Canadian Metalworking June 2015 by Annex Business Media

TIME IS MONEY Workholding solutions for increased uptime — p44

STAYING SHARP Tips to maximize cutting tool life — p50

THE BEAUTY OF TIG GTAW is the pinnacle of welding — p78

OPENINGS IN THE

AUTO SECTOR

JUNE 2015 PM 40069240

CHALLENGES OF LARGE PART FABRICATING Solutions for shop needs — p90

Take 5 for 5-Axis Sometimes we’re moving so fast, it feels like there isn’t time to take a breath…pause…and see if there is a better way…a more efficient way. What if you could produce more parts in less time with less manpower? What if you could instantly increase the profit margin and accuracy of your existing parts? The Take 5 Tour gives you the tools you need to quickly evaluate the merits of 5-sided machining. There is a better way. Take 5 today for the future of your business.

O: E D I V 5

Take e h T bina r e W -Axis take5 / for 5 m o de CO.c HUR the QR Co an or sc TURNING CENTERS

MACHINING CENTERS

5-AXIS

ELLIOTT-MATSUURA CANADA INC.

•

DOUBLE COLUMN

www.elliottmachinery.com

•

BORING MILLS

905.829.2211

Machines shown with options. Information may change without notice.

Hurco.indd 1

15-06-05 3:11 PM

Tungaloy.indd 1

15-06-05 3:14 PM

Sandvik.indd 1

15-06-05 3:14 PM

Will you make the switch? So what does that all mean for you? To start with, you get a parting-off tool with 80% better tool life than any other on the market. But thatâ&#x20AC;&#x2122;s not all. Find out what CoroCutÂŽ QD can do for you at: www.sandvik.coromant.com/make-the-switch

Sandvik.indd 2

15-06-05 3:14 PM

AUTOMATION

NEW SPEEDIO

Elliott Matsuura Canada Inc. 2120 Buckingham Road Oakville, Ontario, L6H 5X2 Tel: 905-829-2211 sales@elliottmachinery.com www. elliottmachinery.com

Elliott.indd 1

15-06-05 3:15 PM

JUNE 2015 ß VOL. 110 ß NO. 05

www.canadianmetalworking.com

A LOOK INSIDE SPECIAL ISSUE: AUTOMOTIVE MANUFACTURING FEATURES LOOKING BACK: CANADA’S FIRST AUTO ASSEMBLY PLANT — 28 110 years of Canadian Metalworking

BUILT FOR SPEED — 38 Machine tools for high volume production

TIME IS MONEY — 44 Workholding solutions for increased machine uptime

COVER STORY — 32

STAYING SHARP — 50

AUTO MANUFACTURING REPORT

Tips to maximize cutting tool life

High-tech vehicles + booming Mexican production = opportunity?

REVVING UP ITS BUSINESS — 54 Rotomaster, Surrey, British Columbia

STRINGENT STANDARDS — 58 Auto manufacturers must meet ever-evolving regulations

THE BEAUTY OF TIG — 78 GTAW is the pinnacle of welding

58 54 www.canadianmetalworking.com

05CMW-Contents.indd 7

 JUNE 2015 | 7

15-06-05 2:34 PM

JUNE 2015 ß VOL. 110 ß NO. 05

www.canadianmetalworking.com

A LOOK INSIDE SPECIAL ISSUE: AUTOMOTIVE MANUFACTURING

FEATURES (CONT.) CLEANING UP — 84 Getting the most out of the wire cup brush

CHALLENGES OF LARGE PART FABRICATING — 90 A look at solutions that fit shop needs

STAMPING SEES MARKET UPSWING — 100

84 100

Macrodyne Technologies, Concord, ON

DEPARTMENTS VIEW FROM THE FLOOR — 10 NEWS — 12 KEN HURWITZ ON FINANCE — 21 BUSINESS OF WELDING — 23 BUSINESS MANAGEMENT — 25 CMTS COUNTDOWN — 26 TOOL TALK — 62 TOOL TECH — 68 CNC SOLUTIONS — 70 FAB AND WELDING NEWS — 72

UPCOMING IN METALWORKING In the August issue of Canadian Metalworking we will be exploring small manufacturing establishments (SMEs) and job shops. Check out profiles and case studies from shops coast to coast. Other topics include heat treating and achieving quality standards for SMEs and job shops, as well as our extended coverage of “Looking back: 110 years of Canadian Metalworking”. Also, on www.canadianmetalworking.com, visit our “Productivity Centre” section on the homepage to get the latest tips, case studies, how-to videos, and articles on ramping up productivity on the shop floor. And don’t forget to follow along and engage with us on social media – look for us on Twitter, Google+, and Facebook!

BY THE NUMBERS — 106

8 | JUNE 2015

05CMW-Contents.indd 8

www.canadianmetalworking.com

15-06-08 11:42 AM

2-2015_CM_IMP_Ad_Layout 1 1/9/15 11:49 AM Page 1

Keith Billings, President (right) and Brian Heins, General Manager Integrated Metal Products

At the Forefront. “Amada’s ability to continuously innovate keeps us ahead of our competitors.” — Keith Billings, President Integrated Metal Products

Integrated Metal Products Retains Their Leadership Position by Partnering with Amada. Located in Guelph, Ontario, Canada, Integrated Metal Products (IMP) is a leading contract manufacturer of precision fabricated metal components. For nearly 30 years, IMP has served a wide range of industries and earned a reputation for unsurpassed quality and reliability. IMP president, Keith Billings, attributes the company’s success to investing in leading-edge technology and state-of-the art equipment. Billings put it in these words, “Amada’s commitment to advancing technology has allowed us to improve efficiencies and attract new customers, as well as keep our long-term customers coming back. We’ve always used Amada equipment. Over the years we’ve upgraded our older models to the latest generation — including press brakes, laser cutting systems and punch/laser combination machines. Amada’s innovative machines and processes keep IMP ahead of the competition.”

Amada’s Networked Solution Provides: • Maximum Productivity (High-speed shuttle tables on the FOM2 ensure continuous processing by externalizing the material setup process. The EMLK combines the punching power of the world’s fastest hit rates with the versatility of a 4kW laser).

EMLK punch/laser combination with MP automated load/unload system.

• Maximum Flexibility (The FOM2 provides high speed processing for a wide variety of material types and thicknesses. The EMLK provides the ability to tap, form, punch and cut on the same machine). • Accuracy and Reliability (The EMLK’s high-speed motion system is repeatable to .0003˝, ensuring accurate parts every time. For more than 10 years, the FO series has a proven reputation for unparalleled accuracy and reliability. As the latest generation, the FOM2 continues to set new standards for precision and performance). IMP’s General Manager, Brian Heins is also impressed by Amada’s service and support. Heins states, “Our Amada service engineer gave us his direct contact information and on one occasion came in at 10 pm on a Saturday night to ensure our weekend shift could continue cutting through the night. It’s great to work with a company that’s committed to our success.”

Amada.indd 1

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 www.amada.ca

15-06-05 3:16 PM

VIEW FROM THE FLOOR

PLANTING THE SEEDS OF CHANGE

Is enough being done in this country to raise the level of awareness of the skilled trades so there won’t be another lost generation?

he energy in the air was contagious on the evening of May 27 at the Prairieland Exhibition Grandstand in Saskatoon as over 500 adolescent competitors from across the country were assembled, grouped by their provincial or territorial colours and then, armed with noisemakers and the excitement of youth, paraded into the stadium. It was the opening ceremonies for the 2015 Skills Canada National Competition, and as each collection of representatives marched out waving their flags you could feel their sense of pride. Congratulations to the Skills Canada organization for doing its part to create a national platform that gets youth engaged and excited about excelling in a skilled trade. For the competitors involved it was a memorable experience, and the opportunity to represent your region at a national level is powerful. But aside from the competitors, to me the greatest benefit of this annual competition that travels the country (next year is Moncton, New Brunswick) is the exposure it provides to youth in the host communities. School buses full of students from Saskatoon and surrounding area filled the halls as the competitors performed. Some 5,000 schoolaged kids were gaining first-hand exposure to occupations they likely didn’t even know existed. This was the win.

PUBLISHER STEVE DEVONPORT 416.442.5125 ß sdevonport@canadianmetalworking.com

In Saskatoon I was speaking with with Dan Tadic, executive director of the Canadian Welding Association, and he expressed the importance of opening the eyes of kids in high school and earlier to these career opportunities. A week prior to the Skills event the Canadian Welding Bureau launched a new comprehensive national educational/training platform called Acorn, which was also rolled out to welding educators at a conference in Saskatoon just days before the skills event. And at the Skills event Deborah Mates, director of the CWA Foundation was promoting the Mind Over Metal week-long summer camps taking place across the country that provide hands-on welding experience to at-risk youth aged 12 to 15. It’s programs like these that are raising the level of consciousness of skilled trades in the minds of kids. As Ian Campbell suggests in his Business of Welding column on page 23, it’s time that the work welding and related professions do be considered a career, not just a job. It’s too late to make up for years of neglect, but it does appear the seeds for a cultural change in the perception of skilled work in this country are being planted and will begin to take root.

DOUG PICKLYK, EDITOR dpicklyk@canadianmetalworking.com

ASSOCIATE PUBLISHER ROB SWAN 416.510.5225, cell 416.725.0145 ß rswan@canadianmetalworking.com

HOW TO REACH US Published by Annex Publishing & Printing Inc 80 Valleybrook Drive, North York, ON M3B 2S9 Phone: 416.442.5600 ß Fax: 416.510.5140

ACCOUNT MANAGER NICHOLAS HEALEY 416.442.5600 x3642 ß nhealey@canadianmetalworking.com

CM, established: 1905 is published 9 times per year by Annex Publishing & Printing Inc.

EDITOR DOUG PICKLYK 416.510.5206 ßdpicklyk@canadianmetalworking.com

SUBSCRIPTION RATES Canada $55.00 per year, Outside Canada $90.00 US per year, Single Copy Canada $8.00.

ASSOCIATE/WEB EDITOR LINDSAY LUMINOSO 416.442.5600 x3645 ß lluminoso@canadianmetalworking.com

RETURN UNDELIVERABLE TO CIRCULATION DEPARTMENT 80 Valleybrook Drive, Toronto, ON M3B 2S9

EDITORIAL DIRECTOR LISA WICHMANN 416.442.5600 x5101 ß lwichmann@canadianmanufacturing.com

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.

ART DIRECTOR STEWART THOMAS 416-442-5600 x3212 ß sthomas@annexnewcom.ca CIRCULATION MANAGER SELINA RAHAMAN 416.442.5600 x3528 ß srahaman@annexnewcom.ca MARKET PRODUCTION MANAGER BARB VOWLES 416.510.5103 ß bvowles@annexnewcom.ca PRINT PRODUCTION MANAGER PHYLLIS WRIGHT 416.442.6786 ß pwright@annexnewcom.ca PRESIDENT OF ANNEX BUSINESS MEDIA MIKE FREDERICKS VICE-PRESIDENT OF ANNEX BUSINESS MEDIA TIM DIMOPOULOS

10 | JUNE 2015

05CMW-Editorial.indd 10

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: vmoore@annexnewcom.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.

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.

www.canadianmetalworking.com

15-06-05 2:35 PM

Chip Formation Taken to the Extreme

Booth #2636

Defined chip formation for maximum chip control. Precision-sintered carbide inserts are the result of a unique molding process of carbide substrates specifically blended to guarantee maximum precision. Indexable inserts with highly complex geometries and unmatched repeatability ensure measureable results. Even in materials that are difficult to machine. www.hornusa.com

www.hornusa.com

HOR N â&#x20AC;&#x201C; EXCEL L E N C E I N T E C H N OL OGY

GROOVING

PA RT I N G O F F

Horn.indd 1 041_A_SinterPlatten_en_USA_206,3x273.indd 1 HORN JUNE.indd 1

GROOVE MILLING

BROACHING

PROFILE MILLING

REAMING

15-06-05 PM 07.10.143:16 10:04 15-05-12 8:56 AM

IN THE NEWS

SKILLS SHINES IN SASKATOON The Prairieland Exhibition grounds in Saskatoon were buzzing with excitement on the evening of Wednesday, May 27, as over 500 highschool and college age participants in the 21st Skills Canada National Competition (SCNC) prepared to march into the Grandstand to take their seats at the opening ceremonies. Teams representing every province and territory chanted their way into the event, and over the next two days the participants were competing in their respective skilled trades. The competition encompasses over 40

12 | JUNE 2015

05CMW-News.indd 12

skilled trades including CNC machining (mills and lathes), precision manual machining (mills and lathes), welding and sheet metal fabrication. The winning competitors were announced at the closing ceremonies on Saturday, May 30. “To those who return home with gold, silver and bronze in your hands, we salute you for your perseverance and congratulate you on your win,” said Shaun Thorson, CEO of Skills Canada. Also on hand was Pierre Poilièvre, Minister of Employment and Social Development Canada. “These trades-

people confirm why we continue to invest in apprenticeships and skills training. We need to get these skills, the skills employers are looking for and the skills that are in demand, into the talented hands of our bright young Canadians.” The real winners to come out of this event may well be the over 5,000 local students who were exposed to these trades, many for the first time, and were able to take part in interactive Try-a-Trade and Technology activities. By all accounts the event was a real success for Skill Canada, whose mandate is to promote skilled trades and technology careers among Canadian youth. Winners of the gold, silver and bronze medals for all of the categories can be viewed at www.skillscompetencescanada.com. www.canadianmetalworking.com

15-06-05 2:42 PM

DiPaolo.indd 1

15-06-05 3:18 PM

IN THE NEWS

THE COQUITLAM MMP EXPO PROVES ITS VALUE FOR A THIRD STRAIGHT YEAR The third annual Coquitlam Metalworking Manufacturing & Production (MMP) Expo took place on May 5, and was met with great enthusiasm from all in attendance. The keynote address by Marcus Ewert-Johns, vice president, British Columbia Canadian Manufacturers & Exporters, reported on the important economic contributions manufacturing makes in British Columbia as well as a look to the future with upcoming initiatives. Ewert-Johns explored the reality of challenges and benefits manufacturers face in the current climate. Despite a bit of drizzle in the morning, throngs of people made their way into the hall of the Hard Rock Casino to check out the latest from industry professionals. With

14 | JUNE 2015

05CMW-News.indd 14

over 100 tables, visitors were greeted with a wide range of technologies, products, and information. After three years, the support for this show remains strong from both visitors and exhibitors. “We were at the first Coquitlam event and frankly, I was very surprised at not just the number of attendees but the sheer spectrum of businesses and interests it attracted...This year was no exception, folks seem to come from far and wide,” says Philip Smith, technical sales manager at Renishaw Canada. “One of the most positive aspects was the attendance; this is the only event where we see a fairly steady stream of attendees… Attendees were very upbeat in their prospects for the coming months; there were no negative comments from a business perspective other than the typical shortage of skilled workers,” says Tom Shannon, sales manager for Mazak Corp. of Canada. “We are looking forward

Marcus Ewert-Johns, vice president, B.C., Canadian Manufacturers & Exporters

to an even more successful show in 2016,” says Stefan Fickenscher, managing director of TRUMPF Canada. “Most positive about the show is that it confirmed the viability of the show with its third year in a row with high attendance and good leads,” says Frank Bolieiro, vice president sales & marketing for Elliott Matsuura. “The third year was critical to confirm it is for real.” “Coquitlam has been our strongest location since we started the MM&P Expo back in 2013,” says Rob Swan, associate publisher of Canadian Metalworking. “This year I really felt was going to provide us with valuable feedback on the greater Vancouver market, and if it could sustain an annual expo. We were once again thrilled with the turnout and feedback from both exhibitors and attendees, and we look forward to returning in 2016.”

www.canadianmetalworking.com

15-06-05 2:42 PM

Meistermacher. Made in Germany.

Jens Lehmann, German goalkeeper legend, SCHUNK brand ambassador since 2012 for precise gripping and safe holding.

German champion with Borussia Dortmund 2002 English champion with Arsenal London 2004

Thomas Retzbach, Head of R&D – Clamping Technology

SCHUNK hydraulic Expansion Technology More than 75,000 Customized Solutions implemented SCHUNK customized hydraulic expansion technology. Perectly custom-made. The know-how of the world’s largest manufacturer and market leader for workholding and toolholding technology in the µ-range for optimal adaptation of the clamping device to your workpiece or machine.

2014_AZ_MM_CS_Hydro-Dehnspanntechnik_CA_206,3x273.indd 1 Schunk.indd 1

www.gb.schunk.com/hydraulicexpansiontechnology

21.04.154:05 14:05 15-06-05 PM

IN THE NEWS

GM CANADA CONFIRMS LAYOFFS AT OSHAWA ASSEMBLY PLANT GM Canada announced that by November 20, 2015, the Chevrolet Camaro will no longer be produced at the Oshawa Assembly. It was first announced in December 2012 that production would move to the Lansing Grand River Assembly Plant in Lansing, Michigan. The company has confirmed that it will begin a voluntary retirement canvass at the plant to minimize employment impacts. However, GM Canada expects to cut upwards of 1,000 positions throughout the year. After November 20, Oshawa Assembly will continue to produce five vehicles, and it will move to three shifts of production. Working with local Unifor leadership, retirement incentives will be

offered to eligible hourly workers at Oshawa Assembly under the terms of the Unifor Master Agreement to manage the expected reduction.

