Canadian Metalworking by Annex Business Media

May 2010 • www.canadianmetalworking.com

Driving Back from the Brink

With the recessionary upheaval behind it, the automotive industry is in comeback mode

23 MACHINING: A research institute’s insights on micro machining point to opportunities for metalworking shops.

38 CUTTING TOOLS: How to select the

right cutting fluid for top performance.

42 FABRICATING: Servo electric press brakes boost productivity by 30% for Ontario grill and fireplace maker.

58 WELDING: A user’s guide to creating a good high stick weld.

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Inside this issue... Volume 105 | No.4 | May 2010 | www.canadianmetalworking.com

INDUSTRY REPORT

FABRICATING

AUTOMOTIVE

SHEARS/PRESS BRAKE CASE STUDY

DRIVING BACK FROM THE BRINK ............................... 14

STOKING THE FLAME.................. 42

With the recessionary upheaval behind it, the automotive industry is in comeback mode.

Servo electric press brakes boost productivity by 30% for grill and fireplace maker.

SAWS

THE AUTOMATIC ALTERNATIVE .... 51

BUSINESS REPORT

Top tips on maximizing automatic saw efficiencies.

SELLING NEW MARKETS

RETHINKING YOUR BUSINESS .. 19 Tough times call for new markets, but selling into new markets isn’t easy.

WELDING ARC WELDING

HIGH STICK WELDS .................... 58

MACHINE TOOLS

A user’s guide to creating a good weld.

MICRO MACHINING

SMALL CAN BE BIG .................. 23 A research institute’s insights on micro machining point to opportunities for metalworking shops.

DEPARTMENTS

CUTTING TOOLS COATINGS

SELECTION GUIDE ................... 32

Any coating will improve a cutting tool’s performance, but each has a particular strength.

CUTTING FLUIDS

FLUID MOTION ........................ 38 Canadian Metalworking asks Craig Brydges from Milacron Canada about selecting the right cutting fluids for your machining operation.

Upfront .............................................. 6

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EDITORIAL ................................................................ EDITOR Mary Scianna

416-764-1540 | mary.scianna@rci.rogers.com

MANAGING EDITOR Daryl Angier

416-764-1508 | daryl.angier@rci.rogers.com ART DIRECTOR Jill Nelson 416-764-1518 | jill.nelson@rci.rogers.com JUNIOR WEB PRODUCER Jessica Mirabelli 416-764-1316 | jessica.mirabelli@rci.rogers.com PRODUCTION MANAGER Jim Howser 416-764-1684 | james.howser@rci.rogers.com CIRCULATION MANAGER Bibi Khan 416-764-1450 | bibi.khan@rci.rogers.com BUSINESS ................................................................. SENIOR PUBLISHER Larry Bonikowsky

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Upfront Going Fishing On a recent family bike ride along Lake Ontario, we met a man fishing. He had a large box beside him with what looked to be about 30 different lures. He explained to us that each lure attracts a different kind of fish. Knowing which lure works best for the type of fish you want is critical to success. The same can be said of the manufacturing industry in Canada. We must create a stronger and more welcoming environment to attract manufacturers to set up facilities in this country. We need to find the right “lures” that are going to bring them in. To do that, we need to understand what companies in different industries need and then invest in the research and development that will help Canadian businesses build up a strength and a specialty in a specific area that no other country offers. As Steve Rodgers, president of the Automotive Parts Manufacturers’ Association says in a discussion with Canadian Metalworking (see Industry News story), “there are 15 global OEMs, all of which are capable of producing world class quality, so the focus [for Canadian industry] has to be on competitiveness and innovation.” Beyond the lures of competitiveness and innovation, Rodgers further suggests that auto parts suppliers and OEMs must work closer together with academic institutions to generate those innovative ideas that will bring more manufacturing into the country. If, for instance, GM, its Tier 1 parts supplier and the McMaster Manufacturing Research Institute (MMRI) developed a novel, economical approach to produce automatic transmission systems, it would encourage GM to build transmission facilities here—and attract other OEMs looking to take advantage of the technology to improve their competitiveness. Such collaborative efforts are being touted by others too. B-Con Engineering, an Ottawa-based micro machining and fabrication shop that specializes in precision optical systems was able to manufacture an aluminum telescope for the weather station for the Phoenix Mars Mission weighing only 132 grams (see the Micro Machining story in this issue). Company president Brian Creber credits MMRI with helping the company reduce the weight of the telescope assembly without compromising performance. Creber thinks it’s important for manufacturers to take advantage of the knowledge that manufacturing research institutions offer. “We have to compete in the world market…our competitors don’t pursue this kind of cooperation with academic institutions nor have the level of R&D, but that’s why we get the orders.” B-Con’s lure, then, is its ability to embrace leading-edge R&D concepts and incorporate them into novel products. Creating the right lures to bring in the manufacturers we want isn’t easy, but it’s necessary. And just as it takes a village to raise a child, it takes a team (governments, academia and industry) to nurture and grow Canada’s manufacturing profile on the world market. So the next time you go fishing, just think about which lures might work for you to bring in the business you want. 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

6 | MAY 2010 | www.canadianmetalworking.com

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News Automotive Industry: Survival of the Fittest Canadian Metalworking Editor Mary Scianna speaks with Steve Rodgers, president of the Automotive Parts Manufacturers’ Association, about the challenges the Canadian automotive industry faces and how to overcome them If the mantra in real estate is “location, location, location,” the mantra for businesses in the automotive industry should be “diversify, diversify, diversify” if they want to survive in the tougher post-recession market, says Steve Rodgers, president of the Toronto-based Automotive Parts Manufacturers’ Association (APMA), who took over the job in January. “The mix of your customer base and the mix of your product base is highly important. It means not being reliant on one or two customers or even one or two types of products. Some OEMs did very well through the recession, such as Hyundai Kia, which picked up marketshare. Honda also remained quite profitable in the global downturn. Why? Honda had a significant amount of two-wheel business—motorcycles and scooters. When people couldn’t afford cars, they still needed to have transportation so they turned to less expensive products. We saw an uptick on a global basis on motorcycle and scooter sales.” From the automotive parts side of the business, Rodgers says diversifying is critical and companies should consider having 15 to 20 per cent of their business outside the automotive market. Diversification isn’t just about products, though. Rodgers says auto parts suppliers, like most of the OEMs, should consider geographic diversification. He cites Markham, ON, auto parts supplier Exco Technologies, which opened a plant in Morocco “and during difficult times when production was down in North America, with a different customer base outside of the region. The company has held on better and this global diversification has given Exco some flexibility because now the company is able to service some of the growing markets in Eastern Europe, such as Turkey,” says Rodgers. The recession decimated the automotive industry, but in some ways, it was a positive turning point that allowed OEMs and auto parts suppliers to reflect on what had gone wrong and what they could do to prevent such a painful downfall in a future economic slide. “If you think of the first 100 years of the automotive industry, from 1900 to 2000, it was about establishing your image as an OEM—the segments to be in, the quality capability and range of vehicles to produce. But that’s over. The next 100 years is going to be about competitiveness and innovation,” says Rodgers. The gap between high and lower quality vehicles is shrinking fast. If you look at cars such as a Hyundai Sonata or a Ford Focus, it’s likely to have leather interiors, electronic controls and Bluetooth capability for cell phones. “Some of the features in these vehicles might be better or equal to what you’d find in a Cadillac Escalade,” says Rodgers. “The fact is, there are 15 global OEMs, all of which are capable of producing world class quality, so the focus really has to be on competitiveness and innovation.” And automotive parts suppliers need to step up to the plate, he adds. They need to be the generators of innovative ideas that can help their automotive OEM customers become more competitive.

How can they do that? One way is by working more closely with academic institutions and their respective R&D programs. Indeed, Rodgers says that both suppliers and OEMs are working more closely with academic institutions such as the University of Waterloo’s WatCAR (Centre for Advanced Research), that focuses on automotive R&D.

Ford EcoBoost Engine: The new 3.5-litre engine is the first in a wave of EcoBoost engines coming from Ford as part of a strategy to bring affordable fuel efficiency improvements to millions.

Another example is GreenARC (Automotive Research Cluster) an industry-driven (OEMs, parts suppliers and universities) research and development initiative formed back in 2008 designed with the aim of ensuring Canada’s global competitiveness in the design and manufacture of the next generation of green automobiles in North America. “We think this is an innovative and spectacular idea but thus far it has not met with great success. It is an example of what can be done to allow suppliers to develop more innovative ideas and push them forward. The idea behind this initiative was to take advantage of the green movement in propulsion systems and drive trains.” And while the program hasn’t taken off, Rodgers says these types of initiatives are critical if the Canadian automotive industry wants to secure its place in the global market. “We’re likely going to see more technological change in the automotive industry in the next 10 years than we’ve seen for a long period of time and the question is, can Canada maintain the level of innovation that’s required? Ultimately, it’s www.canadianmetalworking.com | MAY 2010 | 9

News the innovation that leads to those manufacturing opportunities that create jobs. So are we doing enough as a jurisdiction to remain competitive and maintain at least the status quo in this area? Rodgers says that Canada isn’t doing enough to try and maintain automotive manufacturing in the country. He isn’t pointing fingers at the government; instead he says it has to be a collaborative effort involving OEMs, parts suppliers and academic institutions with automotive R&D strengths that will help create an attractive infrastructure that will bring manufacturers into the country. “In this global market, OEMs have the freedom to put their facilities anywhere they want. The secret to attracting investment isn’t going to be in automotive assembly itself, but in areas where technology is changing—things such as transmissions, engines, drive trains, axles, etc. And the way to get manufacturers to set up facilities in your geographic location is to have the innovation they want. You do that by forming Centres of The 2011 Chevrolet Cruze front suspension is a fully independent, decoupled MacPherson spring over damper design. Lower control arms and front knuckles are lightweight aluminum for better wheel control on rough surfaces. The steering system is a dual pinion rackmounted electric power system that provides precise control, responsiveness and direct on-centre feel.

Excellence which will help the automotive industry to develop stronger capabilities and generate innovative ideas in specific areas.” So if Canada wants to attract an engine and transmission facility in Canada, do we have the innovative ideas and the R&D focus that would bring a manufacturer here? “It’s trying to find those areas that we’re good at and making sure we have the manufacturing capability, the R&D capacity and the innovative ideas to help OEMs develop better vehicles so they can compete in the global market.” To get there, the industry is going to need help. Rodgers recognizes that both the Federal and Ontario governments have introduced many good initiatives such as the accelerated capital cost allowance for manufacturing equipment and the Ontario Advanced Manufacturing Innovation Systems initiative. Those working in the automotive industry recognize that it will not likely return to its pre-recession size. Indeed, Rodgers cites figures to estimate that by 2016, Canada’s share of the NAFTA market will drop even further than the current 18 per cent down to 14 per cent. But it will continue to be an important market in the future. And governments in Canada recognize the importance of the automotive industry and have been supportive, “but there’s also a recognition and the sentiment that at a time when we face significant government deficits that the automotive industry has had its day in the sun. There is a sense of malaise from the government and we have to recognize that.” And recognizing this, he says, means that the industry has to come up with more creative solutions to help generate those innovative ideas that are going to attract more OEMs into the country to set up facilities. Automotive businesses in Canada need to be more introspective. “It comes back to this; are we doing the right things to attract OEMs, do we know exactly where our business is and are we adapting and changing as the industry needs change? “Ultimately, it comes down to a question: what do we need to do to grow and how can we do it?” 10 | May 2010 | www.canadianmetalworking.com

Calendar MAY 17-20 Montreal Manufacturing Technology Show (MMTS) at Place Bonaventure in Montreal. Organized by SME Canada. 888-322-7333 www.mmts.ca MAY 17-18 Ontario Skills Competition, CNC Machining at Mazak Canada, Cambridge, ON. www.skillsontario.com MAY 20-23 Skills Canada Competition at RIM Park and Manualife Financial Sportsplex and Living Centre, Waterloo, ON. Skills Canada Competition CNC Machining at Mazak Canada in Cambridge, ON. www.skillscanada.com MAY 25-27 EASTEC 2010 Exposition in West Springfiled, MA. 800-733-4763 service@sme.org JUNE 3 Industry symposium by Bohler-Uddeholm, ”Presenting the Future of Tooling Materials and Practices for High Strength Low Alloy and Advanced Strength Steel for the Cold Work Industry” at the Delta Meadowvale Resort & Conference Centre in Mississauga, ON. Jamie.mcintosh@bucanada.ca JUNE 3 Canadian Welding Association’s Mike Irvine Memorial Golf Tournament at the King’s Forest Golf Club in Hamilton, ON. 800-844-6790 www.cwa-acs.org June 6-8 Bridging the Gaps: 2010 SME Annual Conference at Sheraton Music City, Nashville, TN. www.sme.org JUNE 20-24 World Tooling Conference at Caesars Windsor Hotel & Casino in Windsor, ON. 519-653-7256 info@ctma.com

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News EASTEC “Go-To” event for East Coast manufacturers

Shop Talk Do you do any business with South America? If yes, what kind of business do you do? If no, are you trying to get work in South America? “Advance Precision does not do any business in South America and we are not trying to develop this market.”

-Ian Barrie, president, Advance Precision Ltd., Mississauga, ON

“We do not do any business with South America nor have we considered it before. Our work is as a job shop, so we do not see [South America] as a market we can access.”

-George Barnes, owner, Foldens Machine Works Ltd., Tillsonburg, ON

“We do not do any business or are looking to do business, with South America.”

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

“We are just starting to look at South America as a possible market for our company.”

-Marco Gagnon, co-owner, Gagnon Ornamental Works, Grand Falls, NB

Since 1979, EASTEC has been the big regional event for East Coast manufacturers in North America. This year, EASTEC 2010 will be held May 25-27 in West Springfield, MA. The conference and trade show is expected to draw thousands in search of local manufacturing solutions. Organized by The Society of Manufacturing Engineers (SME), the event promises to address the issues and concerns facing today’s manufacturers. As an example, attendees will be able to attend the EASTEC Lean and Green Resource Centre. The centre will be offering free education and consulting on value streams, 5S, process mapping and other key lean components. Keynote speakers will also be addressing the hot button issues. Presentations include “Medical Device Manufacturing Outlook” by Bryan Hughes, director of P&M Corporate Finance; and “2010 Aerospace Global Forecasting” by Richard Aboulafia, vice president, analysis, Teal Group. For more details and registration information, visit the EASTEC web site at www.sme.org. For the latest industry news, please visit Canadian Metalworking online at www.canadianmetalworking.com.

“Not right now. [Brazilian aerospace giant] Embraer is booming, though, so I would love to be doing business there.”

-Rob Muru, president, A-Line Precision Tool Ltd., Toronto, ON

“We are not actively soliciting work in South America, but over the years we have done a couple of projects for South America-based companies. These have been references from local companies passed on to our SA colleagues.”

-David Foscarini, president, Mecon Industries Limited, Scarborough, ON

“NO! ... Right now, I am having a [hard time just] keeping up with what we have on our job orders. Manufacturing is always like this—you are maxed out then it goes quiet. I am not sure how to even it out.”

-Steve Cotton, president, Micro Precision Parts Manufacturing Ltd., Vancouver Island, BC

“No. But we recently have started looking at trying to penetrate into that market.”

