SKILLED TRADES IN CANADA Apprenticeships up, but retirements loom - p24
PRECISE PIPE PRODUCTION Lasers for cutting, drilling and marking - p32
STEPPING UP TO CMM Entry-level metrology options that work - p72
HIGH-TECH IN TAIWAN Building high-quality machines - p108
AUGUST 2014
PM 40069240
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Sandvik Coromant : Booth W-1500, IMTS 2014
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Pioneering solutions for years to come Every day, we’re in customer shops solving new machining challenges, finding ways to help them meet ever-increasing demands for quality, cost efficiency and productivity. We’re developing new tooling solutions to machine complex components in materials we didn’t even dream of years ago. Visit the Sandvik Coromant booth W-1500 at IMTS 2014 and check out the new tools and unique solutions we’ve developed for your business today, then get a sneak peek at what your shop might look like in the future - no crystal ball required. Meet your future goals here.
www.sandvik.coromant.com/imts
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AUGUST 2014 ß VOL. 109 ß NO. 6 www.canadianmetalworking.com
A LOOK INSIDE SPECIAL ISSUE: IMTS 2014 CHICAGO PREVIEW THE STATE OF SKILLED TRADES IN CANADA — 24 Apprenticeships up, but boomer retirements loom
THE CANADA JOB GRANT — 28 New initiative hits a few bumps on the road
SKILLS TRAINING PROFILE — 30 Northern Alberta Institute of Technology, Edmonton, Alberta
COVER STORY — 38
INTERNATIONAL MANUFACTURING TECHNOLOGY SHOW 2014: CHICAGO, ILLINOIS
PRECISE PIPE PRODUCTION — 32 Lasers simplify cutting, drilling and marking tube and pipe
32
SUCCESS BY SINTERING — 58 Additive manufacturing moves to metals
GETTING THE FUMES OUT — 66 Portable fume extractors protect welders
STEPPING UP TO CMM — 72 Entry-level metrology options that work
58
THE TRUE GRIT — 78 Quality matters in disk grinding
JOIN THIS! — 86 Is hybrid laser welding in your future?
24 66 72 www.canadianmetalworking.com
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AUGUST 2014 ß VOL. 109 ß NO. 6 www.canadianmetalworking.com
A LOOK INSIDE 86 FEATURES (CONT.) PRECISION IN THE TINIEST OF OBJECTS — 90 Shimifrez uses a novel photo-etching technology
THERE’S A POST FOR THAT — 94 Post processors for the best in CAM/CNC operation
FINANCING YOUR SUCCESSION PLAN — 98 Alma Johns explains the options
94
78 90
HIGH-TECH IN TAIWAN — 108 Building high-quality machines with modern manufacturing
DEPARTMENTS VIEW FROM THE FLOOR — 10
108 WE’RE GROWING… THANKS!
NEWS — 12 WELDING NEWS — 64 TOOL TALK — 102 KEN HURWITZ ON FINANCE — 126
(L-R) Barb Vowles, production manager, Jim Anderton, editor, Lindsay Luminoso, associate/web editor, Stewart Thomas, art director, Rob Swan, associate publisher, Steve Devonport, publisher, Nick Healey, account manager.
Canadian Metalworking Magazine is pleased to announce the expansion of our team to serve the industry even better. Nick Healey moves to advertising sales and Lindsay Luminoso takes over as Associate/Web Editor and the magazine welcomes Stewart Thomas as art director. Thanks to our readers across Canada for helping us grow, again!
And don’t forget to follow along and engage with us on social media – look for us on Twitter, Google+, and Facebook!
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www.canadianmetalworking.com
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Amada_5-2014_CM_Cote_Inox_ad_Layout 1 4/5/14 11:11 AM Page 1
Gaston Côté, Director of Sales & Marketing Nancy Côté, Administrative Manager and Stéphane Côté, General Manager
“Leading-edge technology, combined with unmatched service and support are the reasons we chose Amada.” — Stéphane Côté General Manager Groupe Côté Inox
“It’s The World’s Fastest, Most Productive Fiber Laser.”
www.amada.ca
Groupe Côté Inox, with its two divisions, Côté Équipements and Côté Métal, is the most versatile company of its kind in the Québec metal processing industry. Since 1977, this family-owned business has provided full service sheet metal fabrication as well as design, manufacturing and installation of finished and readyto-use food processing equipment parts. Faced with equipment that could no longer keep pace with everincreasing demands for speed and precision, the company turned to Amada for the optimal solution. Stéphane Côté, General Manager, reflects on their recent purchase, “Our decision to buy Amada’s Fiber Laser allowed us to regain our competitive edge and to once again provide our thin metal industry customers the superior quality they have come to expect. Furthermore, with the addition of automation on the FOL 3015 AJ, the entire system is now autonomous, it loads raw material and unloads finished parts.”
An 8-station changer automatically changes, cleans and calibrates the nozzle based on material processing requirements.
With all three axes driven by linear drives, Amada’s FOL AJ delivers rapid traverse speeds of 13,380 ipm and a 5G acceleration speed for the entire work envelope — the system’s maximum cutting speed of 9,449 ipm cuts processing time in half !
The FOL 3015 AJ Fiber Laser and ASUL Automation Provide: • Non-Stop Productivity (Cutting 3 to 4 times faster than a comparable 4000 W CO2 laser, the FOL AJ is ideally suited to meet the demands of high volume contracts. The ASUL automated material storage load/unload system ensures that speed and productivity are mathematically predictable — delivering around-the-clock production).
Amada Canada, Ltd. 885 Avenue Georges Cros, Granby, Quebec, Canada J2J 1E8
800-363-1220 2345 Argentia Road, Unit #101 Mississauga, ON L5N 8K4
800-561-4578
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• Uncompromising Accuracy (Amada’s 3-axis linear drive system ensures absolute accuracy even at the highest cutting speeds). • Expanded Capabilities (The system’s resonator generates a laser beam with a wavelength that is approximately a tenth of that produced by a conventional gas laser — expanding processing capabilities to include materials that were previously difficult or impossible to cut with CO2 lasers). Gaston Côté, Director of Sales and Marketing, adds, “We are very satisfied with the results we’ve obtained. Amada’s Fiber Laser and automation have greatly improved our productivity and increased profits while reducing lead-time and cutting costs.”
14-08-07 4:00 PM
VIEW FROM THE FLOOR
GM’S BIG RECALL: LESS THAN MEETS THE EYE
I
Do you agree? Let me know, and feel free to drop me a line at the email address below, or buttonhole me at a show or event. I’d love to hear from you!
n the auto industry, recalls, once rare, are now so frequent that they barely warrant mention in the daily news. Of the recent batch, the mother of them all is of course the General Motors ignition switch problem which at press time has resulted in a known 13 fatalities. The problem is simple: the key rotates back to the “off” position, shutting down the engine and power steering as well as the air bags. That’s not good, but it should be noted that the effect is the same as stalling the engine while in motion…steering control is not lost, but the lack of power assist makes it more difficult. Braking is similarly not an issue, as almost all modern systems are boosted by engine vacuum and incorporate a check valve to maintain this boost long enough to bring the car to a safe stop. Tragic as the fatalities are, the defect is not as serious as the mass media would have us believe. If you’re a Tier One or Two, you either build the part to the customer’s drawing or you design the part to your customer’s specification, but either way running changes to improve reliability and reduce cost (or both) are common. In the case of the GM ignition switch, reports of the keys turning back resulted in a running change to the design, one which was not accompanied by a change in the part number. This means that it’s difficult-to-impossible to determine which
PUBLISHER STEVE DEVONPORT 416.442.5125 ß sdevonport@canadianmetalworking.com ASSOCIATE PUBLISHER ROB SWAN 416.510.5225, cell 416.725.0145 ß rswan@canadianmetalworking.com ACCOUNT MANAGER NICHOLAS HEALEY 416.442.5600 x3642 ß nhealey@canadianmetalworking.com EDITOR JIM ANDERTON 416.510.5148 ß janderton@canadianmetalworking.com ASSOCIATE/WEB EDITOR LINDSAY LUMINOSO 416.442.5600 x3645 ß lluminoso@canadianmetalworking.com EDITORIAL DIRECTOR LISA WICHMANN 416.442.5600 x5101 ß lwichmann@canadianmanufacturing.com ART DIRECTOR STEWART THOMAS 416-442-5600 x3212 ß sthomas@bizinfogroup.ca CIRCULATION MANAGER SELINA RAHAMAN 416.442.5600 x3528 ß srahaman@bizinfogroup.ca
switches are bad and hence, a massive recall. The mass media are reporting this as if it’s a criminal conspiracy. The fact is, running changes are commonly tracked by the print revision numbering system, not by part number. Changing part numbers with each print revision would cause supply chain chaos, adding to confusion that already exists when new parts carry numbers that supersede older designs. The move to standardize common parts across multiple models is not only a unit cost control measure; it is also intended to control part number proliferation. That’s a good thing, but if OEM customer feedback results in a demand for changes that significantly alter the part’s form, fit or function, the customer will ask for and get a new part number. Changing to an internal spring with a slightly higher tension wouldn’t justify a new part number since the problem was a convenience issue, not a safety problem when it was first noticed. Has the recall hurt GM? Less than many believed, as sales remain strong. Other manufacturers are cleaning house with recalls of their own, but with the desire to increase parts commonality across multiple models, larger recalls can be expected. Toyota bounced back nicely from their accelerator pedal issue, and GM will do the same.
JIM ANDERTON, EDITOR janderton@canadianmetalworking.com
HOW TO REACH US Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, North York, ON M3B 2S9 Phone: 416.442.5600 ß Fax: 416.510.5140 CM, established: 1905 is published 8 times per year by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. SUBSCRIPTION RATES Canada $55.00 per year, Outside Canada $90.00 US per year, Single Copy Canada $8.00. RETURN UNDELIVERABLE TO CIRCULATION DEPARTMENT 80 Valleybrook Drive, Toronto, ON M3B 2S9 All rights reserved. Printed in Canada. The contents of the publication may not be reproduced or transmitted in any form, either in part or in full, including photocopying and recording, without the written consent of the copyright owner. Nor may any part of this publication be stored in a retrieval system of any nature without prior written consent.
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Content copyright © 2014 by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd., may not be reprinted without permission.
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CM receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. CM, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort.
PRESIDENT OF BUSINESS INFORMATION GROUP BRUCE CREIGHTON VICE-PRESIDENT OF CANADIAN PUBLISHING ALEX PAPANOU EXECUTIVE PUBLISHER, MANUFACTURING TIM DIMOPOULOS
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CM accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DISCLAIMER This publication is for informational purposes only. The content and “expert” advice presented are not intended as a substitute for informed professional engineering advice. You should not act on information contained in this publication without seeking specific advice from qualified engineering professionals. PRIVACY NOTICE From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1.800.668.2374 Fax: 416.442.2191 Email: jhunter@businessinformationgroup.ca Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9 Canadian Publications Mail Agreement: 40069240 ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.
www.canadianmetalworking.com
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Micro Circular Milling Taken to the Extreme
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05.03.14 11:31 14-07-09 14-03-06 1:54 3:29 PM 14-08-07 4:01 PM
IN THE NEWS
GLOBAL GRINDING SYMPOSIUM 2014: SWISS SUCCESS
thanking our customers”, explained Stephan Nell, CEO of the United Grinding Group AG, as he welcomed the participants. “A way of saying thank you for the loyalty and trust which our customers place in us.” The lectures ranged from materials in grinding tool development to increasing productivity in the design of grinding processes, as well as the reduction of grinding forces and processing/auxiliary times. Simultaneous translation into four languages was offered to attendees who filled many lecture halls to standing-room capacity. During
ns
MI TO ns L O fo L T L rS U I pe R NG ci a N l A LA FO pp T R lic HE at io S
S fro ee m Ma a Ne chin w i ng An gl e
On May 21 to 23 over 1,400 daily visitors from 40 nations enjoyed spectacular scenery, fine weather and advanced technology at the United Grinding Group’s Grinding Symposium 2014 in Thun, Switzerland. The theme for the event was “Making our customers more successful” and 30 machines from the Group were presented at 14 stations, including five premiers: BLOHM PROKOS XT, JUNG JE600, STUDER S141, SCHAUDT CrankGrind, and EWAG LASER LINE ULTRA. The program included extensive educational opportunities with 154 tech presentations and 20 lectures by industry experts. “The Symposium is also a way of
the press conference Michael Horn, COO of the United Grinding Group AG, explained the background and effects of the firm’s internal “PuLs” program. “It is more than just production optimization. PuLs illustrates our corporate philosophy, which is to align all processes with our customers’ requirements, to find and utilize potential for optimization and to minimize waste. The level of actual customer satisfaction is regularly surveyed with the Net Promoter Score (NPS) measuring method. The worldwide implementation of both standards demonstrates the aspiration by all companies in the United Grinding Group to set benchmarks with their production processes in the grinding machine industry throughout the world”, concluded CEO Stephan Nell.
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IN THE NEWS
HAAS HOLDS AN OPEN HOUSE IN TORONTO BY NATE HENDLEY The Haas Factory Outlet in Toronto held a packed open house on May 28, offering machine tool displays, demonstrations and plenty of tool talk. Dan Ferko, president of the Haas Factory Outlet (a division of Sirco Machinery Company, Ltd.) was particularly eager to show off the UMC750, a new machining center from Haas Automation Inc., headquarters in Oxnard, California. “We’re really happy to have the UMC-750 here. It’s our newest fiveaxis universal. We introduced it at CMTS last year … and now we have it here at the open house for the first time. It’s just been an incredible success,” said Ferko. The UMC-750 offers X, Y, Z travels of 30 inches x 20 inches x 20 inches
(762 mm x 508 x 508), and an 8,100rpm inline direct-drive spindle. This vertical machining center has an integrated dual-axis trunnion table 24.8 inches x 19.7 inches (630 mm x 500 mm) in size and a standard 40+1 tool side-mount tool changer. Bryan O’Fallon, a Haas product technical specialist, outlined the company’s plans for the UMC-750. “We’re looking at a super-speed version [of the UMC-750] to have a higher rpm spindle, faster rotary speeds, faster rapids. We’re hoping to release it at IMTS this year,” said O’Fallon. Ferko also emphasized Haas’ turning line, “which is taking off gangbusters right now. We’ve got everything from an ST-10 to ST-30. We’ve got a multi-axis DS-30SSY dual spindle machine with C axis and Y axis capabilities. We’ve got a really good assortment
PHOTO: NATE HENDLEY
of equipment here,” he stated. Other Haas machine tools on display included the VF-4SS superspeed VMC, the EC-400 HMC, VM-3 VMC, etc. Ferko hoped the open house gave attendees a sense of the diverse Haas product line. “The breadth of the product line is fairly incredible. Haas is a relatively young company in the machine tool industry. Only been around for 25 years. But volume-wise [in terms of shipping new machines] they are one of the biggest in the world,” he stated.
Visit us at booth N-6698
PHOTO: NATE HENDLEY
COMING IN SEPTEMBER… Canadian Metalworking will feature automotive manufacturing in Canada with a focus on mass production machining and large part fabricating. To learn more, check out our next issue.
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25
Celebrating Years
IN THE NEWS
BSF
Back Spotfacing & Counterboring Tool The BSF tool back spotfaces or back counterbores in one operation without turning the workpiece Counter Bores Up to 2.3xd
BSF
Counter bores up to 2.3xd
For Product Videos and Brochures visit www.HeuleTool.com
IMTS Booth W-1352 16 | AUGUST 2014
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CANADIAN AUTO INDUSTRY SEES SILVER LINING Despite previous projections that Canada will struggle in the upcoming years to compete with Mexico and the U.S. when it comes to auto production, vehicle sales are growing. According to the Conference Board of Canada’s’s Spring 2014 Industrial Outlook publications, pre-tax profits for both Canadian auto makers and motor vehicle parts manufacturers are expected to reach $1.3 billion — a number that hasn’t been seen in over a decade. Could this mean that Canada is becoming wise to the supply and demand issues that had plagued the auto industry in the past? Not exactly, according to CanadExport and Statistics Canada. In 2009, auto exports decreased to a low of $41.7 billion. However, in recent years, there has been a gradual increase to $65.3 billion in 2012. The Canadian auto industry is heavily reliant on exporting and the purchasing power of foreign markets has been thriving. In 2011 alone, 76 per cent of the Canadian production was exported and 97 per cent of those exports were to the American market. What this means is Canada must compete against not only other foreign importers but domestic producers as well in order to continue to grow its auto industry. And it is predicted that Mexico will surpass Canada in vehicle exports to the U.S. for the first time in 2015, according to the Conference Board of Canada.
The silver lining is that there are positive signs in the market and if the Canadian auto industry can stay competitive and grasp the attention of consumers, they may continue to post positive profits. One way they are doing this is through updating several Canadian plants and readjusting productivity models. These upgrades, although for a short time drove down productivity, will better position the sector to take on growing demands. The motor vehicle manufacturing industry is expected to have a strong year due to the high demand for parts by Canadian manufacturers. The Conference Board of Canada expressed that a drop in the Canadian dollar may ease competitive pressure and drive demand for Canadian products up. Parts producers in Canada are expected to generate healthy pre-tax profits of $1.5 billion in 2014. “It was a chilly start to the year for car sales but the spring thaw has brought customers back to the car lots at record-breaking levels,” Jacqueline Palladini, Senior Economist with the Conference Board, said in a statement. “American consumers, in particular, are replacing their older vehicles due to a steady increase in income, jobs, and credit availability.” With both the auto makers and parts manufacturers expected to post strong profit growth, it appears that the demand for Canadian made products is being capitalized on. The key to success in the future will be to produce high-quality and cost-effective parts and vehicles that American consumers want to buy. Sound easy enough? www.canadianmetalworking.com
14-08-07 5:21 PM
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IN THE NEWS
SKILLS CANADA HOSTS NATIONAL COMPETITION IN MISSISSAUGA
WINNERS OF THE METALWORKINGSPECIFIC COMPETITIONS ARE AS FOLLOWS: CNC Machining (Post Secondary) Gold - Metika Olanriksupak, BC Silver - Trevor Fandrick, AB Bronze - Tyler Magri, ON Precision Machining (Post Secondary) Gold - Luc Bergeron, QC Silver - Cory Mailman, NS Bronze - Mohamed (Ben) Rahim, ON Precision Machining (Secondary) Gold - Carl Bouvrette, QC Silver - Alex Hoelzli, ON Bronze - Jorn Peeters, AB
Over June 4-7, Skills Canada held its National Competition at the International Centre in Mississauga, Ontario. The event included over 500 youths competing in over 40 categories of skilled trades, including metalworking specific comepetitions, such as Precision Machining, CNC Machining, Welding and Sheet Metal working. Susan LeFort, a judge in the CNC machining competition, with over 25 years of experience in the aerospace industry, spoke to Canadian Metalworking about the competition. “(The students) don’t see anything prior to coming here. We don’t give any information other than the type of machine... We give them access to the machining manuals, and when they arrive they have orientation for a couple hours on the control of the machine.” The students are also given a part drawing, a blank piece of material, and a work station, and are allowed to use MasterCam for one hour and their machine for three hours. With regards to the judging, “The only thing we measure is your physical part,” LeFort says, “So some people would use different ways to manufacture that part, and that’s where we’re putting them to the test. They have to use their essential skills. They have to look at how the insert is going to act – we’re running 18 | AUGUST 2014
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dry here, so that adds a little more complexity. The students were using Haas machines, supplied by Thomas Skinner, and Mitutoyo equipment for measurement and Sandvik for tooling. Judges used FARO equipment to verify measurements of the part. LeFort also had very high praise for the skill level of the competitors, “The caliber of the students – it’s phenomenal. Everybody here had to go through a process to represent their province, and they’re here for the right reasons.”
Welding (Post Secondary) Gold - Tommy St-Martin, QC Silver - Jeffrey Cloutier, ON Bronze - Shawn Guignard, NB Welding (Secondary) Gold - Elijah Schonewille, ON Silver - Torin Dowe, NT Bronze - Timothy LaTrace, SK Sheet Metal (Post Secondary) Gold - Tom Martin, ON Silver - Steve Lapointe, NB Bronze - Spencer Tomlin, YK
www.canadianmetalworking.com
14-08-07 5:21 PM
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IF IT MATTErS TO YOu,
IT MATTErS TO uS.
Makino_MWM_Spread Ad_IMTS_CanMetal_Aug.indd 1 Makino.indd 1
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“ WE’VE SEEN A 40 TO 60 PErCENT rEDuCTION IN CYCLE TIMES ” We estimate
on all jobs moved to the Makino cell.
“ rEVENuE HAS GrOWN MOrE THAN 14 TIMES.” Since investing in Makino equipment, our
“
Our TOOL LIFE’S BEEN EXTENDED uP TO 23 PErCENT, which has lowered tool costs by roughly 15 percent and our productivity has increased around 25 percent.
”
Every company has its reasons for choosing Makino. PRODUCTIVITY Makino.com/productivity PROFITABILITY Makino.com/profitability TOOL LIFE Makino.com/tool-life
Don’t miss Makino at IMTS 2014, booth S-8700. Go to Makino.com/IMTS to book your personal appointment.
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IN THE NEWS
BRUBAKER, WELDON AND DATA FLUTE LAUNCH NEW WEBSITE, AND NEW BRAND FAMILY HERITAGE CUTTER Brubaker, Data Flute and Weldon are pleased to announce the launch of their new website as well as the introduction of the Heritage Cutter family of brands. These brands are some of the most recognized and long-standing names in the North American cutting tool industry. Brubaker has been making tools since 1881. Weldon is closing in on a century of service to industry and Data Flute has been a pioneer in application specific, high performance carbide end mills. The Heritage Cutter name communicates clearly both the core business, as well as deep and storied roots in cutting tools. Ownership, commitment to North American manufacturing and unwavering dedication to customers remain intact and strong. The only changes are the launch of the new website as well as the adoption of the Heritage Cutter name and logo. The company will continue to use and build strong brands, while at the same time providing a common home and website through Heritage Cutter. Please be sure to visit the new launch page
and gateway to the brands at www. heritagecutter.com. The new website offers easy access and navigation to extensive tool offerings as well as an e-commerce platform for valued distribution partners. Brubaker,
Data Flute and Weldon believe that this new site offers a strong and attractive platform for additional web based functionality and services that will be added in the near future.
IN MEMORIAM: JIM BURROWS Jim Burrows, a longstanding member of the machine tool industry, has died. Burrows had an impressive career, he served as the Executive Director for the Canadian Machine Tool Distributors Association. “For those of us who knew Jim, we can always remember his charm and ready smile, not to mention his
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endless supply of jokes and sense of humor. He was well respected in his professional life as well as his private life which was evidenced by the packed church for his celebration of life service in July 2014,� said Peter Turton, the Executive Director for the CMTDA. The funeral was held in Minden on July 5, 2014. Memorial donations can be made to the Kidney Foundation, Minden Health Care Auxiliary is greatly appreciated by the family.