“GM INSISTS IT IS STILL COMMITTED TO CANADA AND HAS RECENTLY ANNOUNCED MORE THAN $800 MILLION IN NEW INVESTMENT IN ITS CAMI FACILITY IN INGERSOLL, ONTARIO.” The Oshawa Assembly plant currently employs approximately 3,600 hourly workers, of which 2,100 are eligible for the retirement incentives. The total number of retirements will

PHOTO COURTESY OF GENERAL MOTORS

Compact | Quiet | Efficient

Number One Choice For Oil Mist Removal Filtermist units efficiently remove oil & coolant mist, fume and steam in thousands of manufacturing operations around the world.  Prevent harmful oil-mist from being inhaled  Reduce accident risks from slippery surfaces  Minimize fire hazard caused by centralized systems  Most efficient method to collect oil mist

 Designed to integrate with the widest possible range of machine tools  Compact construction minimizes size & weight

AMT Machine Tools Ltd. 73 Galaxy Blvd. Units 15,16,17, Rexdale, Ont. M9W 5T4 Tel: 416-675-7760  Fax: 416-675-6988

www.amtmachine.com 16 | JUNE 2015

05CMW-News.indd 16

be determined through the canvass process and implemented through the remainder of 2015. GM Canada continues to examine a range of longer-term opportunities and competiveness enhancements for Oshawa Assembly working with Unifor, government, supplier and community partners to ensure operations are innovative, efficient and cost competitive. Future product decisions will not be made until after Unifor national bargaining, scheduled for 2016. GM insists it is still committed to Canada and has recently announced more than $800 million in new investment in its CAMI facility in Ingersoll, Ontario. On April 28, GM announced that its Canadian Engineering Centre located in Oshawa will expand as an innovation hub for “the connected car” and green technologies, two areas of critical importance for automotive customers and the future of the auto sector. www.canadianmetalworking.com

15-06-05 2:43 PM

DURATOMIC速 TP0501, TP1501, TP2501 Our new Duratomic line of insert grades for steel-turning applications gives you even more competitive benefits when it comes to high-speed, balanced and versatile production.

SECOTOOLS.COM/CM2

And, new Edge Intelligence makes it impossible to miss which edges have been used, allowing you to make more parts per edge, limit production interruptions and reduce waste.

15-SEC-0369 Seco.indd 1 Duratomic2015_ph3-CM.indd 1

CHROME IS THE NEW BLACK 5/7/15 9:05 15-06-05 3:20 AM PM

IN THE NEWS

RIVALS TOYOTA AND MAZDA TEAM UP TO MAKE CARS BETTER with safety and fuel efficiency. A joint committee will evaluate how best to utilize each company’s respective strengths. “As eviSigning of the partnership agreement. Toyota president/CEO Akio Toyoda (left), and Mazda president/CEO Masamichi Kogai. denced by their PHOTO COURTESY OF TOYOTA SKYACTIV Technologies and KODO—Soul of Motion design, Toyota Motor Corp. and Mazda Mazda has proven that it always Motor Corp. have agreed to build thinks of what is coming next for a mutually beneficial long-term vehicles and technology, while still partnership. managing to stay true to its basic The deal will see the Japanese carmaking roots,” says Toyota companies focusing on developing president Akio Toyoda, marking the technologies specifically dealing

The most accurate. The most choices.

agreement. “In this way, Mazda very much practices what Toyota holds dear: making ever-better cars. I am delighted that our two companies can share the same vision and work together to make cars better. I can think of nothing more wonderful than showing the world—together— that the next 100 years of cars will be just as fun as the first.” “Toyota is a company that has shown steadfast resolve in acting responsibly on global environmental issues and the future of manufacturing as a whole,” says Mazda president and CEO Masamichi Kogai. “I also have tremendous respect for Toyota’s dedication in its pursuit of ever-better cars through ongoing innovation. I hope that by working together to make cars better, we can raise the value of cars in the eyes of consumers while also enhancing the manufacturing capabilities of our home, Hiroshima, and all the communities we are involved in as well.” Previous collaboration between Toyota and Mazda has included the licensing of Toyota’s hybrid technologies to Mazda and the production of compact cars for Toyota at Mazda’s plant in Mexico.

Carbide dead centers by Booth #3909

30 millionths roundness standard. 10 millionths by request. ß Full or partial carbide tip ß Bullnose ß Extended length ß Half centres

ß Female carbide tips ß Draw-off nut ß Morse taper sizes 2-5 ß Customs available

PHOTO COURTESY OF MAZDA

Exclusive USA supplier

Morse Taper 3 & 4 centers in stock

18 | JUNE 2015

05CMW-News.indd 18

P: 800-349-1044 F: 860-349-1815

This latest agreement will go beyond the traditional framework of cooperation, aiming instead to create a whole new set of values for cars through wide-ranging medium to long term collaboration. www.canadianmetalworking.com

15-06-08 11:48 AM

IN THE NEWS

BOMBARDIER SLASHES 1,750 JOBS IN MONTREAL, TORONTO, AND BELFAST Bombardier announced it is cutting 1,750 employees in Montreal, Toronto and Belfast over the coming months—a move expected to save about US$135 million a year. About 1,000 of the lost jobs will be in Montreal, while 480 are in Toronto and 280 are in Belfast. The cuts will begin in June and continue until the first quarter of 2016, said the company, which employs more than 70,000 people, about half in its aerospace division. Bombardier says it’s reducing production of its Global 5000 and Global 6000 aircraft, the largest of its business jets, to reflect challenging conditions in some markets. The company is also making additional adjustments to its business aircraft division by hiring a new president. Effective June 15, 2015, David Coleal will take over as president. Bombardier president and CEO Alain Bellemare says Coleal will succeed Eric Martel, who is leaving the company after 13 years. Before joining Bombardier in 2008, Coleal was president and chief operating officer of Cirrus Design Corp. and has held management positions at McKinsey, Caterpillar and New United Motor Manufacturing. Coleal is not the only new hire for Bombardier who has added procurement expert Jean-Paul Pellissier as a special adviser to conduct an extensive review of its supply chain. Pellissier is an industry veteran with 25 years of experience at Dassault Aviation. He will be focusing on improving sourcing processes and supply chain efficiency. www.canadianmetalworking.com

05CMW-News.indd 19

STAKE IN BOMBARDIER TRANSPORTATION UP FOR GRABS After many changes and adjustments, Bombardier has reviewed its options and concluded that the best course of action for the company is to prepare for an initial public offering (IPO) of a minority stake in Bombardier Transportation. When completed, the IPO is

expected to solidify the full value of Bombardier Transportation and strengthen the Corporation’s currently-challenged financial position. This action will allow for flexibility should the company wish to participate in future rail equipment industry consolidation.

ab ry T R ota es s i x i or hA cess & 5t 4th & Ac

l es

samchullY www.samchully.com | 1-877-750-4747 | info@samchullyworkholding.com

JUNE 2015 | 19

15-06-05 2:43 PM

produCtiVe SolutionS with loCal SerViCe and Support

Mighty Viper Vt SerieS Slant Bed latheS  Full range of slant bed lathes with box ways  Available with live tooling  Swing over bed from 14” to 45” up to 200” centres  Fanuc control VT50A Model

PMC-2622 Model

Mighty Viper pMC-SerieS Bridge MaChineS  83” x 59” x 31” – 398” x 122” x 43” travels  Available 5-Face Machining  Automatic Tool Change in Horizontal and Vertical Position  Full enclosure splash guards available

Mighty Viper hMC SerieS

HMC-630 Model

 28” x 31” x 18” – 67” x 55” x 60” travels  40-120 ATC  6-pallet APC  10,000 / 6,000 RPM

21 Tarragona Blvd. Toronto, ON. M6N 5C2 416.458.7994 | sales@mitchammachinetools.com

www.mitchammachinetools.com Mitcham.indd 1

15-06-05 3:21 PM

FINANCE

WORKING WITH CANADIAN DOLLARS BY KEN HURWITZ

anadian manufacturers face a number of different struggles inherent to any other business, pressure on margins due to fierce competition, keeping up with the latest technology, holding on to top producers or management, and finding new customers to facilitate growth. In a busy market, like we have now, at some point there is saturation and finding new business opportunities locally or even across Canada can become difficult, so the next logical spot to look for business is beyond our borders. At the moment, the U.S. market seems to have recovered; they are now busy to a point where their capacity is reaching its limit. The natural move would be to send their excess work up here. Marv Fiebig, the owner of Ptooling Inc., who had 20 years of industry experience with hands-on manufacturing and engineering experience in industries such as oil and gas equipment, gas compression, aerospace and injection molding, started his own business back in 1999. However, it was during the last four years when he started exporting products into the U.S. where he really experienced a tremendous amount growth. When I asked him what he felt were the most important factors attributed to his success in the U.S. his response was “working with the government, particularly the Dept. of Foreign Affairs and the EDC, as well as finding and implementing the newest technologies so I could compete effectively.” The Canadian Trade Commissioner Service (TCS) provides Canadian manufacturers “with on-the-ground intelligence and practical advice on www.canadianmetalworking.com

05CMW-Finance.indd 21

foreign markets to help you make better, more timely and cost-effective decisions in order to achieve your goals abroad…If you are part of the Canadian business community, and contribute to Canada’s economic growth, have a demonstrated capacity for internationalization and have good potential to add value to the Canadian economy, you can benefit from our services.” Export Development Canada (EDC) essentially assists “Canadian companies sell beyond Canada’s borders, including to the U.S. We do this by providing insurance and financing solutions to companies with export contracts. We also provide guarantees to banks, so they are encouraged to provide their exporting customers with access to more working capital.” When I asked Marv that question I was surprised he did not include a comment on the prevailing exchange rates, which right now make Canadian products relatively competitive. Usually when I hear my customers talk about exchange rates it is related to buying equipment and how a weak Canadian dollar makes expensive equipment that much tougher to buy. Whenever I have this conversation, and without question there is some validity to it, it reminds me of a speech Dr. Masahiko Mori, CEO of DMG Mori Seiki Co. gave many years ago when talking about the price of his machine tools and the pressure he gets from his distributors and customers. “If you really want to save money you should negotiate harder with your tooling suppliers, you will spend more money with them than you’ll ever spend with me.” His comments broke up the room. His point however was right on the money, when you buy a quality machine tool it will be installed in your plant for a long time. I walk through shops all the time and see machines we installed back in the 1980s, where the payback was no more than five years and they’re still

making money for the owner. When the Canadian dollar is weaker it makes buying goods from other parts of the world more expensive, and since Canadians are notoriously price conscience, it leads to hesitation. The reality is, if a quality machine is installed it will work and generate revenue for more than a decade, so even if it means paying a premium upfront, the money will still be well spent. From first-hand experience the best market for machine tools I ever saw, from a seller’s point of view, was the late 1990s. At that time I was working for a machine tool distributor, and we were selling equipment in quantities we had never seen before. At that time the exchange rate was approximately US$1.00 = C$1.48 which was much weaker than it is today, and we could not get our hands on enough machines. Now, as someone who spends his days financing equipment, I regularly remind customers that leasing the machine is a way to alleviate the difficulty of an unfavourable exchange rate as the impact on the monthly payment is nominal. They should use their valuable working capital for things like product development, hiring good people, buying material, and of course tooling—none of which can be financed. When the market is busy, like it is right now, there are always opportunities for growth, not only domestically but globally as well, but in order to take advantage of these opportunities you need to have equipment on your floor to produce product…till next month. Ken Hurwitz is the Senior Account Manager with Blue Chip Leasing Corp. in Toronto. With years of experience in the machine tool industry, Ken now helps all kinds of manufacturers with their capital needs. Contact Ken at (416) 614-5878 or ken@bluechipleasing.com. JUNE 2015 | 21

15-06-05 2:38 PM

• Chip and Fluid Systems Integration • Risk Mitigation • Increased Metal Scrap Value • Wastewater Treatment Systems

Your trusted partner for the last 70 years in complete chip processing and environmental compliance support.

Chip Systems

Dualpak™ Briquetters

Ultrafiltration

Wastewater Treatment Systems

A true performance guarantee ensuring your PRAB equipment achieves the specific results it was designed and manufactured to deliver. And if you need technical support, call us. We are available 24/7.

See how to increase your scrap value: prab.com/reduce-risk

PB134-PRAB_PROCESS_EQUIPMENT_FP-CMW-JUN2015.indd 1 Prab.indd 1

company

5/27/2015 8:21:38 AMPM 15-06-05 3:21

THE BUSINESS OF WELDING

CHANGE AND THE IMPORTANCE OF TAKING ACTION BY IAN CAMPBELL

ometimes change can be difficult. This is a phrase that has been rattling around in my head for the past year as my team and I moved forward with what by all accounts is a major change—namely Acorn. As you may have already read, Acorn is an education program developed to address the short-comings, from an industry perspective, of Canada’s current welding-related education programs. Acorn is big, it is a new way of thinking about training, and it is here now. The truth is it is a huge change for all involved; industry, schools, educators and the CWB Group itself. It has taken a lot of planning, development and money to get here—all things the CWB Group is gladly willing to invest in to address issues that have been long standing and are long overdue for a fix. Is change really needed? Yes, and here’s why: The work welding and related professions like fitters and inspectors (let’s call them collectively “welding trades”) do needs to be considered a career, not just a job. Educators need to start thinking from this perspective and work together across the country to ensure that students see and have access to the “big picture” opportunities that only a career can deliver. This cannot happen at a local level, it needs a national framework and supporting courses, testing, assessments and infrastructure to help guide and measure a welder’s progress throughout his or her lifetime, wherever he or she might be. Educational opportunities should happen everywhere, all the time… www.canadianmetalworking.com

05CMW-BusWeld.indd 23

not just at once, at one location, for one fixed length of time. Welding trades need to be trained, tested and assessed uniformly across the country. This needs to take into account the specific requirements of the industries that employ them. Having good regional training only supports the immediate needs of local industry—however industries are increasingly forced to source their work force from across the country. They need a way to measure real skills and quality. They want a pool of pre-vetted candidates. The current system does not easily support this approach, nor does it provide the tools, systems, people, procedures and consistent funding needed to manage and deliver this at a national level. There’s been too much talk, not enough action. There have been discussions about a national welding trade education “system” for as long as Canada has had welders. Dialog and discussion is good, but at some point someone needs to put the people and, equally important, funding in place that is needed to do the heavy lifting of turning talk into action. We are talking about big change stuff, and big change costs big dollars.

In Canada no one national organization has been willing to make this commitment on behalf of the industry at large. There has been funding at the local and provincial level, maybe even some joint inter-provincial initiatives, but nothing that is truly comprehensive and national, and nothing that has any guarantee of ongoing progress, or even lasting beyond the next election or economic downturn. So, I’m happy to say that over the last year CWB Group, through the CWB Institute, has taken on the heavy lifting required to drive the big change that is needed, and we have moved quickly. We’ve funded and built out the content, the supporting backend systems, and the framework for a truly national system. We’ve put a model in place where this will remain current and up-to-date for the foreseeable future. Acorn is ready now to support industry, are you ready to support Acorn? For more information about Acorn visit CWBGroup.org/Acorn, or reach out to me personally—the CWB Group is here to help. Ian Campbell is Director of Marketing and New Product Development with CWB.

