September 2010 • www.canadianmetalworking.com
Opportunity
KNOCKS Are emerging markets the future for Canadian manufacturing?
23
MACHINING
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CUTTING TOOLS
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FABRICATING
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WELDING
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Inside this issue... Volume 105 | No.7 | September 2010 | www.canadianmetalworking.com
INDUSTRY REPORT
FABRICATING
EMERGING MARKETS
PLASMA CUTTING
OPPORTUNITY KNOCKS.............14
THE “HOLE” PACKAGE ..............50
Are emerging markets the future for Canadian manufacturing?
14
Are bolt quality holes possible with plasma?
WELDING
BUSINESS REPORT
SAFETY
FINANCE
SHOW US THE MONEY..............17 Financing options for manufacturers
EYEING SAFETY ........................55
How to choose an auto-darkening helmet.
OVERSPRAY
MACHINE TOOLS
17
METAL FINISHING/PRETREATMENT
GRINDING
MULTI-TASKING GUIDELINES .......23
Grinding experts weigh-in multi-tasking grinders versus multi-tasking mills and lathes.
PRODUCTS ................................30
SUBLIME GREEN .......................56 A Quebec custom coater is betting on a European finishing concept, sublimation coating, and a green pretreatment system to grow its business. CUSTOM COATING
8 QUESTIONS FOR 5 EXPERTS ...58
CUTTING TOOLS
The challenges and the opportunities facing custom coaters.
BORING & REAMING
HOLE-IN-ONE ............................35 Boring and reaming the tough stuff. PRESETTERS
PREPPING YOUR TOOLS..............38
55
ROBOTICS FINISHING
A COMPETITVE EDGE................60
Paint robots provide increased production and flexibility for one-stop job shop.
56
Zoller Canada’s Chander Bhardwaj discusses why tool presetters matter.
DEPARTMENTS FABRICATING
Upfront ........................................... 5
PRODUCT REPORT
News ............................................. 8
FABRICATING SOLUTIONS ..........42
Suppliers are gearing up for FABTECH and many are launching products. A sneak peek at some recent developments.
Shop Talk...................................... 10 Calendar ...................................... 12 Metal...Works ............................... 63
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SENIOR PUBLISHER Larry Bonikowsky 416-764-1489 | larry.bonikowsky@rci.rogers.com EDITOR Mary Scianna 416-764-1540 | mary.scianna@rci.rogers.com ART DIRECTOR Jill Nelson 416-764-1518 | jill.nelson@rci.rogers.com SALES MANAGER Steve Devonport 416-764-1498 | steve.devonport@rci.rogers.com CIRCULATION MANAGER Bibi Khan 416-764-1450 | bibi.khan@rci.rogers.com JUNIOR WEB PRODUCER Jessica Mirabelli 416-764-1316 | jessica.mirabelli@rci.rogers.com PRODUCTION MANAGER Kristen Hrdlicka 416-764-1692 | kristen.hrdlicka@rci.rogers.com ROGERS PUBLISHING LIMITED .............................................................. PRESIDENT AND CEO Brian Segal ROGERS BUSINESS & PROFESSIONAL PUBLISHING ........................ SENIOR VICE-PRESIDENT John Milne VICE-PRESIDENT, FINANCIAL PUBLISHING, BRAND EXTENSIONS & ONLINE SERVICES Paul Williams DIRECTOR OF AUDIENCE DEVELOPMENT Keith Fulford 416-764-3878 | keith.fulford@rci.rogers.com EXECUTIVE PUBLISHER, INDUSTRIAL GROUP. Tim Dimopoulos 416-764-1499 | tim.dimopoulos@rci.rogers.com CORPORATE SALES....................................................................... Sandra Parente, GENERAL MANAGER, CORPORATE SALES
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Upfront Are China’s Growing Pains Our Gain?
China is on the fast track to becoming the world’s largest economy, but its rise to the top is peppered with growing pains. Earlier this year, Earl Metcalf, general manager and part owner of Global Sticks Inc., a Vancouver manufacturer of ice cream sticks and spoons and related wooded objects that holds 35 to 40 per cent of the North American market, shut down its Chinese plant where it had produced the North American-bound wooden sticks for nine years and moved its operation to Thunder Bay, ON. Why? “It’s got too expensive in China,” he told the Globe and Mail in a May 17 article. Metcalf cited sales tax changes, higher fuel costs and the rise of the yuan, noting these factors have reduced the company’s margin from 20 per cent to less than 10 per cent. Global Sticks is likely one of many companies rethinking their business strategies in China as the costs of manufacturing continue to rise. In recent months, workers at many big name manufacturers—Honda, Mercedes Benz and Toyota among them—have gone on strike for better working conditions and higher wages. The Chinese government has attempted to appease workers with increases in monthly minimum wages, but as workers’ bargaining powers rise, labour tensions—and the cost of manufacturing—will also continue to rise. China’s growing economic clout has shed light on another issue: the environmental damage its multitude of factories have created. In August the Chinese government ordered the closure of more than 2,000 energyintensive old factories in an effort to shift its growing economy toward modern production methods that are less harmful to the environment. It’s a necessary move, but one that will also contribute to the escalating cost of doing business in China for foreign manufacturers. These growing pains may spell opportunity for North America’s beleaguered manufacturing sector. Manufacturing companies on this continent are already in compliance with stringent environmental laws. Labour costs are obviously higher here than in China, but the growing shift toward advanced manufacturing operations—created by a need to become more competitive against low labour cost countries—counters some of these costs. Combined with tax incentives and other recent stimulus policies North American governments have implemented to encourage manufacturing in this country, the prospect of making products here—instead of having them shipped from China— begins to look more promising. We may indeed soon make some gains from China’s growing pains. 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
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News Canadian Manufacturing Week expands offerings
One of the most comprehensive events for Canada’s manufacturing sector is expected to draw more than 5000 attendees from across the country. Canadian Manufacturing Week 2010 (CMW) will run October 5-7 at the Toronto Congress Centre and event organizer, the Society of Manufacturing Engineers (SME), is promising the 2010 event will be bigger and better than ever. “We have brought together the best partners that represent the key industries this event serves,” says Nick Samain, show manager for CMW/Weld Expo Canada. “Our partners include APMA (Automotive Parts Manufacturers’ Association), CanWEA (Canadian Wind Energy Association), CWA/CWB (Canadian Welding Association/Canadian Welding Group), CFPA (Canadian Fluid Power Association), and CME (Canadian Manufacturers and Exporters).”
in many exciting ways. Attendees can identify many possibilities in a short period of time, evaluate face to face, and go back to their place of business with real solutions they can implement now.” Despite the turbulent past year the manufacturing sector has experienced, SME is expecting attendance to be the same or higher than in 2008. “For 2010, we expect total show numbers will be similar to 2008 (4500 to 5000). There will be some increase in the numbers due to greater participation in SME fabricating and automotive repair shops in the WeldExpo portion of the event. Pre-registration is well ahead of the 2008 event.” The trade show is also expected to be about the same size as in 2008. There are currently close to 200 exhibitors booked “and about 10 to 15 new ones are being added each week,” says Samain. For more details about CMW, visit www.sme.org/cmw.
Mori Seiki ties distribution knot with Ellison in Canada
He adds that SME expects to see increases in “quantity and quality” because of its partnerships with these associations. CMW is a well-established event in the Canadian manufacturing industry that has been running for more than 20 years. SME acquired CMW 2007 as part of the organization’s acquisition of Reed Exhibitions Industrial Group and it is only the second time that SME has organized the event. Samain says the 2010 event will be better than ever before. For one thing, the event has a new venue, the Toronto Congress Centre, new industry association partners—who will be contributing to keynote presentations and Town Hall interactive discussions—and Weld Expo, Canada’s only welding industry event. Indeed, Samain says a big difference between CMW and its other regional events such as the Western Canada and Montreal Manufacturing Technology Shows (WMTS and MMTS), is Weld Expo. “It’s such a big influence on the show. It is almost like two major events in one. When you combine welding/forming/fabricating with the advanced manufacturing section (automation, design, rapid prototyping, software) and plant maintenance, we have created an environment where manufacturers can learn, explore and identify opportunities to improve and upgrade their facilities 8 | SEPTEMBER 2010 | www.canadianmetalworking.com
Ellison Technologies, Sante Fe, CA, has been named exclusive Canadian distributor for Mori Seiki, making the company the largest machine tool distributor in North America. Ellison has a history with Mori Seiki and has represented the builder’s line of machine tools in British Columbia for 14 years. While its Canadian activities have been in BC, the machine tool distributor is an established company in the US and has more than 55 years of machine tool experience. “Having Ellison Technologies as our new exclusive distributor in Canada will allow us to leverage our valued partnership and synergy we currently share in the US, says Jim Okada, president of Mori Seiki Americas, Chicago, IL. Graham Hooper, president of Ellison Technologies’ Western Region and Canada adds that “we look forward to this continued partnership approach with the Canadian market by enabling them [Canadian customers] to become globally competitive through the integration of advanced technology, robotic automation and engineering capabilities.” Ellison Technologies, in partnership with Mori Seiki, is setting up an operation in Mississauga, ON. The facility, located at 6497 Edwards Blvd., will house a technical centre and showroom and will provide sales, service and engineering support for Canadian customers.
Hot market for Ontario manufacturer
An Ontario rollforming equipment manufacturing company is betting that the solar market is going to heat up even more in the next five years so it’s formed a new division, Samco Solar, and is aggressively going after new customers interested in manufacturing their solar racking systems in Ontario. “I’ve been traveling across Canada, to Europe and the US to convince large players in the solar racking business who are thinking of investing in Ontario to have their products manufactured at our facility,” says Dave Pichard, vice president of Samco Solar, who was hired earlier this year to develop the solar manufacturing business. Pichard is hoping to have six to eight new customers “very quickly” that he says will sustain the company for the next 15 to 20 years. The company began to retool its shop earlier this year to accommodate its first solar racking customer, Unirac, based in
Shop Talk Does your shop have air conditioning? If yes, has it improved productivity in the summer? If no, is this something you are considering? “No, and we will not consider it. We do keep our bay doors and rear exit doors open—it keeps the air circulating and is much better than air conditioning for the following reasons: green, fresh air, natural gentle breeze and free.”
-Renny Husada, vice president, Yess Products Ltd., Surrey, BC
“We do have cool zones in our facility. It is an expense that we cannot do without. Employee comfort and performance rely heavily on this. Also, it gives our equipment a better environment to work in and is more efficient in helping us maintain a quality product our clients have come to expect.”
-Joseph Manzoli, president, Colourfast, Concord, ON
“Our shop is air conditioned and always has been due to the tight tolerances we work to. I honestly believe people are more efficient when your shop is air conditioned as you become more fatigued when working under very warm conditions.”
-Brian Wetherall, president, Brotech Industries, Barrie, ON
“No, but in the area most affected by heat generating processes, we have installed an air exchange system to both govern temperature and ensure a constant replenishment of fresh air.”
-Debbie Blowe, systems manager, Vibra Finish, Mississauga, ON
“In our current facility, we installed air conditioning four years ago but our high rate of growth and subsequent machinery acquisitions have overcome the capacity of our cooling system. We are in the midst of building a new facility four times our current size, and it will have a climate controlled atmosphere throughout the plant and offices. I firmly believe that the level of comfort has a direct influence on productivity. Particularly those coming in for the afternoon shift on a hot day—they enter the facility with a positive attitude when they are met with this comfortable atmosphere ... We anticipate completion [of our new facility] to be near the end of this summer.”
-Gerry Vandersanden, president and owner, Sciens Industries, Peterborough, ON
“Yes. We recently installed it last summer. It makes a huge difference in productivity and morale.”
-Robert Drake, systems sales and support manager, Proto Manufacturing, Oldcastle, ON
www.canadianmetalworking.com | September 2010 | 9
News Alburquerque, NM. It retooled its facility and invested in a new 24-pass rollforming line complete with pre-punch presses, cut-off presses and assembly equipment. In July, it signed on another customer, SunEdison, a division of MEMC Electronics Materials Inc., which will see Samco Solar manufacturing SunEdison’s solar racking systems for its Ontario customers.
Samco’s entry into the solar industry is an example of how Canadian job shops can diversify into new markets. Since 2008, Samco has seen a 63 per cent decline in automotive sales, traditionally a big market for the company. Other
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key markets include building and construction, transportation (rail, bus, streetcars), HVAC, and shelving and racking. Samco’s entry into the solar market was partly possible because of a relationship with a US customer, American Roll Form, Painesville, OH. American Roll Form purchases its equipment from Samco. “American Roll Form was an early entry into the industry because of the US uptake in solar which occurred much sooner than in Canada. It started getting customers asking for steel for racking systems and because of our strong alliance, Samco was a natural entry point in Canada to help the company deliver products to customers in Ontario,” explains Pichard. Samco is also benefiting from Ontario’s FIT program, the Ontario government’s Feed-in-Tariff program which requires 60 per cent of solar equipment used in projects in Ontario be produced locally by 2011. “This contract [SunEdison] and the FIT program of the Ontario government have helped to stimulate growth in our company,” says Pichard. Samco will use SunEdison’s proprietary solar racking design, which has already been used on more than 300 rooftops. The first solar racking system is expected to come off the line at the Scarborough facility this September. SunEdison says it foresees exporting the solar racking equipment to the US. “We’ve been very pleased with the manufacturing expertise in the province as demonstrated by Samco, says Jason Gray, vice president, Canada, for SunEdison. “Production of the racking is extremely cost competitive here in Ontario, enabling us to produce product for US export.”