www.canadianmetalworking.com
14-08-11 10:41 AM
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STATE OF THE
SKILLED TRADES SECTOR IN CANADA Apprenticeships up but baby boomer retirements loom BY NATE HENDLEY
I
n early June, Skills Canada—a non-profit group that promotes careers in trades and technology—hosted the Skills Canada National Competition. This year’s event, at the International Centre in Mississauga, Ontario, featured exhibitor booths, a closing-day speech by Jason Kenney, Minister of Employment and Social Development and a “Try-a-Trade and Technology” contest. The latter was a hit with the hundreds of young people who attended the National Competition. Boys and girls competed for gold, silver and bronze medals in activities that tested their abilities in robotics, welding, CNC machining, etc. “We invite students who maybe have never participated in the trades or technology area. Here they have a chance to … build a brick wall or wire a circuit board or something like that. Give them a basic understanding [of skilled trades],” says Shaun Thorson, CEO of Skills Canada. Skills Canada also hosts websites, workshops and a National Skilled Trades & Technology week. The aim of such initiatives is to generate interest in trades and technology careers among young people. It appears the pitch is working. While Thorson doesn’t claim credit, the number of new registrations and reinstatements in Canadian apprenticeship training programs rose 6.8 per cent to 104,280 in 2012, according to Statistics Canada. This represents the highest number of registrations and reinstate24 | AUGUST 2014
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ments (i.e. individuals who re-entered training programs in 2012 after being absent for a year or more) since the economic meltdown of 2008. The overall number of people registered in apprenticeship training programs stood at 444,672 in 2012, up 4.3 per cent from 2011. Apprenticeship training programs leading to jobs as carpenter, construction electrician, steamfitter/pipefitter, welder, industrial electrician and industrial mechanic (millwright) were particularly popular. It remains an open question, however, whether the uptick in apprenticeship training and energetic efforts of Skills Canada and other groups are enough to avert an impending crisis: the mass retirement of baby boom era workers. The oldest members of the baby boom generation are now retired senior citizens, the first wave of a huge cohort on the verge of dropping out of the workforce. When all boomers retire for good, industry analysts fear the already prevalent shortage of skilled workers will become acute. “Based on our consultations in major cities across the country, the lack of skilled workers is affecting most sectors and regions. It seems that in virtually every occupation group there is a shortage at some point in some part of the country. Workers cannot find jobs and employers cannot find the workers that they need,” states a 2012 report by the Canadian Chamber of Commerce. “The older average age of many tradespeople and their stated intention to retire suggests that if efforts are not made to train the next generation of skilled workers, Canada’s future economic competitiveness will be in serious jeopardy,” warns the website of the Canadian Apprenticeship Forum, another organization devoted to highlighting skilled trades. “I know when we’re talking to employers they definitely feel that a lack of a skilled workforce is making an impact on their ability to deliver on projects, especially in Western Canada’s energy industry and natural resources sector,” adds Thorson. One challenge facing advocates for skilled trades is the lingering stigma associated with their sector. In some quarters, blue collar industrial jobs are still disdained as dirty and suitable only for people who couldn’t get into university. “We’re trying to broaden the discussion at the secondary school level …. When students are looking at potential careers, I think in many instances, there’s a lack of information or lack of understanding at the secondary www.canadianmetalworking.com
14-08-07 5:24 PM
Visit us at IMTS Booth # W-2245 VARGUS USA
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sales@vargususa.com
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indicated 40 per cent of apprentices who completed their apprenticeship program earned more than $60,000/year, which is higher than the national average of $40,000/ year,” states the website Careers in Trades. Reaching out to “non-traditional groups” is another way to beef up the ranks of skilled tradesmen and women, says Priesnitz. To this end, George Brown offers skilled trades training specifically aimed at aboriginal people, women, young people at risk and even ‘consumer survivors’ (people who have been through the mental health or addiction treatment system). The college just launched a 24-week metalworking program, in which low-income or unemployed youth aged 18-29 are trained in basic sheet metal work, welding, CNC machining, etc. Students also receive classes to upgrade their academic standing and computer skills. The program, which enrolls 24 students at a time, is funded by a grant from the Ontario Ministry of Economic Development, Employment and Infrastructure. “There’s no cost to the student. We cover their tuition fees, cover their supplies, tools, etc.,” states Christine Ovcaric, coordinator of community projects at George Brown. George Brown’s 14-week Mechanical Techniques Program, meanwhile, is designed to give university engineering students a broader understanding Serving the of practical engineering concepts. In Automotive Parts this class, university students receive Manufacturing lessons in machining, welding, Industry for computer aided design (CAD), com55 years puter aided manufacturing (CAM), programmable logic control (PLC) and CNC machining techniques. The Engineered program offers the kind of shop-floor Solutions for learning environment engineering High Production students might lack at university. Manufacturing Thorson, for his part, remains committed to spreading the skilled trade gospel and believes his message is sinking in. “I am optimistic. If you look at five Manufacturer of Exclusive North American Dealer for years ago or further back 10 years Custom Designed Chucks and Fixtures Gamet DELTA Series Jaw Chucks ago, there was a lot less discussion for High Volume CNC Turning Collet, Diaphragm, Offset and around skilled trades and apprenticeBruckner Live and Dead Centers, and Face Drivers Many Other Chuck Designs ship programs and how important they are and how they contribute to the Canadian economy. There’s more discussion about it with senior VISIT US AT BOOTH W-2015 business and government leaders and in the media. There’s a better underOld Indian Trail, Middlefield, CT 06455 USA | T: 860-349-1044 | F: 860-349-1815 standing of how those careers are important,” he says. level about how apprenticeships work … I think people still default to university. For parents … it’s still the case, if their sons or daughters ask what they should do, most still say ‘university’,” notes Thorson. Rolf Priesnitz, director of apprenticeships at Toronto’s George Brown College echoes these sentiments. One way to increase apprenticeship enrolment is to “enlighten guidance counsellors in the elementary school system and secondary school system … when looking at young girls and boys that are thinking about what career path to take [guidance counsellors should] at least give them the option of considering a trade,” says Priesnitz. “We must find the best way to communicate to the public that a skilled job is not only fun, rewarding and full of growth opportunities, but also vital to the success of our country,” adds Joe Poulin, Canadian sales manager for Indianapolis, Indiana-based machine tool company Hurco. Advocates for the sector point to the high wage potential of many skilled trades. “The 2007 National Apprenticeship Survey
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CANADA JOB GRANT New government training initiative hits a few bumps in the road BY NATE HENDLEY
I
n the 2013 budget, Ottawa introduced the Canada Job Grant program, an employment skills training initiative that’s a component of the new Canada Job Fund. The Canada Job Fund replaces the so-called Labour Market Agreements, under which the Canadian government transferred $500 million per year to provinces and territories for job training. “The government of Canada has secured agreements in principle with all provinces and territories on the new Canada Job Fund agreements, which include the Canada Job Grant,” says Eric Morrissette, spokesperson for Employment and Social Development Canada. Ottawa “will continue to provide $500 million annually to the provinces and territories for investments in skills training through the Canada Job Fund … the Canada Job Fund
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will include $200 million of employer-driven training nationally, beginning in 2017-2018,” he continues. Under the Canada Job Grant, businesses can apply for funding to prepare workers for new or better jobs. Ottawa initially envisioned that the federal government would cover $5,000 of training costs, with the provinces and employers paying an additional $5,000 each, for a total of $15,000 per worker. When provincial and territorial leaders balked at this arrangement, the government committed to paying $10,000 per worker, with the remaining $5,000 coming from employers. Thanks to this compromise, the provinces and territories (which traditionally have been responsible for jobs training) have largely come around to support the Canada Job Grant program. Provinces and territories were supposed to implement the Canada Job Grant by July 1. British Columbia, Alberta and Ontario were unable to fulfill this commitment, however, reports the CBC. The federal government claims that 130,000 Canadians will receive job training per year once the Canada Job Grant is fully rolled out. Training will be short-term in nature and offered by eligible third parties including community colleges, career colleges, centers run by trade unions or private groups, etc. The Caledon Institute of Social Policy, an independent think tank based in Ottawa, issued a scathing report on the Canada Job Grant program in 2013 and continues to oppose the program. “I think it’s going to result in a net decrease in training. The money to pay for it is coming out of training programs that are proven and are pretty effective …. The other reason is that many of the firms who will take advantage of it are already providing training with their own money and hope to get government grants,” states Michael Mendelson, a senior scholar at the Caledon Institute and report co-author. Shaun Thorson, CEO of Skills Canada, a non-profit group that promotes skilled trades, has a more nuanced view of the Canada Job Grant program. “I don’t know all the specifics about the program. But I think from our perspective, it’s encouraging people to upskill and develop their skills. I think it’s positive,” he states. www.canadianmetalworking.com
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SKILLS TRAINING PROFILE
NORTHERN ALBERTA INSTITUTE OF TECHNOLOGY (NAIT), EDMONTON, ALBERTA BY NATE HENDLEY
T
he Materials Engineering Technology program at the Northern Alberta Institute of Technology (NAIT) in Edmonton, Alberta, includes an intensive, two-week machine shop and welding component. Machine shop and welding training “is mandatory for everybody … it gives students those skills that they’re not getting prior to coming to NAIT,” says Darcy Corcoran, chair of NAIT’s Materials Engineering Technology program. The Materials Engineering Technology program consists of four semesters of 15 weeks each spread out over two years. Typically, there are 24 students in each year of the program. “Even though [the program is] called ‘Materials’, the emphasis is on metallurgy. We spend the majority of time dealing with metals. We do introduce students to non-metals, like plastics and some advanced materials, but the majority of time we’re spending on metal,” says Corcoran. The Materials Engineering Technology program was launched shortly after NAIT opened its doors in 1963. Through labs and classroom lectures, students are taught destructive and non-destructive testing, welding metallurgy, metallography, corrosion testing, metals analysis, heat treating, etc. Once students complete their second semester, they spend a week in NAIT’s 31,000 square foot, on-campus machine shop. This is followed by a week of welding instruction in a separate facility. “The primary focus [in the machine shop] are lathes and mills. It’s all manual-based for Darcy’s students,” says Loyde Tober, chair of machinist and CNC programs at NAIT. The machine shop is also used by apprentice machinists at NAIT, whose training leans towards CNC machines. “We run the largest apprenticeship training program for machinists in Canada. Annually, we run approximately 800 daytime students through our program area,” explains Tober. In addition to manual machines, NAIT’s machine shop “currently has almost 30 CNC machines. We’re doing an expansion right now — when all the dust settles a year from now, we’re hoping to have approximately 67 CNC machines. That’s a mixture of lathes and mills,” continues Tober.
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The welding segment, meanwhile, focuses on welding theory, practice and safety. As with the machine shop, the welding facility is also used by students taking apprenticeships. “We probably run 1,500-1,800 students per year through our welding program,” says Corcoran, who adds that this number will leap to 2,100 next year. NAIT’s welding and machine shop instructors, “all have a trades background. When we look to hire, we want them to have a minimum of five years industry experience after they receive their journeyman certificate. A lot of them have been in the industry for a period of time,” adds Tober. This being Alberta, most graduates of Materials Engineering Technology end up in oil or gas-related work. Materials Engineering Technology is a tough program to get into; around 300 people apply annually for only two dozen openings. NAIT is thinking of expanding the number of students in the program to 36 in any given year. Good marks in math, physics, chemistry and English (to ensure that graduates can write coherent reports) are course prerequisites, as is NAIT’S an aptitude for machining PROGRAMS and welding. AT A GLANCE The course’s machine shop/welding component is LOCATION: NAIT designed to “give students campus near a foundation before they Edmonton, Alberta go out … they will be able RELEVANT to perform welding and COURSES OFFERED: see how difficult it is … Materials Engineering it really gives students a Technology – four better understanding when semesters of 15 weeks they’re actually looking at each, spread over two the welds … same thing years – slightly over with machine shop train$2,000 per semester ing. When [graduates] are TUITION: NAIT’s doing quality-control work 2014/15 tuition fees are or quality-assurance work, currently being revised they will have a way better understanding of the skill For more information on that it takes for the jourNAIT’s program, visit: neymen to perform those www.nait.ca/77565.htm tasks,” says Corcoran. www.canadianmetalworking.com
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Laser systems simplify cutting, drilling and marking pipes and tubes BY NESTOR GULA
A
ssembling tubes and pipes has always been a tricky proposition. The cuts and angles have to be precise, otherwise the structure is compromised. Back in the day, this work was performed by skilled craftspeople but was labour intensive and occasionally inaccurate. Modern CNC machines revolutionized the cutting process and new laser systems have added greater precision, speed and convenience. The laser tube cutting systems can combine several processes. “It gives you the opportunity of cutting holes without drilling. It is more accurate because it is CNC based,” said Dru Schwartz, Laser Technical Center Manager with Amada. What would take hours for a skilled craftsperson to create, can now be done in minutes with flawless repeatability. “LASER-CUT PARTS ARE TYPICALLY The main advanMORE ACCURATE AND MORE tage of laser cutting REPEATABLE THAN ANY OTHER tubes is the simplicPROCESS.” ity of the cutting without the need for hard tooling, according to Frank Arteaga, Head of Product Marketing for Bystronic Inc. “Any profile that can be designed in the flat can be cut and wrapped around the perimeter of the tube. Macro programming systems include the ability to create transition cuts, which allow tube-totube mating for structural or flow applications.” When cutting with a laser, the ends can be cut off at any angle that you want. Schwartz also added that there is an ease of use when using a laser system; you can put 32 | AUGUST 2014
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some location tabs if you have multiple tubes to simplify the line up that you are welding. The ability to reduce subsequent manufacturing steps is one area where the technology supports the cost of investment. “By laser cutting profiles, a fabricator not only simplifies the welding fixture design process but also the welding process itself,” said Stefan Fickenscher, Product Manager TruLaser Product Group at TRUMPF North America. “In addition, the superior edge quality produced by the laser frequently eliminates time-consuming post-processing steps compared to conventional technologies.” As manufacturers demand streamlined production, more cut features are added to a tube or pipe part design. Laser cutting allows for features like slots of cuts spanning both sides of the tube, which can be difficult with other methods. Not only that, but a laser can cut these features with speed, usually up to 10 times faster than other methods, according to Mark Mercurio, Applications Manager at Mazak Optonics Corporation. “In addition to faster process, many of our customers say that the greatest benefit of the tube laser is in assembly. Laser-cut parts are typically more accurate and more repeatable than any other process. So assembly, bolting, welding or other fixturing processes are much easier because the laser cut part fits better and are always the same. Also, with Mazak’s self-centring chuck design, structural materials like angle iron, C-channel and I-beam can very easily be loaded into the machine and processed, without requiring a setup change.” This technology is not only suitable for prewww.canadianmetalworking.com
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cise manufacturing of high-end products. As we are in the midst of barbecue season, take a look at a humble gas grill. Mine has several through holes either punched or drilled in the square tubing. The tubes are connected by cross-members that, on closer inspection, are quite sloppily hand welded. Besides the bending of the square tube, there must have been at least four processes performed after the tube had been cut. All of these processes could have been performed by a laser tube cutter in the time it took to cut the pipe and transfer it to the first processing station. “Whenever tubes or profiles are used, the tube laser is a cost effective and fast way to process parts,” said Fickenscher. Many industries, big and small rely on tubing for structural applications. “Construction, playground, oil, and steel suppliers are adding value to tubes they are selling,” said Mercurio. “Exercise equipment, agriculture, and transportation are also industries that consume large amounts of tubing. We also see these types of laser in very specialized racing and military applications. The possibilities for using a tube laser are endless. Many products that you see made in fabrication shops feature many sheet metal panels. Most of these sheet metal panels are covering tubes that have made the structure of the assembled component.” Smaller shops will see benefits to converting to a tube laser cutting system due to the machine’s flexibility, speed and accuracy. “A lot of job shops that make frames or product displays, where they are building a custom display and are using angle iron or square or rectangular tubing, [a tube laser system] makes it very easy to program up the parts needed, cut them, put them together and then weld them,” said Schwartz. The laser tube and pipe systems can be processed with either CO 2 or fibre laser technologies. Using CO 2 or fibre for metal applications makes little difference unless it is copper or brass. These metals cut much better with a fibre laser, according to Artega. Both systems are available in the market but CO 2 technology systems are a more popular sell. “The big advantage is the accessibility of the system most customers really appreciate,” explains Fickenscher. “This open concept can only be realized with a CO2 laser, as a fibre system has to be completely closed for safety reasons. Another topic is the maximum achievable cut speed. When you www.canadianmetalworking.com
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compare a tube laser to a flatbed machine the lengths of the cuts are relatively short. Therefore, the laser cannot, in most cases, reach the max possible cut speed even if the laser source would be capable of going faster over a longer distance. This considered, the speed advantages of a fibre system, as compared to a CO2 , cannot be utilized in the way they can on a flatbed machine.” Schwartz said that the Amada systems use CO2 as their laser source. “The CO2 lends itself to a wider range of materials with better edge quality than fibre currently. The advantage of fibre is speed and what you are cutting is not dependent on speed. You are not trying to cut 1,800 inches per minute.” Typically, the accuracy of a laser is within .002 inch for cut profiles, but Artega stressed that with tubing you have to also consider the influence of the tube itself and how accu-
Laser tube and pipe cutting gives you endless precise possibilities. PHOTO COURTESY OF TRUMPF.
Amada’s FOM2 RI 3015 cutting square tubing. PHOTO COURTESY OF AMADA.
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Almost anything is possible with laser tube and pipe cutting. PHOTO: NESTOR GULA.
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Round tubing being held by 4 jaw chuck and kept on centre with pneumatically pressured tail stock.
Square tubing being held by 4 jaw chuck and kept on centre with pneumatically pressured tail stock.
PHOTO COURTESY OF BYSTRONIC.
PHOTO COURTESY OF BYSTRONIC LASER AG.
rate it is over its length. Precision in pipe and tube cutting largely depends on how precise the tube is made. “It is a difficult thing with tubing because it is so all over the place,” said Schwartz. When a tube is measured it can be off only a millimetre, but this makes a big difference. “It is a difficult thing with accuracy because you are dealing with tubing that is inaccurate to start with.” Depending on the system, pipes up to 16 inches in diameter can be cut. Angle iron, square and rectangular tube, c-channels can also be cut on these machines. “Lasers can cut up to one inch thick,” said Mercurio. “Mazak’s tube lasers can cut from one half inch diameter all the way up to 16 inch diameter tubes. These machines can carry very heavy weights so heavy wall tube that is typically difficult and dangerous to do in other methods of fabrication are actually quite easy on a tube laser.” These tube and pipe laser cutting systems tend to be dedicated machines and can’t be used for cutting flat stock. However, systems
can now combine both flat sheet and tube cutting in one unit. “Some flatbed machines can be equipped with a rotary axis and can therefore be used for sheet metal and tube cutting,” said Fickenscher. “The fully automated systems are pure tube and profile cutting systems.” To get the full advantage of the laser system, the system needs to be designed for processing tubes. “A real rotary axis requires that you have a CNC controlled tube axis and a chuck that can be accurately positioned and controlled during cutting,” said Arteaga who explained that the design of the machine is also critical for accessing the tube. Typically, a quality machine will provide good access to the tube for loading and unloading. While some lasers have chucks associated with them and are capable of producing some parts, processing tubes with flat lasers can be difficult with these chucks. “The operator needs to think about fixturing again. Tubes are not normally straight. They typically have some bow to them and square tubes are not always square,” said Mercurio. “Without proper fixturing, the raw material will affect the outcome of the part. On a machine such as this, it is difficult to accurately place a hole on a tube location ... Typically, flat machines are limited to eight-12 feet bed sizes. Indexing tubes on 2D can be difficult and presents accuracy challenges. Also, tube stock normally comes in lengths longer than the standard 2D bed sizes, which means that tubing may have to be cut into smaller sizes before processing on a 2D machine. On a tube laser, the raw material is held very accurately on the centre line of the machine with up to four chucks. This ensures that the machine knows the exact location of the raw material. In addiwww.canadianmetalworking.com
14-08-07 5:29 PM
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tion we always cut very close to one of the chucks. This ensures accuracy because we are cutting very close to the clamp.” The cost effectiveness of a tube and pipe laser system is found in the speed of producing parts without the requirements for hard tooling. “Hard tooling is specific to the tube and shape that you are cutting. The laser adapts to the shape and tube based on the program,” said Arteaga. You have one process if your tubes have holes or cut-outs. “If you are doing it in a conventional method, first you have to take the tube to a saw and cut, and then to a drill press or a milling machine and put it in and mill the part or drill the part where the holes have to be,” said Schwartz. “On a laser it is one process.” Time and money are saved by eliminating secondary processes and the cost advantage is significant even taken into consideration the capital investment. “As stated earlier, you will be cutting a faster, more accurate and repeatable part,” said Mercurio. “This will all be done in one set up and without any fixturing. It will also benefit downstream in assembly to have a more accurate, repeatable part.”
Precise laser cutting for mid to thick tubing and pipe Delivering the power and speed to efficiently cut mid to thick materials, the Amada FOM2 RI 3015 can process round, square, rectangle, C-channel, and angle iron. The rotary system can handle materials up to 441 pounds and has many common shapes and configuraconfigurations pre-programmed, making it easy to fabrifabricate tubular structures that fit together for welding, saving time and reducing the possibility for errors. The innovative Rotary Index is located on one of three interchangeable shuttle pallets, making it extremely easy to switch from flat sheet cutting to tube or pipe cutting. Since the cutting head is positioned near the controllable pneumatic chuck, bowed pipe or tubing can now be cut without vibration while maintaining accuracy from end to end. Featuring a solid-cast frame, water-assisted cutting, and a high-precision motion system, the FOM2 also includes an automatic nozzle changer, cut process monitoring, and auto-pierce detection. Engineered to meet the high quality and shorter lead time demands of today’s fabricating companies, the FOM2 RI 3015 delivers precise cutting for a wide range of mid to thick materials including tubing and pipe. www.amada.ca
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Offering increased efficiency to meet the current marketplace’s strong demand for small-size tube and pipe appliappli cations, Mazak Optonics Tube Gear 2D laser-cutting machine is available with a 2.5kW or 4kW resonator. It can process round and rectangular tube and pipe with diameters of up to 6 inches. It has a standard 5” Servo Focus torch and a new Fanuc 31i control and drive system to dramatically improve processing speed. Equipped with a triple chuck system, which minimizes warp and material vibration, this allows for higher accuracy and faster processing speeds compared to double chuck systems. The additional chuck and the machine’s rigid construction ensure superior cutting precision for material up to 24’ long. Other features of the Tube Gear include an automated lens focal distance measurement system, automated calibration function and a nozzle cleaning system. There is also an optional automated nozzle change system to significantly reduce machine set-up times. www.mazakoptonics.com
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Large sheets and tube cutting CO2laser Available in 3015 and 4020 designs, the ByAutonom can process up to 4 × 2 m sheet metal quickly and economically as well as pipes and tubes. Thanks to Collision Detection, lens-cassette changer, nozzle changer, and automatic nozzle alignment non-productive time is reduced and an increase in process reliability is a result. Fewer operator interventions are required, thus freeing up time to concentrate on planning and control. The ergonomic design and optimal access to the cutting range make the machine extremely user-friendly. This system will increase a manufacturer’s efficiency with a CO 2 laser cutting system in the thin through to the thick range of sheet thicknesses. www.bystronic.com
Dedicated tube cutting laser The new TruLaser Tube 7000 cuts tubes and profiles with large diameters and wall thicknesses without sacrificing productivity. It can processes tubes and profiles up to 10 inches in diameter with a wall thicknesses of up to 0.3-in. in mild steel. The completely automatic machine settings yield increased machine availability and with the integrated touchscreen control panel the machine operator always has everything at his or her fingertips. With a maximum laser output power of 3,600 watts, the system can process parts very quickly. A self-centering clamp chucks assist in consistent production quality and a weld seam sensor option correctly orients the tubes. www.trumpf.com
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BY NATE HENDLEY
T
he International Manufacturing Technology Show (IMTS) is celebrating its 30th edition in style. Held every two years, IMTS takes place September 8-13, 2014 at McCormick Place in Chicago. Organizers estimate over 100,000 buyers and sellers from around the world will attend, along with roughly 2,000 exhibiting companies sharing 1.2 million net square feet of exhibit space. “The show theme for 2014 is ‘Come Together.’ It’s a call to action for the entire IMTS community to interact, see the latest technology and find answers to their manufacturing challenges,” says Peter Eelman, VicePresident, Exhibitions and Communications at AMT—The Association For Manufacturing Technology, which is based in McLean, Virginia and owns and manages IMTS. “The IMTS 2014 conference will feature 69 one-hour presentations over four days that will provide solutions to current manufacturing problems, such as improving productivity, improving part quality, and developing a stable, competent workforce to lower the cost of manufacturing in the United States and create new levels of market demand,” continues Eelman.
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IMTS 2014 will also include a Smartforce Student Summit and two “co-located” shows (i.e. specialty shows held under the IMTS umbrella). The two events in question are the Industrial Automation North America show and Motion, Drive & Automation North America show. There will also be a two-day TRAM (Trends in Advanced Machining, Manufacturing and Materials) conference at IMTS 2014. Organizers also urge attendees to check out the AMT Emerging Technology Center, where an electric car prototype will be created using 3D printers. For people who don’t want to miss a thing, IMTS will be covered extensively via social media and an in-house TV outlet. Eelman offers tips on how to get the most from your IMTS experience. “Both veteran and first-time visitors to IMTS should start by doing two things: visit IMTS.com and while learning about the show, register now. By registering now visitors gain immediate access to the planning tools, all of our newsletters and technology updates that IMTS has to offer. For a show the size of IMTS, with so very many exhibits and attractions in four large buildings, advance planning is key to a successful experience,” he states. While IMTS 2014 is massive in scope and scale, organizers promise a user-friendly conference experience. “To help guide visitors around and find their areas of interest quickly and easily, we organized the show into nine pavilions,” says Eelman. Each pavilion will house exhibitors representing a particular manufacturing sector, product and/or service. This way “a visitor who has a specific interest is able to maximize their time when they’re here. If they’re really interested in say, tooling and workholding, they can spend the bulk of time in the tooling and workholding area and not have to play detective [to find appropriate exhibitors],” explains Eelman. The nine pavilions are: • The Abrasive Machining/Sawing/ Finishing Pavilion. This pavilion will feature technology for applications requiring high tolerance and precision surface finish, including grinding technology, sawing and cutoff machines. A variety of finishing technologies, such as lapping, balancing, honing and polishing machines, will also be on display.
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The Controls & CAD-CAM Pavilion. This pavilion will focus on custom automation and cutting-edge software designed to maximize efficiency in machine tools in order to optimize plant operations and bolster the bottom-line. CAD/CAM systems will be exhibited, plus CNC controls, automation management systems, communications systems, etc. The EDM Pavilion. This pavilion will feature CNC wire EDM equipment and die sinking machines. It will be of particular interest to tool and die professionals who specialize in one-off or specialty components. The Fabricating/Laser/Additive Pavilion. This pavilion will boast the latest technology in fabricating, metal forming, laser and waterjet-based machining and additive manufacturing. There will also be displays of welding equipment, metal treating and marking equipment. The Gear Generation Pavilion. This pavilion will focus on gear cutting, forming and finishing, plus broaching, shaping and slotting machines. It will spotlight traditional gear applications in automotive, construction, mining and ship-building as well new gear applications in the emerging alternative energy and wind power sectors. The Machine Components/Cleaning/ Environmental Pavilion. This pavilion will look at the wide variety of goods necessary to keep a plant in running order. Equipment on display will include water and oil purification systems, safety guards, mats, air filtration gear, sump cleaners, noise control equipment, dust removers, robotics, electrical equipment, etc. The Metal Cutting Pavilion. This pavilion will offer the latest innovations in metal cutting equipment. Expect to see machining centers, turning centers, automated manufacturing systems, milling machines and centers, boring machines, drilling machines, transfer machines, screw machines, CNC lathes, machining cells, etc. The Quality Assurance Pavilion. This pavilion will house metrology equipment and systems designed to keep processes on track, plus equipment that assesses machine accuracy. The latter includes precision measuring machines, laser measurement machines, coordinate measuring machines, precision gauging, automated gauging, tool condition monitoring equipment, measurement software, quality, •
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control, testing and measuring equipment, vision systems, etc. The Tooling and Workholding Systems Pavilion. This pavilion will feature innovative solutions to all manner of tooling challenges. Boring bars, oils, cutting fluids, tool coatings, drills, chucks, milling cutters, form cutters, end mills, fixturing systems, gun drilling tools, hobs, tool inserts, jigs, key seating tools, ball-nose end mills, vises, workholding systems, etc., will be on display.
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
There will be multiple educational opportunities in the form of conferences during the show including the IMTS 2014 Conference and the TRAM Conference. The IMTS 2014 Conference will cover a wide array of topics ranging from process innovations, alternative manufacturing processes and plant operations to quality/ metrology and systems integration. Some of the highlights include presentations entitled, “Additive Manufacturing — the Pros and Cons”, “Capital Equipment Justification — the Truth About ROI” and “Achieving the Best Possible Straightness and Hole Tolerance in Deep Hole Drilling.” The first presentation looks at “what industries are using additive manufacturing technologies and how they are being used,” says Eelman. The capital equipment presentation offers insights on making investments in new equipment while the third presentation centres on the production and use of high-precision, deep hole drills. The TRAM conference, meanwhile, is focused on the aerospace industry. Appropriately enough, the keynote speaker at TRAM will be Dr. Greg Hyslop, vice-president and general manager of Boeing Research and Technology. Boeing is based in Seattle, Washington.