JUNE 2015 | 23

15-06-05 2:30 PM

Ingersoll.indd 1

15-06-05 3:22 PM

BUSINESS MANAGEMENT

FINANCIAL RESTRUCTURING: PART ONE BY ALMA JOHNS

ast issue we wrote about organizational restructuring strategies that enable teams to rejuvenate their companies. While financial restructuring is not a prerogative to restructuring an organization, it is often entailed in the process when a drastic change in company direction is necessary. Since financial restructuring is a subject that needs comprehensive examination, in this article we’ll narrow our focus to debt restructuring for otherwise viable businesses. Let’s start with an example of a fictitious company called Hot Fab Metals Inc. that has been in business for 30 years. It enjoys healthy margins and has had no issues finding work. It occupies a unique market niche and is well-liked by customers. Unexpectedly, purchase orders from one of its three largest customers come to a halt. The management team finds out the customer just filed for creditor’s protection. In a nutshell, 30 per cent of Hot Fab’s business will likely disappear and there is no potential customer in its pipeline to replace that business. In the meantime, the company maxed out its $1 million line of credit and still needs to repay approxiapproxi mately $1 million in property mortmortgage on its manufactur-manufactur ing facility. To make

www.canadianmetalworking.com

05CMW-BusMgmt.indd 25

matters worse, approximately $1 million in accounts receivable from that one particular customer is now in serious jeopardy as Hot Fab was recently classified as an “unsecured creditor” by the customer’s Trustee. Fast forward six months, Hot Fab Metals Inc. finds itself in an interesting predicament. The bank manager complains that the $1 million line of credit has not revolved in the past six months and is threatening to “term out” the line of credit if not paid down soon. While the sales team scrambled to replace the lost customer, Hot Fab’s lawyer broke the news that the company is fortunate to be entitled to $200K of the $1 million owed by the subject customer. In essence, $800K of the company’s receivables vanished into thin air. It is inevitable Hot Fab will show a negative bottom line in the forthcoming year end. While Hot Fab has been a great customer since the relationship’s inception with its bank 10 years ago, the managers have been concerned over Hot Fab’s “concentration risk” and lack of customer diversification. Ideally, banks would like to see sales revenue spread out over several customers, preferably among a few industries, and that the top five customers do not make up 50 per cent of total sales. Two or more possible scenarios can happen in the banking relationship during the annual review. These will depend on the following situations: (1) How strong is the balance sheet? Is the debt to tangible net worth ratio below 2:1? (2) Is there enough equity or working capital circulating in the business to withstand this type of proftemporary setback? (3) How prof itable are the remaining two large customers and smaller customers combined? Would profits from the remaining customers be sufficient to interservice the principal and inter est payments? (4) Were there discretionary (i.e. management

salaries above and beyond market rates) or non-recurring expenses that they can add back to “normalize” the cash flow at year end so that the resulting figure is sufficient to make the required principal and interest payments? (5) Can the owners inject personal equity to temporarily prop up the business? (6) Are there redundant assets that the company can liquidate to service the debt or maintain adequate working capital? These are mitigating factors that owners can discuss with their bank. If two or three of the above scenarios are missing, it is possible that the bank manager will either (A) put Hot Fab on a “Watchlist”, (B) ship Hot Fab’s file to special loans to rehabilitate the relationship, or worse, (C) divest the relationship to another institution that has higher tolerance for Hot Fab’s deteriorated risk profile. If the third scenario occurs, the $1 million property mortgage will likely be taken over by a private lender and the $1 million line of credit will be “termed out”. If the property has surplus equity, both can be lumped into one term loan from a private lender. The “restructured” loans will now be financed at 8 to 9 per cent compared to 4 and 5 per cent previously. This is referred to as debt restructuring. The good news is the reverse can also take place. Once the company bounces back, there is opportunity to restructure the debts back to when the company was healthy. It is highly recommended that Hot Fab establish a relationship with a new bank that has no “corporate memory” of its previous financial situation. It can wipe its slate clean and set up new facilities at previous interest rate levels. Alma Johns is president of Bench Capital Advisory Inc., an independent corporate finance and debt advisory firm based in Toronto. She can be reached at alma.johns@benchcapital.ca or www.benchcapital.ca. JUNE 2015 | 25

15-06-05 2:29 PM

COUNTDOWN T H E I N T E R N AT I O N A L CENTRE

SEPTEMBER 28 – OCTOBER 1, 2015

MISSISSAUG A

SHOWCASING ADDITIVE MANUFACTURING AND 3D PRINTING Internationally-recognized RAPID brand joins Toronto event

s 3D printing continues to gain swift momentum – growing by leaps and bounds in manufacturing, aviation and medical industries in particular – Canada’s comprehensive additive manufacturing/3D printing tradeshow and conference is returning to Toronto. SME announced today that RAPID Canada’s Conference & Pavilion will be featured from September 29-30 at The International Centre as part of the Canadian Manufacturing Technology Show (CMTS) 2015. First introduced to Canada last year, the RAPID conference and exhibition is an industry-leading forum for the exchange of information related to the latest developments in additive manufacturing, 3D printing and 3D scanning. It was first introduced by SME in the U.S. market in 1994 and remains the longest-running and most well-respected event in the additive manufacturing industry. “RAPID has been serving the global marketplace from its base in the U.S. for more than two decades – with the launch of the Rapid Pavilion at CMTS, we’re continuing to give it a uniquely Canadian flavour,” said CMTS event manager Julie Pike, adding that the sale of 3D printing products and services alone is expected to approach $6 billion worldwide by 2017, according to industry consulting firm Wohlers Associates. “Forecasts show that 3D printers and services will increasingly be used to directly manufacture

production parts and finished goods,” she added. “This is still a young market, but with so many industries willing to accept 3D into their practices, adoption is expected to accelerate over the coming year.” Additive manufacturing technology is used for prototyping and distributed manufacturing with applications in architecture, construction, industrial design, automotive, aerospace, military, engineering, civil engineering, dental and medical industries, biotech (human tissue replacement), fashion, footwear, jewelry, eyewear, education, geographic information systems, food, and many other fields. Many manufacturers apply 3D printing to create cost-effective prototypes using advanced materials. At CMTS, the RAPID Canada Conference & Pavilion will address 3D printing/additive manufacturing as well as medical/dental device manufacturing. Highlights include: A keynote address by former Stratasys Vice-President Jeff Degrange, now Chief Commercial Officer, Impossible Objects LLC, the pioneer of composite-based additive manufacturing technology (CBAM). • Two full days of expert speaker sessions, including a panel called Medical Additive Manufacturing: The Canadian Conundrum. • A comprehensive exhibit of the latest technologies, with a special focus on the areas of automotive, aerospace, bio-printing, printed electronics, 3D scanning/imaging and material development. • The 3D Playground – a chance to see stateof-the-art bio-printing capabilities, delectable edibles printed before your eyes, and 3D-scanned creations of visitor busts. •

CMTS 2015 is Canada’s largest and most respected manufacturing event, presentpresent ing the largest display of manufacturing equipment and technology to about 10,000 manufacturing professionals from across the country and around the world. With a theme of “Manufacture the Future,” it will feafea ture the latest advancements in machine tool, tooling, metal forming and fabrifabri cating, automation, 3D printing/addiprinting/addi tive manufacturing, design engineering and plant management segments. For more information about CMTS 2015 and the RAPID Canada Conference & Pavilion, and to register for the event, visit www.cmts.ca or call 1-888-322-7333, ext. 4435.

26 | JUNE 2015

05CMW-CMTS.indd 26

www.canadianmetalworking.com

15-06-08 4:31 PM

RELIABILITY. PRICE. REPUTATION.

Haas DS-30Y Dual-Spindle CNC Lathe w/ Y Axis

= TOTAL CUSTOMER VALUE. WE KNOW what it’s like. We’re MACHINISTS, too. We CUT METAL every day.

That’s why we’re driven to make sure that every Haas CNC machine is trustworthy, affordable, and always backed by the industry’s best after-sale service. Find your local Canadian Haas Factory Outlet 800.331.6746 | find them online @ www.HaasCNC.com Proud sponsor of the Stewart-Haas #41 car

Haas.indd 1

15-06-05 3:23 PM

LOOKING BACK: CANADA’S FIRST AUTO ASSEMBLY PLANT I

n this issue our celebration of Canadian Metalworking’s 110th anniversary takes us back to the December 1905 issue where in a section entitled “Modern Canadian Manufacturing Plants” the magazine profiled the all-new Motor Car Department of Packard Electric Co. in St. Catharines, Ontario. The cars being manufactured in the plant were the Oldsmobile Model N, or Touring Roundabout, a one-cylinder seven-horsepower roadster. The cars were being built on license from Olds Motor Company for distribution in Canada. It was a big deal: “This is the first plant in Canada to be built and designed for the manufacture of automobiles, and in starting this the company exercised faith in the future of the automobile

28 | JUNE 2015

05CMW-LookingBack.indd 28

trade, as well as in the growth and development of Canada.” The author of the article (unknown) wrote about how most car sales to that point were being purchased for private use and for pleasure; although the writer was certain the greater demand for automobiles in the years to come would be for hauling freight. Auto manufacturing and assembly was still new to North America, and the trade was very well respected at the time: “As is well known the manufacture of an automobile requires as fine work as probably any mechanism. The component parts must be of the best material and the workmanship of the latest that human skill and ingenuity have devised.” As expected, the article paid special attention to the plant’s machine shop: “in which are found some of the newest and best designs of machine tools … in fact, when the installation was made three-quarters of these tools were the first of their kind in Canada, and in nearly all cases they are special tools bought solely for the special work to be demanded of them. “The principal machines in this room are three Cincinnati milling machines for milling reamers and special cutters, also used for a large variety of jig work, especially when the various www.canadianmetalworking.com

15-06-05 2:40 PM

holes in the jig require particularly careful locating. “There is also a Lodge & Shipley tool room lathe 14 inches by 5 feet with taper attachment, and one LeBlond 15 inches by 8 feet with relieving I attachment for forming cutters, a Washburn drill grinder, Dwight Slate drill press, Cincinnati Universal tool and cutter grinder, and a Gould & Eberhart 20-inch shaper for general tool work. “The machine shop work for the season has been completed and already arrangements are in progress for next season’s output, the development of the automobile necessitating the building of a large number of new tools, etc.” To offer a glimpse into the workings of the shop, the article follows the path of a cylinder casting from the time it enters until it leaves the shop. “The first operation is to centre and centre-drill the head end, which is done in a Cincinnati drill press. The piece is then taken to a 24-inch Lodge & Shipley all-geared lathe, where it is chucked and turned to fit the crank case.

JUNE 2015 | 29

www.canadianmetalworking.com AD_USA_15_Canadian_Metalwork_114,3x190,5+3_Turbolader.indd 1 05CMW-LookingBack.indd 29

11.11.14 14:00 15-06-05 2:40 PM

“It is then returned to the Cincinnati drill press where the four holes for securing the cylinder to the crank case are drilled and reamed in a special jig. The cylinder now goes to a Lucas boring mill, where it is bored with three cuts. “After the first two are made the cylinder

SumpAd_CanMetal_Layout 1 5/26/15 3:58 PM Page 1

is set aside to cool, and when sufficient time has been allowed for this the finishing cut is taken with a special sizing reamer. It now goes to a 21-inch Lodge & Shipley lathe and is counter bored, from which it is taken to a No. 3 milling machine, where the sides and ends are faced by means of a large end milling cutter, using high speed steel in the blades. “The cylinder is now taken to a 32-inch Cincinnati drill press where it is jig drilled for cam shaft and valve gear, spark plugs and water connection, and the valve seats are bored and faced. These operations place the cylinder ready for assembling room.” The 1905 article draws special attention to some of the machinery, including a 36-inch Fellows gear shaper made by the Fellows Gear Shaper Co. of Springfield, Vt. “This is said to be the only tool on the market that will cut the spur gear theoretically correct.” Another is a Landis grinder, “used for working on the shafts and pistons, besides tool making.” As well as a cutting machine made by Cochrane-Bly Co. of Rochester, N.Y. “This is a circular cold saw, and cuts bar stock up to 1 inch in diameter and is one of the greatest labor-saving devices installed.”

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

30 | JUNE 2015

05CMW-LookingBack.indd 30

www.canadianmetalworking.com

15-06-05 4:07 PM

The list goes on including “a Baker Bros., Toledo, key seater...A No. 1 Lucas 15-ton power press that presses the fly wheels on the crank shafts, and is also used for broaching. In addition to these there is one No. 2 Cincinnati Universal milling machine, three No. 3 Cincinnati plain milling machines, besides nine drills, eleven lathes and two screw machines, and a bolt cutter.” The plant included a blacksmith shop for making frames, an enameling and brazing department as well as an upholstering department “with the very best leather and hair padding.”

“THE PLANT INCLUDED...AN UPHOLSTERING DEPARTMENT ‘WITH THE VERY BEST LEATHER AND HAIR PADDING’”

www.forkardt.us

Prior to assembly the motors were run for about 15 hours. Once the motor was placed on the chassis the car was then “placed on the road in charge of an expert to run it in all conditions of road and weather.” After its work-out (averaging 150 miles) “the rough testing body and wheels are removed and it is taken to Automotive Workholding. another room where it is thoroughly If it’s hard to hold... cleaned and receives its finishing coats of paint and varnish. After the answer’s this is done the body, fenders, new not hard wheels, etc., are fitted to the machine and it is ready for shipment.” to find. Prices for the finished cars began around $800, and production for 1905 was in the hundreds. Manufacturing of the Oldsmobile in St. Catharines ended in 1907, but in 1909, Packard Electric sold the plant to the REO Motor Car Company of Canada Ltd., and REO automobiles were manufactured there until 1913. An interesting note, REO was We’ve developed workholding technologies for rotors, founded by Ransom Eli Olds, the same camshafts, ABS units, compressors and transmissions to name man who founded the Olds Motor just a few. Our technical knowledge and expertise in Vehicle Company (Oldsmobile) in 1897. automotive workholding can provide you with a solution that Olds himself left Oldsmobile in 1904. fits your process. From power chucks and collet chucks, to special The Oldsmobile company was fixtures and cylinders, we offer a complete line of assemblies and acquired by General Motors in 1908 and models of the car were once accessories. Give us a call. again built in Canada, in Oshawa, beginning in 1920. GM discontin2155 Traversefield Drive • Traverse City, MI 49686 ued the Olds brand in 2004. Over its 800-544-3823 • sales@forkardt.us 107-year history some 35.2 million Oldsmobiles were produced. www.canadianmetalworking.com

05CMW-LookingBack.indd 31

JUNE 2015 | 31

15-06-05 2:40 PM

AUTOMOTIVE MANUFACTURING

Do High-Tech Vehicles + Booming Mexican Production = Opportunity? BY NATE HENDLEY

utomotive production is holding steady in Canada, rising in America and booming in Mexico, all of which spells opportunity for Canadian suppliers, say experts. The rise of high-tech “connected”, autonomous, electric/hybrid vehicles is also potentially advantageous for well-positioned suppliers. And other positive tidings include continued government support for automotive innovation and a new federal fund for small-to-medium size suppliers. A total of 2.393 million vehicles were produced in Canada in 2014, according to the Paris-based International Organization of Motor Vehicle Manufacturers (known as the “Organisation Internationale des 32 | JUNE 2015

05CMW-AutoManufacturing.indd 32

Constructeurs d’Automobiles” or OICA). This is a 0.6 per cent increase from the year before. In 2014, U.S. vehicle production stood at 11.660 million (up 5.4 per cent) while vehicle production in Mexico was 3.365 million (up a huge 10.2 per cent). The auto industry has recovered well from the recession which saw Canadian production dip as low as 1.2 million vehicles a year and total North American production drop to 8.8 million. “I think the main thing is really to highlight just how strong North America as a whole is at the moment…we’re looking at production and sales across the region. So we’re looking at Canada, the U.S. and Mexico as three countries combined…our view is the sales and production across the region are www.canadianmetalworking.com

15-06-05 2:28 PM

going to continue to expand,” states Carlos Gomes, senior economist and auto industry specialist at Scotiabank. Gomes authored a pair of highly optimistic Global Auto Reports for the bank. “The strength of the Mexican auto market will help lift North American sales and production to record highs this year, surpassing the peak that has been in place since the turn of the millennium,” reads the Scotiabank Global Auto Report published May 7, 2015. If the overall picture for North America is rosy, the specific situation in Canada is also promising. “Record auto sales and production across North America are reviving the Canadian auto industry. While the sector has undergone significant consolidation over the past 15 years and is much smaller than at the turn of the millennium, most indicators suggest that the Canadian auto industry is now performing at least in line with its two North American partners. In fact, we highlight that the auto sector is leading the manufacturing revival across the Canadian industrial heartland, is gaining market share globally and momentum has accelerated in the opening months of 2015,” states another Scotiabank Global Auto Report published April 10, 2015. That said, Gomes concedes that current production figures are lower than they were prior to the recession. “At the peak, we used to produce in excess of three million vehicles [each year in Canada]. Now we’re producing somewhere around 2.4 million. The reality is that we’ve had some plant closures [since] 2000…it’s very unlikely we’ll ever see production close to three million units here in Canada,” he states. According to Industry Canada, as of early 2015, Chrysler Canada operated two assembly plants in Canada, Ford Motor Company of Canada operated one, General Motors of Canada operated three while Honda of Canada Manufacturing and Toyota Motor Manufacturing Canada each operated two. Recent news from OEMs in Canada has been mixed. While GM has announced a total of $800 million in new funding for its CAMI assembly www.canadianmetalworking.com

05CMW-AutoManufacturing.indd 33

plant in Ingersoll, Ontario, it also announced it will be trimming 1,000 positions from its Oshawa, Ontario assembly facilities by year’s end. At the same time, GM says it will spend billions to upgrade certain American plants and modernize Mexican factories. Also in April, Toyota revealed it was planning to move Corolla production from Canada to Mexico by 2019. On the bright side, Honda recently invested $857 million in its Alliston, Ontario plants. Ten per cent of that total came from the

JUNE 2015 | 33

15-06-05 2:28 PM

Prime Minister Stephen Harper with Diane Finley, Minister Public Works, and Jeff Watson, MP Essex, sit down with Canadian auto manufacturers during visit to Windsor, Ontario. PHOTO: JASON RANSOM

34 | JUNE 2015

05CMW-AutoManufacturing.indd 34

Ontario government. Fiat Chrysler announced in January 2015 it would invest $2 billion in its minivan operations in Windsor, Ontario. As for the future, it’s a sure bet that automotive OEMs will continue expanding manufacturing operations in Mexico—thanks to lower costs. Flavio Volpe, president of the Torontobased Automotive Parts Manufacturers’ Association (APMA), says he’s heard fore-

casts that Mexico will be assembling over five million vehicle a year by 2020. Such numbers don’t scare him. Surging Mexican production represents “the best single opportunity for market expansion for Canadian suppliers. Canadian suppliers are very popular in Mexico and very active. We estimate 55 Canadian automotive companies have established 110 facilities in Mexico to serve their customers,” says Volpe. The APMA has roughly 243 member companies, whose output amounts to over 90 per cent of the volume of auto parts made in Canada. Volpe pegs auto part sector employment at “just under 80,000 people”—a number that’s “been relatively steady in the last couple years, but down from a peak that was probably 25 per cent bigger before the [economic] meltdown,” states Volpe. Annual auto part revenues stand around $24 billion, he adds. Volpe says Canadian high volume part suppliers are the most obvious candidates for establishing manufacturing divisions in Mexico. Such firms can feed the rapidly growing ranks of auto assembly plants and top tier suppliers in that country.

