If, for example, solar-powered aircrafts that don’t require fuel are the future, what type of materials and components are going to be required and does your manufacturing operation have the skills and the know-how to create the products this industry will need? If aluminum is more energy efficient than steel, can you incorporate more aluminum into the steel products you’re making to offer your customers more energy efficient components? And as the wind turbine manufacturing industry continues to grow in North America, can you offer novel components (energy efficient, lighter weight parts, coated with a nanotechnology “smart” finish that detects malfunctions and sends error reports to operators)? You can scoff at the idea, but if Canadian manufacturers can position themselves as the go-to experts in a niche area, they can collectively create a stronger manufacturing environment in the country. In the April 2010 issue, I noted manufacturers must invest in new technologies to gain a competitive edge. But that’s not enough. Manufacturers must use these new technologies to become leaders and go-to experts in their respective areas of specialties. There are resources for manufacturers who want to become more competitive. One is the Scientific Research and Experimental Development program, a federal tax incentive program that rewards Canadian companies who innovate. According to Jacob Senderski of BeneFACT Consulting, manufacturers can recover between 82 and 33 per cent of eligible payroll costs and between 48 per cent and 20 per cent of other expenditures such as materials, sub-contracts and capital. And you don’t need a dedicated R&D facility to participate in the program. If you’re testing new cutting tools, new materials or a new machining process, you can be eligible. So let’s become the go-to experts and drop the me-too products. MARY SCIANNA, EDITOR

If you want to comment on editorial in the magazine, I’d like to hear from you, so please contact me. mary.scianna@rci.rogers.com

HORN - THE LEADERS IN GROOVING TECHNOLOGY GETTING A GRIP ON PRODUCTIVITY PARTING OFF Pity the poor part-off tool. Under pressure all the time. Being worn down on all sides. Engaged in a constant tug of war with the material. Working in hot, cramped conditions. At HORN, we thought about this - a lot. The HORN part-off system draws on our extensive experience of grooving. It has positive geometry to optimise machining performance and tool life. Cutting edge corner and insert flank relief helps to minimise flank wear. And the extra long super secure six sided insert sits in a precision machined seating to maximise security and minimise movement. We couldn’t do much about the hot cramped conditions, but we have equipped our part-off tooling to survive them. HORN – INTELLIGENT TOOL DESIGN AT WORK.

HORN GROOVING • PARTING OFF • GROOVE MILLING • BROACHING • PROFILE MILLING • REAMING HORN USA, Inc. • 320 Premier Ct. • Suite 205 • Franklin, TN 37067 Phone: (888) 818-4676 • Fax: (615) 771-4101 • Email: sales@hornusa.com

•

internet: www.hornusa.com

News Metric Machine to sell Hurco in Western Canada

Hurco Canada Ltd, Mississauga, ON, has selected Metric Machine Tool Service Ltd., Edmonton, AB, as a full service distributor for Alberta and Saskatchewan. The 28-year old distributor has developed a reputation for exceptional service in the region and is recognized for its experience in the machine tool industry, says Joe Poulin, sales and operations manager for Hurco Canada. “I can’t say enough great things about Metric Machine, they impressed me from the day I met them. We wanted to have a company that had first class service support and I am confident they will serve all of our current and future customers beyond our expectations and I am pleased to welcome them to the Hurco family,” says Joe Poulin sales & operations manager for Hurco Canada. Metric Machine’s Dan Smith, service general manager, and Brian Horak, sales manager, are confident the expanded line of Hurco machine tools powered by the integrated Hurco control will have immense benefits for customers in Alberta and Saskatchewan. Hurco recently added a three meter machine to its DCX Series, which is beneficial for energy and mining applications. The dual-column design of the two meter DCX22 and three meter DCX32 provides excellent thermal stability and dynamic behavior, says Hurco. For turning, Hurco has added more machines to its TMX line of high performance slant bed lathes, which also includes turning centers that have multi-tasking features, such as live tooling and sub-spindles.

FMS reps Mitsubishi equipment in Eastern Canada

Fabricating Machining Solutions (FMS), formerly known as Advanced Fabricating Machinery (AFM), Mississauga, ON, is the new Canadian distributor for MC Machinery Systems Canada Inc., Richmond Hill, ON. FMS, which recently changed its name to reflect its growing business, will represent Mitsubishi’s laser, waterjet and press brakes in Eastern Canada (Ontario to the East Coast). “We are excited to partner with Bob Watson, president of Fabricating Machining Solutions, and his organization. The market knowledge and experience that Bob and his staff bring will help support our sale efforts in Canada,” comments Bill Isaac, VP of sales and marketing for MC Machinery Systems Inc. “Customers will also continue to benefit from the support of our sales and technical staff at the MC Machinery Systems Canada Technical Centre.” Chris Linton, regional manager for the fabrication division of MC Machinery Systems Canada will support FMS. Watson says part of the name change to FMS from AFM was to rebrand the company to reflect recent business changes.

Motoman, Tech-Con join forces for robotic waterjet cutting

Tech-Con Automation Inc., Burlington, ON, and Motoman Robotics, Dayton, ON, have formed a partnership for robotic waterjet cutting systems in North America. Tech-Con will be responsible for the integration of waterjet cells for new and existing Motoman customers in North America, and will also handle service contracts and retrofits on existing Motoman waterjet cutting systems in the automotive industry. “Motoman Robotics has an extensive installed base in waterjet cutting applications using Flow pump equipment. With TCA’s co-operative agreement with Flow Corp. [a deal signed in March 2010] and our partnership with Motoman Robotics, we will bridge the three organizations to support the existing installed base in the waterjet market,” says Casey DiBattista, president of Tech-Con Automation. “We will continue to increase our customer base and promote high tech solutions for the marketplace. Tech-Con Automation has long been a Motoman Solution Partner, and we have the technical expertise to successfully execute large programs.” In March, Tech-Con signed an exclusive agreement with Flow International Corp. to provide the North America automotive market (Canada, US and Mexico) with robotic waterjet cutting systems. “Tech-Con Automation has been integrating Motoman robots for many years,” says Roger Christian, VP marketing and international groups at Motoman Robotics. “They have wellseasoned, experienced talent to excel in the robotic waterjet market, as well as the overall automation industry. Tech-Con has our complete technical support commitment to ensure that they offer the highest technology solutions to their customers. We welcome the relationship and are very excited to continue to serve this market with such a strong partner.” 8 | AUGUST 2010 | www.canadianmetalworking.com

“I decided to chart a new direction for the company by acquiring new product lines,” says Watson. “After studying the Canadian market place, we determined that these products were the best choice for our company. At the same time, we decided to change our name and give our company a fresh new look.” As part of its expansion, FMS has appointed Steve Spilak as regional manager for Quebec and Eastern Canada. Spilak has more 25 years of sales experience with manufacturers and distributors of metal fabricating machinery in Canada and is bilingual in English and French.

INTRODUCING

Boxway VMC’s Bridge Mills

Linear Guideway VMC’s

Turning Centers

An ALL-NEW lineup of machine tools with unsurpassed performance and value. These all-new machines feature extensive design and engineering by Methods Machine Tools, Inc., the leader in application expertise, service and support. FFG / FEELER is one of the world’s largest machine tool builders.

IMTS BOOTH S-9119 PERFORMANCE

: VALUE

877-668-4262 methodsmachine.com/feeler MACHINING CENTERS

TURNING CENTERS

BRIDGE MILLS

BORING MILLS

News Calendar AUGUST 23-25 2nd Canadian Quality Congress at the University of Toronto in Toronto. 204-261-6606 TQRFcanada@shaw.ca SEPTEMBER 13-18 IMTS at McCormick Place, Chicago, IL. www.imts.com SEPTEMBER 26-28 Canadian Welding Association’s National Conference. Blue Mountain Resort, Collingwood, ON. www.info@cwa-acs.org.

POLL

No 28.6%

Has your outlook about a manufacturing rebound improved compared to the first quarter of 2010?

Yes 71.4%

By order of Pratt & Whitney Canada, a UTC Company

Exceptionally Maintained CNC Machining, Toolroom & Support Equipment from Design Toolroom

Online Auction Sale Opening: Tuesday, September 14 th, 2010 at 12:00 AM (Midnight) EDT Sale Closing: Thursday, September 16 th, 2010 at 12:00 PM (Noon) EDT Location: Longueuil, Quebec, Canada Inspection: Monday, September 13th, 2010 Assets Include: • CNC Horizontal Machining Center: Toyoda LineaM III High Speed • CNC Mill: Hermlee VFW1000 • Vertical Milling Machines: Bridgeport 2-HP • EDM: Charmilles Roboform 400 Jones & Shipman & Okamoto • Hone: Sunnen MBB-1660K • Press: Greenerd HCTG-200 200-Ton • Optical Comparators: Jones & Lamson Epic 30 & Epic 114 • Fuel Nozzle Test Rigs: Provatech • Lathes; Saws; Welding, Material Handling and Facility Support Equipment For more information please, contact: DENNIS SCHMELING Tel: 920 344 6250 Email: dennis.schmeling@go-dove.com To view and bid on the lots, please visit

www.Go-Dove.com 10 | AUGUST 2010 | www.canadianmetalworking.com

Sandvik Coromant teams up with partner for composites machining

Sandvik Coromant and its Canadian company, Sandvik Coromant Canada, Mississaga, ON, have formed an agreement with Precorp Inc., Spanish Fork, UT, to supply the composite machining market with diamond based cutting tools. As partners, the two companies will supply the market products using PCD (Polycrystalline Diamond) vein technology and carbide solutions. The PCD vein technology incorporates a precision sintered slot of PCD onto the cutting edge to improve the quality and efficiency of the cutting tool. Precorp supplies PCD and carbide tools. Sandvik Coromant acquired 49 per cent of the shares in the company in 2008. Randy McEachern, product specialist for toolholding and holemaking products at Sandvik Coromant Canada, Misssissauga, ON, says that because the aerospace market is an important focus for the cutting tool supplier, entering the composites markets is essential because “it’s a fast growing concern in manufacturing and as an aerospace supplier, we felt we should be able to offer solutions for this area of aerospace manufacturing.” Sandvik Coromant already supplies solid carbide diamond tip cutting tools for composites machines, such as the CoroDrill 854 (which can be used on CFRP/AL – carbon fiber reinforced plastic laminate on aluminum) and 856, “but if customers want enhanced performance and longer tool life from these cutting tools we can go with the PCD vein technology from Precorp and incorporate the company’s experience and knowledge in this area to create higher performance tools for composites machining.” Demand for composites—typically carbon or glass fiberreinforced plastics and multi-material laminates—has been steadily growing in recent years, particularly in the aerospace and wind turbine blade manufacturing markets. According to Dr. Sanjay Mazumdar, president and CEO of E-Composites Inc., Grandville, MI, in a 2005 article he authored on Composites Technology (www.compositesworld.com), global use of composite materials has grown rapidly from 158,800 tonnes (350 million lb) in 1960 to 6.1 million tonnes (13.5 million lb) in 2004, “represent 3,800 per cent growth in the last 45 years.” Since 2002, the global composites industry has been increasing at more than 5 per cent, mainly due to growth in Asia. Indeed, composite volume shipment in China in particular is expected to exceed that of the US by 2013. In a composites report from market research firm Lucintel, the company forecasts that the global carbon fiber composites market will reach $2.4 billion in 2014 and for the next five years, the market is expected to grow 9.8 per cent per year, it notes in its 2009 “Growth Opportunities in Carbon Fiber Composites Market 2009-2014.” And composite materials have been making headlines in recent years with news from aircraft manufacturers such as Bombardier, which will soon launch its composite C Series midsized aircraft. Composite materials are also growing in the wind turbine blade manufacturing market and Sandvik Coromant’s McEachern says that there “are lots of applications for composites and different composite materials that manufacturers are now using to make their products.”

NEW GENERATION After more than 20 years of industry firsts, we figured 2010 would be a good year to “up the ante” again. So we looked at any and every way to make Haas VMCs better, and then made one last change: We added more value.

IMPROVED: motion control coolant containment • chip evacuation CNC interface • ergonomics • serviceability released for active duty: 01.01.10

Find your local Canadian Haas Factory Outlet 800.331.6746 • find them online @ www.HaasCNC.com

VERTICAL MACHINING CENTERS

THE 2010

Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment.

21st International Sheet Metal Working Technology Exhibition

News Shop Talk Do you typically take a summer vacation from work? If no, how long has it been since you had a summer vacation? “No. The last time I had a summer vacation was in university when I took time off to travel and study abroad. That was in 2002.”

-Renny Husada, vice president, Yess Products Ltd., Surrey, BC

“With respect to time off, I just got back from holidays, thanks! I typically do not leave for long periods of time due to the challenges facing the market over the last several years, but strongly believe that without time off to recharge the batteries, I cannot possibly run anywhere close to 100 per cent. Having said that, five to six day stretches away from the ringing phones, constant emails and customer demands are healthy and necessary to ensure productivity. This, by the way, applies to all my staff members. We all need a break from time to time.”

-Joseph Manzoli, president, Colourfast, Concord, Ontario

“As the owner, I honestly don’t remember the last time that I took a summer vacation although last year I managed to get away to a sun location during the winter. This may change, as we are talking about closing down for vacation in the future.”

-Brian Wetherall, president, Brotech Industries, Barrie, ON

26 - 30 October 2010 Hanover, Germany

“Yes. Most full time employees and management staff take one or two weeks off in summer, but the vacations are scheduled to ensure uninterrupted service to our customers. The plants do not close for a summer vacation.” -Debbie Blowe, systems manager, Vibra Finish, Mississauga, ON

• Sheet metal, Tube, Section • Finished products, Parts, Assemblies • Handling • Separation • Forming • Flexible sheet metal working • Tube / Section working • Machine elements • Joining, Welding • Surface treatment • Tools, Dies • Controlling, Regulating, Measuring, Inspection • Quality Control • CAD/CAM systems • Data capture / processing • Factory and warehouse equipment • Safety at work • Environment protection, Recycling • Research and development

“Typically a shut down occurs on the last week of July through to the end of the first week of August. There are a few [employees] that prefer to work, in which case there would be a skeleton crew of staff here through the shutdown at one point or another. As president, I have over the past seven or so years taken two to three weeks off (first week prior to our two week shut down) while being in touch daily during that first week.”

For more information please contact: Co-Mar Management Services, Inc. Email: info@hf-canada.com Phone: 1-800-727-4183

“As a company we do not have a summer vacation shut down. Individually, I usually take one week in July.”

(This is a toll-free number that can be accessed from all over Canada)

www.euroblech.com

12 | AUGUST 2010 | www.canadianmetalworking.com

-Gerry Vandersanden, president and owner, Sciens Industries, Peterborough, ON

-Robert Drake, systems sales and support manager, Proto Manufacturing, Oldcastle, ON

News Aaron Kennette (left) has joined Delcam, Windsor, ON, in the technical support group and John Sare (right) has joined the companyâ&#x20AC;&#x2122;s Toronto sales group covering central and northern Ontario. Kennette has 12 years of experience with three, five and six axis machine tools in the mould industry. Sare has 29 years of experience in the manufacturing industry with the last 10 years managing sales channels in Europe.

Paul Hurtig is the new FEELER product manager at Methods Machine Tools, Sudbury, MB. A Methods employee for 29 years, he will be responsible for launching the new line in North America. He has held various managerial positions in service, product support, technical sales and most recently served as vice president of operations for the company.

George Dunning has been named vice president of engineering at Thermadyne Industries Inc., St. Louis, MO. He will be responsible for leading the companyâ&#x20AC;&#x2122;s global engineering teams and will be based in Denton, TX. He has held senior positions with several North American manufacturers including Door Corp., Stanley Tools and General Electric, and has held a senior engineering position at the US Air Force.

14 | AUGUST 2010 | www.canadianmetalworking.com

People

Ron Rygiel is the new vice president of sales and marketing, North American market for Komet of America, Schaumburg, IL. He has held several sales and marketing positions with North American manufacturers. He holds 10 patents, five awarded while working for Chrysler, and two trademarks.

WEâ&#x20AC;&#x2122;VE BEEN PASSIONATE ABOUT WATERJET FOR YEARS.

Our passion for waterjets, years of experience, and dedication to our customers drives us. Itâ&#x20AC;&#x2122;s a combination that has created the ultimate customer focused waterjet solution. The waterjet that will deliver results, and help grow your business.

At Flow, in 1979, Dr. Mohamed Hashish invented the abrasive waterjet...

...though his passion started well before then.

800.446.3569 | FlowWaterjet.com | info@flowcorp.com

Today he continues to develop breakthrough waterjet solutions with an equally passionate team of experts at Flow.

Waterjet is our life. Driven by passion. Inspired by you.

Industry report

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

Manufacturing Success:

IMTS 2010

Following on the heels of a tough economic period, North America’s biggest event for manufacturers holds the promise of success By Nate Hendley .................................................................................................................................................. Manufacturers from across North American will be flocking to Sweet Home Chicago September 13–18, as the Windy City hosts the 28th edition of the International Manufacturing Technology Show (IMTS). Scheduled for Chicago’s McCormick Place, IMTS will feature more than 1,100 vendors showing off more than 15,000 new machine tools, controls, computers, software programs, components, systems and processes amidst 1.2 million sq ft of exhibit space. Held every other year in Chicago, IMTS is the largest and longest running manufacturing technology trade show in North America. It’s also one of the biggest trade shows in the world. “We are clearly seeing recovery and a sense of vibrancy and urgency in the industry. Certainly, over the past 18 months our industry has faced some of its most trying times. Now, as survivors move forward, they are poised to make serious investments in innovation and productivity. Our projection is that IMTS 2010 attendance will be in line with the 2008 show,” says John Krisko, director of exhibitions at IMTS. IMTS 2008 attracted 92,000 people from 116 countries. “Everyone involved in manufacturing can benefit from experiencing the vast array of technologies available at IMTS; executives building a business, decision makers involved in manufacturing equipment purchases, engineers who identify equipment needs, plant superintendents who will set it up, operators who use the equipment and know it better than anyone else and all staff members and suppliers that companies count on for new ideas,” continues Krisko.

A Better Manufacturing Environment

Despite the speculation of a double dip recession in the US, a wavering North American housing market and nervous stock markets, the manufacturing industry is in better shape today than it was one year ago. In Canada, a recent Bank of Canada Business Outlook Summer Survey notes that Canadian businesses are optimistic about the country’s future economic growth, but are treading cautiously when it comes to large investments in their operations and in employment. And in an earlier June Provincial Outlook report issued by BMO Capital, it notes that the Canadian economy is gaining steam with national growth expected to reach 3.4 per cent this year and 3.1 per cent in 2011. The news south of the border is also more positive with 16 | August 2010 | www.canadianmetalworking.com

US manufacturing technology consumption up 52.9 per cent in 2010 compared to 2009. May monthly US manufacturing technology consumption was US $178.34 million according to the American Machine Tool Distributors’ Association and the Association for Manufacturing Technology (AMT). While the percentage was down 22.9 per cent from April, it was up 58.6 per cent from the total of $112.42 million reported for May 2009. “While we would like to see first quarter growth rates continue, we are not surprised by the typical second quarter ebb and flow in capital spending,” notes Peter Borden, AMTDA president. “We have seen an additional month of substantial orders which helps to confirm that a sustainable recovery is taking place despite the buzz of those forecasting a W-shaped rebound. Industry forecasts for the year have been revised slightly upward by many sources.”