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Depending on what company you represent, the two “co-located” shows at IMTS might also be “can’t miss” events. First launched at IMTS 2012, the Industrial Automation North America show will examine factory, process and building automation solutions and technologies through a series of exhibits, workshops and training sessions. The new Motion Drive & Automation North America (MDA NA) show will feature solutions and technologies from the power transmission, motion control and fluid technology sectors. Industry experts will host discussions on topics such as “Trends in Industrial Communications for the Factory of the Future” and “Practical Application of 3D Machine Vision in Robotic Guidance, Motion and Inspection,” etc. Attend IMTS and you could find yourself on television. As in previous years, conference organizers will be offering IMTSTV — a communications outlet “that delivers ground-breaking coverage [of IMTS] and all things manufacturing,” says Eelman. Airing live from the show floor, IMTSTV will offer eight hours of original programing each day of the show, broadcast on television sets at the conference, in hotel rooms and on shuttle buses. IMTSTV content will include “In Brief” segments (quick updates on manufacturing news, IMTS show announcements, how-to tips and interviews with industry experts), an “Investigates” program (in-depth examinations of important manufacturing issues and their impact at shop-level) and “iSpy” (behind-the-scene looks at innovative manufacturing developments). There will also be commentary and conversation about IMTS 2014 on social media platforms such as Facebook, Twitter and LinkedIn. The Twitter hash-tag for the event is #IMTS. For all the pizzazz, Eelman insists that IMTS isn’t just a showcase for big companies to show off their wares and solicit new business. “Small shops actually stand to gain the most from attending IMTS. It’s the one place where thought leaders and industry experts gather to share information. Often, small shops don’t get called upon regularly by sales and service representatives from large suppliers. By using the tools IMTS provides to plan a visit to the show, a small shop owner and his or her staff can gain access to the resources they need to be highly productive,” he says.
If the last show is anything to go by, small, medium and large companies alike will be well-represented at IMTS. According to a post-show report, a quarter of all visitors at IMTS 2012 represented companies with under 20 employees. Some 18.5 per cent represented plants with 20-49 employees, 14.5 per cent represented plants with 50-99 employees and 26.4 per cent of visitors came from companies with between 100-499 workers. Another 5.9 per cent represented plants with 500-999 employees, with the rest representing plants of over 1,000 workers. The same report indicated that 17 per cent of IMTS 2012 visitors worked at job, tool, mould and die shops while 16.7 per cent represented metalworking machinery and equipment firms. Another 14.3 per cent came from companies that make or distribute fabricated metal products. There were also visitors from aerospace, transportation, computer and farm equipment firms as well as banks, government agencies, the military, etc. The top “product categories of interest” at IMTS 2012 (i.e. product areas visitors checked out) were turning centers and lathes (which some 56.8 per cent of visitors investigated), machining centers (viewed by 54.8 per cent of visitors) and milling, drilling or boring tools (viewed by 53.7 per cent of visitors). These were followed by tools and tooling (44 per cent) and grinding and finishing machinery (31.8 per cent). Other popular product categories included workholding devices, welding equipment, industrial lasers, etc. Students can also benefit from IMTS, says Eelman, pointing to the Smartforce Student Summit. “IMTS has a longstanding tradition of gathering middle school, high school and college students, educators, administrators and parent chaperones to experience advanced manufacturing technology and have direct contact with the industry professionals whose minds move manufacturing forward. The Smartforce Student Summit will encourage the exploration of careers [in] the manufacturing technology industry,” he says. In Eelman’s view, the wide array of events, exhibits, presentations and attractions at IMTS underline the uniqueness of the show. “There is nothing like IMTS. It’s an entire industry of more than 100,000 manufacturing professionals in one place, at the same time, with one focus — advanced manufacturing,” he states.
www.canadianmetalworking.com
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Please visit us at IMTS-Booth W-1645
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SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
IMTS 2014: MANUFACTURING
TECHNOLOGY
MECCA BY NATE HENDLEY
“T
he International Manufacturing Technology Show (IMTS) used to be the Machine Tool Show a few years ago. We changed it to the Manufacturing Technology Show. We’re really encompassing manufacturing technology to a degree beyond what we had before,” says Peter Eelman, Vice-President—Exhibitions and Communications at The Association For Manufacturing Technology (AMT) which is based in McLean, Virginia and owns and manages IMTS. Indeed, IMTS 2014 promises to be a Mecca of manufacturing technology—defined simply as high-tech products and processes that aid manufacturing. There will be presentations and demonstrations at IMTS on everything from additive manufacturing to cloud computing, robotics, nanotechnology, etc. High-tech products and solutions will be on display at several locales including AMT’s Emerging Technology Center, Today’s Technology Center, the Advanced Manufacturing Center, Smartforce Student Summit, the Trends in Advanced Machining, Manufacturing and Materials (TRAM) conference, among others. Arguably, the high-tech highlight of IMTS 2014 will be the creation of a 3D printed electric car in AMT’s Emerging Technology
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Center. The body of this vehicle will be manufactured out of carbon-fiber reinforced plastic using 3D printing techniques. Other parts, such as the engine, will be made by suppliers using more conventional methods and materials. This concept car was borne out of discussions with Local Motors, an innovative engineering and manufacturing firm headquartered in Phoenix, Arizona, that put together “a regular car in the traditional way … using the Internet as a source for design,” at IMTS 2012, recalls Eelman. Local Motors’ efforts in 2012 “really, really created a buzz … so when we were kicking around ideas for 2014 [with Local Motors CEO Jay Rogers], we talked about, ‘How do we top your other car?’” he continues. As it happened, Local Motors had an idea. The company had come up with the notion of making an electric car through 3D printing/manufacturing methods. Local Motors didn’t have a specific design for such a vehicle, and were unsure how feasible the project was. AMT officials, however, were highly receptive and green-lighted the project. Early this year, AMT teamed Local Motors with Oak Ridge National Laboratory (a facility run by the U.S. Department of Energy, in Oak Ridge, Tennessee that offered material science and advanced manufacturing know-how). In April 2014,
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Local Motors launched a contest to come up with the best design for a 3D printed car. Over 200 concepts were submitted, with the winner announced in early June, 2014. The winning concept, called “Strati”, was put together by one Michele Anoé of Italy. Design in hand, IMTS worked with the Oak Ridge National Laboratory to develop the manufacturing processes required to turn Anoé’s winning vision into a functioning vehicle. IMTS 2014 attendees will be able to watch this process in action as the car parts are printed then assembled. The printing will be done on special, 3D printing equipment created by Cincinnati Incorporated, a manufacturer of made-toorder machine tools, from Harrison, Ohio. If all goes to plan, the car will be fired up upon completion and driven out of McCormick Place in Chicago (site of IMTS 2014), says Eelman, who describes the project as “a real head turner.” While he’s not sure if the Strati will be the world’s first 3D printed vehicle, he does say “this is the first time anybody’s [built a 3D car] on a trade show floor.” “The finished vehicle will be used as an example of how sustainable green technologies can reduce life-cycle energy and greenhouse gas emissions, lower production cost and create new products and opportunities for high paying jobs,” adds IMTS literature. The Advanced Manufacturing Center at IMTS is going to feature exhibits and demonstrations on additive manufacturing, automation, future cars and data-driven manufacturing.
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The additive manufacturing exhibit includes a presentation by Greg Morris of GE Aviation (an operating unit of General Electric, based in Evendale, Ohio) and a 3D-printed model aircraft machine. The automation exhibit centers on a presentation about robotics while the Automotive 2025 exhibit features a display that includes the body of a General Motors Silverado. The latter exhibit will also offer a presentation by a representative of the Washington, D.C. based-Steel Market Development Institute on manufacturing structures that are both strong and light.
MILITARY DRONE AIRCRAFT THAT CAN FLY FASTER THAN MACH I AT ALTITUDES OF OVER 45,000 FEET WILL ALSO BE DISPLAYED AT TODAY’S TECHNOLOGY CENTER The data-driven manufacturing exhibit will feature a presentation on emerging technology by Indiana Technology and Manufacturing Companies (ITAMCO) of Plymouth, Indiana and XOEye Technologies of Nashville, TN. The presentation will focus on Google Glass (optical, headmounted technology that users wear) and MTConnect (an open source networking protocol for machines). ITAMCO is a component manufacturer while XOEye produces “smart glasses” which allow users to perform diagnostic and scanning tasks while keeping their hands free.
www.canadianmetalworking.com
14-08-07 5:15 PM
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Today’s Technology Center, as presented by GIE Media of Richfield, Ohio, will feature exhibits of aerospace, automotive, medical and energy-sector technology. Center organizers hope to demonstrate how advancements in manufacturing technology are being implemented by private companies. Exhibits include a 10-foot model of the Dream Chaser Space Utility Vehicle (SUV), which is intended for use by the International Space Station. This spacecraft is under development by Sierra Nevada Corporation of Sparks, Nevada and Siemens PLM Software, a Plano, Texas business unit of Germany’s Siemens Industry Automation Division. Once operational, the Dream Chaser will service satellites, make observations of the earth’s orbit and serve as a microgravity laboratory. Currently under testing, the spacecraft is scheduled to be rocketed into orbit by 2017. Military drone aircraft that can fly faster than Mach 1 at altitudes of over 45,000 feet will also be displayed at Today’s Technology Center. The Center plays host to a more down-to-earth vehicle as well—a 2015
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ATTENDING IMTS IS NO LONGER OPTIONAL. IF YOU’RE REALLY GOING TO BE SUCCESSFUL IN YOUR BUSINESS YOU REALLY NEED TO TOUCH BASE AT IMTS TO SEE WHAT’S GOING ON Chevrolet Corvette that epitomizes cutting-edge engine, materials and transmission design. The hood, spoiler, and body part panels are made from carbon fiber reinforced plastics while the transmission offers eight speeds. According to General Motors, the Corvette maximizes performance while minimizing fuel intake. A medical device exhibit at Today’s Technology Center will feature a clear, life-sized mannequin containing various components including knee, hip and shoulder implants, stents, pacemakers and implantable defibrillators, bone screws, plates, etc. Some of the stand-out tech talks at IMTS 2014 include a presentation on “Cloud Computing: What it is and How it Will Revolutionize the Manufacturing Industry” by Michael Taesch. A senior project manager at Swiss company, Machining Cloud GmbH, Taesch will explain how manufacturers can use cloud-based computer technology to boost their bottom-line. A presentation entitled “Manufacturing the Future” will be conducted by Avi Reichental, president and CEO of 3D Systems, a 3D content-to-print company based in Rock Hill, South Carolina. Reichental will offer an overview of the state of the 3D printing industry and a forecast of the future. Launched at IMTS 2012, the TRAM conference makes a return appearance at this year’s show. TRAM 2014 will focus on trends and advancements in manufacturing technology within the aerospace industry. TRAM displays will examine “advanced machining processes to produce more complex parts for the latest designs in aircraft structures and engines, as well as other industries that can benefit from similar
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machining processes,” says Eelman. Advanced manufacturing technologies and advanced materials, such as composites and titanium alloys, will also be displayed. Speakers include Dr. Greg Hyslop, vice-president and general manager of Boeing Research and Technology based in Seattle, Washington, Ricardo Traven, a Boeing chief test pilot and Peter Hoffman, Boeing’s vice-president of international property management.
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THE HIGH-TECH HIGHLIGHT OF IMTS 2014 WILL BE THE CREATION OF A 3D PRINTED ELECTRIC CAR IN AMT’S EMERGING TECHNOLOGY CENTER If much of IMTS 2014 is devoted to futuristic manufacturing technology, the show will also spotlight future users of manufacturing technology. To this end, IMTS 2014 will feature a Smartforce Student Summit, designed to appeal to young people and educators. “One major area of concern is making certain we are successful at bringing the next generation of manufacturing technology professionals into the industry to fuel innovation. To do this, we are investing heavily and growing the area for the AMT Smartforce Student Summit at IMTS by more than 50 percent … along with a tour, the student area will display a variety of interactive exhibits highlighting technology,” says Eelman. There will be speakers, demonstrations of CAD/CAM technologies, solid modeling
solutions and 3D printing and a town hall meeting for school superintendents at the Summit. The Student Summit will also feature “manufacturing technology ambassadors”—“young manufacturing professionals
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in their twenties who can speak about the wealth of career opportunities in manufacturing and the enormous earning potential. And of course, students gain access to the show floor for quality interaction with exhibitors,” continues Eelman. The basic idea behind the Student Summit is to make IMTS as indispensable to people on the cusp of entering the manufacturing sector as it is to established manufacturers and shop staff. Attending IMTS “is no longer optional. If you’re really going to be successful in your business you really need to touch base at IMTS to see what’s going on. This is your chance as a manufacturer or an engineer to come to an event that brings you up to date … what we’ve endeavoured to do with the Emerging Technology Center and some of the other technical displays is to not only bring you up to date, but tell you what’s coming next, so when you return to your manufacturing facility, you’re more literate about what’s going on and [technological change] doesn’t catch you by surprise,” says Eelman.
SOCIAL MEDIA AT IMTS Organizers of IMTS 2014 are eager to spread the word about their show via social media. Expect to see regular “tweets” about the event on Twitter, using the hashtag #IMTS. Conversations within the IMTS community will take place at the following online locales: Twitter: https://twitter.com/IMTS_2014 or @IMTS_2014 LinkedIn: http://www.linkedin.com/groups/IMTS2014-2987568?mostPopular =&gid=2987568 Facebook: https://www.facebook.com/ IMTS.show
CLAMP. DONE. RUN. Introducing FCS clamping system from SST. It’s that fast. Learn how moving clamping setup time to the CAD/CAM stage can drastically reduce downtime at the point of production. Talk to your SST representative about the latest innovations from FCS clamping system. Learn more at singlesourcetech.com/FCS Visit us at IMTS 2014, Sept. 8-13, Chicago, IL Booths E-5127 and W-2167
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TDM Systems Inc. — Booth E-3264 TDM Systems will showcase how the TDM 4.7 software package for Tool Lifecycle Management makes life easier for machining companies. The TDM software has covered for a wide variety of process steps in tool based machining – from data and inventory management to provision of simulationready 3D data. www.tdmsystems.com
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
GibbsCAM - Gibbs and Associates — Booth E-3310 Gibbs will showcase GibbsCAM UKM (Universal Kinematic Machine), the brand-new engine behind the upcoming release of GibbsCAM 2015, at IMTS. GibbsCAM now has dynamic 3D viewing of tools and tool-holders in the tool dialog, allowing users to accurately visualize the tools they are selecting for the job. www.gibbscam.com
CAMWorks - Geometric Americas, Inc. — Booth E-3320 Geometric will preview its latest release of CNC programming automation solution, CAMWorks 2015. CAMWorks 2015 has over a dozen enhancements focused on shortening the programming time. With an integrated true G-code simulation, CAMWorks Virtual Machine, users can make sure that the costly process of dry-runs on the shopfloor are minimized with one-click verification. www.camworks.com
Sodick Inc. — Booth E-5102 Sodick will display a complete line of wire EDMs, including the top selling cost efficient VZ Series, the new advanced SL series which incorporates the latest industry leading SPW control, the extreme capacity AQ Series and the ‘ultra’ precision AP Series with micro wire and oil dielectric technology. www.sodick.com
NUM Corporation — Booth E-5135 NUM will be highlighting its dual channel CNC kernel for designers of small to medium size machines with up to five axes. The dual channel Flexium+ 8 CNC kernel provides an exceptionally high level of control flexibility. Either CNC channel can be used to control a spindle motor and four simultaneously interpolated axes – or control can be passed on-the-fly from one channel to the other. www.num.com 50 | AUGUST 2014
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Universal Robots USA, Inc. — Booth E-4841 With eight new adjustable safety rated functions, Universal Robots presents a robot that adapts advanced safety settings to each specific application. The new third generation of the collaborative UR5 and UR10 robot arms also comes equipped with True Absolute Encoders that eliminate the need for re-initializing the robot, enabling automatic start-up and easier integration into other machinery. www.universalrobots.com
The Johnson Gage — Booth E-5306 The Johnson Gage Company will feature its full range of new products including External and Internal Variables inspection Systems for NPT, NPTF, ANPT, and NGT Threads in accordance with the new ASME B1.20 Specification. Standard indicating Systems are designed to replace L1 Thread Ring and Thread Plug Gages. www.johnsongage.com
ZEISS Industrial Metrology — Booth E-5504 ZEISS Industrial Metrology will showcase CONTURA at IMTS. It is even more precise than its predecessor and offers a large package of optical sensors on top of additional measuring ranges. It offers outstanding scanning technology, Zeiss’ CALYPSO 2014 software and a highly tuned overall system. The ZEISS CONTURA family has eight different sizes starting with a measuring volume of 700 x 700 x 600 mm up to 1200 x 2400 x 1000 mm. www.zeiss.com/metrology www.canadianmetalworking.com
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Renishaw Inc. — E-5510
Jorgensen Conveyors, Inc. — Booth E-5762
At IMTS, Renishaw will be featuring its AM250 Laser Melting (metal 3D printing) machine. AM250 has been designed with the manufacturing industry in mind, with a simple touch screen user interface and robust construction. With the extended Z-axis option it is possible to build parts up to a maximum height of 360 mm. www.renishaw.com
Jorgensen’s introduce the MunchMan II. Design enhancements include new speed control functionality and a current overload sensor with JamManager programming safety device. The MunchMan II twin-steel belt conveyor employs a unique stacked conveyor arrangement at the lower curve and through the incline and chip discharge of the system. www.jorgensenconveyors.com
Olympus — Booth E-5623 The Olympus booth will be exhibiting the DSX100 microscope system as well as Stream and Inspector software. DSX100 opto-digital microscope technology combines cutting-edge optical performance (opto) with the operational convenience (digital) of a smartphone or tablet, allowing users to easily create, process, and share highresolution digital images. www.olympus-ims.com
PREMIUM WORKHOLDING SOLUTIONS
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Gravotech - Gravograph & Technifor — Booth E-5694 Technifor is excited to showcase the electro‐magnetic XM700, with Touch ’n Mark technology this year at IMTS. This new and innovative marking solution is fully mobile, with Integrated Control Unit and Belt Battery; extremely simple and user‐friendly with Intuitive Programming. It offers the deepest marking possible in its class with brand new stylus technology. www.technifor.us www.canadianmetalworking.com
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BOOTH W-2364
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SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Greenerd Press & Machine Company, Inc. — Booth N-6031
Greenerd will present unique hydraulic press application solutions including a large shaft straightening press with a 63-foot bed. Greenerd presses are available in a variety of styles ranging from gap frame and straight-side to die-spotting and forging presses, with product capabilities to 40,000 tons and bed sizes exceeding 240” (6,100mm). www.greenerd.com
ESAB Welding & Cutting Products — Booth N-6129 ESAB Welding & Cutting Products will showcase the Swift Arc SL system, a side-load robotic cell featuring a new tandem Swift Arc Transfer (SAT) MIG welding process at IMTS 2014. The Swift Arc SL is designed for robotic welding of large parts at high production rates. The new tandem SAT process uses twin welding wires running simultaneously through the cell’s robotic torch. www.esabna.com The idea: Providing a quiet, stable, flexible, and highly-effective milling solution.
Why it’s great: • High number of inserts resulting in quick machining and low cutting forces. • 8 usable cutting edges per insert for cost-effective production. • Available with or without internal coolant. Learn more about this and other great ideas. Go to www.komet.com/greatideas or scan this QR code.
Flow International Corporation— Booth N-6217 Flow International Corporation will exhibit its Mach Series waterjet cutting systems at IMTS 2014. The Mach 4c offers a variety of features unique in the waterjet industry including an expandable modular design, up to 14m (48’) in length. The system’s exclusive roller pinion system provides fast, accurate cutting with zero backlash. www.flowwaterjet.com
TRUMPF Inc. — Booth N-6223
www.komet.com 905-551-1743
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TRUMPF Inc. will exhibit the TruMark 5010 Mobile Marker at IMTS 2014. The mobile marker’s compact and handheld processing unit eliminates the need to move the part in order to complete the laser marking process. It marks static and variable texts, barcodes, datamatrix codes and also graphics and logos in the highest quality. www.us.trumpf.com www.canadianmetalworking.com
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OMAX Corportation — Booth N-6228
Bluco Corporation — Booth N-6563
Omax will be featuring its 1530 JetMachining Center, representing the next generation line of MAXIEM abrasive waterjet systems. At IMTS, the company will pair the 1530 with an optional A-Jet multi-axis cutting head to demonstrate how easy it is to cut beveled edges, angled sides and countersinks. The A-Jet also compensates for taper and creates 3D complex shapes. www.omax.com
Whether you have a specific program that needs tooling, or want to discover the newest fixturing technologies to make improvements to your manufacturing capabilities, visit their booth to learn how modular tooling can benefit your company. Hands-on tooling displays will be available and application engineers will be on-site to discuss your customized application. www.bluco.com
ABB Inc. — Booth N-6251
Rofin-Baasel Inc./Rofin-Sinar Inc. — Booth N-6613
ABB is pleased to introduce the FlexMT. This standardized, yet flexible robot solution sets a new standard in machine tool automation by increasing machine utilization by as much as 60 per cent. Available in two variants, the FlexMT 20 (20kg/1.65m reach) and the FlexMT 60 (60kg/2.05m reach), the FlexMT comes complete with a robot controller inside its fully integrated control cabinet. www.abb.com
ROFIN will exhibit its 35 years’ experience in developing and manufacturing industrial lasers and laser-based products. They not only develop laser sources but also complete turn-key laser systems. With a variety of CO2, rod, disc, fiber and diode lasers, pulsed or cw, ROFIN offers a product range for industrial materials processing. www.rofin.com
Visit us at Booth N-7151
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German Machine Tools of America — Booth N-6670
SEPTEMBER 13, 2014 C H I C A G O McCORMICK PLACE
GMTA will be showing their family of gearmaking machines, grinding, milling and turning centers, plus the newest additions to the line, Rosink parts washers and Arnold laser machines. Manning the booth will be President Walter Friedrich, VP Scott Knoy and executives from the various companies represented by GMTA in North America. www.gmtamerica.com
Laser Marking Technologies, LLC — Booth N-6676
Micro 100 Tool Corporation — Booth N-6698
Laser Marking Technologies will be showcasing their 3D digital scan head at IMTS. This digital scan head offers the user a faster and easier set up due to the Z-Axis scanner and 3-Axis control. You can now program complex shapes in the most time efficient manner. This scan head can be provided inside an enclosure and also can be mounted outside for in process marking. www.lasermarktech.com
The NEW MICRO 100 MEF family of tools are all 2 fluted miniature end mills available as small as .0100” in cutter diameter. These high precision miniature mills are ideal for finishing and semi-finishing cuts in hardened materials 45 to 68 Rc materials. Their extra fine carbide substrate also makes them well-suited for mold making. www.micro100.com
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United Grinding North America, Inc. — Booth N-6800 United Grinding North America will showcase 19 grinding machines. The new MÄGERLE MFP 100 flexible grinding center, available as a 5 or 6-axis system, offers high working speed and expandable tool changer system that can hold up to 60 tools. The MFP 100 can grind, mill and drill heavy, complex parts in a single clamping. www.grinding.com
EMAG L.L.C. — Booth N-6846 EMAG will feature its new modular standard VL and VT product families. The VL vertical pick-up lathe allows for the machining of a wide range of chucked components. The smallest lathe of the VL product family, the VL 2, machines workpieces with a maximum diameter of four inches and a length of up to six inches. www.emag.com
CECOR — Booth N-6789
Marvel Manufacturing Company Inc. — Booth N-6900
CECOR unveils an innovative discharge filter with its Sump Shark. Sharks are high-suction sludge vacs that not only clean dirty sumps, but can separate metalworking fluids from the solids being vacuumed so the fluids can be recycled thereby reducing costs. It comes with nominally rated 10- and 25-micron filter bags for finer filtering. www.cecor.net
Marvel will be featuring the high-speed carbide circular saw P230B. This saw features a 9 inch maximum capacity on rounds and a 6.3 inch maximum capacity on squares. The P230B features 750mm diameter blade with a 3.8mm blade thickness to minimize material loss. The blades can be either carbide tipped or ceramic (cermet). www.marvelsaws.com
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SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Liebherr Gear Technology, Inc. — Booth N-6930 With a one-table design and a new-design grinding head, the new Liebherr LGG 180 will be featured at IMTS. The new grinding head allows for rotation speeds up to 10,000 rpm and has spindle power of 35 kW. The new grinding machine can exploit the considerable potential of the innovative 3M abrasive Cubitron II. www.liebherr-us.com
Norton Abrasives — Booth N-7051 Norton Vitrium will be showcased at IMTS. It features a patent-pending bond technology. This revolutionary bond features an exclusive chemistry that promotes excellent grain adhesion, resulting in improved product versatility across a wide range of applications. It offers a stronger bond construction, an improved holding power utilizing less bond-to-abrasive ratio, and an increased porosity. www.nortonindustrial.com
Fives — Booth N-7018
GMN USA — Booth N-7151
Fives will feature a Y-axis attachment, that combines a C-axis head with table and X and Z-axes motions, at IMTS. The attachment, available fully integrated on new VTCs or as a retrofit, allows for single-setup processing of flanged parts, pumps, compressors, motor housings, fluid routing parts, intakes and exhausts, among others. The Y-axis attachment will be featured in the Fives booth at IMTS. www.fivesgroup.com
GMN USA will be introducing the new GMN Oil/Air Spindle Lubricator for the first time in North America. The new “Prelub GP Series” will have a new look with modular construction and visible lubricant container that can be filled from the outside of the unit. The new units will also have lubrication cycle interruption in case of spindle stoppage, Error Memory and Menu Language Selection. www.gmnusa.com
Strausak Inc. — Booth N-7200
PRAB, Inc. — Booth N-7288
Strausak will debut a new 5-axis CNC tool grinder, U-Grind, at IMTS. U-Grind offers excellent thermal stability and a unique design. It includes standard automatic wheel changer, direct-drive grinding spindle 12 kW (17HP) and optional auto loader. There is also an automatic quick-change system for collet change and for changing basic tool holder ISO-50 taper. www.strausakusa.com
PRAB will feature its full spectrum of industrial wastewater treatment equipment at IMTS 2014. The company has partnered with Veolia Water Solutions of Italy to market and support the exclusive EVALED line of vacuum evaporators in North America PRAB’s line of wastewater treatment systems include particle filtration, membrane separation and now a full line of Vacuum Evaporators. www.prab.com
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NSK America Corporation — Booth N-7321 NSK will showcase the EVOlution series of hand grinder. With speeds up to 40,000 rpm, the EVOlution can utilize two hand motors, comes with a standard load meter. There are 14 attachments that can be added, which allow rotary, reciprocating, oscillation and sanding and movements, depending on the application. www.nskamericacorp.com Continues on page 112 www.canadianmetalworking.com
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Visit us at IMTS
Come see these machines and more! MA-12500H Horizontal Machining Center
MA 12500H
Maximum load capacity of 11,000 pounds Rapid traverse (X, Y, Z) of 1,653 ipm .001 degree B-axis rotary table Parallel-type 2 pallet APC
IMTS Booth S-8500 Bridgeport Conquest V1000
CONQUEST V1000
Direct-drive 20HP, 10,000 RPM spindle motor Travels - X: 40” Y: 24” Z: 24” Mitsubishi M70M control with NAVI MILL Programming and 10.4” LCD
IMTS Booth S-8738 Grob G350 – 5-Axis Universal Machining Center
GROB G350
Compact – Rigid – Accurate Travels - X: 23.6” Y: 30.3” Z: 26. 6” Horizontal Spindle – Unique Axis Configuration Allows Optimized Chip Flow
IMTS Booth S-9490 Tsugami B0326 Swiss Turning Center
TSUGAMI B0326 Mississauga Head Office 205 Admiral Blvd. Mississauga, ON L5T 2T3 Tel. 905-565-3570 Fax. 905-565-3580
Montreal Office 7939 Henri-Bourassa Blvd West, Montreal QC H4S 1P7 Tel. 514-735-6888 Fax. 514-735-6845
32mm capacity Swissturn Electronic servo driven guide bushing Easy access tool zone Modular quick change driven tool positions for maximum flexibility Deep hole drilling positions standard X, Y, C, Z sub side spindle control Sub side cross drilling Easy to use with Abile software
IMTS Booth S-9410 Windsor Office Tel. 519-222-8716 Fax. 905-565-3580 Manitoba Office Winnipeg, Manitoba Tel. 416-896-0489
Western Canada Suite 900,10665 Jasper Avenue, Edmonton, Alberta T5J 3S9 Tel. 780-953-3570 Fax. 780-421-8400
Providing tomorrow’s manufacturing solutions today! www.emecmt.com Emec_8.125x10.75-Aug.indd 1 Emec.indd 1
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SUCCESS BY SINTERING? SLS technology promises to change metal part manufacturing forever… will it live up to the hype? BY JIM ANDERTON, EDITOR
I
Top: TRUMPF and Italian laser manufacturer SISMA have announced a joint venture to develop production metal additive manufacturing equipment. Pictured: laser deposition welding on a small substrate.