-Robert Drake, sales and marketing manager, Proto Manufacturing Limited, Oldcastle, ON

12 | MAY 2010 | www.canadianmetalworking.com

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POLL

Do you think the measures to help manufactuers outlined in the 2010 Federal budget (extension of the accelerated capital cost allowance and elimination of tariffs on machinery and equipment) is enough to stimulate growth in the manufacturing sector? Yes 16.7%

No 83.3%

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industry report

automotive

The automotive sector is in comeback mode, in spite of corporate bankruptcies and major vehicle performance issues. As far as Steve Rodgers, president of the Toronto-based Automotive Parts Manufacturers’ Association (APMA) is concerned, the bottom of the barrel “was definitely reached” last year. True enough, North American vehicle production fell to 8.8 million in 2009 from 12.9 million the year before (and 16.3 million in 2005). Production in Canada went from 2.5 million vehicles built in 2007 to 2.0 million in 2008. Industry Canada believes 2009 production will amount to 1.8 million vehicles. So far this year, production has been on an upswing. From January to March 2010, a total of 1,890,903 vehicles were built in the US, versus 1.1 million for the same period in 2009. Production figures for Canada came to 509,570 vehicles built in January–-March 2010, a considerable leap from January–-March 2009 when 281,388 vehicles were manufactured. The auto assembly and parts industry employs 137,500 Canadians and represents the largest manufacturing employer in the country. Roughly 540 companies make automotive parts for original equipment manufacturers (OEMs) and their suppliers in Canada. Auto OEMs have been having a rocky ride as of late. On April 30, 2009, Chrysler filed for Chapter 11 bankruptcy protection in the US. The US and Canadian government, along with the province of Ontario rushed to provide $14 billion in bailout money to keep the company afloat. In June 2009, auto giant Fiat of Italy took over some of Chrysler’s global assets, which allowed the company to emerge from bankruptcy protection. General Motors—until recently, the biggest car maker in the world—filed for bankruptcy on June 1, 2009. Trying to ward off a black hole of unemployment (it has been estimated that 85,000 assembly and part manufacturing jobs in Canada would be lost if GM went under completely), the US, Canadian and Ontario governments again rode to the rescue. Ottawa and the province of Ontario alone pledged $10.6 billion in repayable loans for GM. The relief funds did the trick; just 40 days after going bust, GM emerged from bankruptcy protection. Even mighty Toyota has been stumbling, despite making record numbers of autos. In 2008, Toyota manufactured 9.2 million vehicles—more than any other car 14 | May 2010 | www.canadianmetalworking.com

Driving Back from the Brink

With the recessionary upheaval behind it, the automotive industry is in comeback mode By Nate Hendley ..........................................................

automotive

maker in the world. Second place GM, top auto maker for decades, made 8.3 million vehicles. In 2009, however, it was discovered that gas pedals in some of Toyota’s vehicles had a tendency to get stuck and cause unintended acceleration. In September 2009, Toyota launched a massive recall to deal with the problem. Toyota soon faced another crisis when Consumer Reports magazine suggested the Lexus GX460 sport utility vehicle was at high risk for rollover accidents when making certain turns. In April 2010, Toyota announced it would temporarily stop selling the SUV until testing determined what was at fault. Toyota Motor Manufacturing Canada (TMMC) has operated an assembly plant in Cambridge, ON, since 1988. The company opened an assembly plant in Woodstock, ON, in 2008, and built a total of 287,395 vehicles that year. Asked if Toyota’s current travails will drag the company down, Rodgers says, “I don’t believe so ... Toyota sales have remained remarkably solid.”

industry report

down to 7,000 employees by 2011 and 4,400 by 2014. For now, however, such cuts have been cancelled or at least postponed. In January 2010, GM said it will add 1,000 new jobs at its Oshawa, ON, operations over the next few years. The plan is to make a replacement for the Chevrolet Impala and a Cadillac sedan in Oshawa. GM has also announced a third shift for one line in its Oshawa plant and will be adding new jobs to its CAMI plant (a joint venture originally established with Suzuki of Japan, now run solely by GM) in Ingersoll, ON. Incorporated in 1918, GM Canada currently employs about 9,000 people. GM made a total of 576,926 vehicles in Canada in 2008. Honda Canada, another “New Domestic” (the name given to auto OEMs besides the Detroit Three) runs two assembly operations in Alliston, ON. In March 2010, the company decided to restart a second shift at one of these plants, a move that will add 400 jobs to the company roster. Honda currently employs roughly 5,100 people in Canada and made 383,011 vehicles in 2008. Some auto part makers have also been doing quite

“The worst is over, the automotive industry has

recovered about 50% of what it lost in the recession.” Indeed, in December 2009, Toyota announced plans to hire an additional 800 workers for a second shift at their Woodstock plant. The workers came on board in March 2010 to make more RAV4 SUVs. Thanks to these new jobs, Toyota’s Canadian workforce now numbers 6,500. Other automotive OEMs in Canada, including Chrysler, Ford, GM and Honda, are also hiring new or retaining old staff. Established in 1904, the Ford Motor Co. of Canada currently employs 6,000 people at two assembly plants and one engine plant. In February 2010, Ford announced it would add 757 jobs to its Windsor, ON, engine plant over the next few years. The plant in question had been shuttered in 2008 then reopened after the province of Ontario provided funding. The news isn’t all good from Ford, however: the company still plans to close an assembly plant in St. Thomas, ON, in 2011, which will result in 1,500 lost jobs. Ford built a total of 308,248 vehicles in Canada in 2008. It’s been the same mix of good and bad news at Chrysler Canada, which was established in 1925. In March 2009, Chrysler cancelled a third shift at its Windsor Assembly Plant, then four months later, reversed course. Healthy sales of the Chrysler Town & Country and Dodge Grand Caravan minivans convinced Chrysler to retain its third shift, a move which preserved 1,200 jobs. As of December 31, 2008, Chrysler had 9,400 employees in Canada. The company made 314,504 vehicles in Canada last year. As recently as 2005, GM Canada boasted 20,000 workers. This was pared down to 10,300 in 2008. The company continued to trim staff and mused about going

well. In June 2009, Linamar of Guelph, ON, snagged a multi-year contract worth $200 million. Linamar will be making driveline modules for an auto OEM in Europe, with production set to start in 2011. Smaller part makers are equally upbeat. “The worst is over, the automotive industry has recovered approximately 50 per cent of what it lost in the recession,” says Ian Barrie, president of Advance Precision in Mississauga, ON. Advance Precision makes “safety related products, such as seat belts and air bag components” and “machines aluminum housings for fluid couplings,” says Barrie. Advance sells to Tier Two and Three automotive suppliers. Automotive experts applaud Ottawa’s decision in April 2009 to pump an extra $700 million into Export Development Canada (EDC), a crown corporation that provides financing, insurance and risk management services to exporters. The extra cash went towards Accounts Receivable Insurance (ARI) for Canadian auto part companies supplying the Detroit Three and their affiliates. Such coverage helps part makers deal with onerous PPAP terms. PPAP stands for Production Part Approval Process. Under PPAP, all components from suppliers must meet exacting standards before being approved for use in an OEM’s production line. Suppliers don’t get paid until all their parts are approved, which can take months, even years. For all their recent turmoil, the Detroit Three remains wedded to PPAP, to the fury of suppliers. “PPAP terms are despicable,” snaps Adriano Oppio, www.canadianmetalworking.com | May 2010 | 15

industry report

automotive

vice president at Classic Tool & Die in Oldcastle, ON. “We are expected to carry the costs of our employee wages, all materials and company overhead until our customer decides it is time to pay,” Oppio’s firm builds metal stamping dies and specialized machinery for the automotive industry and provides services such as wire EDM, machining and CMM. The Canadian dollar has also been negatively affecting the automotive sector. From a low near 60 cents just a few years ago, the loonie zoomed up to $1.10 US by November 2007. It dropped back down again, but in mid-April 2010, went above par again. “The high dollar has a huge impact on our business. Because 80 per cent of our customers are in the US, we are paid in US dollars. When the Canadian dollar is closer to par, or worse yet, beyond, it takes away any monetary competitive edge that we have over US firms,” says Bill Storey, president of Midwest Precision Mould in Oldcastle, ON, which manufactures plastic injection and compression moulds for automotive and non-automotive customers. The dearth of new product is another worry. “Although sales and production have come back, we haven’t had that many new product launches. We’ve probably only had 22 – 23 product launches in the last couple years, whereas in 2010 and 2011 we’ll have almost 45 new program launches. That’s good news because that creates a lot of opportunity for suppliers,” says Rodgers. One of the most anticipated new products is GM’s muchhyped Chevrolet Volt. The emissions-free Volt is intended to be the world’s first mass-produced, nearly all-electric vehicle. It is

currently in pre-production and undergoing testing. GM insists that the Volt will go into mass production later this year. As for the future, CSM Worldwide, an automotive research firm in Michigan, predicts that light vehicle production in North America will climb to 10 million in 2010 then 14.6 million in 2015. Canada’s light vehicle production will drop slightly to around 1.8 million by 2015, predicts CSM. The big winner in North America is Toyota, which CSM predicts will go from making 1.2 million vehicles in 2009 to 2.6 million in 2015. GM is expected to recover from its dizzying downward spiral (3.4 million light vehicles built in North America in 2008, declining to 1.8 million in 2009). CSM projects GM’s 2015 light vehicle production in North America will be 3.3 million. A recent report from Deloitte, an international professional services firm, warns that auto OEMs will be increasingly tempted to open assembly operations and use part suppliers in low-cost locales such as Asia. Rodgers isn’t hugely concerned. Automotive OEMs are “starting to pay more attention to the total cost, and not just the actual piece price itself. What happens if you have a quality issue and you’ve got six weeks of parts on the water?” he asks. Rodgers urges Canadian auto firms to keep on top of new technology, as exemplified by electric/hybrid cars. “We’re coming back. We’re doing a lot of innovative things in Canada. While we can’t be an LCC—low cost country—we can be an LCC—leading competitive country,” he says. CM Nate Hendley is a freelance writer based in Toronto.

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SELLING NEW MARKETS

Business report

Rethinking Your Business Tough times call for new markets, but selling into new markets isn’t easy By Jack Kohane .................................................................................................................................................... Moving into new markets isn’t a walk in the park. Selling to new customers is a radical way to grow your business, one in which the rewards can be significant but the risks higher, says Guy Champagne, senior partner, BC and Yukon for BDC Consulting with the Business Development Bank of Canada (BDC) in Victoria, BC. “The key to accessing new markets begins within your own business,” says the productivity and competitiveness expert. Champagne conducts workshops throughout Western Canada focusing on how companies should look for new opportunities. “You have to assess the readiness and resilience of your company to manage change. Being a resilient company means you can look at all facets of your business through strategic lenses.” Too many companies, he warns, “go into hibernation” when times are tough. They cut costs, conserve cash and act as if they’re on the verge of bankruptcy when, in reality, their balance sheet is still solid enough to reposition the firm. How can a business mitigate risk to reap the greatest rewards? Champagne says there are three main strategies: bankability (staying financially fit), flexibility (being nimble and adaptable), and capability (engaging the whole team and having a business plan). In an economic downturn a common mistake is to circle the wagons and micromanage operations. “The business owner who retrenches and tries to control everything is often at greater risk,” says Champagne. “A nimble company can more easily tackle problems, pursue opportunities and embrace change, especially during an economic slowdown. Look at your customer base and business model and determine what’s needed to move your company forward. Take stock of your strengths and play to your strengths.” Champagne challenges the perception that Canada’s manufacturing sector is often portrayed as an industry in a long, agonizing decline. “Manufacturing is more cyclical than the rest of the economy. As the economy recovers, manufacturing is likely to rebound strongly. Canadian manufacturers have proven to be extraordinarily resilient, overcoming challenges such as recessions, trade liberalization, and a fluctuating Canadian dollar. Whether it’s a recession or a downturn in your industry sector, don’t assume you can wait until the storm has passed before taking action. Use these setbacks to get aggressive now. It can be a great opportunity to build market share.” But before you start, make sure that you have clearly defined goals --- it’s essential that you set targets each step of the way. If you don’t carefully benchmark your progress at every stage, you can spend a lot of time and money on an unsuccessful expansion effort. You’ll need to spend time researching the market fully, so you understand your potential customers as well as you do your existing customers. You also need to understand the competitive environment in the new sector you plan to enter---it won’t be the same as your current market.

Spotlighting green energy as a prime opportunity with huge potential as governments move towards strengthening and mandating more investments in renewable energy sources, Champagne urges companies not to wait until the economy picks up in penetrating this growing market. “Getting in early can help your company stay ahead of the game,” he affirms.

Epitomizing this development opportunity for the Canadian metalworking sector is wind energy. Between now and 2020, it is estimated that $1 trillion will be invested in new wind energy facilities worldwide. By 2015, it is projected that more than $25 billion in new wind energy projects will be constructed in Canada. “And this only scratches the surface of Canada’s massive wind energy potential,” declares Michael Thibedeau, spokesman for the Ottawa based Canadian Wind Energy Association (CanWEA). Over the past 10 years, global wind energy capacity has continued to grow at an average annual rate of more than 25 per cent. As Thibedeau sees it, the wind energy industry is one of the most significant opportunities for Canadian manufacturers for many years to come. “A wind turbine has more than 8,000 separate parts and holds enormous opportunities for manufacturers who have the skills, plant and equipment to contribute to this growing industry.” The rapid pace of wind energy market development in North America is leading wind turbine OEMs to seek capable and experienced business partners and suppliers in North America to meet customer demands. “The added costs associated with transportation, lead time, duties and taxes for products coming from Europe, combined with government and industry preference for the establishment of a domestic North American www.canadianmetalworking.com | May 2010 | 19

SELLING NEW MARKETS

Business report

supply chain, has created an opportunity for manufacturers also cautions that innovation is not just something thatâ&#x20AC;&#x2122;s done and service providers to enter the wind energy industry,â&#x20AC;? in laboratories by scientists. â&#x20AC;&#x153;It means taking on change in a Thibedeau points out. creative way, itâ&#x20AC;&#x2122;s about generating new ideas, conducting R&D, Ron Mantay, general manager, solar, for Mississagua, improving processes or revamping products and services. The ON-based Schuco Canada Inc., specializing in aluminum, steel, purpose of innovation is really to increase your companyâ&#x20AC;&#x2122;s PVC-U and solar products for residential and commercial competitiveness --- something all businesses should do. Itâ&#x20AC;&#x2122;s a building envelopes, is banking on Canadaâ&#x20AC;&#x2122;s need to produce different way of executing a particular business process... itâ&#x20AC;&#x2122;s systems that generate and save energy. At the recent Ontariofiguring out whatâ&#x20AC;&#x2122;s possible,â&#x20AC;? he says. CM sponsored Energy Connections 2010 Summit, focusing on Jack Kohane is a freelance writer based in Toronto. the energy market and diversification opportunities, and hosted by Canadian Manufacturers & Exporters (CME), Mantay addressed 300 delegates (comprising manufacturers, service providers and consultants to the renewable energy sector), stating that / Ă&#x160; 1// Ă&#x160; renewable energy is renewing Ontario manufacturing. â&#x20AC;&#x153;Canada is ideal for Schuco global expansion and Schuco is investing in Ontario.â&#x20AC;? He cited Canadian incentives, including improved incentives for renewable energy, and increased demand for energy efficient buildings. â&#x20AC;&#x153;The Ontario Green Energy Act is attracting international attention...and fast-moving companies are capitalizing,â&#x20AC;? Mantay told delegates, noting that this initiative provides provincial funding of up to $400,000 for commercial solar thermal projects. â&#x20AC;&#x153;Ontario manufacturers can supply material for renewable energy projects, and Ontario manufacturers can invest in renewable energy projects on their own properties. Seize the opportunity now.â&#x20AC;? Business as usual is not an option and neither is complacency. Thatâ&#x20AC;&#x2122;s according to Ron Subramanian, CMEâ&#x20AC;&#x2122;s director of special projects. â&#x20AC;&#x153;Every business needs to think about getting the most out of its marketplace. If youâ&#x20AC;&#x2122;re not increasing turnover every year, your business is shrinking in real terms. Many businesses simply try to pick up extra sales wherever they can. While this approach can be effective in the early days, it is unlikely to sustain longer-term growth.â&#x20AC;?Â UĂ&#x160; >ViĂ&#x160; Ă&#x20AC; Ă&#x203A; } According to Subramanian the *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; UĂ&#x160;Ă&#x160; }Ă&#x20AC;>Ă&#x203A; }Ă&#x160;/ Ă&#x192; best ways forward for manufacturers / 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° to complete and grow their businesses UĂ&#x160;Ă&#x160; *Ă&#x20AC; w iĂ&#x160; Ă&#x20AC; }Ă&#x160; >Ă&#x20AC;Ă&#x192; are to invest in and adopt new technolo 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; gies, develop and commercialize new UĂ&#x160;Ă&#x160; 1 `iĂ&#x20AC;VĂ&#x2022;Ă&#x152;Ă&#x160; Ă&#x20AC; Ă&#x203A; }Ă&#x160;/ Ă&#x192; more specialized and more customized

