Canadian Metalworking by Annex Business Media

April 2011 â&#x20AC;˘ www.canadianmetalworking.com

Aerospace TAKES OFF 30,900 new planes; a $3 trillion-plus global market over next two decades

MACHINE TOOLS Machining at University of Ottawa

CUTTING TOOLS A new turn for multi-tasking

FABRICATING Punching forces

WELDING Is ventilation enough?

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Inside this issue... Volume 106 | No.2 | April 2011 | www.canadianmetalworking.com

INDUSTRY REPORT

FABRICATING

AEROSPACE & DEFENCE

PUNCHING

AEROSPACE TAKES OFF .............. 18

PUNCHING FORCES.................59

30,900 new planes; a $3 trillion-plus global market over next two decades. AEROSPACE CASE STUDY

30,000 FEET HIGH .................... 22

When your components are flying 30,000 feet in the air you better have the right equipment for the job.

BUSINESS REPORT GREEN MANUFACTURING

DOLLARS & SENSE OF GREEN .... 25

Is green manufacturing a competitive tool?

MACHINE TOOLS MILLING

MACHINING RESEARCH............ 27

University of Ottawa’s machine shop pushes envelope on new machining centre.

CUTTING TOOLS

Servo electric drives are being hailed as better alternatives to hydraulics, but are they as good as proponents say? METALS

GLOBAL OUTLOOK ...................68

Metals sector optimistic about future according to the recent PricewaterhouseCooper’s annual global CEO survey.

WELDING FUME EXTRACTION

VENTILATION IS NOT ENOUGH ................................70 Airborne impurities may affect workers from a distance.

OVERPSRAY PAINT HANDLING EQUIPMENT

TOP TIPS ..................................73

TURNING

A NEW TURN ........................... 40 What you need to know when turning on multi-tasking machines.

Automating paint handling operations can cut costs, but is it right for your operation?

A FIRM GRIP.............................. 48 Faulty toolholding systems can wreak costly havoc on tooling and machining processes.

QUALITY

POWDER AUTOMATION

WHEN TO AUTOMATE ..............76

TOOLHOLDING

How do you know if it’s time to automate your powder operation? Powder coating consultant Pierre Bachand has a few pointers that may help.

DEPARTMENTS

CMMS

WHAT YOU NEED TO KNOW .... 55 Canadian Metalworking’s CMM expert and Metrology Matters blogger Bill Reilly offers insight on CMMs.

Upfront .......................................... 6 News ............................................ 8 Floor Space ................................. 15 Metal...Works .............................. 80

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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 Lillian Maksymyszyn 416-764-1690 | LMaksymyszyn@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....................................................................... GENERAL MANAGER, CORPORATE SALES Sandra Parente

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Upfront Blame Canada Once again, Canada’s productivity (or more accurately, lack of productivity), is in the spotlight. Many in the manufacturing sector, including Canadian Metalworking, have commented about Canada’s productivity lag when compared to other countries such as the US. The discussion has been ongoing for decades because productivity has been an issue for just as long. The most recent comments come from Scotia Capital economist Aron Gampel. Commenting in an online Globe and Mail article, he says Canadian productivity “should be a go-go, but still a no-go.” He cites the higher cost structure (labour costs) in the Canadian manufacturing sector as the top culprit. Others have cited multiple reasons to explain the ongoing productivity gap—the strengthening Canadian dollar, the growing emergence in North America of low-cost offshore competitors from emerging markets in Asia, and poor investment efforts in machinery and equipment and research and development. The government has attempted to address the gap through varied measures, to no avail. The productivity gap has continued to widen and some suggest realistically, Canada may never be able to close it. Last year, The Conference Board of Canada noted in its Forecast 2010, “Canada will have a difficult time trying to close the productivity gap with the United States. Evidence has shown that countries with lower levels of productivity not only have to grow faster to catch up, but they have to maintain faster growth for an extended period of time. “If US productivity grows by its 2008-2009 annual growth rate of 1.67 per cent over the next 15 years, for example, Canada’s productivity growth will have to be 3.22 per cent per year to eventually match the US productivity level. That’s a near-insurmountable four times Canada’s annual productivity growth rate between 2000 and 2008. Closing the productivity gap with the US is essential to closing the income gap, but Canada is going in the wrong direction.” How can Canada change direction? That’s a question many have attempted to answer, but so far, most of the measures—more investment in new machinery and equipment (think government extensions on the Accelerated Capital Cost Allowance), more investment in research and development and more efforts for training a more technically advanced workforce—have not appeared to work. If indeed these are the ways to improve productivity in Canada, why haven’t these measures worked? Why is it this country’s productivity has consistently lagged? As far back as the 1970s, labour productivity grew 1.4 per cent annually compared with the US average of 1.5 per cent. That’s not a huge difference, but US productivity growth has remained relatively stable in recent decades, while Canada’s growth has dropped 0.9 per cent per year on average, according to data from The Conference Board of Canada. What are your thoughts on productivity in Canada? Do you think something can be done to improve the productivity gap? Do you think the issue has been overblown by industry pundits? I would welcome your comments on the issue. MARY SCIANNA, EDITOR

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

6 | APRIL 2011 | www.canadianmetalworking.com

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News Joint machine tool distributor event returns to Ontario

For the sixth consecutive year, several machine tool distributors will join together for the largest open house of its kind on May 4 and 5. The Joint Open House has become somewhat of a tradition among Ontario manufacturers searching for machine tools. Six years ago, Ferro Technique, Elliott Matsuura Canada, EMEC Machine Tools and MAG decided to work cooperatively and host a joint open house for customers. The event was a hit with local area manufacturers. This year, machine tool distributor participants include three of the original companies—Ferro Technique, Mississauga, ON; Elliott Matsuura, Oakville, ON; and EMEC Machine Tools, Mississauga, ON—as well as DMG Canada and SSTCanada, both based in Mississauga, ON. Similar to last year, a total of more than 50 machines, ranging from standard three axis to multitasking, will be under power during the two day event. Brian Donnelly, vice president of Ferro Technique, says he and his colleagues expect to see 500 to 600 people this year. Last year approximately 350-400 manufacturers attended the event, but given the improving economic climate and the rising machine tool orders he and his colleagues are witnessing, “we should see more people this year.” Another reason why more people may attend this year is because of the distributors’ plan to offer bus service to and from the far eastern and far western parts of the province. “From the eastern end, we’ll likely have a bus that goes to Kingston with stops along the way back to the area and in the west, from Windsor, we’ll have stops in Chatham, London and Woodstock,” says Donnelly.

Mori Seiki, Ellison Technologies open new Canadian technical centre

Mori Seiki and its distributor Ellison Technologies will celebrate their Canadian partnership with the grand opening of their technical centre in Mississauga, ON, April 27 and 28. The event will be used for the Canadian debut of Mori Seiki’s NVX5080 vertical machining centre from the company’s new X-Class. Other machines on display will be the NMV5000

8 | APRIL 2011 | www.canadianmetalworking.com

DCG five axis vertical machining centre, the NT10000/SZM mill turn centre and the NL2500SY CNC lathe. As part of the two-day event, a lean automation cell will demonstrate how manufacturers can run unattended operation to increase machine utilizaton and machining capacity. Technical demonstrations will highlight new technologies for automotive and energy markets, and multi-tasking strategies. The new facility is located at 6497 Edwards Blvd. in Mississauga, L5T 2V2. For event details and registration, visit the event web site at www.ETGrandOpening.com or call 877765-1331.

New metals research lab

Canadian manufacturers involved in research and development now have a new resource for metal technology, a new metals research lab that opened its doors earlier this year in Hamilton, ON.

From left: Dr. Patrick Deane, president of McMaster; Christian Paradis, Minister of Natural Resources; David Sweet, MP, Ancaster-DundasFlamborough-Westdale; and Zach Douglas, president of McMaster Innovation Park.

The CANMET Materials Technology Laboratory (CANMEtMTL), which has relocated from Ottawa to Hamilton, is a $40-million, 145,000 sq ft lab that will operate under the federal government’s Natural Resources Canada department and conduct research into structured metals and alloys, materials design, pilot-scale processing and performance evaluation. The lab was relocated to Hamilton’s McMaster Innovation Park to be closer to the province’s manufacturing hub. “CANMET’s move to McMaster Innovation Park represents a huge boost for the region’s and country’s economic development and prosperity,” said Patrick Deane, president of McMaster University. “Its central location in the heart of the manufacturing sector, combined with its proximity to McMaster’s research facilities and expertise, has created a dynamic materials and manufacturing research cluster. Not only will this help to keep Canada’s industries competitive on the global scale, it will ensure that we attract and train the best students and researchers.” CANMET-MTL specializes in cast and wrought metals and alloys; metal matrix composites; powdered metals; coatings; and materials for durable infrastructures, all with an emphasis

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News on clean energy and sustainable development, and on transferring materials technology to Canadian companies. Among the projects will be the study and development of lighter, corrosion-resistant automotive vehicles and components, safer military equipment, and more durable pipelines and components for next generation nuclear reactors. The facility will be home to 110 federal employees, mostly scientists and technicians. The lab will also be a temporary home to another 20 visiting researchers. The federal government provided $40 million for the facility in its 2006 budget and allotted another $6 million a year for operational costs in its 2007 budget. With files from Canadian PLANT and Hamilton Spectator.

both industry and government.” While the prevalence of counterfeit parts in the supply chain is difficult to quantify, in fiscal 2009, the US Customs and Border Protection Service seized nearly US$4 million in counterfeit critical technology components, including networking equipment and semiconductor devices that the aerospace industry uses.

Event to give manufacturers leg up in marketplace Mazak Corp. Canada wants to give manufacturers a competitive edge and is holding a special event—Discover Mazak-Canada—to highlight the technologies and technical know-how that it takes to be successful in today’s market.

The event is slated for May 4 at Mazak Canada’s headquarters in Cambridge, ON. In addition to machine tool demos—including Mazak’s “Done-in-One” multi-tasking concept on various machines and five axis simultaneous machining—the event will feature keynote speaker presentations such as “How to do Business with Bombardier.” There will also be presentations on how manufacturers can take advantage of Ontario government grants and financial assistance for capital acquisitions and business expansion. To register for the event, visit Mazak Canada online at www. mazakcanada.com/dmcanada.

Aerospace industry says it’s concerned about counterfeit parts in new report

The volume of counterfeit parts in the supply chain is increasing, with potentially catastrophic consequences. “The use of counterfeit parts in the aerospace industry may have life or death consequences,” says Aerospace Industry Asociation (AIA) president and CEO Marion Blakey. “Reducing their proliferation and potentially harmful effects requires increased diligence and active control measures from 10 | APRIL 2011 | www.canadianmetalworking.com

A new report by the AIA “Counterfeit Parts: Increasing Awareness and Developing Countermeasures”, seeks to raise awareness of the issues associated with counterfeit parts. “Regardless of how counterfeit parts enter the aerospace and defense supply chain, the ramifications can be significant,” says Blakey. “They can jeopardize the performance, reliability and safety of our products.” While profit is the primary incentive for counterfeiting, the long lifecycle of aerospace products also contributes to conditions that make aerospace and defense equipment susceptible to counterfeiting. Aircraft developed in the 1950s, such as the B-52, are still in active inventory while parts from original equipment, component manufacturers or authorized aftermarket manufacturers or distributors may no longer be available. The report makes more than 20 recommendations for industry and government that encourage further discussion among stakeholders on how to most effectively reduce counterfeit parts in the supply chain. The recommendations were prepared by AIA’s Counterfeit Parts-Integrated Project Team and include: • Scrutinize the purchasing process to limit the use of automated systems, which increases the risk of counterfeit products. • Develop an Approved Suppliers list for use by government and industry. • Companies develop a counterfeit parts control plan that documents the processes used for avoidance, detection, risk mitigation, disposition and reporting of counterfeit parts. • Conduct training for employees in the areas of procurement, detection, reporting and disposition of counterfeit parts. • Create standards in the area of mechanical parts and materials. “Our industry makes the best aerospace products available

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News and has an unsurpassed safety record,” says Blakey. ”We feel the recommendations will allow industry and government to address the issue before it threatens that record.” The report is available on AIA’s website at: http://www. aia-aerospace.org/economics/reports_white_papers/?/issues_ policies/reports_white_papers/ Souce: PurchasingB2B online, a Canadian Metalworking sister publication.

Government coffers flowing: Election time?

A federal election has yet to be called, but if the recent slew of government funding announcements for the manufacturing sector are any indicator, we may be heading into a fall election. The majority of the funding announcements are for manufacturers in Quebec, an even stronger sign the government is trying to win votes in a province that has not had much love for the Conservative party in the past two decades. On March 21, the government announced more than $1.6 million in federal funding for two organizations: $915,000 for start-up bus manufacturer Autobus Lion Inc., Saint-Jerome, QC, to build a manufacturing plant; and another $731,250 for Aero Montreal, a public-private partnership think tank (founding member of the organization is Bombardier Inc.’s president and CEO Pierre Beaudoin) with a mission to boost Quebec’s aerospace sector’s competitiveness on the global market.

And in Rouyn-Noranda, QC, MBI Produits Dimantes Group, a manufacturer of large diameter drill stems for the diamond drilling sector, received $107,153 in repayable funding (through the government’s Community Adjustment Fund) for the acquisition of specialized equipment. Specifically, the company plans to purchase a digitally-controlled lathe to expand production. Soudure Saint-Gabriel, Saint-Gabriel-de-Brandon, QC, a manufacturer of steel dump bodies for trucks, plans to use its $198,000 repayable funds to expand its manufacturing plant with the purchase of new production equipment and the addition of a paint finishing operation. Abmast Inc., Saint-Hyacinthe, QC, a manufacturer of bonded grinding wheels for machining centres, received $400,000 (the company is investing an additional $1,160,000) to improve its production operation. It plans to automate its production of grinding wheels with the purchase of new automation machinery. In Saint-Claire, QC, Laforo Iron Foundry will soon be expanding its operation with the purchase of new equipment after it received $330,000 in repayable financial assistance through the federal government’s Business and Regional Growth program. Not all the funding announcements were for the Quebec manufacturing sector. Earlier this month, Manitoba’s manufacturing sector got a $5.9 million dollar boost when the federal government announced funding for Red River College, Winnipeg, MB, to expand testing facilities for the province’s aerospace, transportation and general manufacturing sectors. And in Belledune, NB, the government announced it would provide $1.5 million to the Port of Belledune to help fund the construction of a metal fabrication facility for producing and storing pre-assembled steel units. The new building will be equipped with 20 ton overhead cranes, welding equipment and other metal fabricating equipment. There are likely to be more federal government funding announcements in the coming months as the government continues to establish goodwill among voters in Canada’s manufacturing sector.

Exports spur growth: RBC Economic Outlook At press time, the federal government had announced it would be providing funding for another manufacturer, Produits Metalliques Bussieres, Saint-Henri, QC, a metalworking job shop profiled by Canadian Metalworking last year. Another big recipient of government funding is Technologie InovaWeld Inc., La Pocatiere, QC, a laser welding and laser cutting manufacturer of stainless steel and aluminum products. The company received $450,00 in repayable funding under the government’s Business and Regional Growth program to acquire new equipment. It received an additional $200,000 from Canada Economic Development through the Kamouraska Community Futures Development Corp. The company plans to expand into the aerospace, transportation and agri-food markets. 12 | APRIL 2011 | www.canadianmetalworking.com

In yet another sign the economic downturn is fully behind us, a new economic outlook report released today by RBC conomics says Canada’s economy finished the year with stronger than expected gains and will continue to grow through 2011 and 2012. The most significant gain came from net exports, which added 4.5 per cent to the 2010 fourth quarter gain. RBC says consumer spending also helped spur growth in GDP, “marking the fastest increase in spending since late 2007,” it notes in the report. RBC expects real GDP to increase 3.2 per cent in 2011 as US demand for Canadian exports increases. Growth in 2010 is forecast to rise by 3.1 per cent. “We expect net exports to continue to bolster economic growth in 2011 and 2012, as long as demand for motor vehicles and commodity-related

News products remains robust. These industries account for two thirds of Canadian goods sold abroad,” says Craig Wright, senior vice president and chief economist at RBC. He expects to see the Canadian dollar remain strong throughout 2011, due in part to a rise in commodity prices and adds that the strong dollar will “support Canadian businesses importing capital equipment to improve productivity growth.”

RBC Economics expects labour market conditions to remain firm in 2011 with disposable income expected to post a 4.1 per cent gain, providing support to consumer spending. “Consumers’ earlier confidence in taking on increasing amounts of debt was based on a combination of lower interest rates, a strengthening labour market and a 4.6 per cent rise in disposable income,” says Wright. “An expected slowing in the housing market, rising interest rates and tightening mortgage lending standards all add up to a leveling out in consumer debt relative to income.” RBC has remained optimistic on the US economy, projecting growth of 3.4 per cent in 2011 and 3.6 per cent in 2012. The expectations reflect the passage in that country of a tax cut package in December, continued labour market improvements, low interest rates and “tame underlying inflation (when measured in consumer prices).” For a complete copy of the report visit RBC’s web site at www.rbc.com.

Japan crisis: Special online report

The earthquake and subsequent tsunami that hit Japan on March 11 devastated parts of the country, but most Japanese suppliers to the North American metalworking industry were fortunate and experienced few production disruptions. Many of the world’s major machine tool builders—Mazak, Makino, Matsuura, Mitsui Seiki, Mori Seiki and Okuma—and some cutting suppliers—Mitsubishi Materials, Sumitomo Electric Carbide and Tungaloy—have corporate headquarters and production facilities in Japan. Canadian Metalworking Online contacted many of these suppliers to learn what impact the crisis was having on suppliers and the long term effects. Read our story online at www.canadianmetalworking.com to find out more details.

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www.canadianmetalworking.com | APRIL 2011 | 13

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News Floor Space Have you ever used email to send a quote to a potential customer or do you always phone? “I only use email to send potential customers quotations as this allows both parties to have something to refer to.”

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

“We email 90 per cent of our quotes to our clients. We sometimes call to see if there are any questions from the 10 per cent of our clients who don’t use email.”

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

“Quotes are prepared for “potential” customers using our internal E2 Shop System and sent to them via email. However, our practice is to make a personal connection with a potential customer and discuss their needs to ensure that we fully understand their requirements and expectations. Like all business transactions, there is an element of relationship building that requires personal contact. The quote is always negotiable.” -Ron Marks, president, Techtronics Machine Works Ltd., Musquodoboit Harbour, Nova Scotia

“We always use email.”

-Jason Bannerman, president, Xakt Komponents, Brampton, ON

“Most our quotes are done by email, but if it’s a potential new customer, we always phone first to make sure we understand the requirements, chat them up, etc.”

-Soren Holm, president, Soren Holm Inc., Mississauga, ON

“We try to use different avenues. What we used to send by fax, today we send roughly 50 per cent fax, 50 per cent emails. Some customers prefer emails, while others still want fax. Nothing beats face-to-face discussion when possible.”

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

“Most of our quotations are by email with the occasional fax.”

-Peter Alden, co-owner, Wessex Precision Machining Ltd., Ayr, ON

“About 80 per cent of our quotes are sent to us via email then followed up with CAD sent via FTP or email but almost all of the time quotes are sent to customers via email. Only once every so often, a customer requests to have us send the quote with the good old fax machine. As paper is easily lost and is difficult to track, not to mention killing trees, most of our clients prefer the email method. No quotes are sent by phone unless it is an “unofficial” estimate.”

-Adriano Oppio, vice president, Classic Tool & Die, Oldcastle, ON

“We predominantly use email to quote. It is a quick and easy way to get the information to your customer. A follow-up phone call is made to ensure that the customer has received the quote and then we answer any questions he/she may have. We have found it to be very effective.”

-Debbie Blowe, systems manager, Vibra Finish, Mississauga, ON

“We only use email. Most people send us a drawing [via email] ... we reply back to that same address with pricing and delivery. This way we have the quote in writing and the customer has time to review. This works very well for us and our customers seem to be very comfortable with it as well.”