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t seems too good to be true: complex parts without machining, appearing almost out of thin air right before your eyes. While the technology is in its infancy from a production perspective, years of use in prototyping has brought selective laser sintering (SLS) into the forefront among metal additive manufacturing processes. The process is deceptively simple: successive layers of metal powder are deposited in patterns corresponding to lateral slices of the three dimensional part, while a laser beam heats the line of deposited powder, causing a localized melting of the powder. The laser is key, inputting just enough energy to sinter the powder spherules without permitting a melt pool which might flow away from the trace.
It’s a precise, carefully controlled process operating in an inert gas environment, but floor-ready machinery has evolved to the point where metal 3D printing can be considered a true manufacturing process…”rapid prototyping” is just one application. SLS is mature enough that the technology is beginning to see production applications. TRUMPF, for example, has entered a joint venture with Italy’s biggest laser manufacturer SISMA S.p.A., to co-develop production systems for the 3D printing of metal components. TRUMPF originally entered the additive manufacturing sector in the year 2000, however, with companies from several industry sectors now qualifying components and products for additive manufacturing, TRUMPF is working on rapid entry into the market. “Many machines on the www.canadianmetalworking.com
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market today are aimed more at prototype construction,” explains Dr. Peter Leibinger, head of TRUMPF Laser Technology. “In the future, however, the most important criterion where additive manufacturing lines are concerned will be their suitability for industrial applications.” The target markets of the joint venture are the industrial sector as well as jewellery, fashion and the lucrative dental market.
CAN ADDITIVE PROCESSES REPLACE MACHINING? That’s the core issue in the debate about the future of additive as a metalworking process. Speed and finish are still areas where subtractive (machining) processes maintain an edge, but the gap is narrowing. One way to bridge the gap is with hybrid technology. DMG MORI has developed a hybrid machine incorporating the firm’s 5-axis milling technology with a generative laser deposition welding head, the LASERTEC 65 AdditiveManufacturing. The system deposits material using a powder nozzle and sinters it on the part with a flying laser head, a process which DMG MORI claims can speed the deposition process by 20 times over a powder bed system. In production, the system will machine the major portion of a part and add detail and complex structures with the deposition head. The additively-made portions can then be machined. The ability to machine post-deposition allows the part designer and programmer to specify faster deposition rates and minimize the amount of deposition to reduce cycle times. Interest in hybrids is growing. Matsuura Machinery Corporation has announced that its LUMEX Avance-25 Metal Laser Sintering Hybrid Milling Machine has entered the
North American market (U.S. and Canada) through a distribution agreement with Mitsubishi. The hybrid machine is the result of five years of researcha and development (R&D). Like other laser sintering machines, the LUMEX Avance-25 binds thin layers of metal powder using a laser, but also mills for higher accuracy as well as complex geometry. The machine accommodates a maximum workpiece size of 250 x 250 x 180mm. Hybrids are based on current 5-axis machine technology, but could additive manufacturing be retrofit on an existing machine? Hurco has announced that the company recently filed a U.S. patent application for new technology combining 3D printing and CNC machining. “We designed an additive manufacturing adapter that, in combination with proprietary Hurco control software, effectively turns a CNC milling machine into a 3D printer,” said Gregory Volovic, President of Hurco Companies, Inc. This additive manufacturing technology permits Hurco machine tools to achieve 3D printing directly on the machine tool without the need for a separate 3D printer. Hurco is working on expanding the development to include other additive manufacturing processes. The company has not announced a production date for the retrofit technology; vis-
The EOS M 290 system is the successor to the EOSINT M 280 and is designed for production part making and prototypes. The system is equipped with a 400 Watt laser and can be operated under an inert (nitrogen) atmosphere or under argon, which permits processing of a great breadth of materials. These include light alloys, stainless and tool-grade steels, and superalloys. The EOS M 290 has a build volume of 250 mm x 250 mm x 325 mm, but retains the core elements of the previous system: process chamber, gas stream, process parameters, etc. EOS also supplies its EOS M 290 customers with the EOS ParameterEditor, to allow them to modify a range of exposure parameters for themselves. The tool enables customers to develop their own parameters for specific applications on the basis of the EOS parameter sets. These include laser power and exposure speed or strategy.
This turbine disk shows an application where additive processes shine. The complex, difficult to machine airfoil shape is critical to engine performance, while the hollow section blades must be light, strong and free of stress risers due to porosity or inclusions.
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DMG MORI has developed a hybrid additive/ machining centre called the LASERTEC65 AdditiveManufacturing that combines a powder deposition head with a five-axis machining centre. One strength of this process is the option to successively build up layers of different materials. Wall thicknesses of 0.1 mm to 5 mm are possible depending on the laser and the nozzle geometry. Complex 3D contours can also be generated in layers without supports. The individual layers can then be accurately machined before the areas become inaccessible to a cutter or other tools due to the component geometry. The combination of the two processes is a sensible choice for repair work and the production of moulds as well as parts for the energy and aerospace sectors.
itors to IMTS Chicago in September will be looking for more details. Another emerging technology for large part production is electron beam deposition. Sciaky, Inc., a subsidiary of Phillips Service Industries (PSI) has announced that the firm will become an equipment vendor, offering its electron beam additive manufacturing (EBAM) systems for purchase. Sciaky has preexcludominantly offered its exclu sive additive manufacturing process as a service-only option to manufacturers who required assistance to produce large-scale prototypes and production parts, up to 19 feet in length, made of high-value metals like titanium, tantalum, stainless steel, and Inconel. The technology has been a key driver of several high profile R&D projects involving the U.S. Air Force, Lockheed Martin, DARPA and Boeing. The EBAM process, which has been marketed as Direct Manufacturing (DM), combines computer-aided design (CAD), electron beam welding technology and layer-additive processing. Starting with a 3D model from a CAD program, Sciaky’s fully-articulated, moving electron beam welding gun deposits metal (via wire feedstock), layer by layer, until the part reaches near-net shape. From there, the near-net shape part requires minor post-production machining. Deposition rates of Sciaky’s EBAM process range from 7 to 20 lbs/hr, depending upon part geometry and the material selected. The build envelope can reach up to 19’ x 4’ x 4’ (L x W x H), allowing manufacturers to produce very large parts and structures, with virtually no waste.
ADDITIVE IN PRODUCTION Mass production of additive metal parts is the holy grail of 3D technology, and General Electric has announced a major step toward that goal. Jet engines have been a natural market for additive parts: light weight, high value and low volume. GE is co-developing (with CFM of France) a complex next generation turbofan project called LEAP, which will enter airline service in 2016, powering the new Airbus A320neo, Boeing 737 MAX and COMAC (China) C919 aircraft. The LEAP engine promises 16 per cent better fuel Continues on page 62 60 | AUGUST 2014
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Bicycle hubs in process using an EOS EOSINT M270
Conformal cooling is a potentially game-changing application for laser sintering systems. This Renishawgenerated part shows how complex cooling channels can be designed to optimize heat flow in production tooling like plastic injection molds. The result is parts of greater complexity with faster cycle times and reduced warpage, surface finish problems and fewer residual stress issues from differential cooling in the cavity.
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efficiency than previous generation engines; achieving this efficiency required very advanced gas dynamics and very precise fuel management. In a significant vote of confidence in SLS technology, GE will mass produce a critical component for the engine: fuel nozzles, which will be built at a new facility in Auburn, Alabama. The production volumes will be significant. CFM to date has logged total orders and commitments for more than 6,000 LEAP engines. There will be almost 20 fuel nozzles in every LEAP engine produced, thus setting the stage for prohigh, long-term pro duction volume at the Auburn plant. Production will ramp up quickly over the next five years, going from 1,000 fuel nozzles manufactured annually to more than 40,000 by 2020. Announced at the 2014 Farnborough Air Show, the new plant will encompass 300,000 square feet and cost USD 50 million to implement. Equipment installation will begin in late 2014 and production of additive components will begin in 2015. By the end of 2015, the plant could have as many as 10 printing machines with the potential to grow to more than 50 printers and occupy a third of the facility at full capacity. The operation will also continue to manufacture superalloy machined parts for jet engines. GE expects to hire 300 people when the plant is at full ramp-up later this decade. At press time, the supplier of GE’s additive machinery has not
Large parts can be additively built with this Sciaky electron beam (EBAM) process. Starting with a 3D model from a CAD program, Sciaky’s fully-articulated, moving electron beam welding gun deposits metal (via wire feedstock), layer by layer, until the part reaches near-net shape. From there, the near-net shape part requires minor post-production machining. Deposition rates of Sciaky’s EBAM process range from 7 to 20 lbs/hr, depending upon part geometry and the material selected. The build envelope can reach up to 19’ x 4’ x 4’ (L x W x H)
been announced. The technology for metal additive manufacturing is evolving quickly. Next month, Canadian Metalworking will go in depth to discuss the business case and technical details about introducing additive technology to Canadian production and job shops.
ADDITIVE MANUFACTURING AT AME MISSISSAUGA Additive manufacturing technology will be prominent at this year’s Advanced Manufacturing Expo, to be held September 23-24 at the International Centre in Mississauga, Ontario near Toronto. Nine presentations are available on the 23rd, covering 3D printing topics from self-replicating 3D printing technology for use on the Moon, to more down to Earth subjects such as sensing and real time control of laser metal additive processes. Conformal cooling will be addressed by Lou Young of Linear Mold and Design, while Renishaw’s Mark Kirby will describe collaborative design for additive processes. Dr. Lijue Xue from the National Research Council will speak on converting 3d designs in to functional metallic parts. For more details, visit www.amexpo.ca
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FABRICATING & WELDING NEWS
WELDING CURRICULUM STANDARDIZATION TOPS AGENDA AT CWA WELDING EDUCATORS CONFERENCE
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he Canadian Welding Association’s (CWA) annual Welding Educators Conference was a great success this year as over 50 educators from across Canada participated in the two-day seminar that focused on welding education and standardization of welding curriculum. “I am very pleased with the turn out, the presentations and the round table discussions,” said Dan Tadic, Executive Director of the CWA. “Every year the attendance continues to grow and educators are becoming more engaged, which are all great indicators of the importance of this type of conference. This year, the main topic of focus and debate was welding curriculum standardization. There has been some progress on this front, however, there continues to be gaps that need to be addressed.” This year’s conference was held at Nova Scotia Community College’s Akerley Campus in Dartmouth, Nova Scotia. One of the presenters, Lorraine Coulombe, Chair of the Interprovincial Standards and Examination Committee (ISEC), went into detail of new initiatives being undertaken by the Canadian Council of Directors of Apprenticeship (CCDA) and the importance of harmonization in today’s
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economic climate more than ever before. She also highlighted how CCDA is working collectively with provinces and territories to modernize, grow and standardize curriculum at post-secondary institutions across Canada, as well as the steady growth of the Red Seal program. Joe Rudderham, Director of Apprenticeship Training in the Department of Labour and Advanced Education, Apprenticeship Harmonization also spoke. He focused on how the Interprovincial Red Seal program works from its inception 50 years ago and the changes that have occurred over the five decades. “These efforts are intended to facilitate apprentice completion and encourage mobility,” he said. A presentation on the CWA Foundation was also part of the conference. Deborah Mates, Director of the Foundation, informed attendees how the foundation will support all levels of education across the country through bursaries and scholarships. “We want to ensure that students who are passionate about welding can attain a higher education and become successful in the profession,” she said. “Through our bursary and scholarship programs, we want to make a difference and this is just one way we’re giving back.” She also touched on the Foundation goals to support female welders, aboriginals, persons with disabilities and members of visible minorities. “Anyone can pursue a profession in
welding and sometimes support is needed because of the barriers they encounter,” she said. “That’s why we will support all demographics the best way we can so if someone wants to get into welding, we will do our utmost to support them through various initiatives through the foundation so they have a great career in this diverse profession.” Another topic presented by Craig Martin, Vice President of CWB Group’s Office of Public Safety focused on programs the CWB Group has in place to work with educational institutions to assist students in obtaining nationally recognized welder qualifications under the CSA W47.1 system. “Our test centres provide students with an edge when they try to enter the workplace because CWB welder qualifications are highly recognized in the Canadian welding industry,” he said. “We encourage schools to take advantage of becoming a test centre because it adds value to their welding program and students feel proud of their accomplishments when they pass their tests.” To add a hands-on component to the conference, Ken McKen, Manager of the CWA for Western Canada, hosted a welder practical marking evaluation workshop. “The intent of this strategic workshop was to create a national template that provides consistent welder practical examination in Canada,” he said. “All the educators were engaged and were receptive to the notion of having a grading system in place that is both consistent and cost effective.” www.canadianmetalworking.com
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GETTING THE
OUT
Portable fume extractors that capture fumes at the source are the best way to protect welders BY NESTOR GULA
T
he smoke that rises from the arc when welding contains many elements that can be dangerous to the welder. The composition of these fumes can vary. This depends on the components of the base metal being welded, the fluxes being used and the presence of any coating on the metal. The smoke will also contain particulate matter which can damage the lungs. “There is a bunch of stuff in the fumes that is not good, but in particular it is the particulate matter,” said Keith Daley, Fume Extraction Specialist for Lincoln Electric Canada. “You don’t want to be breathing that in…There are trace contaminants of various things. There could be nickel or chrome in there. There could be manganese. These items are all listed in legislation that governs health in a workplace and there are limits that can be present in the air.” Mild steel welding fumes can contain iron with small amounts of additive metals including chromium, nickel, manganese, molybdenum, vanadium, titanium, cobalt, and copper, among others. When welding stainless steel, larger amounts of chromium or nickel can be present in the fumes. Prolonged exposure to welding fumes containing zinc or copper oxide, commonly found during welding of galvanized metal, can lead to metal fume fever. This is sometimes referred to as “zinc chills” or “zinc shakes.” This flu-like illness can occur eight to 12 hours after exposure and clears up within about 24 hours. Metal fume fever is a warning sign to welders that they are being exposed to unsafe levels of dusts, fumes and gases. If they continue being exposed, more serious health issues can occur. Other respiratory ailments, such as asthma, can be exacerbated by continued exposure to welding fumes.
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Extracting the fumes is critical to the safety of the workforce. “The goal is to protect their breathing cells to make sure they don’t breathe in the toxic fumes,” said Rob Dinsmore, President of Lev-Co. “Typically they are required by law. Fume extractors are very important to the individual welder, as important as a welding mask.” Having a proper fume extraction system in place helps create a safer and more comfortable work environment. Fume extraction also allows for gains in productivity. “In some cases, it can be a means for companies to help attract skilled welders by providing a cleaner environment than the competition,” said Brian Hammers, Senior Engineer, Industrial Systems Group - FILTAIR, Miller Electric Mfg. Co. “Another advantage of fume extraction is that it keeps welders from having to stop as often during the welding process to clean their welding lens. It’s easier for them to see and there is less downtime for cleaning the welding lens.” There are two options when dealing with welding fumes, either removing them at the source or filtering the whole plant’s air. Making the right decision depends largely on what is the best fit for the facility, as well as air sample results. According to Hammers, “Larger facilities may benefit from a centralized system, as it can be less expensive to install over larger square footage. These systems require less interaction in terms of filter changeover and maintenance. That being said, individual fume extraction systems are highly efficient for providing source capture in the weld cell, particularly in smaller operations. Source capture is the preferred method for reducing exposure.” Capturing fumes from the source proves is economically advantageous according to Glen Love, president of Enviroflex International Inc. He says, “It is much cheaper for a company to remove it at the www.canadianmetalworking.com
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A long extension can remove fumes in confined spaces ensuring the health of the welder. PHOTO COURTESY OF LINCOLN ELECTRIC.
source as opposed to a whole plant ventilation system. You only have to capture the fumes at the source rather than having to do so many air changes per hour in the whole plant.” There is a smaller chance that smoke and gas will seep into the breathing area with a source capture system as long as the equipment is working properly. In some instances, however, source capture cannot be done effectively or even at all. “It does not matter on the process – it is more the nature of the work. If you are working on a large jig and you have a number of small welds over a large area, it is not effective to have the welder move the fume hood every time. If there is some sort of coating on the steel, it will continue to smoke even if you have stopped welding. The fumes will continue to go into the air,” said Daley. If this is the case, a buildup of fumes can occur above acceptable levels, and therefore, an entire shop system is needed. While some plants opt for whole plant air purification systems, capturing the fumes at the source is a much healthier option. Where possible, source capture should be used to protect the welder. “It is much more effective. It will capture the fumes before anybody, not just the welder, but the welders associates and colleagues in the plant facility, has a chance to breathe it in,” said Dinsmore. “In a whole plant system, everybody breathes it in on the way to the filter.” In most situations, source capture will preclude welders from wearing cumbersome filters or breathing apparatus. “As long as the fume extractor is well positioned and working properly no other respirator is needed,” said Love. “Usually a welder that is wearing a respirator becomes uncomfortable and hot.” More protection is needed where welding fumes are not captured at the source. Therefore, using source capturing systems can create a more comfortable work environment for the welder. www.canadianmetalworking.com
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However, there are some instances where additional protective equipment is needed. “If they are not capturing all the fumes at the source, or not enough, then they need to have either supplied air or a filter available to the welder,” said Daley. “For environments that need respiratory protection, dust masks, half masks, powered air purifying respirators (PAPRs) or supplied air respirators may also be necessary,” added Hammers. Small, portable, efficient filter units are offered by several companies that provide effective source fume capture. Most units are floor mounted with a long extractor arm and wheels that can be easily repositioned by the weld operator to protect themselves from the welding fumes. Unlike some static mounted fume hoods, which simply vent the fumes to the atmosphere, these units filter the fumes and are usually 99 per cent effective. “The advantage of a portable fume extraction sys-
A mobile portable fume extractor features an adjustable extraction arm that the welding operator can move toward the weld pool to remove the fume from up to 18 inches away. PHOTO COURTESY OF MILLER ELECTRIC.
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tem is that it is versatile and can be moved to various parts of a shop,” said Hammers. “Also, these systems typically offer source capture [as opposed to ambient extraction]. A disadvantage is that they require more frequent filter changeover than a fixed centralized system, because they provide less filter capacity. There are also limits to the accessories [e.g. extra arms, enclosure or overhead collection hoods, back draft or down draft tables, etc.] that can be attached to a mobile unit.” Dinsmore added that “they are usually a little more cost effective per welder.” He also noted that, “some people don’t want anything on the floor – they want the equipment mounted on walls and each machine has to be maintained separately while with a central system only one system has to be maintained.” Besides the vacuum, the most important part of the fume extractor is the filter. “Filter
“[FUME EXTRACTION] CAN ... HELP ATTRACT SKILLED WELDERS BY PROVIDING A CLEANER ENVIRONMENT THAN THE COMPETITION.”
Today’s more powerful portable fume extractors can be made to work in any situation. PHOTO COURTESY OF LINCOLN ELECTRIC.
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elements have evolved more than the fume extractors themselves,” said Daley who explained that fume extractors are now efficient, simple to use and easy to move around. Filters can vary by manufacturer but one of the most important factors to consider, according to Hammers, is the MERV rating. MERV stands for Minimum Efficiency Reporting Value. “These ratings, from one to 16, gauge the ability of the filter media to remove particles from the air and provide a reliable standard for measuring the efficiency of a filter,” said Hammers. “Filters with higher MERV ratings [15 to 16, for example] are ideal. Hammers also suggest considering using a filter media with surface loaded technology as it helps provide a high level of fume capture efficiency combined with a low level of pressure drop to maximize performance and effectiveness. There are several elements in welding fumes, particulate matter and gasses. The most effective way of eliminating particulate is with a HEPA filter, explains Love. “If you are welding with stainless steel you get hexavalent chromium in fumes – they are usually smaller than one micron. You should use a HEPA filter. It is not mandatory. A filter won’t get the gases as they are not a particulate. If you want to capture the gases you need to get a gas type filter, which is an activated charcoal filter of potassium permanganate. Normally you will have a pre-filter and in our systems usually you change this pre-filter two or three times before you have to change the HEPA.” While HEPA filters can be very efficient, the downside is that they are disposable. At the beginning of a filter’s lifecycle, a lot of air through occurs. However, towards the end of the lifespan, there is less air through, making the filter less productive, according to Daley. Dinsmore adds onto this notion by stating that, “the most effective filter element is a cartridge filter that has an integrated filter cleaning system. When activated it takes the dust, created from the fumes, and deposits them into a pail. That pail can be emptied. This is the most effective.” This results in predictable air flow with no loss as the filter becomes clogged up, solving the productivity problem. Filters should be changed when the air flow has declined to an unacceptable level. Proper care should be exercised when dealing with the filter or pail of a self-cleaning system, as the residue can be hazardous. You need www.canadianmetalworking.com
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to wear gloves, goggles and dust masks. “Many fume extraction systems have built-in alerts to indicate when the filter should be changed, while others will simply begin to lose suction,” said Hammers. This depends on fume generation rate and other factors, “including the application, how many pounds of wire are used over the course of welding, the duration of welding, welding wire type, whether the base material has oil, dirt or coatings on it and more. The fume extraction design can determine how often the filter needs to be changed. It determines how much air [cubic feet per meter or CFM] can move through the filter and how much weld fume is occupying the filter. The goal is to gain the best filter cleaning efficiency.” Hammers also points out that handling and disposing of filters is an important component and can vary by geographic location. He stresses the importance of contacting the local authorities for proper disposal methods as well as the need to wear the proper protective gear. When deciding on a portable fume extractor you should get a list of all the contaminants you are dealing with that are hazardous to the health of the welder. “Then you will have to figure out what type of unit you need – a portable unit, a fixed station. I always say try to get source capture,” said Love. “Some people will say that source capture hinders production and I would have to agree with them. If someone is MIG welding something that is five to six feet long, you will not get him to move the arm along. It is hard to build a universal hood for all the applications. The ideal would be a MIG welding smoke exhaust gun, but welders will “SOME PEOPLE WILL SAY THAT SOURCE not take to it. I tried to promote this 30 CAPTURE HINDERS PRODUCTION...” years ago but it did not work out.” You should also look at what type of welding you are performing. “If you are doing a 12 inch welds and have an extractor that will give you a four-inch area of capture than you will only get a third of an area of capture,” said Daley. It is important to consider the ease of application. It can be a challenge to get welders to use them if they are not user-friendly. Daley continues, “If it is too clumsy to get in, then the welder is not going to use it. It needs to be simple and it needs to be appropriate. It has to match the application both in size and the volume of air.” 70 | AUGUST 2014
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Fume extractor captures sparks Well suited for most welding fumes, grinding and non-explosive/flammable dust applications the Roll Flex filter system is compact, very flexible and comes complete with a 7’ or 10’ extraction arm. Unit made of powder painted steel sheet and has a 1.5HP fan that draws 750 CFM of air. It comes standard with 1 washable cartridge filter and an active filter surface of 14 m² (150 +ft².). Best suited for light to medium welding applications, MROmaintenance repair & overoverhaul and training & testing facilities & schools, the Roll-Flex works on standard 120 volt electrical supply and has an internal spark trap to protect the filter from damage. lev-co.com
Where hoods used to be small, they have grown considerably now. Dinsmore explains that the hoods are getting larger; they can reach 24 inches up from the 12-inch hoods. This means that there is less movement of the arm, making them more user-friendly. Dinsmore continues, “You can place it above the process and have the smoke rise to it. You can get anything from a 7 foot extractor arm to a 17 foot extractor arm on a portable unit. It makes a big difference,” he said. “That makes a big difference to a portable unit because it is very effective for the welder because they don’t have to move the unit around. They can just move the extractor arm.” Cost of ownership of a portable fume extractor system is also something to take into account. “It is also important to pay attention to overall cost of ownership, including power requirements and filter cost/lifespan, and to determine whether the higher upfront cost of a self-cleaning unit will provide better cost savings over the long term, compared to units that require the ongoing purchase and replacement of disposable filters,” said Hammers. Whatever the need, getting the appropriate fume extracting system is essential for a healthy and productive work environment. www.canadianmetalworking.com
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Portable unit can be wall mounted as well.