“Can’t Miss” Presentations

According to Krisko, there are several “can’t miss” presentations lined up for this year’s show. Aerospace firm Lockheed Martin, for example, will be exhibiting “a full-scale model of the F-35 Lighting II Joint Strike Fighter,” he states. The Joint Strike Fighter (JSF) Program is an American-led, multi-billion dollar initiative to build a series of state-of-the-art combat aircraft over the next few decades. Hundreds of firms, including scores of Canadian companies, have been jostling to win contracts with this extremely lucrative program. IMTS 2010 will also feature an “Emerging Technology Centre” (ETC) where new industrial technologies such as additive manufacturing, nanotechnology/micro manufacturing, and MTConnect will be showcased. “MTConnect, the open, royalty-free standard developed to foster communication between machine tools, made its debut in the ETC at IMTS 2008 ... IMTS 2010 will feature a live demonstration of MTConnect. The demonstration will focus on the ability of applications to collect data from machines and devices and show how that data can be utilized,” explains Krisko. At the Advanced Manufacturing Center, visitors will be able to experience the power of the Rolls-Royce Trent engine series. A 3D virtual reality presentation will allow people to operate and interact with the Trent 1000 engine used to power the Boeing 787 Dreamliner. And for attendees looking for some combat fun, IMTS is

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

Industry report

McCormick Place. © City of Chicago / GRC

and plants. IMTS is six full days of innovation, technology, best practices, networking and the place where experts come together in one place at one time to share what they know. After IMTS 2008, 88 per cent of the attendees said they were successful in finding specific products or solving specific manufacturing problems.” Krisko adds that IMTS is truly a means for manufacturers to gain knowledge about how to improve their operations. “Visitors tell us they leave IMTS with entirely new knowledge that can serve them for years to come. When they face an engineering challenge, something they learned or someone they met at IMTS is at the top of the mind.” For convenience sake, IMTS will be divided into pavilions featuring similar machines and displays. There will be pavilions exhibiting everything from abrasive machining/sawing/finishing to controls and CAD-CAM, metal-cutting, tooling and work-holding, etc. IMTS is sponsored by the Association for Manufacturing Technology (AMT), a group that supports and promotes the US manufacturing technology sector. AMT will be holding IMTS 2010 in tandem with the National Association of Manufacturers. “We expect IMTS 2010 to be a real rallying cry for the manufacturing technology industry and all of manufacturing. As we begin to see signs of recovery it is the right time to invest in ourselves and our future and that is what we’re hearing from our exhibitors and the thousands of manufacturing professionals registering to attend the show,” says Krisko. For details about the event, visit IMTS’s web site at www.imts.com. CM

Mills Metal

Job Shops

Performance

Steels

Prod

IMTS 2010

Improvement Lathes Grinding

Machinery

Quality

Multi-tasking

Laser

Cutting tools

bringing back Robot Combat areas. Two robot combat arenas will put attendees in head-to-head competitions. One area will be in the North building, Booth B-6875 and the second area will be at the Lakeside Center (East building) Booth E-5066. Additive manufacturing, one of the technologies debuting at the Emerging Technology Centre, is “the process of building objects from 3D model data, allowing design flexibility previously unknown and impossible in traditional subtractive processes. It allows for a more rapid production process as well as materials flexibility,” explains Krisko. Guest speakers at IMTS include Allan McArtor, chairman of Airbus Americas, who will be discussing developments in aerospace, Rene van de Zande, president and CEO of the Emergo Group, who will talk about medical devices, and Jim Tetreault, vice president North American manufacturing for Ford Motor Co., who will address automotive issues. Also speaking is Denise Bode, chief executive officer of the American Wind Energy association, who will discuss new opportunities in energy. John Engler, former governor of Michigan, now president and CEO of the National Association of Manufacturers (NAM), will give a keynote address on the importance of investment in innovation and technology in ensuring a strong manufacturing sector. IMTS will also feature a “Manufacturing Museum” featuring industrial artefacts and video history. “An important activity at IMTS is what we call transfer of technology. The show provides the forum for new equipment and know-how to be shared with shops

Turning

Controls

Growth

Machine Tools

www.canadianmetalworking.com | August 2010 | 17

Industry report

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

IMTS At-A-Glance Show Dates: September 13-18

Show Hours:

Conference Dates & LOCATIon:

Wednesday, September 15: • Productivity Efficiencies in Difficult Materials Require Consideration of the Machine Tool, the Spindle, and the Cutting Tool Sean Holt, industry specialist aerospace, Sandvik Coromant

Editor’s Picks

• Gaining 50 per cent Productivity with Workholding Tim Winard, COO, Kitagawa— Northtech Inc.

East: 9:00 am–5:00 pm West: 9:00 am–5:00 pm North: 10:00 am–6:00 pm South: 10:00 am–6:00 pm Tuesday, September 14 to Friday, September 17 at McCormick Place, West Building September 13 12:00 Noon – 3:00 PM Industry Inspiration Day: Speakers from key industries—aerospace, automative, energy and medical—will discuss industry issues in a roundtable panel discussion. Tuesday, September 14: • Innovative Multi-Tasking Concepts for Turbine Blade Manufacturing Mike Finn, applications engineer, Mazak

• Use of Abrasive Waterjet Cutting for Improving Manufacturing Flexibility and Efficiency Laird Parry, senior applications engineer, OMAX Corp.

Thursday, September 16: • How do Small Shops Break into the World of Automation? John Lucier, automation manager, Methods Machine Tools • Increased Productivity by Effective Thermal Management in Metal Cutting of Titanium Dr. Paul Prichard, staff engineer, Kennametal Inc. Friday, September 17: • Composite Material and Production Technology Developments Enabling Game Changing Designs for Aircraft, Automotive, and Wind Energy Randy Kappesser, vice president and general manager, MAG Composites, MAG Cincinnati City of Chicago

• Multi-Sensor Metrology -Tom Groff, sales mgr., Optical Gaging Products • Cutting Tools Engineered for Medical -Thomas Raun, group specialist, Iscar Metals Inc.

South Building

18 | August 2010 | www.canadianmetalworking.com

IMTS 2008 attendee checks out machinery presented by an exhibiting company.

City of Chicago / GRC

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

Industry report

EXHIBITORS

IMTS will feature more than 1,100 exhibitors. Canadian Metalworking’s preview of the event includes this special report, which features an exhibitor spotlight profiling some key industry suppliers, and a special online report, which includes additional exhibitor information. Please visit our web site for more details about IMTS, www.canadianmetalworking.com.

Who: Sandvik Coromant

Where: Booth- W-1500 Sandvik Coromant is coming into Chicago with high hopes. “We expect IMTS 2010 to be a new beginning for industry. Customers will be looking for ways to improve their productivity, diversify their production into new processes and materials, and buy new equipment to help on both accounts. Sandvik Coromant will show simple methods using new or existing tools to make customers more profitable and productive,” says Rick Hern, a marketing and sales manager with the North American branch of Sandvik Coromant, in Fair Lawn, New Jersey.

such as wind power, automotive and heavy equipment, with industries like aerospace and medical waiting patiently. We see the second half of 2010 as an overall cautiously upward trend and expect stronger growth in the start of 2011.” The Sandvik Coromant booth will include a “Smart Hub” featuring displays of various industrial processes. “Come to the Sandvik Coromant Smart Hub at IMTS to see how to conquer your lathe, machining centre, multi-task or VTL challenges,” says Hern. Sandvik Coromant will be exhibiting a variety of cutting tools, including the CoroDrill 854 and CoroDrill 856 and the CoroMill 490 milling cutter. The latter “can shoulder mill, face mill, edge, contour, slice, and slot in all materials” and “can take up to 0.393 inches depth of cut. The latest release in the CoroMill 490 family from Sandvik Coromant is a 0.551 in. insert designed for larger depths of cut and engagements up to 0.393 in.,” states Sandvik Coromant press material. “We plan to bring together knowledge, tools and techniques with today’s latest technology,” exclaims Hern. www.sandvik.coromant.com/us

Who: Methods Machine Tools

Where: Booth- S-9119 “Methods expects IMTS 2010 to demonstrate—via show attendance and booth traffic—the continuation of the steady resurgence in North American manufacturing and consequently, the need for manufacturers to maximize productivity by obtaining the latest in machine tool technology,” says Phil Janiszewski, marketing manager, Methods Machine Tools,

“IMTS 2010 is important because it forces every manufacturer to show their best products and capabilities,” Hern adds. Sandvik Coromant describes itself as “the world’s leading producer of tools for turning, milling and drilling.” The venerable company can trace its roots back to 1862, when it was founded in Sweden. With 8,000 employees worldwide, Sandvik Coromant’s global headquarters are located in Sandviken, Sweden. In Canada, Sandvik Coromant’s Productivity Centre and Canadian headquarters are based in Mississauga, ON. “Sandvik Coromant is definitely optimistic regarding North American manufacturing,” says Hern. “Many indicators show the market stabilizing and the result will be stronger companies surviving through diversification and becoming more productive. A few industries are showing some strength www.canadianmetalworking.com | August 2010 | 19

Our complete portfolio. Your complete satisfaction.

From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction. Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call 800.446.7738 or visit www.widia.com. ©2010 Kennametal Inc. l All rights reserved. l A-09-02229

SEE US AT BOOTH W-1452

www.widia.com

Industry report

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

Inc. based in Sudbury, MA. Describing itself as “North America’s foremost supplier of leading-edge precision machine tools,” Methods’ partners include FEELER (vertical machining centres, turning centres, bridge mills and boring mills), FANUC (machining centres and wire EDM machines), KIWA-Japan (horizontal and vertical machining centres), Exeron (EDM die sinking), NakamuraTome (multitasking turning centres) and Matsuura (horizontal and vertical machining centres). In existence for more than 50 years, the company supplies machine tools for a range of industries including aerospace, automotive, electronics, energy and medical. “We hope that visitors to our booth will be leaving the show with an understanding that Methods Machine Tools— through the cutting-edge technologies found in our machine tool offerings and also via our machine tool and robotics turnkey automation packages—is the foremost source for companies seeking substantial increases in productivity,” says Janiszewski. Methods will be exhibiting a range of machine tools at its booth, including a new line-up of FEELER machines with extensive engineering by Methods. Eleven FEELER machines including a FEELER FTC-200L turning centre, integrated with cellular automation, will be introduced at the show. Also, a FEELER VB-1650 vertical machining centre will be performing heavy duty cutting. The new KH-55 machining centre from KIWA will make its debut at IMTS. Janiszewski describes the KH-55 as “a large capacity yet small footprint horizontal machining centre with two integrated pallets and a full rotary B axis.” www.methodsmachine.com

positive fiscal results in the machine tool sector. “North America is in a major transition with its manufacturing base. Globalization has made China, India and other foreign markets the new growth areas. To survive as a major participant in manufacturing, we must be global in our strategy and action. For example, in aerospace, both the Boeing 787 and the F-35 Joint Strike fighter are essentially a North American innovation that includes high risks and rewards. But these products cannot be developed without global partners,” says Walker.

Who: Mitsui Seiki USA

Who: TRUMPF

Where: Booth- S-8336 Founded in 1928, Mitsui Seiki boasts that it was the first company in Japan to make precision machine tools. The company supplies machine tools and machining centres for various industries including aerospace, mould and die, precision parts and machinery. Global headquarters are in Tokyo while the North American branch of Mitsui Seiki is based in Franklin Lakes, NJ. “Traditionally, Mitsui Seiki was known in North America for jet engine component machine tool manufacturing. In the last four years, Mitsui Seiki has been working in the aerospace structural components area with titanium and the tougher materials for flaps, landing gear and related support components ... we have introduced new “heavy metal machine” models for these materials, specifically in four and five axis horizontal machine configurations,” says Scott Walker, president of Mitsui Seiki USA. Asked why his company is taking part in IMTS 2010, Walker says, “for me personally, not only is it a good place for Mitsui Seiki to show our newly developed technology, but it is also a great opportunity for me to educate myself on what our suppliers are developing, what direction the other machine tool manufacturers are going with their machine tool designs and learn new needs from our customer base.” He adds that he thinks “2010 will be the beginning of the recovery. Backlogs will start to increase and machine tool factories will start to get busy replacing older technology machines and processes. But it will take until 2011 to see 22 | August 2010 | www.canadianmetalworking.com

As for what they are exhibiting at IMTS—“we are showing modular machine configurations for heavy metal manufacturing,” he states. More specifically, Mitsui Seiki builds jig boring machines and grinders, horizontal and vertical machining centres, five axis machining centres and screw grinders. www.mitsuiseiki.com

Where: Booth-N-6223 TRUMPF was founded 1923 in Germany and still maintains its global headquarters near Stuttgart, in that country. A major manufacturer of fabricating machines and industrial lasers, TRUMPF developed the first “motor-driven hand shears for cutting sheet metal” back in 1934. The company also proudly notes that its “production buildings were undamaged” during the devastation of the Second World War. A North American subsidiary of TRUMPF, TRUMPF Inc. was launched in 1969. Based in Farmington, CT, the North American branch currently employs about 700 people. TRUMPF is particularly well known for its industrial lasers, so it’s no surprise the company plans on showcasing this aspect of the business at IMTS.

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

At this show, TRUMPF will be displaying the right laser marking system for any application. â&#x20AC;&#x153;The laser is an extremely versatile tool that can be used effectively in many materials processing applications. Therefore IMTS is the perfect forum to display the latest in laser technology. For example, we will display the three types of lasers used in todayâ&#x20AC;&#x2122;s high performance marking operations: Nd-YAG, Nd-YVO4 (Vanadate) and Ytterbium (fiber),â&#x20AC;? states Burke Doar, vice president of sales and marketing at TRUMPF Inc. Â Doar adds that â&#x20AC;&#x153;the company will introduce its direct diode, fiber delivered laser, the TruDiode series, ideal for applications such as deep penetration keyhole welding, brazing, laser metal deposition and heat treating. For those interested in sheet metal fabrication, the economical and compact TruLaser 1030 flat sheet laser cutting machine will be on display.â&#x20AC;?

According to TRUMPF, â&#x20AC;&#x153;the TruLaser 1030 features three axis flying optics for high speed and accuracy; an X axis working range of 120 in. and Y axis of 60 in. with a maximum simultaneous X Y speed of 3,340 ipm. The TruLaser 1030 will cut a maximum thickness of 5/8 in. of mild steel.â&#x20AC;? The TruDiode laser series meanwhile, â&#x20AC;&#x153;are available with output powers of 800, 1,000, 2,000 and 3,000 watts for welding, brazing, hardening and heat treatment ... these industrial grade direct diode lasers possess a beam quality comparable to that of lamppumped lasersâ&#x20AC;&#x201D;even at high output powerâ&#x20AC;&#x201D;at significantly lower operating costs,â&#x20AC;? states company literature. TRUMPF will also be introducing the TruMark 6030, a diode pumped, Nd-YAG laser marking system that operates in the infrared range of 1,064 nm. www.us.trumpf.com

Industry report

Who: Tungaloy

Where: Booth- W-1654 John Mitchell, general manager of Tungaloy Canada, a cutting tools manufacturer based in Brantford, ON, offers a commonsense reason for taking part in IMTS. â&#x20AC;&#x153;It is costly and time consuming to reach out to the hundreds of thousands of potential end-users. Having many end users under one roof at one time is a much simpler way to reach out and show these people how our innovative product line-up can save them significant amounts of money in their manufacturing processes.â&#x20AC;?

/ Ă&#x160; 1//

Ă&#x160;

"7Ă&#x160; 6 Ă&#x160; Ă&#x160; 7Ă&#x160; / " Ă&#x160; Ă&#x160;*," 1 /-t UĂ&#x160; >ViĂ&#x160; Ă&#x20AC; Ă&#x203A; }

*Ă&#x20AC;i Ă&#x2022; Ă&#x160; VĂ&#x20AC; Ă&#x160; Ă&#x20AC;> Ă&#x160;- `Ă&#x160; >Ă&#x20AC;L `iĂ&#x160;v Ă&#x20AC;Ă&#x160; }iĂ&#x20AC; / Ă&#x160; viĂ&#x160;> `Ă&#x160; VĂ&#x20AC;i>Ă&#x192;i`Ă&#x160; ii`Ă&#x192;Ă&#x160;> `Ă&#x160;-ÂŤii`Ă&#x192;Â°

UĂ&#x160;Ă&#x160; }Ă&#x20AC;>Ă&#x203A; }Ă&#x160;/ Ă&#x192; UĂ&#x160;Ă&#x160; *Ă&#x20AC; w iĂ&#x160; Ă&#x20AC; }Ă&#x160; >Ă&#x20AC;Ă&#x192;

Ă&#x2022; `Ă&#x20AC;i`Ă&#x192;Ă&#x160; vĂ&#x160;- Ă˘iĂ&#x192;Ă&#x160; Ă&#x160;-Ă&#x152; V Â°

UĂ&#x160;Ă&#x160; -**Ă&#x2030; -*/Ă&#x160;/ Ă&#x20AC;i>`Ă&#x160; Ă&#x192; UĂ&#x160;Ă&#x160; 1 `iĂ&#x20AC;VĂ&#x2022;Ă&#x152;Ă&#x160; Ă&#x20AC; Ă&#x203A; }Ă&#x160;/ Ă&#x192;

Ă&#x2022;Ă&#x192;Ă&#x152; ]Ă&#x160; >Ă&#x152;Ă&#x2022;Ă&#x20AC;iĂ&#x160;> ` ivĂ&#x152;Ă&#x160; > `i`Ă&#x160;/ Ă&#x192;Ă&#x160; Ă&#x203A;> >L iÂ°

UĂ&#x160;Ă&#x160; 1 Ă&#x160; Ă?Ă&#x152;iĂ&#x20AC; > Ă&#x160;/ Ă&#x20AC;i>`Ă&#x160; Ă&#x192; UĂ&#x160;Ă&#x160; >V Ă&#x160; > viĂ&#x20AC;Ă&#x160; Ă&#x20AC; }Ă&#x160; >Ă&#x20AC;Ă&#x192;

/ Ă&#x160;> `Ă&#x160;/

>Ă&#x152;i`Ă&#x160;/ Ă&#x192; Ă&#x160;-Ă&#x152; V Â°

UĂ&#x160;Ă&#x160; Ă&#x160; Ă&#x20AC; }Ă&#x160;-Ă&#x152;>Ă&#x20AC;Ă&#x152; }Ă&#x160;>Ă&#x152;Ă&#x160;Ă¤Â°Ă¤ÂŁxÂťĂ&#x160; > iĂ&#x152;iĂ&#x20AC; UĂ&#x160;Ă&#x160; V iĂ&#x160;> `Ă&#x160;-Ă&#x152;Ă&#x2022;LĂ&#x160; V iĂ&#x160; Ă&#x152;iĂ&#x20AC; > Ă&#x160;/ Ă&#x20AC;i>` }Ă&#x160;/ Ă&#x192;

- / Ă&#x160; 1// Ă&#x160;/"" -]Ă&#x160; Â° ÂŁÂŁĂ¤Ă&#x160;7Â°Ă&#x160; >Ă&#x192;Ă&#x17E;Ă&#x160;-Ă&#x152;Ă&#x20AC;iiĂ&#x152;Ă&#x160;Ă&#x2030;Ă&#x160;- Ă&#x160;6> iĂ&#x17E;]Ă&#x160; Ă&#x160; Ă&#x17D;Ă¤Ă&#x2C6;xĂ&#x160;Ă&#x2030;Ă&#x160;nĂ¤Ă¤Â°Ă&#x17D;nĂ&#x17D;Â°Ă&#x201C;Ă&#x201C;{{Ă&#x160;Ă&#x160;Ă&#x2030;Ă&#x160;nĂ¤xÂ°xn{Â° Ă&#x2C6;Ă&#x201C; Ă&#x160;Âv>Ă?ÂŽĂ&#x160;Ă&#x2030;Ă&#x160; v JĂ&#x192;VĂ&#x152; Ă&#x2022;Ă&#x192;>Â°V Ă&#x160;Ă&#x2030;Ă&#x160;Ă&#x153;Ă&#x153;Ă&#x153;Â°Ă&#x192;VĂ&#x152; Ă&#x2022;Ă&#x192;>Â°V

www.canadianmetalworking.com | August 2010 | 23 SCT Final.indd 1

3/4/10 9:30:49 AM

dmg – technologies for tomorrow

Turn & Mill

Complete machining – ShopTurn 3G for the highest performance ________

Turning and milling on the CTX TC – With top class

complete machining, you will finish your workpiece considerably faster. The CTX gamma 2000 TC with a turret and revolutionary multi-channel ShopTurn 3G programming offer maximum productivity with up to a 60% time savings during programming.