-Larry Stuyt, president, Ontario Laser Cutting, Tillsonburg, ON

“Always email,”

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

“Email is our primary method of delivering significant quotes. We do quote a lot of small stuff over the phone. The emailed quotes are usually followed up one to two days later with a phone call.”

-David Foscarini, president, Mecon Industries Ltd., Scarborough, ON

www.canadianmetalworking.com | APRIL 2011 | 15

News Calendar APRIL 14-15 TRUMPF INTECH North America 2011 laser technology event in Farmington, CT. www.us.trumpf.com

MAY 4 Discover Mazak-Canada technology event at Cambridge, ON, headquarters. www.mazakcanada.com

MAY 17-19 EASTEC 2011 Eastern States Exposition, West Springfield, MA. www.easteconline.com

APRIL 27 & 28 Mori Seiki and Ellison Technologies Canadian facility grand opening in Mississauga, ON. www.ETGrandopening.com

MAY 17 & 18 Westway Machinery open house in Mississauga, ON. www.westwaymachinery.com

MAY 17-19 Plant Maintenance & Design Engineering Show in Montreal, QC. www.sme.org

People Steve Mackay has been appointed service manager at Mazak Corp. Canada, Cambridge, ON. He has an extensive background in the machine tool industry and responsibilities in previous positions have included service, installation and project management. He will be responsible for overseeing machine installations, all warranty and non-warranty machine repair, and managing Mazak Canada’s service personnel and contractors.

Daniel Medrea is the new national sales manager for DMG Canada Inc., Mississauga, ON. He returns to the company after a three-year stint as sales manager for the Ontario division for A.W. Miller, Mississauga, ON, a Mazak distributor. Prior to his time with A.W. Miller, he spent eight years with DMG Canada and served as product manager with involvement in the sales process.

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INDUSTRY REPORT

AEROSPACE & DEFENCE

Aerospace takes off

30,900 new planes; a $3 trillion-plus global market over next two decades By Nate Hendley .................................................................................................................................................. In mid-February 2011, officials from the Aerospace Industries Association of Canada (AIAC) and various aviation firms went on a seven-city, cross-country tour. The assorted group met with the media and local boards of trade and economic development in each city they hit in the first-of-itskind campaign. “Our objective is to inform Canadians about our industry. We need to do a better job letting Canadians know that [aerospace] is an industry that’s good for the whole country,” says Maryse Harvey, vice president public affairs at the Ottawa-based AIAC, which represents some 400 firms. Touring aerospace officials also hope to impart a message of hope about their sector. “The future looks bright,” insists Harvey. Two reports—an industry overview by New York-based Deloitte and Touche, and Chicago-based aerospace giant 18 | April 2011 | www.canadianmetalworking.com

Boeing’s annual market forecast—echo this view. Both acknowledge the recent recession has wrecked havoc with the industry (global passenger air travel declined two per cent in 2009, says Boeing). The same reports, however, paint a rosy future, with dramatic increases in air travel, plane orders and aerospace revenues. As commissioned by the AIAC, the Deloitte and Touche study, entitled The Strategic and Economic Impact of the Canadian Aerospace Industry, was released October 2010. The report puts Canadian aerospace revenues at $22.2 billion in 2009 (last year for which numbers are available) and employment at 78,965 people. This represents a decline from 2008 when revenues were $23.6 billion and employment stood at 83,000. Deloitte and Touche predicts a quick turnaround, however, and forecast revenues of $24.1 billion with employment at 82,956 in 2010.

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INDUSTRY REPORT

AEROSPACE & DEFENCE

Aerospace consists of two separate sectors—civil and The JSF program is a multi-country, multi-decade initiative military. Canada’s aerospace industry leans heavily towards led by the US to build state-of-the-art F-35 Lightning II fighter the former. In 2009, some 83.4 per cent of Canadian aerospace aircraft. The program has a total value of US$383 billion based revenue came from civil markets with only 16.6 per cent on a projected run of more than 5,000 planes. Since Ottawa coming from military. In addition to being primarily civilsigned onto the initiative in 1997, over 65 Canadian companies based, the aerospace sector is export-driven—77.9 per cent of have won $350 million worth of JSF work. revenues in 2009 were derived from foreign sales. Our biggest This revenue, says Harvey, only represents the first phase aerospace customer is the US, which purchased $9.9 billion in of the JSF program. Once the program goes into high gear in Canadian aerospace parts, products and services in 2009. the near future, contracts for Canadian firms “will become Because our industry is so export-focused, the health of bigger,” she states. Canada’s aerospace sector depends greatly on the fortunes Asco Aerospace Canada, the Delta, BC-based Canadian of international aviation giants such as Boeing and Airbus. branch of a Belgian firm, picked up a JSF contract with Fortunately orders have increased at both firms. Lockheed Martin (the main company making the F-35) in July Boeing reported 530 net orders for new planes in 2010 2010. Asco will be manufacturing large complex titanium parts up from 142 in 2009. Despite the uptick, this is still far from for Lockheed in a seven-year deal worth US$25 million. Boeing’s recent record of 1,413 net orders in 2007. Airbus July 2010 also marked Ottawa’s decision to expand from (which is headquartered in France and controlled by parent JSF supplier to customer with the purchase of 65 F-35 planes. company European Aeronautic Defence and Space Co.) Delivery on the $9 billion contract has been pencilled in for reported 574 net orders for 2010, an improvement from 2009 2016. The F-35s are supposed to replace aging CF-18 fighters. when 271 net orders were reported but nowhere near the While the AIAC didn’t lobby for the deal, the association recent peak of 1,341 net orders in 2007. hopes to convince Ottawa to “maximize Canadian content on Several domestic firms and Canadian branches of US the aircraft” now that an order has been placed, says Harvey. companies serve as suppliers to Boeing including Honeywell, The purchase of 65 F-35s did not go without controversy. Messier-Dowty, Thales, Magellan and Goodrich. Canadian The Liberals, for example, criticized aspects of the decision— Airbus suppliers include Honeywell, Goodrich, Messier-Dowty something that makes Harvey uneasy. and Magellan. “We say the political debate Passenger air travel and new plane orders are closely linked around the decision is creating to the state of the economy, says Harvey—an observation uncertainty and investors seconded in the Deloitte and Touche report. According to the don’t like uncertainty,” latter, a one per cent rise in a country’s GDP leads to a one she states. per cent increase in air passenger travel in developed nations and a 2.5 increase in developing countries. The International Monetary Fund (IMF), meanwhile, “expects global GDP to increase by 4.6 per cent in 2010 and 4.3 per cent in 2011,” states the report. Boeing’s Current Market Outlook 2010 – 2029, the latest in an annual series of industry forecasts, takes a similarly upbeat view. Boeing forecasts that international air travel will rise six per cent in 2010 and continue growing annually at the same pace through to 2014. More air travel means more plane orders. To this end, Boeing’s outlook report predicts there will be demand for 30,900 new planes valued at $3.59 trillion over the next two decades. The Asia Pacific region will lead this demand, with orders for 10,320 new planes. By contrast, Boeing predicts there will be demand for 7,200 new planes in North America, 7,190 planes in Europe, 2,340 planes in the Middle East, 2,180 planes in Latin America, 960 planes in the Commonwealth of Independent States (CIS, the successor to the USSR) and 710 planes in Africa. Of the 30,900 new planes, 21,160 will be single aisle. There will also be Our biggest aerospace customer is the US, which orders for 720 large planes, 7,100 twin purchased $9.9 billion in Canadian aerospace aisle and 1,920 regional jets. In addition to an improving parts, products and services in 2009. economy, a pair of government initiatives—the Joint Strike Fighter (JSF) program and the Strategic Aerospace and Defence Initiative (SADI)—have also contributed to the AIAC’s positive outlook.

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20 | April 2011 | www.canadianmetalworking.com

AEROSPACE & DEFENCE

While JSF is an international effort, SADI is a Canadian government program, launched April 2, 2007 with the aim of pumping funds into aerospace, defence, space and security R&D. In December 2010, Longueuil, QC-headquartered aerospace giant Pratt &Whitney Canada (a division of the US parent firm) announced it was investing $1 billion for R&D on new aircraft engines. Some $300 million of this investment came in the form of a repayable SADI loan. Industry Minister Tony Clement said Pratt & Whitney’s initiative had the potential to create thousands of jobs over the next few years. Pratt & Whitney’s research will focus on reducing fuel consumption, emissions and noise in engines for business and regional jets and helicopters. The drive for more fuel efficient, environmentally friendly aircraft technologies is part of a “key technological trend” in the sector, notes the Deloitte and Touche report. Other aerospace firms have also landed sizeable contracts in recent months. Montreal-based Bombardier announced a US $446 million deal in December 2010, with SpiceJet, an Indian company. SpiceJet ordered 15 Q400 NextGen turboprop planes and optioned an additional 15. Should SpiceJet convert the options to firm orders, the deal would rocket up to US $915 million in value. In February 2011, meanwhile, Bombardier penned a deal worth $175 million with Quebec firm Heroux Devtek to make structural components for airplanes. CAE, a Montreal company that makes aircraft flight simulators, announced in January 2011 it had landed a recent series of contracts worth a total of $140 million to provide flight simulator and training technology to militaries in 12 countries. It’s this kind of bustle that prompted a highly favourable conclusion from Deloitte and Touche. Canada “has the potential to double aerospace employment by 2020,” states the report. Such optimism is also apparent on the shop floor, among companies that service the aerospace sector. These firms include A-Line Precision Tool of Toronto where 80 per cent of the workload is aerospace-related, says

INDUSTRY REPORT

company president Rob Muru. A-Line makes “engine parts for supersonic platforms, engine parts for future development engines, radar invisible engine parts, helicopter gear parts, submarine search equipment on helicopter platforms, etc.,” says Muru. A-Line’s website (http://www.a-linetool.com) describes the firm as “a proud supplier of critical components for the world’s most advanced [jet] fighters and weapons systems.” To highlight this commitment, the site contains pictures of Chinook military helicopters, the F-117 Nighthawk fighter and the JSF F-35. Muru frets about competition from offshore locales: “You are on drugs if you are not concerned about competition from offshore,” he states. That said, he’s anticipating more aerospace work in the near future. John Saksun Jr., president of Queensway Machine Products (QMP) in Toronto says much the same. Founded in 1952, the shop has 45 machine operators and roughly half of its business is in aerospace. It manufactures structural aluminum, steel and titanium parts, primarily for tier two aerospace companies. Saksun Jr. says the aerospace part of his business “has been a bit in neutral in the last couple years ... I believe that it is starting to engage and we are doing more than in the past ... I do believe that we will get more as things pick up, maybe in the next six months.” CM Nate Hendley is a regular contributor and freelance writer based in Toronto.

www.canadianmetalworking.com | April 2011 | 21

INDUSTRY REPORT

AEROSPACE CASE STUDY

30,000 ft High When your machined components are flying 30,000 feet in the air you better have the right equipment for the job

Most components machined in shops around the world call for reliability in the end product, but few demand the absolute confidence of performance as those produced for the aerospace industry. Nowhere is this better understood than at Mesotec Inc., a manufacturer of precision aircraft components based in Sherbrooke, QC. The company, that counts Bombardier Aerospace and other leading aerospace OEMS among its customer base, will take in an estimated $15 million in sales this year. Alec van Zuiden, Mesotec’s president and CEO, commands the helm of the company with a management strength forged through years of practical experience and tempered with a proactive philosophy toward resource optimization. The first phase in optimization according to Van Zuiden involves the employees. “It comes down to empowerment,” he says. “Let the people do what they have been hired to do. This is difficult for a lot of managers. People tend to set up little structures around themselves for self-insulation while still making it easy for them to look over everyone’s shoulder and micromanage. You have to make sure they have the proper training for the job and then show them you have confidence in their performance. We have more than a hundred people working here. It’s important that I make it a place where they can grow to meet their personal objectives as well as my corporate objectives, and then we have a winning team environment.” The second phase in Van Zuiden’s optimization involves the equipment in the hands of Mesotec’s trained and experienced employees to produce the company’s output of precision components. Raw materials coming into the 32,000 sq ft plant are first marked for traceability, an important step for the aircraft industry. Materials then travel either to machining cells dedicated to a particular customer’s parts, or to machines set up to handle specific operations, such as bore milling large components, plunge or wire electrical discharge machining tools and fixtures, or grinding round engine-related parts. The accuracy of parts is verified using a wide range of inspection devices, including two computerized coordinate measuring machines.

THE PRODUCTION OPERATION

To keep up with the aircraft industry’s demand for tighter tolerances on many of the machined components’ dimensions, Mesotec purchased a jig boring machine in August 2009, the 6CN-II jig borer from Mitsui Seiki USA, Franklin Lakes, NJ, an approximate $900,000 investment. In addition to the jig borer, the company operates a turning manufacturing cell—which is now a Centre of Excellence for the 22 | APRIL 2011 | www.canadianmetalworking.com

This landing gear part has two holes bored to 0.0005 in. diameter and to within 0.001 in. in line of each other on the Mitsui Seiki jig borer.

AEROSPACE CASE STUDY

Alec van Zuiden, Mesotec’s president and CEO: “It’s a global market now and we have been weak in North America, but we are fast picking up the ball.”

production of seal runners for Pratt & Whitney—and includes three and four axis Mori Seiki lathes and a cylindrical grinder. Another cell, used primarily for tooling and development work, includes four, three axis Hurco milling machines. Van Zuiden says the company is looking to add a fifth Hurco machine in this cell. At the time of publication, the company was in the process of installing two additional cells, one dedicated to the production of aircraft engine parts which will include three, four and five axis milling machines, and the second will be for large (two meters long) structural parts on five axis machining centres. “We have many of the machines in place, but we’ll probably be purchasing more equipment,” says Van Zuiden. “We have a budget with a capital expenditure of $1.8 million; that’s what we expect to spend on machinery.” When asked about the new jig borer’s capabilities, Daniel Rheaume, Mesotec’s technical sales manager, referring to one of the parts currently being processed on the machine, says “that part is one of a pair of matching components that hold the landing gear in place on a commercial aircraft. They come in to us as right and left-hand 70-series aluminum forgings. We do most of the rough and finish machining of the contours and surfaces on a five axis machining center. Then we send them out for shot peening.” Many of the machining processes required for producing aerospace components can result in tensile stress that can lead to part cracking or stress corrosion, reducing component life. In shot peening, spherical particles of one of several

industry report

media are blasted at the surface of the component, which creates a continuous layer of compressive stress. This replaces the tensile stress and prevents fatigue stress and stress corrosion from starting. “After shot peening,” explains Rheaume, “we bring them back in-house and put them on the Mitsui Seiki for boring two critical in-line holes. The required tolerance on the drawing is very close, one thousandth of an inch, but we give ourselves even closer tolerance, five ‘tenths,’ to make it easier for us at assembly. The relationship of the two holes to each other requires three thousandths in-line tolerance, but we keep it to within one thousandth so we don’t have to worry about re-machining the bushings when the part gets to assembly.” After the landing gear components are jig bored on the Mitsui Seiki jig borer, they are sent out to be anodized, primed and top coated. Once back at Mesotec, the bushings are installed and the part is inspected to ensure accuracy conformance. “Since that part holds the landing gear, maintaining precision while machining is very important,” says Rheaume. Another pair of parts set up on the Mitsui Seiki are large 70-series aluminum forgings, each 30 in. by 48 in., (762 mm x 1, 219 mm) that will constitute two sides of the assembly that hold the front landing gear on a business aircraft. Again, the part is first machined, contours and surfaces, on a five axis machining centre, shot peened and then put on the Mitsui Seiki to have two holes bored. Tolerances are held to 0.001 in. diameter and 0.002 in. true position. It is important that the holes align perfectly for the landing gear shaft that passes through them. “The new jig borer has become an important piece of equipment for us,” says Reaume. “Before we had it, we might have gone back and forth between a machining center or grinder and a coordinate measuring machine two or three times to make sure the part was good. On the Mitsui Seiki, the part is good the first time, every time. That’s a great advantage of the jig borer on production parts. On some parts where we have to machine multiple holes or slots, as many as 20 or 30 at a time, going back and forth between the machine tool and the CMM is extremely time consuming.

Holes on this landing gear component are machined to within .002 in. true position of each other on the company’s new precision jig borer for perfect shaft alignment in final assembly.

www.canadianmetalworking.com | April 2011 | 23

industry report

AEROSPACE CASE STUDY

two arc seconds of straightness achieved in all axes. Mitsui Seiki measures ballscrews for “drunkenness,” which is the theoretical path versus the actual ball path. This helps eliminate deviation that could cause wear that results in negative positioning characteristics over time. The machine is also equipped with a patented bearing lubrication system for spindles. The machine has a work surface of 50 in. x 38 in. (1,270 mm x 965 mm) with X, Y, Z and W travels of 40 in. x 30 in. x 11.81 in. x 29.5 in. (1.016 mm x 300 mm x 749 mm). It can precision bore holes up to 11.8 in. (299 mm) diameter, drill holes up to 2.36 in. (60 mm) diameter and handle face mill cutting diameters up to 5.9 in. (149.9 mm) Top: Mesotec’s technical sales manager, Daniel Rheaume (right), discusses programming features for aerospace component set up for machining on the Mitsui Seiki jig borer.

Below and across: A wide view and a close up of the machine in action.

When we got the jig borer, we said, ‘let’s try those parts on here.’ Since then, every part has come out right on spec with only one inspection at the end to confirm tolerances. It’s what happens when the tools you work with have much greater accuracies than the part accuracies you need to achieve.” A look at the anatomy of the 6CN-II machine itself bears out Rheaume’s accuracy-in, accuracy-out contention. Mitsui Seiki uses a gas emulsion process for controlling material composition of the beds and major components, creating a thermally-stable platform for machining critical parts. Rather than simple, integral castings, the ways are made of tool steels, hardened and ground to minimize wear. Hand-scraped way mounting surfaces allow the fitting of components by hand to meet specific geometric tolerances, with less than 24 | April 2011 | www.canadianmetalworking.com

Van Zuiden’s third phase of resource optimization— and the reason for being in business in the first place—is customers. “It is critical that we understand who the customer is and what the customer’s needs are. Many customers have quality programs designed for suppliers like us to follow. It takes a lot of hard work for a supplier to meet the quality standards they set forth. It does not matter whether we are dealing with aerospace or any other industry, people expect the highest quality from us. We like to think we’re a notch above everyone else in who we are and what we do, but the reality is we have to be that good in the eyes of our customers.” Van Zuiden has a positive outlook for the aerospace sector and is confident manufacturers serving OEMs can compete, but they need to take the right steps to be competitive against offshore manufacturers. “It’s a global market now and we have been weak in North America but we are fast picking up the ball. We have proven with Pratt & Whitney that we’re able to manufacture critical parts cost effectively, with respect to the Asian market. But it takes investment [in machinery] and planning and that’s what businesses need to do.” CM

GREEN MANUFACTURING

Business Report

Dollars and Sense of Green Companies are rethinking green as a competitive tool

By Tim Wilson ...................................................................................................................................................... The manufacturing sector is showing signs of rebound. And unlike in past recessions, where ecological concerns took a back seat, modern enterprises are reinventing themselves with a close eye to energy efficiency and environmental responsibility. But as with any smart business, manufacturers need to assess the cost-return benefit of going green. The good news: people get it. “I have been involved in green manufacturing for over ten years, and I don’t have to sell it anymore,” says John Patten, director of Western Michigan University’s (WMU’s) Manufacturing Research Center. “As late as 2005 I had to explain what I meant by green manufacturing; now the awareness is there and I don’t have that stumbling block.” The result of this increased awareness is that manufacturers are quick to engage in a value-based discussion, both with regard to brand promotion and the return on investment (ROI) that comes from green initiatives. They are also, from a purely practical perspective, responding to demand within the supply chain. “We have to look at the suppliers as well,” says Bret Lussow, business development manager at Harrington Hoists in Manheim, PA, which has Kitco Canada as a sister company. “Some of our large customers like General Electric need us to be RoHS compliant.” RoHS, which stands for Restriction of Hazardous Substances, is a European Union directive on the restriction of the use of certain hazardous substances in electrical and electronic equipment. Harrington Hoist’s Manheim plant, located 60 miles west of

Philadelphia, meets the RoHS requirements. “Companies like GE are looking for sales opportunities in green energy,” adds Lussow. “As a result, for us to have a green focus ties in to what they are trying to do.” The challenge is that “green” can be poorly defined – as can the costs associated with the switch to a green manufacturing philosophy. This is where third party certification can come in handy. “RoHS functions something like an ISO standard,” says Lussow. “You want to work with other companies that can provide RoHS compliant components, and that isn’t necessarily cheaper.” But it isn’t prohibitively expensive, either. The company’s head office, Kito Corporation in Tokyo, Japan, reports that RoHS compliance ends up costing about 0.5-1 per cent of sales. Specific to the supply chain, Kito estimates that RoHS compliant components might be1 to 1.5 per cent more expensive. However, though RoHS has a clear focus on environmentally hazardous materials such as heavy metals, it doesn’t address the energy side of the equation, which is where manufacturers can find savings.