Ă&#x2022;Ă&#x192;Ă&#x152; ]Ă&#x160; >Ă&#x152;Ă&#x2022;Ă&#x20AC;iĂ&#x160;> ` products and services to transition into 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; new markets and connect with new UĂ&#x160;Ă&#x160; >V Ă&#x160; > viĂ&#x20AC;Ă&#x160; Ă&#x20AC; }Ă&#x160; >Ă&#x20AC;Ă&#x192; / Ă&#x160;> `Ă&#x160;/ customers and supply chains. He notes

>Ă&#x152;i`Ă&#x160;/ Ă&#x192; 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; thatÂ manufacturers â&#x20AC;&#x153;must undertake Ă&#x160;-Ă&#x152; V Â° all of this with the limited resources 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; and expertise that is characteristic of small business.â&#x20AC;?Â Champagne views innovation as the - / Ă&#x160; 1// Ă&#x160;/"" -]Ă&#x160; Â° key to unlocking manufacturing opporÂŁÂŁĂ¤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 tunities and capturing new markets. He

"7Ă&#x160; 6 Ă&#x160; Ă&#x160; 7Ă&#x160; / " Ă&#x160; Ă&#x160;*," 1 /-t

www.canadianmetalworking.com | May 2010 | 21 SCT Final.indd 1

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Big MICRO MACHINING

Small Can Be

MACHINE TOOLS

A research institute’s insights on micro machining point to opportunities for metalworking shops By Mary Scianna ...........................

Stephen Veldhuis, director of the McMaster Manufacturing Research Institute (MMRI) and the Micro Manufacturing Laboratory, holds an ultra precision single point diamond turned mirror.

The recession and the subsequent fallout of some manufacturing sectors in Canada have left many companies scrambling to focus on alternate markets to replace lost business. Dr. Stephen Veldhuis suggests that manufacturers think small—really small. Veldhuis is the director of the McMaster Manufacturing Research Institute (MMRI), at McMaster University in Waterloo, ON. The $19-million MMRI was formed in 2001 and is the largest university manufacturing research institute in the country. Veldhuis is also the director of one of six research labs within MMRI, the Micro Manufacturing Laboratory, formed in 2003. The other five labs are the Centre for Advanced Polymer Processing and Design, Machining Systems Research, Metal Forming, Robotics and Manufacturing Automation Research and Thermal Processing. “Our research mandate is to understand the cutting process. We now have a better understanding of how cutting occurs at the micrometer level and we’re converting that into better surfaces and smaller geometry www.canadianmetalworking.com | MAY 2010 | 23

Machine Tools

MICRO MACHINING

features. The next step is for companies to pick up on this and covert our findings into a product.” It is important to note that the lab isn’t just focused on the manufacture of micro-sized objects. Indeed, Veldhuis says the bigger focus is surface finishes—measured in nanometers— and tolerances—measured in micrometers.

To put it in perspective, if you were a job shop and someone brought you a set of drawings for a micro machined part, all the tolerances and surface finish requirements would be 1,000 times finer. “We originally had in mind the making of small components, but we’ve found a lot of our activity has looked at very tight tolerances on fairly large dimensions. So you can have a small optical device that is 10 mm in diameter but requires a tolerance at the sub micrometer level and a surface finish of two to three nanometers. You could also have a very small fiber optic lens that is a fraction of a millmeter in size with the same tolerance and dimensional requirements.” The challenge is to have manufacturers transfer the capabilities of machining surface finishes and tolerances at the micrometer level into a commercial product. “It’s now possible to drill a hole a few micrometers in size; so you now have the ability to create holes that are functional on the order of cells and how do you get manufacturers to work with this knowledge and create a product people will want?” 24 | May 2010 | www.canadianmetalworking.com

One manufacturer that is taking advantage of MML’s research findings is B-Con Engineering, an Ottawa-based micro machining and fabrication shop that specializes in the design and development of precision optical systems. The company is the second largest diamond turning facility in Canada. Some of the early work that B-Con asked MML to work on was to study what happens when you diamond cut a metal surface. “We wanted to diamond turn reflective optics out of titanium because in the space industry, a lot of the reflective surfaces are diamond turned beryllium and it’s nasty [toxic] to work with,” explains Brian Creber, B-Con’s president. “If we could get the same optical properties from titanium—it’s a nice material from a biological point of view and it has a similar strength-to-weight ratio [as beryllium]—it would create opportunities for us.” During the research and development stage, Creber says he started to see applications for the company’s traditional diamond turning of reflective optics, the majority of which are made from aluminium. “We were able to describe what happens when you’re cutting a metal alloy and improve our diamond tool designs and our machining methods.” Then the company landed a contract to manufacture a telescope (optics) for a weather station that York University had created for the Phoenix Mars Mission. B-Con was given a weight budget of 132 grams. “So we had to make this telescope that weighed only 132 grams. We produced the entire telescope and it was made of aluminium. We used a lot of the processes McMaster and Stephen’s lab had developed for us to allow us to reduce the weight of that assembly and still have the telescope perform the way it was supposed to.” B-Con has just signed an agreement with MML to extend development work that will focus more on tool designs and cutting titanium surfaces in the nanometer range. “We can almost cut optical surfaces in titanium cutting it with a diamond-coated carbide tool, but we’re not quite there yet. Our target for these surfaces is 5 nm.” B-Con is also working with Algonquin College and Laurentian University on application-specific developments. Creber says it’s important for manufacturers to take advantage of the knowledge that manufacturing researchbased institutions such as MMRI offer. “We have to compete in the world market; 80 per cent of our product is exported so we have to be ahead of the market. Our competitors don’t pursue this kind of cooperation with academic institutions nor have the level of R&D, but that’s why we get the orders.” When the MML was formed back in 2003, one of the events that brought micro machining to the forefront was the requirement in the automotive industry for accelerometers. “This was the big start of the micro electromechanical device industry because suddenly every car needed these accelerometers (sensors in air bag systems) and they needed to be inexpensive and efficient. So this got people thinking about the next natural step of scaling things down to the

MICRO MACHINING

MACHINE TOOLS

“The challenge is to have manufacturers transfer the

capabilities of machining surface finishes and tolerances at the micrometer level into commercial products.”

human body. So people could begin to see how the technology used to create micro mechanical devices could be scaled down to create devices that could work at the celluar level.” Today, much of the research and development work in micro machining at MMRI is in the optics and biomedical fields, says Veldhuis. “In the biomedical field, if you’re looking at the scale of the human body, it demands certain sized instruments. If we want to do non-invasive surgery, we have to put something inside the body and if we want to manipulate something, you need a small mechanical device that can, for example, take a sample of tissue and extract it.” While working at the micro level in manufacturing means that you’re working with measurements that are 1,000 times smaller than the tolerances and surface finishes a typical Stephen Veldhuis

metalworking shop would handle, the issues are the same: tooling, workholding and set-up. “There is the issue of how you hold a drill that is 100 micrometers and how you spin it and move it around. And the same is true of workholding and tooling set-up. The challenges are the same that every machinist deals with except you’re multiplying it by 100,” explains Veldhuis. Veldhuis adds that the work his lab does is only part of the equation and that manufacturers must “bridge the gap” and “leverage” this knowledge to create leading-edge products that everyone will want, much like what B-Con is doing with its diamond turned optical products. “What does a 100 micrometer diameter hole mean to you as a company or to your customers? What does a surface finish on the order of nanomenters mean? Manufacturers need to see the value of what these surfaces and dimensions mean and create products people want.” CM

ADVERTORIAL

Celebrating 60 years of support and service to Canada’s metalworking industry Elliott Matsuura Canada Inc., Oakville, ON, is 60 years old today and the Canadian metalworking machinery distributor has reason to celebrate. None in Canada can boast of the position that Elliott Matsuura holds in industry: one of the largest metalworking distributors in the country offering, nation-wide, a comprehensive—and complementary—array of machinery, equipment and quality control software instruments from some of the biggest names in the market, for chip and sheet metal fabrication shops. “The Canadian market is not big enough to sell strictly Matsuura and Nakamura Tome,” says Frank Haydar, president. “There aren’t enough units sold in the country to justify the overhead operation and the fixed cost of the facility and the people that we’ve invested in, so we need to complement and supplement what we do.” Elliott Matsuura has four core products: Matsuura, Nakamura Tome, +GF+ AgieCharmilles and Carl Zeiss. Other complementary lines include Brother, Toyoda, Tornos, Samsung, Olympia, CorreaAnayak, Tacchi, 600 Group, as well as fabrication machines from Cincinnati and JetEdge. To accommodate its growing range of metalworking machinery, Elliott Matsuura (the distributor, formerly known as Elliott Machinery, was acquired by machine tool builder Matsuura in 1988 and subsequently changed its name to reflect the ownership) moved to a new 32,000 sq ft facility in Oakville, ON in 1992. “We’re now

looking at adding another 7000 to 8000 sq ft this year, but we’re in the exploratory stages at the moment,” says Haydar. As Elliott Matsuura enters its 60th year of business in Canada, the one message that Frank Haydar wants to ensure is heard by all is that the Canadian distributor has been providing advanced technology, quality machine tools and “unparalleled service and support” for 60 years “and this is fact, it’s not something we’re saying for promotional purposes. We provide, without question, the best service and support in the industry. This was something we decided to do 25 years ago; we would build the company by providing the best service and support.” Elliott Matsuura has built a reputation for providing high quality products supported by knowledgeable staff and top-notch service. And there is no doubt in Frank Haydar’s mind that Elliott Matsuura will continue to forge ahead in the coming years and remain a leader in the Canadian metalworking industry. Today, Elliott Matsuura Canada continues to provide that support, which now extends to all of its product lines. And as part of its support of industry, it continues to hold open houses and seminars for customers, including its first open house in the Quebec market last year. This year, during its May 5 and 6 open house at its Oakville, ON, headquarters, Haydar says Elliott will be offering a “Matsuura sales special” to celebrate parent company’s 75th anniversary, which will include “extended warranties, extended payment terms and special pricing on our Matsuura stock machines.” www.canadianmetalworking.com | MAY 2010 | 25

MACHINE TOOLS

GRINDING

Grinding for Success Investment in new grinders helps Ontario job shop capture business in new markets By Jack Kohane .................................................................. Being good is better than being big. Such is Thomas Johansson’s simple secret of success. As president of H&O Centerless Grinding Co. in Waterloo, ON, his approach to sustained growth is building on the company’s strengths and continuously taking calculated risks to improve. Keeping costs down and staying competitive by spending next to nothing on advertising, web pages, commissions or external sales, Johansson’s team supplies large companies such as General Electric, General Dynamics, Ingersoll Rand, Pentair and General Kinetics, a Canadian specialty engineering company servicing the military. Industries H&O now serves include heavy equipment, plastics components, tooling, automotive, and nuclear energy. Its product mix ranges from shafts, bushings, rings, dowels, and valve stems, to spacers, pistons and locating pins But there’s been no cutting corners in allocating large capital outlays in plant, processes and people. Among the 125-plus pieces of equipment housed in the 60,000-sq ft facility are 22 centerless grinders and five Studer CNC cylindrical grinders, as well as honing, milling, drilling and turning machines. “Although centerless grindMike McDougall, plant ing is in our name, we have always manager, with the Studer S22 been a complete machine shop with CNC grinder, which can be all forms of turning, drilling, milling, as used for high speed grinding and high speed machining. well as CNC machining and grinding,” explains Johansson. Founded by the late Herbert Odd in 1945, H&O began with a single spindle screw machine and centerless grinders. Earl Hillier, who had worked with Odd during the war, became an early partner and later purchased the company. In 1996, Johansson (who was just 28 years old at the time) purchased the company from Hillier’s sons. “I had just completed five years at Goldman Sachs, and was looking to run a business with challenges and growth prospects. H&O met all of his criteria and he made the entrepreneurial plunge. Though transitioning from cutting his teeth in finance and credit analysis to cutting metal parts, Johansson says he’s never regretted this career move. H&O’s initiative to segment processes into distinct cells to create more product specific work zones is gaining steam from the company’s staff of about 100. Currently, there are six cells at H&O (including a tube processing area, a shaft cell, and form grinding), with the long term goal of creating 15 semi-autonomous groups. “Efficiency gains by these means can be as important as the gains available by investing in new and 26 | May 2010 | www.canadianmetalworking.com

Mercy Lang, form grinding area leader in front of the Amada Wasino CNC surface grinder. Top Image: A wider view of the machine.

alternative process equipment,” notes Johansson. When purchasing new equipment H&O looks for high quality and good value, coupled with flexibility and simplicity. “However, no matter what machinery we purchase, we believe the greatest gains are achieved by the growing skills of the operator and not the sophistication of the machine tool,” says Johansson. Process planning and lean tools, including one-piece workflow, are further efficiency gains he credits to the expertise of his operators. “We respect and value long-term experience and stability and many of our employees have been with us for 20 years and more.” For many years, the company’s olive-green, cast-iron Cincinnati grinders--rebuilt and rejuvenated over the decades-served the company’s needs well. “They’re our workhorses and they still hold good tolerances,” says Mike McDougall, who has been the plant manager at H&O for more than 25 years.

GRINDING

Yet to take the company into a new era to capture new markets such as aerospace, it was clear that newer technologies had to be taken into the fold. And having partnered for many years with Toronto-based distributor Machine Tool Systems Inc., Johansson knew who to turn to. “First of all, machines with greater tolerances are a musthave for a company like H&O,” says Machine Tool Systems president John Manley. “With old equipment, there’s a lot of quality control required. New machines can make 100 or 1,000 parts the same way so there’s no need to constantly check for errors.” The right fits for H&O’s ambitious expansion plans were the Studer CNC Universal Grinders and the Amada Wasino CNC surface grinder. “The purchase of these machines illustrate our view of the business,” explains Johansson. “For example, most of our Studer machine time has been dedicated to a customer requiring highly engineered chrome plated and profiled tubes (parts that look and work like a landing gear) to be ground. To ensure timely grinding of this product, along with an increasing range of other parts that are being ground on the Studers for other customers, we selected the Studer S22 (just being installed at H&O at the time of writing). The key to the decision was that we have a customer who has put a lot of faith in us, and we want to ensure we continue to give them the turnaround they require.” Manley says that at the heart of the Studer S22 is StuderWIN, a new Windows-based operator interface that offers many new advantages. The S22 is equipped with a 310i-A series Fanuc CNC control with integrated PC. The advanced brain of the S22 provides peripheral device integration via the controller screen directly (no black boxes for gauging, balancing, gap elimination, and length positioning); rapid navigation with quick access Windows Explorer formatted drop-down menus, rather than keypad dependent programming; simplified networking; and material dependent technology pages. It also offers worksharing software for job shop scheduling between multiple machines and multiple workpieces. “The S22 has sophisticated loading, dressing and gauging capabilities that will no doubt contribute greatly to H&O’s grinding expertise,” emphasizes Manley. “And with the tight tolerances afforded by the Amada and Studer S22 (±.005mm or ±.0001 in.), H&O can service the most precision-minded customers.”