www.canadianmetalworking.com

15-06-05 2:28 PM

But what about Canadian automotive suppliers that are either too small or too specialized to set up a Mexican branch? For them, opportunity beckons from another direction. In cutting-edge car circles, vehicles that are either “connected” (that is, equipped with elaborate electronics) or “autonomous” (that is, they can drive themselves) are all the rage. Likewise, electric and hybrid cars are rapidly becoming mainstream and there’s ongoing research in hydrogen fuel cellpowered vehicles as well. “Canadian suppliers that deal with OEMs with vehicles that have electric drivetrains or hybrid drivetrains or have platforms like MORE [Blackberry subsidiary] QNX’s [operINFORMATION: ating system] in a vehicle” are in a vl-vt.emag.com good position to pitch new connectivity ideas, says Volpe. Even suppliers who aren’t hightech can benefit from the new era of “smart” cars. “Connected and [autonVERTICAL MACHINING: omous] vehicles still need suspension, SAFE AND EFFICIENT brakes and wheels,” Volpe points out. The APMA, for its part, has eagerly embraced futuristic cars. The association is now in the second phase of a “connected vehicle” project it launched last year. The project involves a Toyota Lexus RX350 SUV with the latest in high-end communications, infotainment, safety, operating and lighting gear. Canadian firms that assisted with the project include Magna, Lixar, Leggett & Platt, Rogers, QNX Software Systems, the WorkWorkUniversity of Waterloo Centre for SLHFH š P D[ SLHFH š P D[ Automotive Research (WatCAR), etc. 4 in 12 in WorkWorkWorkpiece height Workpiece height And the Lexus was donated by Toyota SLHFH š P D[ SLHFH š P D[ P D[ P D[ 8 in 16 in 6 in 10 in Motor Manufacturing Canada. Workpiece height Workpiece height The connected Lexus RX350 serves P D[ P D[ 8 in 12 in as “a showcase of cutting-edge, Canadian value-added, automotive THE NEW EMAG VL-MACHINES ideas,” says Volpe. The decked out RX350 will be taken on a tour in mid-June, visiting a + Machining of chucked parts = + Short travel distances = series of OEMs and tier one suppliStandardized machine platform Minimal idle time, high ers. The car will be “accompanied by performance + Small footprint = about 20 automotive executives pitchReduced ﬂoor space cost + Operator friendly = ing their technology,” says Volpe. Quick set-up, change-over + Integrated automation = He’s hoping the latter can pick up + Standardized parts strategy = No additional cost new business by showing off their Low maintenance costs + Simple workpiece conveyor & wares. interlinking = Flexibility and + High energy eﬃciency = www.emag.com The APMA only has one connected lower automation costs Reduced energy costs info@emag.com vehicle now, but the plan is to have up to four next year. There have been

Maximum Performance Guaranteed

www.canadianmetalworking.com

05CMW-AutoManufacturing.indd 35

JUNE 2015 | 35

15-06-05 2:28 PM

Now in year two, the Connected Car project is a showcase for Canadian auto innovation and is touring the country this month PHOTO: COURTESY APMA

36 | JUNE 2015

05CMW-AutoManufacturing.indd 36

suggestions of extending the scope of the project to include public transit, Volpe adds. The “smart car” concept fits in nicely with the current mood in Washington, DC and Ottawa. In the United States, strict Corporate Average Fuel Economy (CAFE) rules mandate that all new cars as of 2025 must be capable of achieving 54.5 miles per gallon. This bodes well for automotive companies doing R&D on fuel efficiency or “light-weighting”—simply, making a car as light as possible without sacrificing safety, to ensure maximum gas mileage. In Canada, the federal government launched an Automotive Innovation Fund (AIF) in the 2008 budget. AIF provided $250 million over five years for automotive firms with large-scale initiatives to design, develop and sell greener, more fuel efficient vehicles. In early 2013, Ottawa announced that AIF would be renewed to the tune of $250 million over five years (2013 to 2018). As a bonus, the Canadian government announced an additional $500 million in AIF funding in the 2014 budget. The AIF has been joined by Ottawa’s new Automotive Supplier Innovation Program (ASIP). As outlined in the Economic Action Plan 2015, the new fund will provide $100 million over five years to auto suppliers that want to develop and demonstrate new technologies. The ASIP is designed to complement, not replace, the AIF. The APMA and its member companies strongly supported the ASIP, says Volpe. While the Automotive Innovation Fund mainly benefitted large companies, the ASIP is aimed at small- and medium-sized enterprises (SMEs), he notes.

Innovation isn’t always about spaceage technology. J/E Bearing & Machine in Tillsonburg, Ontario, for one, has an innovative service-offering that can’t be offshored to a low-cost locale. Among other duties, the machine shop does maintenance work on equipment and machines in tier one and two auto plants around southwestern Ontario. The company focuses on “equipment repair and rebuild,” explains vice-president Chuck Hendricks, who cites “conveyors, assembly lines, gear boxes, drives, etc.,” as the kind of equipment they deal with. J/E picks up parts, delivers parts and brings crippled equipment back to life. Sometimes staff fix the problem onsite, while other times they do repairs or make new components in their own facility. It’s a family-run business with roughly 50 employees. About a quarter of J/E’s work at present is automotive-related. Equipment maintenance isn’t anything new for J/E (the company has been doing such tasks since it was founded in 1983). Nor is it as profitable as making vehicle components. “It takes a lot of $5,000 repairs to make up a quarter-million dollar order in production,” says Hendricks. That said, as long as there are auto assembly plants and automotive suppliers in Ontario, J/E will continue to have a huge pool of potential customers. An emphasis on service has allowed J/E to navigate a sometimes tumultuous manufacturing sector. A sector in which production gains in Mexico and the advent of high-tech cars at home present other opportunities for suppliers that feed into Canada’s auto manufacturing market.

www.canadianmetalworking.com

15-06-05 2:28 PM

Join the

REVOLUTION.

The industry’s fastest, most progressive CNC.

Make way for the new

MAZATROL SmoothX CNC. We’re revolutionizing complex, 5-axis part production with our new SMOOTH TECHNOLOGY platform. With the MAZATROL SmoothX CNC leading the charge and modern machine hardware and servo systems driving the change, this platform easily combats any manufacturing challenge that stands in your way.

Find more machining power at MazakUSA.com

DISCOVER MORE WITH MAZAK

™

MAZAK CORPORATION | (859) 342-1700 | Florence, KY | MazakUSA.com Product image is for illustration purposes only and may not be an exact representation of the product. Mazak reserves the right to change product images and specifications at any time without notice.

15-MAZ-0698_SmoothRev-CM.indd 1 Mazak.indd 1

5/22/15 2:40 15-06-05 3:26 PM PM

Machine tools for high-volume production with a focus on automotive parts BY NATE HENDLEY

ass production machining requires machine tools capable of high speed, high volume, repeatability and lights-out operation. It helps if the machine tools are relatively compact (to fit as large a number of them as possible into one spot) and easy to link together to create a true mass production environment. Here’s a look at what’s new and/or noteworthy in mass production machining, with a special focus on producing volumes of automotive parts:

MAKINO

Makino’s a51nx horizontal machining center

38 | JUNE 2015

05CMW-MassProduction.indd 38

The nx-series of horizontal machining centers from Makino are “a staple in the automotive manufacturing market, and are currently being applied by OEMs and tier suppliers alike,” says Mark Rentschler, Makino marketing director in Mason, Ohio. “The a51nx and a61nx offer 400 mm and 500 mm work zones respectively. Both platforms come standard with a 14,000-rpm high-speed, high-power spindle featuring 240 Nm of torque. However, what makes these machines so sucsuc cessful in the automotive market isn’t just their specifications, but their productivity and long-standing durability and reliability,” explains Rentschler. Automotive manufacturers have machinto meet tight deadlines while machin

ing to exacting specifications under intense pressure. Challenges include unreliable processes and unexpected downtime. “As such, [auto manufacturers] need machines and processes that are stable enough to handle punishing 24/7 production schedules [while offering] repeatable performance and maximum uptime … from the stand-point of machining centers, we’ve designed and manufactured our nx-series machines with productivity and reliability as fundamental attributes. “With extra-rigid base castings and sophisticated thermal management of key machine components, these machining centers provide sustained dynamic accuracy and repeatability that reduce and eliminate rework and scrapped parts. Design elements such as one-piece way covers, enable these machines to withstand even the harshest automotive production environments with minimal maintenance required,” continues Rentschler. Of course, the best machine tools in the world won’t offer premium results unless properly used. To this end, Rentschler says Makino Engineering Services personnel, “have an unmatched history of creating robust production-ready processes—including machinery, fixtures, tools, programs and documentation— for parts with complex geometries, demanding deadlines, challenging budget constraints and Six Sigma standards,” he states. Asked to cite the optimal conditions for high production auto part machining, Rentschler says, “It all comes down to robust, reliable machinery and experienced engineering support. When mass producing auto parts, you can’t just have one or the other. When you combine these factors, auto manufacturers can have confidence in their ability to quote and win new business.” www.makino.com

EMAG The VL series of vertical pickup lathes from EMAG can be used “for any sector which has high production parts,” says Jeff Moore, regional sales manager for EMAG in Canada, which of course includes automotive. The VL 2, VL 4, VL 6 and VL 8 are designed for, respectively, components 100 mm, 200 mm, 300 mm and 400 mm in diameter. VL series lathes are modular in design and capable of medium and large batch runs. These lathes have a small footprint, which means reduced floor costs and machine layout flexibility. The VL 2 was released in 2013 while the VL 4, VL 6 and VL 8 were introduced last year. www.canadianmetalworking.com

15-06-05 2:41 PM

AMT.indd 1

15-06-05 3:33 PM

The VL 2 vertical pickup lathe from EMAG

“Every VL machine features an integrated O-automation for transporting workpieces on its left-hand side (conveyor options are available in the VL flexible modular design to meet the needs of each customer). Combined with self-loading pick-up spindles, this ensures short cycle times and high productivity…multiple parts [can be loaded automatically or by an operator] onto the O-loop conveyor for machining,” says Moore. The VL series represents “a different way of thinking because it’s not a standard horizontal lathe…this is a vertical pick-up machine which can be easily integrated without need of external automation such as a robot…the machine is based around a cast Mineralit polymer [concrete] body…this gives us thermal stability as well as vibration dampening—six to eight times more vibration dampening characteristics than a standard, traditional cast-iron [body],” he continues. Moore also praises the VL lathe’s high productivity rates. “Right now, when up against standard cast iron horizontal machines, we’re typically 30 to 40 per cent faster in our feed rate.” Maintenance and servicing areas on the VL series lathes are easily accessible from the rear, and the machines can run in lights-out fashion. Compact design means VL series lathes can be bunched together and linked for mass production in a relatively small space. “We can integrate operations…you can join machines together…[the VL series is] very easily integrated into a manufacturing line,” says Moore. www.emag.com

OKUMA

Okuma’s LU45II horizontal lathe

40 | JUNE 2015

05CMW-MassProduction.indd 40

Okuma has enjoyed a decades-long association with automotive manufacturers. The company states that automotive manufacturers have used its machine tools for over 40 years to “produce a wide variety of parts from diemolds to drive trains, pistons, camshafts, turbo chargers and aluminum wheels.” Okuma machines are prized for being maxiproductive and offer maxi mum uptime on high-volume runs. The company’s LU series of horizontal lathes are particularly attractive to auto manufacturers, states Okuma. The company’s LU35II and LU45II CNC turn-

ing centers both have 22 tool stations, two independent saddles, four power ranges, large hardened box guide ways, a live quill tailstock and THINC-OSP CNC control system. Both turning centers also feature an optional M (milling) function that offers mill/drill operations in the upper turret. In addition , Okuma offers vertical lathes, double column machining centers and grinders for use in automotive manufacturing. “Okuma [machine tools] also employ an Intelligent Technology called Thermo-Friendly Concept, which automatically compensates for ambient temperature and heat generated during machining so that high accuracy can be achieved without interventions from the CNC machine tool operator. The result is increased accuracy, decreased costs and maximized profitability,” explains Okuma. www.okuma.com/americas

DMG MORI SEIKI The i 50 high-speed horizontal machining center from DMG Mori Seiki was put together with the mass production machining of very specific vehicle parts in mind. “This is a special machine. It’s mainly designed [to make] cyl-inder heads for automotive. It’s not like a general purpose machine for automotive,” states Siroos Askari, engineering man-ager for Mori Seiki products at DMG Mori The i 50 high speed Seiki Ellison Canada, horizontal machining Mississauga, ON. center from DMG With the addition Mori Seiki of the i 50, DMG Mori Seiki “now offers a full lineup of models designed for machining the five major automotive engine components called 5C,” says the company. The 5C’s are cylinder heads, cylinder blocks, cam shafts, crank shafts and connecting rods. “[The i 50] can be used for other things [besides cylinder heads] but it cannot replace a standard horizontal machining center,” adds Askari. The i 50 has a compact body (the machine is 1,680 mm wide) which means manufacturers can link a clutch of these HMCs together www.canadianmetalworking.com

15-06-05 2:41 PM

GUARANTEED CYCLE TIMES AND CPKS. LOWER COST PER PART. MAKINO ENGINEERING SERVICES DELIVER WHAT MATTERS MOST.

When it comes to meeting deadlines and hitting specs, Makino Engineering Services deliver solutions that guarantee cycle times, production and throughput rates. With almost 1,000 completed turnkeys for companies like yours, utilizing Makino Engineering Services could be the most important decision you make for the parts that matter. See what makes Makino expertise an integral part of every successful job. MAKINO.COM/ENGINEERING-SERVICES

WHEN YOU MAKE WHAT MATTERS

Makino.indd 1 Makino_MWM_EngineeringServices_CanMetalworking_June.indd 1

15-06-05 3:32 PM 5/12/15 11:15 AM

in a small space for mass producing parts. High speed machining is possible thanks to a spindle that moves on the X, Y, Z axes and lightweight moving parts on the Z-axis. The HMC can achieve a speedy rapid traverse rate of 62 m/min on all axes and a maximum acceleration of 0.7 G on the X and Y axes. A top acceleration of 1.0 G can be attained on the Z-axis, on which a drilling or tapping cycle is repeatedly performed. www.dmgmori.com

HYDROMAT

ICON6-150 Machining Center from Hydromat

HBA-110T-R2 CNC Table Type Horizontal Boring & Milling Machine

ICON Technologies, a division of St. Louis, Missouri-based Hydromat, unveiled the ICON 6-150 mill/turn machining center at IMTS 2014. Among other features, the 6-150 has a six position table and four machining modules, each equipped with a cartridge style motor spindle. High torque spindles are available in 10,000 rpm, 20,000 rpm, 42,000 rpm and 60,000 rpm. Spindles

HBA-110T-R3 CNC Rotary Table Type Horizontal Boring & Milling Machine

HBA-135P-R5 CNC Planer Type with Rotary Horizontal Boring & Milling Machine

Nomura is the oldest Boring Mill manufacturer in Japan and their CNC Horizontal Boring & Milling machines are skillfully designed and superbly crafted to provide decades of accurate and trouble-free operation. Features like a consistently straight nitride-hardened spindle and rigid construction are your assurance of virtually error-free machining of costly materials for many years to come. To learn more about how you can get lasting precision from Nomura, give us a call.

1-589 Middlefield Rd, Toronto ON M1V 4Y6 in Phone: 416-291-9499 Fax: 416-291-4990 Machinesow Stock N Email: peter@compumachine.ca Web: www.compumachine.ca

42 | JUNE 2015

05CMW-MassProduction.indd 42

are air purged, liquid cooled and permanently grease-lubricated, making them maintenance free, says Hydromat. The 6-150 can be fitted with a fifth axis machining unit that boasts a high-speed, integrated, direct-drive motor spindle. Equipped with the optional fifth axis, the 6-150 is “perfect for medical applications and the production of aerospace, hydraulic, automotive and other precision machined parts,” states Hydromat. Multi-station transfer technology means simultaneous machining on all four stations is possible, which makes the 6-150 a good choice for medium to high production of complex work pieces requiring multiple operations and intricate cuts. www.hydromat.com

MAZAK

Mazak showed off its auto-part making prowess at the 2014 SEMA automotive specialty products trade show in Las Vegas last November. During the show, Mazak used the Vertical Center Universal (VCU) 400A 5X, Vertical Center Universal (VCU) 500A and Quick Turn Smart (QTS) 200M machines to cut automotive parts for the benefit of conference goers. The VCU 400A 5X machining center has a five-axis rotary/tilt trunnion table with durable, high-speed roller gear cam technology and can mass produce small complex parts up to 15.74 inches in diameter and 12 inches high. The VCU 500A has a three-axis table and can process basic part geometries up to 19.68 inches wide by 19.68 inches deep by 12 inches tall. As with the VCU 400 series, the VCU 500A’s standard The Quick Turn 10,000 rpm CAT 40 spindle is Smart 200M turning also available in versions that center from Mazak can hit 12,000 and 20,000 rpm. The QTS 200M turning center offers high performance for small to medium-sized parts. As an “M” configuraconfigura tion, the machine adds milling, drilling and tapping abilities to its turning capability. This gives the machine multi-tasking abilities for even shorter part processing times. The QTM 200M has a 25 hp spindle capable of 6,000 rpm. www.mazakusa.com www.canadianmetalworking.com

15-06-08 11:46 AM

OkumaJune2015_CANADIAN_METALWORKING.pdf

Okuma.indd 1

5/15/15

3:33 PM

15-06-05 3:34 PM

TIME IS MONEY Workholding solutions for increased machine uptime BY LINDSAY LUMINOSO

he manufacturing industry has changed drastically over the past several decades. The golden age of automotive manufacturing saw large production runs of tens of thousands of the same part. However, today manufacturers are moving towards short-run production with a large variety of parts to be machined. The days when you could just turn on a machine and let it run is no longer the standard. With small batches and just-in-time production, machine shops are saddled with more machine downtime due to multiple

44 | JUNE 2015

05CMW-Workholding.indd 44

changeovers. The ever-increasing challenge is to find production efficiencies, because time is money and money is made when the machine is running. One way to do this is through adopting new workholding solutions to decrease downtime between jobs.