CTX beta TC / gamma TC HIGHLIGHTS _ Simple and fast Turn & Mill programming with ShopTurn 3G – Easy-to-operate ShopTurn cycles and DIN functionalities can be combined according to your needs _ 12-station turret for additional flexibility and productivity (for the CTX gamma 2000 TC) _ Powerful turning / milling spindle with an NC-controlled B-axis and a torque motor _ Maximum stability and precision with the thermo-symmetric design and active cooling _ Various tool magazines are available for the CTX beta 1250 TC and CTX gamma 1250 / 2000 TC

All DMG news is available online at:

www.dmgcanada.com

DMG Canada Inc.: 165 Admiral Blvd. Mississauga, ON L5T 2T3 · Canada Tel.: (905) 795-2891, Fax: (905) 795-0393 If your mobile phone is equipped with QR code recognition software, you will have direct access to our home page.

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

Industry report

Tungaloy was originally founded in Japan in 1929. An American branch of the cutting tool manufacturer was opened in 1987 in Wood Dale, IL, near Chicago. This was followed by a Canadian division in 2003. The company specializes in making drills, indexable shell mills and end mills, among other products. Tungaloy is bullish about the future. “Tungaloy is very optimistic about the state of the North American manufacturing sector. North American manufacturers can and will excel in producing products for the global market place. It has never been more important to show North American manufacturers what is required to compete in the global marketplace,” says Mitchell. Tungaloy has several new products in the pipeline. At IMTS, the company will be demonstrating the new TecMill series of shoulder milling cutters.

“The TecMill is available as a shell or shank type cutter. The shell type cutter has a close or coarse pitch option with the close pitch cutter having a nine to 11 insert option while the coarse pitch cutter body is available with anything from five to seven inserts ... this new series has an extremely diverse machining range that enables it to comfortably machine grey and ductile iron, low and high carbon steel, alloy and tool steel and heat resistant alloys,” explains the company. Tungaloy has also recently launched a new RoundSplit series of radius milling cutters. These cutters are available as a bore type or shank type with a standard, long or extra long shank. Other new products include the DoPent pentagonal face milling cutter, which “incorporates double-sided inserts with five cutting edges on each side to cut tooling costs by up to 30 per cent and deliver an economical solution to face milling,” according to company literature. “The new products that Tungaloy will be showcasing at IMTS are capable of reducing cycle time, reducing cost per part and making their production much more ready to compete in the global marketplace.” claims Mitchell. www.tungaloyamerica.com

Who: Hurco Companies

Where: Booth S-8319 Asked why it’s important to participate in IMTS, and Mike Garlick, general manager, North America for Hurco Companies, Indianapolis, IN, waxes philosophical for a moment. “There’s been a lot of shake-out over the last few years and we think it’s important that we are there and show that we

believe in the recovery in North American manufacturing,” says Garlick. Founded in 1968, Hurco Companies also operates Hurco Canada, based in Mississauga, ON. Hurco claims it supplies customers with “the most intelligent, efficient and userfriendly computer numerically controlled (CNC) metalworking machinery available.” “Our expectations are to show products we’ve developed through the tough times and to show customers that we are still around, we are strong and look forward to recovery,” says Garlick. “We will be bringing in new equipment ... bringing in a large lathe and new high speed machines that we’ve been working on over the last couple years.” Among the machine tools Hurco plans to display is the VMX30U, a five sided, five axis machining centre designed for job shops of all sizes, and its TMX10MYS turning centre. According to Hurco, more than 80 per cent of what many call five axis is really five sided machining. Converting from a three axis machining centre to a five axis one reduces setup times, costs and improves accuracy. The machine on display will feature Hurco’s WinMax conversational programming, which the company says makes it easy to create a part without an expensive five axis CAM system. The turning centre is a true slant bed lathe, offering more rigidity and facilitating large part capacity. It features spindle motors with 37.3 hp on the main spindle and 20 hp on the sub-spindle. It is designed with a spindle speed of 3500 rpm with a spindle torque to 258 ft lb on the main spindle and 70.4 ft lb on the sub-spindle. www.hurco.com

Who: Haas Automation

Where: Booth S-8119 Founded in 1983 by Gene Haas, Haas Automation is now North America’s leading CNC machine tool manufacturer. The company has four major product lines: vertical machining centres, horizontal machining centes, CNC lathes and rotary tables. Haas builds all products in-house at its one million sq ft machine tool manufacturing facility in Oxnard, CA. To date, Haas has sold more than 55,000 rotary products and 110,000 CNC machines. This prodigious firm will have 17 machines on display at IMTS in 10,000 sq ft of booth space. www.canadianmetalworking.com | August 2010 | 25

Industry report

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

“Our primary emphasis is on our new series of turning centers. We have several new models being introduced at the show. We’ve also redesigned our VMC line, with a variety of improvements across the board and a new look for the machines,” states Scott Rathburn, marketing product manager for Haas.

“For high volume production applications, the Haas new generation 2010 VF-1 through VF VMCs are available with optional chip removal systems that combine multiple side augers with either a front discharge auger or a belt-type conveyor to move chips out of the machines faster and easier than ever.” Haas recently unveiled a new generation of turning centres: The ST-10 is a compact turning centre loaded with full sized features. The machine provides a maximum cutting capacity of 11.25 in. by 14 in. with a maximum swing of 16.25 in. The ST-10’s A2-5 spindle nose is equipped with a 6.5 in. hydraulic chucking system and has a bar capacity of 1.75 in. The spindle turns to 6,000 rpm and a 15 hp vector dual-drive system provides 75 ft-lb of torque at 1300 rpm. The ST-20SSY turning centre is a four axis solution for secondary machining of turned parts. It has a maximum cutting capacity of 10 in. by 20.5 in., with maximum swings of 31.75 in. over the front apron and 20.75 in. over the cross slide. It provides 4 in. of Y axis travel (±2 in. from the centreline) for off-centre milling, drilling, and tapping, and comes standard with high torque live tooling and a servo-driven C axis for versatile 4-axis capability.

The DS-30Y dual spindle turning center meanwhile blends dual spindle turning with a Y axis, C axis and live tooling. Its maximum cutting capacity comes to 18 in. by 23 in., with maximum swings of 31.75 in. over the front apron and 20.75 in. over the cross slide. The machine’s dual spindles provide synchronized turning capability for clean part cut-off, and allow backside machining to reduce handling and increase accuracy. www.haascnc.com 26 | August 2010 | www.canadianmetalworking.com

Who: MAG Americas

Where: Booth S-8519 Global machine tool and systems company MAG will be showing off its “green” side at IMTS, along with a slew of new machines and systems. The company—which is headquartered in Erlanger, KY, but has significant operations in Germany—is the world’s largest US based machine tool builder. “We expect that IMTS will be a very good show, especially considering the economic situation ... IMTS is an extremely important event for manufacturing and the economy is showing improvement,” says Mark Logan, vice president of business development and marketing, at MAG Americas in Kentucky. The company has a long and venerable history, tracing its roots back in Germany to the late 18th Century. Companies under the MAG banner have set impressive manufacturing milestones such as the world’s first hydraulic copy lathe in 1938, the world’s first NC lathe in 1968 and the first doublespindle CNC lathe in 1998. Key MAG markets include aerospace, automotive and truck, heavy equipment, oil and gas, solar energy, wind turbine production and rail.

MAG is eager to show off some new environmentally friendly machine designs and processes, as exemplified by its new NBV vertical machining centre. Said centre has no hydraulics and an “ECO-Mode” feature to save energy. It also boasts configuration for three, four and five axis contouring or five axis mill/turn work, integrated CAM support and four spindle options ranging up to 42,000 rpm. The “ECO-Mode” power saving feature automatically levels speed and acceleration for a balance of cutting performance, energy use and machine component life. MAG will also be exhibiting its new HyperMach GTi series five axis titanium aerospace profiler (designed to process large parts including spars, bulkheads and door edge frames) and what it calls the “industry’s fastest volumetric error compensation (VEC) system.” The latter is capable of analyzing positioning errors in machine tool axes simultaneously for maximum accuracy with large parts. Logan believes IMTS 2010 comes at a conspicuous time, with the North American economy poised to bounce back. “I’m cautiously optimistic. Signs of recovery are visible and we have continued to invest in advanced, practical technology to allow more value added capability and overall competitiveness for our customers. I expect that we will see gradual and hopefully steady improvement in economic activity and growth for late 2010 and into 2011,” he says. www.mag-ias.com

INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW

Industry report

What To Do Guide: Chicago, IL

While many know Chicago as “the windy city” few know that is also known as “the city that works.” And for many who attend trade events such as IMTS, it really is a city that works. From attractions and sports events to restaurants and architecture, Chicago has much to offer trade show delegates. Here’s a sampling of what you can do once your tired feed have finished walking the trade show floor.

Attractions

• Skydeck Chicago’s The Ledge – cityscape view from the 103rd floor Skydeck Chicago, formerly the Sears Tower Skydeck. www.theskydeck.com • Chicago Architecture Foundation – offers more than 80 different tours, including the “Architecture River Cruise.” www.architecture.org • Millennium Park – centre for art, music and architecture and landscape design www.millenniumpark.org • McCormick Bridgehouse and Chicago River Museum www.bridgehousemuseum.com • Shedd Aquarium – one of world’s largest indoor aquariums. www.sheddaquairum.com

Restaurants

• Gibsons Steakhouse www.gibsonssteakhouse.com • Girl & the Goat www.girlandthegoat.com • Osteria Via Stato www.osteriaviastato.com • Giordano’s Pizza www.giordanos.com • Nick’s Fishmarket www.nicksfishmarketchicago.com

An aerial view of Millennium Park. © City of Chicago / GRC

Performance, Precision and Reliability You Can Count On.

Since 1954, YCM Machines have been recognized worldwide for superior precision, exceptional rigidity and outstanding reliability. YCM has a wide range of machine tools to meet today’s manufacturing needs.

Web Page:

Email:

ycmasales

Come and Visit Us

S8129

TEL：562-205-9268 FAX：562-205-9278

www.canadianmetalworking.com | August 2010 | 27

MACHINE TOOLS

CASE STUDY

Machining An Ontario job shop aims to help manufacturers from start to finish

eeler

F TC-50 The F

lathe.

A decade ago when the high tech bubble burst, the negative economic effects rippled from the epicenter in Ottawa to the edge of the Ottawa Valley and beyond. Mid-ripple sat ETM Industries Inc. Based in Renfrew, a rural Ontario town with a population of 8,000, ETM Industries specializes in tooling, design, precision machining and plastic injection moulding. Until the late nineties, a good portion of its metalwork and 70 per cent of its plastics were destined for telecom or aerospace firms in Ottawa and Montreal. ETM not only weathered the economic storm of the March 2000 dot.com crash, but it weathered it well. And in the wake of the recent recession, ETM felt barely a blip. Canada’s manufacturing sector has lost 235,000

ETM’s sh

28 | AUGUST 2010 | www.canadianmetalworking.com

elers.

d lathes are Fe

ining centres an

M’s 22 mach op. Twenty of ET

CASE STUDY

machine tools

from A to Z

By Brynna Leslie .............................................

jobs since October 2008 and jobs in the sector are at their lowest point in 35 years. Yet for the past ten years, ETM Industries has consistently employed 80 people, a mix of licensed machinists and tool makers, in its 80,000 sq ft facility, located 92 km northwest of Canada’s capital. “When you see their operation from top to bottom, you’ll see that they can do just about anything when it comes to machining and turning,” says Chris Chaput, a sales representative

with Ottawa-based Legere Industrial Supplies Ltd., a Feeler distributor. Earlier this year, Methods Machine Tools, Sudbury, MA, became the North American importer of Feeler machines. “They’ve got the people to do it. And they’ve got all the equipment to do the work, to design it, to inspect it and to secure the process. As it’s being done they don’t make mistakes.” Chaput should know. He’s been selling machinery to ETM since the mid-eighties. Chaput was there a few

years after local tradesman Edward Legree launched ETM as a one-man, one-machine tool and die shop in 1977. He was there when ETM expanded to a six-person shop, including the current co-owner and president Jeff Campbell. And he was there when Campbell and the current vice president J.P. Leclerc, and John Robertson, who is now the general manager, jointly bought the company from Legree in 2008 with Campbell. Today, ETM runs three distinct

Booth W-200

schunk.indd 1

www.canadianmetalworking.com |7/29/10 August2:22:24 2010 |PM 29

MACHINE TOOLS

CASE STUDY

eler lathe.

The FTC-280 Fe

operations in two, side-by-side facilities: plastic injection moulding; design and builds moulds tools and fixtures; and CNC precision machining. “It’s almost like having three businesses, but they all intertwine,” says John Robertson, general manager. ETM has pushed its product to the top of the value chain, making parts for aerospace, military, mining, nuclear, and telecom, with 80 per cent of its end product remaining in Canada. “Ten years ago we weren’t doing much value-added work,” 30 | AUGUST 2010 | www.canadianmetalworking.com

says Robertson. “It started with a little push from the telecom industry. Then aerospace really started pushing a lot of the responsibilities down the supply chain.” The tool room, where ETM got its modest start, is at the heart of the company’s distinct advantage over the competition when it comes to value-added manufacturing. A couple of thousand square feet at the back of the main office building and shop, the tool and fixture room is designed for low-volume precision machining, made up of a handful of manual lathes, mills, drills and empty work stations for finishing tiny parts with sandpaper. Among these very simple machines is a five axis Wire EDM. At ETM, what is designed and prototyped in the tool shop at the back of the main building is often mass produced in the machine shop, or sometimes re-prototyped in plastic and then mass produced in the dedicated injection moulding cell. “We’ve become a one stop shop for our customers,” said Robertson. “They can buy everything from us: the material, the casting, the machining, the injection moulding, silk screening, heat treating, plating. Everything we do is value-added.” ETM is certified to ISO9001-2000 and AS9100B certified for the international aerospace industry, as well as Control Goods Registered (CGR) for the military. “For this reason, we are very much into leading edge technology,” Robertson said. At the heart of ETM’s manufacturing shop are a full range of precision machine tools, the majority of which are Feeler machines. “At some point our supplier, Legere Industrial Supplies, saw something they liked in the Feeler line of machining centres, and we did too,” said Robertson. In fact, 20 of ETM’s 22 machining centres and lathes are Feelers. “We like Feeler for its ability to hold tolerance, in addition to repeatability and reliability.” One of the favourites is the Feeler FV-800 APC. ETM has four of them. It has purchased every upgrade available, including high end Fanuc controls, the top of the line software and the best available spindle on the market. “The oil spot spindles are the most expensive spindles available, which means fewer breakdowns over time,” says Chaput. “This machine gives ETM tight tolerance and high

PLEASE VISIT US AT IMTS MAIN BOOTH #S-8754

Achieve more...

What’s at the heart of your shop? The GF AgieCharmilles CUT 20 P can change the way your shop beats. + With an integrated SF module, surface finishes of less than 0.25 Ra can be achieved. + IPG-V Generator delivers finer spark gap for better part geometry and surface finish. + Windows® XP control delivers efficiency through simple, easy to use setup and programming displays. + Low maintenance, reliable automatic wire threading system boosts autonomy and reduces operating costs. + The X and Y-axes incorporate linear scales and encoders to achieve greater positioning accuracy and repeatability. + AC Cam Easy on-board CAM system provides easy generation of 2D geometries for erosion. + Full-time collision protection on the Z-axis prevents damage in the event of accidental movement on the work piece.

At the heart of every shop is a great machine.

Elliott Matsuura Canada Inc. 2120 Buckingham Road Oakville, Ontario L6H 5X2 Tel. (905) 829-2211 Fax. (905) 829-5600

Tel. (800) 282-1336

us.gfac.com

CASE STUDY

MACHINE TOOLS

An injection mould tool ope

n for repair.

“When you see their operation from top to bottom, you’ll see that they can do just about anything when it comes to machining and turning.” yee Marc Beau Shop floor emplo

cham

e. machining centr FV-800 vertical CAP r ele Fe p beside the

accuracy parts over a long period of time, which is exactly what they need for their aerospace clients.” The Feeler FTC 280 CNC turning centres with live tooling have also proven worthy precision machines. Again, current high level volume in the aerospace sector triggered ETM to purchase a third machine in June. “Anyone in the business knows that every time you move a part manually, you lose a little bit, “said Chaput. “For ETM, doing the milling and turning in one machine improves accuracy, throughput and efficiency.” For speed, ETM likes the Feeler QM-22. It’s another machine designed to do a high level of production of small parts. “It’s this type of machine that gives us a competitive edge,” says Robertson. The spindle speed is well above average at 12,000 rpm. “If you don’t keep up with the latest and greatest, you fall behind,” says Robertson. “If my spindle speed runs at 5,000 rpm and the guy down

www.canadianmetalworking.com | AUGUST 2010 | 33

Canada’s 1 choice for metalworking readers and advertisers. #

• More stories. More balance. Better readership. The #1 choice for readers. • More ads. More reach. The #1 choice for advertisers. • Canadian Metalworking is the #1 choice for advertisers because it publishes the complete magazine. Meaty reading every issue is combined with regular opt-in enewsletters. • Circulation results set the bar for both print and online.

www.canadianmetalworking.com Advertising Information: Larry Bonikowsky, Senior Publisher 416-764-1489 larry.bonikowsky@rci.rogers.com

Editorial Information: Mary Scianna, Editor 416-764-1540 mary.scianna@rci.rogers.com

CASE STUDY

ETM employee

A close up view

of the Feeler FT

Tom Johnson ch

ecks the Feeler

FV-1300 vertica l

MACHINE TOOLS

machining centr

C-30 lathe.