The Studer S22 can be used with one or multiple grinding wheels to complete a part with different features in one clamping.

MACHINE TOOLS

PRODUCT REPORT Engis of Canada

The Electrogrip electroplated bond system from Engis features electroplated tools made up of a basic single layer of either Diamond or CBN particles that are bonded to the tool surface by a nickel matrix. The bonding process allows the manufacturing

of tools with various forms and contours. The tools are used in applications requiring the grinding of deep forms such as splines, slots, gear teeth and other deep grooves. These tools offer free cutting action, good form holding characteristics, maximum abrasive particle exposure and high stock removal, says Engis. www.engisca.com

FEIN

FEIN’s new line of WS 14 safety angle grinders are a new generation of compact angle grinders that combine robustness, maximum performance and outstanding ergonomics with different model styles to allow for a match to any user’s individual requirements.

The new technology of the compact angle grinders offers durability, maximum performance and outstanding ergonomics. The series is made up of two model styles: “TIP-START” innovative switch-free angle grinders based on the new FEIN concept of Touch-Integrated-Pads; and “CLASSIC” angle grinders designed with a classic On/Off switch. In addition, several models feature the patented FEIN QuickIN design for fast, easy tool-free accessory changes. The overall features and benefits make them the right choice www.canadianmetalworking.com | May 2010 | 27

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GRINDING PRODUCT REPORT for users who require absolute reliability, performance, plus a high level of safety. “Our new WS 14 grinders allow the user to apply maximum abrasive or polishing power directly to a surface, with minimal vibration or effort, achieving desired results, quickly and easily, says Randy McDonald, national sales manager of FEIN Canadian Power Tool Co. The grinders are available in 4½, 5 and 6 in. models, all offering maximum torque and durability for material finishing applications such as cutting, grinding, sanding, rough and fine brushing, polishing and more, says FEIN. www.fein.com

PFERD

The new depressed centre (type 27) ceramic oxide grinding wheel from PFERD Canada is a high performance bonded tool designed to handle a range of tasks including blending, deburring, shaping, sanding, finishing and polishing. The SG-FLEX is a flexible tool which allows for increased surface area contact for aggressive grinding on steel, stainless steel and aluminium in shipbuilding, automotive, fabrication, tank construction and other areas where large area curved metal surfaces are involved. It’s available in 4 ½ in., 5 in. or 7 in. diameters with a 1/8 in. thickness. It also offers a selection of 36, 40 and 60 grits. www.pferdcanada.ca

Standard Abrasives

Standard Abrasives has introduced a new PSA paper disc roll, the latest in its line of coated abrasive specialities. The coated abrasive features quality aluminum oxide mineral on a strong C-weight paper. The new PSA Disc Roll offers durability, reduced finishing defects, and a consistent finish on substrates. The easy-access roll form and excellent performance, combined with an attractive price, make the switch to the Standard Abrasives brand the right choice for productivity and savings,

MACHINE TOOLS

At the basis of the Studer Model S22 Modular Grinder is its dynamic axis drives with linear motor technology, short reaction times and optimized travel. The high speed grinding option (HSG), with circumferential speeds up to 140 m/s, also contribute to increased productivity. The X and Z axes are designed as cross slides, and the longitudinal table is bolted permanently to the machine. This cross slide system has been used and proven over the past decade. The S22 can be used with one or multiple grinding wheels to complete a part with different features in one clamping. The machine can also be used to do high speed grinding as well as high speed machining in conjunction with the C axis. The machine can even have a rear roll dressing device to minimize dressing time. Specs for the S22 are centre distance 25.59-43.3 in. (650-1100 mm); grinding length of 25.59-31.49 in. (650-800 mm); a centre height of 6.9 in. (175 mm) and a swing diameter of 13.8 in. (350mm). Johansson is also impressed with his Amada Wasino CNC Surface/Centerless grinder. “The purchase decision of the Wasino was driven by the increasing tolerance requirements on small components going into the injection mould industry.” When compared to even his newer machines, some purchased just a couple of years ago, he’s found that the Wasino has superior rigidity and capacity to hold the tolerances required for certain parts. Key characteristics of the Amada Wasino CNC Surface

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MACHINE TOOLS

GRINDING

PRODUCT REPORT claims the company. The strong paper back results in greater tear resistance, longer disc life and increased cut. A special pressure-sensitive adhesive allows for easy on/off and less adhesive residue. The Paper Disc Roll is ideal for the most basic to the toughest applications. Ideal for lighter-duty blending, finishing and polishing on contoured surfaces of ferrous and non-ferrous materials. www.standardabrasives.com

Weiler Corp.

Weiler Corp.’s line of competitively priced Vortec Pro Bonded Abrasives has a new look. Distinctive red and blue blotters have been added to make sure Vortec Pro stands out. The abrasive products are designed for general purpose grinding and cutting applications on steel, iron, and other ferrous metals. All products are resin-bond formulated for aggressive stock removal and fast cutting, and are reinforced with fiberglass webbing for stability.

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Vortec Pro Type 27 grinding products range from 4 in. to 7 in. diameter and are available both in ¼ in. thickness for grinding and 1/8 in. thickness for light grinding or cutting. These wheels are offered in aluminum oxide grain with an option of a 5/8 in. - 11 hub and are used on right angle grinders. Type 27 cutting wheels are offered in .045 in., .060 in. and 3/32 in. thicknesses in diameters from 4 in. to 7 in. These wheels are also available in aluminum oxide grain with an option of a 5/8 in. - 11 hub and are used on right angle grinders. Type 1 cutting wheels are available from 2 in. to 7 in. diameter in various grit sizes, thicknesses and aluminum oxide abrasive grain. All of the these wheels have a metal ring around the hub for additional strength and stability. Type 1 wheels are used on right angle grinders, electric or air die grinders, tool room grinders and circular saws. www.weilercorp.com

Now Methods brings you KIWA Japan – the industry’s most expandable

GRINDING

“ We invest in equipment best

suited to produce the wide range of products we manufacture.”

Grinder are the machine geometry: flatness of 0.000024 in. over the full table, high speed stroking of 600 strokes per minute at 0.625 length and precision stop grinding to within +/- 0.0008 in. of shoulders. The menu driven software affords the job shop the ability to SWOT grind and profile grind with incorporated dress and compensate cycles. Integrating the latest high tech tools on H&O’s shop floor has created challenges, particularly in the filtration of coolants. “When buying our first Studers, the filtration units were underpowered,” recalls McDougall. When H&O purchased the recent Studer machines, Manley provided

MACHINE TOOLS

a Barnes centralized filtration system, requiring less paper and less maintenance. As a job shop with aspirations to take on greater capacity, H&O’s top management is determined to offer clients a comprehensive range of tools and equipment. “We invest in equipment best suited to produce the wide range of products we manufacture,” says McDougall. Grinding machinery that requires large investments makes perfect business sense because of the ability to produce parts to tight tolerances and micro finishes. “We have made a conscious decision to be in the forefront of technology and skill when it comes to precise cylindrical components,” says Johansson. “In this regard, we want to be all things to all customers, be they in medical technology, automotive, aerospace, or oil and gas, whether here in North America or world wide.” CM Jack Kohane is a freelance writer based in Toronto. www.cylindricalprecision.com www.machinetoolsystems.com/Videos/Studer/ www.amadawasino.com/machines_grinding.php www.grinding.com www.barnesintl.com

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CUTTING TOOLS

coatings

Coating Selection Guide Any coating will improve a cutting tool’s overall performance, but each one has its particular strengths By Daryl Angier ............................................................................................ The introduction of coatings for carbide cutting tools in the late 1960s created a major advance in metal cutting productivity. As illustration, Don Graham, turning products manager for Seco Tools, Troy, MI, says that in a typical automotive application machining cast iron or steel, if all other aspects of the machining process remained the same, the coating alone would reduce the number of inserts required from approximately 200 1969 to only one today. (The gains in machining the materials used in the aerospace and medical industries are much more modest; on the order of only a 3:1 reduction.) Whether it is a 200:1 or 3:1 increase in productivity, gains are gains, and a big part of selecting the right cutting tool for your application today is selecting the right coating or combination of coatings based on the material you’re working with and the speeds and feeds you require. All coatings improve an insert’s ability to reduce built up edge, resist abrasion and perform better in high heat conditions, says Graham, but some coatings do each of these things better than others. To help you make the choice, Canadian Metalworking has put together the following selection guide for a few of the most commonly used coatings in the industry.

CVD Coatings

CVD, or chemical vapour deposition, covers a range of coatings for inserts often used in high speed machining and finishing operations. CVD coatings are applied at high temperatures (from 800 to 1,100˚C) and offer the greatest wear resistance. CVD coatings are usually thicker than PVD coatings, and significantly increase the surface area of the edge. They are therefore normally only applied to tools with a honed edge rather than a sharp edge. Cutting tool suppliers Canadian Metalworking spoke to report that sales of tools with CVD coatings are now vastly outstripped by sales of PVD coated inserts. However, CVD coatings still fill important niches in the industry such as machining cast iron. Aluminum Oxide (Al2O3): Aluminum Oxide is highly resistant to heat. This property makes it suitable for machining highly abrasive materials such as cast iron that generate tremendous amounts of heat when machined at high speeds. Seco’s Graham explains that Aluminum Oxide resists heat in two ways. “It’s a very good insulator, analogous to the tiles on the space shuttle. More importantly, chemically, the coating is very stable and will not react with ferrous materials that are being machined.” Robert Sullivan, manager of coatings technologies for Ingersoll, Rockford, IL, adds that the coating’s chemical stability comes from the fact that it doesn’t oxidize, “It’s already oxidized.” Graham says Al2O3 works best at high speeds, in the range of 1,000 sfm, depending on the material you’re machining, of course. 32 | May 2010 | www.canadianmetalworking.com

Iscar’s TANG-GRIP parting line.

Titanium Carbide or Titanium Carbonitride (TiC or TiCN): “Today most everybody uses Titanium Carbonitride. It’s a little bit better than straight titanium carbide,” says Graham. The strength of this type of coating is its high amount of abrasion resistance. It is useful for machining highly abrasive materials such as ductile irons, medium alloy steels and compacted graphite iron for the diesel industry, says Graham. He adds that TiCN is best suited to intermediate speeds in the range of 700-1,000 sfm. However, Iscar’s Geisel notes that TiCN is commonly used as the internal layer on inserts with an external coating of Aluminum Oxide, therefore giving the insert higher speed capabilities. Beyond inserts from Kennametal are CVD coated.

Titanium Nitride (TiN): The desirable property of this coating is its ability to resist metal build up on the edge of the insert. Built up edge can be an issue with gummy materials such as soft steels and titanium and low speed applications (i.e. less than 650 sfm) such as threading operations and cutoff grooving. Graham says that in inserts designed for “heavy interruptions, low speed, bang-em-up hammer grade, they may have no aluminum oxide and quite a bit of TiN and TiCN.”

PVD Coatings

PVD, or physical vapour deposition, coatings have now come to dominate the industry, say suppliers. PVD coatings are applied at much lower temperatures than CVD coatings (in the range of 200-500˚C). This helps reduce the problem of micro cracking in the carbide substrate that can occur under the extreme temperatures required for the application of CVD coatings and lead to insert failure, says Iscar’s Geisel. PVD coatings also tend to be much thinner than CVD coatings. “PVD tends to grow with a fairly significant compressive stress inside the coating,” explains Ingersoll’s Sullivan. “The drawback is if you grow the coating layer too thick, the coating will spontaneously pop off the surface. Therefore, with PVD you’re restricted to a thinner layer. On the positive side, that compressive stress can be advantageous. It can increase toughness of the insert.” Because PVD coating layers are thin, they can be applied to a

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CUTTING TOOLS

coatings

sharp edge unlike the honed edge restriction for CVD coatings. A a PVD coating is its ability to resist metal build up on the sharp edge is often required to machine difficult materials such edge of the insert. as titanium and stainless steels. The extra strength in the edge “We like the idea of a thin top layer of titanium nitride that the PVD coating imparts helps prevent problems such as (on an insert with a TiAlN coating) to increase the chipping and depth of cut notching, says Sullivan. metal buildup resistance,” says Seco’s Graham. The growth in the industry of PVD coatings has also been “Other people argue that it is not necessary. It’s driven by changes in machining practices that dictate the more a corporate philosophy that we follow.” use of slower speeds (e.g. 600 sfm or less). In turning Titanium Carbonitride (TiCN): In the applications, for example, rods used to be the realm of PVD coatings, TiCN is used common shape. most widely in endmill applications, “Now people are dealing with these types says Graham. TiCN has been largely of parts where they’re running a lot more superseded by the widespread use of forgings and castings, a lot of these different Titanium Aluminum Nitride (see below), shapes where you need to balance the machine. but still has applications in lower speed Therefore you’re not going to be running 1,000 applications (e.g. 300-500 sfm) that don’t require sfm,” says Iscar’s Geisel. “Because the machine the heat resistance of TiAlN. is running slower, you need a carbide and coating “There are some users that don’t have speed capability that can support that.” At the same time, “because on their machines, or they have an application where they Sandvik’s S30T customers are sacrificing speed, they want to be more can’t go fast. There might be some part that’s hanging out grade for titanium aggressive as far as depth of cut and feed rate.” 10 ft and flopping around if they spin. At that point, the TiCN milling has a PVD coating. Titanium Nitride (TiN): As with CVD coatings, and TiN coatings can make sense,” says Graham. the main desirable attribute of Titanium Nitride as Titanium Aluminum Nitride (TiAlN): Titanium

PRODUCT REPORT Ingersoll

Ingersoll’s new CVD coated series T-TINOX grades are designed to improve productivity in 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, claims the company. The new T-TINOX series consists of three new grades: TT9215 offers high wear and chipping resistance and is suitable for high speed and continuous cutting in stainless. TT9225 is suitable 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, says Ingersoll. www.ingersollcuttingtools.com

Iscar

Iscar’s new 3P SUMO TEC line is a new series of premium tungsten carbide grades designed grades to meet the contemporary machining challenges of the metal cutting industry. The SUMO TEC grades feature the most advanced coating technology using the CVD and PVD processes, claims Iscar. The 34 | May 2010 | www.canadianmetalworking.com

polishes the surface to reduce friction and workpiece sticking (BUE). A fine-grained alumina layer allows for increases in cutting speed, improving productivity and reliability at high cutting temperatures.