WORKHOLDING SELECTION There are many different types of workholding solutions ranging from the simplest device to highly customizable pieces. Clamps, chucks, fixtures, jigs and vices all ensure that components are affixed in place in order to machine accurately and efficiently. Regardless of the different approaches to workholding, one constant is the trend towards decreasing machine downtime in order to maximize productivity. www.canadianmetalworking.com

15-06-05 3:03 PM

“Standard workholding may be as simple as a vise for a milling machine, a chuck for a lathe or a gripper for a robot,” says Matthew Mayer, CEO of RÖHM Products of America, Inc. “We can offer a customized workholding solution that will enhance a machine’s ability to eliminate operations, provide a more efficient manufacturing process or reduce setup times between operations.” For the most part, manufacturers focus on finding the right machine and proper cutting tools for a job. What they often overlook is choosing the proper workholding solutions. Some shops can be successful with standard workholding; however, exploring workholding options and solutions is a great way to ensure the best production practices. “Manufacturers today are starting to realize that the next area of cost savings is in quick-change fixturing,” says Mark Kubik, product manager at Jergens Inc. “They’ve bought all the best cutting tools, maximized the high-speed spindles to cut the part as fast as possible, the way to get more uptime is to get quick change fixturing, or you’re are going to have to buy new machinery. “[By incorporating improved workholding], it takes a machine and maximizes it to its highest efficiency levels.” Workholding requirements differ due to a wide range of factors including material being machined, tolerance requirements, shape and size of workpieces, production run size, frequency of changeovers, and financial investment. Mass production machining offers a different set of requirements and challenges than a smaller job shop that takes on shorter runs. Maintaining a high level of efficiency, though, is something that all shops should strive for. This is where quickchange workholding can be a great solution. “The more changeovers, the more a quickchange system becomes user-friendly,” Kubik explains.

QUICK-CHANGE SOLUTIONS Although there are obvious implications for quick-change systems in smaller shops, larger companies can also use them to increase their productivity. “There is definitely a trend towards more quick change options for the customers that are operating these systems like Magna and larger companies that are looking for solutions to reduce downtime and changeover,” says Mark Watson, Canadian national sales manager for Halder Inc. The truth is no one, large or small, wants www.canadianmetalworking.com

05CMW-Workholding.indd 45

to pay for changeovers. It’s the one area of business where manufacturers are not compensated. “Customers are really only compensated when the machine is running,” explains Dean Winkel, Canadian regional sales manager for Hainbuch America Corp. “So the faster they can get from one job to the next, they’re ultimately more profitable. So whatever device that can help them to do that, that saves time, or can be configured while the machine is running, helps them to absorb the cost a lot more easily…The more the machine runs, the more money you make.” Because there is such a wide variety of workholding solutions, depending on the application, there is an equally wide range of quickchange options. It is important to choose a system that is suited to the machine’s capabilities as well as the type of work you are doing. Quick-change systems do tend to have a higher initial investment than traditional fixturing systems. “I’ve been selling these products for over 20 years,” says Sidney Roth, president at Samchully Workholding. “I remember reading a prediction in the mid1990s saying that in the next 5 to 10 years, 90 per cent of lathes will be equipped with quick jaw change chucks.” It never really happened though, and Roth believes this is because customers are not willing to spend the initial up front cost. Where you find the savings is in set up time. Roth breaks it down like this: if you figure a job shop will change over two times per day at 45 minutes each time, and there is a $75 overhead rate, you’ve got $112 per day in downtime. If there are 220 workdays in a year, it works out to a pretty healthy number, around $25,000. The cost savings per year minus the initial cost of the chuck still yields profit, and when you factor in that a chuck can last up to 10 years, it clearly demonstrates the cost benefits of using quick-change systems. Opting for a standard system because it JUNE 2015 | 45

15-06-05 3:03 PM

Samchully The Quick-Jaw-Change (QJC) power chuck is the tool for large and small batch production. The QJC chuck allows the machine operator to change the chuck jaws in 1 minute while retaining very high accuracy, conditions not possible when using a standard chuck. Samchully has increased its range of QJC chucks to include the 20” (500 mm) size. The QJC sizes from Samchully now include the 6”, 8”, 10”, 12”, 15” and 20” sizes. Samchully QJC chucks are available with standard soft and hard jaws, as well as soft and hard monoblock jaws. All Samchully QJC jaws fit other manufacturers QJC chucks. www.samchully.com

Hainbuch Today, Tonight, Tomorrow illustrates HAINBUCH’s commitment and focus to helping solve immediate and long-term productivity challenges. Original SPANNTOP chuck system not only mastered the 10-second collet change, but also allows you to go from O.D., to I.D., to 3-jaw clamping in a matter of seconds without readjustment. “Today” features a power chuck SPANNTOP nova. “Tonight” features the Mandrel MANDO. “Tomorrow” features the jaw module. www.hainbuch.com

Jergens Jergens ZPS mounting systems consists of three styles—pneumatic, hydraulic and the new manual version. ZPS combines the steps of fix, position and clamp into a single operation, cutting set-up time by up to 90 per cent. The range of positive locking, locating modules allow operators to quickly change out large and small machine fixtures with minimal effort and extreme accuracy, with repeatability. www.jergensinc.com

Single Source Technologies (SST) FCS Modular Clamping System provides unrestricted access to five surfaces of the workpiece and enables operators to spend less time on setups and more time on machining. Permanent reference points enable easy removal and reassembly of the workpiece on the pallet to keep the zero reference point locked in. The original mounting holes enable quick re-clamping. www.singlesourcetech.com Continues on page 48  46 | JUNE 2015

05CMW-Workholding.indd 46

is the cheap option can end up costing way more in the long run. “[Customers] are really hurting themselves,” he explains. Almost all experts purport that although these systems have a higher upfront cost, they pay off quickly. “Once you’ve made your initial investment, the addition of more quick change plates is much less,” says Kubik. “We’ve done case studies where the customers have paid for their systems in less than a month. Mostly we see it being paid for in less than six months.”

CHANGING PRODUCTION ENVIRONMENT Traditionally, workholding has had a grip on the way work is scheduled in a shop. The use of quick-change workholding solutions has allowed for a shift in production mentality. It allows orders to dictate what work is on the machine instead of the workholding dictating what order is the next to be processed. Winkel explains that many shops operate on this premise: we’ve got this workholding on the machine, we don’t want to waste any time taking it apart, let’s do all of these jobs because we can use this chuck. And then we will do these other jobs that require a changeover. “Unfortunately this limits the ability to take the rush jobs because you don’t want to take the workholding apart,” he says. Quick change options allow for manufacturers to choose the next job in terms of their customers’ needs or by priority. They can quickly change the workholding in minutes and start a job with little downtime. In today’s manufacturing environment, there are more and more unique machining capabilities and customer requirements. “We are seeing more complex workpieces that require more complex manufacturing processes. When you can combine operations and reduce the number of clampings, you can increase accuracy and reduce scrap,” says Mayer. So not only do quick-change options reduce time, but they can also save money by decreasing the amount of scrap, which in turn saves time from having to re-machine a piece. “As more and more manufacturers move toward just-in-time production, the flexibility to change quickly from product to product becomes essential,” says Roth. If you experience frequent workholding changeovers, whether you are working with clamps, chucks, fixtures, jigs, vices or workholding accessories, be sure to investigate quick-change options. One thing is certain, the machining efficiencies and cost savings makes this option well worth it. www.canadianmetalworking.com

15-06-08 11:54 AM

Introducing the Z-Carb High Performance Rougher. Machining titanium has never been this exciting, or this effortless.

The Z-Carb HPR features up to

productivity increase over other endmills in titanium with the SGS Exclusive Ti-NAMITE-M coating.

Call your SGS representative today to request a demo 330-686-5700

www.sgstool.com

Manufactured in the USA SGS.indd 1

15-06-05 3:35 PM

 Continued from page 46

SCHUNK

The line of Dual Force Precision Machine Vises is recommended for use in running production parts where flatness and parallelism are key. The line’s design allows the moveable jaw to deliver a half pound of downward force for every pound of horizontal force. This provides all directional alignment and prevents parts from lifting upward under heavy clamping and machining loads. www.palmgren.com

The quick jaw change system SCHUNK PRONTO is a real set-up time killer for conventional lathe chucks with screw connected chuck jaws. It lowers set-up time of a complete jaw set to 30 seconds, which is about 95 per cent faster than conventional solutions. SCHUNK PRONTO combines fine-serrated supporting jaws (1/16’’ x 90° or 1.5 mm x 60°) with special quick-change inserts, and extends the clamping diameter up to 45 mm in seconds. www.schunk.com

RÖHM

Halder

Quick-change collet chucks enables collet changes in seconds. Each collet consists of three segments separated by rubber joints. Holes in the collet align with pins on the pistol-grip changing fixture. Squeezing the trigger on the fixture with one hand compresses the joints and enables the collet to fit quickly and easily into the collet chuck to drastically reduce setup times. www.roehm.biz

The positioning clamping pin allows fast clamping, fastening, adjusting, and changing of workpieces, plates, fixture systems. Tightening the clamping screws, the pin is centered and clamped with four balls in the locating bush. The pins have high repeatability of ±0,03 mm and offer simple installing/uninstalling. www.halder.com

Palmgren

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

SST_FCS_Clamping_CanMetalworking_June.indd 1

48 | JUNE 2015

05CMW-Workholding.indd 48

5/15/15 9:04 AM

www.canadianmetalworking.com

15-06-05 3:03 PM

Emuge To guarantee the highly precise manufacture of brake discs, Emuge developed a modular quick-change system for internal and external clamping. For high productivity within a size range, only the clamping element and the workpiece end stop need exchanging. When changing from internal to external clamping, the complete clamping head is exchanged over a quick-change mechanism without releasing the draw bar connection in the spindle. Emuge’s System SG or System SZ can be used in the design of the brake disc clamping system. www.emuge.com

Carr Lane Mfg. The CL5 quick-change, 5-axis workholding system consists of three components: a subplate, a riser, and top tooling made up of a vise or a fixture plate. The subplate transforms a T-slot table into a modular fixturing plate, allowing flexible and easy clamping and locating of other tooling/fixtures. Every plate has built-in clamping and locating for risers, allowing quick and accurate set-ups. The Quinus quick-change riser allows 5-side part access. www.carrlane.com

Kurt Workholding The PinLock is a system for precisely locating, attaching and removing fixtures, subplates and vises on machining centers. It reduces part changeover time, reduces cycle time, eliminates previous load/unload time, and increases overall product throughput. The PinLock system consists of high precision pins, bushings and liners that provide locating and locking repeatability up to ±.0005 inch. www.kurtworkholding.com

Are you limiting your workholding options 10-second collet changeovers?

BIG Kaiser Workholding and automation are combined with the addition of Unilock’s new ESA 120/70 automation chuck. Unilock is known for reducing setup and changeover costs, but the standard knob program was limited when it came to automation. The new automation chuck series changes that by allowing for an intelligent interface and communication back to the controller using the standard Unilock knobs www.bigkaiser.com www.canadianmetalworking.com

05CMW-Workholding.indd 49

That’s So Last Century Today, Tonight, Tomorrow illustrates HAINBUCH’s business philosophy, a commitment and focus to helping our customers solve their immediate and long-term productivity challenges. Our original SPANNTOP chuck system not only mastered the 10-second collet change, but also allows you to go from O.D., to I.D., to 3-jaw clamping in a matter of seconds without readjustment. Reliable, flexible innovation from HAINBUCH, the world leader in quality workholding.

1.800.281.5734 Germantown, WI USA www.hainbuchamerica.com

JUNE 2015 | 49

15-06-05 3:03 PM

Tips on maximizing cutting tool life BY NATE HENDLEY

e posed an open-ended question to cutting tool experts: what’s the best way to maximize tool life? Answers we received ranged from highly technical discourses about cutting edges and angles to simple common sense (don’t push your tool past its suggested parameters). One query that elicited widespread agreement centered on the factors that diminish tool life. “Heat has the greatest impact on tool life and the speed at which we run has the biggest effect on heat,” says Brian MacNeil, milling products and application specialist, Sandvik Canada Inc. in Mississauga, Ontario. “Heat is generated four ways. Listed in the order of impact on tool life: (Vc) speed, (Ae) arc of engagement, (Fz) feed, (Ap) depth of cut.” “When we speak about wear, it can’t be avoided. The best wear is slow controlled flank wear. How quickly that wear comes to us is impacted by the type of grade we choose based on material, interruption caused by material conditions and component features in the cutting zone,” MacNeil continues. There was also general agreement that milling is the application that contributes the most to tool wear. “Milling is very demanding on cutting tools. It is always a cyclical and intermittent pro50 | JUNE 2015

05CMW-ToolLife.indd 50

cess. Turning and drilling can experience this but it is not always a constant,” says MacNeil. “I would agree that milling applications have to contend with many machining variables and cutting scenarios that negatively affect tool life, more so than most machine practices,” adds William Fiorenza, product manager die and mould at Ingersoll Cutting Tools, in Rockford, Illinois. In previous stories, it has been suggested that reducing contact time with the work piece is an excellent way to maximize tool life. Taken to a logical extreme, avoiding all contact with the workpiece was touted as the best—if not exactly the most practical—way to enhance tool life. Joking aside, some reasonable suggestions were offered up regarding workpiece contact. “The more cutting edges you can have in a particular application, the faster you’re able to run and faster the penetration rate. You minimize the amount of contact you have with the piece you’re cutting. Lower contact time means less tool wear,” notes Mark Blosser, solutions director at Komet of America, Schaumburg, Illinois. “It’s a balance…how many cutting edges you can put into a particular application based upon the material and what the piece looks like…always maximizing the number of cutting edges in a particular application always gives you less contact time with the part which increases your tool life.” www.canadianmetalworking.com

15-06-05 2:52 PM

tool life but getting closer to the center (either In addition to the benefits of multiple side) when coupled with good tool-path is a edges, tool design and insert shape are also great technique,” says Fiorenza. up for discussion. Experts were asked to identify the biggest “One of the things that customers are lookkiller of tool life in mass-production settings. ing for is the maximum number of usable “There’s so many factors that come into cutting edges per insert. And then they can play there. If the right speeds and feeds are calculate the cost per cutting edge. If you selected and the right geometry has been have three cutting edges versus six or 12 or selected, it comes down to poor tool path 18 or whatever it is, the customer feels he’s management or not addressing spindle rungetting the benefit. But now when you want out, quality of spindle or quality of the holdmore cutting edges on the insert, you also ers,” says Brian Hamil, product engineering have some additional compromises…with cutting tools it’s always a trade-off,” says Pat Nehls, product manager, Walter USA, Waukesha, Wisconsin. “We have a lot of face mills that only have two cutting edges, and then there are some with three or four. When you want to have a face mill with 14 cutting edges or even more, depth of cut becomes reduced, so that starts to have an effect in the application range,” adds Nehls. Grades “The design and chip former of the insert plays a large role in determinChipbreakers ing the proper machining parameters to use to achieve the maximum performance and tool life,” notes CA510 Thomas Hagan, milling product CA515 manager, Iscar Tools Inc., Oakville, P05 CA525 Ontario. “The only reason for double P15 CA530 sided inserts is to reduce the cost P25 per edge to the customer.” Conventional P35 The impact of cutting angle and Coated Carbide depth of cut was analyzed with a Stability view towards maximizing tool life. “The more depth of cut you got, the In comparison tests, KYOCERA’S more heat you’re going to generate… new CA5-Series steel turning inserts [but] if you reduce your depth of cuts combined with the PP, PQ, and it means you’ve got to take more PG smart chipbreaker lineup have passes. If you take more passes, that consistently outperformed adds more machine time … the manuthe competition. facturing process and cycle time has Don’t take our word for it…try it more impact than the cutting tools for yourself! Contact your local will ever have in regards to your total KYOCERA Sales Engineer or visit CPU [Cost Per Unit],” says Blosser. KyoceraPrecisionTools.com/CA5 “So you’re always better taking as to request a FREE SAMPLE. much material as quickly as you can versus taking lesser cuts to maximize your tool life because at the end NEW of the day, time is the biggest compoSPECIAL OFFER nent of cost,” he adds. BUY 20 INSERTS, GET 10 FREE More Information at KyoceraPrecisionTools.com/promo-pack “Minimizing the radial engagements and in some cases the axial depths of cut can be very effective 800.823.7284 ways to increase tool life…center-line cuttingtools@kyocera.com cutting with a milling tool (excluding www.kyoceraprecisiontools.com ball noses) is not wise and degrades