NEW & IMPROVED

Best priced QUALITY coolant in the market!

! w! ed Ne rov p Im

the road is running at 12,000 rpm, he’s going to be making a lot more product.” Of course, with its diverse clientele, ETM needs more than just small, fast precision machines. ETM machines can produce parts 62 in. in length and 48 in. in width. The Feeler FTC-50 and FTC-30 boast huge bores, suited for parts such as large diameter piping. The machines run 24 hours a day, seven days per week. “Feeler has proven to be reliable, and that’s important. If these machines are not running, we’re not making money,” Robertson quips. Robertson boasts that ETM has two of almost every style of Feeler machine. “It’s mitigation of risk because it means we will very likely always have a machine up and running when we need it for the customer. And of course, it gives our customers that warm and fuzzy feeling that keeps them coming back,” says Robertson with a smile. For a diversified company like ETM, Robertson says the Feeler machines’ compatibilities with a variety of cutting tools is also unmatched. ETM purchases cutting tools through Legere from OSG and Iscar, considered the world’s second- largest manufacturer of indexible carbides. “We also make our own tools, fixtures, moulds and special cutters, so we often modify machines to suit our customers’ needs and we can do that very easily with the Feeler machines,” says Robertson. The nature of ETM’s business in high end precision manufacturing

• CHLORINE FREE! • NOW AEROSPACE APPROVED to Boeing BAC 5008 specifications • High quality semi-synthetic metalworking fluid • Now in use in hundreds of machines • 100% Canadian owned • 35 years in business Improve your coolant systems and tool life today. For an evaluation of this product call us or send us an email at info@chem-ecol.com

www.chem-ecol.com

1-800-263-3939 www.canadianmetalworking.com | AUGUST 2010 | 35

01Chem-Ecol V2.indd 1

2/8/10 7:17:00 AM

MACHINE TOOLS

CASE STUDY

ETM’s 86,000 sq ft facility and its materials storage area.

means price is a key factor. “We are always purging and looking for the latest that Feeler has to offer,” says Robertson. “They’re innovative and they’ve got a good product mix, and we are also buying the service from Legere at the same time.” “ETM is making parts to a certain tolerance that Feeler can handle. I could try to sell them a $250,000 machine that will last 20 years, but they don’t need it for twenty years,” explains Legere’s Chris Chaput. “If it can run well for ten years and they can pay less, that’s the best thing for them and Feeler does that.” CM Brynna Leslie is a freelance writer based in Ottawa, ON. www.etmindustries.on.ca www.legereindustrial.com (Eastern Canada distributor for Feeler) www.methodsmachine.com (North American importer for Feeler)

See Hardinge Workholding at IMTS New Products, expanded product offerings, the latest spindle tooling and rotary products

• A complete line of rotary systems

See us at Booth S-8348 ts duc Pro See o new s to hoto p for

FlexC Collet Block

• The FlexC Collet System with new sizes available and the all new Collet Block Contact Hardinge direct at 800-468-5946 or www.shophardinge.com.

• Special Workholding Applications on display HARDINGE

BRIDGEPORT

| AUGUST | www.canadianmetalworking.com 368 Canadian 1 36Ad 2010 Machinery.indd

HAUSER

KELLENBERGER

TSCHUDIN

JONES & SHIPMAN

6/30/10 10:34:20 AM

To Survive In The Medical Device Marketplace You Must...

EVOLVE OR ELSE! More Parts. Less Time. Less Space. More Profits. Send A RFQ And We’ll Prove It.

ydromat introduces the next step in the evolution of high precision medical component manufacturing. The new Hydromat AT (Advanced Technology) 6-100, a design that can be best described as four high-speed mini VTL’s all cutting simultaneously on one platform producing parts fast, complete and totally de-burred. Nice! It incorporates four 5,000 RPM spindle pallets that work in tandem at each station with high-speed horizontal and vertical spindles. Each station sports its own “Direct Connection” tool changer that greatly increases flexibility. These advancements make for a very powerful productivity center in a small footprint. With the AT 6-100 you will be measuring your cycle times in seconds rather than minutes.

Four Tool Changers 50,000 RPM Spindles 5,000 RPM Spindle Pallets Gauge/Invert Station

Vertical Spindle Option

• In-Process De-Burring • No Secondary Operations • Integrated Six Station Pallet System • Four Cutting Stations • One Tool Changer Per Spindle -12 Tools ea. • Four Horizontal Spindles • Vertical Spindle Options • Small Footprint - 15.4 ft. x 6.25 ft. • Five-Sided Full Interpolation Cutting • Milling, Drilling, Boring & Reaming • In-process Gauging • Second Loading Station For Inverting or A/B Load Processes

50,000 RPM Vertical Spindle Option

50,000 RPM Horizontal Spindles

5,000 RPM Vertical Turning

Pallet Loading Station Optional Robot Load/Unload/Invert

See The Fly-Through Animation At: www.hydromat.com 11600 Adie Road • St. Louis, MO 63043 p 314.432.4644 • f 314.432.7552

AMT Machine Tools Ltd. 73 Galaxy Blvd. Units 16 &17 • Rexdale, Ontario M9W 5T4 phone 416.675.7760 • fax 416.675.6988 www.amtmachine.com

ENERGY REDUCTION

Business Report

Energy to $ave Cut energy consumption and costs without compromising your operation

By Tim Wilson....................................................................................................................................................... Manufacturers can cut their energy consumption—and costs—on the shop floor without compromising operations, but they need to start thinking differently, and to look beyond the obvious to truly understand how they use electricity. The first place to start is with your hydro bill. “When we first start talking with people, we want them to understand their electricity bill,” says Ralph Williams, energy services supervisor at Hydro One in Brampton, ON. “Having knowledge on how to use electricity is paramount before you start to put a conservation plan together.” The low hanging fruit—HVAC efficiencies and basic HR practices—can be understood and, hopefully, addressed quite easily. But manufacturers have some unique requirements. “Most metal manufacturers have interval meters,” says Williams. “They can find out what they are using every hour of the day. Then they can break it down: this much for compressed air, this much for production, this much for office, etc.” With a 24 hour view of electricity demand, manufacturers can then work to spread the demand off of peak hours. But what if operations are continuous and peak hours are, essentially, all the time? Then you have to calculate the “power factor” of

your machines. The power factor is the ratio of real power, or capacity, to apparent power, which is the current and voltage on the circuit. “If your power factor is below 90 per cent, then you are incurring a surcharge,” says Williams. “If you take a typical motor, most are over-sized. So, the job may take 20 horsepower, but you use 50 horsepower.” Many manufacturing environments are running at a power factor below 90 per cent, for the simple reason that motors are always overbuilt. They have to be to get the job done. How then can you adjust your power capacity to make things as efficient as possible, while ensuring that you still have enough power? “Power factor correction capacitors can help, and a lot of companies already have them in place,” says Williams. In fact, Williams says that the power factor issue is a fairly straightforward fix, but it requires the right people to check, assess, and suggest a solution. And this is not something that should then be left for many years before re-visiting the issue. “You might have new equipment, an added load, but haven’t added the correction; you need to keep adjusting power www.canadianmetalworking.com | August 2010 | 39

BUSINESS REPORT

ENERGY REDUCTION

“You walk around a plant and you can

hear compressors leaking...that’s just energy being blown out to the atmosphere.”

factors,” says Williams. “The number of people that are still paying a surcharge is sizeable.”

HELP IS ON THE WAY

Utility companies can help manufacturers reduce their energy consumption, but so can consultants such as 360 Energy Inc., a firm that provides energy management programs and energy saving initiatives through its head office in Burlington, ON. “We began as an energy management company and expanded into energy consulting,” explains Dipal Patel, a project manager at 360 Energy. The company has an impressive track record, having helped AcelorMittal Woodstock, which is involved in the processing, finishing and distribution of steel, to save 500 kw over a typical weekend. By identifying and turning down 83 redundant items in AcelorMittal’s plant, it reduced the base load by 20 per cent.

CANADA’s #1 SOURCE FOR COATING INSPECTION and TEST EQUIPMENT

“We get people in all departments—finance, operations, engineering, maintenance—and we put them on a team,” says Patel. “If they spend 10 to 20 minutes a day, by the end of the year they have put a lot of time into energy management.” This solves a problem that is often overlooked: the people who are in charge of energy use are separated from the people who are in charge of energy costs. By bringing them together an organization can develop an understanding of what can be accomplished in-house, what might require outside expertise, and which options would be capital intensive. “It can be complicated,” says Fred Granek, vice president of sustainability and executive director at the Canadian Centre for Pollution Prevention (C2P2). “This is because a lot of energy issues are about process improvements.” Granek says that C2P2, which works on comprehensive pollution reduction strategies, will fit energy conservation into a larger environmental plan. Usually, HVAC and lighting are the places to start, but after that it becomes a challenge. “The processes can be complex,” he says. “Even with ventilation it isn’t necessarily obvious. When you look at a 30-ft ceiling most of the fans are undersized, they just stir air up there, but bigger fans save money and work.” Compressors are another area where plants can do a lot to save energy. Ralph Williams from Hydro One notes that about 70 per cent of all manufacturing facilities have compressed air systems. This is one of the most expensive uses of energy: to generate one horsepower of compressed air requires eight horsepower. As well, typical air leaks in compressed air systems account for up to 30 per cent of the compressor’s output. “You walk around a plant and you can hear compressors leaking,” says Williams. “That’s just energy being blown out to the atmosphere. A lot of people complain about having to get bigger compressors, but really they should be addressing the leaks.”

LEADERSHIP MATTERS

The MBX Bristle Blaster removes corrosion, mill scale, and coatings while creating a 2.7 to 3.3 mil surface proﬁle and near-white/white metal appearance. Light-weight pneumatic and electric tools are ideally suited for spot repairs or jobs where other methods are prohibited.

See our full line of Inspection and Test Products at www.stone-tucker.com

(905) 892-6142 • info@stone-tucker.com 40 | AUGUST 2010 | www.canadianmetalworking.com 06 Stone Tucker.indd 1

7/30/10 9:20:16 AM

Building a culture of energy conservation is something that utilities and consultants can help with, but the willingness has to be there on the part of management. There is perhaps no better example of this than Jim Ecclestone, president of Calstone Inc., a steel furniture manufacturer in Scarborough, ON. “We can reuse 80 per cent of what we produce,” says Ecclestone. “That’s less energy than would otherwise go to recycling.” Mr. Ecclestone is nothing if not resourceful. He has built a culture of conversation in his family-run business that has gone way beyond putting in energy efficient light bulbs. “We have a huge, 2,000 gallon water tank that’s filled with

ENERGY REDUCTION

BUSINESS REPORT

rain water. We flush our toilets with it, and use it to cool our spot welders. Now, those tanks get up to 40º; we’ve hooked up a heat exchanger and fire that heat back into the plant.” This is a remarkable story of innovation and creative thinking, something that any plant could experiment with—assuming management is behind a culture of energy conservation. It also helps that manufacturing plants have ready access to the expertise needed to make a difference. “We are building two more heat exchangers,” says Ecclestone. “We use car radiators and build the casings ourselves; we expect that, other than the front office, we will be able to eliminate the need for natural gas.” And Ecclestone can do this with limited capital outlay. “A car radiator is a couple hundred dollars, and with the fan I can build a heat exchanger for under five hundred dollars. This isn’t a huge amount of money, and it makes a difference.” Ecclestone is ambitious, and has become something of a cause celebre within the green manufacturing community. Part of this is because Calstone is not a large company; many consultants tend to focus on bigger organizations, where the economies of scale bring about more impressive savings. “Our welders are all electrical. We want to reduce our need for energy, our overall cost of electricity, and to reduce our footprint,” says Ecclestone. “I want to be at zero emissions within the next ten years.” For Ecclestone, that means converting his whole operation to electricity. To make this happen he is relying on Bullfrog power, a “100 per cent green electricity provider.” As power is drawn from the grid, Bullfrog’s generators inject the matching amount of renewable electricity. “We also hope to have solar powers, as well as more skylights and by the end of the day we will only need about one third of our present lighting.” Ecclestone’s do-it-yourself approach is a great example for other small manufacturers, many of whom are fighting their way out of the recession and can’t afford the capital intensive outlays that many green initiatives require. “I could go out and spend a million dollars, but who has that kind of money?” CM Tim Wilson is a freelance writer based in Peterborough, ON. www.canadianmetalworking.com | AUGUST 2010 | 41

TURNING

CUTTING TOOLS

Hard Work

Extending tool life in the hot zone

By Tim Wilson ............................... When it comes to hard turning applications, improving tool life requires a good understanding of the factors that contribute to wear. Perhaps the most important is heat transfer from the insert into the toolholder. As heat collects on the tip, wear increases, even with PCBN (polycrystalline cubic boron and nitride), and its cousin CBN, the hardest material next to diamond. “When it comes to CBN a big difference from our perspective is that we don’t braze the CBN tip onto the carbide,” says Steve Geisel, senior product manager for Iscar Tools Inc., Oakville, ON. “This is a major advantage, because when you are cutting hardened steel it produces an amazing amount of heat. A CBN insert that has been brazed will start to melt and liquefy.” When this happens the cutting edge can’t hold to the substrate, and the insert can come off. Iscar’s approach is to sinter right to the substrate. By transferring heat to the body of the insert, and keeping the tip cooler longer, tool life can be extended. “This way the material won’t be weakened because of the heat generated,” says Geisel. “The tip can’t pop off, and it allows for heat transfer from the material to the carbon substrate. You want that, because you don’t want all the heat to be on the tip.” But there are some interesting brazing technologies, too. For example, Tungaloy has developed a patented process for brazing the CBN segments to a carbide insert. “The melting point of the new brazing technology is almost three times greater than with conventional brazing,” says John Mitchell, general manager for Tungaloy Canada in Brantford, ON. The problem is that as things heat up the operator may not be aware

PRODUCT REPORT Ingersoll

Ingersoll’s new CVD coated Series T-Tinox grades bring higher levels of productivity to stainless steel turning. The copper-coloured T-Tinox coating resists material build-up on the cutting edge while Ingersoll’s T-Turn+ technology provides a smooth, stable cutting edge.

The new series consists of three new grades. TT9215 offers high wear and chipping resistance and is ideal for high speed and continuous cutting in stainless. TT9225 is an excellent choice for general purpose stainless steel applications, providing an optimal balance of wear and fracture resistance. TT9235 provides both fracture resistance and toughness and is ideal for interrupted cutting in stainless steel at low cutting speeds. The end result is a grade that offers smooth chip flow, optimal performance and extended tool life. www.ingersollcuttingtools.com

effectively as well. The inserts are made of the company’s grade IC8250, which has proven superior to the familiar grades IC9015, IC9054 and IC9025. The Sumo Tec surface treatment improves tool performance by an average of 30 per cent as it seals surface micro-cracks in the insert. This treatment reduces friction and built-up edge, improving cutting edge chipping resistance. The new grade immediately replaces grades IC 9015, IC 9054 and IC 9025 and eventually will become the mainstay grade across Iscar’s entire groove-turn line. www.iscar.com

Greenleaf

Greenleaf toolholder systems for use with ceramic inserts are based upon industry standard hardware. However, geometry and pocket depth are designed to

Iscar

Iscar has improved its line of Cut-Grip and Heli-Grip groove-turn tools with a new CVD coated substrate that doubles tool life while raising productivity by 15 per cent, claims the company. It performs especially well on steel, but handles other materials www.canadianmetalworking.com | AUGUST 2010 | 43

COME SEE WHAT ALL THE

IS ABOUT!

SECO TOOLS BOOTH W1564 McCormick Place West Chicago, IL September 13–18

Cutting Tool Innovations • Process Improvements Industry Solutions • Daily iPad™ Give-aways

www.secotools.com/us

iPad is a trademark of Apple Inc.

TURNING

of what’s going on. A conventional braze may soften when in cut, and the softened braze can then allow the CBN segment to move and chip. “The machine operator may also get the false impression that the CBN chipped,” says Mitchell. “And he may move to a softer grade to avoid the chipping.”

HARD TURN

When it comes to addressing the issue of tool wear, the answer can be counterintuitive, requiring an examination beyond the obvious. For example, though edge strength issues can lead to tool breakage—a catastrophic failure—it is not the main cause for concern, and neither is abrasive wear. “We have looked at the process of hard turning from the point of view of application demands on the tool materials,” says Gabriel Dontu, global superhard technical leader for Kennametal Inc., Ann Arbor, MI. “In continuous hard turning the prevalent mode of wear is chemical, also known as ‘cratering.’ Due to the high temperature generated by the process, there is a very active chemical reaction between the workpiece material and the tool materials.” This is a defined process, wherein the chemical reaction dissolves the tool materials into a solution. In effect, Kennametal discovered a high temperature chemical reaction between cubic boron and nitride. “You might think: I have the second hardest material known to man (CBN), why not use the highest concentration in PCBN tool material?” says Dontu. “Hardness helps with abrasive wear, but PCBN is a composite material and the chemical wear affects mainly the CBN component.” What to do? Kennametal set out to reduce the chemical reaction itself, and also to determine which binders were most effective. “You need a good interface between the CBN and the binder,” says Dontu. “The binder, which is in powder form and mixed with CBN powder before synthesis, also has to exhibit good chemical wear resistance.” To reduce the intensity of the chemical reaction in continuous hard turning, it is necessary to reduce the chemical that promotes the reaction. For Kennametal, that means dropping PCBN content.

CUTTING TOOLS

PRODUCT REPORT maximize ceramic performance. Negative tools have a 10˚ negative side rake rather than the 5˚ usually found in tools for carbide inserts. This will increase clearance and, in turn, tool life. The additional pocket depth allows for thicker inserts with shims available to adjust the thickness stack-up for thinner tools if necessary. Greenleaf claims that WG-300 and WG-600 are the world’s most productive whisker-reinforced ceramic inserts. These grades can out-perform carbide and silicon nitride-based ceramics in heat-resistant alloys, hard steels, weld overlays and 400-series stainless steels. Turning applications can benefit from using WG-300 and WG-600 by reducing cycle time and extending tool life. www.greenleafglobalsupport.com

Kennametal

The new Beyond line of high performance turning products from Kennametal now include two new geometries in round inserts for improved productivity in turning steel, stainless steels, cast irons, and high temperature alloys–RU (Roughing Universal) and UP (Universal Positive). “Engineered to deliver improved chip control at lower cutting forces, these new geometries mean excellent size control, superior surface finishes, reduced load spikes on capital equipment, and longer tool life,” says Alexander Momm, global product manager, turning products at Kennametal. “Manufacturing new railroad wheels or re-profiling existing wheels are great examples of heavy duty industries that will significantly benefit from these new products.”