The whole picture

“Our focus is 50 per cent environment, and 50 per cent energy,” says Patten from WMU. “We try to play both those cards in terms of opportunities in the manufacturing space.” That blended approach covers off the main areas of environmental concern, while also allowing for a larger view from a cost www.canadianmetalworking.com | april 2011 | 25

Business Report

GREEN MANUFACTURING

perspective. If going green on the materials side costs a per cent or two, but greater savings can be found on the energy side of the equation, then management can argue for the ROI of a comprehensive approach to a truly green manufacturing strategy. “No one size fits all,” says Patten. “Every plant we walk into for a conversion or assessment is unique. You need to have all your eyes and ears open.” Patten is interested in addressing environmental concerns in complex manufacturing environments, providing lean assessments and waste and materials reduction—larger manufacturers in particular have issues with waste powder paints and mixed polymers. To help out, Patten can provide an economic analysis to any of the companies he works with. The results can come in either simple, immediate payback, or something longer term. Usually the manufacturer itself will suggest a threshold.

“ The rule of thumb is for payback on energy at five years.”

“Typically they are looking at 25 to 30 per cent ROI in a two to three year payback period,” says Patten. “We put together a package that reflects a synergy between multiple solutions and projects.” Individual examples can be presented with ROI attached, with the manufacturer targeting areas that can be packaged together and tackled as one single, larger project. Often, the combined effect reveals savings that are not evident when issues are looked at in isolation.

Going green for the long haul

The two to three year threshold mentioned by Patten represents a definite advantage that manufacturing has over many other industries: its tendency to think and plan over the medium to long term. “Manufacturers know that investments made today will help them manage volatility in the future,” says Darin Stahl, lead research analyst at Info-Tech Research in London, ON. “They are also more directly sensitive to the cost of power and materials, and this is typically where you will see more activity from a greening perspective.” 26 | April 2011 | www.canadianmetalworking.com

But after the more obvious approaches are taken—the hoses have been checked, the recycling programs ramped up, and the HVAC systems put through an assessment and refresh—it may be time to think of a complete overhaul. “It can make sense simply to tear the plant down,” says Patten. “Sometimes being astute means steering people away from preconceived ideas that don’t make sense in the bigger picture.” From a facilities perspective, the Leadership in Energy & Environmental Design (LEED) green building certification system is gaining traction in industrial environments, and becoming a de facto standard for greenfields construction. “The LEED system looks at how the building interacts with the site, with water and energy resources, with the materials and their impact,” says Braden Kurczak, division head for green buildings at Enermodal Engineering in Kitchener, ON. “It also looks at how the building functions, such as ventilation, and from the construction side of things it addresses the systems that deal with maintenance and operational issues.” LEED is based on what is called value engineering, which looks at a standard energy model to assess the embodied components in a building, whether steel or concrete. But when quantifying environmental practices, it’s the money that speaks. “It is hard to express what a ton of C02 is,” says Kurczak. “But if I say spend X dollars here, and save Y dollars there, people get it.” When it comes to having a LEED-certified manufacturing plant, the ROI really depends on the starting point. However, the rule of thumb is for payback on energy at five years. “Some owners will entertain only three years,” cautions Kurczak, “yet others are willing to consider timeframes that extend seven or nine years.” For those who want to make a quick buck, or who are going green only for the marketing splash, the value and benefit will be lost, but for those manufacturers who are engaged and interested there is real opportunity. And there is a growing economy supplying to LEED requirements, just as with RoHS. “It can be hard to quantify ROI with LEED,” says Patten from WMU. “But there is a market for manufacturers to supply for LEED requirements, just as General Motors is incorporating green materials into their products.” The argument for going green then becomes not only about the rationale for changing internal processes, but about participating in a whole new green value chain. Multinational companies like Kito, for example, are active in Canada and looking beyond RoHS to REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) certification, a strict European Union Regulation for regulating chemical substances. “There are costs associated with this,” says Stahl from Info-Tech. “Fortunately, capital is cheap now in Canada, which means green investments can position manufacturers for ‘hockey stick’ growth.” As the culture of green certification grows over the next decade, with Canadian manufacturers well positioned to benefit from expansion of a more environmentally responsible economy, the return on investment in going green is easier to argue than ever before. “We will need to maintain the product performance by finding substitutes with the equivalent quality,” says Lussow, “as well as minimizing the cost rises as much as possible to avoid increasing the price of the product. But it will be worth it in the long run.” CM Tim Wilson is a freelance writer based in Peterborough, ON.

MILLING MACHINES/CASE STUDY

Machine tools

Machining Research University of Ottawa machine shop pushes envelope on new machining centre By Nate Hendley When staff from the University of Ottawa machine shop went high speed spindle capable of 10,000 RPM, heavy duty linear rails looking for a new vertical machining centre a few years back, in all three axis, flood coolant assembly and an automatic central they had some important considerations in mind. The main lubrication system. The X, Y, Z axis travel on the VM10 are 26 x consideration was space. The Ottawa shop (which facilitates 16 x 20 (660 mm x 406 mm 508 mm), giving the VM1 Beaudoin research at the university) didn’t have a lot of it, so any machine purchased X, Y, Z travel axes of 26 x 14 x 18 in. (660 mm x 355 mm tool they bought had to be small. x 457 mm). The VM1/VM10’s table size is 30 in. x 14 in. (762 mm x At the 2008 Canadian Manufacturing Technology Show 355 mm) and can take a maximum table weight of 750 lb (350 kg). (CMTS) in Toronto representatives from the Ottawa shop were “Being an R and D shop, we use [the VM1] mainly to fabricate drawn to a Hurco Canada booth and to that company’s VM1 or make modifications to new or existing research projects ... machining centre. Machine shop officials were impressed by the most of our project demands are from researchers, and enginVM1’s diminutive footprint and conversational WinMax control. eers,” explains Beaudoin. “When we visited the tool show ... there was some compariExtreme precision rather than super-fast productivity is the sons [with other vertical machining centres] in terms of mechanshop’s main goal, he adds. ics, but in terms of control, the WinMax was better, easier “Our first mandate is to support teaching and to work with, more efficient. It had more capacity research laboratories for the Faculty of Sciences— and memory space,” recalls University of Ottawa departments like chemistry, biology, physics, earth machine shop supervisor Herve Beaudoin. sciences, math, etc. We also interact with all other In March 2008, a Hurco VM1 was installed faculties and departments, such as medicine, at the University of Ottawa machine shop. human kinetics, animal care, engineering, physical Installation took only one day (“My guys resources, to name a few,” says Beaudoin. are pretty efficient,” notes Joe Poulin, sales The somewhat crowded machine shop now and operations manager for Hurco Canada, boasts six machine tools, including a Hardinge Mississauga, ON). Bridgeport three axis knee mill and a Haas lathe Once the machine was in place, Hurco TL1 with turret. The shop also has a welding offered a day-and-a-half of training, in both facility with spot welders and plasma cutters. French and English. The VM1 has been involved in some intriguing Beaudoin describes training as “really projects, such as fabricating parts for a “skate helpful.” He also gives Hurco props for postlauncher” which was used by a laboratory run The Hurco V1/V10 model in the installation support. by the Faculty of Health Sciences School of University of Ottawa’s machine shop. “Service is good. If you’re stuck or have a quesHuman Kinetics. The lab in question conducts tion, [Hurco] technicians call you back quickly to tests on sports equipment by Reebok, Nike, and get you going,” he states. CCM, among others, to evaluate the effectiveness of protective The VM1 is no longer available from Hurco. A series athletic gear in preventing injuries. of upgrades have transformed the VM1 into the current Best things Beaudoin likes about the Hurco machine: “Small VM10 model. footprint, reasonable price ... and the [WinMax] control is According to Poulin, the tech specs of the VM1 are almost absolutely great.”

“Now we can produce parts faster, more precisely and effectively.” identical to the VM10. “There are two inches less travel in the Z and Y axis ... all else is the same,” he explains. As it stands, the VM1/VM10 has a very small footprint, 70.9 in. x 62.5 in. (1,800 mm x 1,587 mm), and large work envelope measuring 26 in. x 16 in. by 20 in. (660 mm x 406 mm 508 mm). It weighs 6,200 lb (2,812 kg) is servo-driven and comes with a 20-station automatic swing-tool changer, a 15 hp spindle motor, a

Asked if there are any research projects that his shop can perform now with the VM1 that they couldn’t before and Beaudoin says no. “We’ve always managed to do all the work needed but now we can produce [parts] faster, more precisely and effectively. When it comes to moulding, it is day and night.” CM Nate Hendley is a freelance writer based in Toronto, ON. www.canadianmetalworking.com | April 2011 | 27

Machine tools

MILLING MACHINES/CASE STUDY

PRODUCT REPORT AgieCharmilles

The Mikron HSM 500 from GF AgieCharmilles is a vertical machining centre that provides three axis high speed milling in a compact design. Capable of machining cubic workpieces up to 200 kg, the machine is equipped with an HSK-E40 tool interface and a vector-controlled motor spindle for short run-up and brake times and high torques at low speed. Ceramic hybrid ball bearings, a liquid cooled stator jacket and bearings ensure high speed spindle output of 13 kW at 42,000 rmp with more than 4.2 Nm torque.

The machine’s base is made of monobloc polymer concrete with high vibration dampening properties, providing strength and rigidity in high speed machining. The single casting construction also improves machining accuracy, producing better thermal stability for excellent workpiece surface quality and minimal tool wear. Additionally, the HSM 500 is fitted with absolute optical linear scales on the X, Y and Z axes that operate with a measuring step of .02 µm to guarantee positioning precision. User-friendly features include Smart Machining Modules, which operate sensors that allow machinists to utilize the Advanced Process System (APS) for monitoring and recording spindle vibrations. The machine is equipped with an iTNC 530 Heidenhain control system. www.gfac.com/us

DMG

The DMU 85 monoBlock is a new generation five axis milling machine with SK50/HSK-A100 standard interfaces. Similar to its sister machine, the DMU 65

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monoBlock launched last year, the new generation machine features flexible expansion options, from three to five axis machines with a swivel rotary table, and covers all aspects of milling technology, from roughing to finishing. Key to the machine is its small footprint, 11.6 m2 (124.9 sq ft) allowing the machine to be used in small shops. The three axis version can accommodate workpieces up to 1,200 mm (47 in.) long, weighing 2000 kg

MILLING MACHINES/CASE STUDY

(4,409 lb). The five axis machine supports a 1,040 mm (41 in.) diameter and a workpiece weight of up to 1,500 kg (3,307 lb). Travel distances are 850 mm (33 in.) in X and Y axes, and 650 mm (26 in.) in Z axis. In conjunction with its SK50/HSK-A100 toolholder, the DMU 85 monoBlock is the only machine in its class that supports heavy machining with 288 Nm/44 kW. Other features include a fast swivel rotary table and a tool changer with 30, 60, or 90 tool positions, located at the front of the machine to enable the operator to work in a normal machining environment at all times. The machine features a flexible design, which means it integrates turning and milling technology, allows for the option of using the company’s Ultrasonic for ultrasound-driven machining of hard/brittle materials, or for using DMG’s Lasertec Shape, for milling and laser processing in one machine. www.dmg.com

Doosan Infracore

Doosan Infracore’s DNM 400A is vertical machining centre designed for high productivity

with precision tolerances, and built to fit the most crowded shop floors, all at a price below US $70,000.

The one-piece casting is ribbed to prevent distortion during heavy or interrupted cuts. Fine grain Meehanite is selected for its superior dampening characteristics and ability to dissipate heat. Widely spaced linear guideways give excellent support to the saddle in all locations, regardless of the table’s load distribution. Each guideway is

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induction hardened and precision ground. Rapid traverses are 1181 ipm along all three axes. Powering the DNM 400A is a 15 hp spindle motor that drives ISO#40 taper tools at speeds up to 8,000 rpm, while delivering 52 ft. lb of torque. The cartridge-type spindle is supported by precision class, permanentlylubricated bearings. A heavy duty drive belt eliminates slippage, reduces vibration, and contributes to thermal stability. A 20 station, double-arm ATC changes tools in a quick 1.3 seconds. The Big Plus dual-contact tooling system creates full contact along the spindle taper and the toolholder flange. This assures maximum rigidity for greater precision and longer tool life. Both Big Plus and standard toolholders can be mounted at any ATC station with no need for special adaptors. The 86.7 in. (2,202 mm) x 87.2 in. (2215 mm) footprint is perfect for buildings with standard 8 ft ( m) x 8 ft ( m) doors. Maximum part size is 25.0 in. (635 mm) x 17.1 in. (434 mm) x 20.1 in. (510 mm) and 881 lb (400 kg).

360º SUPPORT IS A PARTNERSHIP THAT WORKS FOR YOU. North America’s most trusted machine technology partners bring superior service, application support and product selection to Canada Ellison Technologies and Mori Seiki: A powerhouse combination of superior product selection and machining expertise. A proven model in the United States, Canadian customers can now reap the beneﬁts of one of the most dependable, accessible and knowledgeable service and application support networks in the industry. It’s just one aspect of Mori Seiki’s 360° Support—total customer care from a global leader in advanced machine tool technology.

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Machine tools

MILLING MACHINES/CASE STUDY

PRODUCT REPORT Additional features of the DNM 400A include rigid tapping capability, an auger-type chip conveyor, cooling and lubrication systems, a program and data protection key switch, and a portable manual pulse generator with movement in increments of x1, x10, and x100 to make fixture or part alignments quick and easy. The colour controller is a Fanuc Oi-MD. www.infracoreemt.com

Feeler

The Feeler HV series vertical machining centres available in North America from Methods Machine Tools Inc. are designed for high speed machining with circularity accuracy of 2.7 Âľm. The machines use a finite element analyzed, honeycomb ribbed cast column, which Methods say offers superior torsional torque resistance and superior low frequency resonance stability. The Z axis is driven by a direct servo-motor and uses a nocounterbalance design, eliminating chain vibration for high quality surface finishes. The machine is equipped with roller guideways on the X and Y axes and has 1G x axis acceleration. A 15,000 rpm, 30 hp direct drive neo spindle provides speed

and power required for high efficiency machining. Tool change time is 1.8 sec, tool to tool. The machines are equipped with a Fanuc 18i-MB control and AI Nano CC with 189 block look ahead. The series includes the HV-800 with an X/Y/Z work cube of 31. 5 in. x 20.5 in. x 19.9 in. (800 mm x 520 mm x 505 mm) and the HV-1000, with an X/Y/Z work cube of 39.4 in. x 20.5 in. x 19.9 in. (1001 mm x 520 mm x 505 mm). www.methodsmachine.com

Haas

Haas has redesigned its VF product line to create a new generation of vertical machining centres. Launched last year, the new machines use next generation digital servo motors and high resolution encoders on all axes. Software and motor control advancements result in higher accelerations and better surface finish performances. Enclosures are redesigned to prevent chip and coolant egress during machining. Redesigned chip pans and coolant flow reduce chip buildup and flush chips more efficiently into the auger trough for removal. For high volume production, the VF-1 through to the VF-6 models 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 machine faster and easier than in previous models. Windows and doors on the machine are stiffer, move more smoothly and close tightly. And the new thin design control pendant mounts directly to the enclosure, providing what the company claims is a lighter, more stable operator interface than with previous models. There is also a storage compartment behind the pendant. www.haascnc.com

Hardinge

Hardingeâ&#x20AC;&#x2122;s newest version of its Bridgeport GX-1000 40 in. x 21 in. (1,016 mm x 533 mm) vertical machining centre is equipped with the Okuma OSP-P200 control, drives, motors and encoders. The OSP-200 is an open architecture Windows based CNC control enabling users to take advantage of industry standard and off-the-shelf plug and play devices by using the onboard Ethernet or USB slots. Its open architecture means almost any software can be installed. This series VMCs include a stiff and thermally stable spindle, a rigid C-frame fixed column design, and fixed pre-tensioned double-nut ball screws on all axes. The unique Bridgeport designed linear guide and guide truck configuration provides added stiffness, damping and surface contact area. The unit is configured with three guideways and five guide trucks 30 | April 2011 | www.canadianmetalworking.com

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One Small Step With one small step, a man became a hero and the impossible became a reality. The same heroic spirit that fueled the space race and placed the ﬁrst man on the moon still lives within the people who support NASA’s continued pursuit of innovation. Using GF AgieCharmilles HPM 800U machines, NASA experts manufacture the technology that continues to propel science beyond what we think possible. From that ﬁrst lunar landing to modern space exploration, the heroes behind these accomplishments take small steps every day that amount to giant leaps for mankind. Read more about how GF AgieCharmilles helps NASA achieve more at us.gfac.com/hero.

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

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Machine tools

MILLING MACHINES/CASE STUDY

PRODUCT REPORT on both the X and Y axis; two guideways and six guide trucks on the Z axis. The VMCs are equipped with a powerful spindle motor for aggressive cutting capabilities. A 15kW (20-hp 1min) spindle drive is included on GX 480 and GX 710 machines; GX 600 and GX 1000 machines feature a 15-kW (20-hp) drive; GX 1300 and GX 1600 machines feature an 18.5-kW (25-hp) drive. The rigid spindle design includes four angular contact bearings at the front and one roller bearing at the rear for optimum performance and long life. The non-contact magnetic encoder design eliminates noise and vibration, while providing more accurate spindle orientation feedback. www.hardingeus.com

Kitamura

Kitamura Machinery’s latest high speed seven axis simultaneous horizontal machining centre Mycube has the ability to machine multiple surfaces in one clamping, reducing part set-ups and cycle times. The clamping system allows for the machining of the back side of

the part, offering the user single operation, complete six sided machining. The two sided clamp mechanism rotates and swings the part during machining, eliminating surface contact, stroke limitations, and the necessity for changes in set-up, increasing overall accuracy of the part. By combining X,Y and Z linear axes and direct drive A,B,C rotary axes with a W axis (spindle movement in/out), the Mycube offers a high speed angled approach to small and medium sized parts, increasing flexibility while decreasing the necessity for

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special fixtures in changing set-ups. It comes standard with a #40 taper, 20,000 rpm, energy efficient built in spindle. The solid box way construction combined with hand scraping techniques ensures True Geometric Accuracy and long-term reliability. It features 1969 ipm rapids on the X, Y, Z axis, 787 ipm on the W axis and 33.3 rpm on the B axis for six-sided machining of complex parts for the aerospace, medical and semiconductor markets. The Mycube comes standard with a Kitamura-Fanuc 300iMA control. www.kitamura-machinery.com

Long Chang Machinery

The First LC-185VS-B vertical milling machine, distributed in Canada through Heinman Machinery Ltd., is an affordably priced machine designed for long lasting performance. Long Chang Machinery has been manufacturing the First brand of milling machines in Taiwan for more than 50 years and received ISO 9001 certification in 2002. These milling machines already meet PHSR Pre-Start Health and Safety review requirements. Features on the machine include a rigid head tilting system, a Z axis box way design for heavy duty work, rapid up and down, Meehanite casting structure and hardened and ground Turcite-B coated ways. The R8 spindle unit is made from one piece of Ni-Cr alloy steel and is supported by two precision angular contacts and one ball bearing to ensure rigidity. The spindle is driven by a 3 hp motor. The inner taper has been hardened and precision grounded. An ISA40 spindle taper with a 5 hp motor is also available. The X, Y and Z axes travels are: 31 in. (790 mm), 16.3 in. (415 mm) and 15.3 in. (390 mm). The machine offers a working surface of 50 in. x 10 in. (1270 mm x 254 mm) with a maximum table load of 440 lb (200 kg). Standard components include one shot lubrication, variable speed head, a set of eight R8 German collets, and a Heidenhain two axis readout installed. www.heinmanmachinery.com

MILLING MACHINES/CASE STUDY

MAG IAS

MAG’s new U5-3000 Universal Machining Centre combines massive platform capacity with long-reach three meter Z axis and five axis, five side contour machining for efficient processing of large aluminum and composite parts. The newest addition to the U5 family of gantry mills, the U5-3000 is engineered to machine at extreme limits and into deep cavities of large prismatic parts. Combined with Y axis travel of over 6 m (20 ft), unlimited X axis travel, and high speed, 15,000rpm, five axis spindle, the new machine brings never-before-possible machining efficiencies to extremely tall, wide and long parts.