Robot steals the show at groundbreaking event
Motoman Robotics’s recent groundbreaking ceremony for its new 300,000 sq ft facility in Miamisburg, OH, featured a special guest—a robot that turned the first shovel of dirt that will begin the 10-month construction of the company’s new headquarters and main manufacturing facility for its North and South American operations. Dexter Bot, Motoman’s dual arm SDA10D robot, donned a hard hat to turn the first shovel of dirt. The new facility will combine the company’s current Ohio headquarters in West Carrollton, OH, and a manufacturing plant and a warehouse in Troy, OH. “The new facility has been designed and will be built with a customer and employee focus,” stated Steve Barhorst, president and COO of Motoman Robotics, a division of Yaskawa America Inc. “Our desire is to further enhance our customers’ experience while driving improved efficiencies to help our customers be more
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competitive. Our customers are why we are here today and are the key to our future. We owe it to our customers to serve them more efficiently and effectively.” The new facility will house approximately 250-275 employees, with the plan to expand the employee base and facility as the company expands its operations. The 25 acre (8 hectare) site allows for the building to be expanded by an additional 200,000 sq ft to support this growth. Scheduled move-in is June 2011. In Canada, Yaskwawa Motoman Canada Ltd. has two operations in Mississauga, ON, and Pointe Claire, QC.
People Mike Hannan has been appointed executive vice president for YG-1 Canada Inc., Burlington, ON. A 25-year veteran of the cutting tool industry, he began his career with Indexable Cutting Tools, where he served as vice president of sales and marketing for 10 of the 14 years he remained with the company. After a brief five year stint with the Ontario government’s Ministry of Economic Development and Yes Trade, he returned to the metalworking industry working 50.0% with Triumph Tool and Tyson Tool. He left Tyson in 2009 and joined YG-1 Canada as business development manager before taking on his new role as executive vice president.
SEPTEMBER 13-18 IMTS at McCormick Place, Chicago, IL www.imts.com SEPTEMBER 26-28 Canadian Welding Association’s National Conference, Blue Mountain Resort, Collingwood, ON www.info@cwa-acs.org OCTOBER 5-7 Canadian Manufacturing Week, Toronto Congress Centre, Toronto www.sme.org/cmw OCTOBER 28 Innovate or Else Symposium at the Toronto Congress Centre, hosted by Canadian Metalworking and Design Engineering magazines. mary.scianna@rci.rogers.com
Poll No 50.0%
Do you plan to attend the International Manufacturing Technology Show (IMTS) in September?
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INDUSTRY REPORT
EMERGING MARKETS
Opportunity
KNOCKS
Are emerging markets the future for Canadian manufacturing?
By Nate Hendley ............................................................................................. As Canada continues to shake off the lingering effects of the recession, certain sub-sectors of the economy are booming. In the battered automotive sector, the mass production of “green” (i.e. electric and hybrid) vehicles bodes well for metal and machine shops while in aerospace, the Joint Strike Fighter (JSF) program continues to reel in Canadian suppliers. It’s the same with energy: if oil no longer seems like a sure thing, industry experts see great potential in renewable and nuclear power. Of all the emerging markets in Canada, the advent of “green” vehicles has arguably
for Canadian suppliers. It is more than a niche market and it is a market that will continue to become more mainstream,” says Rodgers. Just like automotive, the aerospace sector has
“Electric cars and other ‘green’ cars will make up 20 per cent of sales in urban areas of emerging markets by 2010.” received the most media attention. Later this year, the Chevrolet Volt by General Motors is supposed to hit auto dealerships in the United States. A Canadian launch is scheduled for mid-2011. The emissions-free Volt is designed to travel 65 km on electrical battery power alone (sufficient for most office commutes), at which point an internal combustion engine kicks in. GM is touting the car as the world’s first mass-produced nearly all-electric vehicle for consumers. Nissan Motors, meanwhile, has come up with its own zeroemissions vehicle called the Leaf. Unlike the Volt, the Leaf is fully electric. Nissan claims it will start mass manufacturing the Leaf in 2012 to directly compete with the Volt and earlier green vehicles, such as the hybrid electric Prius from Toyota. The hoopla over green vehicles isn’t just corporate hype: a recent report from international professional services firm Deloitte, predicts “electric vehicles and other ‘green’ cars” will make up a third of total global sales in developed markets and up to 20 per cent of sales in urban areas of emerging markets by 2020. Steve Rodgers, president of the Toronto-based Automotive Parts Manufacturers’ Association (APMA), hasn’t heard of any plans to assemble the Volt or Leaf in Canada. Rodgers does say “there are some Canadian suppliers who have content on the Volt, Leaf and Prius” but won’t reveal who they are, citing privacy concerns. “I think [green vehicles] definitely represent a growth market 14 | SEPTEMBER 2010 | www.canadianmetalworking.com
endured fluctuating fortunes in recent years. One particular initiative, however—the Joint Strike Fighter program—keeps soaring higher. The JSF program is an American-led multi-national effort to build state-of-the-art F-35 combat aircraft. The program is expected to last 40 years with a price tag around US$276 million. Ottawa announced plans on July 16, 2010 to purchase a fleet of JSF F-35 jet fighters for $9 billion dollars. One of the largest purchases in Canadian military history, this price-tag might double, once maintenance contracts are factored in. The jets will be purchased from aerospace giant Lockheed Martin, with the first delivery scheduled for 2016. Needless to say, Canadian aviation experts are delighted. “The [F-35 contract] is the single largest military aircraft procurement program of the government of Canada in the foreseeable future and will positively affect the Canadian aerospace industry for decades to come,” said Claude Lajeunesse, president and CEO of the Ottawa-based Aerospace Industries Association of Canada (AIAC) in a July 16, 2010 press release. “AIAC urges the government to ensure that conditions are created for Canadian industry to access an increasing amount of meaningful, high value roles in both the production and sustainment of the aircraft,” adds the press release. Canada signed onto the JSF initiative in February 2002. Since then, dozens of Canadian companies, including metal and machine shops have picked up JSF-related contracts, to
EMERGING MARKETS
the tune of roughly $350 million. Rob Muru, president of A-Line Precision Tool in Toronto, estimates JSF work accounts for “about 5 to 10 per cent” of business at present. The company makes precision engine components for the program. “We are at a development stage,” he adds, stating that his firm’s percentage of JSF work “may ramp up significantly, starting in 2012.” Renewable energy, particularly wind and solar, remains another growth area, propelled by massive government investment. On January 21, 2010, for example, the government of Ontario signed an energy deal worth an estimated $7 billion with a consortium led by Korean corporate giant Samsung. The latter will manufacture wind towers and solar energy facilities around the province. If all goes to plan, wind and solar will provide “energy equivalent to four per cent of Ontario’s total electricity consumption by 2016,” states a press release from the provincial government. The Samsung deal represents part of an ambitious plan to phase out coal-fired power plants in Ontario. To kick-start the initiative, Samsung will construct a cluster of wind turbines and solar facilities in south-western Ontario, with an activation date of 2013. According to the Canadian Wind Energy Association (CanWEA), total installed wind power capacity in Canada grew from 137 MW in 2000 to 1,846 MW in 2007. Capacity has continued to climb, reaching 3,319 MW last year. CanWEA aims to push the total of installed wind energy capacity to 10,000 MW by the end of this year—enough to generate five per cent of Canada’s electricity. Ontario Laser Cutting, a small custom manufacturer in Tillsonburg, ON, spent much of last year doing work for a Courtland, ON, wind turbine firm called Windmiser. Ontario Laser Cutting president Larry Stuyt offers the following words of wisdom for shops looking to pick up work from manufacturers of renewable energy systems: “My advice is, be patient ... there are a lot of changes happening in technology and therefore there will be lots of changes to manufacturers’ designs. Be prepared to do a lot of prototyping with small orders.” Mecon Industries in Scarborough, ON has also been winning wind contracts. The company is working with Cleanfield Energy, a start-up wind turbine firm based in Ancaster, ON which develops and markets proprietary renewable energy products. Mecon president David Foscarini estimates that 15 per cent of his company’s work is in renewables—“about the same as last year.” “We are still doing work for Cleanfield. We just completed a batch of 10 windmill parts. We are trying to pick up more work in the green/renewable energy sector. We do think the field is growing, but slowly and in fits and starts,” says Foscarini. While the Samsung deal might be the game-changer that makes renewable energy a wildly lucrative proposition—at least in Ontario—nuclear proponents continue to expound on the virtues of their sub-sector. At present there are 17 operating nuclear reactors in Canada, most of them in Ontario. Three additional reactors are in refurbishment while two have been retired. Overall, about 15 per cent of Canada’s electricity is generated by nuclear power. The benefits of nuclear power have been somewhat
INDUSTRY REPORT
overlooked by a press and public enamoured by the prospect of easy money in the tar sands of northern Alberta. While the Athabasca tar sands do contain an enormous bounty, oil prices have been on a rollercoaster ride for the past few years, making suppliers wary. By contrast, nuclear looks to be a stable and potentially expanding market. “The province of Ontario has confirmed that it will refurbish the Darlington nuclear station in—I think—2016. This project has not been fully costed yet but it could be up to $10 billion and work has already started on planning the project,” says Dr. Neil Alexander, president of OCI (Organization of CANDU Industries) based in Pickering, ON. The OCI features 165 member companies, representing about 35,000 jobs in the nuclear sector. “With hydro pretty much tapped out we cannot run Ontario on renewables at any price until there is a step change in technology. So the choice is fossil fuels and their greenhouse gas emissions or nuclear. Nuclear still provides 50 per cent of our electricity [in Ontario],” says Alexander. International demand for nuclear power remains voracious, he adds. Japan has announced plans to open 14 new nuclear plants in the near future while India and China have mused about opening dozens of nuclear stations. “India and China have powerful governments who control their power production. They are both moving ahead with their nuclear programs. We are also seeing the renaissance pick up speed in other countries where there is political will such as the United Arab Emirates that ordered four reactors recently,” says Alexander. Nuclear already represents the lion’s share of work at Promation Engineering, a self-described “leading designer and manufacturer of high quality tooling, automation and robotic systems for the automotive and nuclear industries.” About 80 per cent of the Oakville, ON-based company’s work is in the nuclear field, with the remainder in automotive. The firm provides “engineering services, tooling and robotics for the refurbishment of Canadian nuclear reactors,” explains Promation president Mark Zimny. “The nuclear sector is slowly rising in North America and it will accelerate in a few years when clean electricity will be in demand ... expanding into nuclear from automotive requires a significant investment [however]. Those who are prepared to do it over three to four years have a chance. Only strong companies can consider the investment. I suggest teaming up with smaller businesses and looking for synergies before entering nuclear,” Zimny continues. A-Line Precision seems undaunted by this prospect. “Nuclear is one of the industries we are targeting for growth. It seems to be a maze of companies in there and it’s hard to figure out who you are selling to. We will figure it out though,” says Muru. As for tips to shops angling for nuclear contracts, Dr. Alexander says, “Barriers to entry in the nuclear industry are high ... relationships are needed as are skills and qualifications ... but at the same time, there is a lull in business just at the moment. So it’s probably best to keep a watchful eye on progress and be prepared to move quickly as the business develops.” Good advice for any shop looking for work in Canada’s emerging markets. CM Nate Hendley is a freelance writer based in Toronto. www.canadianmetalworking.com | SEPTEMBER 2010 | 15
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FINANCING
Business Report
Show us the money Financing options for manufacturers
By Tim Wilson ...................................................................................................................................................... One of the biggest challenges for manufacturers is getting the finance and credit to support business expansion. To do that, manufacturers need to find organizations that understand their business, are skilled at assessing risk, and can take a creative approach. Often, it is the leasing companies that are leading the way. “The banks have really tightened down on manufacturing,” says Victor Galvao, district manager of the Oakville, ON, office for Easylease Corp. “This is where leasing comes in—we haven’t got as tight as the banks, and we provide the opportunity for manufacturers to acquire new equipment at fairly reasonable terms.” Interest rates are at historic lows, but that doesn’t mean much if lenders are gun shy and unwilling to put risk capital to work. Although lease companies have slightly higher rates, they can also be easier to work with, allowing manufacturers to, in effect, get access to capital that the banks are reluctant to lend. “We have slightly higher risk because we are not securitizing the entire company,” says Galvao. “All we have is the equipment security and the company guarantee.”
As a result, in this ultra-cautious economic climate, leasing may be one of the best ways to help finance operations. “A leased piece of equipment is going to generate labour savings and revenue with limited capital expenditure,” says Galvao. “Typically, the banks aren’t interested in equipment because they wouldn’t know how to deal with it if they repossessed.” In effect, the leasing companies are there to help manufacturers in areas where the banks aren’t participating. One area is with lease-backs. “We can look at the existing assets in a business to create cash,” says Curt Elchuk, president of Edmonton, AB-headquartered Lease Link Canada Corp., which provides equipment lease financing and asset management services to a wide variety of industries, including manufacturing. “It can be any asset with value, from lathes to machine tools. We can get them appraised and create some cash flow,” says Elchuk. “The reality is that third party leasing companies or brokerages like ourselves have the capital to help manufacturers through tough times.” www.canadianmetalworking.com | September 2010 | 17
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FINANCING
To do this, a broker like Lease Link Canada Corp. will conduct due diligence of financial statements, usually in greater depth than the banks. This can make the process slower, but can also result in more flexible options. “We look at a company’s wish list, at what they are trying to accomplish, and do our homework to get the deals bought,” says Elchuk. “We are seeing a bit of a rebound, but the banks are still ultra cautious, which creates opportunity for us; we put a lot of thought into processing an application, and as a result can often find ways to extend credit.”