The RU geometry features a proprietary wavy design with optimized size and spacing of the chipbreaking element. This contributes to improved chip control at lower cutting forces, resulting in longer tool life and higher performance in heavy duty

roughing tasks. The UP geometry is designed for medium machining and finishing and also features a unique chipbreaker design with optimized size and spacing of the chipbreaking element for improved performance. As both new geometries are available in Beyond grades, superior edge strength and longer tool life are added benefits. Both new geometries are also available in Kennametal’s Fix-Perfect or traditional pin-clamping styles. “Whether roughing or finishing railroad wheels or attacking any new turning job, machine uptime and tool life are critical,” says UJ Baid, global product manager at Kennametal. “These new geometries deliver superior chip control, longer tool life and provide improved operating conditions for capital equipment, meaning more success in turning operations.” www.kennametal.com

Seco Tools

Seco Tools Canada has expanded its MDT (MultiDirectional Turning) system with hundreds of new holders to accommodate a broader range of standard and special machining applications. These new offerings include long reach holders able to handle up to 8 times the insert width, face machining holders available in Seco’s unique Jetstream Tooling System in up to 6 times insert width, an expanded internal operations product line, and an array of modular systems including 45º holders and long reach machining blades that can achieve up to 5 times the insert width. The MDT system uses a single toolholder and insert for turning, profiling and grooving in both axial and radial directions. The clamping action provides a rigid and stable contact surface several times stronger than competitive systems. MDT’s versatility offers improved productivity through fewer tool changes and machine stops. It also simplifies tool handling and stocking requirements by replacing the need for several conventional tools. The MDT system can be used for turning, profiling, grooving, and www.canadianmetalworking.com | AUGUST 2010 | 45

TURNING

“We can bring PCBN content down by 50 per cent, and design very chemically inert binders for the other 50 per cent. The main binder components used in hard turning grades are titanium carbide, titanium nitrate, and titanium carbonitrate,” says Dontu.

The ceramic solution

However, in hard turning CBN/PCBN are not the only options. In some cases ceramics are the right choice, but ceramics require an understanding of the application to get the most out of a tool.

“ Ceramic is more cost effective

on a cost per corner basis than PCBN, but CBN is capable of running at speeds of up to twice as fast as ceramics and lasts much longer.”

“Generally speaking ceramic is more cost effective on a cost per corner basis than PCBN, but CBN is capable of running at speeds of up to twice as fast as a ceramic insert and generally lasts much longer,” says Mitchell from Tungaloy. Mitchell adds that major cost savings are had through reducing cycle time rather than the cost per edge of an insert. This can make the PCBN insert better at reducing the true cost to machine a part, regardless of the price difference. “Ceramic is very brittle, whereas CBN has a large application range,” adds Alex Livingston, a product manager at Tungaloy. “However, ceramic is capable of running in material as soft as 50 Rockwell, where CBN prefers to run in the harder materials.” As well, grade selection is more complicated with PCBN than with carbide or ceramic inserts. Simply put, CBN content affects the toughness of a grade: the higher the CBN content the Walter Valenite tougher the cutting edge. And, as is so often the case, getting it right often involves trade-offs. “There are many factors to consider when selecting a PCBN insert,” says Mitchell. “CBN content, grain size, binder, edge prep, coating and segment size—to name a few. When machining with CBN it is best to run dry when looking for better surface finish or chip resistance. However, running CBN wet may help to extend the tool life.” As well, extending tool life in hard turning means assessing the factors involved in selecting the proper CBN insert, such as surface quality, size control, burrs, and chip formation. The right coatings, which allow for better surface finish, reduced burrs, and extended tool life, are a big help, as are the

cutting tools

PRODUCT REPORT parting-off. Suitable applications include turning of parts with many different diameters, complicated profiles and grooves. For complex parts of this type, several standard and special tools can be replaced by one Seco MDT tool. Savings can be achieved through fewer tool changes and reduced stock. MDT’s stability comes from its unique Secoloc clamping action. The clamp combines a V-location in the top of the insert with serrations underneath, so the contact surface between insert and toolholder is exact and stability complete. To help with MDT tool selection, Seco has developed an MDT Facing Tooling Selection Calculator available at the Seco website. Just choose your application and the calculator will pick the correct tool along with the ordering number. www.secotools.com

Sumitomo

The Super FF coating (Fine and Flat) on Sumitomo’s new grades AC820P and AC830P is not only more wear resistant than conventional coatings, it also reduces the possibility of chip adhesion due to its smoothness. Combined with newly developed carbide substrates, the AC800P series offers higher speed capabilities and a greater resistance to breakage than conventional carbide grades when machining steels and stainless steels. The AC820P excels in general purpose machining and is

COOL BREEZE UTILITY SERIES Solid Micro-Grain Carbide End Mills Coated Variable Helix End Mills for Materials up to 55HRC • Coating for improved lubrication and high hardness • Special cutting edge design provides high rigidity • Flute design promotes efficient chip evacuation • Cool Breeze tight tolerances Diameter

L.O.C.

Chamfer

O.A.L.

Price CAD

¼” �⁄��” �⁄�” ½” �⁄�” ¾” 1”

¾” ��⁄��” �⁄�” 1” 1 ¼” 1 ½” 1 ½”

.008”x45° .008”x45° .012”x45° .012”x45° .015”x45° .015”x45° .020”x45°

2 ½” 2 ½” 2 ½” 3” 3 ½” 4” 4”

$9.96 $13.66 $17.28 $29.69 $50.77 $78.07 $141.96

C.N.C. VARIABLE HELIX: 4 Flutes 10% Co, 0.6µm grain size

www.pctcarbide.com Phone: 888-398-9449 2010 PCT Carbide www.canadianmetalworking.com | August 2010 | 47 TNT Tools April.indd 1

3/23/10 9:37:10 AM

CUTTING TOOLS

TURNING

application of chip-breakers, which can control the chip to avoid chip packing and “bird-nesting”.

PRODUCT REPORT

A BLACK ART

When moving into hard turning applications, an operator needs to know when carbide will no longer do. This can be a tough call, because the out of pocket costs for CBN can be steep, and it’s important to know that the tool life—and the quality of the work—will make it all worthwhile. “Some people consider material hard at 45 Rockwell, and others think hard is 55 Rockwell,” says John Kollenbroich of Horn USA, Inc., Franklin, TN. “But there is a big difference: at 45 you can get away with cutting with carbide, but at 55 it is really difficult.” Which is to say, once you hit that level of hardness you have no choice but to consider CBN precision inserts. On the grooving side of the equation, heat treatment can also have a big effect on tool life, because if done wrong it can result in additional work. “Often a pre-cut groove shrinks during heat treat, and a lot of times CBN inserts at an exact width are simply not available,” says Kollenbroich. “We work with the customer to address issues like the depth of the cut, how much material to remove, and what kind of tool life to expect.” Knowing what a normal tool life is goes a long way to assuring that the best practices are in place. Kollenbroich says Horn can provide some support over the phone, but ideally it’s better to have someone on the floor with the customer. “It comes down to your experience cutting bigger chips. With heat treatment, parts have a tendency to do some very odd things. Grooves can shrink, distort, twist, even collapse.” There are a lot of variables here, and no guarantees. “This is specific to the material,” says Kollenbroich. “It’s a black art. You don’t want it to fall undersize after heat treat, and you want room for the cut to avoid tool failure–—you want to actually cut it, not rub against it.” CM Tim Wilson is a freelance writer based in Peterborough, ON. www.horn.com www.iscar.ca www.kennametal.com www.tungaloy.com 48 | AUGUST 2010 | www.canadianmetalworking.com

Walter Valenite

available in a wide variety of chipbreakers, including the new high efficiency EGE. For interrupted applications, the AC830P is the first choice among P30 grades. Its exceptional toughness can sustain more impacts than conventional P30 grades. www.sumicarbide.com

The increasing importance of titanium materials in aerospace, medical, and other precision component industries demands the best possible machining solutions. Walter Valenite is tackling this challenge with the Sky·tec family of products, and the latest additions of three insert geometries to machine the full range of titanium applications. These three new geometries from Walter Valenite make turning titanium alloys (e.g. Ti6Al4V and others) much more cost-effective and more reliable than ever.

Tungaloy

Tungaloy’s new line of turning inserts are the PremiumTec post treated inserts. The post treatment is a special surface technology that creates an extra smooth surface which prevents chip adhesion and improves chip flow.

Adhesion Reinforcement Technology is a special treatment that enhances the bond between the coating and the substrate. This means the coating will not flake or chip, giving the insert longer tool life. Columnar Stabilization Technology is the manner in which the crystal structure of the coating is oriented. This technology provides excellent fracture resistance and extended tool life. With Tungaloy’s new Premium Tec line of carbide turning inserts the user can expect longer, more stable and more predictable tool life capable of running at higher speeds and feeds. www.tungaloy.com

Details of the new titanium geometries: NFT: Finishing to the highest accuracy at high cutting speeds; available in periphery ground or as-sintered versions. NMT: Medium machining with low cutting forces due to the curved cutting edge. Effectively handles unstable components and internal machining; available with as-sintered periphery. NRT: Roughing—rigid geometry for high metal removal rates; as-sintered periphery. The Sky·tec program has an optimized combination of substrate, coating and geometry working together to minimize crater wear and provide excellent chip control. The performance improvement compared to conventional solutions is considerable; customer results have yielded tool life improvements of more than 150 per cent, says Walter. The inserts are available in the C, D, S and V styles with negative edge geometry. Two cutting tool grades are available: the new addition to the range, the uncoated grade WS10, and WSM20 with PVD aluminum oxide coating (“PVD-Tiger”). For the majority of applications, the uncoated WS10 is the first choice for machining titanium alloys. www.walter-tools.com/us

You have to

be there! In today’s economy, it’s not the strongest who survive, but those who are most adaptable to change … at IMTS, you’ll see what’s coming … • New technologies • Innovative approaches • Breakthroughs to the next level More than 90,000 manufacturers, including many of your toughest competitors, will see and compare the latest in machines, tools and software at IMTS 2010. At IMTS, you will … Get new ideas: 95% are satisfied with exhibit visits. Solve specific manufacturing problems: 88% are successful in finding specific products or solving specific manufacturing problems. Build future success: 51% make new business contacts.

When you attend IMTS, you maintain your competitive edge. You have to be there to stay in the game. Register Today at IMTS.com!

W h at W i l l i t s pa r k i n yo u ? I N T E R N AT I O N A L M A N U F A C T U R I N G T E C H N O L O G Y S H O W SEPTEMBER 13-18, C h i C a g o

IMTS.com

Spark your productivity with ESAB. with ESAB.

At ESAB, we have everything you need to get the job done – whether it’s arc welding, plasma or mechanized cutting, gas apparatus, or welding automation. Plus, you can count on us for a wide range of ﬁller metals and top-of-the-line personal protection equipment. What’s more, our experts are ready to help you choose the products that best ﬁt your application. So let ESAB power the production of your next project.

ESAB Welding & Cutting Products / esab.ca / 1.877.935.3226

Be sure to visit us at Weld Expo booth #11023.

WATERJET CUTTING/CASE STUDY

FABRICATING

Cutting Costs with Waterjet Ontario fabricating shop cuts costs, improves turnaround with new waterjet cutting system Since the early 1990s, Stainless Outfitters, Barrie, ON, has outsourced a large portion of its work. But when costs started to escalate and the shop missed some deadlines, the company decided to bring all of its work in-house. Within a short time the new Flow waterjet cutting system that the company installed in its shop helped improve turnaround from weeks to days, reduce waste and attract new customers. Stainless Outfitters has been in business since the early 1990’s, serving primarily the marine industry. It fabricates any stainless steel products on a boat including boat railings, T-tops, radar arches and anchor carriers. Its work includes prototyping for boat manufacturers, insurance repair work and customizing boats for individuals. The shop uses mostly stainless steel, but does fabricate using other materials too. Over the years it has expanded into medical and industrial markets and added a variety of machine tools ranging from CNC turret punch and tube benders to milling machines and polishing equipment. But it was still outsourcing a lot of its work.

THE PROBLEM WITH OUTSOURCING

Stainless Outfitters outsourced laser as well as some router work. “There were a couple of years that we were paying a laser shop $50,000 to $70,000 annually,” says Andrew Fenton, owner. “I used to run a laser and I know it’s not easy to set it up to run just one part. So, it made sense that they had a minimum charge. But there were many times that we were scrambling to find other work to go with the one part to make the minimum charge reasonable.” In addition to the high cost of outsourcing, the timing of getting their parts back could cause problems. “The boating season in Canada is short. Sailboat racers regularly break something on their boats and they need the part right away. The laser shop’s delivery times were a big problem for us. When someone has a half million dollar boat break, he doesn’t want to wait; and he is willing to pay for fast turnaround,” says Fenton. It was time to bring that work in-house. The company was considering a laser or a high definition plasma machine when Fenton saw a Flow waterjet in operation on the popular television show featuring Orange County Choppers. “The broad range of materials they could cut and the ease of programming one-off parts looked like it would fit our needs perfectly,” explains Fenton. “We looked for a company and a machine tool we could

Top: Bringing outsourced work in-house has paid off for Stainless Outfitters. Left: Extrusion die cut by waterjet (top) and EDM (bottom).

depend on. We also wanted to bring as much work in-house as soon as possible. Selecting a system that we could quickly learn was important.” The new waterjet system was a 4 ft x 4 ft (1.2 m x 1.2 m) Mach 3 Bengal with FlowMaster software. The new waterjet allowed the shop to bring all of the work in-house that had been previously outsourced to laser and router shops. It also help cut turnaround time significantly. The versatility to cut nearly any material on the waterjet is part of the reason, but the quick set up time of a waterjet and the power of the FlowMaster Intelligent Control System are also key factors, says Fenton. “By bringing in the waterjet, our turnaround time went from weeks to days.” FlowMaster is a powerful, yet simple control system designed for waterjet cutting. The Windows-based software uses SmartStream modeling that takes the guesswork out of creating a part. All an operator has to do is input material, thickness and edge quality and FlowMaster takes care of the rest behind the scenes. The software sets the correct acceleration, speed, and piercing parameters with its advanced capabilities and integral modeling. All machine and pump functions are controlled and displayed by FlowMaster, allowing operators to control the cutting system and monitor the progress of a cut. www.canadianmetalworking.com | AUGUST 2010 | 51

WATERJET CUTTING/CASE STUDY

“The FlowMaster program was easy to learn and it has kept pace with us as we have become more experienced,” says Fenton. “Our customers are amazed at how we are able to turn their ideas into a finished product so quickly.” FlowMaster Intelligent Control System allows Stainless Outfitters to program and cut a part in minutes. Fenton says the learning curve was fast. Now, the job shop can quickly design and cut a replacement part of any size or shape. The waterjet also allows the shop to cut unique designs out of unusual materials at high speed and precision, such as carbon fiber and StarBoard, a non-slip polymer. “Now we are able to cut swim platforms and ladders with radius cut slots and lay them in a stainless steel frame. They look like show pieces on our customers’ boats,” says Fenton.

UNEXPECTED BENEFITS OF THE WATERJET

Stainless Outfitters has not only met its goal of reducing outsourcing cost and time, it’s finding new customers, optimizing material usage, and increasing quality. By adding waterjet, it has attracted new customers such as local machine shops who have them rough out die blanks to save machining time. The company has picked up work ranging from custom sinks and countertops to cutting architectural rails and tile. It even custom cuts stainless and other materials for kinetic and architectural artists. “With the waterjet, we’ve been so busy, we haven’t had to advertise. All of our business comes from word of mouth,” says Fenton. “We aren’t outsourcing anything to the laser shop anymore. In fact, they are now outsourcing their glass, bronze and copper work to us.” Stainless Outfitters is now able to maximize the number of parts it gets when waterjet cutting. The width of cut (kerf) is only 40 thousandths of an inch. FlowNest optimizes the use of material by tightly nesting parts and even allowing common line cutting where geometry permits. The shop can stack thin material and cut out multiple parts at once. Before the waterjet system, the company had to handle a lot of scrap material in different sizes and thicknesses. With the new system, programming to fit odd shaped scrap is easy and the company has now found uses for material that had once been waste. “When we buy our stainless, it comes with a sheet of plywood,”

FABRICATING

PRODUCT REPORT Bystronic

The Bystronic Byjet L is an abrasive waterjet cutting system for processing large sheet sizes. The machine is ideal for steel service centres and other companies that need to process large volumes of waterjet parts or large sheets. The base frame of the machine is a modular construction that can be expanded in 6.5 ft (2 m) increments based upon the end-user’s needs. Models offered range from Byjet L 2030 with a 6.5 ft x 10 ft (2 m x 3 m) cutting area, up to the Byjet L 16030 with a 52.5 ft x 10 ft (16 m x 3 m) cutting area. All models include two High Precision Technology (HPT) abrasive waterjet cutting heads with automatic head spacing, height sensing and collision protection on each cutting head. Optional third and fourth cutting heads are available for even higher productivity. “The Byjet L offers an impressive combination of precision and production while also reducing the user’s cost per part by minimizing abrasive, electric and water consumption,“ states Frank Arteaga, head of product management, market region NAFTA. “The use of two or more cutting heads does wonders in the absorption of overhead and labour costs.”

Output of the systems is enhanced by the use of removable cassettes, which allow for quick loading and unloading of material. Options for abrasive removal and water leveling are also available. The use of bulk abrasive bags is facilitated by the bulk bag extension kit, allowing the machine to run uninterrupted for longer periods of time without the need for abrasive replenishment. The CAD/CAM software package Bysoft is included with the system and optimizes nesting for multihead waterjet cutting. The ByVision control provides an easy-to-use interface for the operator in a Windows-based environment. www.bystronicusa.com

Flow

Flow International Corp. has released Dynamic Waterjet XD, which the company claims is the fastest and most accurate beveling, 3D and 2D waterjet cutting technology available. Now the benefits of Dynamic Waterjet are available for complex multi-dimensional cutting.

Flow invented abrasive waterjet cutting in 1979. Recognizing the inherent errors caused by a non-rigid (waterjet) cutting tool, the company invented Dynamic Waterjet in 2001 to eliminate stream lag and taper errors. It brought accuracy and speed to 2D cutting. Now the technology is available for 3D parts, enabling manufacturers to cut a wide variety of intricate designs, usually eliminating any secondary processing. By incorporating SmartStream technology, cut speed is two to four times faster than conventional abrasive waterjets while producing parts with higher precision. The time to program and complete mulit-dimensional parts has also been shortened. By developing FlowXpert software, parts are programmed with its intuitive, graphical user interface. “The Dynamic XD is awesome. It is saving me time and money, and the part quality is excellent,” says Brad Davidson, owner, Electro Mechanical Solutions. “I’m realizing huge labour savings; for example, to produce one part in the past took two guys one and a half weeks to complete. Using Dynamic XD, that same part takes one guy two days to complete, which is huge labour savings and translates to tremendous cost savings. Plus, the part requires no secondary finishing.” www.flowcorp.com www.canadianmetalworking.com | AUGUST 2010 | 53

FABRICATING

WATERJET CUTTING/CASE STUDY

PRODUCT REPORT Jet Edge

Flow Corp.’s FlowMaster software has helped Stainless Outfitters cut turnaround from weeks to days.