NEW INNOVATIONS in Steel Turning

CA5 Series

Wear Resistance

P Series

www.canadianmetalworking.com

05CMW-ToolLife.indd 51

JUNE 2015 | 51

15-06-05 2:52 PM

manager, SGS Tool Company, headquartered in Munroe Falls, Ohio. “[Maybe they’ve been] using same holder for 20 years. Holders do wear out and that has a big influence on the tool life,” he says. Speaking of tool holders, Hagan advises customers “to try to use the shortest holder possible. This will provide more rigidity in the setup and reduce any vibration that could cause premature tool life in the insert. Another suggestion is not to a use a cutter that is bigger than your spindle can handle.” Sometimes, very small, seemingly obvious, things can have a big impact on tool life, such as proper care and handling of tools and inserts. “When indexing inserts or placing inserts, always make sure the pockets are free from debris. Pay close attention to the insert screws. We recommend changing them often, especially if the application is really severe. Just making sure the insert is [secured] properly in the pocket, helps gain [tool] life,” advises Nehls. These cutting tool experts also shared some personal, shop-floor observations: “In my experience in the field, I often discover that when people run into problems they tend to SMALL THINGS CAN HAVE A BIG IMPACT reduce the feed rate. This can have a detON TOOL LIFE, SUCH AS PROPER CARE AND HANDLING OF TOOLS AND INSERTS. rimental effect on the chip thickness (hex)… reducing the feed too far can reduce the chip thickness below what the geometry is designed for and you essentially start rubbing more than cutting. This creates heat in the process that gets absorbed by the tool and the workpiece instead of the chip where you want it,” says MacNeil. It was also observed that some job shops, faced with short runs and a wide variety of different projects, deliberately sacrifice tool life for ease of use and lower inventory costs. “We have a customer right near our office, they use one grade. They cut hard P20 steel all the way down to 4140 using one grade. They know they could be more productive in some ways by going to a different grade and harder materials but they choose to compromise the increased cutting data. They like the security of the grade. Many times I’ve said to him, “We could probably get a 30 per cent [increase] in your tool life and productivity if we change grades, and they said, ‘No, we’re quite happy. It runs securely and we have one grade in the shop, that’s it’,” says MacNeil. 52 | JUNE 2015

05CMW-ToolLife.indd 52

When asked about the impact of high-pressure coolant, it was clear that increasing tool life wasn’t the primary benefit of this feature. “High pressure coolant in general milling materials is mainly used to clear the chips away so there will be no recutting of the chips…the high pressure is ideal for high temp alloys to help keep the material cool [to prevent] work hardening. High pressure also plays a role in machining of aluminum as the material has a tendency to stick to the insert and the high pressure is able to keep the edge free of the material,” notes Hagan from Iscar. In terms of future technology, it was asked how cryogenic machining impacts tool life. “[Cryogenic machining] is in its infancy in development. I know a couple studies in Europe [involving] recirculation of liquid nitrogen through tool holders…is it ready for mass production yet? No, but it’s something they’re looking at. To increase tool life, you have to get the heat out of the process. [Cryogenic machining is] one of the things they’re looking at to do that,” says Blosser. Other tips on enhancing tool life include technical pointers: “Reducing the length of your chip is another factor with regards to increasing your tool life, because the heat being generated stays in the chip. The longer the chip is, the more time it’s sitting on the face of the insert. So if you can control the chip to make the cross section of the chip smaller, you reduce the amount of heat being generated in the cutting aspects,” says Blosser. “Efficient, well planned tool-path plays a large role in maximizing tool life. Programing techniques that address tool pressure through management of cutting forces and techniques that promote constant chip load will increase tool life significantly,” adds Fiorenza. And just simple common sense: “Find the sweet spot for a particular [tool]. If you take titanium, you’re going to be using starting parameters of 170–190 sfm. We know we can run faster on that—depending on the cut we can run 225–250—but if you’re cutting [at that speed] all the time, you’re going to give up some tool life. For optimal tool life, maybe 140 sfm is the right number for you,” says Hamil. This might seem sluggish, but by optimizing tool life, machinists don’t have to constantly replace cutting tools that have been pushed beyond their limits. Nate Hendley is a regular contributor to Canadian Metalworking. www.canadianmetalworking.com

15-06-05 2:52 PM

ISCAR's High Productivity Machining Solutions for the Railway Industry

Round inserts and holders with screw and top lever robust clamping for new wheel production

High feed turning for wheels re-turning

Switcher/separator â&#x20AC;&#x153;Iâ&#x20AC;? profile shoulder milling

The most productive and profitable solution for the hole making industry

Machining Intelligently

ISCAR HIGH GH Q LINES Iscar2.indd 1

Tangential indexable slotting cutters for high productivity

www.iscar.ca 15-06-05 3:35 PM

BUSINESS PROFILE: MACHINING

ROTOMASTER, SURREY, B.C. Turbocharger manufacturer is revving up its business BY DOUG PICKLYK

otomaster, a manufacturing company located in Surrey, B.C., Nick Augustine, plant provides aftermarket manager (left) and Lester Lee, director of global turbocharger products to manufacturing at the automotive industry. Rotomaster headquarters in Turbochargers harness Surrey, B.C. otherwise wasted exhaust pressure to force air into a combustion engine to increase power and improve efficiency. Rotomaster specializes in the CNC machining and assembly of heavy-duty diesel turbochargers. The Rotomaster brand name has been around since the late 1970’s however the brand was acquired by the B.C.based turbocharger rebuilder ADP Distributors in 2002. After the acquisition Rotomaster was rapidly rebuilt from the ground up. Castings were sourced from overseas and a single CNC lathe and mill were purchased to begin the local manufacturing operation. Rotomaster has since grown from three employees to over 80 running three shifts. The business now includes product design, manufacturing, assembly and testing of turbocharger products. “We primarily manufacture heavy-duty diesel engine turbochargers” explains Nick Augustine, plant manager, who joined the company in 2010 when the shop already 54 | JUNE 2015

05CMW-Rotomaster.indd 54

had six lathes and three mills. Now operating 14 lathes and six mills, the company continues to grow at a rapid pace expanding into high-volume, small displacement turbochargers. “Many of our turbochargers provide a direct replacement for generators, semi-trucks and buses. We also manufacture high-performance automotive and aerospace products” While the focus of the B.C. headquarters is on commercial and industrial engine products, Rotomaster is also heavily involved with two joint-ventures overseas where

Assembled Rotomaster turbochargers.

www.canadianmetalworking.com

15-06-05 2:46 PM

BUSINESS PROFILE: MACHINING they manufacture high-volume turbochargers for small displacement vehicles for the European market, which accounts for nearly 50 per cent of its business. From the first day of operations, Rotomaster has been focused on low-volume production runs with high changeover frequencies (often less than 100 pieces in each run). This focus gives Rotomaster a unique advantage over the competition. “We are able to provide rapid product development with low- to medium-volume production often with a few weeks. Anything under 10,000 pieces, that’s what we’re good at,” says Lester Lee, director of global manufacturing with Rotomaster. As part of the business development over the last few years, Rotomaster has invested heavily in quality control and testing including the construction of a unique hot-gas turbocharger test stand. Running trials from behind bullet-proof glass, the operators are able to execute several different tests including efficiency, endurance, cycle, and burst testing. “The testing facility has proven to be an invaluable addition to our company particularly in areas such as product development, quality control, and overall consistency,” says Lee, noting that several companies, including OEMs, have used their testing facility and technicians for contract testing services of their products. “We can even burst test a turbo if need be to see how fast it can spin!” The testing facility required a significant investment from the com-

pany however it has easily paid itself off over the years. Lee estimates a total investment in the neighborhood of half-a-million dollars. Between their own work and external testing the test stand is in constant demand. Most of the parts produced in the CNC department are machined from castings (cast iron or aluminum). “We are also starting to produce cast titanium, Inconel, and stainless steel components,” says Augustine. Most operations are performed by multi-axis CNC machines, allowing for multiple operations with one set-up. A toolmaker by trade,

Turbine wheels prepped for testing.

www.canadianmetalworking.com

05CMW-Rotomaster.indd 55

JUNE 2015 | 55

15-06-05 2:46 PM

BUSINESS PROFILE: MACHINING coolant is not sticky and our machine Augustine and a colleague spent operators are happy with the change,” years designing and developing innonotes Lee, adding that the health and vative jigs fixtures for common comsafety rating is another improvement ponents. These developments provide over their prior coolant. rapid changeovers while maintaining Rotomaster was also tasked with the rigidity required to utilize high achieving a particular customer spec production tool paths with accelerwhen it began machining titanium ated feed rates. A collection of turbine wheels prior to assembly. compressor wheels last fall. Once “We are constantly in a state of again Bonakdarpour helped along the changeover, so any time we can save a way, bringing in new cutting tools, minute, we will,” says Lee. “Our lathes different grades of carbide, and working through the outnumber the mills, so we often make up for that by setissues with Rotomaster to get them where we needed ting up multiple fixtures running on the same mill.” The company is always seeking ways to gain efficiencies. to be. “It’s beyond the tools themselves, but definitely the service that has made the difference for us,” says Keeping the work environment bright and clean is priorLee. Bonakdarpour admits that he feels like part of the ity one. “I’ve worked in other machine shops and they are Rotomaster team. “Every time I visit the shop I’m thinkoften dingy and dark,” says Augustine. “From experience, ing about how can I save some money in a process, or I know that you cannot retain staff in that kind of envihow can we save some cycle time?” he says. ronment. If you can provide a clean, efficient work enviA growing part of the Rotomaster business is supplying ronment, people will naturally take pride in their work.” OEMs with components, and more recently the company Augustine also encourages ongoing training and retrofitted a former warehouse to dedicate space for the development for his machine operators and frequently assembly of a complete turbocharger model for one OEM receives support from the company’s local supplier, customer. It’s a contract the company has been developing Thomas Skinner. “Our previous supplier was not providfor a while, and production began ramping up this year. ing the customer service we needed,” says Augustine. Traceability is a large issue for this customer, so a laser “Thomas Skinner, and specifically their representative etcher is being used to code each component going into Ali Bonakdarpour, does a lot of research for us. We the turbo. The entire assembly process has been simexplain our challenges and he finds a solution for us plified with fail-safe parameters built in to ensure no right away. You can’t ask for better service than that.” missed steps and accurate repeatability. “Right now we One example of this problem solving customer serare putting in a lot of time and effort to create the pervice was related to the coolant in their CNC machines. fect environment for manufacturing and assembling the Machining cast iron is messy, and it can be a challenge finished product for this OEM,” says Lee, who has been keeping the machine, parts and the operators clean. with Rotomaster since 2004. “We believe in the processes Rotomaster was experiencing a sticky residue from its being developed for this project and know our team can coolant which was compounding various issues includhelp to grow this side of the business.” ing a material buildup of metal dust and chips on the That OEM relationship is a great success for the cominterior machine surfaces and creating paint adhesion pany, but becoming an OEM supplier within the competissues for parts. itive automotive market in Canada is a challenge. “Price Bonakdarpour recommended bringing in a Blaser is always a driving factor,” says Lee. Swisslube cutting fluids representa“But with some thought and ingenutive to source a solution. After initial ity it is possible here.” testing of the new coolant Rotomaster For Augustine, he would like to see witnessed the old residues disappearsome of the current manufacturing ing from the interior surfaces of the occurring in China moved to B.C. to machines, and the residue issue on improve control over the quality and the parts was also resolved. “The new scheduling. “There are several product lines we could easily transfer over to North American manufacturing here,” he says. With its singular focus on the turbocharger market and its emphasis on continuing to increase efficiencies, Rotomaster is upping its game and gaining greater traction in the autoRotomaster’s CNC line-up includes 14 lathes and six mills. motive industry. 56 | JUNE 2015

05CMW-Rotomaster.indd 56

www.canadianmetalworking.com

15-06-05 2:46 PM

A new Coating Center in Guelph, Ontario from the global leaders in Surface Solutions

Full Service for Cutting Tools: Regrinding and PVD Coating Services PVD Coating Services for Forming Tools

OPEN HOUSE June 30th, 2015 9 a.m. to 3 p.m. R.S.V.P. June 20th. daryl.frankowski@oerlikon.com

935A Southgate Drive Guelph, Ontario N1L 0B9 T: + 1 519-829-1035 www.oerlikon.com

Oerlikon.indd 1

15-06-05 3:36 PM

PHOTO COURTESY OF PERCEPTRON

Canada’s auto manufacturers are challenged with meeting ever evolving regulations BY LINDSAY LUMINOSO

hen it comes to automotive manufacturing in Canada, OEMs and Tier companies are required to followed standards and regulations put forth by the Federal Government. However, multinational corporations like the Big Three automobile makers, Ford, General Motors, Fiat Chrysler, have to contend with standards across all countries in which they export. For this reason, automotive manufacturing regulations are being standardized between Canada and the United States. Within Canada, any vehicle manufactured and sold within the borders must comply with a set of guidelines that deals with everything from emissions requirements, child restraint system information, and side door strength to driver impact protection.

CANADIAN STANDARDS OEMs and Tier companies that manufacture within Canada have standards set out by the Federal Government and the Motor Vehicle Safety Act (MVSA). According to Transport Canada, “As a vehicle manufacturer established in Canada, you are required to ensure that your entire vehicle production meets all the applicable standards and maintain such 58 | JUNE 2015

05CMW-QualityAuto.indd 58

records.” This is recognized through the National Safety Mark (NSM), which is property of the Government of Canada, authorized by the Minister of Transportation to manufacturers of new vehicles offered for sale in Canada. Any company that manufactures vehicles within Canada, regardless of classification, is required to affix this mark to the vehicle. This mark gives manufacturers the ability to certify their vehicle production to comply with the regulations under the Motor Vehicle Safety Act. “Canadian manufacturers must therefore design, build and certify their vehicles to meet these standards in order to sell their vehicles in Canada,” explains Transport Canada.

CANADIAN-U.S. HARMONIZATION Although the NSM is only required by Canadian auto manufacturers for vehicles sold in Canada, there is a push for Canada and the U.S. to collaborate on developing jointly recognized standards. In February 2011, Prime Minister Stephen Harper and President Barack Obama announced the creation of the Canada-U.S. Regulatory Cooperation Council (RCC) to better align the two countries’ regulatory approach. This www.canadianmetalworking.com

15-06-05 2:46 PM

Council is currently working on developing joint auto manufacturing standards. As auto makers are manufacturing and exporting in a global market, the push towards developing unified standards comes as no surprise. One of the biggest challenges now is adopting vehicle inspection and gauging systems that accurately and efficiently determine if auto parts and assembled vehicles meet the requirements.

AUTO MANUFACTURING METROLOGY This push towards harmonized standards has forced some OEMs to rethink their metrology systems, opting for a unified system across all Canadian and U.S. plants. Auto manufacturers are moving away from traditional metrology options like metrology labs with coordinate measuring machines for a more in-line/near-line approach. The challenge with removing a part from the assembly line is that it “often created a bottleneck [in production],” says Scott Everling, product development manager at Hexagon Metrology. “I think [auto manufacturers] are really looking to have what we call “traceable metrology data” on the shop floor, that gives

them the ability to react to problems, solve them, and keep the process moving along.” One of the biggest trends when it comes to automotive inspection and gauging is robotic metrology on the shop floor. “The three areas that we are seeing big growth are robotic metrology, dimensional gauging (robot guidance) and gap and flush,” explains Keith Mills, the vice president of global marketing for Perceptron Inc. Each auto manufacturer will have its own unique way of inspecting parts and features in order to meet standards. One of the key factors right now “is to understand from a market standpoint where each OEM or Tier One supplier values the data versus the cycle time,” explains Everling. “There is a trade off between more information and individual data points on every feature. It’s interesting because every OEM and Tier One has a different emphasis on what point works well.” In Canada, Fiat Chrysler, Ford, General Motors, Honda, and Toyota have all set up shop. Within their facilities, they have a variety of different inspection equipment and systems in place to ensure they are able to apply the NSM. As Everling points out, each

METROLOGY SOLUTIONS

PORTABILITY. ACCURACY. SIMPLICITY. Creaform has it all!

www.canadianmetalworking.com

05CMW-QualityAuto.indd 59

Are you looking for a seamless 3D scanning experience that gets the job done—and gets it done well? Get ready for Creaform’s line-up of portable 3D scanners. Contact us today! 1 855 939-4446 | www.creaform3d.com

JUNE 2015 | 59

15-06-05 2:46 PM

individual OEM has a different interpretation of what systems work and what features they need to focus on. For example Chrysler has always like vision systems, according to Mills.