A modular, heavy duty gantry design delivers the stiffness, range and performance to machine complex part geometries with exceptional accuracy. A rigid boxway roller bearing rail system and dual motor rack and pinion X axis drive provide smooth precise movement and high thrust levels on long travel cuts. Feedrates up to 20 m/min (787 ipm) optimize processing efficiencies on large part surfaces. It comes standard with a 15,000 rpm, 30 kW (40.2 hp), HSK63A gimbal-style contouring spindle that delivers up to 57 Nm (42 lb-ft) torque for high speed, high throughput cutting performance. As options, 20,000 rpm and 24,000 rpm five axis spindles are available. The five axis head features continuous C axis to keep the spindle in-cut without running out of C axis travel or waiting for C axis to unwind. A rigid Z axis ram with 508 mm (20 in.) cross section provides high rigidity for superior precision and surface finish, especially with longer tools and extended Z axis reach. Flood and through-spindle coolant keep cutting zones clear, with automatic chip and coolant collection systems available. www.mag-ias.com

Machine tools

provides unparalleled productivity and reliability for a machine of this type, which helps customers reduce costs from their manufacturing operations. It has a quick tool-to-tool time of only 1.7 seconds, with a similarly brisk chip-to-chip time of 4.2 seconds. The integral drive spindle

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Makino

Makino’s a81M horizontal machining centre is designed for machining tough and hard materials. It is ideally suited for large diameter boring and face milling on such challenging materials as stainless steel, titanium, titanium alloys, inconel, ductile iron, cast iron and CGI (compacted graphite iron). The high torque and high thrust spindle

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MILLING MACHINES/CASE STUDY

PRODUCT REPORT outperforms all other spindles on the market, claims the company, due to the nature of its efficient design, which provides significantly higher torque at a low rpm. Other high torque spindles utilize a geared-type head. Such a design causes a loss of significant power that further drops spindle efficiency, slows down the

spindle performance and adversely affects cycle times. The built-in motor method provides an advantage against vibration as compared with the gear-type. The spindle has no corresponding loss of acceleration and deceleration. The quick acc/dec ranges are from 4.4 seconds to 3.8 seconds at 8,000 rpm. To match that

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torque, the spindle employs 50 hp from 2,000 to 5,000 rpm. The a81M has X, Y and Z axis of 35.4 x 31.5 x 40.1 in. (900 x 800 x 1,020 mm). It has a rapid feed rate and cutting feed rate of 1,420 ipm (36 m/min) in X and Z axis and a 1,182 ipm (30 m/min) in Y axis. It has a 25 in. pallet (630 mm) able to handle workloads of up to 10, 800 pounds (4,900 kg). The thrust capacity has 25 per cent more axes thrust than the previous a81 machine. The centre trough hinged conveyor provides for fast and effective chip evacuation. www.makino.com

Matsuura

Matsuura Machinery Corp., represented in Canada by Elliott Matsuura Canada, has developed a new five axis vertical machining centre with user friendly and safe concepts. The MX520 in its compact form assures high rigidity as well as a generous machining envelope with operability. The MX520 can hold workpieces with sizes up to 20.47 in.

• Special-accuracy • Extruded stock • Overgrip pickoff • Short gripping • Stepped gripping • ID gripping • Non-marking • Pushback • Tool clearance • Synchronization • Part ejectors • Small diameter feed (520 mm) in diameter and 13.77 in. (350 mm) in height. A 12,000 rpm spindle speed is standard and a 20,000 rpm spindle is available as an option. The machine’s functions are controlled by a user friendly Fanuc GTech 31i CNC. www.elliottmachinery.com

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Mazak

Mazak’s j-400 represents the company’s commitment to providing a full range of multitasking solutions. The Integrex j-series contains multiple models and falls in the middle of the spectrum of Mazak’s multi-tasking machines. It performs four axis simultaneous machining with five axis tool tip positioning, providing significant advantages in productivity, accuracy and flexibility. Unlike multi-tasking machines with a drum

MILLING MACHINES/CASE STUDY

turret type, this machine accommodates 20 tools in a tool magazine (36 and 72 tool optional) and increases versatility in part production. The machine’s main turning spindle offers a maximum speed of 3,300 rpm. It also includes a powerful 30 hp, 12,000 rpm milling spindle that can be indexed in 5º (or optional 1º) increments from –30º to 210º (B axis control), making it possible to perform outer diameter machining, as well as turning, facing, grooving and threading with the same flash tool. It also makes it possible to perform incline machining and all other conventional machining processes. Additionally, the milling spindle can be radially indexed and clamped, enabling the same tool to be used for turning in both forward and reverse directions. While compact, the machine offers a maximum machining diameter and length of 19.7 in. (500 mm) with minimum tool interference for large workpieces. Its long axis strokes allow face milling, end milling and drilling to be performed above and below the centerline without C axis indexing. In

addition, the true Y axis design allows for a larger machine envelope and tool reach, reduced interference and excellent chip evacuation when compared to conventional machines.

Machine tools

increases vibration dampening to extend tool life, handle higher load capacities, accelerate and decelerate quicker to shorten cycle times, consume less oil for “greener” operations, and last longer with less required maintenance. Programming of multiple surfaces is easy with Mazak’s Matrix Nexus CNC Control. The control allows for both conversational and EIA/ISO programming, and ensures easy programming for C axis, Y axis and angle machining. www.mazakcanada.com

Mitsui Seiki With a high rigidity construction and new high response servo motors, the j-400 delivers a positioning repeatability of tool tips that is better than 0.00004 in. (0.001 mm), and Double Ball Bar testing that is within 0.0003 in. (0.0007 mm) The new Mazak MX Hybrid Roller Guide System is integrated into the machine and

Mitsui Seiki’s new HU100 series is the first range of configurable machining centres aimed at a variety of manufacturing industries interested in versatile equipment for heavier applications. Configurable machines are those that are based on a set of standard modular components that can be arranged to suit specific customers’ needs easily and affordably. Mitsui Seiki’s approach to providing

www.canadianmetalworking.com | April 2011 | 35

Machine tools

MILLING MACHINES/CASE STUDY

PRODUCT REPORT customers with a technical solution has just become easier. For example, users can choose axis travels from 1300 mm to 2500 mm, four, five, or six axes of continuous motion with a choice of a rotary table, trunnion table, or table on table. There’s also a variety of spindle choices, including fixed spindles from 6000 rpm (50 hp, 2000 ft./lb torque) for heavy milling up to 25,000 rpm for high speed applications. Tilt or swivel spindle choices are available from 6000 rpm (800 ft./lb torque) for heavy milling up to 12,000 rpm for high speed machining. Mitsui Seiki also offers quill type spindles for precision boring with shorter tools.

The HU100 series is ideal for larger aerospace and power generation parts with a work zone capacity of up to 2500 mm dia. x 2000 mm height. The machines accommodate weights from 4400 lb (2000 kg) to 17,500 lb (8000 kg). These machines can be equipped with simple pallet changers to fully integrated FMS systems for work and raw material handling. Likewise, tool handling systems range from on-board magazines to central systems for more than 2500 tools. Launched earlier this year, the HU100 line is already one of Mitsui Seiki’s most popular products, and has been sold to industries as diverse as aerospace, refrigeration compressor, mould and die, heavy equipment, and energy. All of these industries have fundamental common requirements: machine rigidity/stiffness and high accuracy. www.mitsuiseiki.com

Mori Seiki

Mori Seiki’s NHX4000 is a new series of next generation standard machines in the company’s new X-Class family of machine tools. It features extended stroke and tool length (450 mm/17.7 in.) compared to 36 | April 2011 | www.canadianmetalworking.com

conventional machines #40 taper spindles and also features increased feed rate (0-60,000 mm/min or 2,362 ipm), accelerations and B axis speeds with reduced downtimes. The newly designed machine features X, Y and Z travels of 560 mm (22 in.)/560 mm (22 in.)/660 mm (26 in.) respectively. The machine achieves high rigidity and stable machining by using a thick, high rigidity bed with the X and Z axis linear guides placed in a high position, and by incorporating a spindle with a large diameter bearing, as well as a table and pallets with powerful clamping forces. The machine features an energy saving design. While a hydraulic unit pump used in the conventional model rotates all the time to maintain pressure, the pump used in the NHX series can be stopped during standby because an accumulator is attached to the hydraulic unit.

32-position ATC. Thermal deformation is minimized with Okuma’s TAS-C/TAS-S compensation system. The M460-VE features the operator-friendly THINC-OSP control, a true PC, Windowsbased platform with open architecture, plug and work USB capability and 40GB of memory. This unique control makes it easy to connect to peripheral equipment and utilize other machine tool accessories, improving productivity and data gathering. http://oac.okuma.com/m460ve

Stama

Also the number of motors in the machines has been reduced. The machine can achieve approximately 40 per cent reduction in total power consumption compared to the conventional model. www.moriseiki.com

Okuma

Okuma’s Genos M460-VE CNC vertical machining centre features a powerful double column structure to deliver the most machining in the least floor space, according to the company. A versatile, yet compact machining centre that is extremely rigid, in a ready-to-run package. Total travel measures 30 in. (762 mm) in X axis, 18.11 in. (460 mm) in Y axis and 18.11 in. ( 460 in) Z axis with a rapid traverse rate of 1574 ipm. Standard features include a high power 40 taper 12,000 rpm spindle with a 30/25 hp VAC liquid cooled integral motor and a

The new MC 833/MT Twin five axis milling-turning centre from Stama America is designed with the company’s “Stama PEPS (Performance Efficiency Per Square Meter) concept to delivery high performance on a minimal amount of space. The machine is designed for complete machining of cast blanks, cut-offs, or semifinished goods with diameters up to 350 mm and lengths of up to 250 mm. The machine features integrated automation; the loading portal is equipped with a tool grabber integrated into the centre and no crane loading for workpiece handling is required. A large tool magazine has a short chip-to-chip time outside of the chip and coolant area. Depending on the machining job, the 120° milling-turning centre integrates one or two turning spindles. All pivots have bearings on both sides, and a 4th axis with torque technology is designed for high precision and positioning security. www.stama.com

Heinman Machinery Ltd.

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Heinman Machinery Ltd.

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First Milling Machine LC-1 1/2VS Table 42”x9” R8, 2HP Mills equipped with: German Collet Set Heidenhain 2-Axis Readout

LC-185VS-B R8, 3HP LC-185VSX-B ISA40, 5HP Table 50”x10” Rapid up & down Z-Axis box way

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SUPERIOR FINISH LC-20VHS Vertical/Horizontal LC-20VSG Vertical Table 51”x10” ISA40, 5HP Rapid up and down Gear box long table feed

Chevalier Handfeed Surface Grinders Grinders that will last for years ACCU-618SP Super Precision FSG-618M Includes: 6”x18” Walker Neo Micro magnetic chuck

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Forthworth Bed Type Mills CS-VBM-5VHL Vertical & Horizontal CS-VBM-5VL Vertical Table 86.5”x20” Metric ball screws Pneumatic clamping AC servo motor CS-VBM-4V Vertical Table 74.5”x17.5” Metric ball screws Spindle head feed 2-Axis feed

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CUTTING TOOLS

TURNING

A New TURN on Multi-tasking Multi-tasking machines present unique challenges for turning tools By Tim Wilson Getting the right cut is always important, and no less so for a turning application within a multi-tasking machining centre. Yet these machines present unique cutting tool challenges for turning. “There has been a lot of attention given to milling in turning centres, but turning on machining centres is innovative,” says Chuck Birkle, vice president, sales and marketing for Mazak Corp., Florence, KY (Mazak Canada is based in Cambridge, ON). Mazak has a range of machining centres, with four having particular applicability to turning: the Integrex i-150 (a high speed, small footprint multi-tasking machine); the Variaxis 630-5X II T (a five axis machine that Birkle says is “the gold standard in machining centres”); the Integrex e-Ramtec (for large cylindrical workpieces); and the Integrex 1-630V (machining harder materials).

THE RIGHT TOOL SYSTEM

The advantage of turning in a multi-tasking centre is that processes are more efficient, reducing production times. However, cutting tools designed for turning within these machines have to be compatible with the technology. Often this means working with quickchange tooling systems that aren’t fully automated. One example is Coromant Capto from Sandvik Coromant, which some studies have shown is the strongest quick change system on the market. “Coromant Capto has a unique shape at the connection,” says Dave Andrews, product manager for threading, turning, parting, and grooving at Sandvik Coromant Canada. “It’s self-locking, a tapered polygon, with lobes that don’t allow the coupling to twist. It also has face contact on the flange, so it is a very strong connection.” Switching from a conventional shank to the Capto quick change system means that new cutting heads can be swapped out in less than 30 seconds—a much shorter cycle interruption than would be required when changing inside the machine. Repeatability is within two microns, with the Capto “sister tool” approach keeping a machine running longer than would an insert index. This is a big help, because when 40 | APRIL 2011 | www.canadianmetalworking.com

Mazak’s Integrex i-150 turn-mill centre is a new generation multi-tasking machine. Centre image: Walter’s NFT geometry in its Sky-tec family of turning tools for cutting titanium.

turning in machining centres, the key to success from a tooling perspective is flexibility. “You can adapt in different ways,” adds Randy McEachern, product specialist for toolholding and holemaking products at Sandvik Coromant. “Machines with the correct flange holder can adapt to Coromant Capto, and any one of our toolholders can go on the end of that.” From there, extensions can make a tool longer by putting a male Capto on one end, and a female on the other to build out the assembly and also reduce the adaptor size. “This offers total control over the length and size of the assembly,” says McEachern. “For internal machining we have an anti-vibration product that can deliver to twelve times the length to diameter on a boring bar, with Capto as the interface.”

BEYOND ISO INSERTS

For general turning applications ISO inserts function as an international standard. Iscar, which provides a full range of carbide inserts, is one company trying to look at ways of advancing tool applicability for turning in multi-axis machining centres. “We want to look at how to enhance ISO,” says Steve

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Some things never change Yes things may look a little different today but fundamentally the message then is every bit as relevant today. With close to 70 years experience, we have a long history of helping companies to maximize productivity and profitability. This is not something that is about to change. Whether it be new machine investments, training, solving a bottle neck in your production, increasing productivity, setting up electronic ordering or streamlining how you handle inventory we are ready to work with you throughout your entire manufacturing process. With all this (and inflation of course) you will discover your savings will add up a little bit more.

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.

CUTTING TOOLS

TURNING

is “easily possible.” The only risk? If you increase the speeds in the machining centre too aggressively you might throw a part, and downtime in a multi-tasking machine can be expensive. “The newer machines change everything you do,” says Graham. “You have to be conscious of the set-up, because a long, slender shaft with greater depth of cut may require cutting back on spindle speed due to vibration.” The balancing act has to allow for the fact that when turning in a machining centre the tool will have a heat band that it has to cut within. By applying the right cooling approach, higher cutting speeds are an option without compromise to tool life and chip control. In fact, it then makes low cost, unmanned production a real possibility. CM Inner diameter turning on a Mazak multi-tasking machine.

Geisel, senior product manager at Iscar in Toronto. “Our CNMX and DMNX lines are ISO inserts on steroids.” These inserts are designed especially for machining stainless steel and high temperature alloys, with cutting force reduced due to helical cutting edges and positive rake angles. “They can run at a much larger depth of cut and greater spindle speeds,” says Geisel. “It’s often a race between us and the machine supplier, but the end result is the best tools on the best machines.”

Kennametal’s Beyond Blast, which made its debut at IMTS 2010, delivers coolant to the point of contact of the insert.

One example is Iscar’s Heliturn LD (for “lay down”), a helical cutting edge with high metal removal rates. This is an advance in turning, but the process itself would not necessarily be any faster if integrated with a multi-axis machine. “When it comes to turning, you will still have the same general speeds and feeds as a standard machine,” says 42 | APRIL 2011 | www.canadianmetalworking.com

Tim Wilson is a regular contributor and freelance writer based in Peterborough, ON. Geisel. “But the advantage with a multiaxis machine is the upper and lower turrets—one can be rough turning and the other can be drilling the hole and threading, even finishing behind the first turret.”

STAYING COOL

To get the most out of a turning application within a multi-tasking machine, however, the revolution may be more relevant to coolants than inserts. As cutting methods have improved, heat control has remained a major challenge. “We have Jetstream Tooling, which I consider a revolutionary new coolant system,” says Don Graham, a manager at Seco Tools, Troy, MI. Graham says Jetstream Tooling can deliver coolant to the optimum position close to the cutting edge, thus lifting the chip away from the rake face and improving chip control and tool life. Working within a machining centre, Jetstream can remove heat quickly from the cutting zone, and cool chips rapidly. “We used to see 100 psi to 200 psi, but Jetstream can deliver from 300 psi to 1,000 psi,” says Graham. “The implications for this high pressure coolant on turning is very dramatic. I’ve been in this business for thirty years, and this system is the most revolutionary since the advent of coatings.” The result is increased cutting speeds for all materials, from hard Inconels at 50 per cent faster, to aluminium at 30 per cent, which Graham says

www.iscar.ca www.mazakcanada.com www.coromant.sandvik.com/ca www.secotools.com

PRODUCT REPORT Ingersoll

CNMX and SNMX turning inserts with HB chipbreaker are designed to deliver low cutting forces and better surface finish in medium to rough machining, compared to equivalent CNMG/SNMG inserts. Offering performance comparable to single-sided CNMM and SNMM inserts, the unique seating configuration of the Gold Duty inserts provides the advantage of double-sided insert economy.

The HB chipbreaker provides steady chip evacuation and prolonged tool life with a stable seating configuration. Four rest pads on the top and bottom sides of the insert allow the cutting edge of the insert to be raised above the top surface, resulting in lower cutting forces and excellent chip flow even at large depths of cut. www.ingersollcuttingtools.com

Four Brands. One Mission... To ensure success in all of your aerospace milling applications. For over half a century, we have been known worldwide for high performance, made-in-USA cutting tools. Our products are supported by the most skilled and experienced applications engineers in the industry. We are second to none in the manufacture of a complete selection of high-speed steel, cobalt, powdered metal and solid carbide end mills for machining aluminum, steel, stainless, titanium, and exotic alloys. We have the right stuffâ&#x20AC;Ś.

800-522-8665 www.brubakertool.com

800-447-1476 www.dataflute.com

800-682-8832 www.fastcut.com

800-622-7742 www.weldontool.com

CUTTING TOOLS

TURNING

PRODUCT REPORT Iscar

Iscar has improved its line of Cut-Grip and Heli-Grip groove-turn tools with a new CVD coated substrate that doubles tool life while raising productivity by 15 per cent, claims the company. The cutting tools perform especially well on steel, but also handle other materials effectively.

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

Kennametal

Kennametal has introduced the first Beyond inserts for Kennametal’s FixPerfect system, promising improved toughness and wear resistance, resulting in higher turning productivity and safety. The FixPerfect system features a proprietary shaped pocket that, together with a clamping stud, locking pin, and tangentially mounted precision ground insert, result in high clamping forces and very low cutting forces for excellent chip control and improved process stability. The inserts are shaped to match the pocket, which protects unused cutting edges. Productivity improves as well because the pin simply needs to be loosened, not removed, to index the insert. The inserts feature micro-polished edges that improve edge toughness, proprietary post-coat treatment that reduces depth-of-cut 44 | APRIL 2011 | www.canadianmetalworking.com

notching, and a fine-grained alumina layer that enhances coating integrity at higher cutting speeds.