Jet Edge’s Mid Rail Gantry water jet cutting machine is designed to cut virtually any material. It is available in 5 ft x 5 ft, 8 ft x 5 ft, and 21 ft x5 ft, (1.5 m x 1.5 m, 2.4 m x 1.5 m), 8 ft x 13 ft, 21 ft x 13 ft and 5 ft x 13 ft (2.4 m x 4 m, 6.4 m x 4 m, 1.5 m x 6.4 m) work envelopes. The machine comes standard with one abrasivejet

7 Simple Tips To Improve Your Waterjet Cutting Performance By Mohamed Hashish

When cutting material less than 0.10 in. (2.54 mm) thick, little is gained by using medium (50 hp) or large (60 to 100 hp) waterjet cutting head combinations (orifice sizes of .013 in. or larger). Using a small head combination (25 hp each or less than 0.010 in.) can be just as efficient and in some cases allow you to consider multiple cutting heads.

Avoid cutting through air gaps greater than 0.020 in. (0.5 mm). The jet tends to open up in the gap and may cause the lower layer to have a rough edge. When stack cutting, keep the sheets together by using a weight, clamps or even tack welding the pieces together.

3. 4.

Smaller abrasive grains (120 mesh or finer) will require a slightly slower cut speed but will produce a smoother edge surface than that produced by 80 or 50 mesh.

If you intend to pierce composites, glass, or stone on a regular basis, ensure the system has the ability to have the water pressure lowered and raised by the controller. Also, consider using vacuum assist or other techniques to ensure the abrasive is entrained in the water as it first strikes the material surface. Otherwise, the water will act like a hammer on brittle materials and could cause delamination or cracking.

Ordinary tap water is used to feed the waterjet systems. About 90 per cent of all waterjet and abrasive waterjet users require only water softening prior to sending that water through the pump’s inlet water filters and then to the intensifier. Reverse osmosis (RO) and de-Ionizers tend to make the water so pure that it becomes “ion starved.” This aggressive water seeks to satisfy its ion starvation by taking ions from surrounding materials, such as the metals in the pump and high pressure plumbing lines. A simple water quality test performed by your waterjet manufacturer will determine the needs for your individual system.

cutting head; a second cutting head can be added. Optional mirroring cuts part cycle time in half. The machine features an exposed tank that accommodates overhead loading. It uses an industrial PC controller and can be configured so that all three axes are fully programmable (Z optional). It also features direct-couple AC brushless digital servo motors and single or double carriages. Critical bearing components are protected with heavy metal covers with brush seals. www.jetedge.com

Mitsubishi

Mitsubishi Waterjet is now available with 125 hp, 90,000 psi KMT pump. Increased cutting capability and waterjet pressure delivers twice the power of conventional 60,000 psi waterjet systems, claims the company.

If you plan on using different abrasive mesh sizes for different jobs, consider using separate bulk transfer hoppers. The size required depends on the length of the job. Otherwise, you may incur downtime and nuisance while your operators clears out your abrasive hopper. It is important to purge the abrasive feed line between jobs.

Stainless Outfitters used break out tabs and interlocks to ensure accurately welded parts. Break out tabs can also be useful when cutting of materials less than 0.30 in. (7.6 mm) thick. Although break out tabs generally guarantee you’ll need a secondary operation of grinding off the tabs, material handling can be performed faster; you simply unload a cut sheet with the cut parts still intact. The harder the material, the smaller the break out tab should be. Consult your manufacturer for detailed suggestions. Dr. Mohamed Hashish, senior vice president of technology at Flow Corp., Kent, WA, is the inventor of abrasive waterjet cutting.

54 | AUGUST 2010 | www.canadianmetalworking.com

The intelligent high pressure pump design includes synchronized dual top ends, which allow for constant jet pressure. One-head applications can run with a .15 in. diamond orifice for an increase of 40-60 per cent over the 60 hp 90,000 psi waterjet system. The unit also allows faster access to seals and wear parts for easier maintenance. Software includes

WATERJET CUTTING/CASE STUDY

FABRICATING

remote access and the ability to network multiple pumps. www.mitsubishi-world.com

MultiCam

MultiCam Inc.’s threehead 1000 Series waterJet is designed for high production cutting of materials such as foam, tile, linoleum, fabric, gasket, rubber, and other soft materials. Equipped with a 50 hp, 60,000 psi pump, the pure water cutting CNC machine optimizes the water flow for each of the three cutting orifices. Each head is independently adjustable across a 48 in. extrusion, which allows customers to modify the cutting configuration based on part size and the CNC job file. The three-head 1000 Series saterJet offers customers exceptional cut quality coupled with high production and quick turn-around, according to MultiCam. www.multicam.com

OMAX

OMAX Corp.’s new 120X JetMachining Center is designed for manufacturers with large scale abrasive waterjet requirements. Four specific models of the 120X are available, with lengths of 4 m, 6 m, 8 m, 10 m, 11.5 m, and 13.4 m. Each of the models is 3 meters in width and features work envelopes capable of handling standard domestic and international sheet material sizes. The 120X was developed in response to a rise in demand for large scale precision machining from manufacturers serving a variety of industries, including aerospace, petroleum, food processing, and equipment fabricators. By doubling the traverse speed, the machine ensures the high productivity levels that have come to be associated with abrasive waterjet machining. Featuring a patent pending drive system with closed loop, high pole vector drives, the machine achieves accurate and precise movement. The Intelli-TRAX traction drive further ensures higher accuracy. The traction drive system makes the 120X a robust and reliable system that is well suited to harsh environments and requires little maintenance. The worktable comes standard with submersible cutting capability. The waterjet machine incorporates OMAX’s Intelli-MAX Premium Software, which runs on a Windows operating system. The system can calculate the precision of a tool path at over 2,000 points per inch, allowing for complete control over the motion of an abrasivejet, and enabling precise, rapid machining. Additionally, a USB port on the Y axis bridge allows direct connection to a machine controller and additional E-stop/Pause button pendant. The 120X has the ability to cut with an accuracy of motion up to +/- 0.005 in. Additionally, it does not require tool changes or complex fixturing, reducing setup times by at least 50 per cent, claims the company. OMAX waterjet machines are distributed in Canada by Spark & Co., Blainville, QC. www.spark-co.com

Pivot for swim platform and davit systems for boats.

explains Fenton. “I’d try to send it back but material suppliers didn’t want it. So, we’d store it or give it away. With the waterjet and FlowMaster, I can cut the exact size and shape of the outer perimeter of the work piece into the plywood, fit the work piece into the cutout, and use it to secure the part. You can’t do that on a laser.” Stainless Outfitters has not only met its goal of bringing work in-house previously outsourced, but also found a tool that expands its capabilities and quality, and brings in new customers. “Everything we do needs to look good. We have faster turnaround and better looking parts. Having the waterjet has increased our productivity ten-fold,” says Fenton. CM www.stainlessoutfitters.com www.flowcorp.com

See us at Fabtech Booth 3906

www.canadianmetalworking.com | AUGUST 2010 | 55 Jet Edge Aug.indd 1

7/26/10 6:42:36 AM

PRODUCTS

MACHINING/FABRICATING/WELDING

Tools of the Trade 1

50-TAPER VMC

Hardinge Inc. has added two new Bridgeport 50-taper vertical machining centres to its growing machine tool product line—the Bridgeport GX 1300-50 and the GX 1600-50— to complement the 40-taper models released previously. The new machines are designed for heavy cutting of the toughest materials. In addition to a rugged 50 taper spindle, they are manufactured with a heavy duty cast iron base for added stiffness, superior damping characteristics and increased thermal stability. The standard Fanuc spindle motor provides 47 hp (35Kw). A 24-tool capacity, bi-directional automatic tool changer is standard. In addition to the many standard features, a host of options are also available including 4 fourth and fifth axis drive packages, rotary tables, tool probe, part probe, spindle oil chiller and many others. James Langa, vice president of global engineering, says that “new product development is a key component of the company’s strategic plan. These new machines show the commitment from Hardinge in supporting its role as a leading provider of high quality machine tools to the global market.” www.hardinge.com

MULTI-AXIS VMC

Mitsui Seiki’s Vertex high precision line of vertical machining centres just got bigger with the addition of a new, larger machine, the Vertex 750-5X. The new Vertex 750 offers the following benefits for high performance machining: a work envelope of X axis 750 mm, Y axis 800 mm, Z axis 700 mm; weight capacity 500 kg (1100 lb); a small footprint 2200 mm X 3740 mm (87 in. x 147 in.); hand-scraped casting for ultra high geometrical accuracy; a rapid traverse rate of 48m/min (1890 ipm), a feed rate of 20m/min (787 ipm); an integrated trunnion offering fourth and fifth axes with a maximum work size of 950 mm diameter and 650 mm high; 15,000 or 25,000 high stiffness spindles with 40 taper or HSK63 tool types; ergonomic access for loading and operation; and a Fanuc 31i CNC with the latest features for multi-axis contouring. According to Mitsui Seiki, the accuracy of the Vertex line rivals its best jig boring equipment and offers the machining performance of its larger machining centres. Typical applications for this model include aerospace components, mould and die, and other precision components. www.mitsuiseiki.com

MINI TOOLHOLDER

Schunk continues to expand the Tribos toolholding family and now offers mini toolholders and SVL extensions. Tribos mini toolholders and extensions now have clamping diameters as small as 0.3 mm (0.012 in.). This means that circuit board tools with straight shanks can be held directly in a holder. With the introduction of the new Mini, Schunk eliminates the need for many special cutting tools with larger tool shanks. The clamping principle of the toolholders is based on the elastic forces of material to clamp the tool shank. The clamping process can be done within 30 seconds by means of a clamping device, either the manual device SVP-2 or the automatic clamping device SVP-3, together with corresponding reduction inserts. The run-out accuracy and repeatability is less than three microns. Due to the rotational symmetric design, a basic counter balance of less than 4 g/mm is guaranteed. Tribos Mini offers all the benefits of the existing Tribos toolholding family. Since the Tribos system has no moveable components, it is maintenance free, extending tool life. www.schunk.com

EXTREME TEMPERATURE WORKHOLDING

DE-STA-CO has developed the Vulcan series high temperature gripper for foundry and casting applications— especially those seeking to enhance safety through automation. With certain options, the gripper

56 | AUGUST 2010 | www.canadianmetalworking.com

With our nesting software there isn’t much left to talk about. SigmaNeSt is simply the most advanced and efficient nesting software for sheet metal fabrication and profile cutting. That means less waste and huge savings on all your machines—laser, plasma, waterjet, flame, punch, router or knife. Visit talk.sigmanest.com/5 to find out how much we can save you.

Visit SigmaNEST at IMTS booth E-4059.

PRODUCTS

MACHINING/FABRICATING/WELDING

can operate in temperatures up to 450O C (842O F). The Vulcan Series gripper comes in three sizes, with holding capacities from 91 Nm (67.12 ft-lb) to 414 Nm (305.35 ft-lbs). Each can be used for angular and parallel motion applications. The gripper is tested to withstand five million cycles in the most difficult work conditions. Vulcan’s base model has a hard-coat treated body to enhance durability, while an optional fireproof Kevlar boot is available for applications up to 450O C (842O F). The Kevlar boot also protects the gripper from carbon, dust and metal debris often experienced in foundry settings. An optional stainless steel heat shield is also available. A port that enables low pressure air to be blown into the gripper body is also available on certain models. The low pressure air helps extend the gripper’s life by keeping it cooler and by preventing dust from entering the mechanism. For the most demanding, heat intensive settings, the Vulcan Series High Temperature Gripper is the ideal choice. www.destaco.com

WIRE EDM

GF AgieCharmilles’ new Cut 20P wire EDM features a new dielectric unit with three vertical Grundfos pumps for increased performance. Cut 20 P handles wire diameters from .10 to .30 mm with ease and offers the flexibility to satisfy requirements in the fields of general engineering and standard stamping. The wire EDM is equipped with Integrated Collision Protection (ICP) on the X, Y and Z axes. The ICP system prevents any breakage of sensitive parts and costly elements, allowing the operator to work with more confidence during job preparation and execution. Additionally, the Cut 20P features faster wire rethreading, reducing time by 70 per cent over GF AgieCharmilles’ previous Cut 20 model. Features include a new 17 in. LCD console, as well as the HMI (human-machine interface), which is built on the Windows XP platform to enable easy integration into a data network via LAN. This unique programming increases flexibility in the production environment and also allows new users to learn and understand the wire EDM process quickly. Adding to the smart design of control is the inclusion of GF AgieCharmilles’ “Speed” technology package, which allows the Cut 20P to achieve competitive results in terms of precision, time and surface roughness when machining jobs with two to four cuts. The wire EDM’s low energy consumption combined with the long working life of the wear parts reduces operating costs and helps to ensure profitability. Options include: auxiliary M functions with PLC device to make it possible to run or synchronize an indexer or an alarm lamp alerting errors and finished processes. www.gfac.com/us

FIVE AXIS WATERJET CUTTING

“GREEN” LASER CUTTING

Water jet manufacturer Jet Edge Inc. is now offering five axis waterjet cutting technology with Intelligent Kerf Compensation (IKC). Available on select Jet Edge five axis waterjet cutting systems, the innovative IKC 5 Axis waterjet cutting head is capable of making inclined cuts and controlling kerf to ensure optimal part quality. The IKC’s capabilities include 600º rotation, a maximum angle of +/- 60º, and dynamic precision from +/-0.2 to +/-0.5 mm/m, depending on the tilt of head. www.jetedge.com

Bystronic has incorporated a power saving mode into all machines equipped with the ByLaser 6000 and ByLaser 4400BCL series resonators. The new Power Saving Mode reduces the electrical power consumption of the complete laser cutting system by 50 to 70 per cent during standby or non-cutting times. Customer benefits include reduced energy costs, reduced carbon footprint and possible local incentives for electrical efficiency. www.bystronicusa.com 58 | AUGUST 2010 | www.canadianmetalworking.com

6 7

TRUSTED

When you choose MATE tooling, youâ&#x20AC;&#x2122;re specifying the most trusted name in the punch press industry. A reputation earned over 50 years. Thatâ&#x20AC;&#x2122;s because Mate tooling lasts longer, sets up faster and produces the highest quality sheet metal parts. Add to that field service and factory support rated best in the industry. And the broadest range of tooling styles for all major punch press brands with global supply and support. All backed by the Mate exclusive, unconditional 100% customer satisfaction guarantee. See the proof at mate.com or call 1.800.328.4492

PRODUCTS

MACHINING/FABRICATING/WELDING

HIGH POWER PLATER ROLLERS

Oil and gas and power generation fabrication industries are always looking for alloys that allow them to build high pressure vessels, heat exchangers and boilers with very thick high resistance plates. Over the years these industries have moved to extremely resistant steel. For this reason, the fabrication industry requires plate rollers with rolling power in the thousands of tons, i.e. up to 6-7,000 tons. The plate roll suitable for this use is the Davi Mav with variable axis. Davi has built this model for many years and with continued technological innovation. The new Mav (2009 Design) has extensive improvements in the steel frames and the movement of the rolls. The frames have been designed to resist the highest loads to help eliminate the pre-tensioning systems, used in older designed machines. The top roll is controlled by two hydraulic cylinders that work in “pull-mode”, pulling down the top roll when rolling. For this reason the cylinders have been designed to be of adequate size with optimal load allocation. The frames are now connected with an “H system” while other machines still use a reversed C system, which doesn’t guarantee suitable rigidity. As well, the new design allows the use of a smaller pit; approximately a 30 per cent reduction). Another big innovation is in the rotation of the rolls. DAVI is the only manufacturer to utilize all three side rolls to roll these thick plates, which require a higher torque divided by all three rolls. Davi adopted the innovative Multi-Gear system, using multiple reducers applied to the rolls to assure the right amount of rotation power in the most difficult rolling conditions. The Davi Max with variable geometry is also used to build the very thick “Monopile” used in offshore platform construction. Davi has a large number of these machines already installed all over the world for this specific use. In the last 24 months (during the global economic crisis) Davi has sold 80 per cent of the plate rolls to the oil, gas and offshore drilling industries. www.davi.com www.westwaymachinery.com

8 8

PLASMA CUTTING

Hypertherm has released a new 800 amp HyPerformance HPR800XD plasma system for cutting thick stainless steel and aluminum. In addition to its ability to pierce 3 in. (75 mm) and sever 6 ¼ in. (160 mm) thick metal, the system just as easily cuts thin metal—including gauge—without the need to switch torches. The new system’s thick piercing capability is attributed to PowerPierce. This patent pending technology eliminates the need for pre-drilling and minimizes damage to the torch by using a liquid cooled shield to repel molten metal during piercing and cutting. In testing, Hypertherm found there was no damage to its consumables or lessening of cut quality, even after piercing 3 in. (75 mm) thick stainless steel 400 times. The system delivers the industry’s widest process range, giving operators a new level of versatility. From 30 to 400 amps, operators can utilize HyPerformance Plasma processes to mark, bevel, and cut mild steel, stainless steel, and aluminum. This versatility is extended up to 800 amps so operators can also cut thick stainless steel and aluminum with the same system. Until now, fabricators needing to cut a wide range of metals and thicknesses had to use two or more systems to complete the job. “The HPR800XD extends the versatility of HyPerformance Plasma to address customer need, giving industrial customers the ability to cut, mark, and bevel the thickest stainless steel and aluminum and thinnest metal with just one system,” said Aaron Brandt, leader of Hypertherm’s mechanized systems team. “In addition, it delivers the consistent cut quality, high productivity, and reliability HPR owners have come to expect.” A number of industries—including the nuclear, petroleum, and defense sectors— are expected to benefit from this new Hypertherm system. Steel service centres will also benefit as the HPR800XD will allow them to utilize a single HyPerformance Plasma system to meet a range of industry and customer demands. www.hypertherm.com 60 | AUGUST 2010 | www.canadianmetalworking.com

AUTOMATION

welding

Is it Time to Automate? Five factors to consider before making the decision By Rob Ryan, Thomas Jaeger, Tregaskiss, and Kevin Summers, Miller Electric Mfg. Co................................................... Making the decision to automate your welding process isn’t something to be taken lightly. It requires a careful assessment of your current welding process, a detailed plan to automate and, in most cases, the ability to justify the capital expenditure—tasks that together can take months to complete. Still, automating your welding process can bring many advantages that make the work worthwhile. These include: increasing productivity, improving weld quality, and lowering material and energy costs, among other benefits. In many cases, you can also obtain a quick return on your investment through such advantages. The key to successful automation is to consider some important factors before purchasing and implementing your robotic welding system.