A bank for SMEs
The small and mid-sized enterprise (SME) in the manufacturing sector often has a tough time getting financing. The sector has a lot of unique challenges, yet banks often have a limited view, in which they focus heavily on balance sheets with little understanding of the sector itself. An organization like Business Development Bank of Canada (BDC) can help. “We are strong in support of manufacturing companies,” says Patrick Latour, BDC vice president and area manager for Eastern Ontario. “We not only support credit-worthy manufacturers on the lending side, we are also active on the consulting side.” BDC, a financial institution owned by the Government of Canada, has been around for more than 65 years and operates out of 100 offices across Canada. BDC is a “complementary lender,” offering loans and investments that supplement services available from commercial financial institutions, including highly tailored financing, venture capital and consulting services. “It is on the consulting side that we’re a different animal,” says Latour. “We provide advice, and spend a lot of time assessing a company’s needs. This could be for marketing or a business plan, or as part of our lean practice; we have lean practitioners who work with manufacturers to make them more competitive.” Latour says BDC’s focus on entrepreneurial culture, and its emphasis on the SME space, means it can have a positive impact on the requirements of manufacturers in what is now an extremely competitive environment. “We are close to SMEs, we know our clients and know the marketplace,” says Latour. “Our companies have to compete globally, and our employees share a passion for entrepreneurial culture. In this economy manufacturers have to be agile, they have to adapt very quickly; that is key.” To accomplish this, the BDC has launched its new online business Advice Centre, while also partnering with Sun Life Financial to enhance access to financing for SME finance and leasing companies. “Manufacturing is capital intensive,” notes Latour. “Their [manufacturers] equipment is utilized as much as possible— that’s the only way to grow from a small, to medium, to large business. But they also need to know how to do it right, and that’s why, when we go in and visit a company, we do more than lend money, we look at a company’s needs.”
The macro matters
Some help for manufacturers is also coming from Canada’s federal government, which is set to eliminate all tariffs by 2015.
Business Report
“This is a broad-based measure and the inputs and machinery affected are used across the full range of manufacturing,” said a finance official from the federal Department of Finance in an e-mail exchange. The tariffs range from 2.0 per cent to 15.5 per cent, though it should be noted that imports of inputs and machinery and equipment originating from the US were already duty free under the North American Free Trade Agreement (NAFTA). Tariffs on 1,160 items were eliminated effective March 5, 2010, and tariffs on 381 items are being gradually eliminated by no later than January 1, 2015. “Businesses that used inputs and imported machinery with higher tariff rates will save more, but it depends on the specific business’s input and machinery mix,” said the spokesperson, adding the duty savings will nonetheless benefit businesses of all sizes. The government has also brought in tax relief, with the federal general corporate income tax rate dropping from 22.12 per cent (including the corporate surtax) in 2007 to 15 per cent in 2012. And there has been an extension to 2011 for the
50 per cent straight-line accelerated capital cost allowance (CCA) rate for investments in manufacturing or processing machinery and equipment. That should make the job for the BDC and traditional banks much easier, because it means they can lend money to manufacturers who can get their capital investments off the books faster, while also making it easier and less expensive to purchase equipment from abroad. “We can make the terms attractive, at 100 per cent of equipment, and structure terms to include training,” says Latour. “We can go out six months until the equipment is productive, because it makes sense for payments to begin when the equipment is adding value.” Bottom line: manufacturers should be approaching banks and leasing companies with an eye to innovative solutions that can maximize tax benefits and preserve lines of credit, with manufacturers only “paying as they profit” and revenue matched closely to expenditures. CM Tim Wilson is a freelance writer based in Peterborough, ON. www.canadianmetalworking.com | September 2010 | 21
GRINDING
Machining
Multi-tasking Grinding
Guidelines Grinding experts weigh on multi-tasking grinders versus multi-tasking mills and lathes
By Mary Scianna .................................................................................................................................................. Life was simple in the old days. If you were working in a machine shop back in the 1950s chances were you would find a different machine tool for each machining task: a grinder, a mill, a lathe and a drill. Fast-forward to 2010 and suddenly you’re confronted with a multitude of new high performance, multi-tasking machines that can mill, turn, drill and grind in one set-up.
improving productivity. In practice though, multi-tasking machining centres may not be the cost cutting, productivity enhancing panacea machine shops envision. That’s because one machine can’t do it all, particularly when it comes to grinding, a complex machining process that experts Canadian Metalworking spoke with say is somewhat of an art form. “People are taking lathes and mills and trying to adapt grinding to them. It looks great and can make all the mechanical moves and include a wheel changer, but when you start to look at the surface finishes and tolerances, they’re not where a traditional grinder is,” says John Manley, president of Machine Tool Systems, Toronto. When is a multi-tasking grinder better than a multi-tasking lathe or mill? Here are points to consider.
Know Your Application Needs
One of Hardinge Grinding Group’s Kellenberger grinders, the Kel-Vera 175/400, is suitable for production environments.
“The distinction between the two types [multi-tasking machines and grinders] are becoming more blurred,” says David Dreschler, vice president of marketing, Huffman Corp., Clover, SC. “In the past people would take low cost machining centres, make the necessary alterations to use a grinding wheel and then if it wore out, they’d just replace it. Today, there are higher end machining centres that are capable of grinding but grinders are typically built to be more robust, stiffer and more accurate; they’re still much more substantial in terms of weight, dampening characteristics and accuracy.” In theory, the all-in-one type of machining centre is a great concept. With only one set-up, a part can be (depending on the style of machine tool) milled, drilled, turned and ground,
Machine Tool Systems represents some of the industry’s best-known grinders from United Grinding, including Blohm, Mägerle, Studer and Walter. Manley’s advice to manufacturers is to first look at your application needs. “Applications we look for in a combination machine, or what I would call a profile surface grinder with drill capability and/or mill capability, is one where the mill/drill requirements are 5 to 20 per cent of the time and 80 per cent or more of the requirements are for grinding.” As an example, he sites aerospace components such as shrouds or turbine vanes. “There’s a lot of grinding required for complex profiles such as shrouds and vanes and a small amount of time for milling and drilling. In this instance, why would you unclamp it and lose all your accuracy and have to create sophisticated fixtures? In our case the Bohl Aeromat production grinding machine uses very simple fixtures to do multiple operations,” he adds. It’s also a good idea to examine the specific features of the multi-tasking grinder you’re considering. That’s because, for obvious reasons, not all machines are created equal, nor do they all offer the same multiple tasks. For instance, one of Hardinge’s highest capability grinders in its Kellenberger line has the ability to perform OD, ID and surface grinding, but it can also grind C axis or out-of-round shapes and perform thread grinding. “Most people associate grinding with cylindrical round www.canadianmetalworking.com | September 2010 | 23
Machining
GRINDING
Huffman Corp.’s multi--axis grinding centre for complex parts requiring multiple wheel packs or multiple machining processes such as grinding, milling, drilling and probing.
breaks apart. Also, vibrations break down wheels, hence it’s important to have a stiffer machine with high vibration dampening characteristics. Studer CNC universal and out-of-round grinders, for example, are made from Granitan, a polymer base, that dampens very well.”
Dressing Up
parts, but with a lot of customers, especially in Canada where mould making is so strong, there is a requirement for outof-round grinding,” says Jeff Hilliard, North American sales manager for Hardinge Grinding Group, Elmira, NY. He adds that for small round carbide shapes, the machine can grind from a solid. “You can’t mill or turn a block of carbide; it has to be ground and this is where the C axis capability of a universal grinder comes in handy. It is truly multi-tasking because you’re combining what would be four or five different machines and four or five different operations into one machine with one operator.” If you run a high production operation, you may want to consider pallet changers, a relatively new and significant advancement in grinding. “Ground parts typically require sophisticated clamping and the clamping can take as long as the grinding cycle,” says Manley. “Today we can have a pallet changer up in front of the machine. It allows you to put a robot in front and have the robot load the parts and you can preload all the parts while the machine is grinding and making you money on the far side.” Experts advise that you consider the design of a multitasking grinder. It’s critical that the machine is equipped to handle high levels of vibration. A big misconception about grinders is that abrasion— caused by vibrations and micro collisions—breaks down the grinding wheel. “Everyone thinks grinding wheels break down by abrasion, but they don’t,” says Manley. “It’s heat or chatter that breaks down the wheel. If you don’t have enough coolant, the bond 24 | September 2010 | www.canadianmetalworking.com
A significant difference between multi-tasking grinders versus multi-tasking lathes or mills is grinding wheels. Grinders are equipped with wheel heads that can be dressed (cleaning) and trued (forming) while lathes and mills with grinding capabilities are typically equipped with fixed abrasive wheels that are difficult to dress and true. The problem with fixed abrasive wheels is you can’t change their shape. So they may work for 500 parts but at the end of their life, they have to be thrown out. “It’s a one size fits all concept,” says Machine Tool System’s John Manley. By contrast, on multi-tasking grinders, when the shape on a wheel is worn down, it can be dressed and trued to get the wheel’s original form back. In addition to this, multi-tasking grinders have tool changers that allow machine operators to bring in 20 to 30 different wheels in different shapes for specific applications, bringing more flexibility to the operation. On the Mägerle grinding systems, United Grinding has developed what it calls a continuous dress (CD) mode. The diamond roll dresser remains in permanent contact with the grinding wheel and feeds into the grinding wheel by a set amount with each grinding revolution. But this process will wear down the grinding wheel faster than the dresser. To counteract this, United Grinding has also developed “Dressing Roll downfeed compensation.” Manley says CD grinding offers several benefits including high stock removal rates, high profile accuracy, lower power consumption, a cooler grinding process and the ability to grind longer workpieces while remaining engaged. It’s a capital intensive process though, because each work piece uses a diamond roll.
Watch Your Head
Multiple wheel head configurations and grinding stations are good features on a multi-tasking grinder, says Hardinge Grinding Group’s Jeff Hilliard, because it allows for parts to be completely finished in one set-up from rough grind from a solid to semi finished state and to final polish. “Our goal is to arrange a wheel head configuration where
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GRINDING
Machining
problem is that one machine can’t handle both types of waste: multi-tasking mills and lathes are not typically equipped to handle the fine abrasive mix generated from grinding. The fine particles attack the machine tool and get into the spindle bearings, ball screws and rotary tables. Grinders, in turn, are not equipped to handle milling and turning chips because they get tangled up in the machine. Recent developments in multi-tasking grinders though may put this issue to rest. United Grinding’s answer is its Studer S242. Designed with a slant bed with telescopic covers, the machine pulls back one set of covers during milling or turning operations and chips fall into a screw-type conveyor. When milling or turning operations are complete, the door closes and the second set of covers for grinding swarf opens collecting the waste in a separate conveyor that moves the opposite way from the conveyor for chips. Asked what we can expect to see in multi-tasking grinders in coming years, our experts concur that we will continue to see a move to more automated systems with robotics and pallet changes, linear drive machines and more sophisticated software with the ability to compensate between different machining processes. CM www.huffmancorp.com www.kellenberger.com www.machinetoolsystems.com www.unitedgrinding.com A close up view of United Grinding’s Mägerle MFP five axis CD grinding centre tool changer.
Wasted: Chips and Swarfs
One big difference between grinding versus milling or turning processes is the metal scrap. Grinding processes generate swarf, tiny particles that look like steel wool which may contain carbide or diamond debris. In milling and turning you generate thin shavedlike strips of metal or chips. The
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the operator can push a button, grind the part complete and in many cases eliminate the polishing operation,” says Hilliard. “And we can do this in minutes on the grinder because of improvements in the multi-wheel head configuration. We’re still polishing, but we’ve reduced the time to do it and sometimes we can eliminate the polishing stage. We take the process down from hours to minutes because the machines have the ability to get so close to polish finish in a grinding operation that you need just a short time to do the final polish.” One issue that arises when you’re dealing with a multi-wheel head/multitasking grinder is clearance issues. Our experts concur; the more multi-tasking you do in a machine, the more you have to be aware of collisions during indexing and machining.