PVD process is composed of ISCAR’s AL-TEC coating technology. The CVD coating is based on ISCAR’s ALPHA-TEC technology. The even surface contributes to smooth uninterrupted chip flow, less generated heat and less friction. The new process improves toughness and chipping resistance, thus reducing friction and built up edge. www.iscar.ca

Kennametal

Kennametal has launched Beyond, an entire platform of new high-performance turning products. Due to higher metal-removal rates and extended tool life, these products promise to push productivity 30 per cent higher or more for a broad spectrum of metalworking users, claims Kennametal. Beyond products comprise a complete line of 11 new grades applicable to steel, stainless steel, and cast-iron turning applications. A new post-coat surface treatment improves edge toughness, reliability, and depth-of-cut notch resistance, and micro-

All the new Beyond inserts are CVD (chemical vapor deposition) coated, but whereas conventional CVD coatings are under tensile stress, Beyond inserts undergo a proprietary post-coat treatment on all surfaces to reduce this stress, which improves coating adhesion and reduces microchipping, says the company. www.kennametal.com

Sandvik Coromant

Sandvik Coromant has launched two new grades to tackle the extreme demands of titanium milling. Grades S30T and S40T are available for a variety of CoroMill cutters for face, shoulder, long-edge and high feed milling, plunging, profiling and slot milling. S30T has been developed with productive titanium milling in focus. It combines the

coatings

CUTTING TOOLS

Aluminum Nitride is by far the biggest selling PVD coating because of its heat resistance and versatility. Iscar’s Geisel says it can run in just about any material, including steel, cast iron, aluminum, stainless steel and hardened steel. He notes that many job shops he deals with will standardize on just a couple of Iscar grades that have a TiAlN coating “because they know they can put them on anything. It may not be the best but it will work. It also helps them eliminate carrying lots of inventory.” Some cutting tools suppliers refer to this coating as Aluminum Titanium Nitride to indicate a high percentage of aluminum content. High aluminum content is desirable because it increases the maximum operating temperature. “But if you increase it too far you get some structural problems that result in a softer coating,” says Ingersoll’s Sullivan. However, “today the average aluminum content in pretty much everybody’s coating is about 68 per cent,” even if it’s still called Titanium Aluminum Nitride, says Graham.

Coating Care

Purchasing inserts with expensive PVD coatings won’t improve your tool life if you don’t look after them properly. “Even two inserts touching each other on the table top can chip each other and those chips can reduce tool life by half,” says Sullivan. Rather than simply dumping the box of inserts into a drawer on the workbench, Sullivan recommends keeping them in the package and storing the whole box in the drawer, or storing the inserts in a way so that they don’t touch each other such as in a cellular tray. CM

properties of micro-grain carbide and a wear resistant PVD coating. This enables very sharp cutting edges that resist fatigue and micro-chipping and result in cutting edges that are preserved for longer times in cut at higher cutting speeds. S40T is developed for difficult conditions. It combines high toughness cemented carbide with a

thin CVD coating. The result is a grade that withstands vibrations and other difficult cutting conditions for longer times in cut, says Sandvik. The wear is predictable, making the cutting edge gradually duller without breaking. www.sandvik.coromant.com

can also optimize stainless steel turning and cast iron applications, effectively machining materials from K10 to M40. TP2500 was developed through Seco’s DurAtomic process, where the coating is actually manipulated at the atomic level. In TP2500, the basic structure is aluminum oxide (AL2O3), but the overall ductility has been significantly enhanced through the DurAtomic process, claims Seco. The multi-functioning, wide application capability of TP2500 is achieved because the grade features a functionally-graded substrate structure that provides impressive edge toughness with no sacrifice in strength for the bulk of the material. TP2500 has been field-tested in more than 80 applications including roughing, facing and finishing in a variety of

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Seco

Seco Tools Canada has announced its first DurAtomic-developed coating, turning grade TP2500, which offers an unprecedented level of wear resistance and toughness to outperform and outlast any other grade on the market today in ISO P applications, says the company. TP2500

materials; reflecting improvements of 18 to 400 per cent improvement in tool life, 55 to 100 per cent productivity increase and a 40 to 80 per cent decrease in wear. www.secotools.com

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www.canadianmetalworking.com | May 2010 | 35

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CUTTING TOOLS

CUTTING FLUIDS

Fluid Motion Canadian Metalworking asks Craig Brydges, sales and marketing manager for Milacron Canada, about selecting the right cutting fluids for your machining operation

Machining processes and machine tools have changed significantly in recent years to address the market need to remain competitive. Today, multi-tasking machines, high speed machining, advanced smart machining and “green” machines are among the new machines and machining processes being embraced by the industry. How have these changes influenced developments in cutting fluid technology? We have seen significant growth in our line of High Fluid Pressure (HFP) metalworking fluids designed to meet the demand of not only high pressure applications but in high flow type applications as machine tool “foot prints” become smaller. We are also seeing increased demand for high lubricity synthetic type fluids, especially in the aerospace industry with the introduction of HVOF thermal spray coatings and 555-3 titanium. These new high lubricity synthetics are designed to equal or exceed the cutting performance of conventional cutting fluids. New products are also constantly being researched and developed as new materials are introduced such as compacted graphite iron (CGI) and high-strength low-alloy steel (HSLA), for example.

What challenges do cutting fluids present that could compromise machining and cutting tool performance?

We typically see two main challenges that could comprise machining and cutting tool performance: • I mproperly specified/selected cutting fluids in use for the customer’s application. •L ack of an in-house maintenance or control program for cutting fluids in the shop. Recent economic constraints have forced more interest in achieving optimum cutting fluid performance at the lowest possible cost. Most Canadian manufacturers understand that buying at the lowest possible unit price from the supplier can ultimately result in higher process cost. Cutting fluids typically represent between one and three per cent of the total manufacturing cost, however when miss-applied or not properly maintained, optimal benefits of the cutting fluid will not be achieved.

Are there differences in quality of cutting fluids? If so, how can a manufacturer distinguish between high and low quality products?

The short answer–yes. However, it is very difficult if not impossible for most manufacturers to determine the quality of a cutting fluid by reviewing a product brochure or material safety data sheet. Many machine shops make the mistake of buying a 38 | May 2010 | www.canadianmetalworking.com

cutting fluid on price only to find out you get what you pay for after they have put the “cheap” fluid in the tank. A lower quality cutting fluid can result in issues like: • rancidity • part and/or machine tool corrosion • increased machine downtime • possible damage to their machine tools • increased scrap rates • poor tool life.

If you were to create a checklist of the top things to consider in selecting the right cutting fluid for the right application what would it be? First, consult a reputable metalworking fluid company and have a site survey conducted. Most metalworking fluid suppliers have specialists on staff to properly evaluate your manufacturing operations and make the appropriate product recommendations. How do you find a reputable supplier? Talk to people you know at other machine shops or industry contacts you might have. A good supplier referral can help you narrow the choices down when it comes time. Next Steps: • Do you need one cutting fluid for all operations and materials in your shop or do you need an application specific type cutting fluid? • Know your water quality. • Part type and material. • Machine type and operation. • Coolant tank size and filtration. • Desired improvement(s). • General plant environment/conditions. • Does your company have any chemical restrictions or industry approvals that are required for your operations?

In today’s environmentally-conscious marketplace, reducing the carbon footprint, energy and waste material reductions, green processes, etc. are now common demands from customers. How do cutting fluids contribute to this growing trend and customer demand? The best way for machine shop owners to “reduce their carbon footprint” in respect to cutting fluids is to maintain their cutting fluids within the manufacturer’s recommended operating parameters and therefore reduce the amount of waste generated. Following these simple steps can increase the useful life of the cutting fluid:

CUTTING FLUIDS

CUTTING TOOLS

PRODUCT REPORT Chemetall

Chemetall has developed Tech-Cool 35052, a premium grade, chlorine EP activated, heavy duty semi-synthetic metalworking fluid designed for use with aluminum alloys (cast and wrought), stainless steels, titanium, and high nickel alloys such as Inconel and Hastalloy. According to the company, An important differentiator of Tech Cool 35052 in the marketplace is the product’s unique blend of chlorinated EP ingredients. The optimization of these ingredients ensures that Tech Cool 35052 delivers the best lubricity, corrosion resistance, and cleanability to a wide range of metalworking applications. In addition, the product’s excellent emulsion stability allows for extremely clean, residue free operation, even in difficult water conditions, says Chemetall.

Highly bio-resistant, it provides protection against bacteria growth without the use of biocides, DCHA, or other secondary amines. It is formulated to be low foaming without the use of undesirable silicone defoamers, even in foam generating operations such as creep feed grinding. Applications include roll threading, thread tapping, drilling, milling, and creep feed grinding. It also extends tool life during tough worm rolling and roll-tapping operations performed on cold-formed steel. According to Ron Felber, president and CEO, “Tech Cool 35052 represents a gigantic leap forward in the field of chlorine activated semi-synthetic metalworking fluids. Because it provides enhanced bio-resistance, excellent lubricity, and corrosion resistance, Tech Cool 35052 is specially suited for even the most challenging metalworking operations.” www.chemetallamericas.com

ITW Rocol

NEW Rustlick PowerCool MaxLife and PowerCool MaxLife CF coolants are longlasting water-soluble oils with new additives specifically formulated to give maximum

biostability and performance for heavy-duty cutting and grinding applications. The advanced technology used to formulate PowerCool MaxLife coolants ensures the highest fluid performance, dramatically increases sump life, and decreases overall fluid use, says the company. PowerCool MaxLife coolants are safe for all metals, including ferrous/non-ferrous metals, aluminum, brass, bronze, and copper. The products can be used for a range of low to heavy-duty applications including machining, cutting, grinding and milling. They are available in chlorinated or chlorine free versions. Rustlick PowerCool MaxLife contains chlorinated EP additives and PowerCool MaxLife CF contains non-chlorinated EP additives and is recommended for use on titanium. The products are available in 5 or 55 Gallon containers. www.rocolnorthamerica.com

Master Chemical Corp.

Master Chemical Corp.’s TRIM C380 is a premium synthetic metalworking fluid, optimized for hightech ferrous materials including stainless steel and Inconel. These materials are widely used in the aerospace, medical, and electronics industries. Additionally, C380 provides superior resistance to corrosion on these high-tech ferrous materials and is easily removed from parts for easy cleanup before assembly, painting, or plating operations. Using C380 will produce excellent surface finish in finish-grinding operations and is high performing in a wide range of operations from general grinding to heavy-duty machining, says the company. Low operating cost is a major benefit of C380 because of its ease of maintenance, low carryoff, and long sump life. C380 readily rejects process oils, such as hydraulic and way oils, which also makes it easy to keep clean and working at top performance.

C380 uses the best of the new ester technology to yield a very “high performance, easy to use and maintain” metal removal fluid. District sales manager Mike Weston, says that he has “a customer that makes engraving rolls for the print industry who has replaced two products with C380. They love the C380 because it has less residue, no sticky or gummy problems, improved corrosion protection, and provides the lubricity they need to get the job done.” According to the company, the combination of the proven synthetic ester technology and nonhalogenated EP package produces very high levels of usable lubricity at the point-of-cut. C380 utilizes unique low-foam detergents to keep process soils from redepositing on machines and parts. Using C380 creates a very clean manufacturing environment because it is water white, low foaming, low odour, and is low mist. C380 contains no chlorine, phenol, nitrites, copper, triazines, silicone, phosphorous, or SARA 313 reportable chemistry and is PRTR compliant. www.masterchemical.com

Milacron

CIMCOOL Global Fluids’ latest metalworking fluid is CIMPERIAL 861, a premium soluble oil fluid engineered and manufactured in Europe that is now available in the Canadian marketplace. CIMPERIAL 861 is recommended for moderate to heavy duty machining and grinding operations on non-ferrous and

ferrous metals including exotic alloys like titanium and Inconel. CIMPERIAL 861 offers the following benefits: • Proven European Technology • Boeing Approved • Chlorine free • Excellent rancidity control • Very low foaming in high fluid pressure applications. www.cimcool.ca www.canadianmetalworking.com | MAY 2010 | 39

CUTTING TOOLS

CUTTING FLUIDS

• Assign the responsibility for control in your shop. •A lways maintain the fluid concentration according to the manufacturers recommended ranges. •E mploy good housekeeping practices in your shop. •K now your water type for your area. • Use additives only as needed. • I nvolve your metalworking fluid supplier in training and laboratory support.

What will customers be demanding of cutting fluids for their machining operations in the future?

Over the next five years we expect to see increasing regulatory requirements including raw material availability due to Europe’s Registration, Evaluation, Authorization and Restriction of Chemicals (REACH) legislation effect on chemicals around the world and the new Global Harmonized System compliant (GHS) material safety data sheets. Many countries including Canada are moving to the GHS msds format.

What government regulations should a manufacturer be aware of when selecting a cutting fluid?

The Canadian government has put a number of regulations and guidelines in place to help ensure workplace and product safety. Since these regulations apply to all metalworking fluids used in Canada, knowledge and awareness of them is essential. These

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regulations include: Product labels: The product label for your metalworking fluid should contain the following basic information • Product and supplier identifier • Notification that an MSDS is available • Any applicable hazard symbols • Possible risks, precautionary measures and appropriate first aid measures. WHMIS: The Work Place Hazardous Material Information System is in place to ensure workers have access to the information they need to safely use and handle materials in the workplace. This also applies to cutting fluids used in your shop. WHMIS labels should be on the containers you receive from your supplier and must include the following: • Cross-hatch border • Available in both official languages • WHMIS Hazard Symbol • Product name • Safe Handling instructions • Reference to the Material Safety Data Sheet. Material Safety Data Sheet (MSDS): The material safety data sheet must be made available to all workers and will be supplied to you from your supplier. Most reputable cutting fluid suppliers will have their data sheets available on-line for convenient access and must meet the following: • Consist of a 9 or 16 section format • Available in the official language of choice • Must be re-issued every three years at a maximum. Canadian Environmental Protection Act (CEPA): One aspect of the Canadian Environmental Protection Act is the Domestic Substance List (DSL). The DSL is a list issued by Environment Canada and includes all chemicals that can be used and/or imported in Canada. Not all substances in use in other parts of the world (including the US) are approved in Canada. Your metalworking fluid supplier has the responsibility to ensure all ingredients in their cutting fluids are in compliance with CEPA Regulations.

• 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

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If your metalworking fluid supplier can’t supply you with a cutting fluid that uses this type of product labelling and can’t answer questions regarding their compliance to these Canadian regulations, you need to ask yourself “do I want or need this type of cutting fluid in my shop?” CM Craig Brydges is the sales and marketing manager with Milacron Canada Corp., Burlington, ON. www.cimcool.ca

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fabricating

PRESS BRAKES

Stoking the

Flame

Servo electric press brakes boost productivity by 30% for grill and fireplace maker In 1976, Wolfgang Schroeter began manufacturing steel railings in Barrie, ON. At the time, few observers could have predicted the successful future that lay ahead for Wolf Steel Ltd., and eventually Napoleon Fireplaces and Napoleon Gourmet Grills. Schroeter built his first fireplace in the early 1980s for a friend. The next year production rose to five units. Since the first wood stove rolled off the production line, Wolf Steel has earned a reputation for outstanding design, innovation, and success. The original stove featured a solid cast iron, two-door design and was produced in a 1,000 sq ft manufacturing facility. By 1981, the trade name “Napoleon” was born, and with it, the industry’s first single-glass door with Pyroceram high temperature ceramic glass. This was the first of many milestones for Wolf Steel and over the next few years, the demand for Napoleon’s wood stoves grew beyond Ontario’s borders to the rest of Canada and into the US. Today, the family-owned business management team includes Wolfgang Schroeter, president, his wife Ingrid, vice president, and their two sons Chris, operations manager, and Stephen, business administration manager. The company has grown dramatically with more than 500,000 sq ft of manufacturing space and over 400 employees. Wolf Steel is now North America’s largest privately-owned manufacturer of quality wood and gas fireplaces (inserts and stoves), gourmet gas and charcoal grills, outdoor living products and waterfalls.

Sheet metal fabrication

Bill Fulton, project coordinator at Wolf Steel, holds a part formed on a FinnPower E Series servo-electric press brake.