Plan Accordingly

Transitioning to an automated welding system can increase production dramatically; however, it should never be done impulsively. It is expensive and does not suit every application or facility. Instead, prior to implementing an automated welding system, work with an integrator or robot OEM to develop a plan that accounts for factors such as: the part and volume to be automated, your facility and available Making a careful assessment of the current welding process and creating a detailed plan is key to gaining the many advantages of an automated welding system. personnel for overseeing the system. Completing an upfront evaluation of your current welding process, as well as the outcome you desire, is a good example, if you currently weld a part well suited to a fixed place to start. It will also help you avoid implementing an automation system, but you aren’t certain you will be welding automated welding system that requires constant supervision. that part three years from now, consider a robotic welding After all, the goal is to have an automated process that requires system. It can be reprogrammed and retooled to accommodate only nominal supervision, while still improving productivity and your needs in the future. weld quality. Evaluate Your Application A good first step is to consider whether you need a fixed or Regardless of the type of automated welding robotic welding system. Fixed automation is efficient and cost system you choose, these systems are effective, and works well for welding parts that require straight significantly faster than semi-automated welding, or curved welds along a single plane. An example would be a provided the process suits the application at lathe-type application in which a simple part is spun, welded hand. Simply put, your application needs to be and ejected from the process. Another example would be a repeatable. Parts with large gaps, fit-up or access straight-line weld, in which the torch advances, makes a six-inch challenges are best left to a welding operator who can weld in weld and retracts to the neutral position in preparation for the obstructed or precarious positions and compensate for such next weld. conditions. Similarly, parts that require intricate clamping and Conversely, a robotic welding system features guns mounted tooling to hold them in place will often hinder the productivity on arms with articulated joints that can reach, rotate and benefits of an automated welding system. pivot to gain access to the part. They can be programmed to If you are considering an automated welding system, be complete more intricate welds than a fixed automation system. certain that the parts manufactured upstream are as simple and If you anticipate frequent job changes or need to weld complex consistent as possible, and that they allow the robot to execute parts, this type of automation can offer the flexibility to be the weld repeatedly. Working with a robot OEM or integrator re-tasked as needed. is a good way to determine if your parts are well suited to an Also, think of your company’s future welding needs when automated welding system. Provide them with a blueprint or an determining which type of automation is best for you. For

www.canadianmetalworking.com | August 2010 | 61

welding

AUTOMATION

“If you want your automated welding system to relieve a bottleneck at the

welding cell, be certain there are no delays in upstream part fabrication.”

electronic CAD drawing of the part you wish to weld. Doing so helps improve the quality of the planned weld and determines how the part and its tooling can be fine-tuned to optimize the automated welding process. Prior to automating, you should also assess the parts flow. For example, if you want your automated welding system to relieve a bottleneck at the welding cell, be certain there are no deIays in upstream part fabrication. Similarly, you should ensure that there is no rework required before sending parts to the welding cell or that the employees supplying parts to the robot can match the cycle time of the automated cell. After all, the efficiency of each of these situations directly affects efficiency of the automated welding system—if they are too slow, they

including important safety regulations that apply in the fabricator’s region, country or state, in addition to those specified by OSHA and RIA (Robotic Industries Association). That said, the first step in assessing your facility is to determine your available space. Remember, the physical footprint necessary for a robotic welding system, as well as the room needed for the flow of raw materials, is significantly greater than that of semi-automatic welding processes. By considering your available real estate, you can be certain that you have the physical space to accommodate the new system, and you can also avoid having to customize products, such as unicables, peripherals or torches to fit the work envelope. Instead, you can rely on standard products that will work within your allotted area. And, don’t worry if you have a small facility. There are still ways to make automation work. One option is to purchase fewer pieces of automation equipment capable of performing multiple tasks. Regardless of the size of your facility, you should also consider the power sources required to operate an automated welding system—a 480-volt three-phase power source is usually considered optimal. Also, consider your gas and wire requirements. Due to the higher volume of welding possible with an automated welding system, you will need to purchase, store and place larger packages of wire (for example, 600 or 900 lb drums compared to 40 lb. spools). In terms of gas delivery, limiting robot downtime is the top priority. Investing in bulk delivery of gas and using a manifold system can eliminate the downtime associated with frequent bottle A robotic system from Tregaskiss. change-outs and is key to adding to the productivity of an automated welding system. can cause significant downtime and negate the speed sought Determine Your Available through an automated welding system. Personnel and Training If you cannot guarantee fast upstream workflow, you may Automated welding systems need human want to consider an automation solution for upstream applicasupervision and maintenance. When considering tions. These machines feature sophisticated part recognition whether to automate your welding system, you systems that can pick up parts, manipulate them to the correct should evaluate the skill set of your available orientation and deliver them to the automated welding cell. welding operators, as well as the resources you These systems add to the expense of automating, however, they have for training them. may be an option if you are concerned about the consistency The personnel who are most viable for training (and and cycle time of your manual upstream processes. ultimately the oversight of your robotic welding system should Assess Your Facility you proceed with the purchase) are skilled welding operators You might consider working with a third party or those with previous robotic welding management experiintegrator to help you decide whether your ence. These individuals should, after training, have the skills to facility suits the installation of an automated program the robot and to troubleshoot the automated welding welding system. System integrators are process as needed. They should also be able to perform routine, knowledgeable about all aspects of facility preventive maintenance on the system, as it can significantly modifications necessary for automation, decrease downtime in the long term and increase the life

62 | August 2010 | www.canadianmetalworking.com

AUTOMATION

WELDING ADVERTISERS INDEX

Lincoln Electric’s robotic arc welding system for submerged arc welding with a robot.

of the system and its components. Consider vetting robot OEMs to determine the availability and costs associated with the training of your personnel. Typically, robotic integrators and OEMs training last one to three weeks depending on the certification level desired. Also, look for robot OEMs or integrators that have resources available after the training has been completed. These resources may include online tutorials or troubleshooting information, additional onsite training and/or service team members you can reach by phone with any questions you and your team may have.

JUSTIFY THE EXPENSE

Finally, before transitioning to automation, you will need to justify the expense—either to your superiors, or to yourself if you are the decision maker. To do so, first consider whether the volume of parts you need to produce necessitates automation. Remember, the key benefit of an automated welding system is the ability to produce high volumes of quality welds. If you have a smaller facility with lower runs of parts, however, you may still be a good candidate for an automated welding system. With the help of the integrator or robot OEM, you may be able to select two or three smaller volume applications and program a robot to weld those different parts instead. Calculating payback requires you to assess your current part cycle times and compare them to the potential cycle times of an automated welding system. Determining this volume is a critical factor to estimating your potential return-oninvestment, as up to 75 per cent of the cost of a semi-automatically welded component is the labour. That said, even if you produce the same number of parts, you might be able to justify the investment by the amount of labour you can reallocate elsewhere in your operation. Specifically, you can use the skills of your semi-automatic welding operators toward the completion of challenging welds that cannot be completed with an automated welding system—adding further to your overall productivity. Smaller companies that transition to an automated welding system, or those with frequently changing parts, often seek a shorter payback period (no more than 12 to 15 months) to justify the investment. Conversely, if you know that your production needs will not change for years, you may be able justify a longer payback period. Remember, the key to successful automation is planning. Work with a trusted integrator or robot OEM to assess your current welding process and to determine the best type of automation for your application. Don’t forget to consider your available personnel, options for training, and any facility accommodations needed for a new automated welding system. Each of these factors is crucial to realizing the advantages of automation and can help you achieve a faster return on the investment. CM Rob Ryan is the product manager, and Thomas Jaeger is an engineering manager at Automation Group, Tregaskiss. Kevin Summers is the manager, Automation Business Development and Customer Support, Miller Electric Mfg. Co. www.Tregaskiss.com www.MillerWelds.com

ADVERTISER PAGE AMT Machine Tools 38 Agie Charmilles Corp 31 Association of Manufacturing Technology (IMTS Show) 49 Bohler-Uddeholm Limited 37 Chem Ecol Ltd 35 DMG America 24 ESAB Group Canada 50 Euroblech 2010 12 Fagor Automation 46 Feeler by Methods 9 Flow Industrial 15 10 Go Industry Haas Automation 11 Hardinge Inc 36 Horn USA 7 Hurco 2 Iscar Tools 66 Jet Edge 55 Makino Inc 32 Mate Precision Tooling 59 Motoman Robotics 15 PCT Carbide (TNT Tools) 47 Reid Tool Supply Company 41 Sandvik Coromant Flap, 42 Schunk Intec Corp 29 Scientific Cutting Tools 23 Seco Carboloy 44 SigmaTek 57 Society of Manufacturing Engineers (SME) (CMW Show) 14 Stone Tucker 40 Toyoda (Elliott Matsuura) 4 Trumpf Inc 52 Tungaloy Canada 3 WIDIA 20, 21 YCM 27 QUALITY CANADA ADS Carl Zeiss (Elliott Matsuura) Flir Systems Minitab 8CMM20186 Mitutoyo Canada01/07/2008 Renishaw Canada Ltd

4 9 12 08:192 AM 5

IN STOCK

American Standards and specials. Japanese Standards inch or metric.

FOR FAST DELIVERY: Contact your local tooling dealer or order direct. TEL 937-686-6405 FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O. Box 61 Bellefontaine, OH 43311

www.canadianmetalworking.com | AUGUST 2010 | 63

Pag

Metal...Works A New Manufacturing Model North America’s manufacturing industry is in trouble; Charles Ruecker thinks he can save it By Mary Scianna ........................................................................................................................................................... When Charles Ruecker read an editorial in a recent issue of Canadian Metalworking about job shop cooperatives, he contacted the magazine to let us know about his new manufacturing model, a network of independent machine shops that have teamed up under Ruecker’s umbrella company, Core Powered Inc., Mississauga, ON, to deal with offshore competitors. A tool and die maker by trade who began his career in his father’s shop in Uxbridge, ON, Ruecker began to see cracks in the manufacturing industry in the late 1990s. Increasing competition from offshore companies was wreacking havoc on manufacturers that didn’t know how to handle these aggressive competitors. “I wanted to build something that would help companies become more profitable. So I looked at all the companies I’d worked with over the years and thought if I could take the specialized expertise from each of these individual shops, wow I’d have a high performing business.” Core Powered Inc., formed a year and a half ago but brewing in Ruecker’s mind since the late 1990s, is partly a single-source manufacturing company offering varied skills and technologies, and partly a manufacturing consulting firm. Members bring unique machining skills to the group and in turn receive business advice from each other on how to run smarter and more competitive companies. Members include Precision Components Ltd., a Hamilton, ON, tool shop that specializes in indexable cutting tools and holders; Holmes UK, a British firm that Ruecker says is also one of the driving forces creating stronger supply networks in Eastern Europe and India for Core Powered members; Micrometric Ltd., a precision machining shop in Scarborough, ON, which focuses on automated machine building and assembly production systems; Echo Hill Automation Inc., Beamsville, ON, which specializes in centreless grinding solutions; and Quality Inspection Technologies and Elite Tool and Gauge, a Beamsville, ON, machine shop with expertise in metrology inspection for production processes. Another key member is RH Collets, a workholding manufacturing company Ruecker formed in 2006 to test the Core Powered business model. “RH Collets is now a North American recognized brand name for specialized workholding. Under the new Core Powered umbrella, RH Collets has become a Core Powered brand and a specialized business offering a unique product and expertise just like our other members.” How does a member company benefit from being part of the Core Powered group? Free access to business expertise they wouldn’t otherwise have, and opportunities to tap into new markets and new customers in the US and abroad in emerging

countries such as China and India. Ruecker says his business model allows each member company to be more competitive because they’re able to work on what they do best and bring that to the table. He cites as an example a specialized collet for a US customer who required 10 such collets for one machine tool. “When the machine was built, each collet was $700 from the OEM in St. Louis, MO. This American customer went to Hardinge and it said it could do it for $500. Then we came along and sold each collet for $300.” The collet was blanked out by the UK member, jig ground in Toronto, sent back to the US for some finish grinding and then returned to Toronto for the final jig grind and finish. “Each shipment back and forth was about $100, so it wasn’t expensive,” explains Ruecker. “This is an illustration of us as a group using best practices from each of our operations rather than one company trying to change equipment to get the job done.” Members of Core Powered operate as separate departments within a large company and invoice to Core Powered for their respective work.

“When I go to different machine shops everyone has

something good to offer... it’s not what you’ve got but how you operate your business that can bring success.”

64 | AUGUST 2010 | www.canadianmetalworking.com

While Core Powered is open to adding new members, Ruecker says businesses wanting to join must meet certain criteria. “One criteria is that a company has to have a demonstrated capability that is unique or can go toe-to-toe with anyone in the world. Another criteria is that 80 per cent or more of a company’s revenue comes from other streams. You have to have a demonstrated sustainable business.” Ruecker says his model is working. Sales have averaged 30 to 35 per cent with 2009 sales at 17 per cent, reflecting the downturn in the economy. “When I go to different machine shops, everyone has something good to offer, but it’s not what you’ve got but how you operate your business that can bring success; a lot of smaller job shops don’t have the training in how to run and grow a business and that’s where Core Powered can help by offering businesses advice that’s shared among members and accessing new customers and markets on jobs that are shared.” He adds that “if we don’t make a change to how we manufacture in Canada, manufacturing in this country is on the way out.” Visit www.canadianmetalworking.com for an extended version of this story. CM www.corepoweredinc.com

Perfect performance.

ESAB Coreweld C6 – the best in metal core-wired performance. Welding with metal-cored wire can reduce weld cycle times, yield higher deposition rates than solid wire, and increase travel speeds, signiﬁcantly improving your welding process. Ideal for applications in the automotive, railcar, agricultural, heavy equipment, and food and chemical industries. With local warehousing and distribution across Canada, ESAB ensures you have your product when you need it.

Find out why Coreweld C6 could be right for you.

To register for a free trial and consultation, visit www.esab.ca/C6 or email us at CanadaMktg@esab.com.

esab.ca + 1.877.935.3226 IntEgrIty + ExpErIEnCE + InnovAtIon + pArtnErShIp

Technologically Advanced Solutions for Maximizing ProďŹ tability in the Oil and Gas Industries

www.iscar.ca

AUGUST 2010

A new te

HANDHELD GAUGES

An expert’s outlook on where developments for handheld gauges are heading.

chnology

IMTS PREVIEW

Vision

ar t s

BETTER

f u n ma y f i to ver

North America’s biggest event for manufacturers holds the promise of success.

re u t ac

SPC SOFTWARE 8 Do’s and Don’ts.

from

SJ-210

High accuracy and measuring speed plus innovative features creates a new class leader in surface inspection. • Large 2.4” colour LCD display with backlight • Display direction can be changed for viewing horizontally or vertically, left or right handed • All data can be displayed in any of 16 languages, including colour tolerance judgments and evaluation curves • Self-timed measurement and optional foot switch • MicroSD card supports high volume portable data storage • Multiple output options (USB, SPC, RS-232C) • Minimum resolution of 0.002 µm • Supports 1,000 or more measurements (battery) • Available in Standard type, Vertical drive type or Lift type • Wide selection of optional drive units and detectors

Special Introductory Offer For a limited time only

Contact your Mitutoyo distributor for details and pricing.

Portable Surftest®

Standard drive type

Vertical drive type also available

Lift drive type also available

Model No. 178-561-02A 4mN type/Standard drive unit

Precision is our profession.

Mitutoyo Canada Inc. Toronto (905) 821-1261 Montreal (514) 337-5994 www.mitutoyo.ca info@mitutoyo.ca

MEASUREMENT/HANDHELD GAUGES

Expert’s Outlook Quality Canada speaks with L.S. Starrett’s Scott Robinson about developments and where gauges are heading Quality Canada: How do you define a handheld gauge for manufacturing operations? Well let’s start with defining what exactly a handheld gauge is.You have to remember that handheld instruments are basically divided into two groups, the tools capable of linear measuring and those that are attribute style or really go/no go. When I think of handheld gauges, especially when tied to the word quality, I naturally think of micrometers and slide or electronic calipers. The reason I think of these is that they can give you a reading because they incorporate a sliding or rotating precision mechanism and a stationary anvil, and also give an actual dimension. There are a limited number of dial type tools that incorporate this stop but most dial indicators are open ended. With attribute gauges, Scott Robinson handheld devices are the radius gauge, the thread gauge, the feeler gauge, etc. They may not be as noticeable as the tools previously mentioned, but we can’t forget them as they still play a big part in measurement. QC: What have been the top three developments in handheld gauges? There have been several changes in the last few years, but [they have not been] the introduction of revolutionary new instruments. It’s been more of a step back, with more advances in electronics and improvements to existing products. My case in point is electronic micrometers and calipers that are now I.P rated. When

Volume 3 Issue 4 Senior Publisher Larry Bonikowsky 416-764-1489 larry.bonikowsky@rci.rogers.com Editor Mary Scianna 416-764-1540 mary.scianna@rci.rogers.com Art Director Jill Nelson 416-764-1518 jill.nelson@rci.rogers.com Sales Manager Steve Devonport 416-764-1498 steve.devonport@rci.rogers.com Circulation Manager Bibi Khan 416-764-1450 bibi.khan@rci.rogers.com Junior web producer Jessica Mirabelli 416-764-1316 jessica.mirabelli@rci.rogers.com Production Manager Kristen Hrdlicka 416-764-1692 kristen.hrdlicka@rci.rogers.com

ROGERROGERROGERROGERROGERS PUBLIUBLIUBLIUBLISHINGHINGHINGHING LILIMITEDITEDITEDITED

these tools were first introduced 20 years ago they were miracles. The ability to change from metric readings to imperial, hold readings, set limits and send findings to a computer or printer with just a push of a button was unbelievable. The fact that if they got wet or filled with dust and stopped working was accepted. Now these same tools can be submerged and sprayed with coolant and continue to function. The tools have been hardened but accuracy has not changed, and they’re still at the mercy of environmental factors. They still must be held in the hand and used in areas where heat, cold and humidity are not controllable. So asking the tools to measure accurately to tolerances greater than one ten thousandths I just don’t see happening. Second, there has also been a tremendous influx of offshore hand tools.You can find calipers for sale as you walk down the aisle of supermarkets. These tools vary greatly in capability, quality and accuracy and I worry about products being produced using these devices as their inspection medium. Third development would be battery improvement. Cells are now lasting longer and providing more power so tools can provide more functions. Another development is advances in wireless communication. Gone are the necessities of stringing rubber cables across the floor to computers situated in cleaner environments. Now small radios are attached to the tools and the signal is sent

President & CEO Brian Segal

ROGERROGERROGERROGERROGERS BUBUSINEINEINESS & PROROFESSIONIONIONAL PUBLIUBLIUBLIUBLISHINGHINGHINGHING Senior VP John Milne VP, Financial Publishing, Brand Extensions & Online Services Paul Williams Director of Audience Development Keith Fulford 416-764-3878 keith.fulford@rci.rogers.com Executive Publisher, Industrial Group Tim Dimopoulos 416-764-1499 tim.dimopoulos@rci.rogers.com

CORCORCORPORORATETE SALELES General Manager, Corporate Sales Sandra Parente

416-764-3818 sandra.parente@rci.rogers.com WEBWEBWEB

General Manager, Online Operations David Carmichael

416-764-3820 david.carmichael@rci.rogers.com RERESEARCHRCHRCH

Senior Director, Rogers Connect Market Research

Tricia Benn 416-764-3856 tricia.benn@rci.rogers.com EVENTENTENTS

General Manager, Conferences & Events Stephen T. Dempsey

416-764-1635 steve.dempsey@mtg.rogers.com HOWHOWHOW TOTO REREACHCH US One Mount Pleasant Rd., Toronto, ON M4Y 2Y5 Tel: 416-764-2000 Fax: 416-764-1735

subscriber Services To subscribe, renew your subscription or to change your address or information… please visit us at www.rogersb2bmedia.com/cmm

Mail Preference Occasionally we make our subscriber list available to reputable companies whose products or services may be of interest to you. If you do not want your name to be made available please contact us at rogers@cstonecanada.com or update your profile at www.rogersb2bmedia.com/cmm. Canadian Publications Mail Agreement No. 40070230 QC receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. QC, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. QC accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. QC, established: 2008 is published quarterly by Rogers Publishing Limited, (www.rogerspublishing.ca), a division of Rogers Media Inc. ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities. Our environmental policy is available at www.rogerspublishing.ca/environment. Content copyright ©2010 by Rogers Publishing Limited, may not be reprinted without permission.