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MACHINE TOOLS
HAAS
Haas has redesigned its VF product line to incorporate a wide range of enhancements to its line of VMCs. Haas engineers reviewed all aspects of the machines, including motion control, coolant containment, chip evacuation, ergonomics, and serviceability, made improvements, and put everything into an new package. To ensure smooth, precise motion control, the 2010 Haas VMCs use next generation digital servo motors and high resolution encoders on all axes. Combined with significant software and motor control advancements, it results in higher accelerations and better surface finish performance. With an eye toward preventing chip and coolant egress during machining, Haas invested up front to optimize the enclosures on the new VMCs, paying close attention to panel fit, service access, and internal routing of plumbing and cables. The result is a better enclosure and a much simpler overall design that contains chips and coolant, while increasing reliability and simplifying service. People buy CNC machines to make parts, so the last thing they want is stop production to remove chips. Haas redesigned the chip pans and reviewed coolant flow in the new VMCs to reduce chip buildup and efficiently flush chips into the auger trough for removal. For high volume production applications, the 2010 Haas VF-1 through VF-6 VMCs are available with optional chip removal systems that combine multiple side augers with either a front discharge auger or a belt-type conveyor to move chips out of the machines faster and easier than ever. Haas engineers reevaluated the machines to make everything the operator touches work even better. For example, the machines’ windows and doors are now stiffer, move more smoothly, and close tightly. The new thin design control pendant mounts directly to the enclosure, providing a lighter but more stable operator interface than the previous version. And there’s a convenient storage compartment behind the pendant. www.haascnc.com
2
HURCO
Hurco’s five axis VMX30U provides an affordable machine with X/Y/Z travels of 30 in./20 in./20.5 in. ( 762 mm/508 mm/521mm), a 12K spindle standard with 15K high speed and 10K high torque options available, a 24-station swing-arm automatic tool changer, and X/Y/Z rapids of 1,378/1,378/1,181 ipm. Many shops believe that five axis technology is out of their reach, but more than 80 per cent of what many call five axis is really five sided machining used to reduce multiple part setups. Converting from a three axis machining centre to five axis for five sided machining promotes reduced setup times, cost savings, and higher volumetric accuracy. Hurco provides a solution with its WinMax conversational programming, making it easy to create a part without an expensive five axis CAM system. The flexibility of Hurco’s control also allows shops to use existing three axis CAM systems to produce G-code programs for each side of a multi-sided part and then combine them with the simple addition of a transform plane code. Hurco also offers the ability to place part after part on the table without having to repost the G-code program by using tool center point management, a feature only found on high end controls. Given that the VMX30U is a full five axis simultaneous machine, shops also have the flexibility to move to full five axis contouring when they are ready. www.hurco.com
3
MAG
MAG’s modular HMC 1250/1600 Series features a new 180,000-position A axis tilt spindle for five axis horizontal machining on large aerospace and energy parts. The Series now includes six spindle options to suit special purpose or general machining requirements. The new 6000 rpm/46-kW (61.6 hp) tilt spindle joins an all-around 10,000 rpm/56 kW (75 hp) spindle, high speed 24,000 rpm spindle, high torque 2600 Nm/80 kW (1918 ft lb) spindle and two live spindles (110 or 130 mm diameter). The high torque spindle is suited for aerospace titanium cutting, while the live spindles extend W axis reach by up to 800 mm (31.5 in.), enabling deep cavity milling to high precision with shorter, more rigid tool lengths. Standard on the live spindle, MAG’s exclusive Z axis thermal compensation software offsets spindle 30 | SEPTEMBER 2010 | www.canadianmetalworking.com
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HORN - THE LEADERS IN GROOVING TECHNOLOGY
FOCUS ON THE ESSENTIAL SYSTEM DR Urma licence
Sensitivity instead of gross motor skills – this is the motto of the new HORN “System DR” reaming tools. Very narrow cutters, simple handling, and high repeatability when replacing inserts. A large selection of base material, coatings, and cutting geometries make the DR from HORN the perfect tool system for high precision bore machining.
HORN – INTELLIGENT TOOL DESIGN AT WORK.
HORN GROOVING • PARTING OFF • GROOVE MILLING • BROACHING • PROFILE MILLING • REAMING HORN USA, Inc. • 320 Premier Ct. • Suite 205 • Franklin, TN 37067 Phone: (888) 818-4676 • Fax: (615) 771-4101 • Email: sales@hornusa.com
•
internet: www.hornusa.com
PRODUCTS
MACHINE TOOLS
growth to maintain tight tolerances. The HMC 1250 Series is engineered for high precision, high productivity machining of large aerospace, power generation, pump, valve, and off-road equipment parts. Designed for extreme application flexibility, the machine offers maximum 3000 mm (118 in.) work zone swing, 2050 mm (81 in.) work height capacity and 7000 kg (15,400 lb) pallet load capacity. Major machine components, including the X bed, Z bed and column, are cast ductile iron, with 1250 x 1600 mm pallets, headstock and rotary table housings of gray cast iron. Modular design provides a range of machine travels, 60 to 120 tool magazines and two control choices. The new HMC offers 56 to 80 kW (75 to 107 hp) spindle power, 35 kN (7870 lb) Z axis thrust, and super rigid, full contouring hydrostatic rotary table. The 360,000 position contouring table provides a rigid work platform, while a rugged worm gear drive with clamp securely holds axis position. Rotary table positioning accuracy is 10 arc seconds, repeatable to 5 arc seconds. Positioning accuracy of the tilt spindle is 4 arc seconds, repeatable to 2 arc seconds. The HMC Series comes standard with linear scale feedback in X, Y and Z axes, providing 8 micron (0.0003 in.) positioning accuracy and 5 micron (0.0002 in.) repeatability. Heavy duty hardened and ground roller guide ways enable a rapid traverse rate of 40 m/min (1575 ipm) with high acc/dec rates, double the load capacity and nearly 10 times the wear life of ball-type ways. The full work zone enclosure on the machine is pre-engineered for mist collection and includes a doorway for operator access with a walkway/platform inside. www.mag-ias.com
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MAKINO
Makino had developed its latest Ram EDM machinery, the new EDAF Series, featuring a new mechanical design for increased rigidity and reduced thermal distortion. The EDAF series is ideal for manufacturers facing uncontrolled thermal environments and long hours of unattended burning. EDAF series machines are also equipped with an improved servo system for rapid response to signals from the spark gap monitoring circuits, enabling cycle time reductions of 10-20 per cent in burns common to today’s job shop applications. The series features two models, the EDAF2 and EDAF3. The sizes of the EDAF2 and EDAF3 are 53.2 in. x 95.5 in. x 98.4 in. (1.3 m x 2.4 m x 2.5 m) and 59.1 in. x 102.4 in. x 100.8 in. (1.5 m x 2.6 m x 2.5 m) with X, Y, and Z axis travels of 13.8 in., 9.8 in., 9.8 in. and 17.7 in., 13.8 in., 13.8 in. (350 mm, 249 mm, 249 mm and 450 mm, 350 mm, 350 mm) respectively. The EDAF2 provides worktable dimensions of 21.7 in. x 13.8 in. (551 mm x 350 mm) with a payload of 1102 lb (500 kg), while the EDAF3 offers table dimensions of 27.8 in. x 19.7 in. (706 mm x 500 mm) with a maximum payload of 1764 lb (800 kg). The EDAF-series is equipped with spark gap monitoring and arc prevention technology. Makino’s new ArcFree technology helps prevent destructive DC arcs that typically lead to time consuming clean-up procedures or scrapped parts. With ArcFree technology, manufacturers can burn any application, fully unattended, worry-free. Even applications with unfavourable electrode/work piece geometry can be started with unusually high current density, and relied upon for flawless results, claims Makino. Makino’s new on-board programming system, Makino Program Generator (MPG), makes the Makino MGH control more user friendly, while generating more aggressive model plans to meet the demands of shortened lead times on today’s shop floor. By providing answers to simple prompts, and inputing basic data, even novice operators will be able to generate efficient and safe burn routines. This new program generator also allows for programming of multiple electrodes and multiple burn locations. Makino’s High Quality Surface Finish (HQSF) technology provides the EDAF-series with improved electrical conductivity for more consistent discharging and spark diffusion. HQSF technology eliminates secondary discharges that waste energy while permitting increased efficiency of the sparks for a superior finish without a loss in metal removal rates. In addition, the HQSF technology allows for achievable surface finish capabilities that are 50 per cent better than that of conventional achievable surface finishes, regardless of discharge surface area. www.makino.com 32 | SEPTEMBER 2010 | www.canadianmetalworking.com
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MACHINE TOOLS
5
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METHODS
Methods Machine Tools Inc. has introduced high performance Feeler vertical machining centres featuring extensive engineering by Methods, designed to provide users performance and value. The vertical machining centre line includes the HV-Series, VB-Series and VMP-Series. “The rugged, reliable Feeler VMC line is now further enhanced with design and engineering by Methods,” says Mr. Paul Hurtig, Feeler machine tools product manager, Methods Machine Tools Inc. The HV-Series VMCs, including HV-800 and HV-1000 models, offer high performance machining featuring 1G X axis acceleration and 1.9 second tool change time in 800 mm (31 in.) or 1,000 mm (39 in.) X axis travels. Roller guideways are on the X and Y axes. A 15,000 rpm, 30 hp direct drive, 40 taper spindle, FANUC 18i-MB Control with 4th Axis prep. and 30-tool automatic tool changer are standard. The VB-Series VMCs are heavy duty boxway machines featuring a high torque two stage gearbox and spindles from 15 to 30 hp, available in 40 or 50 taper. Models include VB-900, VB-1100, VB-1300, VB-1400, VB-1650, VB-1900 and VB-2200. X axis travels range from 900 mm to 2,200 mm (35 in. – 87 in.), Y axis travels range from 610 mm to 1,000 mm (24 in. to 39in. ) and Z axis travels are from 600 mm to 800 mm (24 in. to 31.5 in.). A 30-tool automatic tool changer and FANUC 0i-MD control are standard. The VMP-Series includes the VMP-580, VMP-800 and VMP-1100 models with 10,000 rpm spindles ranging from 15 hp to 25 hp. The VMP-580 machine is also available in an APC pallet changer version. Machines feature linear guideways on X and Y axes and boxways on the Z axis. X axis travels range from 580 mm to 1,100 mm (23 in. to 43 in.), Y axis travels range from 420 mm to 610 mm (16.5 in. to 24 in.) and Z axis travels are from 510 mm to 600 mm (20 in. to 23.6 in.). The VMP580 features a 24-tool automatic tool changer and the VMP-800 and VMP-1100 use a 30-tool automatic tool changer. A FANUC 0i-MD control is standard on the VMP-Series machines. The rigid FEELER VMCs range in weight from 6,600 lb (3,000 kg) to 48,400 lb (22,000 kg) and include a two year warranty. www.methodsmachine.com.
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PRODUCTS
SNK AMERICA
The SNK Nissin BP130 Series horizontal boring and milling machine from SNK America, Inc. is engineered for fast and accurate operation. The BP130 Series’ high powered boring spindle (5.1 in./130 mm diameter) performs at speeds from 5 to 2,500 rpm (optionally 3,500 rpm) with a torque of 2,793 ft/lb. A built-in rotary table provides a fifth axis of operation, and positioning control within 0.001 degree. Featuring cast iron construction, 2.5 in. (63. 5 mm) diameter double anchor ball screws and heavy-duty box ways (6 in./152 mm wide), the 130 Series is built rigid for exceptional accuracy. The hardened box ways achieve excellent lubricity through SNK’s advanced in.mirror surfacein. technology. Further enhancing precision, W-Axis Thermal Growth Sensors are positioned around the spindle casting and bearing. These sensors continually read temperatures (within microns) in five areas - more than most competitor machines. The additional sensors reduce the risk of false readings, and ensure accurate compensation. The table size of the BP130 -3.5 model 63 in. x 86 in. (1.6 m x 2.2 m) with a maximum load capacity of 33,000 lb. Strokes are 13 in. (330 mm) for X axis, 98 in. ( 2,489 mm) for Y axis, 63 in. (1600 mm) for Z axis and 27.5 in. (699 mm) for W axis). X, Y, Z and B axis scale feedback is included as standard. The 60-tool ATC features a pneumatic pedal for ease in loading and unloading tools. All SNK Nissin HBM machines are equipped with Fanuc 16iM CNC controls. www.snkamerica.com www.canadianmetalworking.com | SEPTEMBER 2010 | 33
NEWS: CO
Turning geometries for HRSA and titanium
RO M
ILL
COR OM
ILL®
®1
70
325
The six insert geometries are designed to handle GC1040 depths of cuts from 0.2 to 10mm (0.008 - 0.393 inch) with great chip control and low tool pressure. Four COROTHREAD® geometries are introduced for moderate to small 266 C-GEOMETRY depths of cuts in light roughing to finishing applications. Two stronger geometries are introduced CC6060 for larger depths of cut in roughing or light roughing.
ES
Sialon grade
CoroMill® 325
CC6060
Thread whirling tools
CoroMill® 170 Precision cutter for gear milling
R
-SGF
-SF
M
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-SM
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CoroThread® 266 C–geometry Chip former for maximum security!
New milling grade
GC1040 Contact your Sandvik Coromant representative for more information about these and other new solutions. Think smart | Work smart | Earn smart
Call your local Sandvik Coromant Productivity Engineer at 1-800-268-0703 today or visit us at www.sandvik.coromant.com/ca to locate your local authorized distributor.
BORING/REAMING
CUTTING TOOLS
Hole-in-one
By Tim Wilson ...........................................................................................
Boring and reaming the tough stuff
Depending on material and application requirements, hole making can be a big challenge. Fortunately, the technology is better than ever, and completing a hole quickly and accurately, with close attention to finish and chip control, is within reach for even the toughest metals. “With boring, to get the chips out can be an issue,” says Thomas Sandrud, product manager for drilling, reaming, and boring at Seco Tools Inc., Troy, MI. “You don’t want to re-cut the chip, or have chip jamming problems.” Drilling removes the bulk of the material, with boring then positioning the hole, and reaming determining its final size. In very deep holes most applications are for softer metals like cast iron, though there are occasions where alloys are also used. As boring becomes smaller, harder materials are more common, with the smallest bores —as in medical devices, for example —tending to super alloys. Either way, when it is time to ream, the geometry has to be right. “Lead geometry is important for chip control and tool life,” says Sandrud. “We recommend a four to five degree lead geometry for our reamers.” This is crucial because it is reaming, the final step, that determines a hole’s use. As a finishing operation, reaming requires the removal of less material, and the necessity of superior surface integrity to ensure the highest functionality. “Built up edges and high cutting forces can give you long stringy chips,” says Sandrud. “You can increase the feed to break the chip, but it is also important to have the right lead geometry to give you a thicker chip.”
Flushed and cool
Newer reaming tools are notable for their advanced coolant capabilities. For example, Guhring Inc.’s HR 500 line of reamers generates extremely small chips that are easily flushed out of the way. “There is high accuracy on the bore hole, surface quality is unbelievable,
Seco’s Steadyline vibration damping shell mill holders for boring, which feature a passive dynamic damping system for greater productivity, longer tool life, and improved quality.
and there are radial coolant ducts so that chips won’t get lodged,” says Jim Gale of Guhring Canada, Kitchener, ON, adding that the holes deliver impressive surface quality of Rz 1.84. Gale says the enhanced chip control is true not only of Guhring’s HR 500 D straight flute for through holes, but also for blind holes being reamed by the company’s HR 500 S model. “The chips are so small that there is great flow,” he says. “The chips evacuate right out of there.” www.canadianmetalworking.com | September 2010 | 35
CUTTING TOOLS
BORING/REAMING
“ For through holes, helical reamers can be a better bet than flute reamers for
the simple reason that a left-hand helix will drive the chips and heat forward, though at the chamfer, a left-hand helix won’t deliver a positive angle.”