“There are five new Beyond grades for FixPerfect with either two, four, or eight cutting edges, depending on your application and needs,” says Alexander Momm, global product manager, turning products. “With a variety of geometries, lead angles, and rake angles to choose from, metalworking companies can achieve improved chip control and process stability in roughing, medium machining, or finishing tasks, while adding the long tool life and increased performance Beyond provides.” www.kennametal.com

A specially designed adjustment key with integral Bluetooth interface is also part of the system. The display unit and the adjustment key can be used for every MicroKom BluFlex precision adjustment head. This reduces costs when investing in several precision adjustment heads. Another benefit is the ability to use common batteries that can be easily changed in all components, as well as the option to use batteries in the display unit and adjustment key. The adjustment head also offers improved performance to the integrated balance compensation. It allows greater rotational speeds that are achievable due to the separate display. The modular Komet ABS interface makes adaptation to different machine spindles much easier. Instead of using two different connection variants (ABS or shank connection on the tool side), in the future there will only be one design with a universal tool interface that is suitable for clamping both. www.komet.com

Sandvik Coromant

Sandvik Coromant’s new ISO S insert program, which features more than 300 inserts, boosts turning of heat resistant super alloys and titanium. According to the company, the inserts come with easy-tochoose guidelines for every machining operation.

Komet

By introducing Bluetooth to the Komet MicroKom BluFlex tool system, tool developers at Komet have separated the display from the tool head making it more convenient to read off the data in a greater variety of ways. When adjusting the precision adjustment head, the user can attach the external display unit in any position within his field of view. The larger numbers and illumination of the display also make it easier to read off the settings. Used for turning HRSA and titanium alloys for roughing to finishing through continuous to interrupted cuts, these new geometries ensure easy optimization, improved productivity, first rate process security and surface quality demands. The six different geometries are designed to handle depths of cuts from 0.2 to 10 mm with great chip control and low tool pressure. Four geometries are for moderate to small depths of cuts in light roughing

Passion.

Potential. Perfection.

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Milling steel or cast iron? Increase output up to 75%!

Our passion. Your potential. They drive us to create the perfect tool for every application. Call us with your toughest challenge. 800 945 5554 www.walter-tools.com/us

• Extremely stable cutting edge • Extremely smooth rake face • Easy wear detection thanks

to Tiger·tec® Silver indicator coating

The machining age is over. It’s time to Tiger.

CUTTING TOOLS

TURNING

PRODUCT REPORT to finishing applications. Two stronger geometries are for larger depths of cut in roughing or light roughing. www.coromant.sandvik.com/ca

Sumitomo

The Super FF coating (Fine and Flat) on Sumitomo’s new grades AC820P and

AC830P is not only more wear resistant than conventional coatings, it also reduces the possibility of chip adhesion due to its smoothness. Combined with newly developed carbide substrates, the AC800P series offers higher speed capabilities and a greater resistance to breakage than conventional carbide grades when machining steels and stainless steels. The AC820P excels in general purpose machining and is available in a wide variety of chipbreakers, including the new high efficiency EGE. For interrupted applications, the AC830P is the first choice among P30 grades. Its exceptional toughness can sustain more impacts than conventional P30 grades. www.sumicarbide.com

Walter

Walter recognizes the ever increasing importance of titanium materials in the aerospace, medical, and other precision component industries. To tackle this challenge, Walter Valenite has introduced three new geometries in the Sky·tec family to make turning titanium alloys (e.g. Ti6Al4V

| APRIL 20111| www.canadianmetalworking.com 46schunk.indd

and others) more cost effective and more reliable than ever. Customer results have yielded tool life improvements of more than 150 per cent, claims the company. The Sky·tec program has an optimized combination of substrate, coating and geometry working together to minimize crater wear and provide excellent chip control. The three geometries include NFT, finishing for high accuracy at high cutting speeds, available in periphery ground or as-sintered versions; NMT, medium machining with low cutting forces due to the curved cutting edge

7/29/10 2:22:24 PM

TURNING

(effectively handles unstable components and internal machining; available with assintered periphery); and NRT, for roughing featuring rigid geometry for high metal removal rates, as sintered periphery. The inserts are available in the C, D, S and V styles with negative edge geometry. Two cutting tool grades are available: The uncoated grade WS10, and the PVD aluminum oxide coating (“PVD-Tiger”) WSM20. For the majority of applications, the uncoated WS10 is the first choice for machining titanium alloys. For CNMG (80° corner angle) inserts in the NFT geometry, Walter offers a special feature: the 80° corner has the NFT finishing geometry, and the 100-degree corner has the NRT roughing geometry. Essentially the user has the added benefit of two inserts in one, thereby further reducing tooling costs. www.walter-tools.com/us

Widia

New high performance Widia Victory turning grades, part of the new Victory

platform of advanced turning, milling, and holemaking tools, are delivering higher productivity results, including improved surface finishes and longer tool life, for steel and cast-iron applications, says the company. The benefits are lower manufacturing costs for users.

The Victory TN7100 series is a new range of coated-carbide inserts engineered for finishing, medium duty, and rough machining of all types of alloyed and unalloyed steels. The TN7100 series delivers exceptional value on key productivity

CUTTING TOOLS

metrics such as higher metal removal rate, surface finish, longer tool life, consistent performance, and lower manufacturing costs. TN7100 series has a combination of wear resistance and toughness with a coating that is micro-engineered in both composition and post-coat treatment to emphasize outstanding coating adhesion and resistance to built-up edge/workpiece sticking. Specifically, Victory TN7105, TN7110, and TN7115 grades are new grades for light and medium turning applications in steel with a projected 30 per cent performance increase over competitive products. “Increased wear resistance means longer tool life at high cutting speeds, and enhanced edge strength resists depth of cut notching, even in interrupted cuts,“ says UJ Baid, senior global product manager, turning. “Simply stated, these inserts are an outstanding combination of increased wear resistance and toughness, meaning more value for the customer.” www.widia.com

THE CUTTING EDGE We use Premium Micro grain solid carbide for longer tool life and increased feeds and speeds. Tools are stocked uncoated and ALTiN coated. Designs for threading, grooving, PCD, and CBN-tipped inserts

Solid carbide grooving, boring and threading tools.

Set includes boring bar, 5 inserts, 5 screws, and a torx plus key

Threadmills

Available in coated AlTiN or uncoated sub micrograin carbide

Port tools

Hardened steel head features proprietary mechanical attachment... no annealing from brazing heat Pocket keeps chips away from machined surface Fits into SCI standard QHC coolant tool holders Inserts lapped and ground to fine finish for maximum chip flow Available in right-hand and left-hand versions Bars stocked with or without locating flat... Low profile screw keeps chips flowing

SCIENTIFIC CUTTING TOOLS, INC. 110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com www.canadianmetalworking.com | APRIL 2011 | 47

cutting tools

toolholding

A Firm Grip Faulty toolholding systems can wreak costly havoc on tooling and machining processes By Mary Scianna.................................................................................................................................................. You finally find the dream machine you want for your shop and better yet, the $450,000 price tag fits your budget. There’s only one problem; you forgot to include the cost of tooling in your budget. Now you have to scramble to find a low cost tooling package while your spanking new machine sits idle, not making money for your company. This, say suppliers, is where many manufacturers go wrong. “It’s important to consider a tooling budget right from the start when you’re purchasing a new machine,” says Randy McEachern, product and application specialist, hole making and tooling systems for Sandvik Coromant Canada Inc., Mississuaga, ON. “In fact, Sandvik thinks this is so important that we have a group that focuses on toolholding and tooling packages for customers to ensure the right types of systems for the application.” Unfortunately, many people regard toolholders as commodity products, adds Mike Smith, toolholding product manager for Seco Tools, Troy, MI. “You have to have a high quality tooling package and it’s often an overlooked piece of the equation of machining. Low quality tooling will create run-out, wear down or tool breakage.” Indeed, Emuge Corp.’s David Ridenour, toolholding expert, sales, OEM manager at Emuge Corp., West Boylston, MA, says using the wrong type of toolholder can create “excessive tap breakage, threads that don’t gauge properly (oversized), torn and ragged finishes, bad thread flanks on the cutting profile, and reduced tool life caused by the one-sided flank abrasion on the threading tool which will lead to material build-up.”

Know your application needs

Knowing what you need seems like an obvious point to make, but industry experts say shops often don’t understand that different machining operations require different tooling packages. “The insert you’re using for your machining process will determine the type of toolholder you’re going to use,” says Steve Geisel, senior product manager, Iscar Tools, Oakville, ON. “If you’re finishing, it’s a light cut with tight tolerances so your toolholder has to be able to handle this. There’s nothing worse than taking a finishing insert designed for that purpose and putting it into a toolholder that is loose and worn out as you won’t be able to hold the tolerance. For finishing, you want a toolholder that is perfectly round so it fits the insert properly and you want high tolerance inside the toolholder pocket. The better the tolerance on the toolholder, the better the repeabability you’re going to get on insert indexes.” You should also consider the flexibility of your toolholding system, says Scott Leitch, sales manager, Exsys Tool Inc., San Antonio, FL. “By flexible, I mean a system with different types of attachments that could fit inside the toolholder and the 48 | April 2011 | www.canadianmetalworking.com

standard collet. If a collet is slipping inside the collet pocket while it’s going into the material, it means you need a much more rigid set-up, otherwise the collet will damage the cutting tool and the toolholder. It would be useful to have an adapter or an accessory to the toolholder that would create more rigidity.”

Iscar’s TorqueBeam is used for clamping screws to the correct torque. A light indicator lets the operator know when he has reached the maximum required torque.

Using the wrong toolholders can lead to a host of costly problems, including tooling (holders and inserts) breakage, and incorrect part tolerances leading to part rejects and lost productivity. “You have to be aware of the application. If you have an ER collet chuck with a drill, for example, and you’re running that ER collet chuck at 15,000 rpm, the collet will expand and create run-out. In this case, you may want to consider a hydraulic or shrinkfit holder,” advises Seco’s Mike Smith. In milling applications, “one of the most common problems we see is machine shops using collet type holders for milling and thread milling,” adds Emuge’s David Ridenour. “With side thrust [forces] you really do not want to use an ER collect type holder. Milling and thread milling require something more rigid, like a solid endmill holder, shrinkfit holder or a PowRgrip system.” David McHenry, product engineer with Rego-Fix, Indianapolis, IN, adds that different toolholding systems are designed for specific applications and “you have to find a system that allows you to get the most of your application needs. It can be extreme rigidity and no forgiveness, or a system with rigidity and some forgiveness and very high clamping forces or a design that can’t be pushed as hard and is forgiving. There are different paths that you can take to

Manufacturing Success

Aerospace

LOFTY DEMANDS

Making things that fly begins with having your feet firmly planted on the ground. At Seco, we understand that and employ a globally-linked network of experts who support your applications and come prepared with the latest innovations in cutting tools and process technology.

CBN170, The first ever PCBN grade specifically designed for machining nickel based superalloys has three unrivalled advantages: PCBN ■ Unique whisker ceramic binder ■

■

Specifically-engineered cutting edge

Together, they ensure consistent part quality, long tool life and fewer indexes for the greatest productivity.

MILLING • TURNING • THREADING • HOLEMAKING • TOOLHOLDING

www.secotools.com/us

cutting tools

toolholding

get the tooling system that is going to best fit your machine shop’s needs.” The right toolholder for the right application is not the only concern; Sandvik Coromant’s Randy McEachern says “you also have to consider the metal properties and the finish that you required to machine. “Are you machining bar stock, castings, carbon steel, heat resistant super alloys like titanium? If you’re cutting certain materials, lighter tools will work, but with tougher materials, you’ll need a stronger spindle, stronger toolholder and stronger cutting unit.”

Torque: Finding the balance

The single most important piece of advice suppliers concur on is: don’t over torque or under torque retention knobs or screws on toolholding systems. Indeed, over tightening screws and retention knobs has become such a problem that ASME has established torque specifications for standard toolholders such as CAT systems. “The biggest thing I see is that shops either drastically over tighten the screws or they completely under tighten them,” says Iscar’s Steve Geisel. “We list the pounds per square foot recommendation for tightening all of our screws and we hope people read this and understand that sometimes an insert doesn’t have to be as tight as you can make it because that can cause problems; you can’t get the screw out because it’s too tight so you may have to break the insert to get that screw out or if you don’t tighten it enough the insert may bounce inside the pocket and you won’t be able to hold size or finish on your workpiece. The insert will vibrate and the screw can unravel itself.” Sandvik Coromant’s Randy McEachern adds with basic CAT V or ISO taper holders contact is made at the top and bottom of the taper and “they’re supposed to make taper contact all the way and have a taper lock but no taper is that perfect. Customers tend to over torque the retention knob on the back and if they over torque it, it bulges at the bottom end of the taper and now there’s no contact between the top and bottom of the taper and you don’t have a good solid taper lock. This in turn invites vibration into the toolholder and your tools vibrate and the tool always get blamed first but in this case it’s the over torquing of the retention knob.” While over tightening can be a problem, suppliers have responded in recent years with torque sensitive screwdrivers that indicate when you’ve reached the right tension. A word of advice for manufacturers though: “you use these torque sensitive screwdrivers to tighten the insert only; you don’t use them to remove the insert. Instead you should use a regular screwdriver to take the insert out. The only time you need to be careful is when you’re tightening the knob so you need a high precision tool,” says Iscar’s Steve Geisel.

A debris-free environment

Manufacturers underestimate the importance of shop maintenance and often don’t recognize how poor maintenance can lead to machining process breakdowns. “Always keep bore, taper, spindle and shanks clean,” advises Tom Hagan, 50 | April 2011 | www.canadianmetalworking.com

TOOLHOLDING

milling product manager, Iscar Tools, Oakville, ON. “Dirt, debris, surface damage such as rust, corrosion, nicks and gouges cause runout and result in costly tool breakages.” Many manufacturers rough-handle toolholders not realizing how they can quickly become damaged, adds Keith Wiggins, global tooling systems team leader Widia-Erickson toolholders, Latrobe, PA. “As a tooling supplier, we always treat our tools like jewels and have proper receptacles to keep them in. Most manufacturers are good with their tools when they first use them and then they throw them into a drawer and tooling gets scratched. Top: Exsys Tool’s Preci-Flex Then they don’t understand why toolholder. Below is they’re not getting full accuracy Sandvik Coromant’s Capto toolholders. from their tooling systems.”

RIGIDITY IN HIGH SPEED MACHINING: WHAT WORKS BEST

Nowhere is rigidity more critical than in high speed machining applications. Whether it’s milling, turning, boring or drilling, toolholders play an especially important role in these applications. “Rigidity in milling is critical,” says Emuge’s David Ridenour, “to eliminate chatter and harmonics and to obtain good tool life.”

CUTTING TOOLS

“If you were to take all three products—HSK, Capto and KM—and look at a cross-section, you would see that the Coromant Capto has the strongest coupling and the strongest interface in a polygon shape; there is full contact in the polygon, shoulder and then we have a taper lock. Other clamping units work on a key-way. There is a key on the face of the spindle and a key on the holder and there’s a little bit of play between the key and key way and this creates what I call a click clack effect, which invites vibrations into the tool.” Widia’s KN toolholder line also offers three points of contact at the bottom and top of the taper and at the face. “These are full surface contacts, not point contacts. With HSK and BIG Plus systems, you only get contact at the top of the taper and at the face,” explains Widia’s Keith Wiggins. On the other side of the toolholder equation is the holding mechanisms that actually hold inserts in the toolholder pocket—collets, chucks and clamps. Rigidity is important and press-in collets such as Rego-Fix’s PowRgrip, the generic Shrinkfit, Sandvik Cormant’s Hydro-Grip HD and Iscar’s R-clamp work well in high speed applications. And while rigidity is key, “you don’t want to have a system that is too rigid; you need to have some forgiveness or the vibration from the cut will vibrate back into your spindle and into your workpiece, making it more difficult to machine a part,” explains RegoFix’s David McHenry. And the need for rigidity calls for more complex toolholding systems, adds Iscar’s Steve Geisel. “We make simple systems to complex systems depending on the operator’s level of experience, but with the more complex systems, there’s the potential of more going wrong with them. When you get into high end roughing, heavy duty metal removal and high cutting forces, you have to have a very secure clamping tool. If not, the tool pressures and cutting forces have a greater possibility of moving the insert around inside the pock, so in this case you need a rigid clamping system. We have a system called R-Clamp and it’s the most rigid way of holding the insert inside the toolholder, but we’re not the only supplier that makes this; everyone makes these types of more complex tooling.” CM

“Best types of toolholders for high speed and heavy

machining applicatins are dual contact ISO standard systems such as Capto, KM, BIG Plus and HSK.”

Experts concur that the best types of toolholders for high speed and heavy machining applications are typically dual contact ISO standard systems such as Capto (originally a Sandvik Coromant product), KM (originally a Kennametal product), BIG Plus (originally a BIG Kaiser product), HSK and other company branded variations. “These toolholders are designed to have dual contact, meaning they have contact along the taper and along the face,” says Rego-Fix’s David McHenry, (the company has its BIG Plus version toolholder which it calls Rego-Plus). “So now you have a stopping point when the tool is pulled back into the spindle and this secures the toolholder. Manufacturers are making robust spindles for machine tools so they can take a lot of load and it’s up to us to make sure we can hold the tools properly and dual contact toolholders definitely do that.” Not all so-called dual contact toolholders are created equal though, according to industry experts. Sandvik Coromant Canada’s Randy McEachern says the Coromant Capto has the strongest coupling when compared to HSK and KM systems.

www.coromant.sandvik.com/ca www.emuge.com www.exsys-tool.com www.iscar.ca www.rego-fix.com www.secotools.com www.widia.com www.canadianmetalworking.com | APRIL 2011 | 51

cutting tools

toolholding

PRODUCT REPORT Emuge

Emuge Corp. offers a tool clamping system known as the PGR for carbide and HSS cutting tools, taps, thread mills, and endmills. It achieves the higher mechanical grip and torque transmission required by high speed cutting and high performance cutting applications while achieving the precision and surface quality demanded by customers. The PGR System solves the problem of clamping shortcomings and runout inconsistencies associated with conventional colletbased toolholders. Hydraulic expansion chucks, while stronger than collets, still have grip

limitations when used in high performance cutting applications. Compared to shrinkfit toolholders that require heat and cooling cycles to set their grip, the PGR System requires no operator heat shielding or waiting time after setting the desired mechanical grip. Unlike shrinkfit holders, the PGR System generates no heat, a safety issue requiring cooling time and caution when handling shrinkfit tooling. The tooling system consists of a benchtop press with a quickchange adaptor with a special tapered collet and toolholder. The cyclindrical cutting tool shank is inserted into the collet and placed in the tool holder. The holder is designed with a gap between the collet shoulder and the toolholder that creates an interference fit. The benchtop press generates six tons of force to push the collet through the

1 | April 2011 | www.canadianmetalworking.com 52SGS_609_GIE_R2.indd

interference gap, making the toolholder expand slightly and allowing the material’s elasticity to clamp back on the tool. Assembly requires ten seconds or less. Total indicated runout measured at four times the tool diameter from its tip, is 0.00012 in. or 3 microns. Since the process generates no heat, the adapter requires no cooling period and is ready for immediate use. www.emuge.com

Exsys Tool

Exsys-Eppinger Preci-Flex tooling system is a unique product that uses a single base holder for collect and multiple other tooling adapters. The modular system offers precision—a conical and flat face planar interface ensures high accuracy and rigidity—and flexibility—collets, endmill

holders, expanding collet chucks and shrinkfit tooling can all be mounted on a single base holder.