Quality Canada August 2010 3

MEASUREMENT/HANDHELD GAUGES great distances to where receivers gather the information and deliver it to computers for processing. QC: Have advancements in information technology helped to improve handheld gauges? The biggest improvement I have found is the ability to get information to the customer quicker. Being able to email manuals greatly improves the customer’s ability to use a tool that may have had its instruction sheet misplaced. Also it allows customers to send prints or digital photos to engineers to help The 795 gauge includes an RS232 output port for data transmission and works well with Starrett DataSure Wireless Data Collection Systems.

them understand the problems end users have in gauging particular objects, greatly speeding up the process. QC: Has “smart” technology been incorporated into handheld gauges? When I hear the term “smart systems” I don’t necessarily think of traditional handheld gauges but tend to wander toward the multi-sensor systems now offered.Years ago, coordinate measuring systems were thought of as the ultimate answer to all gauging problems. A special irritant was the occasional task to measure thin sheets of material [that were] so thin as to not allow a cross section for the probe to touch. This problem was solved with the inclusion of vision capabilities. With their ability to use edge detection capabilities, they cast multiple points about a circle to gather information be it form or diameter. Now we offer machines with touch, vision and laser.

The value leader just got more productive. The new CONTURA G2 navigator combines our popular CMM with the superb mechanical properties of the VAST XT Gold sensor and the navigator scanning engine to give it even better throughput and accuracy.

Tangential Approach

Helical Scanning

See us at ITMS Booth e5510

Elliott Matsuura Canada Inc Metrology Department Call: (905) 829-1188 www.elliottmachinery.com

QC: What changes do you expect to see in the near future? I expect greater advances in electronic miniaturization driving more capabilities, smaller tools with longer battery life and larger reading screens. [With] miniaturization, electronic caliper bodies have been downsized because of developments in electronics. They’re now lighter weight and have more capabilities than before. QC Scott Robinson is the technical support manager at L.S. Starrett, Athol, MA. www.starrett.com

4 | August 2010 | Quality Canada Carl Zeiss Aug.indd 1

7/26/10 6:58:21 AM

extreme

speed

makeover

Transform your CMM with state-of-the-art Renishaw technology.

Your CMM still has a lot of life left and this is hardly the business climate in which to replace it. Instead, upgrade your sensors, control systems and software and make virtually any brand of CMM the ultimate in performance and precision. A certified Renishaw retrofit™ is the ideal way to boost measurement throughput, future-proof your CMM, reduce operating costs and minimize your capital investment.

Begin a complete makeover with the confidence an experienced metrology leader like Renishaw can provide. • Open controller based error map • ‘One shot’ calibration for infinite number of head angles with REVO™ • Powerful MODUS™ software functionality • Compatible with most CMMs and software Your

ONE

Renishaw (Canada) Limited, 2180 Dunwin Drive Unit1 , Mississauga, ON T 905 828 0104 F 905 828 5519 E canada@renishaw.com

www.renishaw.com/cmmretrofit

STOP SHOP for CMM retrofits

SHOW PREVIEW/IMTS

Manufacturing Success Following on the heels of a tough economic period, North America’s biggest event for manufacturers holds the promise of success Manufacturers from across North American will be flocking to Sweet Home Chicago September 13–18, as the Windy City hosts the 28th edition of the International Manufacturing Technology Show (IMTS). Scheduled for Chicago’s McCormick Place, IMTS will feature more than 1,100 vendors showing off more than 15,000 new machine tools, controls, computers, software programs, components, systems and processes amidst 1.2 million sq ft of exhibit space. Held every other year in Chicago, IMTS is the largest and longest running manufacturing technology trade show in North America. It’s also one of the biggest trade shows in the world. “We are clearly seeing recovery and a sense of vibrancy and urgency in the industry. Certainly, over the past 18 months our industry has faced some of its most trying times. Now, as survivors move forward, they are poised to make serious investments in innovation and productivity. Our projection is that IMTS 2010 attendance will be in line with the 2008 show,” says John Krisko, director of exhibitions at IMTS.

significant venue for quality products, services and new technologies for manufacturing. Most of the leading suppliers will be present.

IMTS 2008 balloon debuts at McCormick Square.

2008 - Exhibitors and attendees examining details on a machine tool.

IMTS 2008 attracted 92,000 people from 116 countries. “Everyone involved in manufacturing can benefit from experiencing the vast array of technologies available at IMTS; executives building a business, decision makers involved in manufacturing equipment purchases, engineers who identify equipment needs, plant superintendents who will set it up, operators who use the equipment and know it better than anyone else and all staff members and suppliers that companies count on for new ideas,” continues Krisko. Quality at IMTS There is no doubt that IMTS is the biggest North American venue of suppliers to the manufacturing industry. It is also a 6 | August 2010 | Quality Canada

Among those suppliers will be: • Blum Laser Measuring Technology (E-5530) • Carl Zeiss IMT Corp. (E-5510) • Hexagon Metrology (E-5115) • Fagor Automation (E-5136) • FARO Technologies (E-5435) • Heidenhan Corp. (E-5131) • Mahr Federal (E-5048) • Mitutoyo Corp. (E-5126) • MTS Systems Corp. (E-5148) • Nikon Metroloy (E-5325) • Optical Gaging Products (E-5525) • Renishaw (E-5515) • L.S. Starrett Co. (E-5403, N-7210) IMTS is managed by the Association for Manufacturing Technology (AMT), a group that supports and promotes the US manufacturing technology sector. AMT will be holding IMTS 2010 in tandem with the National Association of Manufacturers. “We expect IMTS 2010 to be a real rallying cry for the manufacturing technology industry and all of manufacturing. As we begin to see signs of recovery it is the right time to invest in ourselves and our future and that is what we’re hearing from our exhibitors and the thousands of manufacturing professionals registering to attend the show,” says Krisko. For a full list of exhibitors and details on presentations at the conference visit www.imts.com. QC

By Patrick Beauchemin

MACHINE VISION

Technology Spotlight: Digital Optical Comparator VISIONx has launched a patent pending technology that it says is a better way to verify that manufactured parts match up with their CAD data. The company explains the merits in this special product spotlight. Optical comparators, also referred to • Using overlays necessarily introduces an error when printing as profile or contour projectors, were the part’s drawing onto the overlay (no printer is perfect); first introduced in the 1940s and are • Overlays can tear, get damaged, stained and worn; still used in a range of industries to • Overlays need to be physically stored and retrieved, verify that manufactured parts are taking time and storage space; within tolerance. These instruments • There is a risk that the operator may select the wrong overlay; are well suited for use on the shop • Overlays can be used by only one person at a time; floor as well as in the metrology • If you want your suppliers to verify with an overlay the and quality control labs because parts that they are sending you, you need to physically they are versatile, easy to use and send it to him, which results in costs and delays; robust. They also deal well with • Setting up overlays on a comparator is a slow and complex geometries (i.e. shapes operator-intensive process; not easily described by simple • It’s impossible to “recall settings” for an overlay (i.e. elements like lines and position and orientation). The operator needs to circles) and, up until realign every time that he sets up a part. now, they have been VISIONx has recently developed its the easiest way to quickly patent pending VisionGauge digital compare a part to its drawing optical comparator which solves to allow the operator to make an all of these problems and many overall Pass/Fail determination. others as well. And while optical comparators This new instrument uses a are considered to be a cost effective high resolution digital camera The overlay of a knee implant measuring tool, it is also widely and a low distortion telecentric CAD drawing onto the live video recognized that they rely on old lens to capture a high resolution image of the part. technology and suffer from a number of and geometrically exact image shortcomings. The most important is the of the part. The software that is at need to use an overlay, also called a template the heart of this instrument then or a Mylar. With traditional optical comparators, projects this image, along the part’s drawing is scaled to match the comparator’s optical with the part’s CAD overlay, onto a high magnification and printed on a transparent overlay. This overlay resolution quad monitor display. This is then placed on top of the comparator’s screen and aligned approach produces images with an with the image of the part. The operator can then ascertain if on-screen resolution better than that of the part is within tolerance. There are many problems related traditional 30 in. optical comparators. to the use of these overlays, including the following: It also allows for a number of benefits • The cost of the overlays; over traditional optical comparators. • The cost and maintenance of the equipment required • It produces a very high contrast to print the overlays; image so that there is no problem • The cost and maintenance of the equipment required viewing it in full daylight. to calibrate the overlays; • It is much more accurate than • The time required to print the overlays; traditional optical comparators. • The time required to calibrate the overlays • It can carry out automatic Pass/Fail (and verify this calibration); determinations, completely eliminating

Quality Canada August 2010 7

MACHINE VISION operator subjectivity and error. • It can automatically send measurements and data to a spreadsheet, text file, or a database. • It allows the user to be more productive and get more work done with a single machine. • It works directly with the CAD data so that no overlays, templates, or Mylars are required. • It can be used to collect images (either with or without the CAD data overlay and with or without annotations), measurements and data. • It can also carry out automated measurements (like a video CMM). • It has a smaller footprint and uses less floor space than a traditional optical comparator. • It can be moved more easily and without requiring re-calibration (i.e. “rolling cart” configuration is standard). • It has a much greater depth of field, i.e. “everything is in focus all at once.” • It has a longer working distance so there is more clearance between the part and the lens. • It allows you to compare a part to its CAD data beyond the optical field-of-view (because the CAD data tracks the part and follows the stage motion). • It has LED illumination for stable illumination over a 10 year life. This means that there are no more bulbs to change. This instrument is the ideal tool when you need to compare a part to its CAD drawing. It is appropriate for a wide range of industries including orthopedics, medical device manufacturing, automotive, aerospace, energy, and precision mechanical components and assemblies. It is also appropriate for higher magnification and high accuracy applications such as Micro Electro-Mechanical Systems (MEMS) device manufacturing, electronics and semiconductor. Early adopters include the orthopedics, automotive and aerospace industries, among others. In the orthopedics industry, 100 per cent of parts must be inspected and compared to their CAD data during the manufacturing process, directly on the shop floor. These are implants with complex geometries and tight tolerances. In this application, the digital optical comparator’s higher accuracy provides an obvious benefit. Also, because parts can be made in small batches, there is a constant need to change the overlay. With traditional optical comparators, this involves removing the overlay, walking over to the overlay storage area, finding the correct overlay, walking back to the machine and positioning the overlay. All of these operations can easily take a few minutes. With the digital optical comparator, the operator only needs to scan in the work order’s barcode or press a button on the screen to 8 | August 2010 | Quality Canada

Overall view of the VisionGauge digital optical comparator: the collimated LED back illumination module (on the left), the stage and column (towards the middle of the picture) and the quad monitor display (top).

automatically call up the correct overlay, which comes up already correctly positioned over the image of the part. The productivity gains are immediate and all possible errors are eliminated. In the automotive industry, this instrument is used to check flexible parts, among other things. Comparing flexible parts, such as door and window trim, to their CAD data is notoriously difficult and the digital optical comparator’s ability to quickly and easily align the part and the drawing using an intuitive three axis three speed joystick makes the job much simpler. In the aerospace industry, customers are checking critical areas such as the fir tree on engine blades.

A typical application for this new instrument in the automotive industry.

Like traditional optical comparators, this one uses collimated back illumination to produce clear and crisp images with sharp edge profiles. However, while traditional optical comparators typically use halogen bulbs that need to be replaced on a regular basis, this new instrument uses up-to-date LED technology that provides stable illumination over a ten year life. As is the case with traditional optical comparators, front illumination is also available (to carry out surface inspection, for example). There are two main reasons why the digital optical comparator is more accurate than traditional optical comparators. The first has to do with the size of the lens. As with all things manufactured, it is impossible to produce a perfect lens and all lenses have defects and

MACHINE VISION imperfections, to a certain degree. have a part that is larger than the field of view, you can move Furthermore, the difficulty in producing a lens increases the stage to see another portion of the part and the overlay will rapidly with the size of the lens. Traditional optical comparators follow the stage.The CAD drawing moves with the part. need to use large lenses to project the image of the part And because these systems are completely software-driven, onto their 30 in. screen. The optical comparator it is possible to automate all of the operations. As a result, it only needs to project the image of the part is possible to operate this new system using only a barcode onto the camera’s sensor, which measures reader and a joystick. This results in significant productivity slightly less than one inch. This lens gains. Users typically report a doubling of their productivity can be manufactured much more with this instrument, i.e. they can get twice as much work accurately and the raw image that is done with a single machine. projected onto the camera sensor The new optical comparator is an easy-to-use system of the instrument is thus more for the shop floor and the metrology lab. It is available in geometrically accurate than the horizontal and vertical configurations and with industryimage projected onto the standard 5X, 10X, 20X, 50X and 100X magnifications. This 30 in. screen of a traditional new instrument brings optical comparators into the 21st optical comparator. century. It uses advanced technology to offer a better solution The instrument’s camera produces to the classic manufacturing problem of ensuring that parts a digital image that is sent to the match up with their CAD drawing. QC system’s on-board computer. The Patrick Beauchemin, P.Eng. Ph.D. is with VISIONx Inc., software can then carry out further Pointe Claire, QC. corrections on this image to eliminate the last minute geometric distortions and Methods Machine Tool Inc., Sudbury, MA, is the North American inaccuracies. And this is the second reason for distributor for the VisionGauge digital optical comparators. this new system’s increased accuracy: the optical FLIR Research QualityCanada 1/3 :4.625x4.875 7/28/10 10:57 AM Page www.visionxinc.com comparator carries out mathematical corrections to the image to make it virtually perfect. Overall, this new instrument is roughly 10 times more accurate than traditional optical comparators. The use of a small Introducing Affordable Real time camera sensor, instead of a large 30 in. Thermal Imaging solutions for Research projection area, is also at the root of the instrument’s superior optical properties: a much greater depth of field and a FLIR Infrared longer working distance. It is also the Research Cameras: principal reason why these systems have a much smaller footprint and use up less manufacturing floor space than traditional optical comparators. And, i5 i-Series Starting below with Quickplot of course, because this new instrument $2,200 package works with a digital image, it is able to carry out fully automated measurements, with sub-pixel accuracy, just like a video CMM. The digital image can also be saved to disk, either with or without the T-Series SC-Series CAD data overlay and with or without with Quickplot package Handheld annotations, along with measurements, annotations and other data. Another significant benefit to this approach is the fact that the comparator Quick image and data can compare a part to its CAD drawing recording replaces cumbersome SC-Series SC-Series HD Starting under up to 200Hz thermocouple technology beyond the optical file of view.With $10,000 frame rate traditional optical comparators, the overlay is fixed on the screen and doesn’t move www.flir.ca l IRCanada@flir.com when the stage carrying the part moves. But with the new comparator, the overlay “tracks the part.”This means that if you

+ Portable

Quality Canada August 2010 9

SOFTWARE/SPC

| By Les Galicinski

Do’s and Don’ts of SPC

Eight factors to consider when implementing SPC software in your manufacturing plant Statistical Process Control (SPC) is a technical tool for process control and improvement. It uses graphical charts to depict process characteristics such as the process centre, the process spread or the defect rate. The idea of charting process characteristics was pioneered by Walter A. Shewhart in 1924. Shewhart’s charts spawned a huge improvement in industrial quality control and were widely promoted by the American Society for Quality (ASQ) and by consultants such as Dr. D. Edwards Deming, who introduced them to Japan in 1948.Today, SPC is a critical part of practices used to control and improve quality, not only in manufacturing but in all sorts of transactional endeavors. Many organizations have embraced SPC because they have been told that it is the right thing to do. Some are not sure why they are doing it. For this reason, here’s a checklist for your own organization. Do Develop a passion for reducing variation in all processes. Variation is the enemy of quality because it masks accuracy and destroys consistency. Measuring and reducing variability are the keys to success. This is why companies such as Motorola pioneered programs like Six Sigma.These are all designed to give new language to the task at hand, which is to reduce variation as near to zero as possible. Critical in successful implementation is to infuse a passion into the organization to reduce variation and defect rates in all processes. Management must understand and champion this. Get Educated. SPC is a big subject.You will need to understand that there are different types of variation, piece to piece, time to time, and occurrence rate variation. For each of these types there are specific charts that must be used. Using the wrong chart, such as a classic average range (Xbar R) chart for time to time variation, will not work. It will be pointless and lead you to wrong conclusions. In process industries, most processes exhibit autocorrelation, which just means that data values are not statistically independent but are related in time sequence. A Shewhart Control Chart cannot be used in these situations.Time series models and residual charts must be used instead. Another potential problem is non-normal data where special techniques such as power transformations are necessary. Provide training. Use training to instill into people a deep appreciation for the purpose of SPC.Training should be participatory and allow people to experience first hand how variation is reduced. In our courses, we use the Statapult (Statistical Catapult) as a hands-on tool to involve people in appreciating the power of statistical thinking and to provide 10 | August 2010 | Quality Canada

a laboratory for learning.Then we transition into the specific types of charts that people will be using. Finally, we show how software can automate the process and ensure people learn how to interpret and apply what they have learned. Put SPC in the hands of the process operator. If SPC is not in the hands of the person who can actually make adjustments to the process, then what you have is not SPC but SPM (Statistical Process Monitoring).That is great information but not real time and not control. It is also important to empower the operators to make changes to the process, taking advantage of the signals that the charts are giving. In one radiator plant, operators discovered that variation was greatly reduced after a maintenance cycle. By increasing the frequency of maintenance, they were able to reduce variation by 50 per cent.That enabled them to use a thinner wall tubing, saving thousands of dollars a month in material cost. Don’ts Don’t make SPC another legalistic requirement. People must understand why you are doing it, or it will just become another burden. Application without understanding is always a waste of resources. Don’t just buy software and stick it on the process. Again, if people do not understand what the charts are saying, they will be bewildered and conclude that it is just another way of checking up on them. That can lead to all kinds of aberrant behavior. Don’t use it as a policing tool. It only increases fear and anxiety often leading to increased process variation. A police force approach to quality will not help you in the long run. People will always find ways to escape detection or feed you misinformation. Don’t confuse system problems with sporadic ones. The point of the charts is to help differentiate between these. There is nothing that the local operator can do to solve a system problem. That is management’s job. Berating the operator for a system problem is the same as beating them over the head for that which they have no control over. SPC is a powerful tool for process control and for continuous improvement.To be effective, people must understand the purpose and benefits of controlling and reducing variation. Training and empowering people to use it properly will always lead to process improvements and reduced costs. Added benefits are the sense of achievement that comes from making a positive difference to the quality and productivity of the organization. QC Les Galicinski is chief consultant and president of Qualitran Professional Services Inc., a Barrie, ON, consulting and training organization. He has authored a number of texts, including “The SPC Book.” www.qualitran.com

Reach 40,000+

Decision makers in Canadaâ&#x20AC;&#x2122;s Quality Market.

Advertise in Quality Canada to hold the winning hand

To Advertise: Phone: 416-764-1489 E-mail: larry.bonikowsky@rci.rogers.com

Give everyone in your organization the power to improve it.

Introducing

Minitab 16 Statistical Software www.minitab16.com