Coolant supply has to be consistent to avoid thermal shock, which can be as disastrous as not running a coolant at all. But when the delivery and pressure are accurate and consistent, the benefits are huge. “High pressure coolant is really helpful,” says Randy McEachern, product specialist for toolholding and hole making products at Sandvik Coromant Canada in Misssissauga, ON. “If you can focus it right under the chip area you will have better chip control.” McEachern says that it is possible to have coolant jets aimed at specific, high pressure cutting edges. Sandvik Coromant has a reaming tool program where the cutting fluid holes are located directly behind each cutting edge, flushing the chips forward, thus avoiding re-cutting of chips and damage to the surface. “The coolant is blasting under the chip, which gives the chip a lift and has a good effect on the breaking actions,” says McEachern. When it comes to small boring —something that Scientific Cutting Tools in Simi Valley, CA, specializes in—coolant injectors are particularly essential because there is an even greater risk of re-cutting a chip. “What can happen is that a material work-hardens on you,” says Dale Christopher, president of Scientific Cutting Tools. “These chips are harder than regular materials, and floating around. At this point, your enemy is really side cutting pressure; small boring’s tight diameter ratios are almost always unfavourable in this regard.” Christopher says that Scientific Cutting Tools’ QHC holders can provide coolant through the holder, something that is crucial when it comes to small boring. “The tool itself takes up almost the entire bore, and the head of a tool holder will block coolant access,” says Christopher. “At the beginning of a cut things can be fine, but the end of a cut 36 | September 2010 | www.canadianmetalworking.com
can be blocked, which is why we have coolant injectors. These are holes in the holder itself. That helps a lot.” For through holes, helical reamers can be a better bet than flute reamers for the simple reason that a left-hand helix will drive the chips and heat forward, though
Top: Sandvik Coromant’s Reamer 830 for finishing through holes. Across: The company’s CoroBore 825 fine boring tool.
at the chamfer, a left-hand helix won’t deliver a positive angle. Beyond having the correct lead geometry and speeds for chip control, Sandrud from Seco Tools says it is also important to get the coolant concentration right. “When reaming super alloys the coolant concentration is more important than the coolant pressure. Those materials generate a lot of heat, and with normal friction what you try to do is keep a decent concentration of 10 per cent or higher to reduce tool wear.”
All in one
A boring tool is usually a modular tool with a holder, adapter and boring unit, often cartridge-based. By comparison, a
reamer has a tool shank and a head with brazed blades. To increase efficiencies and save money, many customers are looking to improve the quality of the initial drilling to reduce the number of the hole making functions. “In the past customers have been accustomed to drill, bore, sometimes semi-finish, and then ream,” says McEachern. “At Sandvik Coromant we now have our 880 drill. This is an excellent tool that can off-set a drill to a specific size, so that we can eliminate the boring tool function and go straight to reaming.” In most cases an application is still rough-bored and then heat-treated before finishing, with reamers able to deliver high surface finishes. “The pre-operation when reaming is very important,” says Sandrud. “The reamer will always follow the hole, so the rough boring has to be right. And when it comes to cutting speeds, the working window for reaming hard materials is very narrow. You don’t have too much to play with, which is why you need the right recommendations from the manufacturer.” However, with Inconel and some austenitic stainless alloys, a user may choose to be on the low end of supplier recommendations for speeds, and on the high side end for feeds. As well, more heat is generated as cutting edges decay, which means the workpiece material will expand more when the tool is in use, with greater contraction as it cools.
Titanium: a special case
Titanium is a popular, and at times difficult, material when it comes to hole making, because the workplace materials can move, and then shift back. Titanium is not necessarily a “hard” material, and its elasticity is complicated by the fact that it doesn’t conduct heat well. For coolants, sulfo-chlorinated oils are a good bet for titanium, but water-based oil emulsions can also be effective with softer,
BORING/REAMING
particularly relevant for silent tools, which are designed to absorb vibration. At negative three degrees, the vibration is sent back into the bar as a dampening effect. Vibration can also be a major issue when boring very small holes. “It is important when small boring titanium that the tools don’t vibrate and deflect into the hole,� says Christopher of Scientific Cutting Tools. “As well, sometimes a tool will move
CUTTING TOOLS
in the holder, which is why our QHC holders have four locks instead of one or two, because deflecting into the holder will mess you up big time.� CM Tim Wilson is a freelance writer based in Peterborough, ON www.guhring.com www.sandvik.coromant.com/ca www.sct-usa.com www.secotools.com
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Seco’s Precimaster reaming system with throw-away head reamers for adjustment-free hole finishing.
unalloyed titanium. “Let’s not confuse titanium with hard material,� says McEachern. “A hard material is a high alloy steel that has been heat treated, like stellite. About 10 to 15 per cent of our applications are in hard metal.� Knowing the material is essential in order to get the right power balance, speed and feed rates, and geometries for a secure cutting process. In this regard, titanium is something of a special case. It usually reams small, and can be abrasive. “It is important to get the feed rate up with titanium, because it’s a pretty abrasive material,� says McEachern. “When boring titanium, we like to go with a negative three degree lead angle on the cutting tools.� McEachern says that this advice is
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www.canadianmetalworking.com | September 2010 | 37 SCT Final.indd 1
3/4/10 9:30:49 AM
CUTTING TOOLS
PRESETTERS
Prepping your
Tools
Canadian Metalworking speaks with Chander Bhardwaj of Zoller Canada about why tool presetters matter
Q&A
What are the key benefits of using a tool presetter in a shop? Benefits are tremendous. Even though it is not a metal cutting machine it helps your CNC machine cut more. Tool presetters can increase machine cutting time by up to 30 per cent. Some other benefits include reduced setup time, reduced scrap, increased accuracy, material cost saving, reduced chance of human error, time savings, inventory control, tool inspection, complete tool management and data transfer performed electronically/RFID.
38 | September 2010 | www.canadianmetalworking.com
The Zoller Smile CNC is an entry level presetter and measuring device designed for small scale manufacturing.
What is the approximate cost of installing a tool presetter and what is the ROI? Cost varies from 20K to 200K depending upon applications and automation needs. Return on investment is very fast. For example, aerospace. Part of the cost can be recovered in day one. In job shops typically the ROI is within six months, depending upon how many machines you are feeding it with. Machine tools in metalworking operations have changed significantly in
PRESETTERS
Zoller’s Redomatic 450, a heat shrink, presetting and measuring device.
recent years. Today, there are more automated operations with robotics on multi-axis, high speed machining centres. What impact do these multi-axis/high speed machines have on tool presetters and what should operators be aware of when setting them up? The multi-axis, high speed machines need high accuracy in the tools, hence the need for automatic CNC controlled presetters. They allow for the set up of tools at high tolerances of one to two microns to achieve the results and finish needed for high speed cutting. With robotic systems like Fastams, which load the tools automatically in the machines, presetters such as the ones Zoller makes offer direct interfaces with machines such as Mazak, Okuma, Hass and others. The presetter works in conjunction with the machine tool to transfer offsets to the robotics system, which in turn uploads the tools when needed to the machines, with the offsets. Also, if you have machines equipped
with ATC that holds many tools you should not waste time in changing the tools nor waste time on machine set ups. It should be a continuous and simultaneous activity with the least amount of manual involvement outside the machine so machine time is used for cutting rather than setups. Today’s presetters offer solutions for most of the issues customers face everyday with their tooling. The important point is to identify the bottlenecks in the production process, the areas that need improvements, and the extent to which the operation needs automation. Presetter companies can help by providing optimum solutions for machine tools, software, tool management systems, data transfer and inspection that fit customers’ requirements and their budgets. What are the key considerations when installing a tool presetter in an aerospace parts or automotive parts manufacturing operation? Considerations are different in each sector. In aerospace, human errors must be
CUTTING TOOLS
zero because aerospace components are expensive and one mistake will be costly and time consuming to fix. Presetters ensure the offsets generated are the same, and are not operator dependent, ensuring accuracy of tools and no part rejections. In the aerospace industry you need to ensure tools are preset before you start machining, and presetters provide piece of mind because you know your tools are properly set up when you put them in the machine. The automotive industry is a high production environment and there are fixed per piece costs. Any rejection can result in a whole batch being rejected and penalties for late deliveries. A presetter ensures the rejections are minimized and tool inventories are optimized to achieve high tool life and cost savings for customers, with higher production rates. Cutting tools and toolholders have also changed in recent years. Today’s advanced cutting tools have varied geometries and special coatings and more and more people are adopting Shrinkfit and HSK technologies. What impact do changes in cutting tools and toolholders have on tool presetters? New cutting tools and toolholders such as Shrinkfit and HSK have had an impact on tool presetters. Presetters have been redesigned and adapted to different types of tools in the same setting. Zoller has developed a unique system called ACE spindle, which clamps the tool from the retention knob; all tools can be clamped in the www.canadianmetalworking.com | September 2010 | 39
CUTTING TOOLS
PRESETTERS
“Tool presetters should have the ability to measure different types of
tools and the software on that presetter should be capable of handling all the data and having it input with the least amount of programming.”
Zoller Canada’s Chander Bhardwaj. Right: The Smile EDM presetter from Zoller.
same spindle with different tool posts. This is popular with customers because it saves money and time, and it’s easy to operate. Presetter software must be a step ahead of tool profiles and geometries so that users can measure them in one click rather than struggling with setups and offset angles. An example is angle heads, which have different angles depending on whether they’re used on the left or the right side. The Zoller Pilot 3.0 software has up-to-date data on the latest tools because we develop the software in conjunction with cutting tool manufacturers. The point is that tool presetters should have the ability to measure different types of tools and the software on that presetter should be capable of handling all the data and having it input with the least amount of programming. An example is heat shrink technology for high speed machining applications. Zoller was first to develop CNC controlled heat shrink and tool presetting machines that can shrink in a tool to an accuracy of less than 10 micron in 40 | SEPTEMBER 2010 | www.canadianmetalworking.com
height, measure it and send the offsets electronically to the machine control/ RFID. The tool is ready to use in less than two minutes. This machine is one example of developments that meet the changing needs of the market and of customers. In the past customers would have had to cool the tools, which could take hours and there was uncertainty about the height as operators didn’t know when the tool would shrink. What are the top three developments in tool presetters? High tech software like Pilot 3.0 with
Lasso DXF file comparator and tool scanner for collision detection, which provides an interface for automation and user-friendly programming; ACE spindles; and heat shrink presetter combinations. Do you expect to see any major advances in the next five years? As manufacturers continue to change [adopting more automation and multi-tasking machines] presetters need to change too... [suppliers] will continue to develop more machines to meet the changing needs of the market. CM
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PRODUCTS
FABRICATING
Fabricating Solutions A look at recent products to help improve productivity
1
PRESS BRAKES
Bystronic has expanded the standard range for the Xpert press brake up to 1000 ton (1100 US tons) and 10.2 m (33 ft) in length. Formerly the standard range extended to 800 ton (880 US Tons) and 8.2 m (27 ft). The Mammut range of press brakes is still available with the range now starting at 1250 ton (1375 US tons) up to 3000 ton (3300 US Tons) and up to 18.4 m (60 ft) in length. The Bystronic Xpert press brake, with its Dynamic Hydraulic Crowning system, is ideally suited for the bending of heavy plate and or very long parts. The press brake offers an accuracy and repeatability unmatched in its class, according to the company. The hydraulic press brake is equipped with the pressure reference system, controlled by a precise multi-axis controller engineered by Bystronic. The control system is based on a modular electronic system in conjunction with modern block hydraulics. A comprehensive and expandable database supplies all necessary values during the bending process. The database, which contains all of the relevant bend-technology data, is activated by a push of a button. With the embedded database, both the programming and the operation of the machine become very simple, even for inexperienced operators. The Bystronic Xpert press brake features automatic frame deflection compensation, pressure reference technology, dynamic hydraulic crowning of the lower beam, dynamic pressure regulation, automatic tool protection and material thickness measurement compensation. With these features the Xpert press brake delivers the greatest accuracy for exceptional part quality, superior repeatability, easy operation, reduced setup with less scrap, and an excellent return on investment. www.bystronicusa.com
2
1
PLASMA CUTTING & CONTROLS
Hypertherm’s new 800 amp HyPerformance Plasma system cuts thick stainless steel and aluminum. In addition to its ability to production pierce 3 in. (75 mm) and sever 6 ¼ in. (160 mm) thick metal, the system just as easily cuts thin metal—including gauge—without the need to switch torches. The system’s thick piercing capability is attributed to PowerPierce. This patent pending technology eliminates the need for pre-drilling and minimizes damage to the torch by using a liquid cooled shield to repel molten metal during piercing and cutting. In testing, Hypertherm found there was no damage to its consumables or lessening of cut quality, even after piercing 3 in. (75 mm) thick stainless steel 400 times. The system delivers the industry’s widest process range, giving operators a new level of versatility. From 30 to 400 amps, operators can use it to mark, bevel, and cut mild steel, stainless steel, and aluminum. This versatility is extended up to 800 amps so operators can also cut thick stainless steel and aluminum with the same system. Until now, fabricators needing to cut a wide range of metals and thicknesses had to use two or more systems to complete the job. To complement the system, Hypertherm’s CNC, EDGE Pro, is easy to install, easy to use, and more reliable than other computer numeric control, claims the company. It does not require any sort of intermediary device to run and supports both oxyfuel and conventional plasma cutting systems. Hardware and software advancements include both analog and SERCOS motion control connectivity, a touch screen display and an integrated operator’s console. The EDGE PRO also comes pre-installed with Hypertherm’s Phoenix software, including the patent pending CutPro Wizard to simplify learning and operation of the entire cutting system. www.hypertherm.com 42 | SEPTEMBER 2010 | www.canadianmetalworking.com