The short design ensures maximum torque transmission and rigidity, which results in increased machining accuracy and improved productivity. The full Eppinger range of products feature different ratios for ideal cutting conditions. All wear parts are case-hardened and tools are available with internal coolant supply. Set up time, machining time, cutting tool life and production

9/23/10 5:23:11 PM

CUTTING TOOLS

TOOLHOLDING

PRODUCT REPORT interruptions are all improved. According to company literature, set up time with a standard toolholder system is approximately 460 minutes versus that of the Preci-Flex at 70 minutes. Machining time per part is 2.98 minutes versus 3.27 minutes with standard toolholders. In all, users can achieve a 36 per cent total cost saving by using the Prec-Flex tooling system. www.exsys-tool.com

ISO inserts: DN 33, TN 33 and WN 33. The company says it offers excellent performance in heaving and interrupted cut machining. As part of the company’s toolholder product line, it offers the TorqBeam for

connected to the handles by a quick change system. www.iscar.ca

psi, it’s also available in coolant flush for peripheral cooling. www.rego-fix.com

Ingersoll

Sandvik Coromant

Unlike most lever-lock holders, the exclusive lever found on Ingersoll’s new H-type holders provides multi-directional clamping force and outstand-

Iscar Tools

The R-Clamp holders from Iscar for ISO turn small size inserts feature what the company describes as “strong and reliable” clamping mechanisms and “excellent” corner location reliability. The user friendly indexing operation uses a single key for insert indexing. The tools are available for the following 3/8 in. inscribed circle negative

clamping screws to the correct torque. It uses an LED light indicator when it reaches the maximum torque required for clamping. Two types of keys are available, flag and double flag handle shapes. The keys range from T6 to T15 and are

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ing stability, according to the company. The result is a fast indexing clamping system that eliminates the need for top clamps that often wear out due to chip wash. www.ingersollcuttingtools.com

The latest addition to the Hydro-Grip product family brings secure tooling performance to the heavy roughing area. Hydro-Grip Heavy Duty, with unique dampening features offers the high level of power and stability of a hydraulic power chuck. This ensures a good torque transmission to improve the performance of solid carbide end mills, drills and reaming tools.

Rego-Fix

Rego-Fix describes its powRgrip toolholder as a precise and cost effective press fit system for high speed, high performance cutting applications. It achieves “superior” runout using a toolholder, versatile collect and a compact benchtop hydraulic clamping unit. The collet’s built-in set screw provides precise setting, repeatable to less than 0.0004 in. (10 microns). Its slightly tapered shape, combined with the nine-ton tabletop clamping unit, delivers high clamping force without dangerous heat or hazardous EMF radiation. It has a 10 second clamping cycle and a tool ready for immediate use without the need for cool-down, allowing for complete tool changes in less than 30 seconds. The collet on the toolholder clamps all types of tool shanks and materials up to 1 in. in diameter in h6 tolerance. Metallically sealed for coolantthrough capability up to 2000

It securely clamps cylindrical shank tools with a symmetrical force to minimize tool run out and ensure high torque transmission. This performance is repeated over multiple clamping cycles to retain high quality component surfaces and extend tool life, while each chuck is individually balanced to 2.5 G, for high speed capability. Quick and easy tool set-up, and tool changing, helps to shorten planned machine stoppages. The toolholder is based on a hydraulic tool clamping system, which can be tightened and released quickly with a torque wrench, with tightening to the correct level. The Hydro-Grip family of high precision toolholders offers secure tool clamping for many applications, from finishing to heavy roughing between 6-32 mm bore diameters. They work to tolerances within microns to improve tool accuracy, component surface and enhance the machining experience. www.sandvik.coromant.com/ca

CMMs

Quality

What you Need to Know Canadian Metalworking’s CMM expert and Metrology Matters blogger Bill Reilly provides insight on CMMs By Bill Reilly What are the key factors to consider when choosing a CMM?

This is a big question. First, CMMs are very versatile, but you need to be clear about what the CMM’s function will be. For instance, will it be in a lab inspecting first-off parts or on the shop floor checking production parts 24/7? Will it be checking simple parts or parts with complex geometry? Will it be checking precision machined parts or castings or plastic moulded parts, etc. What are the tightest tolerances you’ll need to inspect and what types of tolerances (i.e. form, position and orientation)? Will the speed of the inspection or cycle time be an important factor? The difference between CMMs has a lot to do with the materials used rather than the basic design, which doesn’t seem to have changed drastically in decades. Modern CMMs are built with lighter materials and smaller, more powerful servo motors allowing them to accelerate to scary speeds (hint: never lean over the bed of your CMM while a program is running to have a closer look at the part. You could end up the victim of a 500mm/sec CMM head-butt, or worse, impaled by the styli.). I’ve personally experienced the head-butt, although not at 500mm/sec, but the styli impaling was a story told by a CMM calibration technician I know. Materials such as aluminum and ceramic are used to lessen the thermal effect but for different reasons. Ceramic has a very low coefficient of expansion and is therefore very stable throughout temperature fluctuations. Aluminum, while having a much larger coefficient of thermal expansion, reacts to temperature changes rapidly and in a linear manner and therefore can be compensated for accurately and in real time. Having said all that, it still seems the biggest advancements in technology have been made in the area of probing systems and software.

Image: Zeiss

and is one of the most important factors to consider. A fixed head means you’ll be relying strictly on the probe build-up (you may need to get creative here) to reach the features to be measured whereas an articulating head gives you the flexibility of hundreds or thousands of probe positions, allowing you to reach many different features with a single probe. There are articulating heads that lock every 7.5° and 2.5° and more recently, a head with infinite possibilities. Another key factor to consider is whether to get a manual indexing head or a motorized head. If you’re only measuring 2D parts and a simple “down” probe is all you’ll need, then of course the motorized head may not be necessary, but if you’re measuring more complex 3D geometry, then I would absolutely go for a motorized head. Having a motorized head on a CNC or DCC machine allows you the freedom to run parts completely un-manned. Take the same CMM and stick a manual indexing head on it, now

As far as probing systems go, there are many to choose from so I’ll just touch on the main categories. There are two distinct methods, single point probing systems and scanning systems. Single point probing systems take individual “hits” on a given surface whereas scanning systems stay in contact with the surface being measured, gathering hundreds or thousands of points in single sweep. The big difference is point density and how much of the surface you can sample. Behind the probing system is the probe head, which can be fixed or articulating,

you’ll need to do some babysitting when running programs that have more than one probe position involved. Equally as important as the probing system, is the software you choose. Off the top of my head, I can think of at least a dozen different CMM software packages on the market but it seems the lion’s share of the market consists of the big three OEM’s; Browne & Sharpe (Hexagon), Mitutoyo and Zeiss. At Quality Inspection Technologies, we use all three. Being a contract inspection lab we come across all sorts of applications and www.canadianmetalworking.com | April 2011 | 55

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CMMs

I like each software package for different reasons and wouldn’t dare pick a favourite (at least not here). These days you can mix and match CMM manufacturers and software. For instance, my Mitutoyo CMM also runs with PCDMIS and could potentially run with Calypso if I so desired. My advice would be to take a couple of sample parts, typical of what you will want to inspect, and have each potential OEM create a short sample program in your presence, so you can witness how user friendly it is. Take a few features you consider to be your biggest inspection challenges and compare how each software package is able to handle them. While all packages do the simple stuff very well, each has their own special features the others may not have and could make all the difference for your application. This should help you conclude which software is the best fit for your application. In the end it’s the combination of the machine, the probing system and the software that you’ll base your decision on but it’s a good idea to look at each factor individually as well.

Quality

hard collision; they do happen and it’s imperative to know whether it has a negative impact on the accuracy of the CMM. A periodic check can be as simple as running a program on a retained sample part or test block through a program or as involved as something like the Renishaw MCG (Machine Checking Gauge), which checks the volumetric accuracy of the CMM and is sometimes part of the annual calibration process. It’s best to run your periodic check directly following the annual calibration so you can establish a baseline from which you’ll compare the results from subsequent checks. You could make the argument that running periodic checks

Where is the best place to install your CMM?

In an ideal scenario, your CMM belongs in a separate room that is temperature controlled, free of dust (as much as possible), with a clean and dry compressed air supply, and as far away from the chips, coolant and vibrations of a typical manufacturing floor. Not all scenarios are ideal, which is why CMM manufacturers have answered some of these challenges with such features as real-time temperature compensation and air cushion vibration damping systems, which are extremely important in these less than ideal scenarios. Some pretty rugged shop floor CMM’s exist on the market with completely enclosed air bearings and guideways that can handle the dirt and dust of a manufacturing environment that would ruin a traditional CMM in no time. Some shop floor CMM’s have even done away with air bearings altogether. In either case, there’s nothing to prevent dirt and oil from collecting on the styli so it’s good practice to regularly clean the styli to ensure reliable measurements. There’s also a breed of ultra high accuracy CMMs which call for a clean-room type of environment to produce the sub-micron accuracies but these are the exception and not nearly as common.

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Tangential Approach

Helical Scanning

Calibration: Is it a given that CMM’s are calibrated once per year?

While a one-year calibration cycle is pretty typical, there are periodic checks that should be done to maintain confidence throughout the year. It’s also a good idea to perform a check after a particularly

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www.canadianmetalworking.com | April 2011 | 57

Quality

CMMs

“ The most interesting

emerging technology is computed tomography.”

would allow you to extend your CMM’s calibration frequency but there’s more to consider than just maintaining accuracy. In addition to calibrating your CMM, your calibration technician normally performs routine cleaning and preventive maintenance and believe me, I’ve seen CMMs that look like they are cleaned once a year at best, and that’s probably done by the CMM calibration technician. Given the extreme accuracy of modern CMMs and the tight tolerances we rely on them to inspect, choosing to extend your calibration cycle to save money, in my opinion, is a risky proposition.

What key advancements in CMM technology do you expect to see in the next 5 years?

Alright, so don’t get me wrong, I love CMMs and I don’t expect they’ll ever be obsolete, but there have been some extraordinary advancements in technologies such as laser scanning, white light scanning, camera systems and computed tomography (CT). Laser and white light scanners can rapidly scan complex geometry for comparison to nominal data or for

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reverse engineering and have accuracies reaching 0.0005 in. or better in ideal conditions. Camera technology overall has blown up over the past 10 years leading to advancements in photogrammetry (taking measurements from photographic images) and handheld probing systems that rely on camera tracking systems, soon to leave the portable arm in the dust. Probably the most interesting emerging technology is computed tomography. Originally developed for the medical industry, it’s been further developed for use in metrology and has the ability to measure internal features, hidden passages, wallstock, defects, porosity and density. CM Bill Reilly is the quality assurance and technical manager at Quality Inspection Technologies and Elite Tool & Gauge Co., Beamsville, ON. Reilly is also a blogger on Canadian Metalworking’s Metrology Matters, where he posts articles about CMM issues. Read Bill Reilly’s blogs at www.canadianmetalworking.com, and email your comments and questions to mary. scianna@rci.rogers.com.

Conference streams

The Future of Metal Cutting Conference is a one-day conference organized by Canadian Metalworking. One conference stream will educate you on where metal cutting technology is going. The other conference stream will help you address issues surrounding key management issues. You can mix and match the presentations you hear based on your needs.

Exhibits

As part of the conference leading machinery, equipment and services suppliers will be available during breaks and at lunch to discuss problem solving.

FABRICATING

PUNCHING

Punching Forces Servo electric drives are being hailed as better alternatives to hydraulics, but are they as good as proponents say? By Mary Scianna ................................................................................................................... Energy efficient technologies are not new to the fabricating industry. Servo electric drives in punching machines date back more than a decade. What is new is the big push by industry proponents. “We see a trend worldwide towards servo electric,” says Lutz Ehrlich, punching and automation product manager for Prima Finn-Power North America Inc., Schaumburg, IL. “One reason is that the cost of electricity isn’t going down and therefore the economics for the servo electric side becomes very attractive, especially in those countries where businesses pay a premium for electricity.” Prima Finn-Power is one of the early adopters of servo electric drives in punching machines, and developed its first servo electric machine in 1998.

Recent developments in energy conserving technology have reduced the electrical power consumption in LVD Strippit’s hydraulic press drive systems.

Another big adopter of servo electrics is Amada America Inc., Buena Park, CA. (Amada Canada has a head office in Granby, QC, and another facility in Mississauga, ON). In 2004, the company stopped producing its hydraulically driven punching machines and switched to servo electric drives. “Two fundamental things drove our transition to servo ram drives,” says David Stone, product manager for turret punch presses, stamping and general fabrication for Amada America. “Even back then we could see the hand writing on the wall for electrical costs and the cost of maintaining hydraulic systems.” According to Stone, routine maintenance on a hydraulic system typically occurs at 2000 hours. At that point you need to replace and dispose 50 gallons of old oil. “Over a conservative ten-year machine life, you’ll spend $25,000 to $35,000 just on routine maintenance.” Secondly, hydraulic punching machines have more components than a servo electrically driven unit.

“Our old Vipros series of hydraulic machines have almost 500 components—an oil tank, a pump, valves, hoses, fittings, chillers to cool down hydraulic fluids and many other parts—all of which are shifting, sometimes thousands of times per minute, and with all the seals and packings in these systems there are hundreds of different points of failures,” explains Stone. Compare that to a servo electrically driven machine that, in Amada’s case, has 64 components, and it’s easy to understand Stone’s rationale about lower maintenance costs on these newer energy efficient punching machines. Is the hydraulic punching machine then a thing of the past? Not so say some industry experts. Indeed, even some proponents of servo electric machines say hydraulic systems are here to stay, at least for now. “The servo hydraulic side will continue until we as manufacturers [of fabricating equipment] find a way to produce the newer technology more economically because right now you’re paying a premium for this technology because it is more complex.” Some industry experts go further and say hydraulics are here to stay not because they’re more economical, but because they offer performance benefits over servo electric models. “Hydraulic technology has, and always will, serve diverse and demanding industrial applications,” says John Quigley, vice president of marketing for LVD Strippit, Akron, NY. “Recent developments in energy conserving technology have reduced the electrical power consumption in our hydraulic press drive systems. LVD Strippit hydraulic press drive designs offer the best balance of energy consumption, durability and productivity when compared with other press drive systems, such as electric ram designs.” Can hydraulic systems be energy efficient? Yes, says TRUMPF, which produces “energy efficient hydraulic” machines as well as servo electric machines (launched two years ago). “The reason we call our hydraulic system ‘energy efficient’ is that we do not use an external chiller to cool down our hydraulic fluid,” explains Mike Kroll, product manager for TRUMPF’s TruPunch and TruMatic machines, based in Farmington, CT. “We use the power of our own machine to cool the hydraulic fluid, so you don’t need the external chiller and we don’t use a lot of energy. Average energy consumption for our typical hydraulic system is about 17 kW of energy per hour.” How TRUMPF uses the power of its own machine to cool the hydraulic fluid is attributed to its two-circuit system and single head punching technology. “We engage only one tool in the head at any given time rather than having a turret system machine where you have all your tools in a machine at once; it’s more of a machining style concept www.canadianmetalworking.com | APRIL 2011 | 59

fabricating

punching

and by doing this, we’re able to contain the hydraulics.” Modern hydraulic press drives, adds LVD Strippit’s Quigley, are indeed energy efficient. “We have an installed power of 11 kW and an average power consumption of 6.9 kW, [by comparison, TRUMPF’s servo electric punching machines consume approximately 6 kW of energy per hour] which is slightly higher than the electromechanical press drive. Hydraulic press drives of previous generations had an installed power of 2 kW and consumed 13 kW. Our new VX-Series feature a new technology called Energy Reduction System (ERS) developed to reduce the consumption of energy during periods of low hydraulic pressure or drops in machine activity, and to optimize and minimize power consumption.” Hydraulic press drives are also more flexible, says Quigley. Electro mechanical press drives are “better applied to lighter tonnage applications due to the effect of shock from the punching process. Shock has a negative effect on the components [ball screws, encoders and servo motors] of mechanical systems. Hydraulic press drives can span the array of applications from light to heavy punching as they have no mechanical linkages or ball screws that can be impacted by shock.” Another plus on the hydraulic side according to Quigley is the controlled force this technology offers throughout the entire stroke of the ram. “Electro mechanical systems provide full tonnage only at a certain position above die height and therefore

60 | April 2011 | www.canadianmetalworking.com

Prima Finn-Power’s Lutz Erlich says there’s a worldwide growing trend in punching machines toward servo electric drives.

do not have consistent and full tonnage throughout the full stroke of the ram.”

Accuracy and Speed

When new technologies get launched they’re designed to overcome issues existing in old technologies. In punching machines, proponents of servo electric drives say not only do these machines reduce energy consumption, they also perform better. “The primary reason for development [of servo electric drives] was [reduced] energy consumption,” says Prima FinnPower’s Lutz Ehrlich. “What we have learned since then is this

Now, more than ever, Canadian tooling manufacturers Exacta Precision and Exacta Fabtool offer the most comprehensive selection of tooling solutions for the metal stamping and fabricating industries. Whether you need to punch it, bend it, or stamp it, Exactaâ&#x20AC;&#x2122;s standard, precision, or custom tooling is

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EXACTA FABTOOL

FABRICATING

PUNCHING

punching mechanism, which is now a CNC axis, allows you to control the speed and positioning precisely, so you have better control of the punching process.” Amada’s David Stone concurs. When his company made the switch to direct drive servo electric motors, “we increased the speed of the machine and increased the accuracy of it because we’re now using direct drive servos that use encoders to communicate with the machine control the exact position of the ram.” Amada says its machines have higher accuracy due in part to direct drive servo motors.

LVD Strippit’s John Quigley has a different opinion. While he concedes that press drive designs of hydraulic and servo electric drives are different and therefore affect performance differently, it is the hydraulic press drives that offer the higher precision and speed in the movement and control of the punch press and ram. “A hydraulic press drive in a typical four mm stroke length can produce all movement necessary to punch a hole within 30 milliseconds. In an electro mechanical design, the servo motor must be accelerated and then decelerated. Because of the necessity

of controlling this inertia, the fastest time it can produce for the same stroke length is 50 milliseconds. Consequently, hydraulic press drive machines offer high productivity rates.” Ultimately, fabricators need to assess which technology best fits their application because both offer advantages and disadvantages. With hydraulics you have a long-standing, field-proven technology, which suppliers have built upon and improved. With servo electric technology, you have a relatively new technology that still has room to grow and improve. One of the challenges is kinetics, says Prima Finn-Power’s Lutz Ehrlich. “There is always a challenge between mechanical transfer and in this case, a force to punch a hole in a sheet of metal; there is always room to do better.” “We’re just starting with electric technology and introduced an electric version, a 20 ton TruPunch 3000 last year at FABTECH. Our 4 ft by 8 ft (1.2 m by 2.4 m) model came out in February and a larger 5 ft by 8 ft ( 1.5 m x 2.4 m) version will be introduced later in the year.” For Amada, the focus is now on achieving high throughput with its servo electric machines. “We achieved as fast a ram speed as we can get so we’ve been working to improve throughput with automation and cycle times or loading and unloading parts. We’re improving the ability to finish parts out of a sheet and stack them on a pallet and not have an operator present to do so,” says Amada’s David Stone. No doubt proponents of both drive technologies will continue to voice the benefits of their respective machining solutions. One common thread among them is the recognition of the evolving nature of technology and the responsibility suppliers have to continually improve it. CM www.amada.ca www.lvdgroup.com www.primafinnpower.com www.us.trumpf.com

NEW IN CANADA

PRODUCT REPORT

CMA X-Y-Z RAPID DRILL

Amada

Gantry and Bench-Type X-Y-Z Coordinate Drilling Machines for Metal-Fab & Machine-Shops: Easily Drill & Tap Long & Small Parts alike up to 40’. Plates, Proﬁles, Tube / Pipe / Beams Etc... www.smdmachinery.com Canadian ImporterDistributor: 905 473 9095 sales@smdmachinery.com 62 | APRIL 2011 | www.canadianmetalworking.com SMD Machinery April.indd 1

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According to Amada America’s David Stone, turret punch press and stamping product manager, “the EM-series turrets have raised the bar for measuring turret punch press productivity.” The machines perform functions that would normally have to be done as a secondary operation, such as high speed contouring with close-to-laser edge quality, burr-free slotting, high speed marking at up to 1,800 hpm, and complex forming that may normally have to be done in a press brake. The press is designed for the high production of short-run sheet metal parts, particularly those that incorporate forming or require many holes. As far as hole punching is concerned, the EM-series is capable of delivering 500 HPM on 1 in. centres, the world’s highest hit rate, claims the company. The machines are available in 22 and 33-ton versions. Large sheet capacity of either 50 in. x 100 in. (1,270 mm x 2,540 mm) or 60 in. x 100 in. (1,524 mm x 2.540 mm) (depending on model) allows the use of full size sheets up to 10 gauge thickness without repositioning. The 22-ton machine is available with either a 45 station turret with four auto-

HACO Q5

The Haco Q5 is based on over 50 years of experience in manufacturing of CNC Punching Machines. With its 22 or 30 tons high-speed servo hydraulic punching head, Y-axis ( throat) of 60" and rotation axis for all tools, the Haco Q5 is the perfect and most flexible CNC turret punching machine.