A LOOK AT CHRYSLER With the announcement of a US$ 2 billion investment in the Chrysler minivan plant in Windsor, the addition of new lines means a need for more inspection. Perceptron has 10 stations going into that plant. “A typical OEM plant has standard vision measurement systems which include: pallet, underbody and framer,” explains Tom McDonnell, Business Development Manager - Asian / Chrysler Accounts for Perceptron. “Our systems measure the pallet that holds the body. If there is pallet variation then there is body variation”, explains McDonnell. Once the pallet PHOTO COURTESY OF HEXAGON is inspected, the vehicle will go to an underbody station where there is a four robot cell to measure the vehicle underbody. Then it will go to a framer station where the Perceptron confirms the body is dimensionally built correctly. Recently many OEM’s have been adding a gap and flush station. These are located either in the body shop or in the final assembly area where a finished vehicle is checked by a Perceptron 4 robot Gap and Flush measurement system. The station measures the gaps between doors, doors to fenders and doors to roof. It checks gap and flushness to ensure they are correct dimensionally. Variations in colors of paint, chrome and plastic are do not effect measurement quality. At the Brampton facility, where they make the Charger, Challenger, and 300, Perceptron has several systems at the plant which have been there for many years.

FORD IS DOING IT DIFFERENT Ford is adopting a different approach with the “Vehicle on Wheels” system. Traditionally, most inspection systems focused on body-in-white or in-production inspection. Ford announced earlier this year that they would be producing the Edge at the Oakville Assembly Plant and invest60 | JUNE 2015

05CMW-QualityAuto.indd 60

ing over $700 million in the facility. They highlighted that one of the major transformations included robotics, more than 250 of them with a vision system that improves efficiency, precision and quality. The new “Vehicle on Wheels” vision system was put in place to “ensure the flushness of doors, hoods and lift gates through laser and optical images for a seamless fit,” says Ford. According to Mills, this system has been rolled out in every Ford manufacturing plant. “What we are now doing is Vehicle on Wheels where the complete finished vehicle comes off the assembly line and is rolling down the end of the assembly track. And we have robots on either side, measuring real-time the gap and flush of the finished car, we are tracking a moving vehicle,” he says.

GLOBAL COMPETITION In terms of systems requirements across Canada and the U.S., McDonnell asserts that the standards are the same. The push towards robotic metrology and unified standards is making it easier for companies to adopt new and efficient systems. “It’s common knowledge that in automotive [manufacturing] the turnover from model to model has shortened drastically in time. And there is a lot of pressure to get these cells up and running from new product development to the introduction phase,” says Everling. Auto manufacturers must meet requirements in order to receive the NSM, adding new gauging and inspection systems to a facility can make it much easier to bring vehicles to the mark. “The move is to make the systems more flexible, to gather more information than just a single point, which gives [auto makers] the ability to really see, from a 3D perspective, what’s going on,” explains Everling. “It gives them the ability to solve it much quicker.” The competition is fierce, not only with North American companies but European and Asian OEMs. With strict North American auto manufacturing regulations, other OEMs are taking note in order to compete. Meeting auto manufacturing standards is becoming ever more important in today’s global economy. The Canadian Government has set out strict regulations that all OEMs and auto parts manufacturers are required to achieve. Through technology advancements and listening to market needs, metrology companies are able to create systems that allow auto manufacturers to meet these standards and deliver the best vehicles possible. www.canadianmetalworking.com

15-06-05 2:46 PM

Renishaw.indd 1

15-06-05 3:37 PM

TOOL TALK

INGERSOLL’S GOLD RUSH SHINES IN CLEVELAND

Powerplay

Berthiez Bumotec Dörries Droop+Rein Heckert Scharmann SIP Starrag TTL

We know how to move BIG by using power! 66 kW

power are available if needed.

13’000 kg

is the max workpiece weight of a HEC 1600.

Worldwide service presence 300 service experts in more than 60 locations

62 | JUNE 2015

05CMW-ToolTalk.indd 62

Horizontal machining center Heckert HEC 1600 www.starrag.com

Ingersoll Cutting Tools returned to its roots in late April to celebrate the company’s 125th anniversary and show off the latest products in its diverse line-up. This year’s Ingersoll Gold Rush event, named for the company’s signature line of tools, took over the venerable Cleveland Public Auditorium in downtown Cleveland, where Jacob Harpaz, president and CEO of the IMC Group (Ingersoll’s parent company) delivered new product presentations to bus loads of employees, distributors and customers, a crowd of over 800 people. Cleveland was selected to host the event because it’s where Ingersoll Cutting Tools was founded in 1887. Now, 125 years later, the company is based in Rockford, Illinois with another division in Germany, and as part of the IMC Group has representation around the world. In his presentation, Harpaz outlined the growth of the IMC Group with sales exceeding $3 billion in 2014, eight per cent growth over the year prior. The IMC Group is 100 per cent owned by Warren Buffet’s Berkshire Hathaway and is the second largest cutting tool manufacturer in the world. The core message delivered by Harpaz throughout the day-long event was the importance of the productivity to machining shops. Productivity is gained through the ability to reduce time in setups and with higher cutting speeds being able to deliver more products in less time. “There is no time for down time,” he repeated. Harpaz dove deep into the cutting tool technology, delivering each new product release with a flourish. New product announcements were made in each category including turning, milling, and drilling. For Ingersoll, the latest Gold Rush event demonstrated not only the company’s vast selection of leading-edge cutting tools, but it also positioned the 125-year-old business as a resource for metalworking shops to rely on for technical and business process knowledge. “We wish to be a full solution to our customers,” insisted Harpaz. www.ingersollcuttingtools.com

www.canadianmetalworking.com

15-06-05 2:57 PM

MORE DURABILITY, MORE FORCE, MORE BITE. Tiger·tec® Silver turning inserts for ISO P, ISO K and ISO M materials New cutting materials and new geometries – coming together to increase performance by up to 75 %, giving you a whole new dimension to your machining. Tiger·tec® Silver turning inserts consist of a new aluminum oxide coating combined with Tiger·tec® Silver processes that enhance reliability. Together they deliver the Tiger·tec® Silver performance you have come to rely on. Tiger·tec® Silver – because process reliability deserves more bite.

www.walter-tools.com/us

Walter USA.indd 1

15-06-05 3:37 PM

TOOL TALK

PETER DETMERS TAKING OVER AS MITUTOYO CANADA’S EXECUTIVE VP Peter Detmers (pictured) will transition into the role. Detmers has been with Mitutoyo Canada since 1991 and became vice president in 2012. He has been a key contributor to the company’s past accomplishments and brings with him the expertise and knowledge for a seamless transition that will support its development going forward. www.mitutoyo.ca. When the coolant becomes a liquid tool. becomes a liquid tool. When the coolant

Mitutoyo Canada’s executive vice president, Jay Summers, an employee with the company for 27 years, has announced that he will be retiring as of June 30, 2015.

GILMAN PRECISION ANNOUNCES NEW CANADIAN REP Metalworking fluids to optimize productivty, economic efficiency and machining quality.

Our specialists support you to get the best out of your machines and tools with the Liquid Tool. Please contact us for your local distributor.

Blaser Swisslube Inc.

64 | JUNE 2015

05CMW-ToolTalk.indd 64

Goshen, New York Phone 845-294-3200

mailboxusa@blaser.com www.blaser.com

RGW Sales Canada is now the exclusive representative in Ontario and Quebec for Gilman Precision. Effective immediately, RGW Sales Canada, will be promoting Gilman Precision products and services and exploring new business opportunities. Based in Hamilton, RGW Sales represents eight different organizations throughout Canada and boasts over 30 years of industry experience. Robert Webb, president of RGW Sales Canada, stated, “RGW Sales Canada is pleased to be partnering with Gilman Precision, and to have the opportunity to promote their products in Ontario and Quebec.” www.gilmanprecision.com www.canadianmetalworking.com

15-06-05 2:58 PM

TOOL TALK

SIRCO MACHINERY AND HAAS AUTOMATION HELP FUND SKILLS ONTARIO ACTIVITIES BY NATE HENDLEY Young people thronged RIM Park in Waterloo, Ontario May 4-5 for the 26th annual Ontario Technological Skills Competition (OTSC). Things kicked off May 4 with a series of workshops and challenges for grade-school kids. May 5 was devoted to contests for high school and college students. There were competitions in everything from brick masonry, plumbing and precision machining to culinary arts and cutting hair. At the CNC machining contest, eight youthful competitors worked on two Haas VF-2 vertical machining centers and two Haas ST-20 turning centers. A Haas Mini Mill VMC was also on hand, for demonstration purposes. The machine tools were provided by the Sirco Machinery Company Limited, a Haas factory outlet based in Toronto, Montreal and Windsor. Cutting tools were provided by Sandvik Coromant and measuring equipment by Mitutoyo. Sirco president Dan Ferko described the atmosphere as “incredible.” He expressed delight at the opportunity to enlighten young people about CNC machining—an application many kids might not know much about.

Ferko also took the time to present a $50,000 cheque to help fund Skills Ontario activities. The check was gratefully accepted by Barry Harrison, competition manager of Skills Ontario.

The OTSC wrapped up May 6 with the announcement of contest winners and a closing ceremony in the Waterloo Memorial Recreation Complex.

Sirco Machinery Company Ltd. president Dan Ferko presents Barry Harrison of Skills Ontario with a $50,000 cheque.

www.canadianmetalworking.com

05CMW-ToolTalk.indd 65

JUNE 2015 | 65

15-06-05 2:58 PM

TOOL TALK

DMG MORI CHICAGO HOSTS 2015 INNOVATION DAYS The DMG Mori Chicago Innovation Days kicked off on May 19 and continued until Friday May 22 with a wide range of products and information. At the event, DMG MORI demon-

strated two North American premieres, the DMU 65 monoBLOCK 5-axis universal machining center and NRX 2000 production turning machine.

Visitors were also given a sneak peek at the LASERTEC 4300 3D additive manufacturing prototype, which was running at the show. The event also marked the return of the Wasino name, with demonstrations of the DMG MORI WASINO JJ1 two spindle lathe. DMG MORI recently acquired the Wasino brand from Amada Machine Tools. us.dmgmori.com

NRX 2000 production turning machine

CUSTOM ANGLE HEADS FOR TIGHT MANUFACTURING

Swiss Precision Finish & Rough Boring Heads

Unsurpassed quality, Right Angle Head Options: performance and value • One or Two Spindles • Slim Line Heads Torque arm is ﬁ xed on the Angle Head for higher • Offset rigidity and accuracy • Offset Narrow 3-point torque arm is available • Adjustable for processes requiring • Standard: CAT, additional rigidity HSK, SK, BT Flexible manufacturing with • Custom the BENZ Solidﬁ x ® modular quick change system

Machine close tolerance parts with high repeatability Sold and serviced in the US by Powered by the

704-529-5300 • benztooling.com/anglehead SEE MACHINING FROM A NEW ANGLE

66 | JUNE 2015

05CMW-ToolTalk.indd 66

• Fine Adjust Twin Boring Heads • ER25 & ER40 Finish Boring Heads • Micro Boring Heads - ø0.018 - 0.752 (0.3 - 19.1mm) • Large Diameter Heads up to 86”

ERI AMERICA ERICA TOOLHOLDING SOLUTIONS

www.eri-america • info@eri-america.com • 877-374-8005 www.canadianmetalworking.com

15-06-05 2:58 PM

TOOL TALK High-Speed, Compact, Dual-Axis Rotary Table The new TRT100 dual-axis rotary table from Haas Automation provides high-speed, accurate, 3+2 positioning and full 5-axis machining of small, complex parts. The unit’s compact size and light weight make the TRT100 the perfect dual-axis solution for small machining centers. Fast indexing speeds ensure short cycle times, and powerful brakes on both axes guarantee extreme accuracy. The TRT100 uses powerful brushless servomotors to provide 35 ft-lb

of spindle torque on the tilt axis and 16 ft-lb on the rotary axis, with indexing speeds of 1,000 deg/sec on both axes. The unit provides ±120 degrees of tilt and 360 degrees of rotation to position parts to almost any angle for machining. The 100 mm platter features multiple bolt patterns and a precision through-bore for versatile fixturing, and will swing parts up to 8.4” diameter. The maximum platter capacity is 15 lb for 3+2 machining, and 5 lb for 5-axis machining. www.haascnc.com

Extensive CNC machining capacity for heavy-duty cutting Okuma’s new MU-8000V vertical machining center is built for 5-axis multi-sided machining. Standard ball-screw cooling and a highly rigid left-right, mobile trunnion table support high precision and power. The low center of gravity in workpiece movement allows the machine to handle difficult materials and a range of workpieces. It’s available with a standard No. 40 or 50 spindle. Close proximity of the spindle and control panel along with easy access to the workpiece give the machine functionality. www.okuma.com

Milling inserts for smooth finishing Seco introduces two new PCD-tipped milling insert grades for use in its Turbo 10 cutters. PCD05 and PCD20 are proven grades that produce improved surface quality in finish machining, primarily in aluminum and titanium alloys. PCD05 and PCD20 milling insert grades work alone or alongside carbide inserts in the same Turbo 10 cutter body. When used with carbide inserts, the PCD insert grades serve as wiper inserts in fixed pockets. Featuring solid carbide insert bodies, the PCD05 and compaPCD20 come in the compa ny’s X010 insert size with a corner radius of 0.4 mm and wiper length of 1.08 mm. www.secotools.com

www.canadianmetalworking.com

05CMW-ToolTalk.indd 67

JUNE 2015 | 67

15-06-05 2:58 PM

TOOL TECH

TURBO-CHARGED PRODUCTIVITY BY JENS TEMPEL

urrently, lightweighting and downsizing are the dominant issues in the automotive sector. All of the German auto manufacturers, as well as manufacturers from Korea and Japan, are following this trend by developing engines with a considerably reduced cylinder capacity yet achieving the same performance of V6 or straight 6 power units today through the use of turbochargers. Since the 2014 season even Formula 1 has joined this trend. Engineers developed 1.6-litre V6 engines that provide over 800 horsepower by means of turbochargers and the aid of kinetic energy recovery systems (KERS) units which capture waste energy during braking and transform it into electrical energy. The target of downsizing is to steadily lower the consumption of the engines while keeping up performance. This results in a constantly growing demand for turbochargers. Manufacturing and machining of turbocharger components is highly complex and requires high productivity of the manufacturer and particularly process reliability. The following test case conducted in Germany shows how innovative cutting tools can provide economical and process-safe machining. For commonly used materials, e.g. heat-resistant cast steels, cutting tool manufacturers customize tool systems. Any specialty metal requires special demands from the cutting tool material and coatings. Due to the continuously unstable cost of nickel (between 2005 and 2013 the fluctuation varied between 5 to 13-Euro per kilo), producers of turbochargers attempted to develop and use mate68 | JUNE 2015

05CMW-ToolTech.indd 68

rials with low nickel elements. In order to follow this trend and react to the latest developments, three independent Iscar technology centers Fig. 1 worked on developing new cutting materials, insert geometries and coatings. The newly developed S845 SNHU 1305 Fig. 3 ANR-MM MS32 with adjustable face milling cutters (fig. 1) for example was found to achieve up to 25 per cent longer tool life compared to alternative tools. Turbine housings, rotor shafts, turbines, as well as compressor wheels, are of paramount importance in terms of focus components in turbocharger manufacture. For the complex V-band machining of turbine housings a plunge operation with tangential inserts was developed. This system is characterized by its high stability as well as its soft cutting geometry (fig. 2). It consists of an insert type fitting into any insert pocket and hence is very user-friendly. Turning proves to be the most economic machining strategy for the V-band contour as the component allows this way of machining and no collision occurs. For this machining a five-edged Penta insert was used. The star-shaped insert is available in two standard sizes, depending on the depth of the V-band groove. An advantage of the Penta system is the broad product portfolio which provides a large amount of various standard geometries, chipformers, and coatings, as well as solid carbide substrates which were especially devel-

oped for this application. For example see fig. 3, a tool designed for interpolation turning operaFig. 2 tions. This tool can be adjusted radially and axially so that narrow tolerances of the V-band contour can be realized. For the bushing bore for the butterfly valve of the turbine housing a modular drilling system with an exchangeable head Fig. 4 SUMOCHAM and the modular reaming system BAYO T-REAM were put into action. Like the SUMOCHAM system, the BAYO T-REAM system (fig. 4) provides exchangeable reaming heads. Especially for reaming high heat resistant cast steels, this reaming head was developed and achieves up to 20 per cent longer tool life compared to competitive tools. Possible due to cooling at the cutting zone. In 2013 ISCAR Germany conducted research focused on machining turbine housings, and successful tests were completed in cooperation with the cooling lubricant manufacturer Blaser Swisslube. A customized benchmark in solid carbide drilling was performed. Using tools designed for each machining operation and the optimal coolant strategy tool life increased up to 1,200 holes at the customer site and 2,000 holes at Blaserâ&#x20AC;&#x2122;s Tech Center. In face mill roughing, improvements of up to 25 per cent were possible compared to the customerâ&#x20AC;&#x2122;s previous tool life. Even face mill finishing increased by 45 per cent. Jens Tempel, business development with ISCAR Germany. www.canadianmetalworking.com

15-06-05 2:58 PM

THE ULTIMATE TURNING SOLUTIONS

GOODWAY TURNING TECHNOLOGY: FROM HIGHLY RELIABLE HIGH VOLUME SINGLE PROCESS LEAN MANUFACTURING SYSTEMS TO MULTI-TASKING SINGLE SET-UP TURN/MILL APPLICATIONS

Download the new 2015 Goodway product journal

7100 Edwards Blvd, Mississauga, ON L5S 1Z1 T 905.565.8888 TF 1.888.565.8807 3930 Griffith St., St-Laurent, QC H4T 1A7 T 514.333.0717 TF 1.888.595.5157 5290 Brendan Lane, Oldcastle, ON N0R 1L0 TF 1.888.565.8807 info@megatelcnc.com ● megatelcnc.com

Megatel.indd 1 GOODWAY.indd 1

15-06-05 3:38 PM 15-05-28 10:45 AM

CNC SOLUTIONS

IMPROVING PRODUCTIVITY WITH USER-FRIENDLY EDM BY BRIAN PFLUGER

ompanies today strive to process more work faster and attempt to do so despite the challenges of attracting qualified operators. he shortage of skilled labor brings varying experience levels to the shop floor, and ensuring that quality and productivity are maintained no matter who is running a machine is a business requirement. Historically, training a new operator to be fully proficient on an EDM machine required specialized on- or off-site instruction. For that operator to truly learn the art of EDM work, including the myriad of settings, adjustments and machine maintenance procedures, it took countless hours of on-the-job, hands-on learning to perfect his or her craft. Knowing the complicated nature of EDM work and the current labor issues facing the industry, many companies want to know how to make EDM more user-friendly.