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PRODUCTS
3
FABRICATING
WATERJET CUTTING
Jet Edge has developed a five axis waterjet cutting machine, the Idro, available in three sizes: 5.5 ft x 6.5 ft nominal (1700 mm x 2000 mm), 5.5 ft x 13 ft nominal (1700 mm x 4000 mm) and 6.5 ft x13 ft nominal (2000 mm x 4000 mm). It features the IKC five axis water jet cutting head, capable of making inclined cuts and controlling kerf to ensure optimal part quality. The IKC’s capabilities include 600º rotation, a maximum angle of +/- 60º, and dynamic precision from +/-0.2 to +/-0.5 mm/m, depending on the tilt of head. The precision ground rack and pinion X and Y axes and ball screw driven 5.9 in. (150 mm) Z axis make it one of the most accurate waterjet systems available, claims the company. It maintains a cutting tolerance +/- 0.004 in. (0,1 mm/m), and repeatability accuracy tolerance of +/- 0.001 in. (0,025 mm) and supports a contouring and rapid feed rate of 0-1575 ipm (0-40000 mm/min.) Motion components are protected by steel covers with labyrinth lip seals to ensure lasting performance. The Idro line is equipped with programmable contact height sensing and comes standard with one five axis cutting head; a second five axis or three axis cutting head can be added. Other standard features include a stainless steel tank, automatic safety guards with clear windows on front and back, and a dredge conveyor for abrasive removal. Its many options include a rotating axis for pipe cutting, fire jet etching system, a drill and twin shuttles. www.jetedge.com
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PUNCH PRESS TOOLING
Unlike standard multi tools having just one angle setting, Mate’s Ultra IMT fully indexable multi tool can achieve any angle setting on the workpiece. Patent pending, Ultra IMT is designed to use Mate Ultra punches, strippers and Slug Free dies eliminating the need for specialized tooling inventory. Assembly and disassembly is simple—no tools are required for punch, striker and stripper retention/removal. The tool features a drop-in quick tool change design that allows for fast tool changes, reducing machine downtime while increasing productivity. The tool maximizes existing punch press output with features such as: integral punch length adjustment, variable stripping force options, fully ported lubrication, easy active station identification, ergonomic design and many others. Available in three-station and eight-station versions. Mate’s new Ultraform FX AND XT holders provide affordable interchangeability with Mate’s top-of-the-line Ultraform insert system. These holders reduce holder complexity for machines with precise stroke control and for machine users who infrequently use or don’t want length adjustment. The holder system is the ideal forming tool system because fabricators may use one holder with a wide variety of special forming inserts. The benefits include reduced tooling cost and increased flexibility. Mate’s new Rollerball Deburr tool eliminates burrs and secondary operations on punched parts. It pushes the burr away and creates a radius on the side of punched parts. Using a special ball in the upper and lower part of the tool, all part contours can be processed and deburred, even in tight corners. Rollerball Deburr is available for Thick Turret and TRUMPF Style applications. www.mate.com
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LASER CUTTING
Mazak Optonics’ new STX Mark III RTC cuts thin to thick sheets, tubes, pipes, cubic components, taps and even chamfers, all on a single machine. A rotary table is standard equipment for cutting round pipe up to a maximum diameter of 14.76 in. (375 mm), and square tubes up to 6 in. (152 mm). The large 16.14 in. (410 mm) range of Z travel enables you to laser cut preformed parts and other 3D shapes requiring greater cut height. The STX Mark III RTC is available in 2,500 (.87 in. MS) or 4,000 (1 in. MS) watt configurations and accepts up to a 5 ft x10 ft (1.5 m x 3 m) 44 | SEPTEMBER 2010 | www.canadianmetalworking.com
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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
World’s first! “TIP-START”
FOR BROCHURES AND DISTRIBUTOR INFORMATION CALL FEIN CANADA 1 (800) 265-2581 www.fein.com
CLASSIC
NEW! FEIN WS 14 Grinders Safe, durable, reliable “CLASSIC” and new “TIP-START” versions, QuickIN models Compact slim-shape, extremely low vibration
NEW! FEIN Abrasives High quality grinding and cut-off wheels, superior performance and great value
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FEIN WS 14 Grinders FEIN Abrasives
W S NE E D LI N AN CT BR DU O PR
SAFETY FIRST!
FABRICATING
PRODUCTS
sheet of flat material. It can be delivered with a large range of automated material handling systems including load/unload cells and flexible manufacturing systems. It uses many leading edge features developed for Mazak’s Hyper Series machines, such as intelligent setup functions for automated nozzle spatter removal, a three station nozzle changer and focal point measurement and adjustment capability. These features are components of Mazak’s Opti-Pod that minimizes system setup time and improves extended unattended operation while maintaining optimized machining conditions. The Mark III also incorporates a new Servo Focus Torch. This servo driven system significantly reduces piercing time and increases productivity. Additional new technology includes a High Accuracy Auto Centering lens and nozzle design that further reduces setup and increases productivity as well as pierce, plasma and burn sensing to ensure consistent performance over a wide range of materials. www.mazakoptonics.com
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LASER CUTTING
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BEAM DRILL
MC Machinery Systems Inc.’s Mitsubishi 700 Series CNC control delivers advanced programming capabilities for high precision machining and high productivity. The control enhances the Mitsubishi laser line with expanded cutting conditions and functionality. It allows greater compatibility between machines. The BrilliantCUT technology produces a cutting surface roughness near machine finish, eliminating secondary operations and decreasing production times. BrilliantCUT also provides better part straightness, optimal processing conditions, reduced taper, and reduced discolouring on the heat affected zone. Jet Pierce technology decreases part time by allowing material to be pierced faster and more aggressively during small-hole processing, while improved height sensor hardware provides better tracing ability than older lasers. The unit is controlled on a 15 in. LCD touch screen display, allowing operators to easily monitor the machine from a distance. The control’s simple menu configuration allows for easy navigation on the Windows XP operating system, and on-board manuals keep rarely needed information close at hand. www.mitsubishi-world.com
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Peddinghaus Corp. has introduced its latest drilling innovation, the Advantage 2 high speed beam drill line. The all new beam drill line is capable of high speed drilling, tapping, countersinking, and multi axis scribing for a wide variety of profiles including beams, channel, angle, square/ rectangular hollow sections, and flat bar. The beam drill uses three drill spindles each accompanied by an optional five station automatic tool changer. Automatic tool changing paired with carbide drilling of up to 2250 rpm and 27 ipm/685 mmpm feed rates make this machine unmatched in speed for profiles up to 447 kg/300 lb per ft, says Peddinghaus. Features of the Peddinghaus Advantage 2 drill line include: • Carbide drilling but also capable of accepting HSS inserts, or twist drill tooling allowing for a wide array of tooling options in any situation. • Optional five station automatic tool changers eliminate operator intervention increasing efficiencies and decreasing potential safety hazards. • New Peddiflex3D CAD programming, batch nesting, and production reporting software. This new 3D software package is offered first on the Advantage 2 drill line. • Electronic motion and spindle control as a part of Peddinghaus’ green initiative. • Siemens 25 hp /18.5 kW spindle specific electronic drilling motors for unmatched electronic spindle control and feedback. www.peddinghaus.com www.canadianmetalworking.com | SEPTEMBER 2010 | 47
PRODUCTS
8
FABRICATING
LASER CUTTING
Automotive part manufacturers striving for the shortest cycle times and highest quality cutting and trimming of hot-formed steel parts now have a solution with PRIMA North America’s latest Rapido Evoluzione 2 five axis laser system. With 175 m/min linear speed and 1.4 g acceleration, the five axis laser system produces high quality cut edges free from oxide that are weld and paint ready. Using this system, a typical automotive part made of hot-formed steel such as a B-pillar has a cycle time of less than 50 seconds. “These systems are designed to operate non-stop in a 24/7 manufacturing environment to handle very large quantities of parts,” reports Terry L. VanderWert, president of PRIMA North America. “With the Rapido, PRIMA provides a complete turnkey package including load/unload stations integrated with the CNC control to enable continuous part laser processing. Our automotive customers report achieving up to 30 per cent productivity increases using these new Rapido Evoluzione 2 systems compared to the previous model.” The new laser system has a 160 x 60 x 30 in. (4080 x 1530 x 765 mm) work volume with sleek, compact and ergonomically designed machine architecture. The cabin design has enhanced ergonomics and accessibility to the workpiece, including its ceiling for increased safety and optimal fume and dust evacuation. The workpiece is fully accessible, allowing the operator to move comfortably around parts during programming, loading and unloading operations. Standard cabin designs for the RAPIDO systems include integrated dual shuttle tables (Photo Four), split cabin configuration and a three meter integrated turntable configuration that meets CDRH Class I and CE requirements. Rapido systems are available “turn key” with all fixture operations controlled via the CNC. Available laser sources include up to 5 kW CO2 and up to 3 kW fiber laser. Other features include: • Latest generation Primach, 30L control for high performances, advanced control algorithms, HMI with web technology and 17 in. touch screen and trackball. • Heavy duty, integrated synthetic granite structure with low shop floor space requirements. • Perfect Tool, an automated system for precision laser beam to cutting nozzle alignment. • Flying optics with the workpiece remaining fixed throughout the work process. • Safe Impact Protection System (SIPS) for full detachment of the head in the event of accidental impact, preventing damage to the machine, parts and equipment while ensuring immediate restarting of production. • Adaptive C-adaptive axis with capacitive sensor (± 10 mm stroke; 4g acceleration). The Rapido Evoluzione 2 system also has application in appliance and aerospace manufacturing and is being adopted by an increasing number of contract manufacturers serving these industries. www.prima-na.com
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LASER MARKING
TRUMPF’s newest laser marking system is the TruMark 6030. All TruMark Series 6000 lasers stand out due to their short processing times and high quality marks, but the TruMark 6030 is particularly noted for its versatility. This laser enables users to perform any marking process quickly and with a high level of quality, including annealing, engraving, depositing, colour change, and foaming. The selection of materials is just as flexible. The laser marking system performs on metals, ceramics and plastics. The new TruMark 6030 laser features a considerably shorter mark time when compared to other products in the TruMark Series 6000. TRUMPF has increased the output of the new marking laser by 35 per cent reducing cycle times by the same percentage. The TruMark 6030 is a diode pumped, Nd: YAG laser and operates in the infrared range of 1064 nm. The laser is designed for high pulse energy and superior pulse peak power to create crisp and high contrast marks. Engraving rates on metals satisfy stringent requirements for deep engraving in high volume manufacturing. www.us.trumpf.com 48 | SEPTEMBER 2010 | www.canadianmetalworking.com
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Fabrication challenge? We’ll solve it. Mate will take your sheet metal forming problem and develop a fully vetted tooling solution. Once we do, Mate will deliver your tools to you fast. Really fast. • Lightning fast quotation response rate – 99% same day. • Expert consultancy. Our team of Applications Specialists has over 170 years of combined sheet metal experience to evaluate your toughest applications and design solutions. • All Mate special assembly tools are fully tested to guarantee your uptime. • Delivery times are fast and getting faster!
See more at mate.com, call 1.800.328.4492, or scan the tag below
MATE on the move find out more at FABTECH, Booth #1825
Fabricating
PLASMA CUTTING
Plasma:
The “hole” package Are bolt quality holes possible with plasma?
New technology means operators can now use plasma to achieve holes that rival laser cut or drilled holes.
50 | September 2010 | www.canadianmetalworking.com
For years, plasma operators have faced what they considered their number one process issue: hole quality. Despite the many benefits of plasma—including fast cutting speeds and low operating costs—creating a bolt quality hole was difficult. Fortunately, new technology is changing the game. So much so in fact, operators can now use plasma to easily and quickly achieve holes that rival laser cut or drilled holes. In the past, operators using plasma to cut holes faced two main challenges. The first was edge quality. When cutting, a ding or divot would form along the edge of the hole, resulting in both an out of round shape and a cut susceptible to stress fractures in high strength applications. The second challenge was that the top of the hole was often wider than the bottom. This taper, caused by a lag angle from the plasma jet, meant fabricators had to undertake secondary operations to get a hole capable of accepting a bolt. Despite an awareness of these shortcomings, plasma manufactures were never able to come up with a solution. Until now. After months of research and testing in Hypertherm’s advanced engineering labs, engineers realized they could create good holes with plasma. Unfortunately, the list of equipment and parameters needed to create the “perfect” hole was lengthy. For starters, engineers discovered they needed five different components to provide an optimum hole: the best possible plasma technology, an advanced CNC control, a height control, an on-site CAD programmer, and a cutting table capable of delivering precise motion control. They also needed an extensive amount of set up parameters. Making matters worse, the set up parameters were not static. Any time hole diameter, material thickness, or power levels changed,
PLASMA CUTTING
the parameters all needed to change. While many operators could master a large number of parameters, the reality for many fabricators was that it would be difficult to find enough operators with that high level of expertise. For that reason, engineers knew they had to automate the process as much as possible by inputting the varying parameters into a large database. Once inputted, CAM nesting software could then automatically apply those parameters. Quite a few companies create nesting software for CNC plasma cutting systems. Nesting packages make the jobs of part programmers easier by automating much of the process. At the same time, the software helps companies save money by recommending the best placement of the parts during cutting so the plate is used efficiently; with as little waste as possible. Like most anything though, the level of sophistication among this software varies. More advanced software have features that take aggressive control of the machine code. In doing so, the software can manipulate feed rates, plasma on/off timing, torch height control, and inventory control of plate remnants. After taking a close look at the different software brands, Hypertherm decided to partner with MTC Software, a US developer of nesting and optimization software. This mutual development effort led to Hypertherm acquiring MTC in early 2009. Through the sharing of propriety data and engineering expertise, Hypertherm and MTC were able to finish
Fabricating
Hypertherm partnered with MTC Software to create the new technology now called True Hole.