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• • • • • •

CNC PLASMA CUTTING MACHINES

Improved tooling loading system Siemens control Indexed speed: 1200 hpm or 122ms/90 deg. tool rotation Maintenance-free Punching head situated outside of the turret With appropriate tooling: shearing, bending, forming available Tools can be loaded during punch process by robot = virtual unlimited turret stations

KINGSLAND IRONWORKERS

CORNER NOTCHERS

• Large Part chute door (28.7” * 30.3”). With part detection sensors and integrated conveyer

ROBOT

• The 3 hydraulic plate clamps with minimum ‘dead zone‘ are automatically set by the CNC control

HYDRAULIC PRESS BRAKES

CNC PUNCHING MACHINES

HYDRAULIC PLATE BENDING ROLLS

HACO CANADA INC. Mississauga Office

2550 Dunwin Drive Mississauga, Ontario L5L 1J5

Ontario

Tel: 905.828.1087 Fax: 905.828.2062 Toll Free: 1.866.605.1087

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Vancouver Calgary Edmonton Winnipeg

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Tel: 604.214.4455 Tel: 403.281.1600 Tel: 780.426.0008 Tel: 204.942.4877

FABRICATING

PUNCHING

PRODUCT REPORT index, or a 58 station with two auto-index. The 33-ton machine is available with either a 58 station “King” turret with four auto-index (including two 4.5 in. stations), or Amada’s exclusive “Z”-turret, with 45 stations, including four auto-index. This allows the user the flexibility to run a wide variety of jobs with minimal setup and tool change downtime. Amada thick-turret tooling is used in all stations. Three low-profile clamps are provided for the reduction of dead zones to maximize material utilization. The EMK3610NT can be equipped with an optional 19.68 in. x 19.68 in. (500 mm x 500 mm) work chute for automatic parts removal. A wide range of automated sheet and finished part load/unload options are also available to further enhance productivity. The energy-efficient design characteristics of the AC-servo twin drive system help to cut operating costs. The EM-series saves on electricity costs by minimizing the stroke length according to the job at hand, while it stores energy generated during ram deceleration and reuses it during the punching stroke, resulting in up to 50 per cent documented cost reduction over conventional hydraulic turret presses. www.amada.com

Ermaksan

The ETP series CNC turret punch presses from Ermaksan, available in Canada through distributor Ferric Machinery, feature a strong mono-blocked rigid O type body built up by stress-relieved welded steel construction and high acceleration axes. Sheet processing can be done in multi-directions and is flexible up to 6 mm thicknesses. A 33-station turret can handle thick turret type Wilson or Mate brand quality tools, three of them indexable D stations which may include 8 A or 3 B or 1 C stationed tools, increasing the tool quantity option up to 54. A hardened steel coated tool adaptor system ensures a maintenance-free, long working4548 life. CStrip 178x38 (L) AW.pdf 3/3/08 The maximum punch stroke for 1 mm C

CMY

64 | APRIL 2011 | www.canadianmetalworking.com

step movements on X and Y axes processing 1 mm thick mild steel is 1100 per minute. Marking speed is 1800 stroke/min, and X and Y dependent velocity is120 m/min. Positioning accuracy is +/-0.1 mm and repetition accuracy is +/-0.05 mm.

The punching machine comes with 2500 x 1500 mm dimension processing table and brushed and/or ball bearing type table for easy sheet feeding. The machine is equipped with a GE Fanuc 18i-PB CNC controller which features such functions as a reader/puncher interface 1, cutter compensation C, extended part program editing, a graphic display, multipiece machining, multiple tool control and a clamp zone avoidance function. www.ferricmachinery.com

Haco

The revamped Omatic-Haco punching line features Siemens controls and have been renamed Q2 Q3 and Q5. The Q10 version is currently being developed and will feature punching from the top and from the bottom. Tools can be loaded during punch process by a robot, offering virtual unlimited turret stations. The newly designed punching head has eliminated gears. Other key features include an improved tool-loading

17:39:43

system and a maintenance-free punching head located outside of the turret. On the Q2 and Q3 models, a robust high speed hydraulic head ensures 22 tons of punching capacity through material thicknesses up to 6 mm. The Haco Q series in general feature 18, 22 or 30 ton high speed servo hydraulic punching heads, Y axis (throat) of 1525 mm (60 in.) and rotation axis for all tools. The series feature positive tool clamping. The punch holder is clamped automatically into the punching head during the tool change. A hydraulic quick-clamping system pulls the punch holder into the punching head. While punching, the punch holder and punching head are always connected. www.hacocanada.com

LVD Strippit

LVD Strippit’s new compact material storage and retrieval tower (CT-P) for Strippit turret punch presses, including Strippit V, VT and VX-Series models provides full capabilities for loading, unloading, and storage of raw material and finished parts, thus enabling automated production from stored raw material to stacked finished parts, as well as providing increased storage capacity. The unit facilitates unmanned, “lights out” production in a compact cell environment.

LVD Strippit’s compact tower is offered in two configurations of 6-pallet and 10-pallet units. The system handles workpieces as large as 98.4 in. x 48.2 in. (2500 mm x 1225 mm) and sheet weights up to 198 lb (90 kg) with a maximum load/unload pallet storage capacity of 5511 lb (2500 kg).

fabricating

punching

PRODUCT REPORT Pallet construction is engineered for compact setup and safe forklift manipulation. Spreading magnet, air knife, and peeling cylinder sheet separation devices are used to prevent loading of more than one sheet at a time and effectively separate sheets for automatic loading. www.lvdgroup.com

Prima Finn-Power North America

Fabrication challenge? We’ll solve it.

The new Finn-Power E5x features a new, easy way of operation, a high degree of productivity and accuracy as well as low energy and maintenance cost. All the benefits of versatile, servo electric punching technology are now within easy reach. The E5x comes with the Lite version of TULUS, a member of a software suite developed by Finn-Power. It makes the machine easy to use even for operators without prior experience of Finn-Power technology. Convenient downloading of programs, instructive task lists and set-up screens giving clear indication of material and tooling requirements are just some of the standard features adding to ease of operation. The number of rotating tools can be increased by using indexable Multi-Tools. Thus programming is simplified and set-up times are shortened. New quick-change tool holders can be used for even shorter set-up. A major contribution to operating efficiency is made by easy load mechanism and automatic clamp positioning and closing function as well as a large 500 mm x 500 mm work chute for components. A lifting brush table mechanism provides extra protection for materials with a sensitive surface.

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A three–stage system makes the machine safe to operate and minimizes downtime in case of failure. The machine is equipped with sensors that automatically stop the machine if the sheet comes loose or the tool jams. As an option, a sensor with similar function for sheet distortion can be added. Instantaneous machine stop prevents further damage to the machine and makes re-start of operation fast and simple. www.finnpower.com

TRUMPF

TRUMPF’s new 3000 is available in a 4 ft x 8 ft ( 1.2 m x 2.4 m) format and offers a novel skeleton-free punching technology. Its electric punching head technology averages electrical consumption of about 5 kW, which makes the machine energy efficient. With skeleton free processing, an average of 10 per cent higher material utilization is realized as well as additional process reliability. Part sorting or tabbing are available, and the machine also features scratch-free small part sorting for parts from the parts flap or the scrap sorting unit. “TRUMPF is the first manufacturer to offer skeleton-free processing directly on the punching machine,” says Mike Kroll, product manager of TruPunch and TruMatic machines, who adds that skeleton-free punching is possible for all types of geometric shapes.

The basis of this new development is powerful software with all the right nesting algorithms, combined with the option of rotating parts and leftover pieces with innovative tool technology. The result increases reliability in several areas. For example, parts no longer get stuck in the sheet skeleton; the operator no longer has to remove the leftover material from the machine table; and sorting is improved due to a turnout underneath the parts chute that automatically separates the finished parts from the scrap. Because the punching head is not in continuous use in the TruPunch 3000, another innovative feature has been added to the machine: an electric punching head. It’s not only quiet, but in contrast to the hydraulic version it uses very little power in standby mode. In punching mode, it’s also more efficient, which adds up to power consumption that’s two kilowatts less per hour than the predecessor model. And, on top of that, it is more productive. Thanks to its high rotation speed, the electric punching head is very fast when it comes to rotating tools or forming threads. www.us.trumpf.com

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FABRICATING

METALS/CEO SURVEY

Global Metals Outlook: CEO SURVEY

Metals sector optimistic about future: PricewaterhouseCooper’s annual Global CEO Survey

By Jim Forbes ....................................................................................................... Across all industries, CEOs are generally confident about the prospects for future growth. However, a summary of the metals sector from PricewaterhouseCooper’s (PwC) 14th annual Global CEO Survey, found metals CEOs are slightly more cautious about the future than their counterparts in other sectors. The report found only 41 per cent of metals executives are very confident about generating higher revenues over the next three years, compared to 51 per cent of their peers. Reason being is that the metals sector was one of the hardest hit during the downturn. For example, prior to the crisis, steel prices hovered around US $1,200 and when the crisis hit, prices dipped to under US $500. Although there have been positive indicators within the sector that the worst may be over, many issues are weighing on their minds.

“We’ve found metals CEOs are still focused on reigning

in expenses...95% have implemented a cost reduction initiative in the past 12 months....and 73% expect to repeat the exercise in 2011.”

We’ve found metals CEOs are still focused on reigning in expenses. In fact, 95 per cent of metals CEOs have implemented a cost reduction initiative in the past 12 months—and 73 per cent expect to repeat the exercise in 2011. This focus on reducing costs is a departure from what we’ve seen in previous down cycles when cost cutting was typically viewed as a temporary measure until demand recovered. But, executives seem wary this time around, with the outlook for the global steel industry still uncertain. In 2011, we expect all eyes to be on emerging markets like China, Brazil, Russia and India, which are seen as main sources of growth. The International Monetary Fund forecasts global growth at 4.2 per cent for 2011, but developed economies are growing at only half that rate. As such, 73 per cent of metals CEOs agree that emerging markets are more important to their company’s future than developed markets, compared to 59 per cent of CEOs overall. As a result, competition is likely to be fierce. Metals 68 | APRIL 2011 | www.canadianmetalworking.com

companies will need access to raw materials and the energy to process them reliably and at a reasonable cost, which is no easy feat. This explains why 65 per cent of metals CEOs—nearly twice the overall average—told us they’re concerned that scarcity of natural resources could put the brakes on growth. Although the global economy has improved, 89 per cent of metals CEOs are still worried about uncertain or volatile economic growth hurting their business as demand for metals generally follows GDP levels. One of the biggest perceived threats is the exchange rate volatility with 51 per cent of metals CEOs expressing they are extremely concerned compared to just 22 per cent in the overall survey sample. Similarly, inflation and instability will likely remain key concerns throughout the year. The good news is nearly half of all metals CEOs plan to expand their workforces this year. The bad news, however, is that the majority believe there is a lack of skilled candidates to choose from. Contributing to their worries, almost half are also concerned that competitors will snatch their best talent and many are facing difficulties attracting younger employees into traditional career paths. Finding talent in emerging markets and moving experienced people on global deployments are high on the executive agenda. Seventy percent of metals CEOs (versus 59 per cent overall) are making changes to their people strategies to deploy more staff on international assignments. While global deployments are a first step to address shortages as company footprints change, CEOs know they need to nurture local talent in the long run. Building on the workforce issues above, technological advances are increasing the complexity of metals production and processing, so finding skilled talent in engineering and other areas is becoming even more vital. To address this challenge, 65 per cent of metals CEOs would like to work more closely with governments and education systems to improve skills in the talent pool. As well, nearly three-quarters of metals CEOs plan to support new government policies that promote “good growth.” It seems as though metals CEOs don’t believe they’re out of the woods just yet. The impact of the recession is still being felt across the industry and has shaped the CEO agenda for the coming years. As CEOs shift their focus from survival to growth, we expect competition for skilled workers and the emerging markets to intensify. However, it’s also clear that metals CEOs are taking somewhat of a more cautious approach to growth while the economy recovers. For more information on the metals industry summary of the Global CEO Survey report, visit www.pwc.com/ceosurvey. CM Jim Forbes is Global Metals Leader, PwC

More power in the world. A new world is born. Two leading specialists in laser and sheet metal fabrication technology – Prima Industrie and Finn-Power – have joined forces through a merger of equals to create the third largest market player in the world called PRIMA POWER. This new brand identity is the culmination of 30 years of innovation, installation of 10,000 machines and systems in over 60 countries, 1,400 employees, and production facilities in Italy, Finland, the USA and China. Prima Power is also an absolute leader in 3D laser machinery for automotive, aerospace, and energy applications. Prima Power’s creation also marks an outstanding commitment in environmental sustainability. With the creation of Prima Power, we have demonstrated our strong commitment to product innovation, service, and sustainability to enhance our customers’ productivity, quality, and bottom line proﬁtability. There is more power in the world!

www.PrimaPower.com

welding

fume extraction

General Ventilation is not Enough Airborne impurities may affect workers from a distance

By Guy Arsenault ............... Clean air in the work environment is not only a question of the employee health, safety and comfort. Today clean air in the workshop is also an important factor for all companies to keep and develop their position in the market as a safe, efficient and highly productive organization. Good industrial ventilation is becoming increasingly important as it can directly impact the company’s energy efficiency and the environment. In the production and manufacturing industries, the cost of heating and air conditioning can be more than a third of the company’s energy costs! Welding should always take place in a well ventilated area to actively remove the toxic fumes and gases. General ventilation systems such as opening doors, roof fans, ceiling fans, heat exchangers ceiling hung circulators or extraction hoods over workbenches are often completely inadequate: the welder or operator cannot avoid inhaling the fumes as these always contaminate the general airflow. The welding fume travels through their breathing zone to the “extraction” point, so the workers are now considered part of the filtration system. To put it into perspective the diameter of welding fume particles can be from below 0.01 to over 0.1 μm at source. When the particles reach the welder’s breathing zone agglomeration has occurred (where by the particles form a small mass, creating fume particles in the size of 1- 2 μm). The size of the particles is important because it controls the depth to which they penetrate the respiratory system. Particles larger than 5 μm are deposited in the upper respiratory tract. Particles in the range of 0.1 - 5 μm, which includes welding fumes, penetrate and deposit the inner parts of the lungs (the alveoli). Nor are systems like these necessarily cost effective: with general ventilation, large volume of heated / cooled air needs to be exhausted and this requires a great deal of power to operate. 70 | April 2011 | www.canadianmetalworking.com

The additional cost of running the system is added to the cost of re-heating or reconditioning the air in the plant. A number of studies show that a well designed and efficient capture at source (CAS) system has the potential to drastically lower a plant’s total energy costs. It shows that a combination of balanced removal of fumes and ventilation with energy recycling is often so cost efficient that the investment in the new technique is paid off faster than other production solution investments in the companies. Wherever it is a viable solution, it has been said that capture at source is the most effective and efficient method of capturing and removing welding fumes. Using this method, the risk to the welder or operator being subjected to hazardous fumes is minimized. For instance, a capture at source system focuses the suction on the specific area where the fume is produced, capturing the fume before it can dissipate into the workshop. The localized capture of fumes requires much smaller airflow volume than would a general ventilation system. In a larger workshop with multiple work stations, the use of automatic dampers and speed control on the extraction fan allows for even greater savings in power consumption and re-heating cost. There’s a handful of suppliers that have the knowledge, experience and the capacity to design, deliver and install an optimal, efficient and cost effective solution for a clean and safe work environment. Here are some factors a pollution control expert will take into consideration when determining the right solution: • Define your welding process (MIG, TIG, plasma cutting). This will indicate the fume extraction capacity for each workstation; in some cases you will find a particular welding process that will generate more fumes than others. • Is filtration required? A suitable filtration system will be needed if you choose to recirclulate the clean filtered air back into the workplace. Some jurisdiction will mandate a filtration system even if you exhaust the fumes outdoor.

THERE’S A LOT OF CHOICES OUT THERE.

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EVERY TIME.

Randy Shewmaker PROFESSION: Welding and Engineering Instructor COMPANY: Franklin County Career and Tech Center NAME:

JOB EXPERIENCE: Now in his 6th year as a certiﬁed welding instructor, Randy Shewmaker is constantly challenging his students to be self-driven individuals. In the classroom they learn how to execute a variety of welding applications on Thermal Arc® Portable DC Welders. Outside the classroom Shewmaker enters his students in welding competitions to give them a greater sense of self-discipline and real world responsibility. TOOL OF CHOICE: Thermal Arc 95 S Portable DC Welder WHY THERMAL ARC 95 S PORTABLE DC WELDER? “The versatility and amperage output of the 95 S is great for teaching, especially when you consider how small they are. Overall I think the industry is on the move towards smaller, more portable welders.”

“Thermal Arc is second to none” , 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

Randy carries the torch... will you?

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welding

fume extraction

• What will be the load on the filter? The airflow is not the only factor in sizing an adequate filtration system. Some processes generate a thicker and denser smoke requiring a larger filter surface area. You may calculate the same airflow requirements for two different processes but one of the two could require 50 to 100 per cent more filtration surface area. • Is recirculation permitted? Some jurisdictions do not allow recirculation back into the workshop. When recirculation is allowed, the client may want to consider redundancy in the filtration system with the use of a “safety filter” that will stop the fume if the main filter were to fail. • Determine the size of the operation, i.e. how many work stations, how many will be operating at the same time on average (duty cycle). Even though a welding shop may have 25 welding stations, it may not be necessary to fully size the extraction system for 25 work stations all operating at one time. In discussion with the client, it could be determined that no more than 60 per cent of the work station will ever be working CONFERENCE at the same time, therefore allowing cost savings in sizing a smaller system. Furthermore, even if all work stations are operating at the same time, the welders are not all striking an arc at the same time in unison. The use of automatic dampers

UTURE OF

ating Cutting

with fan speed controls allows for suction to happen where needed when needed, resulting once again in the possibility to size a smaller system and exhausting less heated air outside. Taking this in consideration, this also allows to size a smaller filtration system if applicable. • Determine the dimensions of the work shop, what will the distance be between the exhaust fan and the furthest point in the shop? This information is important for fan sizing and ductwork design as well as installation consideration. With a greater understanding of your welding process and work environment the consultant will design a solution tailored to your group’s specific needs. At the end of the day to survive as a lean business, it is now standard for all manufacturing groups to run a multifaceted process by thinking green, maximizing production, efficient energy usage, reducing expenses, implementing a strong health and safety agenda which will result in having happy employees, improve product quality and last of all a being known as reputable company who produces great product and takes care of their employees. CM Guy Arsenault is project specialist with Nederman Canada, Mississauga, ON. www.nederman.ca

Mark your calendar for Conference streams

The Future of Fabricating Cutting Conference is a one-day conference organized by Canadian Metalworking. One conference stream will educate you on where fabricating cutting technology is going. The other conference stream will help you address issues surrounding key management issues. You can mix and match the presentations you hear based on your needs.