42 | May 2010 | www.canadianmetalworking.com

As Wolf Steel’s production increased, the sheet metal fabrication equipment list grew to a dozen stand alone turret punch presses and nearly as many hydraulic press brakes in its manufacturing plants. When the company needed to increase its bending capacity in 2007, it investigated new servo electric bending technology. Wolf Steel chose the Finn-Power E Series servoelectric press brake. The Finn-Power E Series servo-electric press brake is a fast, accurate bending solution. By applying mechanics and electronics, a unique, patented, mechatronic drive was developed. This drive is based on the pulley principle, resulting in an even distribution of forces in the top beam, high accuracy, increased productivity, and decreased energy consumption, and few maintenance requirements. The frame concept makes it possible to utilize the back gauge system across the entire working length.

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fabricating

PRESS BRAKES

PRODUCT REPORT Baykal

An upper end fireplace made by Wolf Steel/ Napoleon Fireplace.

The patented servo-drive system offers many advantages. When performing batch work of any size, the rapid advance, programmable working speed, programmable stroke parameters, and rapid return speed of the ram enables maximum cycling rates without compromising control. The fast positioning speeds ensures that the back gauge will be ready when the part is presented for each operation. The Power Belt System virtually eliminates ram deflection and the need for compensating bed crown. By using the pulley principle–a system with fixed and moving rolls spread over the total working length of the upper beam with a belt–equal force transmission is achieved. By applying servo-motors and regulators, an extremely simple and secure construction is obtained. Since the first purchase of an E Brake in 2007, Wolf Steel has purchased an additional unit each year, for a total of four E Brakes. “The high accuracy and speed, consistency, and low power consumption of the Finn-Power E Brake were all features that caught our attention,” explains Bill Fulton, project coordinator. “They perform better than the hydraulic brakes. The E Brake is so much quicker to set up than the hydraulic models, especially on jobs with six to eight bends. We’ve seen a 30 per cent increase in productivity with the E Brakes. And with the Quick-Change Tool, setup times are 25 per cent faster.” The Finn-Power E brake is available in tonnages from 27 to 220 (250 kN to 2000 kN) and bed sizes from 4 ft to 13.5 ft (1,250 mm to 4,100 mm). The E brake uses less energy than hydraulic models. It only consumes energy when the beam actually moves. This can result in energy savings of up to 50 per cent compared to conventional hydraulic press brakes. There is also no need to adjust the settings of pressure relief valves, nor are there filters to be checked and replaced. Another servo-electric product that Wolf Steel added to its sheet metal 44 | May 2010 | www.canadianmetalworking.com

The Baykal CNC Syncro Press Brake comes with multiple axis and control possibilities. Machines are available in capacities up to 6,000 tons. They are high quality built machines with excellent repeatability and longevity with a very competitive price, according to distributor Westway Machinery, Mississauga, ON. The company has been

building machines for more than 50 years and boasts a work force of more than 600 people. It is accredited the ISO 9001 Total Quality Certification by TUV of Germany. www.westwaymachinery.com

Bystronic

Bystronic has developed a new high speed ram option for the standard range Xpert series press brake. The new high speed ram positioning system is capable of reducing bend cycle times by 15 to 35 per cent, in reaching approach speeds of up to 600 ipm and bending speeds up to 47 ipm without sacrificing accuracy. It is the only press brake that introduces no angle errors itself with a ram positioning accuracy of .00015 in.

(.00381 mm), claims the company. Xpert technology dynamically adjusts ram position and crowning in response to material properties, achieving unmatched accuracy. The Xpert series covers 60 tons to 4,000 tons and bed lengths from 6 ft to 60 ft in length

(1.8 to 18 m). The Xpert series is available in Standard, Large, Mammut, Tandem, and Robot configurations. www.bystronicusa.com

Cincinnati

Cincinnati Inc.’s Proform press brakes have been enhanced for 2010 with features traditionally found on higher-priced, high-performance machines. • A bolt-on “quick clamp” ram nose as standard equipment. • An optional bolt-on power clamp system designed to accommodate major manufacturers’ die designs. • An innovative, optional 5-axis back gauge replaces the previous 4-axis back gauge option. • Enhanced software capabilities. The Proform’s PC-based control combines 3D graphics interface with simple touch-screen operation to speed setup and programming times, as well as optimize throughput. Precision servo hydraulics on a proven, rigid press brake platform allowing the press brake to hold ram repeatability to ±0.001 in. (0.025 mm) along its entire length. The Proform is available in 60- to 350-ton versions in overall bed lengths from 6 to 14 ft (1.8 to 4.2 m). The bolt-on “quick clamp” and optional bolt-on power clamp reduce setup time, while the optional 5-axis back gauge, with fast positioning speeds, flip back gauge fingers with hardened dowel pins, 40 in. gauge points and auto flange correction, provides the capability to handle a wide variety of complex parts. Absolute linear transducers mounted on both ends of the machine provide automatic leveling control by maintaining parallelism between the bed and ram. The transducers are referenced below the neutral axis of the throat to avoid ram reversal errors due to side housing deflection. Each Proform press brake is tested before shipping to ensure ram repeatability to ±0.001 in. (±3 Sigma). Cincinnati has also integrated proven press brake design principles to ensure reliable, long-lived operation. Among them

PRESS BRAKES

are clevis-mounted cylinders and centerline loading that confine operating stress within the main housing to eliminate cylinder misalignment, and a Variable Volume Load Sensing (VVLS) hydraulic system for lower maintenance costs and greater energy efficiency. www.e-ci.com

Ferric Machinery

The FERRIC-ERMAK CNCAP series of press brakes answers today’s demand for more productive and reliable equipment by the manufacturing industry, says the company. The key factors are setup, speed and repeatability. In standard configuration the CNCAP machines are equipped with hydraulics that allow approach speeds up to 8 in./sec. and bending speeds of 0,7 in./ sec. Together with the heavy duty X-R back gauging system with positioning speed of 8 in./sec, it is one of the fastest machines in its league and can be expanded to a full six axes back gauge system, says Ferric Machinery. To make the machine even more versatile, the standard tool clamps are designed to accept North American style and European style tooling, however other tool clamps are available to suit every need.

The ER90 Touch screen CNC control opens a complete new vision on programming and productivity. Multi-tool set up in a one part program is no longer a complicated process with the standard included off line program software. Multiple users can be programmed to track the productivity and down time during shifts. To minimize the downtime in case of a machine issue, the ER90 can be equipped with a direct net connection allowing the service department to log in directly into the machine for troubleshooting. The CNCAP series of press brakes are compliant with the latest safety requirements for the North American market. www.ferricmachinery.com

LVD Strippit

LVD Strippit’s PPEC press brakes are designed as a mid-range bending solution, offering a balanced mix of performance and value for less challenging forming applications. The series include PPEC-6 and PPEC-7 models, available in capacities from 80 tons, 2 m up to 220 tons, 4.2 m, with four to seven CNC controlled axes, depending upon machine model.

These press brakes feature a rugged, welded one-piece frame, machined without repositioning, guaranteeing machine precision. Hydraulic cylinders are machined from a solid steel billet. Pistons are steel forgings, precision ground and micropolished for years of trouble-free service.

fabricating

additional flexibility of Z1 and Z2 motorized backgauge movement. The standard PPEC backgauge fingers allow gauging to 39.4 in. (1000 mm) and also serve as material supports. PPEC-4 and PPEC-5 models can be fitted with an additional third finger support, which is ideally suited to the bending of channels. A V-axis crowning system fitted to PPEC-5 and PPEC-7 models ensures parallel and consistent bending results on longer bending length over the different tonnage levels. PPEC press brakes are equipped with LVD Strippit’s new CADMAN Lite control. Based on the same platform as the fullfeatured CADMAN Touch control. CADMAN Lite offers a number of the same key features, including 2D graphic programming with automatic collision detection, direct angle or Quick Bend programming, and connection with LVD Strippit’s CADMAN-B offline programming software. Unlike traditional pneumatic type sheet supports that typically do not support the part during the entire bending process, the T-axis system features synchronous brushless motors to follow and support the sheet before, during and after bending. The sheet supports are synchronized with the bending speed of the press brake, providing smooth operation and facilitating an accurate, consistent bending process. T-Axis trajectories are calculated automatically by the press brake control depending upon the size of the V-die. The sheet is completely supported during bending by the synchronized action of the rotation movement. www.lvdgroup.com

Prima Finn-Power North America

Microprocessor technology is linked to servo-controlled state-of-the-art hydraulics and electronics to ensure perfect control of the bending process and optimum precision. Double bed referenced encoders are connected to the bed in such a way that deformation of the side frames during bending does not influence the positioning accuracy of 0.01 mm of the upper beam (Y1-Y2). The PPEC’s two axis backgauge allows depth (X axis) and height (R axis) positioning of the two standard backgauge fingers. The PPEC-6 and PPEC-7 models offer the

The E Series Servo Electric press brake is designed for high precision in the most demanding production facilities. By applying mechanics and electronics, the company developed a patented “mechatronic” drive. The result is even distribution of forces in the top beam, high accuracy, increased productivity, high reliability, less energy consumption, and few maintenance requirements. A Touch Screen (TS) control using a user friendly programming system in a Windows operating system controls machine functions. When doing batch work of any size, the rapid advance, programmable working speed, programmable stroke parameters, and rapid return speed of the ram enables maximum cycling rates without compromising www.canadianmetalworking.com | May 2010 | 45

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PRESS BRAKES

fabrication arsenal in 2007 was the Finn-Power EBe automated bender. The EBe provides the high bending quality required in demanding applications. This is achieved through precise control of bending axes, fast and smooth bending, open programmability, and construction that is immune to variation in thermal conditions. The EBe bending operation cycle is automated--from the loading of the flat parts to unloading the bent components. It provides complete bending automation, including manipulation and rotation during the bending sequence, bending, and unloading of the bent component. The EBe works the edges of the panel. Generally, the process starts at the external edge of the sheet and continues to the inner part of the sheet, working one side after another in sequence until all bends have been completed. During the bending action, the upper tool of the bending unit holds the required portion of the sheet in the proper position. Two blades, mounted on the C-frame, manipulate the protruding portion of the sheet. The C-frame moves vertically and horizontally. The motion is programmable according to material type and the required bending angle. The bends can be made either upwards or downwards, depending on whether a positive or negative bend is required, without turning over the piece. A fundamental characteristic of the EBe bending technology is the movement of the blades. For optimum product quality, a new bending principle is now available. With this new principle, when the Rolling Mode is used, there is a wider contact surface between the blade and the sheet with no relative friction. Alternatively, when using a standard Circular Mode, the contact point remains constant whereas the contacting point of the blade changes during the bending movement. The contact line of the blade to the material being bent remains constant. This is achieved by numerically controlled interpolation of the two axes that operate blade movement. This is coordinated by the CNC, which manages the angle dimension and the thickness of the sheet while automatically adjusting the position of the blades. “The EBe has performed very well for us,” says Fulton. “We have quite a few parts that are dedicated to the bender. We definitely see an increase in productivity compared to the press brakes–as 46 | May 2010 | www.canadianmetalworking.com

PRODUCT REPORT

control. The fast positioning speeds ensures the backgauge will be ready when the part is presented for each operation. The Power Belt System virtually eliminates ram deflection and the need for compensating bed crown. By using the pulley principle –a system with fixed and moving rolls spread over the total working length of the upper beam with a belt–an equal force transmission is achieved. The press brake is available in capacities of 27 to 220 ton US (250 kN to 2000 kN) and bed lengths from 4 to 13.5 ft (1,250 mm to 4,100 mm). The press brake utilizes a universal upper and lower beam so the machine can be configured with the appropriate clamping for any of the major tooling styles—Wila, American or European—allowing customers to use existing tooling. www.finnpower.com

Salvagnini

The 2010 Roboformer G2X is not your typical press brake, but rather an automated stand alone bending cell that makes lean manufacturing possible for companies engaged in heavy gauge bending. It can also be integrated into a flexible manufacturing system (FMS) with the addition of an L1X or L2 laser for heavy gauge production, or with an S4X for light and medium gauge production. The unmanned press brake bending system accommodates single piece part flow and kit production capabilities in a hard working cell that assures consistently high part quality in the safest of environments. One difference between the Roboformer G2X and conventional press brakes is the addition of a robot—a Kuka robot mounted on a seventh axis—and rail

system, enabling precise registration no matter its position relative to the centre of the press brake. The moving robot eases restrictions on part size capacity because the robot can move out of the way and still centre a large or oddly shaped part in a manner that would be impossible if the robot were stationary. In addition, the movable robot permits the use of multiple feed and stacking zones to provide throughput buffers when required. One shop floor supervisor can oversee the operation of up to 5 Roboformer G2Xs. And with its EasyForm Laser for in-process angle control, it means assured repeatability and confidence that the first part produced will be a good part, says the company.

Roboformer G2X is designed for companies that work with small, often varied batches and are seeking ways to improve their quality, competitiveness and time-to-market. www.salvagnini.com

TRTRUMPF

TRUMPF’s TruBend Series 7000 precision press brake, the most popular press brake the company has ever launched in Europe, is now available in North America. The TruBend Series 7000 is a compact machine that offers a high quality, efficient solution for the production of small bent parts for up to 40 in. (1,016 mm). Typical applications include sheet metal parts used in the production of vending machines and electrical equipment as well as in the telecommunications and aerospace industries. Bending such parts with large, heavy press brakes is typically inefficient because of the space and energy requirements involved. The press brake has the ability to increase its bending speed simply by making adjustments to the machine parts relevant to the bending process: the back gauge and the beam. The back gauge is made with lightweight carbon fiber, and the surfaces on which the bent part contracts the fingers of the back gauge are

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allow symmetrical and asymmetrical positioning. The carriages can carry different tools, which can be easily changed according to product requirements. The short blades can be mounted onto the carriages for panels that require partial bends not occurring on the same line lengthwise, or when ‘small wings’ need to be bent in order to weld corners. “We have three different styles of short blades,” says Fulton. “We use them often for tabs and corner flanges. We use ASP on 30 to 40 per cent of the parts we bend.”