Negative pressure creates positive air flow
The unique shape of the Lincoln Miniflex weld fume control system houses a pridual-filtration system made up of a pri outmary Long Life-H filter and a HEPA out put filter. This system is constructed from lightweight, synthetic materials and is mounted on wheels and has a handy carrying handle. It allows users to check the extraction performance of the unit and indicates when a filter is saturated and requires replacement to maintain optimal performance. Other useful features include multiple extraction settings where the operator can choose extraction capacity setting based on environmental conditions – 94 CFM (Low) or 135 CFM (High). It operates at a sound level of less than 70dB and can be ordered in 110 and 220 volt models. The system weighs 38 pounds for the 220-volt model and 47 pounds for the 110volt model and can even be wall mounted, with an optional kit, to free up floor space if necessary. www.lincolnelectric.com
Creates a much larger capture area than existing source-capture products and minimizes arm interactions, the Miller Capture 5 is far more effective than ambient fume extraction systems. This ZoneFlow technology creates a negative pressure zone that extends the weld particulate capture distance. Air moving into the arm is still about 900 CFM. However, ZoneFlow technology also moves clean, filtered air out of the arm at approximately a 90 degree angle which creates a large negative pressure zone. This negative pressure zone forms a type of curtain that funnels the weld fume particulate towards the centre of the arm, maximizing capture and extending the capture zone up to five feet deep and four feet wide. An easy-to-operate extraction arm has external adjustments so air can pass through with less airflow resistance, giving stronger airflow and offers reliable and accurate positioning across the full range of motion of the arm, as well as easy adjustment and maintenance to ensure long-lasting operation. Pre-assembled extraction arms are available in 10- and 12-foot lengths. www.millerwelds.com
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STEPPING UP TO CMM to the amount of time, money and energy that can be spent in part inspection and often, it’s the customer that drives the process. Regardless of where the motivation begins, that first machine is the essential starting point for advanced production quality. A basic bridge-type coordinate measuring machine uses a software-controlled motorized contact probe operating in the three Cartesian coordinates (x,y,z) to build a user-defined profile of a part’s critical dimensions.
WHY COORDINATE MEASURING?
Getting into coordinate measuring technology isn’t difficult…if you do your homework BY JIM ANDERTON, EDITOR
I
f there’s one universal truth in machining, it’s this: if you can’t measure it, you can’t make it. Metrology in one form or another predates mechanized metalworking, but it’s really the drive to mass production and the need for standardized parts that drove the need for better ways of understanding part dimensions. Metrology has become a science in itself, which creates a natural conflict with production and custom machining processes alike. Fast, cheap and good are mutually exclusive properties in most job shop and production environments. Coordinate measuring machines (CMMs) are a great equalizer, allowing smaller job and production shops the ability to monitor and control part quality in terms of accuracy and repeatability. CMMs are cost effective, but they are not cheap, making the decision to make the move to machine metrology an important one. There is almost no upper limit
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For production shops, CMM technology is an obvious necessity, but more and more smaller job shops are embracing the technology. According to Rob Johnston, Carl Zeiss product manager, Elliott Matsuura Canada, the productivity argument for machine measuring can be as compelling for a small shop as it is for an OEM or Tier One part supplier. “If you’re a small shop, take a step back and quantify the time you’re spending manually gauging parts and documenting parts”, says Johnston. “Big shop or small shop customers need documentation so without a CMM you’re buying multiple, often custom gauges, many of which may be undocumented. [Manual measuring] is also error-prone and can take hours to document a simple part. It’s possible for a third of a machinist’s time to be spent measuring rather than cutting and running parts. In many cases it’s difficult to see how much time is wasted. Job shops often also don’t realize how much money they spend on custom gauging. Often they may be halfway through a job and then realize they don’t have a gauge to measure the part. Then they’ll spend a great deal of money to buy a gauge used for a single application that then goes on the shelf and is never used again. And every individual measuring tool has to be recertified and recalibrated periodically. In many cases the overall cost is the same or more than owning a CMM.” Johnston notes that CMM ownership often generates significant savings by the third year of ownership, but the technology www.canadianmetalworking.com
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also allows the shop to change the way they think about part measurement. The obvious benefit is the ability to check more attributes more often, but a hidden benefit is the ability to use process control strategies for short runs that are usually reserved for mass production. Instead of a “first off, last off” approach, a CMM allows a thorough check of several early run parts to solve potential problems earlier. There’s also a significant marketing benefit to machine metrology, says Johnston, “It also allows them to show the customer their commitment to quality and it provides an internal yardstick to measure their how good their process is. CMM is as much of a sales tool of how good you are and your commitment to quality as it is a measuring instrument.”
Portable arms are now a valid technology for entry-level users. The FaroArm is a portable coordinate measuring machine that allows manufacturers easy verification of product quality by performing 3D inspections, tool certifications, CAD comparison, dimensional analysis, reverse engineering, and more. With the ScanArm, the addition of the FARO Laser Line Probe to the FaroArm adds non-contact 3D scanning capabilities for detailed measurement of surface form, making the ScanArm the perfect combination of a contact and non-contact portable CMM.
MANY MACHINES, MANY CHOICES It’s easy to justify the step up to coordinate measuring technology, but starting the process can be challenging. Mitutoyo Canada CMM sales team coordinator Gord Homann explains, “When making that first CMM purchase, a shop should look at the type of
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work they’re doing. Never buy a machine just based on price, it should be the right tool for the job. It’s essential to meet the needs of what you are manufacturing. When buying a machining center, shops buy on the specifications they need....they should do the same thing with the CMM. It’s important to know what features must be measured, what tolerances exist, how tight they are and the volume of parts manufactured. Is it The Mitutoyo Crysta-Apex S500/700/900 series one million pieces or Coordinate Measuring Machines can be upgraded a ‘one-off’”? with Renishaw’s PH20 probe head. The Crysta-Apex series machines are affordable and support a wide Just like machine range of inspections solutions including laser tools, there is a scanning, optical, and surface roughness inspection. bewildering array of With the addition of the high-speed scanning capabilities of the PH20 the Crysta-Apex CMM adds features and options wide ranging measuring capability in the quality lab to choose from. To or on the shop floor. The PH20’s unique ‘head start, Homann rectouches’ allow measurement points to be taken by moving only the head, rather than the CMM ommends starting structure. Using only the rapid rotary motion of the with the basics,“In head, points can be taken faster, and with improved terms of CMM accuracy and repeatability. specifications it’s important to look at measuring volume and the accuracy specifications of the CMM compared to the tightest tolerance on the part being measured. Not all CMM’s are equally accurate. Is a manual machine good enough? Is it necessary to go to CNC to achieve higher accuracy? Traditionally, a CNC (coordinate measuring) machine is twice as accurate as a manual machine. Volumes are important. A manual machine may easily suit the need if shop is doing series of ‘one offs’.” Simple machines aren’t expensive by machine tool standards. A small manual CMM can be purchased for as little as $20,000 for a unit with a basic probe system, a computer and software. The automated solution can be bought for $50-60,000, depending on options and the measuring volume of the machine. Bigger costs more, as does measuring speed and accuracy.
THE ARM OPTION While bridge-type CMM’s are used industry 74 | AUGUST 2014
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wide, there are other options. Laser scanners and other non-contact devices are widely seen as the future of metrology, but for entry-level operators, contact type portable arms are a relatively new option with several advantages in a smaller shop setting. Compared to conventional CMM’s, arm type instruments appear much less sophisticated. In fact it’s a highly advanced technology that measures movement in articulated joints in multiple dimensions to define a series of points in three-dimensional space. The arm analogy is apt; the user leads the instrument by the hand touching off desired points in the measured object while the software builds a picture of the part form. For a shop just beginning with machine metrology, is an arm the right first machine? According to Canadian Measurement and Metrology president Elliott Foster, “most small shop owners from fabrication to machining are looking at space, expense and employing the resources to operate the equipment. It can be an onerous cost up front. There are several types of equipment a small shop owner should look at. One is the portable arm. Today they’re inexpensive; the accuracy has increased by 70 per cent in the last 10 years and are able to measure machined parts as well as other structures such as fixtures, castings and weldments and they’re entirely portable. Many have built in temperature compensation. For a probing only system, the price can be below $40,000 for a new system. The skill level is lower to run a manual device; you still have the ability to read the CAD file, but can also add a laser scanner. For first machines we’re seeing interest in portable arms. Today, we sell as many portable arms as CMMs. They’re a great tool; you can bring them to the machine tool and measure in the chuck, you can mount them to a plate, you can measure fixtures and the complexity is less so there’s less training. For inspection at 30 micron and less an arm is an ideal solution. At the 10, 15 micron level it‘s different.” Foster notes that it’s more important to match the measuring technology to the process, rather than the other way around. “It’s all about ‘horses for courses’” he states, adding, “if I am measuring batches of 20 or 30 parts, perhaps hundreds of parts it’s painstaking work generally to do that with an arm. For one-offs, fixtures, weldments, castings and short run work the arm is ideal. We’ll see machine shops making batches of 500 parts requiring 100 per cent inspection using an arm. It’s painstaking work. The www.canadianmetalworking.com
14-08-11 10:44 AM
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other factor is precision. They don’t look at the CAD file or blueprint and miss the true positional tolerance of 10 µ for example. The arm may be repeatable at the 10 µ level, but unless you know the calibration procedure used to certify that performance, it’s difficult to know if it’s usable for a given application. It’s important to talk to experts, regardless of the machine brand. If you’re going with an arm, make sure it fits the application.”
ACCURACY VERSUS REPEATABILITY Many entry level buyers of CMM equipment focus on accuracy when really precision (repeatability) is the more important performance metric. A machine with proven precision can produce reliable data with fewer measurements and less time in inspection. An important factor for first time buyers is the machine builders’ stated performance, but there’s a catch, testing methodology. Machine builders use internal procedures to qualify machines, using standard geometric shapes; real world parts have a multitude of possible quality issues such as flatness, roundness, straightness and others that are important to the end user but aren’t addressed by the manufacturer. Real parts create less than ideal testing conditions, making it importimport ant to try a new machine with actual parts to verify repeatrepeat ability. The precision issue is also a reason to buy a machine from a dealer with technical assets on the ground in Canada. Bankruptcies and auction houses can offer tremendous deals on used equipment, but CMM’s are not punch presses … a cursory inspection simply isn’t enough to weed out a “lemon”. It is possible to find a bargain, but for a first time The Carl Zeiss CONTURA G2 is designed for small and mid-sized companies wanting the benefits of high-speed scanning. VAST scanning technology enables form inspections at maximum speed with high-quality measuring results. Process changes are detected at an early stage, high production quality is ensured and rejected parts are reduced. Sizes are available from 28x28” to 40x96”, with accuracy from 1.8um +L/300. The CONTURA offers three sensor system options.
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buyer, the unit should have an extensive service history, be supported by a Canadian dealer with technicians familiar with the brand and have up to date calibration logs. While the auction route carries risk, used equipment, if bought from a reputable dealer, can offer considerable savings. Foster relates, “For a mid-sized machine there are lots of great machines available from $2025,000. Many mid-90’s machines are excellent and can generally be upgraded with new software. Entry level machines may have five year old software, but the rule of thumb is that a used machine is 50 per cent cheaper than new. For mid-90’s machines replacement parts are available and they’re reliable. If you stick with major name brands you can’t go wrong. FARO, Zeiss, Hexagon, Mitutoyo and others can be supported.”
MAINTENANCE: NO PROBLEM Maintaining modern CMMs are not an issue for shops using modern machining equipment, as the basics still apply. Standard housekeeping regarding fluids, vibration and dust apply, although many units can tolerate shop floor environments, reducing or eliminating the need for a clean room. Temperature compensation is important if the unit is portable, since the ambient next to five-axis mill is unlikely to match the QA room or engineering office temperature. The overair supply is important, and is often over downlooked. Many shops routinely add oil down stream of the desiccation/filtration pack, which is great for cylinders and motors, but is a contaminant to a CMM. Air consumption is moderate; a dedicated supply from a small compressor is an easy solution. In a five-axis CNC capable shop, it’s not a question of “why” CMM, it’s a question of “when”. Canadian shops have options at every price point, multiple brands to choose from and a qualified service infrastructure to keep the equipment calibrated. If you’re using hand instruments to measure parts made on CNC machine tools, you’re ready for a CMM.
www.canadianmetalworking.com
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TRUE
GRIT It never makes sense to opt for low-quality grinding disks BY NESTOR GULA
O
ccasionally, we see a flyer that advertises a deal in it — “10 bucks for 10 disks.” Sometimes the deal is great and other times, not so much. But when you look at any deal you may be tempted to ask yourself, “How bad can these disks be?”
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PHOTO: NESTOR GULA
GET THE When considering purchasing a grinding wheel, safety should be a concern. “Safety is one of the most important reasons to use a high-quality grinding wheel,” said Marc Brunet Gagné, Product Manager of Bonded Abrasives at Walter Surface Technologies. “Compared to discount brands, high-quality grinding wheels retain the bond of the particles much better, therefore, significantly reducing the amount of breathable dust and projectiles ejected into the working environment. This also results in a longer life of the grinding wheel, which reduces the amount of wheels needed and, therefore, also reduces the expenditure needed.” Using a grinding wheel as intended by the manufacturer — including the power output of the angle grinder, work piece material and the application — is important for overall safety concerns, according to Jim Ballou, Marketing Manager/Product Manager of Grinding and Cut-Off Wheels for Pferd Inc. Even when used properly, though, “buying the very cheapest wheel might bring about a series of issues including lack of manufacturer adherence to safety codes, potential fillers that may be harmful to breathe or may contaminate work pieces, lack of lateral stability/wheel strength, which may lead to wheel breakage, etc. Low quality wheels usually mean higher risk.” Brands that focus on producing high-quality www.canadianmetalworking.com
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products are manufactured to higher standards with tighter tolerances. “This provides a safer running grinding wheel that will offer longer service life with faster cut and grind rates over discount brands,” said Mr. Bob McDonough, Technical Liaison at Flexovit USA, Inc. Purchasing a high-quality grinding wheel not only means safer conditions, but “ultimately saves the customer money in wheel replacement, wheel changeovers, and labor.” Does anyone really want a low-quality product? The answer is no, according to Rick Hopkins, Product Manager of Abrasives & Maintenance for Weiler Corporation. However, he continues, “quality and performance are words that are often incorrectly interchanged. It is important to get a clear understanding of the desired level of performance before we recommend a product to a customer.” It is important to understand the performance needs of customers when buying and selling products. Ballou explains, “When you buy a drill bit, you are really paying for holes. How many holes can one make with a single drill bit? Then, it is possible to calculate the cost per hole. Grinding wheels can be measured similarly.” When
applied to a grinding wheel, performance is measured based on the metal removal. High-quality wheels are produced with the goal of high service life and removal rates. However, some “QUALITY AND PERFORMANCE discount brands ARE WORDS THAT ARE OFTEN may also perform at INCORRECTLY INTERCHANGED.” standard removal rates, yet with lower quality results. This reasoning suggests that the higher the quality of the wheel the higher the overall performance and, therefore, enhanced productivity. However, there are standardized tests that measure service life and efficiency of grinding wheels — G-ratio and Cutting Efficiency tests. The G-ratio test measures the service life of the grinding wheel. The latter measures the rate of material removal achieve by the wheel. Ballou explains, “These two tests, in unison, allow users to build a comprehensive assessment of overall costs. The price of the wheel itself is insignificant when compared to labor costs. If a user saves money by purchasing an inexpensive, low-quality wheel, the price advantage will be more than
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offset by poor removal rates and/or poor service life. This means reduced productivity and increased overall costs.” All grinding wheel manufacturers who sell and distribute in North America must, at a minimum, comply with ANSI B7.1 standards. Some companies, such as Walter Surface Technologies, choose to comply to both the ANSI B7.1 standard as well as the more stringent European EN12413 standards. “For example, on the burst speed test, where we run the wheel free at an over speed r.p.m., ANSI requires that the grinding wheel must resist to at least 1.5 times the maximum r.p.m. speed indicated on the label of the wheel. For the EN12413 standards, the same wheel needs to resist to a safety factor of 1.87, which is 25 per cent higher,” said Gagné, demonstrating the enhanced safety standards of the European system.
PHOTO COURTESY OF WALTER SURFACE TECHNOLOGIES
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With higher standards also comes enhanced comfort. “Since grinding is most probably the headache of all welders, a high-quality grinding wheel will be much more comfortable to use,” continues Gagné. “The wheels will be well balanced, which eliminates the vibration caused by unbalancing. A high-quality grinding wheel will also provide better control since you will have to push less on the wheel to have a great removal rate. High-quality grinding wheels not only provide consistency from one product to another, but also from one batch to another.” The general characteristics of high-quality products include wheels that are manufactured to tighter tolerances providing a comfortable running wheel with less vibration and fatigue on the operator, McDonough explained. Comfort is a major feature of high-quality grinding wheel that is often overlooked.
Gagné explains that grinding is normally a very demanding job and it’s important that operators feel comfortable while working with a grinding wheel. He continued by saying, “Normally, uncomfortable wheels are defined by … the feeling to over push on the wheel to have a good removal rate and the difficulty to control the wheel because it is digging too much into metal. Those are all comfort consequences that can be avoided by using a high-quality grinding wheel.” When cutting or grinding a discount brand can cause discomfort due to the fact that, “mineral gets dull and it no longer cuts, requiring more force and leading to heat-related defects in parts,” said Gabi Miholics, Specialist Technical Service for the 3M Abrasive Systems Division of 3M Canada Company. “You want to be able to have a high stock removal rate, minimize heat defects and enough wheel breakdown to expose fresh mineral without compromising wheel life too much,” she continued. Highest quality products exhibit consistency in weight, balance, concentricity, thickness and flatness making their use easier and more comfortable. One of the biggest challenges when it comes to quality is overheating, which can definitely affect the overall cost of production. By using a high-quality grinding wheel, you can avoid having the material overheat. Using higher quality grinding and cutting wheels offer both better cut quality and cost savings. “There is less burning and fewer heat defects because of cutting action. They are able to cut more material so throughput (parts/hour) is maximized,” said Miholics. Not only that, but when a grinding wheel overheats, it can change mechanical properties of the material and diminish the life and performance of the wheel agreed Gagné. He continued by discussing how quality affects labour, which in turn affects cost. “The results of leveraging a high quality product are a drastic reduction in labor cost ... Customers need to understand that paying more upfront … is worth the investment since it will drastically increase productivity while reducing production cost.” The grain selection will most often affect the cost of the wheel. “The grade (hardness) of the wheel will more directly affect the quality of the cut,” said Hopkins. “Softer wheels have a higher cut-rate and leave a finer finish while harder wheels will last longer but cut more slowly and may require additional steps to achieve the final finish.” Continues on page 82 www.canadianmetalworking.com
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Continued from page 80 Cut quality is an appropriate consideration for cut-off wheels and for some grinding wheels. “For bonded grinding wheels, the issue is removal rates. If the issue is also surface finish, then there are products developed that will remove materials as well as leave a good surface finish,” said Ballou, who agrees that there “CUSTOMERS NEED TO UNDERSTAND are several options THAT PAYING MORE UPFRONT… to accomplish both IS WORTH THE INVESTMENT.” objectives. Although he does believe that people who are interested in grinding wheels are generally not concerned with surface finish in the rough grinding stage. Generally speaking, bonded products can be separated into two categories, according to Hopkins: Vitrified bonded, consisting of abrasive grain held together using a clay or ceramic bonding agent that do not contain reinforcement layers. The second is Resinoid bonded wheels, consisting of abrasive grain, which is typically anchored to fibreglass reinforcement layers using an organic resin. Hopkins goes on to explain that Weiler’s
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Resinoid bonded products “utilize an even distribution of grain throughout the thickness of the wheel. This provides a consistent rate of cut for the entire product life. Some manufacturers will use filler grain at the top of the wheel, which will deteriorate more rapidly, dramatically shortening life.” All grinding wheels feature some common components such as abrasive grain, fibreglass reinforcement, and resin. High-quality wheels include ingredients that are generally more costly than those used in discount brands, but the result is better overall performance. “For example, the most common mineral ... intended for use on steel is aluminum oxide. This mineral may be purchased in various grades by wheel manufacturers. Brown aluminum oxide is inexpensive and does a good job. White aluminum oxide is significantly costlier, but provides sharper cutting edges and longer service life. Similar performance advantages exist for most ingredients in the wheel.” said Ballou. Different abrasives can be better suited to different materials like mild steel, aluminum, stainless steel. “Since different materials have different mechanical properties,
www.canadianmetalworking.com
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the usage of different abrasives is necessary because they have different cutting abilities,” said Gagné. The important thing is finding out the best possible wheel for any given application. An example is aluminum, which is a very soft material with a low melting point. Gagné explains that aluminum will clog a normal grinding wheel and, therefore, a soft wheel made of special additives and crumbly grains would be the best option. Steel, on the other hand, is easy to grind, “the usage of a wheel made of brownfused alumina, zirconium or ceramic grains are normally recommended since it provides toughness and good removal,” he said. However, if you are working with stainless specific applications is important. Highsteel, “it is normally recommended to use a quality grinding wheels tend to be produced wheel that contains less that 0.1 per cent of for use on specific materials unlike discount iron, sulfur and chloride in order to be sure brands that claim to be good for all materito not contaminate the stainless steel. It als. “Aluminum oxide, zirconia and ceramic is extremely important to choose the right oxide all work on steel and stainless. Silicon wheel for their application in order to be more productive while increasing the quality carbide is used for grinding masonry, stone, and natural materials,” said Ballou. Often, of their work,” continued Gagné. minerals are blended to achieve better The challenge when purchasing a grinding results on specified materials. “In addition wheel is knowing what you want and need. to grain Choosing a grinding wheel designed for CanMetalWork_XtremeAd0814_Layout 1 7/14/14 1:21 PM Page 1selection, other ingredients are
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Walter Surface Technologies’ Xcavator features an extra strong disc base/backing for more powerful and aggressive grinding action, a patented UHR multi-layer manufacturing technology to prevent edge flaking – keeping the wheel edge symmetrically round for more safety and longer life. It removes over 30% more grams per minute compared to other Ultra High Removal wheels, while at the same time absorbing vibrations. www.walter.com
The CC-GRIND-SOLID lowers operating costs and increase productivity by removing twice as much material per minute compared with conventional grinding wheels. Suitable for surface grinding, weld removal and all common grinding applications is available for Steel or Stainless in 4-1/2”, 5” and 7” sizes. The CC-GRIND-SOLID reduces dust emissions, noise and vibration by 50% or more, making it operator friendly. www.pferdusa.com
The Vortec Pro Type 27 grinding products from Weiler range from 4- to 7-inch diameter and are available both in 1/4-inch and 1/8-inch thicknesses. Featuring aluminum oxide grain, they are specifically designed for general purpose grinding and cutting applications on steel, iron, and other ferrous metals. All products are resin-bond formulated for aggressive stock removal and fast cutting, and are reinforced with fiberglass webbing for stability. www.weilercorp.com
The new abrasives in the Cubitron II lineup help save time, lower manufacturing costs and can help reduce fatigue and stress. Using 3M’s patented, precision-shaped grain technology where every grain is identical in size and shape, the abrasive continuously fractures, forming sharp points that slice through metal and provide long life and consistent finish. www.3M.com/abrasives
The Z5000F Zircotex premium zirconia alumina discs are extremely productive and efficient and suitable for high production grinding, blending, deburring and finishing. They perform well on a wide variety of material including stainless and carbon steel. They resist loading or clogging on softer materials such as aluminum, brass, bronze and fiberglass. www.flexovitabrasives.com
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The SlimCut SRT is an INOX wheel, which does not contaminate stainless steel, making it suitable for manufacturing and fabricating food storage and processing equipment. They are available in 4-1/2, 5, 6 and 7 inch sizes. www.pearlabrasive.com
equally critical to achieving good performance. For grinding steel, it is common to include iron pyrites, which acts as a lubricator and improves grinding results. But this is a contaminant on stainless steel, and so alternate cooling agents that will not contaminate must be used on stainless. Aluminum wheels are typically produced with aluminum oxide grain, but require additional material to prevent loading up, or clogging.” Finding the right grinding wheel is important, but maintaining its quality helps to extend its working life. Storing them in a clean, dry place, using them correctly, not applying extensive pressure, and making sure the work piece is secure are all ways to ensure longevity. Using a high-quality grinder that has enough torque to keep the r.p.m. stable is another way to extend the life of grinding disks. Gagné explains, “If the grinder doesn’t have enough torque and if you press too much on it, the r.p.m. of the grinding wheel will go down and the wheel will glaze rapidly rendering it unusable, reducing drastically the removal rate of the abrasive, overheat the work piece, or overheat the grinder. Normally, you can find the right grinding angle on the label of the grinding wheel but, a traditional depressed centre grinding wheel (Type 27) needs to work at an angle of 20° to provide best performances in term of life and removal. Special wheels such as type 28 and type 29 have to work respectively at lower angles.” Hopkins has a unique method of extending the life of grinding wheels. “To take full advantage of your product, think S.P.O.T.” he said. “Speed — Ensure that the wheel is properly rated for the r.p.m. of the tool. Pressure — As pressure increases, friction and heat climb. This dramatic rise in temperature can cause softer bonded wheels to wear more quickly. Orientation — Minimize wheel contact area for faster, cooler cuts that will extend life. Time — Never dwell in one location and always use the recommended feed rate for the material.” www.canadianmetalworking.com
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When it comes to GRINDING Walter Surface Technologies sets the standard
ALLSTEEL XX Tough on Steel and Stainless High Removal Rate & long life
HP XCAVATOR Ultra High Removal Rate Heavy Duty performance even in the hardest metals
Aggressive bite Ultimate comfort
For more information, visit: walter.com or contact your Walter Representative.
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showed a reasonable, four-year amortization on the costs incurred when adding the technology to their existing production. But if the company were to redesign the product, amortization would take less than a year, thanks to reduced material use. In another example, one redesigned rail car’s weight was reduced by 30 per cent. This translates into 30 per cent more payload for each rail car.
JOIN THIS! Hybrid laser welding expert Ed Hansen looks inside the multi-faceted future of hybrid laser welding
H
ybrid laser welding started in the ship building industry. What progress has it made here? Major shipbuilders in Europe are systematically implementing hybrid laser welding. The technology generates enormous savings. Cruise ship manufacturer Meyer Werft, for example, has reported reducing total build time by 30 per cent due to implementing hybrid laser welding.
WHAT PARTICULARLY COST-EFFECTIVE APPLICATIONS HAVE YOU SEEN? Hybrid laser welding is particularly well suited for mass production welding at high capacity utilization. Depending upon the application, hybrid laser welding can be three to ten times faster than conventional processes. The technology can lower heat input by as much as 90 per cent and this reduces the typical macroscopic distortion. Additionally, we’ve seen benefits in weight-sensitive applications. We’ve also seen significant fatigue life improvement in products exposed to cyclical loading, such as car suspensions, pressure vessels, and bridge components.
WHAT DEVELOPMENTS IN LASER TECHNOLOGY HAVE INFLUENCED HYBRID LASER WELDING? The continued development of high-power solid-state lasers with smaller form factors, greater efficiency, and lower cost has had a big effect on hybrid laser welding. Our transition to solid-state lasers in 2001 made it feasible to apply the technology to industrial settings. New technologies, particularly fibre delivery, let us integrate the process into conventional motion systems — robots, gantries and automation — which increased acceptance. Many laser improvements benefit other applications more than ours. We’re currently limited in how much laser power or brightness we can use productively. But in the future I see less expensive, compact lasers, which are easier for us to incorporate into existing production operations.