NOVEMBER 8, 2011 TORONTO CONGRESS CENTRE

Exhibits

As part of the conference, leading machinery, equipment and services suppliers will be available during breaks and at lunch to discuss problem solving. SPONSORS canadianmetalworking.com house adV4.indd 1 | April | www.canadianmetalworking.com 72 FC 2011

3/21/11 11:07:55 AM

Paint handling tips Automating paint handling operations can cut costs, but is it right for your operation? By Nate Hendley ....................................................................................... We recently ran a few questions about automating paint handling systems past a few experts. Here’s what they had to say: How do you know if your paint handling system is suitable for automation? “If there are enough parts and these can somehow be placed on a jig or a conveyor and go through a spray booth, there is a good chance you can convert to automation,” says Hans Wolf, liquid group manager, Wagner Systems, Elgin, IL. “Generally speaking, it is time to automate when you can no longer meet production or quality requirements. An automated system can provide higher throughput and also improved quality with regards to finish, uniformity and reduced rejects. Additionally, an automated system will also provide increased transfer efficiency or improved utilization of the coating material. This will in turn reduce material usage and other related costs and improve the margin,” adds John Owed, business unit manager, transportation group, ITW Ransburg, Toledo, Ohio.

Wagner’s automatic AirCoat gun uses the company’s new AirCoat air atomization process.

Are there levels of automation and can a company gradually move to a fully automated paint handling system? “There are different levels of automation, but investing in automation all comes down to payback time. Sometimes it is possible to gradually move from semi-automated paint handling systems to fully automated paint handling

systems,” says Wolf. “Automation can be employed at various stages of the painting process: application, mixing, part handling, material delivery, tracking, etc ... each area can be analyzed to find where automation can be of benefit (in terms of labour cost reduction, material cost reduction through reduction in overspray, quality improvements through more consistent paint application, worker safety improvements through reduced exposure to hazardous chemicals, etc.),” says Blake Erickson, worldwide marketing manager of Graco, Minneapolis, MN. “The amount and level of automation is typically determined by production rate requirements. How many parts need to be processed in a specified time frame? What are the [company’s] future expansion plans and opportunities? Often we see a coating operation evolve over a period of time. With regards to liquid coatings, an end user may start out with a conventional spray gun and pressure pot. As the demands increase, the user may graduate to an electrostatic gun supplied from a small pumping system. A greater leap is then made when the user moves to an automated system,” says Owed. What’s the best way to control the cost of automation? “Implement the automation in phases, by applying it to areas that bring greater return on investment and have www.canadianmetalworking.com | APRIL 2011 | 73

PAINT HANDLING

a high probability of success. Once the automation process is running well, you can look into further areas that might allow automation to be a benefit. Graco, for example, introduced the ProMix 2KS proportioning system designed to integrate into an automatic painting operation. This system mixes two component paint and can be driven by automation to control mixing, colour changes, flow rate and material reporting,” says Erickson. An electronic proportioner, such as Graco’s ProMix 2KS, can handle solventborne, waterborne and acid catalyzed materials and is designed to boost efficiency on the finishing line. Equipment purchases in general are sometimes the key to controlling future costs. “Obviously, automation is capital investment. A lot of companies can amortize that over three to five years ... the big advantage is, a robot will work 24 hours a day, seven days a week and it doesn’t stop for the flu, smoke breaks or body breaks ... and you don’t pay it benefits. In today’s marketplace [managing] benefits plays a big part in keeping

your fixed costs to a minimum,” says Brad Sparkman, president of Innovative Finishing Solutions, Orangeville, ON. Simple things, such as how you set up your plant floor or finishing process, can also have an enormous bearing on cost. “Sometimes what happens, you have the paint kitchen miles away from application area ... that is a waste of travel, waste of changing colours, waste of solvents ... all of that can be controlled if the location of the paint kitchen is properly designed,” says S.T. Rajan, vice president of Exel North America’s Canadian branch, based in Scarborough, ON. “Invest wisely and assemble a team that consists of an equipment supplier, system integrator and coating company,” adds Owed. What are the essential components of an automated paint handling system? “Historically, an automated system would consist of automatic electrostatic guns or rotary atomizers mounted on a long or short stroke reciprocator. Today, an automated system usually consists of

Fanuc’s Paint Mate 200iA is one example of how you can automate your paint finishing line.

PAINT HANDLING

“Repeatability is critical in finishing and robots are servo-driven, so they’re incredibly accurate on repeatability.”

ITW Gema’s automated powder handling system.

application it is has, “feeding pumps, perhaps agitators, a light barrier system to keep track of the parts to be painted, mixing units, spray guns/high rotation bells and control units are the most common [pieces of] equipment,” says Wolf.

an electric painting robot. With today’s manufacturing trends, robots offer end users a very flexible system that is adaptable to coat a wide variety of part configurations. The robot can then be coupled with a fluid delivery system and applicator that will permit quick and efficient colour change,” says Owed. While a finishing shop will need different equipment depending on what

What impact does automating the paint handling system have on the paint finishing process? According to Sparkman, the answer is repeatability. While “people get tired, working eight hours in a booth” and become prone to making mistakes, robots don’t. Repeatability is one of the most critical things in finishing ... robots are servo-driven, so they’re incredibly accurate on repeatability. So with that, we can maintain consistent gun to target distance, consistent tip speed ... and then the applicator quite often will have a closed loop fluid control system so the fluid delivery stream is exactly what you want and doesn’t vary and spike. And that all results in a beautiful [and] consistent finish overall.” Has your company released any new automatic paint handling system components recently or have anything new on the drawing boards? DeVilbiss, part of the network of companies that makes up ITW Finishing Technologies, recently released the

Compact Automatic X spray gun. Said gun has a quick-release mechanism that reduces change-out time to three seconds and doesn’t require any tools for detachment. This feature is designed to speed up production. The gun also boasts a flow rate of up to 600 cc/minute. Wagner, meanwhile, recently released the GA 4000AC automatic AirCoat gun. The gun offers fast application speed, low overspray and high transfer efficiency. Its compact size (the gun body weighs under 500 grams, making it “the smallest and lightest automatic AirCoat gun on the market,” according to Wagner literature) is also a bonus. For its part, Innovative Finishing Solutions has been doing “a lot of business” with the new PPH 707 bell, a robot mounted bell manufactured by Sames, a branch of Exel Industries, says Sparkman. The bell offers “incredibly high transfer efficiency” says Sparkman and can be mounted on all types of multi-axis robots. CM Nate Hendley is a regular contributor and freelance writer. www.kremlinrexson-sames.com www.graco.com www.itwfea.com www.innovativefinishing.ca www.wagnersystemsinc.com www.canadianmetalworking.com | APRIL 2011 | 75

FINISHING/POWDER GUNS

When to Automate How do you know if it’s time to automate your powder operation? Powder coating consultant Pierre Bachand has a few pointers that may help. By Pierre Bachand

Investing in an automatic paint system is always a question of money, but it’s also the reason a company should invest in it. The real question is when to invest. 1. When it is necessary to increase income (business) 2. When it is necessary to keep the present level of income (business) 3. When it is necessary to stop loosing money Here are the key factors and situations you may find yourself in that will help determine if your operation requires an automatic finishing system. 1.Requirement to increase work volume There is an increased demand for the manufactured goods produced. There may come a time when the paint line simply can’t handle the volumes. You have the very best and latest powder units but you still can’t keep up with production volumes. You can’t add another painter as there’s no more place in the booth and you can’t more parts per rack because the painter can’t keep up. And there are costs and problems associated with opening another shift. 2. Requirement to increased line density There is a lot of space between parts or not enough parts per hook/rack but because of the square footage to be covered or complexity of parts once the painter has completed the main surfaces, he doesn’t have enough time to do any reinforcing. 3. Requirement to reduce cost per unit This is another way to say ‘we have to paint more parts in the time we have.’ We may be able to increase conveyor speed but the personnel will not keep up. It may also mean that by installing an automatic system, we can do the job of two shifts in one more efficiently. 4. Demand for repeatability This is the need for better quality parts. Parts that consistently have similar coating thicknesses and optimum coverage time after time. 5. Need to improve productivity Productivity means doing it right the first time in the most efficient way. If I’m to paint a large number of parts consistently at minimum cost, an automatic system may be the 76 | april 2011 | www.canadianmetalworking.com

answer. It is easier and more economical to put in an automatic system than to hire and train additional painters.

Automation and ROI

The most important factor to consider in deciding when automation may be a good option for your finishing operation is the return on investment. The main thing to remember is that fixed costs are variable on the number of items painted, but variable costs are fixed on those items. Here’s an example of what I mean by this: if I invest $100,000 on a automatic system (add-on to an existing booth) it may be possible to increase production by 3,000,000 sq ft per year. My cost per part is an additional $0.03 per sq ft based on a one year payback or $0.015 over two years). Presently we are painting approximately 1,000,000 sq ft with two painters at $25,000.00/yr per painter or $0.05 per sq ft, always. Remember that paint is a variable cost but is a fixed cost per part painted. This thinking is good for manufacturers and custom coaters. For the manufacturer, the need to install an automatic system from scratch may become necessary because of poor quality sub contracted parts, late reception of parts (i.e. JIT problems), increasing costs, time lost in communication, parts lost, and mistakes. There is a simple calculation you can do to determine powder cost and estimated savings if you were to convert to an automated system. First, you would need to know the estimated quantity of paint used annually and the approximate price per kilogram. Your coatings supplier would be able to provide this information based on the square feet of product painted per year, the number of colours, the types of coatings and whether your finisher works with a “spray-to-waste” or closed loop reclaim or recycling powder system. To calculate the savings you could achieve with an automatic finishing system, you would estimate a reasonable profit margin (e.g. 30 per cent) of your annual cost for painting plus transport costs and any other cost that would disappear when painting in-house, so an approximate total of 40 per cent. The calculation then goes like this: $600,000 x 40 per cent =

FINISHING/POWDER GUNS

coaters work exclusively by batch production of small to medium volume. They do a multitude of colours and finishes and frequently specialize in parts that require masking. Some may have a small conveyor system but all the painting is done manually. The smaller coater may be forced to invest for the very same reasons the manufacturer does. To go automatic for this coater is a major change and may imply a large risk factor, especially if there is not a large pool of potential high volume manufacturers that can feed him. The other category of coater may have a batch system but already uses automatic guns with (ideally) a reclaim/recycle system for the paint when he does large volumes of one colour. Colour change time usually dictates if it’s spray-to-waste or reclaim/recycle.

Equipment advantages in automation

One of the advantages in moving to an automated system is the powder application equipment. Equipment suppliers have made significant improvements on electrostatic powder application systems. Two key areas of improvement are amperage control and powder flow control. Developments in these areas have improved first pass transfer efficiency and repeatability.

Amperage Control

Lab and field tests have shown that 100 kV is the maxium useful voltage that can be efficiently applied consistently to powder paint particles. Image: Nordson.

$240,00/year. What do I need to paint this quantity of material, what needs to be purchased for this amount of money, how much labour would be required, where would I set up the system? These are the questions you need to answer.

Custom Coaters

The custom coater’s vision is a little different. Some custom

Extensive lab testing and field experience has shown that 100 kV is the maximum useful voltage that can be efficiently applied consistently to powder paint particules. Above 100 kV the improvement is negligible at best, and the dependability and life of the cascade are reduced, due to the extra stress on the insulation material associated with high voltage. High voltage constantly seeks ground; any weakness in the plastic will eventually result in high voltage pinholing. Powder equipment suppliers all offer units that control the available amperage. These units have basic settings or recipes, typically three or four are used for specified target types. These settings are somewhat similar. Here are a few: • easy targets • difficult targets (recesses) • recoat targets • metallic powders • low or high powder flow • small targets All the units offer additional programmable settings that

Industrial Solutions

Quality Finishes

F I N I S H · F U N C T I O N · F L E X I B L E

Perfection right down to the finish - with coating technologies from Wagner you can put the finishing touch on your products. You can rely on innovative ideas, protected and user-friendy application technologies and excellent service from WAGNER. For value solutions contact us. Wagner Systems, Inc. Phone: 630-503-2400 Fax: 630-503-2377 www.wagnersystemsinc.com

www.canadianmetalworking.com | april 2011 | 77

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FINISHING/POWDER GUNS

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Agie Charmilles Corp 31 Bohler-Uddeholm Corp 37 Brubaker 43 Canadian Metalworking 5, 79 Carl Zeiss Imt 57 Chem-Ecol Ltd 32 43 Data Flute Delcam International Inc 30 Dmg/Mori Seiki Usa 28 Elliott Matsuura 4 Esab Canada 19 Fastcut 43 Ferric Machinery 67 Future of Fabricating Conference 72 Future of Metal Cutting Conference 58 Gibbs & Associates 33 11 Haas Automation Haco Canada Inc 63 Hardinge Inc. Workholding Div 34 Heinman Machinery Ltd 38 Horn Usa Inc 7 Hurco Machine Tool Products 2 Ingersoll Cutting Tools 53 Iscar Tools Inc 82 Lvd Strippit 64 Mate Precision Tooling 66 13 Messe Dusseldorf Osg Canada Ltd 50 Pct Carbide/TNT 54 Prima Power North America, Inc. 69 Reid Tool Supply Company 74 Renishaw (Canada) Limited 14 Sandvik Coromant Company Cover Flap, 41 Schmolz & Bickenbach Usa Inc 35 Schunk Intec Corp 46 Scientific Cutting Tools Inc 47 60 Scotchman Industries Inc Seco Tools Inc 49 Sgs Tool Company 52 Smd Machinery 62 Sme Canada - Cmts 56 Sme Canada - Wmts 16 Sumitomo Electric Carbide 9 Technique for Ferro Technique Ltd 17 Thermadyne 71 Trumpf Inc 65 Tungaloy Canada Ltd 3 Wagner Systems Inc 77 Walter Usa Inc 45 Weldon 8CMM20186 01/07/2008 08:1943AM West Jet 81 Wilson Tool International 61

IN STOCK American Standards and specials. Japanese Standards inch or metric.

FOR FAST DELIVERY: Contact your local tooling dealer or order direct. TEL 937-686-6405 FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O. Box 61 Bellefontaine, OH 43311 78 | april 2011 | www.canadianmetalworking.com

“ Technological advances have improved powder flow control and delivery at the nozzle.” Page 1 tailored by the operator for specific parts, powders and can be

thicknesses, for example. One controller can store as many as 250 recipes or more, which is significantly more than 95 per cent of all finishers with automatic system use. The main advantages of these new control parameters include: • reduced or eliminated picture framing • better penetration of recesses • easier recoats • easier application of specialty powder such as metallics and blends • precise thickness control • overall better repeatability of results

Powder Flow Delivery

One additional area that has benefited from technological advances is the significant improvement in powder flow control and delivery at the nozzle. A couple of years ago I completed an audit at a client’s facility where the equipment manufacturer stated one per cent variation on powder flow over a specified range. After sampling and weighing all the guns’ powder delivery it was right on target; there was not more then one per cent variation over the 12 automatic guns. CM Pierre Bachand is a regular contributor to Overspray, and president of Chromatech Inc., a finishing training and consulting firm based in Quebec.

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Metal...Works Extending Cutting Tool Life Cost cutting tips to maximize cutting tool performance By John Mitchell ................................................................................................ Flank Wear

Crater Wear

Notch Wear

Corner wear width VBc (in)

Flank wear width VB (in)

Corner wear width VBc (in)

Flank wear width VB (in)

Flank Wea At the heart of your machining operation is the cutting tool. CRATERING Excellent performance on cast irons after 30 mi .003 Competitor A When your cutting tool fails, your machining process fails. This appears as a crater or pitting on the top of the insert’s rake Competitor A Canadian Metalworking asked John Mitchell, general manager face. Cratering is generally caused by a chemical reaction CM type T5115 .006 for Tungaloy America, Brantford, ON, how manufacturers can between the material being cut and the insert itself. The crater extend cutting tool life. appears behind the cutting edge and leaves the cutting edge in .004 There are many factors that contribute to tool life. You need tact. Eventually the crater expands to the cutting edge,CMcausing type T5115 to consider the failure mode of the insert to determine a plan unpredictable catastrophic failure. Cratering can be caused by .002 to extend tool life. There are many failure modes; recognizing excessive speed, excessive feed, the wrong grade selection, or them will help determine an action plan to correct and extend the wrong insert geometry. 0 5 10 15 20 25 30 Flank Wear Crater Wear Notch Wear tool life. Cutting time T (min) Check the insert before THERMAL CRACKING Flank Wear: Excellent performance on cast irons .010 after 30 min Competitor A AH725 is more wear resistant th catastrophic failure. A broken insert Thermal cracking appears as small crack .003 Competitor A conventional and competitor’s c Competitor A Conventional leaves no clues remaining as to why lines on an insert, caused bygrades. fluctuations .008 CM type T5115 .006 the tool broke. Check the tool at one in temperature, caused by an Workintermittent material : 1045 SAE Steel .006 Cutting speed : v c = 650 SFM third and two thirds of it’s estimated coolant supply. The insert gets extremely Depth of cut : a p = .040 in .004 Feed cooled: fby = .006 ipr tool life. hot .004 when in cut. When quickly CM type T5115 AH725 Cutting fluid : Water soluble type (Int The ideal failure mode is flank a burst of coolant, it causes small cracks. .002 .002 wear caused by abrasive wear. These cracks eventually chip, causing 0 Flank wear is inevitable and unpredictable catastrophic failure. One 5 10 15 20 25 30 0 30 60 Cutting time T (min) indicates normal and predictable solution isCutting to ensure a constant flowA of Conventional Competitor time (min) .010 wear. The process needs little coolant. Be careful about coolant flow Competitor A AH725 is more wear resistant than and competitor’s coated change. A harder insert grade should be.008tried up to the Conventional point conventional grades.direction. As the part is being machined, the chip comes off another failure occurs, such as chipping. There is a trade off the part and Work material : 1045 SAE Steelcreates an umbrella, blocking the coolant from .006 speed : v c = 650 SFM between hardness and brittleness of an insert. Run the hardest Cutting reaching the cutting area. The coolant should be directed to get Depth of cut : a p = .040 in Feed under : f =the .006 ipr .004 insert grade that will create flank wear and not chip, thereby chip. Often, directing the coolant to approach the AH725 Cutting fluid : Water soluble type (Internal supply) extending tool life. part from the side, or slightly under the holder can prevent the .002 North American machine shops measure tool wear by the umbrella effect caused by the chip formation. When machining number of parts machined per edge. Japanese manufacturers in an interrupted cut, the coolant should be shut off completely. 0 30 60 Conventional Competitor A AH725 time (min) measure flank wear at predetermined intervals. Cutting The insert with Reducing the speed may help to reduce the heat. Select a the least flank wear is the insert that should have the longest, grade with a high thermal shock resistance. most predictable tool life. Your plan should be to remove the following failure modes CHIPPING AND FRACTURING until the desired flank wear is achieved. This failure mode appears as a chip out of the cutting edge. This is not cutting tool wear and is unpredictable. Some ways to prevent chipping and fracturing are to select a softer grade of insert. Select BUILT UP EDGE (BUE) a holder or cutter with a different lead angle so the insert leads into BUE occurs when the material being cut adheres to the insert. It the part with the strongest part of the insert. Increase the hone size can be prevented by running a higher RPM and using an insert on the insert (accomplished with the selection of a chip-breaker). with a slippery surface so the chip flows over the insert without Improve the set up to improve rigidity. sticking. A heavier flow of coolant may help prevent BUE. Cermet cutting tool materials help reduce BUE.

NOTCHING

A notch that appears on the insert, generally at the depth of cut, occurs most often where the outer surface of the part being machined is harder than the rest of the material. This is common in case-hardened parts, or parts with a scale such as forged parts. Varying the depth of cut (DOC) will help to reduce the effect of notching. This can be accomplished by cutting a taper on the first pass and then cutting a straight pass, producing a constantly changing DOC. Other solutions include changing the grade, lead angle and chip-breaker. 80 | APRIL 2011 | www.canadianmetalworking.com

DEFORMATION

Deformation occurs when the insert deforms or softens from heat or pressure. The cause is normally an insert grade that is too soft. To reduce deformation: • select a harder insert grade • reduce the speed to decrease the heat • reduce pressure by using a positive cutting geometry and reducing the feed. John Mitchell is general manager for Tungaloy America, based in Brantford, ON. www.tungaloyamerica.com