Full automation

Top: The in-line EBe bender is fed by the Night Train material management system. Bottom: Close up of the Finn-Power E brake in action.

much as 40 per cent on the majority of parts. One part that we run on the EBe is a left hand and a right hand kit part. On a press brake, we used to produce 25 kits a day. On the EBe, we average more than 120 kits a day. The EBe is also great for large parts. On a press brake, large parts often require two people to run the parts through. With the EBe, one person can load and run the part. Accuracy is also quite reliable and consistent. The only time we see any inconsistency is in the material.” Fulton adds that several features on the machine have helped improve productivity. For example, the Automatic Tool Change reduces setup time and operator error. It automates the changing of upper tool dimensions, allowing the machine to run unattended. “The operator doesn’t have to do anything,” explains Fulton. “There is no chance of error. Each time you call up the job it is always correct.” The Additional Upper Tool mechanism changes the upper tool mechanism by lowering an additional tool below the standard upper tool segments. “We bend a lot of stainless steel parts,” says Fulton. “The AUT allows us to run bumping radius on stainless with no tooling marks.” The Additional Short Blades option is installed within the C frame and consists of two numerically controlled carriages, sliding from the sides on linear guides. Two independent axes 48 | May 2010 | www.canadianmetalworking.com

In late 2009, Wolf Steel needed to add punching capacity and automation. The company’s latest acquisition was a Finn-Power Night Train Material Management System and Shear Genius Flexible Manufacturing Cell with an in-line EBe Bender. The centerpiece of the Finn-Power automated sheet processing system is the Night Train Material Management System, which is the inventory and material transporting center. The Night Train FMS provides a total solution for unmanned operation for sheet metal fabricators by automating system control, as well as material flow within the system. This includes supplying raw material as well as removing and storing work in process. With the Shear Genius concept, the objective is to provide one machine capable of transforming a full-sized sheet into punched parts. These parts can be moved to secondary operations utilizing the sorting and stacking automation into the Night Train system and onto bending operations without being touched by human hands. As loading, punching, and shearing of parts become automated, the result is finished parts with a dramatic reduction in scrap and manual labor while increasing profitability. “We are limited to 4 x 8 sheets with our stand alone turrets,” says Fulton. “However, we can load full-sized 5 x 10 sheets with the Shear Genius. The automation process is so much easier once we load the sheets in the Night Train and the operator is able to call up the material. We don’t have to wait for the fork lift. The parts are automatically punched, sheared, and sent to the stacking table. The finished parts from the Shear Genius are queued into the Night Train. The in-line EBe automatically receives material from the Night Train, which gives us more fabrication flexibility.” The Shear Genius eliminates wasteful skeletons and costly secondary operations such as deburring. Nibble edges on the part exteriors were eliminated through the use of the integrated right angle shear. In fact, the same clamps that hold the sheet for punching also hold it for shearing. In essence, the Shear Genius allows the automated process to begin with a full-sized sheet of material and end with a punched part after automated loading, punching, forming, shearing, stacking and unloading--all in one operation. “With the Shear Genius there are no skeletons and much less scrap,” says Fulton. “We estimate that we are saving 10 per cent in material handling alone. Our production has increased 50 per cent with the Shear Genius compared to the stand alone turret punch presses.” The investment that Wolf has made in sheet metal fabrication equipment underscores the company’s commitment to manufacturing in North America. “We’ve been able to remain very competitive in the marketplace because of our investment in automated sheet metal fabrication machines, cells, and systems,” says Fulton. CM www.napoleonfireplaces.com www.finnpower.com

PRESS BRAKES

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PRODUCT REPORT made of hardened steel, features which the company says allows for accurate results. In addition, the torque motor, which drives the beam, can deliver power even at low speeds. It ensures rapid axis movements and is low maintenance, since it has no gears and therefore needs no gear oil.

Optimum working conditions and userfriendly operating elements are integrated into the machine design. The operator can control the machine while sitting down and work without becoming fatigued, which helps ensure the quantity and quality of the fabricated parts. Gas spring supported pedals allow the height and angle of the foot rests to be adjusted. The arm support is also adjustable in height, so that every operator can set up his or her workplace individually. In addition, the monitor for the TASC 6000 control system can be adjusted electronically and set to the appropriate angle. Optional TRUMPF LED lighting, tried and trusted in medical technology, illuminates the area in front of and behind the beam, ensuring correct lighting conditions precisely at the bend, without heat radiation. A laser diode also projects the bend line onto the surface of the sheet metal, simplifying the accuracy of guiding the workpiece into the back gauge. www.us.trumpf.com

Wila

Wila’s new line of New Standard Pro Clamping, Crowning and Tooling systems are designed to bring the added productivity of ultra-fast setup time and high quality bending results to more press brake users

by offering exceptional value at affordable prices, claims the company. The New Standard Pro line offers many of the same product features as in Wila’s New Standard Premium line, such as the patented Safety-Click buttons in the punches for fast vertical loading/unloading, self-seating of tools when used with a Wila clamping system, and crowning systems outfitted with the patented “Wila Wave” bed deflection compensation system. Like Wila’s other press brake tooling lines, this tooling is precision ground, CNC-hardened at the wear areas, and segmented in lengths of 515 mm (20 in.) or shorter for easy operator handling and for complete versatility in making any tool length combination in increments of 5 mm (0.2 in.). The tooling line is available for use on new press brakes and can be retrofitted in the field to practically any brand or size of press brake. They’re available with hydraulic or mechanical clamping. The clamping systems can be supplied for mounting to a flat upper beam on a new press brake or with either an American safety tang or European style Z1 or Z2 tang for retrofitting to a current press brake at a customer’s location. For retrofit purposes, Wila offers a completely self-contained hydraulic power pack which allows Wila tools to be clamped, seated and aligned automatically within five seconds.

New Standard Pro Crowning Systems can be supplied with CNC Motor Drive for integrating to the press brake controller or with manual hand crank assembly and counter. The crowning systems offer proportional bed deflection compensation over the full machine length from a single point operation as well as localized adjustment capability with scaled dials every 200 mm (8 in.) for compensating for machine

or tooling tolerances or wear. Single V-dies can be clamped automatically via hydraulic clamping pins or manual clamping system models are in the crowning program. www.wilausa.com

Wilson Tool

New urethane products from Wilson Tool are designed to help press brake operators reduce or even eliminate sheet marking during bending operations. Wilson’s mark free bending solutions, including urethane dies, holders, pads and rolls, save operators time by eliminating the need to clean up unwanted marks on sheets after bending.

Urethane Dies: Available in Wilson Tool’s American Precision and European style dies, urethane dies greatly reduce and in some cases completely eliminate sheet marking on the press brake. Urethane Holders and Pads: Urethane holders are manufactured using 6061-T6 aluminum and hold a pad of urethane for mark free and radius bending. Two pad hardness options are available: Blue/90A, the most commonly used, or Red/80A, which helps reduce tonnage in the application by approximately 20 per cent. Urethane Rolls: Available in two styles, urethane rolls provide a protective layer across the top of standard dies to prevent sheet marking. Wilson’s standard roll of urethane is available in thickness of .015 or .030 in., depending on the application. New highdensity urethane rolls, offered exclusively by Wilson Tool, are .022 in. thick and last significantly longer than standard urethane, says the company. www.wilsontool.com www.canadianmetalworking.com | May 2010 | 49

KOMPAKT

Plasma Systems The design of the HACO KOMPAKT is based on a long experience in the field of CNC Plasma Cutting Machines. The large range of tables sizes and Plasma Cutting Sources (conventional as well as high-definition), means that we can offer you the perfect machine for your specific application. The Haco KOMPAKT is manufactured to the highest standards. The optimum price/quality ratio of the Haco KOMPAKT translates itself into a profitable investment.

HACO PRESS MASTER Press Brakes

• SIMPLE • FAST • ACCURATE • RELIABLE Affordable Bending Solutions • Capacities: 44 to 450 Tons • Bending lengths: 5’ to 20’ • Equipped with: • Synchro type Depth Axis (X1-Y2) • Heavy Duty Two Axis Back Gauge (X-R) (R-Height control) • Manual Adjustable Crowning Table • N.A. Style Top & Bottom Tool Clamping

Optional : • CNC Crowning • ATS 9000 2D Graphic Control • Different Style of Tooling Clamping

CNC PUNCHING MACHINES

HYDRAULIC PLATE BENDING ROLLS

HYDRAULIC SHEARS

CNC PLASMA CUTTING MACHINES

KINGSLAND IRONWORKERS

CORNER NOTCHERS

HYDRAULIC PRESS BRAKES

HYDRAULIC PROFILE BENDING MACHINES

HACO CANADA INC.

www.hacocanada.com

Mississauga Office

2550 Dunwin Drive, Mississauga, Ontario L5L 1J5

Tel: (905) 828 1087 Fax: (905) 828 2062 sales@hacocanada.com

saws

fabricating

The

Automatic Alternative Top tips on maximizing automatic saw efficiencies By Nate Hendley

One of DoALL Sawing Products saws in action.

What is the most important thing a machine shop should keep in mind when purchasing an automatic saw? “The most important thing to consider is local service. No matter what kind of machine [a shop] buys, problems [are likely] to happen,” says Patrick Chen, from the marketing and communications department at Taiwan saw giant, Soco (sold in Canada through distributor Westway Machinery, Mississauga, ON).

“You need to know you can count on local service and quick delivery of parts,” agrees Jerry Kroetch, president of Scotchman Industries, a Philip, South Dakota-based company which manufacturers saws and other equipment. Juergen Meckle, general manager of TecSaw International, a metal cutting equipment distributor in Mississauga, ON, takes a different tack. “The most important thing is to identify the application. A machine that is perfect for one application might be completely wrong for another one,” states Meckle, whose company sells saws made by German firm Kasto. Once the application has been identified,

shop owners should source a machine that suits their cutting capacity. “Obviously, the machine has to be big enough to cut the largest materials the customer wants to cut. The next step is to find out if a manual, semi-automatic or a fullyautomatic machine is required,” says Meckle. As Meckle notes, shop-owners who only use their saw a few times a day to cut very small batches can probably make due with a manual or semi-automatic machine. If the shop owner is dealing with larger batches, then automatic is the way to go. Of course, there are automatic alternatives to consider. “Sometimes it is more cost effective and also more user-friendly to add an auto-feed system to an existing semi-automatic machine” rather than buying a brand new saw, says Kroetch. How can companies maximize the efficiency of their automatic saws? Pay attention to blade selection—“using the correct blade will increase blade life and also increase cutting times,” states Kroetch. “Use a quality saw blade. The best machine will not achieve good cutting results with a low quality blade,” agrees Meckle. “It’s a common mistake to think that a cheap blade results in less production costs. In fact, in many cases, it is better to spend more for a blade that lasts longer and cuts faster, because the price of the blade itself is only a small part in the whole cutting operation. The purchase of “cheap” blades can result in a very expensive undertaking in the long run and the machine cannot be used to its full potential.” According to TecSaw, carbon steel blades, bimetal blades and coated and uncoated carbide-tipped blades are ideal for wood, steels and nonferrous metals. Carbide-grit and diamond-grit blades are appropriate for cutting abrasive building materials, fibreglass and silicon. Soco, for its part, has a line of tungsten carbide-tipped (TCT) blades that can “ saw mild steel and high tensile steel tube,” says Chen. In addition to blade selection, Meckle says proper maintenance and setting the correct cutting parameters are vital for getting the most from your automatic saw. “Among other components, the guidance system and condition of the wheels are www.canadianmetalworking.com | May 2010 | 51

BEYOND LEAN

...MATE TOOLING takes you there. Thatâ&#x20AC;&#x2122;s because Mate tooling lasts longer, sets up faster and produces the highest quality sheet metal parts. With Mate, you accomplish more lean objectives because you get so much more. More machine uptime. More throughput. Greater productivity. More options for eliminating secondary operations. A broader range of tooling styles for all major punch press brands. The highest rated field service and factory support backed by global supply. Plus the Mate exclusive, unconditional 100% customer satisfaction guarantee. See the proof at mate.com or call 1.800.328.4492

saws

especially important for performance, accuracy and long-blade life,” he states. “Use the right cutting parameters. The best machine with the best blade will not achieve good cutting results when incorrect cutting parameters are used. The use of incorrect parameters can even damage a blade. [Consequently] cutting results are poor and productivity is low,” adds Meckle. Are there any disadvantages to using an automatic saw (such as cost)? “There is no disadvantage to an automatic machine as long as an automatic machine is required for the application. If a customer only cuts five pieces per day, an automatic machine is certainly overkill and shouldn’t have been purchased in the first place, but as long as the machine runs (more or less) constantly and cuts large amounts of pieces in automatic mode, there are only advantages,” says Meckle. While automatic saws are more

expensive than manual or semiautomatic models, Meckle points to the labour cost savings the former entails. Manual and semi-automatic machines require constant attention: an operator “has to feed the material in manually, clamp it, start the cutting process and remove the cut-off piece for each individual cut. In the best case scenario one operator can handle maybe two machines more or less efficiently,” says Meckle. “An automatic machine does all this automatically and idle times are reduced tremendously. The operator only has to load new bars into the machine and remove cut-off pieces once in a while. Depending on the application, one operator can easily handle three or more machines at 100 per cent efficiency.” Automatic saws also offer better length accuracy and can be programmed to work without a human operator in “lights out” fashion, Meckle adds.

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Compared with semi and manual saws, “automatic saws absolutely cost a lot, but they can make you more money, if you get more orders,” points out Chen. Soco recently introduced the SA-78NCE, a machine that is “specialized for high tensile steel tube cutting. High tensile steel is used for the automotive industry. It’s lighter than traditional steel,” says Chen. Indeed, the SA-78NCE is particularly adept at cutting automotive parts such as impact beams, chassis and cross bar tubing. The SA-78NCE can saw various shapes of profiles, including round, rectangular, square tubes and round bars, and features touch-screen graphical controls with automatic recommendations of cutting parameters. Scotchman just released a semiautomatic DS-20 Band Saw 20 inch double miter machine. The DS-20 has a band driver motor of 5-hp (3.75 Kw), and a swivel head capable of moving 45º right

PRODUCT REPORT Behringer

A line of automatic and semi-automatic band saws designed to efficiently cut larger sized materials is available from Behringer Saws Inc. The HBP Series Bandsaws can accurately and economically cut solid forgings, slabs, profiles, moulds or bundled materials up to 82.6 in. (2,098 mm) in diameter.

Each saw in the HBP Series is constructed with cast iron frame construction and a twin column parallel down feed design for proper saw blade tensioning to deliver quick, efficient and forceful low vibration cutting for smooth cuts. These large saws are available in automatic, table and gantry designs. The band saws also come with roller conveyors in the tabletop or gantry versions with a traversing saw frame for quick and efficient handling of heavy materials preand post-cut. Utilizing 3 in. width bandsaw blades, the saws feature frequency controlled 20.1 horsepower main drive motors with a variable speed range of between 27-275 Surface Feet Per Minute (SFM) as the standard. Options are available for 49-443 SFM and 66-558 SFM motors. Hydraulic and hardened clamping jaws on the bandsaws ensure steady and precise cuts at all speeds. They require minimal operator intervention as they are controlled by a programmable logic controller (PLC) and feature an easy-to-use

operator’s terminal with diagnostic display, data entry and program storage. The speed is easily set, controlled and monitored before and during the cutting process. www.behringersaws.com

DoALL

DoALL Sawing Products’ new StructurALL series of band saw machines are designed for cutting all types of structural materials. All machines in the series incorporate swiveling scissor-head designs for ease of miter cutting. Some of the standard features throughout the family include: • Rounded band doors, covers and panels, for a sleek modern look; • Larger pentagonal base for better chip and fluid management; • Integrated fork-lift pockets for easier transporting of machine; • Standard flood coolant-thru-the-guides system (mist is optional); • New “easy-to-handle-n-dump” chip totes; • Relocated and improved operator controls.

The 400S is the family’s introductory machine. Swiveling 45º, it is suitable for the small to medium fabricator or machine shop looking to make accurate (straight or miter) cuts in smaller quantities. The 400S features a 9 in. high x 16 in. wide (229 mm x 406 mm) capacity of rectangles and 10-3/4 in. rounds, at 0º. This manual machine can be equipped with a variety of options to further ease operation, such as pneumatic head-lift and pneumatic vise attachments. www.canadianmetalworking.com | May 2010 | 53

Easy-Form Laser Press Brake

perfect bending Perfect bending can be difficult to achieve. At LVD Strippit we have THE solution. With an LVD Strippit Easy-Form® Laser Press Brake your parts will be perfect every time, from the first bend to the last – how many other systems can REALLY guarantee that? You’ll save time, improve accuracy and reduce scrap... how assuring. To help your shop on the way to perfection call us at 800-828-1527. Perfect.

saws

and 60 degrees left. The DS-20 also has hydraulic powered vise clamping with variable vise pressure, remote control console, a chip shovel/rake, a bimetal saw band and a band speed of 50 – 400 fpm (15 – 122 mpm). Kasto also has some product launches in store. “The KASTOmaxcut series will be introduced in a few weeks. This series of large, fully automatic, gantry-style band saws will be available with cutting capacities of up to 80 in. x 80 in. and will also offer extremely high cutting performances,” states Meckle. TecSaw also sells automatic saw accessories such as automatic loading magazines, automated storage systems and automatic discharge and palletizing systems. Fully automatic storage and retrieval

systems not only save expensive floor space, they also improve material flow, inventory control and work safety. They will streamline internal processes, simplify material access and cut down

The HCS 150 NPG is a new automatic circular cold saw from Behringer Saws.