WHAT’S PREVENTED MORE WIDESPREAD ADOPTION? Early adopters have been very secretive owing to the strong competitive advantage the technology creates. Without published case studies and data on economic return, it’s been difficult to grow awareness and acceptance of the technology.
WHAT ARE THE ECONOMIC BENEFITS? In one automotive industry example, we 86 | AUGUST 2014
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Lasers
INNOVATION ENDURANCE PERFORMANCE
Automation
CINCINNATIR cincinnati incorporated
Shears Press Brakes sales@elliottmachinery.com www.elliottmachinery.com (905) 829-2211
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fast as conventional butt welding. There’s a big advantage to one-sided welds, particularly inside pressure vessels like those used for petrochemical tanks, hot water heaters, and in power plants. Using laser-augmented welding with filler wire, we can weld thicker segments with a non-penetrating hybrid laser variant. Our thickest one-sided, single-pass application was in half-inch thick steel, butt welded at 2.3 metres per minute.
WHAT APPLICATIONS SHOW THE MOST PROMISE?
WHAT DOES THE FUTURE OF PROCESS CONTROL LOOK LIKE? So far, most advances in process control have focused on visible surface features. In the future, we’ll look inside the weld and manage the process based on what we see below the surface, using a closed-loop, real-time control system. Improving weld stability inside the material and preventing the creation of discontinuities inside the weld will enhance quality control and allow us to reliably apply the process to thicker, larger sections.
EVERY TECHNOLOGY HAS ITS LIMITS. WHAT ARE THE CURRENT LIMITATIONS OF HYBRID LASER WELDING? The thinnest application we’ve seen is around one millimetre. The fastest is a pressure vessel, three to four millimetres thick, welded at 6.1 metres per minute. This, by the way, makes it almost seven times as
We’ve seen significant interest from the energy industry. Over the next twenty years, production will be increased and many pipelines will be replaced. Many of these applications use high-strength materials and manufacturers will have to automate to keep up with demand. Promising opportunities exist in bridge building, where designs are moving toward more cable-stayed suspension and long span bridges. Weight is critical here. As manufacturing moves to lighter products, structures get thinner and distortion becomes a bigger problem.
HOW IS THIS TECHNOLOGY EXPANDING IN AUTOMOTIVE MANUFACTURING? Transportation — shipbuilding, rail cars, truck trailers, mobile equipment, automobiles — offers the biggest area of growth. New efficiency standards and high fuel prices are driving higher structural efficiency. Hybrid laser welding is an enabling technology for the distortion reduction, mass reduction, and high-strength alloys important in steel and aluminum vehicle construction. In one recent project, an automotive manufacturer redesigned a product for hybrid laser welding and high-strength material. It not only improved the structure’s crashworthiness; it also reduced the weight by 40 per cent. Generally, automotive manufacturers find the cost per pound goes up when using high-strength materials, but when the overall weight drops, so does the total cost.
WHAT ROLE WILL HYBRID LASER WELDING HAVE IN THE FUTURE? It’s exciting to think about the global effect hybrid laser welding can have in creating lighter, high-strength structures and reducing material consumption. Hybrid laser welding will change the way structures are built. I think we’ll see larger scale adoption of the technology, particularly as costs drop and more welding codes incorporate the technology. 88 | AUGUST 2014
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www.canadianmetalworking.com
14-08-07 5:09 PM
MATE Press Brake Tooling
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Photo-etching firm supplies many industries BY NESTOR GULA
D
riving through most industrial areas can be an unnerving experience. The areas are filled with parking lots and nondescript buildings. The buildings and areas rarely give a hint as to what is happening behind the silent walls. Tucked into a standard looking industrial mall in Concord, just north of Toronto, is Shimifrez. It occupies a 4,000 square foot unit that is virtually indistinguishable from its neighbours. Yet here, like perhaps in the neighbouring units, something fascinating is happening. Shimifrez means chemical milling in Farsi, according to the CEO and President, Hassan Nojoumi. There are many names for what the company does: photo chemical milling, chemical blanking, photo etching, chemical milling, to name but a few. The company manufactures precision photo chemically A metal photo-etched scale model of the Eiffel Tower made by Shimifrez. The parts are assembled with some folding but no gluing or welding.
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machined metal parts for a host of clients. The process begins when the client sends a drawing to Shimifrez and a very high resolution photo master is created. The process is not unlike photography. The metal is cleaned and coated with a light-sensitive resist, according to Nojoumi. “The coated sheet is then exposed to ultraviolet light through the photo master from both sides, hardening the photo resist where exposure takes place. The unexposed areas are developed away, thereby removing the resist and leaving the metal bare where etching will occur. Etching solution is sprayed under pressure onto the top and bottom surfaces, accurately producing the component by removing the unwanted metal. The resist is then removed to leave burr and stress free components.” The later points are extremely important for the production of tiny precision parts. Unlike stamping or even laser cutting, “photo chemical machining has no effect on magnetic properties or deformation. Without stresses or thermal effects, it produces a burr-free product,” he said. Many of the parts that are produced at Shimifrez are extremely tiny. The company can manufacture parts that range in size 0.06 by 0.06-inches up to a foot and a half square. The material that is worked in is quite thin from about 0.019-inches thick to as thin as 0.0005-inches. The components are manufactured in stainless steel, brass, nickel alloys, beryllium copper, kovar, invar, phosphor bronze and aluminium. The process has the flexibility to produce unusual configurations while maintaining very tight tolerances to within 0.0005-inches or 10 to 15 per cent of part thickness. The roots of the company lie in Iran when Hassan’s father, Mustafa, started a photo etching company in 1981. “We came to Canada in 1997, I was 14 years old,” said www.canadianmetalworking.com
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Hassan. Working on a master’s degree in renewable energy at the University of Ontario Institute of Technology, he needed some specialized components for his thesis work. “I came up with some new processes for photo etching that involve plating at that time,” he said. “I wanted to start the business in 2008, but 2008 was not a good time to start anything with the bubble bursting and all. So I held off for a year and a half and when we saw some indicators that business is at least getting from a minus to a plus, we decided to start a business that can cater to 30-40 different businesses.” He adopted the name his father used as a sign of legacy and says the company now is, “30 per cent of what my dad had and 70 per cent of my input.” Photo etching is a very flexible process and can be applied to many industries. “As components are getting smaller photo etched parts will be used more and more,” said Nojoumi. He pointed to the microphone/recorder on the desk, “We can make the mesh for that. Your camera — there are photo etched parts in there. We can make them.” They make tiny components for pacemakers and stents for
aortic surgery. Nojoumi says parts produced by Shimifrez can be found in aerospace/ satellite, automotive, computer/telecommunications, defence, ornamental, jewellery, medical and electronics sectors among others. “Most of the clients are in Ontario,” he says. “Aerospace in Quebec, universities in Ontario and in the U.S. are big clients.” Hassan said that some items, like the cheaper parts and basic utility items, don’t necessarily have to be made in Canada. You can get it cheaper somewhere else. “But if you are making a pacemaker, a body implant…. Because those items are not driven by costs but on quality and there is no reason Canada cannot compete,” he said. There are eight people directly employed in Shimifrez. “These are operations and sales,” said Nojoumi. “We have roughly 10 people in R&D which work at universities. They are both in material and in manufacturing fields. The university take care of one half of their salaries and we take care of the other half.” Since the company deals with high-end precision components it carries several quality standard designations — ISO 89001: 2008, and ISO 9100 Rev C. The latter covers
Cuts
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The anonymous façade of the 4,000 square foot Shimifrez facility masks what happens inside.
13” x 20” Programmable Auto Miters up to 60°
SVT-6070H • 10 HP Motor • Linear Guide Workbed • HMI w/ Touchscreen • Blade Speed Display • For Cutting Blocks, Plates, and Steel Molds Height: 23.6” Throat: 27.6” Length: 49.2” Table Moving Vertical Saw
Hassan Nojoumi and his father Mustafa stand in the production area of Shimifrez
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A sampling of parts made by Shimifrez with a Canadian dime used for reference.
the aerospace field. “This lets me approach companies like Airbus and Boeing. If I do not have this, they will not even want to talk to me,” said Nojoumi. “Because I have it, the conversation turns to what I can do for them. We also are on the Control Goods Registered with the Department of Defence in Canada.” Although happy where his business is and where it is going, he does have one stumbling block that he has yet to overcome. “We in Canada can improve on the supply of raw materials,” he said. “We have an abundance of raw materials but no one makes metal here. If they do, they just want to make the big stuff. No one makes thin material.” Nojoumi notes that he has a difficult time sourcing the thin sheets of ram material he needs for his production
Photo-etched parts are precise, intricate and strong.
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in Canada. “Price is not an issue here. We need a supply of material so we can fabricate. If we can get the material we can make the part,” he said. “We source the raw materials from the States. It is not a problem but if you want the part in three days, it might take me seven days just to get the material in. It is the lead times. Sometimes lead times are what make or break a contract. There is also the question of minimum quantities that we have to buy. You might want just 20 or 50 pieces and I have to by 200 pounds of the raw material. You might use 20 or 50 pounds in a run and you end up with 150 pounds in the inventory. I then have to hope that the next client wants the exact same alloy in the exact same thickness. I don’t know who the next client will be. It could be a watchmaker or aerospace company. We have a storage space with some inventory but we try to keep it at a minimum because we really don’t know what the next job will be. I have some copper, brass and stainless steel in stock. In some applications the alloy does not matter but if there is heat involved or other requirements then it is important. We can’t stock everything.” For the clients of Shimifrez, cost is important said Nojoumi. “But it is not just how cheap it is but how fast we can deliver and if we can deliver on time. What manufacturing can do in Canada is use that lead time. Shipping is quick, but even getting something couriered from China is going to take three days — express. We have done things here in less than 24 hours — from PO, to drawing to part. Per piece price is not always the main thing.”
Tiny components can be etched/scored to be folded into intricate shapes.
www.canadianmetalworking.com
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THERE’S
A POST
FOR THAT Postprocessors help get the most out of CNC equipment and CAM software BY CHRIS MCINTOSH, TECHNOLOGY MANAGER IN-HOUSE SOLUTIONS, INC.
C Well-conceived carefully written post insure that a CNC machines will behave exactly how the user wants them to and consistently from one machine to the next. PHOTO COURTESY OF MASTERCAM (FROM CNC SOFTWARE, INC. TOLLAND, CT.)
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NC machines and CAM software think and communicate in different languages. The brains of CNCs—their controllers—are practical and literal minded. They do what they are told and think in linear G-code and M-code. CAD systems are creative and intuitive. Show them a picture and their powerful multithreaded computer software algorithms will figure the best way to do what you want. CAM systems cannot communicate directly to machine controllers. They must rely on a postprocessor, middleware that translates the computer output of a CAM system into instruction sets that are meticulously executed by CNC controllers. There are thousands of new and used CNC machines available today, and more coming. Each one needs a post.
A good post will discriminate between unique controller conventions and speak to these controllers in a language that is machine-specific. The post can also take into account the individual preferences of end users so that machines routinely execute in a way that the user prefers and expects. Finally, posts can be used to give CAM software the ability to program new machines and equipment add-ons that have just come on the scene. Every CNC user will benefit from having a basic familiarity with posts—even if the primary objective is to never have to think about it once it has been purchased, which brings us to the first category of post user.
JUST A GOOD POST This group of users just wants a good reliable post and for it to behave normally. Is that too much to ask? If their new machine is a common one, these users’ needs may be readily satisfied with a “generic post” which their CAM Reseller may be happy to furnish at little or no cost. If some minor adjustments are required, then the Reseller may make them, or a shop staffer who understands how a post works can do it himself. These users have very simple requirements and are frequently upset when they discover that an off-the-shelf post is not available to suit their exact needs. This often happens when the equipment purchased is very new and has a unique controller that has to be addressed. Another problem arises when CNC users have different ideas about how they would like their machines to behave. For example, users in different parts of the country or in different industries frequently have different expectations about how their machine should behave in terms of: • Formatting • Approaches to the part • Retracts • How rotaries are positioned between moves • Start of file • End of file Your post developer also needs to know about the unique conventions used by the machine’s controller and the release of the CAM software your shop is working with. For relatively simple CNC equipment, these seemingly trivial issues can and should be identified and problems ironed out in discussions with the machine dealer’s application engineers and/or the CAM Reseller, ideally a number of weeks before taking delivery of the equipment. www.canadianmetalworking.com
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ENHANCED FUNCTIONALITY As CNC machines become more complex, progressively more detailed thought and longer lead times should be devoted to nailing down postprocessor issues. It is important to include your CAM software Reseller or post developer early in the pre-delivery stages of this advanced CNC acquisition process. This will allow equipment that may cost hundreds of thousands of dollars, to start delivering on the expected quality and productivity expectations in weeks instead of months. Getting ahead of the curve on these advanced posts can be tricky because the new users cannot meaningfully discuss many of the machine behavior expectations affected by the post until they have had sufficient training in it. So the post developer may work in stages, taking an early lead from discussions with the machine builder prior to delivery and working closely with the end-users once training has been completed. With more advanced machines, a post may also be used to add additional layers of functionality (apart from modifying individual toolpaths) to the interface with a CNC controller. Here are a few examples: Dynamic Work Offsets: More and more CNC machines are coming with dynamic work offsets that allow the user to position the workpiece anywhere on the rotary table and the CNC controller will map the offsets correctly. This functionality eliminates the hours it typically takes to set up a part the old-fashioned way and makes programming far easier. Work Tables: Some machines (routers especially) will have two side-by-side tables, so that one can be set up while work is being performed on the other. Sometimes the posts will include logic, which allows work to be automatically initiated in a continuous
Posts Are Powerful Middleware applications that allow a single CNC manufacturing program created in CAM Software to be used on a wide range of manufacturing equipment.
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loop, back and forth Dynamic work between table A and offsets allow the user to position the table B until the stop workpiece anywhere button is pushed. Or on the rotary table perhaps there is a and the CNC controller will map prompt that allows the offsets correctly. the user to choose Post-processors can table A or table B or mediate this functionality to to work in tandem variety of controllers; when a large workeliminating the hours piece is mounted it typically takes to set up a part the across both tables. old-fashioned way This type of funcand makes tionality, which is not programming far easier. difficult to create, PHOTO COURTESY OF can be used to subMASTERCAM (FROM CNC stantially improve SOFTWARE, INC. TOLLAND, CT) machining productivity and safety. Tool Inspection: The user needs to drill a large number of holes in some very tightly dimensioned parts made of hard material. The nature of this process requires the user to periodically take a look at tool wear to determine when a tool change will be needed. Some of this functionality already exists in CAM software like Mastercam and more is being added routinely. However, this situation is a little unusual and the post developer can help by adding prompts that allow users to set the number of holes to be drilled before initiating a special inspection routine for which the code can be created in the CAM System. In-Process Gaging: Until recently, spindle probe moves to accommodate in-process gaging were typically handled via the CAM software’s customized drill cycles. Today, probing cycles can be programmed in CAM via Productivity+ software that may reside in Mastercam and other CAM programming environments. Productivity+ communicates with a set of macros that amount to a secondary postprocessor within the primary CAM post. The primary and secondary posts may also communicate with each other, for example when offsets are to be reset based on information generated via probing routines. Embedded gaging like this has become very popular for 3 + 2 machining applications and it is likely that systems of all types will be using this functionality more frequently to eliminate multiple set-ups for gaging and to reduce scrap via integrated process control. Secondary posts
Unique Heads and Attachments allow their users to capture specialized work. All of the major controller manufacturers support this type of add-on functionality, but they each do it in their own way. The post allows the CAM software to callout many functions in a language that the controller understands.
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like Productivity+ will handle the lion’s share of this work but there will always be unique applications that will require custom posts. Unique Heads and Attachments: We are sometimes astonished by the unique manufacturing Machine tools with two side-by-side tables can have applications cusposts with logic that, allows work to be automatically tomers are taking on initiated in a continuous loop, back and forth between table A and table B until the stop button is pushed. to fully utilize their expensive CNCs. To win this work, users may further extend their equipment’s capabilities by installing such things as 5-axis articulating heads, aggregate heads, etc., so they can manufacture specialized parts more efficiently. These add-on devices amount to machines within the machine, and posts must be created to support them. All of the major controller manufacturers (Siemens, Okuma, Mazak, Fanuc, etc.) support this type of add-on functionality, but they each do it in their own way. The post allows the CAM software to callout many functions in a language that the controller understands. In addition, there are a variety of functions (e.g. smoothing parameters) that are not accessible from the CAM software, at least not yet. However, users can fine-tune these parameters via special menus that the user can call up from the post.
SOMETHING VERY SPECIAL
Author Chris McIntosh, Technology Manager for In-House Solutions, Inc., in his native environment writing blocks of code for a Mastercam post.
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Almost everyone understands the roll standard and customized posts play in optimizing the performance of standard mills, lathes, routers, wire EDMs, and the like. Beyond that, there are unusual machines on this planet that do all kinds of off-the-wall things that you will never see in your average machine shop but that give their users a tremendous competitive advantage. Here are a few I have been involved with: • Sculpting granite columns. Imagine a humongous 5-axis machine with a circular saw mounted on the spindle. We wrote a post for that. • The same customer also had us develop a post for a large machine that behaved somewhat like a wire EDM but instead of wire it used a band saw blade to cut granite. • A 6-axis shot peening machine with three rotary tables that made it possible to harden exotic materials by blasting them
with hard pellets. A 5-axis wire EDM machine for cutting styrofoam. Instead of uv and xy axes, it actually uses rotary movements to create the orientation of the wire to the foam being cut. • A post to create a lathe-style etching or chiseling motion on a machine that was not a lathe. • A A 5-axis CNC mill that uses grinding disks and wheels to cut and polish optical lenses. When you ask a post developer to create a post for a unique machine, it is important that you educate him in what you are hoping to accomplish and how. Then he can help you devise a viable programming process along with a post that will do the job. When we write the posts for one-of-a-kind machines like these, we sometimes have to bend the rules a little regarding what is being represented within the CAM programming environment. The post developer my wind up using slot mills to represent grinding disks. That may offend some, but if a flexible CAM programming environment allows the post developer to do that, then he can create a custom interface for a unique machine for thousands of dollars as opposed to tens of thousands. •
POSTS OF THE FUTURE Our company has been writing posts for the Mastercam X series of CAM products for nearly a decade now. Nearly all of those posts have been generated using a postprocessor generating engine that is part of the CAM package itself. That means that the user is free to develop his or her own posts, and some actually do. However, I think these users have much better ways to use their time and should leave postprocessor development to professionals. Because the post development engine itself adheres to strict standards, the posts generated from it also behave very consistently. Having a decade-long familiarity with a post generating engine that has changed only in small increments can be a tremendous advantage for the post developer. But all things must eventually change. Our company is being allowed to look over the shoulders of Mastercam’s developers as they begin to introduce the postprocessor engine of the future. We are grateful for this because we do need to get up-to-speed with it quickly, as soon as it is available. It will give us the tools we need to address the vast multi-threaded processing and data accessing capabilities that will be required to write posts to take advantage of the incredible CNCs that are just around the corner. www.canadianmetalworking.com
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SUCCESSION PLANNING
FINANCING YOUR SUCCESSION PLANNING ALMA JOHNS, PRESIDENT, BENCH CAPITAL ADVISORY INC.
I
t is wellknown that a wave of baby boomer business owners will exit their businesses over the next decade. Nearly 40 per cent already have a well-planned exit strategy or a robust succession plan in place, but the remaining 60 per cent are still in the process of planning, contemplating or, worse, have no plan at all. Because the succession planning process typically takes at least two to five years, many of the remaining 60 per cent will have no plan by the time they wish to retire. Unfortunately, by then it is often too late. The owners are left scrambling and the business value could be driven down as a result. In some instances, this creates strife and potential conflicts among family members or management. Here, we will focus on one particular and common aspect of this problem: financing a succession plan for the next generation of owners, whether children of founders or management. The financing aspects, if not properly planned or executed, can not only create disruptions during business transitions but may leave both parties involved in the transaction with less than desirable outcomes. There are two common ways to transfer ownership — sale of assets and sale of shares. 98 | AUGUST 2014
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Various considerations determine which type of transfer takes place. These are usually tax considerations and potential liabilities. The most common method to transfer ownership of small-and-medium-sized businesses is sale of shares. There are various options or ways to structure financing during transfer of ownership via sale of shares method: • Cash Equity Cash equity may be available from personal assets like bank savings, liquidation of non-registered marketable securities or stocks, personal lines of credit, refinancing a home, etc. • Senior Secured Loan Senior loans provide access to capital by leveraging a company in order to acquire the majority ownership of a target company. These loans can be obtained by borrowing against the fixed assets of a business. For example, a buyer can take out a certain amount of equity from the owner-occupied property by refinancing it,
or by taking a term loan against unencumbered equipment. In both cases, an appraisal may be required to determine the value of assets the bank can lend against. Typically, this can range from 50-70 per cent, depending on the type of assets and your company’s risk profile. This financing option depends on the buying company’s leverage and cash-flow situations. Let’s use the scenarios below to demonstrate the impact of a new term loan on the company’s leverage ratio and cash flow.
LEVERAGE RATIO As an example, the company currently has debt to tangible net worth of 1:1, meaning that for every $1 of debt, there is a corresponding $1 of equity. Let’s assume that a buyer will take over the existing debt of $1 million under the line of credit. Let’s further assume that line of credit usage fluctuates monthly and the interest payment on the line of credit is $20,000 per year. All things being equal, a buyer will need to borrow $2 million in term loan to purchase the company, payable over a 7-year period. Therefore, debt increases to $3 million in Year 1. When all is said and done, the debt to tangible net worth ratio increases from 1:1 to 3:1. Banks consider 2:1 a healthy leverage ratio but will tolerate higher thresholds depending on other risk factors affecting the company.
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14-08-07 5:24 PM
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SUCCESSION PLANNING
the seller to use VTB including, last year. On a Term Loan of $2 mil(1) Trust in their management’s lion over 7 years, the buyer will pay ability to run the business properly the following in Year 1: and thus ensure they are paid $ 286,000 per year in principal (2) Facilitate the friendly sale of +$80,000 per year in interest, the business assuming 4 per cent (3) Tax implications +$20,000 per year in interest on VTB loans are subordinated to line of credit the bank. In the event of liquida=$386,000 per year in total princition or bankruptcy, the bank is pal + interest repayment paid before the seller. VTB notes As with any debt, interest payments can also impact your financial gradually decline as the loan prinratios — they are taken into concipal decreases. In Year 1, EBITDA sideration in calculating all of your of $500,000 against principal and financial ratios including debt to interest of $386,000 results in a debt tangible net worth, debt servicing service ratio of 1.30x. Typically, and working capital. banks will be looking at a minimum • Earn-Outs debt service ratio of 1.25x. Earn-out is a common approach • VTB that partially pays the seller out of Vendor Take Backs (VTBs) are prothe future earnings of the business. vided by the seller in the form of a It is a condition whereby a portion promissory note and are paid over a of the purchase price is deferred mutually agreed upon time period. ERI America_CMW_06-14.pdf 1 6/5/2014 PM and3:04:59 payments are conditional upon There are various motivations for
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achievement milestones, i.e. sales targets. If the company performs well, the seller is able to benefit from the upside. At the same time, the seller continue to carry future risks associated with the business. Therefore, earn-outs protect the buyer from downside volatility or any other unintended consequences upon purchase. Regardless of the company’s performance, earn-outs align the interest of the buyer and the seller. • Subordinated Debt Financing (Sub Debt) Sub Debt is a hybrid of debt and equity in that the Borrower has to be able to afford repayment and the sub debt provider can participate on the upside via stock options or royalties. The structure provides more flexibility than senior term loans because payments can be structured based on the availabil-
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SUCCESSION PLANNING
ity of cash flow. For example, the borrower may pay interest only for a period of 12 months or longer, or until the company can afford to make principal repayments. It bridges temporary gaps in cash flow during the transition process. The sub debts provider ranks in priority behind secured lenders in that, in the event of bankruptcy or non-performance, the traditional bank has priority over the assets of the company. There are numerous factors that the sub debt lender will consider in extending this type of financing, primary of which are the historical performance of the company and the anticipated future cash flows that it will generate. Because sub debt lenders participate in both the upside and the downside, they may impose more restrictive covenants than traditional banks. Sub debt can be used in management buyouts and in most cases of buying and selling businesses. This is due to the fact that these types of transactions have potentially large “goodwill” components (i.e. intellectual property) which traditional banks typically do not finance. Almost invariably, banks treat goodwill as “intangibles” and has the effect of increasing a leverage ratio beyond a threshold that banks are willing to tolerate. Finally, sub debt is less dilutive than equity financing and it does not restrict access to financing due to lack of collateral in the form of hard assets. There are other options to financing the purchase of your company including private equity financing, which we would rather leave for another time. The financing structure can include a combination of two or three of the above. Please discuss your options with your banker. Otherwise, use an independent advisor who will negotiate your deal on your behalf. Also, be aware that fees for advisors vary www.canadianmetalworking.com
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significantly and may or may not be dictated by the level of involvement in structuring and negotiating the deal. Insist that fees are discussed up front and that there is clarity and transparency prior to engaging the advisor. The quality of advice you get and the probability of the financing process going smoothly will depend
on the level of experience of your advisor. Alma Johns is President of Bench Capital Advisory Inc., an independent financing consulting practice based in Toronto. She can be reached at alma.johns@benchcapital.ca or www.benchcapital.ca.
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TOOL TALK Okuma America launches new app store On August 1, 2014, Okuma launched a new online app store to provide visitors with applications for CNC control functionalities that increase productivity and streamline machine tool processes. The new app store can be viewed at MyOkuma.com. Apps will continually be added and users can even create custom apps that address their individual needs. Okuma users can visit MyOkuma.com and download apps for useful functionalities such as: • Machine Alert: Monitors machine alarm status and automatically sends an email, text or phone message to the user when an alarm condition is activated. • Part Flip Monitor: Checks the chuck clamp status to be sure the operator has opened/closed the chuck before cycle start is pressed for Op20 of the part flip program. This reduces the chances that a part will be scrapped.