®
The world’s most advanced machines demand the world’s most advanced nesting software. SigmaNEST® 9.0 brings ease of use and higher efficiency for: Optimal nesting Superior quality parts ■ Order management
Raw material and remnant management Automation/integration ■ One software for all major profile cutting and punching machines.
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For a better software experience, call:
Visit us at CMTS 2009, booth #9014.
513.674.0005 SigmaNEST® is the leading CAD/CAM nesting software for plasma, punch, laser, waterjet, oxyfuel, router and knife machines.
www.sigmanest.com SIGMA3608_Bucyrus_Half Page_CanMetWork-CMTS.indd 1
©2009 SigmaTEK Systems, LLC Mining equipment shown manufactured by Bucyrus International, Inc. using SigmaNEST.
8/21/09 9:03:49 www.canadianmetalworking.com | September 2010 |AM 51
CHANGING THE
GAS INDUSTRY
Darrell Adcocks PROFESSION: Master Welder COMPANY: Voith Paper Rolls NAME:
JOB EXPERIENCE: With 21 years in welding, it’s safe to say that Darrell Adcocks knows his tools. At his current job, where he rebuilds bearings, paper rolls and housing for use in large-scale printers, his productivity hinges on efficient equipment. So when his company chose to make sweeping shop renovations, Adcocks got an upgrade. TOOL OF CHOICE: Victor® Edge™ Series Regulators WHY THE EDGE SERIES REGULATOR? “We’re in the middle of a major shop overhaul right now. For three months we’ve been using the Edge Series regulators and they’re making us much more efficient than before. As far as I’m concerned, they’re the best in the industry. I don’t think Victor has ever made a bad product.”
“It’s Victor. It’s all around
the best you can get.”
, A GLOBAL CUTTING AND WELDING LEADER, joins the American Welding Society in encouraging individuals to practice the art, craftsmanship and professions of welding, metalworking and fabrication. Victor, Thermal Dynamics, Thermal Arc, Arcair, Tweco, Stoody, Cigweld and TurboTorch are among the Thermadyne
Darrell carries the torch... will you?
family of brands that you can count on for safety, reliability and quality. www.thermadyne.com
Canada Customer Service
Phone: 905-827-4515 • FAX: 1-800-588-1714 • Email: canadacs@thermadyne.com
PLASMA CUTTING
Fabricating
“ By combining a
HyPerformance auto gas system, an EDGE Pro CNC, ArcGlide THC and MTC’s ProNest 2010 nesting software, any company can create better holes using the True Hole process...however a fabricator’s cutting table plays a vital role in the level of hole quality that can be delivered with this process.”
Examples of hole cuts with and without the True Hole technology.
development of the process, now called True Hole. By combining a HyPerformance HPRXD auto gas system, an EDGE Pro CNC, ArcGlide THC, and MTC’s ProNest 2010 nesting software, any company can create better holes using the True Hole process. However, a fabricator’s cutting table plays a vital role in the level of hole quality that the True Hole process will deliver. Certain integrators have invested heavily in research and development to ensure their tables deliver precise motion and it is these tables that are best suited to the True Hole process.
The four step True Hole process:
4548 CStrip 178x38 (L) AW.pdf
The operator imports standard CAD drawing files into ProNest. The programmer chooses the material thickness and amperage, the quantity required for each part and the plate size. ProNest creates a file that is then sent to the Hypertherm CNC, either through the network or a USB mini drive. The CNC prompts the system operator to check the consumables HPRXD plasma torch (there is 3/3/08in the 17:39:43 a picture on the CNC screen with part
numbers for verification) and also prompts the operator to make sure the right thickness and size plate is loaded. The operator pushes the start button, without having to worry about gases, amperage, arc voltage, delay times, kerf adjustment, machine code changes or anything else. Based on a given material thickness and power level, the nesting software will sort all holes by size and will gather the data developed during the more than three years in Hypertherm’s research and development labs. It then applies the data in a few milliseconds, modifying the machine code with corrections to make extremely high quality holes without any time or expertise required. The benefits of the True Hole process are numerous for both the operator and the fabricator. Now every operator—even those with less experience—can cut like an expert since no operator intervention is needed. Fabricators, for their part, enjoy consistency from the first to the last hole knowing the entire process is automated. Plus, they get the benefits of more accurate hole cutting processes like laser and drills, at a fraction of the cost. CM www.hypertherm.com
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The power to choose. Choose your feature-set. Basic – MA23 A manually set feeder for reliable MIG and stick welding.
Choose your power level. MIG 4002c – 400 A For every type
Building your ultimate machine has never been easier.
of welding.
Guided – MA24 Features QSet,™ which automatically selects the correct welding parameters for the required wire/gas combination. MIG 5002c – 500 A For heavy-duty welding of solid and flux-cored wires.
Advanced – U6 Offers pulse MIG capabilities, more memory, and the ability to create synergic lines.
MIG 6502c – 650 A Designed for the most demanding heavy-duty, high-duty cycle welding, carbon arc gouging. Sophisticated – U82 Plus Our topof-the-line feeder – includes USB capability, user synergic lines, and SuperPulse™ for superior control of heat input.
ESAB has revolutionized the way you select your welding equipment. With our new line of power sources and feeders, you can match the components that best fit your application. And should your needs change down the road, we make it easy and cost-efficient to upgrade either component, rather than buying a whole new system.
Start building your ultimate machine – visit esabna.com/choose today. ESAB Welding & Cutting Products / esabna.com / 1.877.935.3226
SAFETY
welding
Eyeing Helmets How to choose a helmet for eye safety By Jamy Bulan ................................................................... Welding helmets are available in a wide range of colours and graphics, making them a welder’s most personalized accessory. These visual features are often what catch our attention, but it’s important to look for features that best protect our eyes. Today the most popular helmets sold are equipped with auto-darkening capabilities. These helmets protect from harmful light emissions at all times, and automatically darken in milliseconds to an appropriate shade when an arc is struck. In addition to providing critical protection from damaging arc flash, any helmet must be comfortable enough for a full day’s work with flexible and adjustable headgear. Newer, lightweight helmets make welding safer, easier and more comfortable.
Most helmets today are equipped with auto-darkening capabilities.
Helmets now are considerably more functional to accommodate a welder’s specific needs. Although any helmet should protect your vision, an autodarkening cartridge makes it easier to adapt to the requirements of a wide variety of welding cutting and grinding applications. The quick-changing LCD technology in an auto-darkening cartridge allows a welder to see clearly while the helmet is in the down position. This feature allows continuous work, reducing unnecessary stop-and-start time and the need to readjust or lift then flip the helmet down. Most importantly, the display protects against harmful UV and infrared radiation light. So how do you choose the right autodarkening helmet? There are a number of factors to consider when selecting a helmet that is safe, comfortable and functional.
Taking the time to ask yourself the following questions will help find a helmet that best meets your needs. For anyone involved in extensive welding, a heavy helmet can significantly increase fatigue. Newer, lightweight helmets make welding safer, easier and more comfortable. Likewise, check that the headgear is adjustable up, down, forward and back; and that it is easily tightened around your head. See if the rate of fall and degree of tilt allow the helmet to lower in a controlled manner. Many helmets today have light sensitivity settings on a scale of 9 through 13. This allows welders to optimize the shade for greater comfort. Anyone who changes power settings and welding processes can benefit from this flexibility. If you are TIG welding with low-end amperages, the cartridge should be able to darken to an appropriate level. Most helmets are powered by either batteries or solar panels. While both work well, some welders prefer not to be bothered by changing worn-out batteries in inopportune moments. Another convenience for many welders is the ability to access the front spatter lens, inside cover lens and auto-darkening cartridge. And of course, every helmet should meet current safety standards (ANSI Z87.1) that address light leakage as well as flame and impact resistance. Once these functional issues are settled, you can chose from a myriad of cool and goofy graphics. But don’t discount cosmetics. Chances are if it’s a good helmet, you’ll be wearing it for years. Pick one you really like. CM Jamy Bulan is the commercial equipment product manager for Lincoln Electric Co., Cleveland, OH. www.lincolnelectric.com www.canadianmetalworking.com | September 2010 | 55
tag line
Headline to go here to deck to go here
Sublime Green A Quebec custom coater is betting the Canadian market will embrace a European finishing concept, sublimation coating, and a green pretreatment system By Pierre Bachand
Running a custom coating operation can be a challenging business. Add a new and promising, but relatively unknown finishing operation, and the challenge increases tenfold. Denis Pilon and his family, wife Manon and daughter Melanie, formed the Al-EX Concept Inc. in 2008 to offer a sublimation coating process, a well-established concept in Europe, but not well-known in North America. Sublimation coating is a process by which solids are heat converted into vapour and then back into solids. It is an image transfer technology, and as with many brilliant ideas, the concept is simple, but the technology and the chemistry associated with it, is not. It’s a versatile process because the coating can represent just about anything, wood, decorative/artistic representations, metal and marble finishes, and the process can be used on glass, wood and metal. The process is relatively simple if you have the right equipment, the right powder coatings and the right films. It starts with cleaning and surface pretreatment, drying, electrostatic application of a specially formulated powder, curing and then the final wrap/ cure/unwrap on the same machine. When Pilon decided to start his business and focus on this unique finishing concept, he purchased the equipment from Decoral, an Italian firm that invented and now markets the process. Seeing the growing stringent regulations for finishing materials, Pilon wanted an environmentally friendly system and the Decoral process fit his needs. Each finishing process is critical in AL-EX’s shop because the company is also a certified applicator that must meet the American Architectural Manufacturers Association (AAMA) 2604 standard for coated aluminum extrusions. At the heart of the sublimation coating system is the pretreatment system, supplied by Chemetall Americas. The titanium/zirconate pretreatment system is considered leading 56 ■ September 2010
Overspray
The powder spray booth used to apply the specially formulated powders on parts. Inset image, left, shows the sublimation unit.
edge and consists of a four stage process—cleaning (Chemetall’s Gardoclean S 5657), a two to four minute process for aluminum and five to ten minutes for steel; city water rinse cycle for 60 seconds; conversion coating (Chemetall’s Gardobond EPP 870 and 872) at 70ºF for two to five minutes, and a final city water rinse cycle that runs 60 to 120 seconds. After cleaning and pretreatment, parts are either air dried or dried in a Rapid batch oven. The next stage is the powder coating application. Parts on a conveyor pass through ECE Canada’s System Division’s spray-to-waste paint spray booth. Powder application equipment is supplied by ITW Gema, which includes the manual Optiflex box and hopper units. A cartridge type collection attached to a galvanized steel booth confines and
FINISHING MATERIALS/PRETREATMENT
collects the overspray powder. Depending they remain for six to nine minutes. The on the part, a batch style booth may be pattern is transferred from the film support used to apply the powder coatings. This inside the coating/powder layer for 2.3 to system also uses a spray-to-waste booth. 2.7 mils in depth. Powder coatings, specially formulated The frame is equipped with a temperature for easy absorption and retention of inks heat sensor ensuring proper cure. from the carrier film onto the powder When doing wood motifs, small variations surface, are supplied by Erie Powder, in curing will give slight variations on part Sherwin Willians and Decoral. The finishes, giving products a more realistic powder coatings are applied at three to appearance. This is where experience Examples of the colourful and varied four mils and cured at 380˚F to 400ºF for completes the science part of the process. images possible with the sublimation approximately 10 minutes. Once the curing is complete, the trolley coating process. Parts are cured in a Vulcan IR multi-zone exists automatically from the oven. When the control gas oven or the Rapid batch oven; parts have cooled, the film is removed and batch size determines which ovens are used. parts are checked before being unloaded. The final process is the wrap/cure/ Pilon has found a process that meets his unwrap. The operator lays down the parts needs for a green system. Now his challenge already wrapped in the transfer film on is market the process to the Canadian the frame that is resting on a moving market and make customers aware of the trolley directly in front of the oven. A versatility of this green finishing process and vacuum starts between the two membranes how it can benefit daily life. that are closed and fixed in the frame. This helps the film follow the shape of the parts. With the vacuum in operation, Pierre Bachand is president of Chromatech Inc., a finishing training the frame and trolley move into the oven automatically where and consultancy firm.
®
GFS_coatings_sept09.indd 1
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September ■PM 57 24/08/092010 3:46
SPECIAL REPORT/CUSTOM COATING
8 Questions for 5 Experts Challenges and opportunities facing custom coaters By Nate Hendley
The custom coating industry has faced some tough challenges in recent years, but just like its manufacturing counterparts, companies in this market are seeing somewhat of an upturn with some indutry sectors beginning to show tepid signs of recovery. We ask some custom coaters who have survived the past year the challenges they face and the opportunities they see for future growth.
In your opinion, is the trend towards powder coating going to continue? “Yup,” notes Bala Sathy, plant foreman of Colourific Coatings in Mississauga, ON. “I would think so,” agrees Burke Dolomont, manager, RiteWay Powder Coatings, Calgary, Alberta. “I hope so—I’m counting on it. It’s my living—it’s what I do. There’s definitely a continuing trend [towards powder]. We’re getting busier and busier all the time,” adds Joseph Manzoli, president of Colourfast Custom Coatings, Concord, ON.