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on the inefficient use of time in your facility resulting in further cost savings, says the company. What’s the biggest advantage of using automatic saws? “Labour [cost] savings and higher productivity are the biggest advantages,” says Chen, an observation seconded by others. “If you have the need for automation, an automatic saw will be a huge benefit. Time is money and the more productive you are, the sooner the saw will pay for itself. If your production warrants an automatic machine you will save on labour cost, increase production and have less scrap,” states Kroetch. CM Nate Hendley is a freelance writer based in Toronto. www.kastoracine.com www.socomachinery.com www.scotchman.com www.tecsaw.com www.westwaymachinery.com

PRODUCT REPORT Next in the line is the fully hydraulic (clamping and head-lift) 500DS. Double-swiveling 45 degrees in one direction and 60º in the other, it’s the ideal machine for a fabricator cutting multiple angles in the same work piece. The 500DS features a 14 in. x 20 in. (356 mm x 508 mm) capacity of rectangles and 15 in. rounds, at 0º. The fully automatic member of the family is the newly designed 500SNC. This model incorporates new, relocated NC touch controls. Now swiveling 60º, this model is even more versatile for production cutting of a variety of structural materials, straight or miter cuts. The 500SNC features a 14 in. x 19 in. (356 mm x 583 mm) capacity of rectangles and 14 in. rounds, at 0º. Speed of cutting is increased with its 40 in. stroke, and 8 x multiple index. Adding an optional nesting fixture will increase production exponentially, says DoALL. www.doallsawing.com

range. This new model combines most of the features on other saws, such as the patented Easy-Load blade guides, quick change column adjustable from 90 to 3 forward cant and our 48 in. double ball screw automatic bar feed with high speed travel for faster cycle times. Additional features include linear ways on the column travel, automatic bar feed and guide arm as well as two position hydraulic vises. The 380A-PC60 also includes two new innovations: Direct Force Sensing Electric Feed that combines more consistent feed force with greater control. The new Marvel PC3 Programmable Control that features a colour touch screen control, graphical part programming, user friendly interface and memory for up to 500 jobs and parts stored on removable media. www.sawing.com

Marvel Manufacturing Co.

Pat Mooney

Marvel Mfg. Co.’s Marvel 380APC60 is the newest model in the company’s line of fully automatic vertical tilt-frame saws. It features 15 in. x 20 in. (4,572 mm x 6,096 mm) capacity, 1.25 in. blade, 60 mitering in both directions and a standard 48 in. automatic bar feed. With a smaller capacity and foot print than the company’s 2000 series, the 380 was designed for those customers who need production cutting in the 10 to 12 in. (3,048 mm x 3, 658 mm)

Exclusively available from Pat Mooney Saws, the new Nishijimax NHC-SQA Plate Saws are fast and accurate enough to replace three to four band saw machines. In addition, the surface finish and surface quality of the cut plate is dramatically improved compared to band sawing, claims the company. The NHC-SQA Plate Saws are available in two models. The NHC-850SQA is designed for traverse sawing of plate. The NHC-8310 is designed for sawing longitudinally. Both machines are automatic, and the plate is positioned and cut to an exact size simply by programming the NHC-SQA. The NHC-850SQA can saw plate up to 3 in. thick and 24 in. wide (76 mm x 610 mm). The NHC-8310SQA can handle plate that is 4 in. thick and 20 ft long (102 mm x 1.2 m). A unique saw spindle drive system for the NHC-SQ Series results www.canadianmetalworking.com | May 2010 | 55

fabricating

saws

PRODUCT REPORT in 15 to 115 rpm blade speeds with unusually precise torque control, says tge company A 21 hp induction motor drives the saw blade spindle via a reduction gearbox. The rpm of the gearbox is controlled by a FREQROL Inverter Drive. The Spindle Feed Axis ensures that a precise feed rate is set automatically and input chip load is maintained. The saw blade feed rate is controlled via an AC Servo Motor with Encoder, a Mitsubishi Programmable Servo Drive and a precision ball screw. Compared to hydraulic systems, there is no fluctuation for temperature or condition of the oil. Job set up takes less than five minutes with the CNC Controller. Further increasing precision, the NHC-SQ Series is equipped with a horizontal and an overhead clamping hydraulic clamping system. This ensures that material is flat and square during cutting. www.patmooneysaws.com

Scotchman Industries

Scotchman Industries’ new Double Swivel 20 in. band saw, the DS-20, will swing 45º right or 60º left. DS-20’s capacity at 90˚ is 14 in. high x 20 in. wide (356 mm x 508 mm), at 45˚ is 14 in. high x 14 in. wide, (356 mm x 356 mm) and at 60˚ is 14 in. high x 10 in. wide (356 mm x 254 mm). This machine comes standard with a quick-slide vise for swinging from right to left, hydraulic clamping and head lift combine to make a semi-automatic cycle control. The band saw comes with a 1-1/4 in. blade, saw guides with carbide inserts, large material bed, and a remote control console as well as other standard features. This band saw provides maximum versatility and longevity, with minimum maintenance. With their massive heads, large blades, and array of standard features, these machines are designed to handle the toughest applications for years of production. www.scotchman.com

TecSaw

BOMAR, supplied in Canada by TecSaw International, has introduced the new BOMAR EXTEND series. This line of heavy duty, large band saw machines covers cutting capacities from 20 in. x 20 in. to 80 in. x 80 in. (508 mm x 508 mm to 2032 mm x 2032 mm) and includes semi-automatic and fully automatic models. All machines feature double column design, powerful saw drives, precise linear guides for the saw head and heavy blade guide systems for accurate cuts. The saw head, the machine base and the machine columns are filled with polymer cast in to eliminate vibrations and to achieve high cutting performance and long blade life. The modular design makes the EXTEND series flexible and suitable for a wide range of applications. Options include a variety of different infeed and oufeed systems, special clamping devices and much more to adapt the machine perfectly to the requirements. www.tecsaw.com 56 | May 2010 | www.canadianmetalworking.com

Welding

ARC WELDING

Creating High Stick Welds A user’s guide for success

By Harry Sadler .................................................. Stick welding is the most common form of arc welding, but creating a good weld may not be easy for the beginner. Unlike wire welding where you basically “point and shoot,” stick welding has a higher skill level and requires mastery of certain techniques. This article will offer tips that you can follow to increase your chances of creating a high quality stick weld right from the start. It will also discuss how to troubleshoot problems and correct them.

Tips

1. Select steel in the normal range Whenever possible, select steel within the “normal range.” These include AISI-SAE 1015 to 1025 steels with 0.1 per cent maximum silicon and sulfur content under .035 per cent. Selecting these steels will make the stick welding process easier since they can be welded at fast speeds with minimum cracking tendencies. If you are welding with low alloy steels and carbon steels with chemistry compositions above the “normal When stick welding in confined spaces, special ventilation is required. Always use a fume range,” they will have a greater tendency to crack, extraction device such as the one pictured here. particularly when welding on heavy plate and rigid structures. Because of this, special precautions may the entire joint. Any variations in a given joint will force the be necessary to avoid cracking. In addition, steels with high operator to slow his or her welding speed to avoid burn-through sulphur and phosphorus contents are not recommended for and manipulate the electrode to adjust for the fitup variation. production welding. If they must be welded, use small diameter, b) Sufficient bevel is required for good bead shape and low hydrogen electrodes. Welding with a slow travel speed will penetration; insufficient bevel prevents the electrode from further keep the puddle molten allowing gas bubbles time to getting into the joint. For example, a deep, narrow bead may boil out, creating a better-finished weld. lack penetration and has a strong tendency to crack. c) Sufficient root opening is needed for full penetration, while 2. Choose a joint position and electrode that is conducive to excessive root opening wastes weld metal and slows welding the metal speed. It is important to note that the root opening must be Joint position can have a great affect on finished weld quality. consistent with the diameter of the electrode being used. When welding on 10 to 18 gauge sheet steel, the fastest travel d) A root face or a backup strip is required for fast welding speeds are obtained with the work positioned at a 45˚ to 75˚ and good quality. Feather edge preparations require a slow downhill angle. Also, don’t overweld or make a weld that is costly seal bead. However, double V butt joints without a larger than needed for joint strength--this may lead to burnland are practical when the seal bead cost is offset by easier through. edge preparation and the root opening can be limited to For welding mild steel plate with a thickness greater than approximately 3/32 in. or equal to 3/16 in., it is best to have the work positioned flat, In general, weld seal beads on flat work with 3/16 in. E6010 because this will make operator manipulation of the electrode at approximately 150 amps DC+. Use 1/8 in. at approximately 90 the easiest. Lastly, high carbon and low-alloy steel plate can amps DC+ for vertical, overhead, and horizontal butt welds. For best be welded with the work in the level position. low hydrogen and seal beads, weld with an EXX18 electrode at approximately 170 amps. 3. Follow simple principles for joint geometry and fitup Joint dimensions are chosen for fast welding speeds and 4. Avoid buildup and overwelding good weld quality. Proper joint geometry is based upon some Fillets should have equal legs and a nearly flat bead surface. simple principles: Buildup rarely should exceed 1/16 in. Extra buildup is costly a) Fitup must be consistent for the entire joint. Since sheet in material and time, adds little to weld strength and increases metal and most fillet and lap joints are tightly clamped for their distortion. For example, doubling the size of a fillet requires four entire length, gaps or bevels must accurately be controlled over times as much weld metal. Also, it costs two thirds more to butt 58 | May 2010 | www.canadianmetalworking.com

Perfect performance.

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Welding

ARC WELDING

weld a single-V with 1/8 in. land and 1/32 in. root opening when the excess buildup approaches 1/8 in. 5. Clean the joint before welding To avoid porosity and attain the ideal weld travel speeds, it is important to remove excessive scale, rust, moisture, paint, oil and grease from the surface of joints. If such elements cannot be removed, use E6010 (5P+) or E6011 (35 or 180) electrodes to penetrate through the contaminants and deeply into the base metal. Slow the travel speed to allow time for gas bubbles to boil out of the molten weld before it freezes.

arc length. If the molten metal is running in front of the arc, change the electrode angle. Finally, look for arc blow conditions (commonly referred to as a wandering arc), and be sure the electrode is not wet. Undercutting Undercutting is frequently just an appearance problem, but it can impair weld strength when the weld is loaded in tension or subjected to fatigue. To eliminate undercut, reduce current and slow travel speed, or simply reduce size until you have a puddle size you can handle. Then change the electrode angle so the arc force holds the metal in the corners. Use a uniform travel speed and avoid excessive weaving. Wet electrodes If polarity and current are within the electrode manufacturerâ&#x20AC;&#x2122;s recommendations but the arc action is rough and erratic, the electrodes may contain excessive moisture. Try dry electrodes from a fresh container. If the problem recurs frequently, store open containers of electrodes in a heated cabinet. Wandering arc With DC welding, stray magnetic fields cause the arc to wander from its aimed course. This is a greater problem at high currents and in complex joints. To control a wandering arc, the best option is to change to AC welding. If that doesnâ&#x20AC;&#x2122;t work, try using lower currents and smaller electrodes or reduce the arc length. In addition, you can change the electrical path by shifting the work connection to the other end of the piece or by making connections in several locations. You may also do this by welding toward heavy tacks or finished welds, using run-out tabs, adding steel blocks to change work current path or tacking small plates across the seam at the weld ends.

Troubleshooting Weld Defects

Porosity Most porosity is not visible. However, since severe porosity can weaken the weld, you should know when it tends to occur and how to combat it. Begin by removing scale, rust, paint, moisture and dirt from the joint. Be sure to keep the puddle molten for a longer time to allow gases to boil out before it freezes. If the steel has a low carbon or manganese content, or a high sulfur (free machining steel) or phosphorus content, it should be welded with a low-hydrogen electrode. Sometimes the sulfur content of free machining steels can be high enough to prevent successful welding. Minimize admixture of base metal into weld metal by using low current and fast travel speeds for less penetration. Or, try using a shorter arc length. A light drag technique is recommended for low hydrogen electrodes. For surface holes, use the same solutions that are used for porosity. If you are using AWS E6010 or E6011 electrodes, make sure that they are not too dry.

Spatter Although spatter does not affect weld strength, it does create a poor appearance and increases cleaning costs. There are several ways to control excessive spatter. First, try lowering the current. Make sure it is within the range for the type and size electrode you are welding with and that the polarity is correct. Another way to control spatter is to try a shorter

Poor Fusion Proper fusion means the weld must physically bond strongly to both walls of the joint and form a solid bead across the joint. Lack of fusion is often visible and must be eliminated for a sound weld. To correct poor fusion, try a higher current and a stringer bead technique. Be sure the edges of the joint are clean, or use an AWS E6010 or E6011 electrode to dig through the dirt. If the gap is excessive, provide better fitup or use a weave technique to fill the gap.

During stick welding, the arc is established and the flux coating on the rod becomes a gas to shield the welding arc and puddle from the atmosphere. The flux forms a slag coating over the weld to prevent the weld metal from oxidizing.

6. Choose the right electrode size Large electrodes weld at high currents for high deposit rates. Therefore, use the largest electrode practical to be consistent with good weld quality. But, electrode size may be limited, especially on sheet metal and root passes, where burn-through can occur. As a general rule, 3/16 in. is the maximum electrode size practical for vertical and overhead welding, while 5/32 in. is the maximum size practical for low hydrogen. In addition, joint dimensions sometimes limit the electrode diameter that will fit into the joint. Here are some of the most common stick welding problems and how to correct them.

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Shallow Penetration Penetration refers to the depth the weld enters into the base metal, and usually is not visible. For full strength welds, penetration to the bottom of the joint is required. To overcome shallow penetration, try higher currents or slower travel. Use small electrodes to reach down into deep narrow grooves. Remember to allow some gap at the bottom of the joint. Cracking Cracking is a complex subject because there are many different types of cracks that occur in different locations throughout a weld. All cracks are potentially serious, as they can lead to complete failure of the weld. Most cracking is attributed to high carbon or alloy content, or high sulfur content in the base metal. To control this cracking, try these tips. • Weld with low hydrogen electrodes. • Use high preheats for heavier plate and rigid joints. • Reduce penetration by using low currents and small electrodes. This reduces the amount of alloy added to the weld from melted base metal.

• Fill each crater before breaking the arc. • On multiple pass or fillet welds, be sure the first bead is of sufficient size and of flat or convex shape to resist cracking until the later beads can be added for support. To increase bead size, use slower travel speed and a short arc technique or weld 5˚ uphill. Always continue welding while the plate is hot. • Rigid parts are more prone to cracking. If possible, weld toward the unrestrained end. Leave a 1/32 in. gap between plates for free shrinkage movement as the weld cools. Peen each bead while it is still hot to relieve stresses.

Conclusion

By following these tips, even a beginner can create a high quality weld. And, if you are experiencing problems, being able to troubleshoot and make corrections will also turn a beginning stick welder into a professional in no time. CM Harry Sadler works in applications engineering for The Lincoln Electric Co., Cleveland, OH. www.lincolnelectric.com

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