Visual Assistance Support: Displays helpful on-demand images for the operator at any point in a part program or process. The images assist with machine setup, visual part inspection, and other functions. • Scheduled Maintenance: Shows a reminder of the scheduled maintenance needed for the specific machine where the application is installed. This prompts the user to complete daily inspection tasks that maintain optimal machine performance. The App Store helps users to achieve productivity gains with minimal investment of time and resources. The •
ability to use apps is made possible by Okuma’s revolutionary THINC-OSP CNC control, which is built using a Windows-based open architecture platform that allows users to easily install PC applications. “We designed the App Store with one primary goal: to empower machine tool users so they can continuously improve and customize their processes,” says Brian Sides, director of technology for Okuma America Corporation. “Apps help Okuma users grow their business, reduce overall costs, improve quality, and even compensate for a scarcity of skilled labor.” For more information, visit www.MyOkuma.com
GF Machining Solutions strengthens presence in aerospace sector GF Machining Solutions has agreed to acquire Liechti Engineering AG of Switzerland. Liechti is currently creating 5-axis milling machines designed for aerospace manufacturing, specifically producing blades and blisks for aircraft engines and power generating turbines. “Liechti Engineering AG brings a wealth of know-how and a well-established reputation for high performance and superior service for its customers”, comments Yves Serra, CEO of GF. “Together, the two companies offer a wide array of technologies for the production of aircraft engine parts as well as a worldwide
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sales and service organization to support its customers.” This acquisition comes with the latest promising reports of the global aerospace indusindustry forecast. The demand for aircraft equipment, especially engine parts, is a key factor in the deci-sion to focus on manufacmanufacturing in the aerospace sector. Numerous reports have come up with major contracts in the works for some of the world’s largest aerospace manufacturers for state-of-the-art aircraft. Aircraft production is expected to remain strong for the foreseeable future. GF Machining Solutions will be able to significantly strengthen its presence in this promising market sector with the acquisition of Liechti Engineering AG. GF Machining Solutions has previ-
ously acted as a supplier for Liechti, with complimentary product ranges. The current management under Ralph Liechti will remain in place and the company continues to operate out of its present premises in Langnau/BE. The two parties agreed not to disclose the purpur chase price and further details of the transaction. “All of us are proud to become a part of GF Machining Solutions, and I am sure to have found the right partner to continue with our business”, Ralph Liechti says in a news release. “We are excited about the idea of combining our know-how with GF Machining Solutions to serve our customers in the aerospace and energy sectors with an even wider range of products and services.” For more information, visit www.georgfischer.com www.canadianmetalworking.com
14-08-07 5:27 PM
Visit us at Booth W-2217
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TOOL TALK Does the name Fadal sound familiar? The name Fadal may sound familiar to some but soon will be commonplace among machine tool proponents. The machine tools builder of VMCs, closed down its manufacturing facility in 2008 but will be returning to California and opening a facility in Michigan to sell globally through a distributor network. Fadal Engineering and Merrill Technologies Group,both Michiganbased, worked together to launch a new Fadal CNC full-range product line. Fadal has updated the Americanmade VMCs with the latest in engineering enhancements. “The new Fadal is all about bringing back to market an easy to use, CNC machine tool of sound design and stateof-the-art technology.” said Tim Consalvi, Director of Sales. After establishing itself, Fadal will release its VMC Performance series in later 2014. This series offers larger traveling, greater weight capacity, higher traverse rates and greater CAT50 spindle speeds. Eventually, Fadal wants to offer customers a wider range
of large machines, which will be its focus in 2015. This new series will have extremely large machining and turning ranges and capacity, making it desirable for the energy, offroad, aerospace and defense markets. After being sold by its founders to Giddings & Lewis in 1995, the Fadal name has changed hands numerous times through a series of mergers and acquisitions. “Fadal was once synonymous with quality, affordable CNC machinery and we look forward to restoring that reputation,” said Michael Naert, Vice President of Operations. “There is something kind of nostalgic about bringing a once family-owned company back to its roots,” said
Robert Yackel, CEO of family-owned Merrill Technologies Group and now Fadal Engineering. “The founding family of Fadal was a lot like my family. Entrepreneurial, hardworking, resourceful and determined. We’re proud to lead Fadal into its next era of success and the market is hungry to have Fadal back.” For more information, visit www.Fadal.com.
Hurco files CNC-based 3D printing patent On July 15, Hurco announced the company recently filed a U.S. patent application for new technology combining 3D printing and CNC machining. “We designed an additive manufacturing adapter that, in combination with proprietary Hurco control software, effectively turns a CNC milling machine into a 3D printer,” said Gregory Volovic, President of Hurco Companies. “Hurco has a long history of inventing technol-ogy that allows our customers to be more productive and profitable. This is yet another Hurco innovation making advanced technology accessible to a broad range of customers. With this new additive manufacturing capability, users may go from print to plastic prototype to finished metal part on one machine without repeated set-ups and without multiple prototyping utilizing costly metals and raw mate104 | AUGUST 2014
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rial,” explained Volovic. The patent application filed by Hurco is for an adapter to allow basic CNC milling machines into fully functioning 3D printers. Becasue 3D printers use generally the same parts as a typical CNC machine and work in a similar way, Hurco was able to take the initiative to develop an adapter and expand machine tool uses with additive manufacturing technology.
This new development could end up saving manufacturing companies millions, allowing current machines to be modified to meet users needs. Hurco’s design will allow companies to affordably add 3D printing to their capabilities. For more information, please visit www.hurco.com
www.canadianmetalworking.com
14-08-07 5:28 PM
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TOOL TALK RPC 700 represents the perfect combination of metrological features
The New DoveLock Quick-Change Jaw System Kurt Workholding DoveLock QuickChange Jaw System allows jaws to be quickly changed out and repositioned with high precision. This system reduces jaw change time 90% to less than one minute while at the same time positioning the jaw with repeatability of up to ±0.001”. Unique to the DoveLock Quick-Change Jaw System, the machinable jaws can be flipped 180° and machined on both sides for two different part setups. The swappable jaws are precision machined from 6061 aluminum (not extruded) to ensure highly precise and repeatable setups. The workstop located on the master jaw allows for quick and repeatable location of up to ±0.001”, without measuring. The swappable jaws are available in 6”, 7”, 8”, and 10” widths. www.kurtworkholding.com
The RPC 700 is a new, smaller development extending the range of systems to meet customer requirements. It joins the RPC 1000 and the RPC 1600 in the R&P Metrology lineup capable of form, profile and generative gear inspection. The RPC 700 is designed for accurate profile and form measurements on rotationally symmetrical workpieces, such as bearing rings and races, as well as demanding aerospace and cylindrical workpieces. www.kapp-usa.com
Simotics FD motor series more flexibility and high power With the new Simotics FD motor series, Siemens Drive Technologies Division is presenting a new type of motor design with powers ranging from 200 to over 1,600 kW in the maximum configuration. The motors are constructed as an intelligent modular system with a design featuring internal cooling ribs. This enables many different types of cooling and mounting positions, which increases flexibility of plant planning and multiplies applications for motors in pumps, fans, and compressors, as well as conveyor systems and hoisting equipment. www.siemens.com 106 | AUGUST 2014
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Walk-in oven for heat treating steel parts No. 835 is a 1200OF electrically-heated walk-in oven from Grieve, currently used for heat treating steel parts at a customer’s facility. Workspace inside this oven measures 48” wide x 72” deep x 72” high and a maximum temperature of 1200OF is provided by 120KW power, installed in Incoloy-sheathed tubular heating elements. A 10,000 CFM, 7 ½-HP recirculating blower provides combination vertical/horizontal airflow to the load. No. 835 features an aluminized steel exterior, 16 ga. stainless steel interior and 10” thick insulated walls, comprising 2” of 1900OF block and 8” of 10 lb. density rockwool insulation, as well as a 7” insulated floor with integral truck wheel guide tracks. www.grievecorp.com
Tate Industrial Sales offers wide range of lifting magnets The PML line of heavy-duty lifting magnets range in capacity from 220 up to 4400 lbs. and are priced accordingly. They are great for use on round stock. Right now, Tate is offering great deals and discounts on this product. www.TateIndustrial.com
www.canadianmetalworking.com
14-08-07 5:28 PM
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HIGH-TECH IN
TAIWAN The island nation leverages machine tool know-how to compete with the world. BY DAN ILIKA
S
ometimes perception is a hard thing to shake. It’s often easier to assume something to be true than to find out for yourself. If you assumed the country’s industry is chalk-full of low-cost, low-quality machines
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you’re probably not alone. You’re also wrong. Located about 180 kilometres off the coast of mainland China, the tiny island nation of Taiwan—officially known as the Republic of China, or Chinese Taipei in trade circles—is home to about 23 million people and factories as far as the eye can see. Look clearly and you will find a vibrant and valiant group of machine tool makers set to take the world by storm and change the global perspective on what ‘made in Taiwan’ is all about.
PERCEPTION PROBLEM Ask any one of Taiwan’s machine tool builders, and they will likely tell you they are not surprised there’s a global perception deficit when it comes to what the nation’s industry has to offer. The country’s reputation as a high-quantity manufacturer of standardized products precedes it and seems to transcend all industries. From matchbooks to machine tools, Taiwan seems to rank somewhere near mainland China and India when it comes www.canadianmetalworking.com
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to how its goods are viewed by the West. Whereas Japan and Germany have reputations for precision and quality, Taiwan is consistently cast as a maker of all things crude and cheap. A trip to any of the country’s machine tool builders would surely change that perception in a hurry. From floors you could eat off of to work stations organized like surgery rooms, the industry is built on the Japanese principles of just-in-time manufacturing. The only variation from one company to the next is who can come up with a more creative or effective way to organize work flow. Each build is marked by destination country and customer; all tools and materials have their respective homes; and all facilities are barrier-free to ensure work is completed easily and effectively. On a recent tour through a host of Taiwanese firms there was a sense of transparency not typical for these kinds of visits—and for good reason: They’ve got nothing to hide. In fact, they have a whole lot to brag about.
CONSTRUCTIVE COOPERATION For Taiwan’s machine tool industry, collaboration is key. Living so close to mainland China has a way of breeding that culture of cooperation. Made mostly of small and medium-sized firms, the industry lacks the individual clout to compete with the world’s largest companies one-on-one, relying instead on a collaborative approach that sees rivals become friends in a bid for survival. That cooperation has allowed the industry to not only survive but thrive, forging a path to becoming the sixth-largest machine tool manufacturing country and the fourth-largest machine tool exporting country in the world on the back of high quality and low price. And, of course, collaboration. As industry watcher Giant Chang puts it, in the marketplace Taiwanese firms are competitors, but on home soil they are partners,
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working for the greater good of the industry as a whole. It’s a unique formula, and one that doesn’t work for every country—or even every industry—but it works for the Taiwanese machine tool industry and its customers, driving innovation while keeping prices low. Perhaps the best example of collaboration at work in the Taiwanese industry is through the so-called M-team, a group of 34 machine tool builders and suppliers that uses its collective size to negotiate deals with suppliers and garner global attention usually reserved for more reputable firms. Established in 2006, the M-team doesn’t only benefit builders and suppliers, but end-users, too, as the group approach to business helps drive down prices while improving quality across the board. Aside from the improved quality and cost synonymous with all members of the M-team, customization seems to play an integral role from one company to the next. Gifu Enterprise Co., Ltd., a Taichung-based firm specializing in automatic tool changers, estimates that more than 80 per cent of its orders are custom-built for clients. It’s a step not many companies are willing to take, but a necessary one for companies clamouring for attention in a national industry made up of more than 1,000 firms.
SIZING UP THE COMPETITION For some of Taiwan’s larger machine tool firms, M-team membership isn’t necessary,
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development—his firm only focuses on what customers want and need, and does it all on the same campus. “We like to see each process controlled,” Chen said on a tour around his company’s ever-expanding facility. “It’s a very complete supply chain around here.” Honor Sekei Co., Ltd., of which the Tongtai Group owns 50 per cent of, has also taken to manufacturing its own spindles to bolster quality, and for the family-run operation the numbers don’t lie: only three spindles of the 500 or so it has produced over the last two years have been sent back for defect-related issues. It’s a commitment to quality across the board you’d be hard-pressed to find anywhere else in the world, and one that makes Taiwan a bang-for-your-buck sleeper among other, more high-profile machine tool producing countries. as they can use their respective size to command the same cost control over suppliers. Those suppliers, its important to note, are the same ones that supply parts and systems to M-team members, another spin-off of the close quarters and cooperative approach unique to Taiwan. The biggest machine tool builders of the bunch in Taiwan—namely the Tongtai Group, made up of five firms, and the Goodway Machine Tools Group, a trio of machine builders led by industry veteran Edward Yang—leverage their respective sizes just as well as the collective M-team, but benefit from one-on-one negotiating power and cost control that stays in a single boardroom. And they all seem to focus just as hard as their smaller colleagues on quality. Whereas a small firm like Quaser Machine Tools Inc. has taken to manufacturing its own spindles to ensure top quality throughout its entire lineup of products, Taichungbased Yeong Chin Machinery Industries Co., Ltd. (YCM), a do-it-all, CNC-making powerhouse, takes it to the next level, even producing its own castings in a bid to control every last aspect of quality. YCM chairman and chief executive Bryan Chen estimates his company makes 70 per cent of the components used in its machines in-house—including spindles and castings— to minimize the potential for poor quality. The company has even developed its own operating software that runs on third-party controllers in an attempt to ensure customers get YCM-level quality from top to bottom. Chen calls it customer-driven research and 110 | AUGUST 2014
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STUCK IN THE MIDDLE Taiwan’s machine tool industry finds itself somewhere in the middle of the pack, it seems. There’s no mistaking the matter-of-fact approach these businesses take to the global market. Wrestling the quality brands, leadership from German and Japanese builders is a challenge;where they see an opening, however, is with a uniquely Taiwanese combination of quality and price. And that combination is hard to argue with. Many of these companies pride themselves on the fact they have learned from the best before building their own machines, utilizing Japanese and German solutions and technology in a low-cost package not available from those countries. In fact, a number of Taiwan’s machine tool builders, including Quaser, which president Rock Liao estimates produces about 20 per cent of its machines under contract for Japanese, German and American firms, actually manufacture branded machines under contract for some of the world’s biggest and most highly regarded machine tool builders. Taiwan is in near the mainland, yes, but for many Taiwanese firms it’s a relative sweet spot to work from as they continue to hone the craft of delivering high quality and low cost products to a rebounding global market. For Taiwan, there’s a perception deficit the world over of what the island nation has to offer. Left in the hands of the country’s machine tool builders, however, and it won’t be long until the global view of ‘made in Taiwan’ changes for good. www.canadianmetalworking.com
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8.125”
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NEW! Depressed Center Grinding Wheels, Cut-Off Wheels, Cut & Grind Wheels & Flap Discs! Cubitron™ II grinding discs and cutting wheels are revolutionizing the grinding process. With 3M precision-shaped grain technology Cubitron™ II abrasives cut faster, last longer and require less pressure than conventional abrasives. It’s grinding reinvented.
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Shigiya Machinery Works Ltd. — Booth N-7353
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Shigiya will exhibit its GPV-10 Vertical CNC Grinder. The GPV-10 Cylindrical Grinder is designed to grind small workpieces with precision. A top beam securely connects the upper portion of the two columns. The GPV-10 feature a ø 100 mm swing over table, and 150 or 200 mm distance between centers. Wheel sizes are ø 305 (O.D.) x 25 (W) x 127 (I.D.) mm. www.shigiya.co.jp
Bunting Magnetics Co. — Booth N-7358
Pat Mooney, Inc. — Booth N-7429
Simonds International — Booth N-7472
Pat Mooney will demonstrate the Bunting Magnetics will exhibit a OMP KR3 Fully range of magnetic products Automatic Circular at IMTS, including Bunting Miter Saw at IMTS. Magslide. Bunting The KR3 is designed for production conveyors are fitted with sawing applications requiring straight powerful magnets which move ferrous and miter cuts on bars, tubes and parts and material in the manufacturing structural work pieces. The KR3’s environment. Bunting personnel will be upcut design provides a large cutting available to explain the differences and capacity of 8.5” and the ability to cut advantages of Neodymium, Samarium angles in the automatic cycle from Cobalt, Alnico, Ceramic, and other 75° to the left to 60° from the right. magnets in product design. www.buntingmagnetics.com SumpAd_CanMetal_6_14_Layout 1 5/5/14 4:51www.patmooneysaws.com PM Page 1
Simonds will be introducing and demonstrating at IMTS 2014, the world’s first Band Saw Blade Simulator Program. The Simulator enables a user to model their sawing application and compare the results obtained with conventional saw technology to unique blade/tooth configurations designed specifically by Simonds/WESPA for the user’s application. www.simondsinternational.com
Cleaners for Every Sump! Eriez offers everything from drum top vacuums to 1,000 gallon dual tank sump cleaners to remove coolant, sludge and chips from your sump, then: • Filter the sludge and chips from the coolant • Return the filtered coolant to the sump, or transports it for recycling or disposal Fluid Recycling Selection Guide See the whole line-up! visit Hydroflow.Eriez.com
Sump Cleaners • Tramp Oil Removal • Coolant Recycling Systems
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Doosan Infracore Machine Tools — Booth S-8100
INDEX Corporation — Booth S-8136 The new INDEX G220 Turn-Mill Center includes a fluid-cooled, motorized 18,000-rpm 5-axis milling spindle and a tool turret with Y-axis, providing maximum machining flexibility for turning and milling complex parts in a single setup. With a distance of 1280 mm between the main and counter spindle and a maximum turning length of 1000 mm, the G220 provides a generous work area. www.index-usa.com
Doosan’s all-new Puma SMX 3100 S Mill-Turn Multi-tasking Machine will be featured at IMTS. The Puma SMX Series offers a rigid 90° vertical axis and forward positioned automatic tool changer. The Puma SMX Series will initially be made available in two sizes, the Puma SMX2600, with a 10” chuck and 3.1” bar capacity, and the Puma SMX3100, featuring a larger 12” chuck with 4” of bar capacity. www.doosanmachinetoolsusa.com
VISIT US AT:
I NTERNATIONAL M ANUFACTURING T ECHNOLOGY S HOW September 8 - 13, 2014 | McCormick Place | Chicago
Booth N-6846
Hass Automation, Inc. — Booth S-8119 Haas will be featuring its heavy-duty, large-bore turning center, the ST-55. The machine offers twin-chuck capability, high-torque spindle, and 12.5” diameter through-bore. It has a maximum cutting capacity of 25.5” x 80”, with swings of 34.5” over the front apron and 25.5” over the cross slide. A servo-driven tailstock (MT5 taper) is standard, and a steady rest provision is available for additional support of long shafts. www.haascnc.com
Hwacheon Machinery America, Inc. — Booth S-8129 Hwacheon will showcase a large Big Bore turning center. This machine offers spindle torque, permitting productive cutting in tough material up to 36 in. diameter and more than 216 in. in length. The turning centers feature through-spindle holes from 7.08” to 14.57” in diameter for large pipes. Ultra-precision recuperative cylindrical roller bearings and the multiple thrust angular bearing have been incorporated. www.hwacheon.com www.canadianmetalworking.com
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VLC 200 H VERTICAL PICK-UP HOBBING MACHINE
Precision Gear Cutting 1
2
FOR WORKPIECES š 8 IN AND MODULE 4
3
INTEGRATED AUTOMATION
FLEXIBLE SOLUTION
VERTICAL CHIP FLOW
}
}
}
Built-in pick-up spindle and conveyor belt
Easy integration into manufacturing systems
Well suited for high performance dry hobbing
www.emag.com
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Kitamura Machinery of USA, Inc. — Booth S-9148
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Mazak Corporation — Booth S-8300 Mazak will demonstrate 21 highly advanced machine tools cutting parts. It has designed the new INTEGREX j-200S Multi-Tasking machine featuring a main 5,000-rpm turning spindle, 12,000rpm milling spindle and a second turning spindle for DoneIn-One capabilities, meaning it can complete machining in single setups and improve overall part accuracy. www.mazakusa.com
Kitamura Machinery will debut its Mytrunnion-4G full 5-axis Simultaneous Vertical Machining center at IMTS 2014. It has been designed for manufacturers and job shops that require higher levels of flexibility and versatility in the materials that they machine with unbeatable tool life and ultra-high level accuracies of ±0.00079” and repeatability ±0.000039”. www.kitamura-machinery.com
Hurco Companies, Inc. — Booth S-8319
Edge Technologies — Booth S-8348
Hurco will feature the 5-axis VMX42SRTi machining center, designed with a flush rotary torque table. For 5-axis parts, the embedded C-axis rotary table supports taller parts due to more than 3.5 additional inches in Z. Basic specifications include X/Y/Z travels of 42/24/24 inches, a 12K spindle standard, a 40-station swing-arm automatic tool changer, X/Y/Z rapids of 1,378/1,378/1,181 inches per minute. www.hurco.com
Edge Technologies introduces the new FMB 20-100 bar feeder at IMTS 2014. This unit expands on the already established Turbo “Heavy Metal” line of hydrodynamic 12’ through 24’ bar loading magazine feeders. Quick change polyurethane guide channels allow for quiet operation at high RPM while feeding round, square or hex bar stock. www.edgetechnologies.com
Hydromat Inc.— Booth S-8348 Hydromat will showcase updated features on EPIC R/T 45-12 Rotary Transfer Machine. This collet style rotary transfer machine utilizes 12 horizontal tool spindles and has the capacity of up to 6 vertical tool spindles. The updated two axis programmable flange offers up to +/30mm of extended travel for offset features, rotary O.D. and I.D. recessing, thread milling, chamfering and in-process de-burring. www.hydromat.com
YCM Yeong Chin Machinery Industries Co., Ltd. — Booth S-8450 The DCV2018A-5AX is 2 meter x 1.8 meter complex 5 axis machining center that comes standard with an 18,000 rpm 90HP HSK-63A taper spindle, the YCM/ FISCHER B&C axis headstock is positioned by HEIDENHAIN ERA-180 rotary encoders for high accuracy positioning, and a dual internal disc braking systems to minimize vibration delivering high quality machining at high speeds. www.ycmcnc.com
DiPaolo Machine Tools Ltd. — Booth S-8384
Okuma America Corporation — Booth S-8500
The Th 5 Series of high speed machining centers feature X-axis travels 2000-4000 mm, vertical travels 1500-2500 mm and Z-axis travels 1500-2500 mm. Linear guide ways permit excellent dynamics and productivity – rapid feed rate 40,000 mm/min, and acceleration 3 m/s2. Symmetrical column-headstock and 4 vertical guide ways guarantee exceptional rigidity and thermal and mechanical accuracy. www.dipaolocnc.com
Okuma’s MA-12500H horizontal machining center will be showcased at IMTS. The MA-12500H incorporates Okuma’s exclusive Thermo-Friendly Concept to achieve unparalleled thermal stability and accuracy. Standardly-equipped with a 50 taper 6,000 rpm, 60/50 horsepower spindle, it is also available with either a 12,000 rpm wide range spindle or 4,500 rpm heavy duty spindle, with a maximum load capacity of 11,0000 pounds and rapid traverse (X, Y, Z) of 1,653 ipm. www.okuma.com
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POWERFUL, PRECISE, RELIABLE. Walter BLAXX, from Walter Valenite is a new generation of mills that stands for a reliable system which captivates the user with its absolute precision and stands out through its extremely high productivity. The Walter BLAXX F5041 and F5141 shoulder mills are therefore based on a newly developed, incredibly robust tool body, which is fitted with the most efficient of Walter indexable inserts, powered by Tiger·tec® Silver. Find out more about the unbeatable combination of Walter BLAXX and Tiger·tec® Silver now: www.walter-tools.com/us
Visit us at IMTS Booth W-1700 WALTER NORTH AMERICA Walter USA, LLC N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.us@walter-tools.com
Walter Canada N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.ca@walter-tools.com
Walter Tools S.A. de C.V. Carr. Estatal KM 2.22 #431, Módulo 3, Interior 19 y 20 El Colorado Galindo, Municipio El Marqués, Querétaro, C.P. 76246, México +52 442-478-3500 service.mx@walter-tools.com
www.walter-tools.com/us
www.youtube.com/waltertools
www.facebook.com/waltertools
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Toyoda Machinery — Booth S-8519 The newly redesigned GE4-i CNC cylindrical grinding machine features enhanced thermal stability and ergonomic dual pulse generators to increase flexibility and ease of part setup in part programming. This series offers options of 19.6 in., 39.3 in., and 59 in. distance between centers, and ø 12.59 in. to ø 15.75 in. swing over the table. www.toyodausa.com
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Elliott Matsuura Canada — Booth S-8640 Elliott Matsuura Canada Inc. is an industry-leading supplier of quality machine tools in Canada. We will be on hand at IMTS working with our suppliers to service our Canadian visitors. At Booth S-8640, Matsuura will be exhibiting 5-axis and multi-pallet premium machine tools; H.Plus-300 20K, LX-160 42 Pallets, CUBLEX-35 20K/HSK 63 with Tailstock & Grinding, MX-850 15K/High Power/CAT40, and the MAM72-100H 10K/50 Taper. Visit your Elliott Rep at IMTS. They will be available at their Machine Suppliers’ s Booths. www.elliottmachinery.com
During IMTS 2014, Makino plans to showcase several of its latest machine technologies, including the new a51nx-5XU 5-axis horizontal machining center with a unique work changer, the new a81nx horizontal machining center, EDBV8 EDM hole-drilling machine and the D800Z 5-axis vertical machining center. Makino will also demonstrate a variety of new technologies designed to produce aerospace jet engine components, including grinding of high temperature nickel alloys. www.makino.com
Star’s new SR‐20RIV machine with additional tool positions and full “B” axis on cross working offers additional capability for machining of very complicated components in one operation. As many as 41 tools can be accommodated on its 27‐ position tool station, providing variety of tools for any machining requirements such as deep‐hole drilling, full “B” axis machining, with “C” axis on main and sub spindle. www.starcnc.com 116 | AUGUST 2014
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Hardinge will exhibit the CONQUEST H51 Super-Precision. The machine is available high precision and SUPER-PRECISION models. The CONQUEST H51 features a 20hp, 5000rpm A2-6” main spindle with 2” bar capacity. It offers a maximum turning diameter of 12.3” and a maximum turning length of 25.6”. The 12 station turret offers ½ station index for up to 24 tools. www.hardinge.com
GF Machining Solutions — Booth S-8754
Makino — Booth S-8700
Star CNC Machine Tool Corp. — Booth S-8874
Hardinge Inc. — Booth S-8738
The CUT 200 Dedicated features a built-in, B-C tilt/rotary table using C-axis rotation and +/- 20-degree B-axis tilt. It incorporates on-machine, in-process inspection. The latest generation of Agie Charmilles spark generators allows the machine to cut up to speeds of 38”2/hour (400 mm2/ min) and up to 30-degree tapers in the Z-axis height. www.gfms.com
DMG MORI — Booth S-8900
FANUC — Booth S-8919
DMG MORI will exclusively feature its NHX series of high-precision, high-speed horizontal machining centers. The NHX 4000 2nd Generation is ideal for machining workpieces of up to 31.4 x 39.3 in., with a loading capacity of up to 1,100 lbs. The versatile machines offer 15,000 rpm and an excellent power-to-torque ratio of 29.5 hp. with 93.7 ft/lbs. www.dmgmori.com
FANUC America Corporation introduces the new Series 0i-F CNC with new commonality of design and 15” display option, a new CNC platform with built in Bluetooth technology and digital servo adapter with new EtherCAT interface. The Series 0i-F boasts common operability, maintainability and networking options as the Series 30i CNC along with having a highly compatible PMC ladder. www.fanucamerica.com www.canadianmetalworking.com
14-08-07 5:13 PM
Our Latest Innovative Solutions Set New Standards For Manufacturing Introducing the SW-20 and SR-20RIV for maximum output & precision. Consistently on the leading-edge of innovation, Star CNC’s two new models are designed for complex component machining that can transform productivity into profitability. The evolutionary SW-20 offers a multitude of functions to minimize non-cutting time to a new low, improving production output and profitability. With an h 8-spindle tool post and “Y” axis control function exclusively for back-end working, the SW-20 provides greater freedom for overlapping efficiency. The new SR-20RIV accommodates up to 41 tools on 27 tool positions. This machine offers ‘two-in-one’ machining options, equipped with both “Guide Bushing” and “Non Guide Bushing”. With full “B” axis with three (3) tools on the main side and 8-spindle tool block for back machining with “Y” axis for overlapping on a variety of operations. Two sophisticated machining solutions can play a big role in medical technology. Star CNC…continually raising our own bar.