Is this mainly because of environmental concerns and cost reduction? “I think for a little bit of both,” says Dolomont. ‘That certainly plays a role in it. It’s also due to technology— powder [technology] is developing, allowing us to coat other substrates above and beyond metal,” adds Manzoli.
What other trends have you noticed in the custom coating sector? “I think the customer now is ordering smaller batches but more frequently,” says Kevin Bilan, general manager at Pro-Tek Surface Technologies, Winnipeg, MB.
Is being a custom coater a good way to compete with low-cost, low-wage countries such as China? “We can’t compete head-on with these guys, with what we pay. Our environmental and labour laws make it very difficult for us [to compete with low-cost countries]. Where we can compete and where we are far superior is in quality and delivery to local markets. What the off-shore people can’t do and we can do is offer quick service on small quantities. Quick delivery, very good quality and quick turnaround,” says Manzoli. “We’re doing on average 40 to 50 colour changes a day. Speed and quality are definitely the reasons why we’re getting busier and busier,” continues Manzoli, adding that 58 ■ September 2010
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A special coating system keeps John Deere’s Gator Utility Vehicles looking good under the toughest conditions. Photo: Powder Coating Institute.
two years ago his company was doing “less than half” as many colour changes. China, notes Bilan, is “still a very hard supply chain to manage”—delivery can take weeks, while language, culture and technology barriers remain formidable. That said, custom coaters have come to accept the offshore threat with a degree of fatalism. “The reality of it is China is not going to go away. If it does, there are a dozen other countries that are willing to compete against us that are a lot cheaper than us. So I think this is our new reality. We have to adapt to our market’s needs a lot more than ever before. We have to be faster, we have to be cheaper, and we have to be better,” says Manzoli. “I’m not going to lie, all the big volumes have gone offshore ... the orders that contain thousands of components in one colour no longer exist, not in my business anyway,” he adds.
How has the recession affected your business? “I think certain sectors of the industry saw the impact in a very negative way—automotive refinishing, industrial coatings. We saw a lesser [impact] on architectural coatings because there’s some good [government] stimulus packages out there. We still saw a decline, but certainly it could have been worse had it not been for the stimulus activity which lead to increased construction and that sort of thing,” says Jim Quick, president of Canadian Paint and Coatings Association (CPCA) based in Ottawa. The lingering impact of the recession has led some custom coaters to get inventive. “We’ve been toying with a lot of other processes but [the rocky economy] is certainly driving us to look and experiment with a lot more processes now. We’re
SPECIAL REPORT/CUSTOM COATING
getting into more surface treatment versus surface finish,” adds Bilan.
Davidson and some of the local bike shops,” says Manzoli.
Is there a trend towards automatic equipment?
“We’re optimistic. Certainly what we see in the first half of the year is that some of the sectors that were having trouble during the economic recession are showing pretty good performance ... [those sectors would be] automotive refinish, architectural, industrial maintenance,” says Quick. “I’ve got to be honest with you, I haven’t been this optimistic in a long time. I see that we have a very strong customer base that’s well networked internationally. We’re relying on those customers to keep us busy ... we’re running two full shifts now. Had it not been for the trouble associated with finding a really well-trained crew for a third shift, we could potentially go three shifts, around the clock,” adds Manzoli.
Are you optimistic or pessimistic about the future?
“No. I wouldn’t say we’ve seen that,” says Bilan. Bilan believes the custom coating sector will retain its preference for manual and semi-automatic equipment for the immediate future—an opinion seconded by others in the field. “We’re a manual shop [with] manual spray guns,” says Dolomont. “We have [automatic equipment] but we haven’t turned that aspect of our equipment Powder coated on in the past two years. The only time that we heat-senstive would use the automatic systems would be on long substrates. runs, and they no longer exist,” adds Manzoli.
Are you offering any new services?
Photo: Powder Coating Institute.
“We’re further developing our coatings to offer airbrushing—custom finishes for a motorcycle restoration division ... we’re right in the middle of launching it ... we’ve been doing a lot of work with Harley
Nate Hendley is a freelance writer based in Toronto.
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September 2010 ■ 59
ROBOTIC FINISHING/CASE STUDY
A Competitive Edge Robot provides increased productivity and flexibility for one-stop metal shop The Paint Mate 200iA has a payload capacity of 5 kg and a reach of 704 mm; a longer reach version, the Paint When Classic Metal Finishing and Classic Metal Turning, Jackson, Mate 200iA/5L, is available with a reach of 892 mm. Ideal MI, decided to incorporate automation into its one-stop CNC for small part applications, the Paint Mate 200iA is a cost machining and industrial finishing shop, automation system effective replacement for fixed automation. It’s also approved integrator Thierica Equipment Corp., Grand Rapids, MI, came for FM and ATEX Hazardous locations, Class I, II, III and up with a unique solution incorporating Classic’s two recently Div. 1 environments. purchased FANUC Robotics Paint The FANUC R-30iA Controller Mate 200iA robots. and iPendant offer a multi-window Classic Metal Finishing supplies colour display, which allows easy input components for the aerospace, and adjustment of system parameters motorcycle, racing, and medical and provides quick access to built-in industries. Classic Turning performs diagnostic and help information. high end CNC machining of Custom user-developed screens and components and Classic Metal messaging, and the iPendant’s ability Finishing performs anodizing and to access specific work instructions dry film lubricant applications. The and machine setups on the plant anodizing line can anodize with two network, maximize overall system different types of corrosion inhibitors, uptime and productivity. and can die aluminum in eight Thierica Equipment’s spray system different colours. Dry film lubricant design in Classic’s facility uses an AB is applied to parts to help with high PLC with a touch screen that is able to friction tolerance fits and moving handle one thousand jobs, well suited assemblies. Today, the company’s team for communication with the R-30iA leaders have 25 years of experience in robot controller. The operator’s end manufacturing and engineering. of the two-position index table has a “Classic Metal Finishing and Classic pair of safety light curtains for intrusion The FANUC Paint Mate 200iA Turning is a one-stop job shop, we detection. Once the job is selected, the robot in action at Classic’s paint finising shop. machine from the raw material to operator simply adjusts the gun spray to the metal finish to deliver complete a predetermined setting, loads the part components to the customer,” says Phil Morrison, plant manager. into the machine, and selects the finger sensor start button. Thierica Equipment’s solution includes two FANUC Thierica designed an end-of-arm-tool capable of spraying Robotics Paint Mate 200iA robots in a table-top paint booth with two guns and a quick tool change capability. The two design. “It’s a great compact system that uses minimal floor position index table has twin spindles, rpm control for space,” explains Morrison. spindle speed, and adjustable fan air dials on each gun. The Thierica Equipment and Phil Morrison had worked together integrated two-position index table and Paint Mate 200iA for more than 12 years to pioneer systems that sprayed dry film robot system handles components sized from 3/16 in. to 5 in. lubricant to the outside diameter (OD) and inside diameter (4.7 mm to 127 mm)diameter, and is capable of spraying two (ID) of many industry parts using a two axis (X, Y, tilt) fixed types of material and two different part configurations with gun spray machine. In late 2008, the job shop began discussing any combination. For example, it can apply a type of dry film the purchase of automated machines. Thierica Equipment lubricant to the ID of the component, and a second type of presented an alternate solution to incorporate FANUC Robotics’ dry film lubricant to a section of the component’s OD. new Paint Mate 200iA mini-paint robot, the latest and smallest The robot system is required to apply dry film lubricant to a six axis coating robot designed to meet the automation needs wide range of components with a consistent film thickness. The of a variety of industries including aerospace, alternative energy, dry film lubricant is sprayed with an air brush gun due to the automotive component, appliance, agricultural equipment, required minimal film thickness. This type of material has a short consumer goods, plastics and many others. two-second flash time, making it difficult to apply without dry By Brent Lamarand
60 ■ September 2010
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ROBOTIC FINISHING/CASE STUDy
spots and runs which makes this a perfect application for Paint Mate 200iA robot. The dry film lubricant supply system consists of Graco pressure pots, a fluid pressure regulator, and a back pressure regulator. The air brush gun has a “Y” fitting attached so the dry film lubricant continuously re-circulates and agitates to keep the dry film lubricant flowing past the gun needle. This fluid system design prevents plugged, dried out gun tips and also keeps the dry film lubricant system ready to spray at a moments notice.
Increasing speed with robotics Classic Metal Finishing can spray parts the same as an operator can by manually spraying. System payback is in the production speed, repeatability, and labour. Hand spray of a dry film lubricant produced 65 parts per hour and a servo controlled two axis fixed gun spray machine produced 125 parts per hour. The Paint Mate 200iA system with only one gun can produce 250 parts per hour with a single spindle, but with a duel spindle load, it can produce 500 parts per hour. That is a 770 per cent production increase over hand spraying, and 400 per cent production increase over a servo controlled two axis fixed gun spray machine. The accuracy of the robot means that the system requires less masking fixtures versus a manual spray operation or servo controlled two axis fixed gun spray machine. Classic Metal Finishing expects a labour cost savings of 30-
50 per cent and a system ROI of three years. “The small premium far exceeds the benefits of part run flexibility and increased production with the Paint Mate 200iA versus a servo controlled two axis fixed gun spray machine,” says Morrison. Classic Metal Finishing discovered that the Paint Mate 200iA sprays the dry film lubricant faster than a human can load the part, so the robot process speed has now been slowed down for the operator to keep up. To speed up production, the company is eyeing a FANUC LR Mate 200iC robot with vision to handle loading and unloading dry film lubricant applied components from the 200iA two-position turn table to a chainon-edge conveyor system for final curing. “I would suggest the FANUC Robotics Paint Mate 200iA and Thierica Equipment Corp. to any company that wants to remain competitive in today’s global market,” adds Morrison. The company’s investment in automation will help it gain a competitive edge and secure future growth. Brent Lamarand is an engineer with FANUC Robotics America Inc., Detroit, MI. www.fanucrobotics.com www.classicturning.com www.thiequip.com
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Metal...works A Man With a View Job shop owner Al Rutke says Canada needs to rethink its economic policies
By Mary Scianna ................................................... Al Rutke, owner of Lasertek, a laser cutting job shop in Newmarket, ON, is a man of many words. Ask him about the state of manufacturing in Canada and the words—and opinions—spew out in rapid fire. “Manufacturing is the only wealth-producing sector of the economy and we’re moving towards a service-based economy and that’s not good. The [federal] government says we need more engineers but there’s no future in a bunch of engineers working on a project for a few months if the product they create is then manufactured somewhere outside of the country. The formula for Canada’s success is to design and engineer products here, patent them, build them here and export these unique products to the world; Don’t sell the rights to make a Canadian product around the world because then the money leaves the country.”
“Don’t sell the rights to make a
Canadian product around the world because then the money leaves the country.”
HST? “HST is a tax upon a tax. This tax is going to kill manufacturing. Thousands of tax payers will become net takers because so many people in manufacturing will be out of business…and business owners aren’t allowed to claim EI so people like me who are nearing retirement are going to have to retrain for a new career and who’s going to hire a 62-year-old with no experience? So what the hell were these stupid people thinking of when they came up with this HST?” Canada’s environmental initiatives, including the Ontario Government’s Green Energy Act? “The solar panels Dalton McGuinty is pushing only work for five hours a day; they’re the wrong types. You need the amorphous silicon solar panels that are made in layers and then assembled seven layers deep. As the intensity of the light diminishes, it still continues to put out half the power. And these silly wind mills are so inefficient that you have to have coal or gas-fired generators of the same capacity in the background because the power from wind mills fluctuates so much and that’s expensive, so winds mills, at least the
Al Rutke, beside one of his Mitsubishi lasers, is an Avro Arrow enthusiast. So much so that he found the Avro Arrow logo online and created a metal logo, seen on page 64, on his laser cutting machine.
www.canadianmetalworking.com | SEPTEMBER 2010 | 63
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horizontal ones being put up across the country, are not viable for putting into the grid.” He’s quick to point out he’s not against bettering the environment; he simply thinks the government isn’t pursuing the right technologies to make alternative energy sources a viable option. His case in point is vertical wind mills. He says the federal government should be pushing the use of these wind mills. “They start to generate power at 10 km/hour. These types of wind mills are much more efficient than horizontal ones and less dangerous. All of the roofs of buildings in downtown Toronto could be equipped with them. Imagine if you had a cylinder on every corner of each building that followed the height of the building and inside of this cylinder would be the wind mill. There would be an upfront cost and the cost of an engineer on site for maintenance, but businesses would be generating power at no cost.”
18
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Page 1
Born in London, ON, but raised in Markham, Rutke is not only a man with strong opinions, but a Avro Arrow aircraft aficionado who has a museum-like room in his shop dedicated to all things Avro. “I admire the Avro team because they developed a lot of aerospace concepts that are copied today, like the final outlay for an instrument panel on jet fighter planes. During difficult times I go into my Avro Arrow room and I think how the Avro team would have dealt with the problem I’m facing. It helps me to think in ways that I haven’t before to try to come up with a solution for a job.” He’s also been influenced by his dad. “My dad, who was an engineer and an inventor, used to say there are three ways of doing everything: the easy way, the hard way and the way you haven’t thought about yet. I try to follow that thinking, but it’s a hard act to follow sometimes.” While he initially wanted to be an engineer, circumstances changed his career path and lead him down many different paths, including working as a photographer and a courier. But it was laser technology that he found of most interest, so 13 years ago he opened his job shop to pursue a technology he describes as “fascinating.” Business has not been easy in the past several years and he’s frustrated with current government policies for manufacturing. He’s uncertain where his job shop business will be in a few years, but if he could get the ear of some government officials, there’d be no shortage of opinions he could offer to turn things around. CM
64 | SEPTEMBER 2010 | www.canadianmetalworking.com
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