SR-20RIV Tool Post
P ERFECTION I N M OTION
www.PerfectionInMotion.com AMT Machine Tools Ltd 73 Galaxy Blvd. Units 15,16,17. Rexdale, Ont. M9W 5T4 Tel: 416-675-7760 Fax: 416-675-6988
SW-20 Tool Post
Visit us at S-8874
www.amtmachine.com
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Hyundai WIA Machine America Corp. — S-8948
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Chevalier Machinery, Inc. — Booth S-8986 Chevalier’s FBL-520D heavy-duty horizontal turning lathe, perfect for machining heavy parts and large pipe threading, is in demand by the energy and aerospace industries. The series features highly accurate machining that can handle rough- and fineturning operations. The gear box provides enough horsepower for heavy-duty turning. www.chevalierusa.com
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The Hyundai-Wia HS4000i Horizontal Machining Center has been designed with both speed and rigidity in mind. The heavy duty machine bed is constructed from one piece Meehanite processed cast iron. Extremely high productivity can also be realized by the high speed, rapid travel positioning of the X/Y/Z axes at 1,969ipm. www.hyundai-wiamachine.com
Fuji Machine America Corporation — Booth S-9059
SW North America, Inc. — Booth S-9080
Fuji will be exhibiting its DLFn module. Raw materials go into the DLFn for turning, measuring, drilling, deburring, parts cleaning and other operations, and then exit as a finished part. DLFn work removal is performed in 5.8 seconds load/unload. DLFn occupies less than half the space of a conventional machining line. Up to 10 modules can be combined to form a maximum 14 3/4 ft (4.5 m) line. www.fujimachine.com
SW North America will exhibit its BA 322 horizontal machining center at IMTS. The BA 322 is a twin-spindle horizontal machining center targeted for 4- or 5-axis machining of small to mediumsized steel, cast iron, and light metal workpieces. BA 322 is equipped with two spindles, a specially developed twin swivel trunnion, and twin or quadruple 5-axis models. www.sw-machines.com
www.canadianmetalworking.com
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Methods Machine Tools, Inc.— Booth S-9119
BLM Group USA Corporation — Booth S-9174
The new, compact KMH-300 Direct Drive 30-Taper, 15,000 RPM, 300 mm dual pallet machine will be featured at IMTS. The KMH-300 Series offer an integrated full rotary B-Axis and a reliable FANUC Oi-MD control with a 15 in. Travels on the KMH-300 machine are 18.1 in. on the X and Y-Axes, and 13.7 in. on the Z-Axis. www.methodsmachine.com
BLM GROUP USA will showcase the EM80, a combined automatic sawing and end machining center for tube and bar processing at IMTS. The EM80 is an integrated CNC end machining center ideal to cut, chamfer, face, bore, thread and profile tube and bar. The EM80 handles tube diameters from 10 to 80mm and with wall thickness from 0.8 to 12mm and solid bar from 10 to 65mm. www.blmgroup.com
Koma Precision, Inc. — Booth S-9153
TOS AMERICA INC. — Booth S-9259
The newly designed E346 has a radial travel capacity of an X-axis of 14.2”(360mm) and a Z-axis of 18.1” (460mm). The vision system for tool measuring includes a TFT 9” color touch screen with 110 mm x 200 mm image size and 25X magnification. www.komaprecision.com
TOS AMERICA will display the WFT 13R CNC machine, equipped with a 5” spindle, table travel (“X” axis) of 177”, headstock vertical travel (“Y” axis) of 98”, column travel (“Z” axis) of 59”, and spindle travel (“W” axis) of 28”. The WFT 13R design also includes a ram travel (“V” axis) of 27.5” which provides a spindle support while reaching to the center of the table while maintaining rigidity and stability. www.tosamerica.com
CLAMP. DONE. RUN. Introducing FCS clamping system from SST. It’s that fast. Learn how moving clamping setup time to the CAD/CAM stage can drastically reduce downtime at the point of production. Talk to your SST representative about the latest innovations from FCS clamping system. Learn more at singlesourcetech.com/FCS Visit us at IMTS 2014, Sept. 8-13, Chicago, IL Booths E-5127 and W-2167
© 2014 Single Source Technologies.
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Yama Seiki USA, Inc. — Booth S-9476 Yama Seiki will be exhibiting its GV-1 series vertical turning center. With GV-1200M maximum turning diameter up to 1,350 mm, maximum weight load up to 5,000 kg, and available live tooling spindle & CF-axis capabilities, turning, milling, contour milling and drilling applications may be completed in one single machine. www.yamaseiki.com
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Grob Systems, Inc. — Booth S-9490 Grob Systems brings the G-Series universal machining centers to IMTS. The smallest machine in the line, G-350, requires less floor space. GROB’s original spindle design accommodates very long tools with no interference. The maximum part is a 600 mm cylinder with 500 mm in height. www.grobgroup.com
Toshiba Machine Co., America — Booth S-9493
ITI Tooling Company — Booth W-1199
Toshiba is featuring the newest addition to the TUE Series of vertical boring and turning mills at IMTS this year, the TUE-100. With a one meter (40”) table diameter, this VTL is designed for high speed, heavy-duty cutting with a max load up to 2000 kg. Sitting within a more compact 5m x 3.5m x 4m footprint, the TUE-100 showcases feed rates up to 2000 mm/min. www.toshiba-machine.com
Automatic tool changers, type CTM are suitable for applications on NC milling machines, vertical and horizontal machining centers, CNC lathes, transfer machines, laser and plasma cutting machines. In addition, they are effectively applied on wood and granite routing machines and machines designed specifically for cutting extruded luminum. www.indexingtechnologies.com
Lexair, Inc. — Booth W-1322 New Multi Mini Rhinobar bar feeder adds multi-diameter stock versatility with 3-bar cartridge. Lexair bar feeder makes multiple-stock-diameter indexing simple, combining three sizes of feedtube in a standard aluminum barrel. Available in three size ranges for increased productivity on Swiss-style CNC screw machines and small, fixed- or sliding-head lathes. www.lexairinc.com
Heule Tool Corporation — Booth W-1352 Heule Precision Tools will launch their latest development at IMTS 2014. The new BSF tool extends their range for automated high volume production of back spotfacing and counterboring. Now, a counter bore ratio of up to 2.3xd is possible. The tool is used for diameters from 6.5 to 20 mm without needing to turn over the workpiece. www.heuletool.com 120 | AUGUST 2014
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Sandvik Coromant — Booth W-1500 Sandvik Coromant will exhibit the innovative CoroMill 5B90, a high-performance tool for finishing aluminum components. The state-of-the-art tool delivers excellent surface quality, without burr formation and reduces cost-per-part by up to 30 per cent. CoroMill 5B90 is ideally suited for typical automotive industry applications. www.sandvik.coromant.com
Emuge Corp. — Booth W-1536 Emuge will be showcasing its Z-Taps. GLT-1, a newly developed multi-layered coating, produces a consistent, controllable chip formation that is released smoothly for fast and efficient chip removal. GLT-1 is uniquely structured with advanced heat resistance characteristics, along with an outer anti-friction layer. Emuge Z-Taps feature an increased number of flutes and a shortened thread section. www.emuge.com www.canadianmetalworking.com
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COME TOGETHER. DENIS BYRNE Field Engineer, Service and Applications Hopkins Machinery Co. YEARS ATTENDING IMTS 28 GOAL FOR IMTS 2014 It’s all about learning at IMTS. Whether that’s achieved through networking, live demonstrations, or seminars – there’s so much knowledge to absorb. We’ve been able to expand our sales territory as a result of attending IMTS. I don’t think you can say that about every trade show.
LEAVE CONNECTED. Where else can you meet the minds that are moving manufacturing forward? Nowhere but IMTS 2014. With a focus on success through cooperation, the week will be filled with technology, education, and ideas that we can all benefit from. Join us at McCormick Place Chicago, September 8–13, 2014. Learn more at IMTS.com.
LAST CHANCE TO REGISTER • IMTS.COM
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COME TOGETHER. LEAVE YOUR MARK.
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Kennametal Inc. — Booth W-1522
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
NOVO is an advanced digital tool selector and process planner with real-world productivity results and will be exhibited at IMTS. Kennametal’s NOVO digital tool and process planning application has continued growing by adding process capability constantly. NOVO Version 1.3 is connecting via the cloud to tool management, e-commerce, and other shop systems, reducing data errors and making non-value-added data-transfer efforts things of the past. www.kennametal.com Kyocera Precision Tools, Inc.
— Booth W-1556
Kyocera’s latest milling innovation, the RAD-6 (MRX) Radius Cutter, features six-edge positive inserts for increased machining efficiency. With an insert lineup that includes 4 grades and 3 chipbreakers, the RAD-6 tackles a variety of materials and applications. See the RAD-6 in action during our live tooling demo. www.kyoceraprecisiontools.com
Niagara Cutter, LLC — Booth W-1564 Niagara Cutter will feature its MZN 410R solid carbide end mills at IMTS. They provide high-feed machining capability to reduce cycle times in moldmaking operations on hardened steels, cast irons and super alloys. The tools transfer cutting forces axially into the machine tool spindle. The cutters also generate less cutting tool pressure than ball nose or round inserted tools. www.NiagaraCutter.com
Seco Tools, LLC— Booth W-1564 Seco Tools will unveil the new Square T4-08 shoulder milling solution at IMTS. Made for roughing and semi-finishing operations, it brings smooth cutting action and good surface finish to slotting and contouring applications. The tangential mounting of the tool’s inserts increases the surface area of contact between the inserts and cutter body, resulting in increased rigidity and machining stability. www.secotools.com 122 | AUGUST 2014
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Big Kaiser Precision Tooling Inc. — Booth W-1600
Tungaloy America, Inc. — Booth W-1654
KAISER’s new Series 112 EWD 2-32 made for small machines with tight work envelopes will be on display. It features power management for optimized battery life, a display that can be changed to show diameter adjustment in millimeters or inches, IP 69K seal rating, minimized imbalance with tool carrier in center position and optimized bore depth by a through-hole tool carrier. www.bigkaiser.com
Tungaloy has introduced the world’s first indexable drill to use double sided inserts providing six cutting edges per insert. The Tung Six drill offers reduced cutting forces, increased insert toughness, extended tool life, improved surface finish, increased speeds and feeds and of course incredible economy. www.tungaloyamerica.com
Data Flute — Booth W-1645
Exsys Tool, Inc. — Booth W-1671
At Data Flute, we have a strong belief in tailoring the substrate, geometries and coatings to the work material and operation at hand. The primary focus of this series is on high temperature, difficult to machine nickel and cobalt based alloys. Our AMA series incorporates a combination of macro geometries, micro geometries, coatings and substrate that are particularly well suited to the challenges posed by nickel and cobalt based high temp alloys. www.heritagecutter.com
Exsys will showcase the PRECI-FLEX modular quickchange tooling system at IMTS 2014. The PRECI-FLEX features a selection of adapters engineered to hold different cutting tool and shank designs. The adapters’ common connecting feature locks into a standard base unit on the machine turret, enabling tool/adapter assemblies to be preset offline then quickly switch in and out of the base unit. www.exsys-tool.com
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Fixtureworks — Booth W-1686
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Fixtureworks will exhibit Fairlane Products full line of fixturing accessories including grippers, rest pads, Swivots swivel/pivoting positioning components, Quick Release ball-lock pins, rollers and bumpers. Included in the lineup are the new Urethane Covered Bearing Rollers available with hardness ranging from 35 to 95 durometer in 1 to 3 in. diameters. www.fixtureworks.net
Walter USA — Booth W-1700
Horn USA, Inc. — Booth W-1722
Iscar Metals, Inc. — Booth W-1800
Walter USA will showcase the new Blaxx F5055 slitting cutter. The mill has similar technology to the Walter Cut SX grooving system which is based on self-gripping, formlocking indexable insert. The SX parting and grooving system features coolant supply through the tool for optimum cooling of the cutting edge for all monoblock tools in the SX system. www.walter-tools.com
Produce higher quality grooves and increase productivity with throughcoolant tools. The versatile S100 grooving and parting-off system with through-coolant port supplies fluid directly to the cutting zone ensuring optimal cutting conditions. The nozzle shape guarantees a targeted jet of coolant that aids in chip formation, evacuation and reduces tool wear. www.hornusa.com
Iscar is introducing the new ECA-H3CF-C CHATTERFREE solid carbide endmills. They are available in a diameter range of 6 to 25 mm with corner radii of 0.20 mm and milling depth to endmill diameter ratio of 2XD. Each tool diameter is available with 3xD and 5xD neck relief. 3 flute solid carbide endmills offer 39-41° different helix, neck relief and coolant holes. www.iscar.com
Ingersoll Cutting Tools — Booth W-1822 Ingersoll has extended the application range of its Gold-Twist drilling line by introducing a flat-face geometry tip for flat bottom machining, in a diameter range of 8.00mm to 25.5mm. The new line reduces the number of tools required to generate a flat bottom hole. These new tips are fully compatible with the Gold-Twist’s current line of bodies in the same size. www.ingersollimc.com
SCHUNK, Inc. — Booth W-2000 SCHUNK will exhibit the new TENDO Series, which includes the TENDO E Compact, TENDO Platinum, and TENDO Tech toolholders. “The Tendo Platinum line ... can be used with all clamping diameters, has multiple gage lengths, and can be directly clamped, all with its integral one-piece design.” www.schunk.com 124 | AUGUST 2014
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www.canadianmetalworking.com
14-08-07 5:14 PM
ZOLLER Inc.— Booth W-2022 ZOLLER’s automation solution »roboSet« loads the ZOLLER presetter fully automatic and unmanned, 24 hours a day, 7 days a week. At IMTS »roboSet« will be shown in combination with ZOLLER’s heat-shrink machine »redomatic« for a fully automatic shrinking of tools to nominal value. www.zoller-usa.com
Lovejoy Tool Company, Inc. — Booth W-2214 Lovejoy Tool Company will display standard and application designed cutters and inserts including face mills, ball nose end mills available in a wide range of indexable inserts suited for milling, turning and boring applications. Cutters and milling tools suit requirements in sizes ranging from 55” diameter and more to 1” diameter and less. www.lovejoytool.com
SGS Tool Company — W-2217 SGS Tool Company will feature its T‐Carb End Mills, ideal for high speed machining using Trochoidal and Peel Milling techniques. The 6‐Flute design excels at higher feed rates while reducing loads. The variable pitch geometry provides superior performance in multiple operations resulting in faster cycle times and is exclusively available with SGS’s proprietary Ti-NAMITE-X coating for ultimate protection. www.sgstool.com www.canadianmetalworking.com
07CMW-IMTSproducts-p50-130.indd 125
Rego-Fix Tool Corporation — Booth W-2239 REGO-FIX will introduce several precision tooling products at IMTS. SecuRgrip brings effective tool locking to challenging metal removal applications. This anti-pull system locks the collet and cutter to the toolholder body to eliminate cutter slippage. It does so via a patented locking system that includes a small, profiled locking key insert that fits into a standard Weldon endmill flat. www.rego-fix.com
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AUGUST 2014 | 125
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FINANCE
GETTING THE MOST OUT OF IMTS Show offers great deals and rare access to equipment manufacturers—if you’re prepared
W
ith IMTS just around the corner, I thought this month, it would be relevant to discuss why visiting this show could be a very productive use of time along with how to get the most out of the experience. IMTS, the International Manufacturing Technology Show, is one of the largest industrial trade shows in the world and is held every two years in September at McCormick Place, Chicago. This year will be the 30th edition of the show and it will occupy over 1.2 million square feet of exhibit space featuring 1,900 exhibitors and 100,000 buyers and sellers from over 112 countries. It’s not only the sheer size that distinguishes IMTS from every other show in North America, it’s the people you meet there. The exhibits are arranged by equipment manufacturers, unlike regional shows such as Montreal Manufacturing Technology Show (MMTS), Western Manufacturing Technology Show (WMTS), or for that matter, Canadian Manufacturing 126 | AUGUST 2014
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Technology Show (CMTS), where the booths are—for the most part— arranged by local representation. Not only will you find the latest technology from the exhibitor but the people working the booth will be a combination of the smartest and most successful individuals from both the manufacturer and the distributor. In many cases the machinery and equipment is manufactured in another part of the world. As a buyer, it might not be feasible for you to travel overseas to visit equipment manufacturers’ experts, but many of these individuals will be at IMTS. It’s the exposure to these types of people that makes the trip to Chicago worth the time for anyone interested in learning about and potentially purchasing the newest technologies.
PRESSURE TO SELL Exhibiting at a show the size of IMTS takes a lot of time, planning and of course, money. In some cases, exhibitors invest millions of dollars.
With such a large investment, there’s a huge amount of pressure to sell product and justify the expense. There’s also a unique opportunity to meet and engage with the principles for each of these equipment manufacturers. So you have an incredible opportunity to negotiate a great deal on a piece of equipment. I can tell you first hand that working this show as a seller meant spending many hours in my hotel room at night cranking out quotes and finalizing pricing so I was ready to continue a discussion which started with a customer on the previous day. It also meant sitting quietly and watching someone like Dr. Masahiko Mori, president of Mori Seiki Co., Ltd., make a phone call to wake up a plant manager in the middle of the night (for him) and re-arrange the factory assembly schedule so a delivery could be secured for an important customer. There’s no doubt traveling to Continues on page 128 www.canadianmetalworking.com
14-08-07 5:10 PM
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FINANCE Continued from page 23
Chicago will not only take time but also cost, so if you’re going to make the trip, you need a plan! First, keep in mind there’s much more to the show than just the machinery and equipment. You’ll get access to software, measuring and tooling experts. Upgrading in these areas is just as important—if not more so in some cases—than installing a new 5-axis machining centre or multiaxis CNC lathe in your shop.
PRE-APPROVAL ADVANTAGE It’s also a very good idea to ensure the funds are available or secured for a potential purchase. This could be as simple as taking the time to work with your chosen financial institution and getting a preapproval in place. In order to get pre-approval, you just need to provide a one page credit application and some current
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financial information. An efficient institution can review and comment on the request within 24-48 hours to either provide a pre-approval for a specific amount, detail what a potential approval may look like from a pricing and structure standpoint, or simply request some additional information for further analysis. Regardless of where the actual capital comes, the signal sent to the seller by simply telling them you have been pre-approved for financing is very strong. They will immediately know their potential customer has been checked out, is credit worthy, and therefore, to be taken seriously. It also means they will know a potential purchase will be paid in full either upon delivery (usually with a hold-back until the equipment is running) or installation completion and they can essentially negotiate a cash price. At the end of the day, whether the
funds come from your own account or that of your chosen financial institution, the seller knows the buyer is someone who is to worth their valuable time. Before you head to IMTS, take a little time to plan the equipment, accessories and people you want to see. Get your financing in place ahead of time to maximize your ability to cut a deal you likely wouldn’t get at local trade shows. Good luck! Ken Hurwitz is the Senior Account Manager with Enable Capital Corp., an asset-based lending company in Toronto. Ken has years of experience in the machine tool industry and now works to help all types of manufacturers tap into their own capital to optimize their operations. Contact Ken at (416) 614-5878 or via email. Learn more at www.enablecapitalcorp.com
www.canadianmetalworking.com
14-08-11 12:02 PM
ADVERTISERS INDEX Advertiser
Page#
3M Canada
111
ABB Robotics Inc.
46
Amada Canada, Ltd. AMT Machine Tools Ltd.
9 19, 117
Benz Inc. Blaser Swisslube Inc.
12 101
HORN USA, Inc.
11
Retention Knob Supply
Hougen Manufacturing Inc.
28
& Mfg. Co. Inc.
Hurco USA Hydromat Inc. IMTS 2014 Ingersoll Iscar Tools Inc.
IFC 19 121 17 OBC
Rofin-Baasel
35
Samchully Workholding, Inc.
51
Sandvik
4, 5
Scientific Cutting Tools
118
Scotchman
37
Brubaker Tool
41
ITI Tooling Company Inc.
Canadian Measurement-Metrology
73
Kinetic Cutting Systems Inc.
82
Seco Tools Inc.
Cincinnati Incorporated
87
Koma Precision, Inc.
48
SGS Tool Company
Cosen Saws
91
Komet Canada
52
Shop Data Systems
97
CWB Group
71
Kyocera Cutting Tools Division
125
Sirco Machinery Co.
27
13
Lincoln Electric Company of Canada 65
SME AM Expo
LOSMA
SST Canada
DiPaolo Machine Tools Elliott Matsuura Canada Ltd. EMAG L.L.C. Emec Machine Tools Inc.
6, 87 113 57
Makino Inc.
54, 55
129
124 20, 21
Mate Precision Tooling
89
Schunk Intec Corporation
105 31 103
63 49, 119
Star CNC Machine Tool Company
117
Tate Industrial Sales
100
ERI America Inc.
100
Mazak Corporation Canada
43
Thomas Skinner
27
Eriez Magnetics
112
Megatel Inc.
29
Toshiba Machine
99
Exsys Tool, Inc.
122
Methods Machine Tools, Inc.
107
Company Canada Ltd.
FARO Technologies Inc.
75
Micro 100 Tool Corporation
14
TRUMPF Inc.
Fastems, LLC
93
Multicyl Inc.
36
Tungaloy America Inc.
Ferro Technique Ltd.
45
Okuma
15
Universal Robots USA, Inc.
Flexovit Canada Abrasives Ltd.
79
Pearl Abrasive Co.
83
Vargus USA
25
GMN USA
53
PFERD
81
Victor Technologies
69
Gravotech - Technifor
23
Powerhold Inc.
26
Walter Surface Technologies
Haas Automation Inc.
27
PRAB
47
Walter USA, LLC
Heule Tool Corporation
16
Renishaw (Canada) Ltd.
61
Yaskawa Motoman
www.canadianmetalworking.com
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IBC 3 123
85 115 77
AUGUST 2014 | 129
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Vargus USA — Booth W-2245
SEPTEMBER 8-13, 2014 C H I C A G O McCORMICK PLACE
Vargus USA had an application they were conventional hobbing. They had three main objectives which were cost, productivity, and quality of the part. What the customer required from Vargus USA was a faster more reliable tool to manufacture their splines. The Vargus process is faster and more cost effective. Vargus Gear Milling tools solved all of the customer needs for the application. www.vargususa.com
Genevieve Swiss Industries, Inc. (Genswiss) — Booth W-2356 GenSwiss will exhibit its new MultidecLUBE Coolant Thru Tool Holder Clamp for CNC Swiss Machines that permits optimum coolant jet positioning, eliminates time bending and aiming coolant lines, drastically reduces overall setup time, and prevents stringy chips collecting on cutting tools. www.genswiss.com
Oerlikon Balzers USA, Inc. — Booth W-2380 Oerlikon Balzers is presenting a revolutionary generation of wear protective coatings based on their innovative S3p technology at IMTS. The initial coating products, BALIQ MICRO ALCRONOS for micro-tools and BALIQ TAP ALCRONOS for tapping tools are impressive with their precision-tailored microstructure. Its manufacture represents a technological milestone. www.oerlikon.com
Samchully Workholding, Inc. — Booth W-2364
KOMET of America, Inc. — Booth W-2400
Samchully Workholding will feature the new TR-320FF heavy duty 5th axis rotary table at IMTS. This high capacity 12” rotary table uses high torque motors for both the tilt and turn axes giving this table a 330lbs load capacity. The included 12.5” faceplate with a 4”+ through hole. www.samchully.com
KOMET’s hi.aeQ face-milling cutter will be featured at IMTS and is ideal for the shoulder and face milling of cast iron workpieces, as well counter-boring and milling operations. The nickel-plated body of the hi.aeQ features tangentially positioned Q80 indexable inserts. Each indexable insert has eight usable cutting edges. The hi.aeQ is available in diameters ranging from 63 to 160 mm. www.komet.com
Benz Incorporated — Booth 2445
Röhm Products of America — Booth W-2464
BENZ will demonstrate its new LinA and LinS broaching tools during IMTS. LinA broaching tool system changes the rotary motion of the live tool turret into a linear motion for broach and spline machining. LinS enables programmers to broach splines, torx, hex and keyways on their machining centers. The LinS provides broaching solutions without compromising spindle or spindle-bearing integrity. www.benz-inc.com
Röhm will showcase advanced clamping and gripping technologies at IMTS. Among the new and innovative products on display will be the new Orange Line of products. The Orange Line expands continually with new products such as the RB-M and RB-K machine vices featuring modular designs that permit them to be offered with either a mechanical spindle (RB-M) or power intensification (RB-K). www.rohm-products.com
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Fastems Maximizing productivity requires more than great machine tools, you must also flow work through the manufacturing process as efficiently as possible. That’s the role of a Flexible Manufacturing System. And no one has more FMS experience, technology and solutions than Fastems. Our modular components can service one CNC machine or hundreds, and our unique, user-friendly operating system manages material loading and unloading, production scheduling and much more. www.fastems.com
www.canadianmetalworking.com
14-08-07 5:14 PM
Please visit us at Booth N-6223
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4/21/14 1:13 PM 14-07-16 11:48 AM 14-08-07 5:00 PM
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3/24/14 1:03 PM 14-08-07 5:02 PM