INTUITIVE INTERFACE It all starts with the machine. Unlike the standardized FANUC control interface commonly used on milling machines, EDM interfaces are typically proprietary and can require retraining for even the most experienced operator. Without industry standardization, it is easier to look for features that operators are already familiar with using. The intuitive touch-screen tap/ drag/pinch interface found on all modern smartphones and tablets is one such example. Leveraging this design makes it possible to create something that anyone immediately feels comfortable using and exploring. By removing the typical 70 | JUNE 2015

05CMW-CNCsolutions.indd 70

Simplified interface makes operating EDM easier.

learning curve for interacting with a new interface, an operator with no prior knowledge about a particular machine, or even EDM in general, can quickly be brought up to speed. Similarly, an intuitive machine control interface that includes extensive on-board training and support makes operator transition to any new machine a non-issue, by avoiding the interruption to productivity that often accompanies off-site training. With text, audio and video training available on the machine tool, the answer to any potential question is literally at the operator’s fingertips. A new operator may immediately progress from learning how to do things on the machine to learning

Large touch screen displays are operator friendly.

how to do things with the machine. Of course, nothing replaces specialized training to achieve maximum efficiency and throughput, but having on-board tutorials provides an excellent educational resource to help maintain productivity levels.

BUILT-IN EXPERTISE Like most machining, EDM is as much of an art as it is a science. Observing an operator who truly understands the numerous adjustments and settings on a given machine is like seeing a master sculptor create something not possible without specific expertise. When lesser skilled operators run into problems, they often rely on their more experienced colleagues, or they contact the machine’s manufacturer to discuss ways of achieving the desired performance results. This is time consuming and can drastically affect throughput until the issue has been resolved. The creation of an intelligent “app” on a machine can transform a basic operator into an expert through automatic manipulation of the machine parameters based on the particular results that are being seen. The machine can analyze the issue and automatically modify cutting conditions to compensate withwww.canadianmetalworking.com

15-06-05 4:10 PM

CNC SOLUTIONS out the need for consulting in-house engineers or contacting the machine tool OEM’s technical support. This intelligent software approach empowers operators to resolve these production issues quickly and easily in real time, thus increasing overall efficiency and productivity.

EFFICIENT MAINTENANCE AND ERGONOMICS Machine maintenance can also benefit from the integration of advanced interfaces built on PC platforms. Not only can these newer EDM machines supply information on how to perform regular maintenance tasks with text, photos, audio and video, but it is also possible to intelligently track all machining hours and maintenance performed. Alerts pop up when maintenance is needed, along with direct instructions and video on how to perform the work. Also facilitating EDM maintenance is equipment that is ergonomically designed to easily accommodate physical access to the machine. Such a design helps reduce operator fatigue and errors, and it can also accelerate part changes and eliminate potential interference problems, bringing efficiency to part production. Some features of EDM machines include: • Fully retracting doors for unrestricted access to the work zone and workpiece, including the bottom side of the workpiece and the machine’s lower head. • Large doors for open access to machine maintenance items.

Wheeled wire collection bin makes for easy disposal.

www.canadianmetalworking.com

05CMW-CNCsolutions.indd 71

Wheeled wire collection bins offer easy movement and quick disposal. • Tool-less component design to reduce the time and tools needed to perform machine upkeep, such as energizer plate indexing. • Advanced hand control boxes (pendent) with digital displays and access to all functions help to set up a machine without having to go back and forth to the main control panel. • Large displays with touch screens make it easier to access information. • The ability to customize and streamline the machine control is based on preferences, shift changes or operator skill level. •

DATA REPORTING The features mentioned above may make EDM machining easier, but almost every mold maker knows that key metrics must be tracked in order to fully analyze and understand the operation. These metrics help identify additional efficiencies for throughput and profitability as well as deficiencies and bottlenecks that should be corrected. Often, in the push to get more out the door faster, many companies don’t properly track these metrics due to the level of manual involvement required to record, compile, analyze and report this data. Today’s intelligent machines can automate the entire process of tracking use, consumables, maintenance and literally every other operational parameter on the machine in order to provide insightful and actionable reporting. A shop manager can analyze operational efficiency and know exactly

Easy access allows for simplified guide cleaning.

Change Filters: Easy access for changing filters speeds productivity.

how much machine time is being used by tracking these details: • Machine filters • Deionizing resin • Wire consumption • Water reservoir level • Detailed cycle time information • Actual cycle time vs. estimated/ quoted time • Machine utilization time (machining time / setup time / idle time) This data makes it possible to know where improvements should be made and can be the difference between a shop having a good year or a great year.

EASE OF USE IS KEY TO PROFITABILITY It’s very easy to get caught up in the speeds and feeds when evaluating today’s EDM machines, but if shops can’t make the machine perform to its limit, they are missing opportunities. Truly maximizing throughput and profitability requires getting the most performance from equipment and personnel. Ease of use might just be the feature that changes an EDM cell from one that just gets the job done to one that is a true profit center. Brian Pfluger is the EDM product manager with Makino. JUNE 2015 | 71

15-06-05 2:32 PM

FABRICATING & WELDING NEWS

CWB LAUNCHES A NATIONAL TRAINING PROGRAM: ACORN Elected officials, school board delegates, educators and students joined the Canadian Welding Bureau (CWB Group) in Toronto on Tuesday, May 19 to announce the official launch of the CWB Institute’s new Acorn training resource program, a comprehensive nation-wide training system that includes generating trade awareness, providing practical skills development and educational tools for life-long learning as well as standardized assessments and new Acorn Credentials. The invited group assembled at the welding classroom at Western Technical-Commercial School, a high school in the west end of downtown Toronto. Peggy Nash, the local Member of Parliament and official opposition critic for industry, welcomed the program announcement, commenting on the country’s need for greater infrastructure building

and the desire to have more homegrown skilled tradespeople to fill those infrastructure jobs. “To all of the young people here—you’re looking forward to a bright future,” said Nash. Doug Luciani, president and CEO of the CWB Group, addressed the skilled trades gap in our country, noting the average age of skilled welders is now 60. “What we need

Western Tech instructor (left) educating Toronto City Councillor, Sarah Doucette (centre) and Member of Parliament for Parkdale-High Park, Peggy Nash.

Doug Luciani, president and CEO of the CWB Group, announcing the launch of Acorn, CWB’s new national training resource.

to do is develop the next generation of Canadian welders,” said Luciani, who noted that the program is available to high schools free of charge. The roll-out of the broad-based Acorn program includes a element to train and assess educators to be followed by the implementation of programs including a pre-employment course. The Acorn program includes a hybrid of online and in-shop lessons, with an emphasis on visual learning tools, supported by interactive 3D models and online video and augmented reality visuals. www.cwbgroup.org

GEORGE BROWN DESIGNS NEW FAB/WELDING PROGRAM WITH SUPPORT FROM JPMORGAN CHASE On May 11th George Brown College in Toronto hosted industry partners and program coordinators,

Students from the new welding and metal fabricating program along with George Brown College president Anne Sado accept grant cheque from David Rawlings, CEO JP Morgan Chase Canada (front right) and Michael Haberman (far left), managing director, northeast region, global philanthropy at JP Morgan Chase.

72 | JUNE 2015

05CMW-FabWeld.indd 72

along with a cohort of 22 students, to acknowledge a $170,000 grant from JPMorgan Chase and tour the school’s welding, metal fabricating and machining facility. This new program was designed to target marginalized and under-employed youth (19-29 years old) across the Greater Toronto Area, at no cost to the students. The 26-week journey includes eight weeks of academic upgrading, followed by 10 weeks acquiring practical skills in the welding shop and concludes with an eight-week job placement. “Our primary goal was to develop a skillset that is highly employable,” said David Rawlings, CEO JP Morgan Chase Canada, at the event. “Just look up at all of the cranes around the city,” said

Rawlings, noting how it was important to be funding a program that could add real value to the community and could also result in well-paying jobs. Speaking to the students, he noted, “We put up the money to get you started, now take advantage.” On hand to accept the cheque from Rawlings was Anne Sado, president of George Brown College. Other guests included Dan Tadic, executive director of the Canadian Welding Association, who spoke about the many opportunities and ongoing developments in the welding trade. This first cohort of students will complete their in-class training at George Brown on Friday, July 3rd and will be workplace-ready on July 6th. www.georgebrown.ca www.canadianmetalworking.com

15-06-05 2:37 PM

Lincoln.indd 1

15-06-05 3:39 PM

FABRICATING & WELDING NEWS

BEHLEN UPS PRODUCTIVITY WITH ELLIOTT ROBOTIC WELDING STRATEGY MATSUURA PARTNERS WITH ALL FABRICATION MACHINERY

BEHLEN Industries is introducing a new one-of-a kind technology. The in-house engineers have explored the benefits of robotics and advanced software in welding, removing certain limitations. Through this initiative, the company has announced its new robotic welding strategy for enhanced productivity. Every project at BEHLEN is custom, so robotic technology had only a small place in their plant for the few repetitive processes that they do, almost everything else was done manually. There are many benefits to an automated process in steel manufacturing like increased product quality & capacity, decreased errors at every level of the business & in the product itself, and increased communication with clients. BEHLEN’s strategically chosen and innovative combination of software, robotics and processes has allowed them to successfully implement the use of robotic technology for custom manufacturing. “Robotic welding is typically a high volume, low variable type of process, but at BEHLEN, we needed the opposite. Since almost all of our production is custom-designed, we needed to find 74 | JUNE 2015

05CMW-FabWeld.indd 74

a way to make our robotic welding cell be used for high variable, low volume work,” says Pat Versavel, vice president of engineering and innovation. The three step process starts with a detailing program allowing BEHLEN engineers to create a hyper-detailed and organized 3D model, including specs of each individual part of a project. That model is then fed into a second piece of software. The second phase, a robotic simulation program uses touch-sensing with the robotic arm to detect any potential errors or crashes and then produces a real time, visual simulation of the weld. This is the first time this software has been applied to welding, a process that was more than one-year in the making. Phase Three is when the robot welding arm goes to work. Using a metal-cored arc welding technique, the robot is able to make any kind of weld imaginable. The robotic arm is connected by a power source that was strategically chosen to create the fastest possible machine of its kind, to date. BEHLEN has been able to increase its plant productivity. www.behlen.ca

After recently taking on the LVD product lineup, Elliott Matsuura Canada is making great efforts to support the brand. The company is partnering with All Fabrication Machinery in Western Canada, who will provide additional sales coverage for the LVD line. All Fabrication is familiar with LVD, having represented them in the past. Elliott Matsuura Canada has also hired several new employees to support LVD. Joey Casavant joins to support LVD in the province of Quebec and is dedicated to servicing the LVD products. Steven Sorokin is responsible for servicing the LVD line in Ontario. Mathew Snow has been added for servicing the provinces of Manitoba and Saskatchewan for LVD products and the rest of the Elliott line-up of CNC machines. www.elliottmachinery.com

www.canadianmetalworking.com

15-06-05 4:11 PM

Once he reduced his energy costs by 55% after installing a VFD, savings in other parts of his business went into overdrive. Once you start seeing the benefits from our incentives for installing premium efficiency motors and VFDs, youâ&#x20AC;&#x2122;ll want to look into making other areas of your business like lighting, compressed air and pump systems more efficient too. When you do, youâ&#x20AC;&#x2122;ll be joining thousands of organizations across Ontario who are already enjoying the savings that our programs deliver. Take a look at their stories and our incentives at

saveonenergy.ca/business

Subject to additional terms and conditions found at saveonenergy.ca. Subject to change without notice. OM Official Mark adopted and used by the Independent Electricity System Operator.

IESO.indd 1 OPA_10232590_14_B2B_CDN_Mining_Jnl_VFD.indd 1

15-06-05 3:40 PM 5/12/2015 4:27:36 PM

FABRICATING & WELDING NEWS

HYPERTHERM OFFERS GRANT PROGRAM AND FREE PLASMA CUTTING CURRICULUM Hypertherm is committed to welding schools and training programs by making all 10 hours of its AWS SENSE approved curriculum available for free download to teachers. At the same time, the company is launching a new educational grant program designed to place Powermax systems in North American schools. Hypertherm’s “Plasma Cutting Technology: Theory and Practice” covers the plasma cutting process, common industrial uses, the differences between various cutting methods, safety procedures, as well as proper setup and operation.

Electronic versions of each lesson, a facilitator’s guide, student workbook, and supporting reference material are all available on the Hypertherm website. “Though we believe schools would benefit from obtaining the full Plasma Cutting Technology: Theory and Practice kit including the hands-on materials we understand the constraints many schools are facing,” explained Betsy Van Duyne, who manages Hypertherm’s educational program. “Welders are already in short supply making it critical that new welders have the tools and

training they need to enjoy a successful and rewarding career.” In addition to free curriculum downloads, Hypertherm is launching its “Spark Something Great” educational grant program. The program will award a Powermax45 plasma cutting and gouging system along with the full Plasma Cutting Technology: Theory and Practice curriculum kit to 10 schools in the United States, Canada and Mexico. Applications for 2015 are due on or before July 1 with grant decisions communicated by July 31, 2015. www.hypertherm.com

Auto-darkening helmet with high optical performance

Aluminum welding wire for use in heavy-duty applications

ESAB Welding & Cutting Products introduces the Aristo Tech HD welding helmet, its first auto-darkening helmet with an optical class of 1/1/1/1, which indiindi cates the highest optical performance possible according to the rigorous EN 379 Standard. The Aristo Tech HD features an advanced LCD lens with a 100 x 62 mm viewing area – 12 mm larger than the previous lens – for wider visibility and better spatial awareness. ESAB’s new X-TIG mode provides superior performance when TIG welding down to 5 amps. In the X-TIG mode, the helmet uses electromagnetic arc sensors that automatically react to the magnetic field of the arc. This eliminates interference from sunlight or other electrical/electronic equipment, as well as ensures that the helmet darkens when the sensors are blocked, such as when welding pipe or in awkward positions. A grind mode is activated at the lowest sensitivity, so operators don’t have to shift between the helmet and a face shield and safety glasses when grinding. The grind mode also works well for plasma and oxy-fuel cutting. The Aristo Tech HD weighs 515g and features a unique matte carbon rubberized finish. www.esab.com

Lincoln Electric introduces SuperGlaze HD. This new aluminum welding wire is used in heavy-duty applications where wire feeding can be a challenge and arc performance is critical. SuperGlaze HD delivers a steady wire feed from the payoff to the arc and eliminates wire shavings, resulting in a uniform and uninterrupted weld. In demanding welding environments, using standard aluminum wire can result in inconsistent wire feeding and poor arc characteristics, resulting in costly downtime. SuperGlaze HD ensures smooth and trouble-free wire feeding. Key features of SuperGlaze HD include the elimination of shavings from the feeding process, which results in reduced gun chatter and burnbacks. It also offers improved arc performance and finished weld quality with a nearly 20 percent improvement in feedability. SuperGlaze HD 5xxx series wire is available in standard diameters of 1/16 in. and 3/64 in. www.lincolnelectric.com

76 | JUNE 2015

05CMW-FabWeld.indd 76

www.canadianmetalworking.com

15-06-05 2:38 PM

SEPTEMBER 28 - OCTOBER 1, 2015 | THE INTERNATIONAL CENTRE | MISSISSAUGA, ON

89% HAVE RECOMMENDED CMTS TO A COLLEAGUE CONNECT WITH

TOP 3 REASONS GIVEN BY 2013 AUDIENCE FOR ATTENDING:

700+ SUPPLIERS

75%

SEE NEW PRODUCTS IN ACTION

66%

LEARN ABOUT NEW TECHNOLOGIES

46%

COMPARE TECHNOLOGIES SIDE-BY-SIDE

OF TECHNOLOGIES AND SOLUTIONS UNDER ONE ROOF DEMONSTRATING LIVE, WORKING EQUIPMENT.

ED THE RAPID CANADA CONFERENCE AT CMTS 2015.

AT IO

WHY CMTS?

UC LEARN HOW TO APPLY ADDITIVE MANUFACTURING/3D PRINTING TO GAIN COMPETITIVE ADVANTAGE IN YOUR INDUSTRY AT

BU Y

KIN

N O I T A V

3,000,000 LBS

OF MANUFACTURING EQUIPMENT IN ACTION

G IN

INN O

EXPERIENCE MORE THAN

W T E N

8,000+

MANUFACTURING PROFESSIONALS

ATTEND CMTS TO SOURCE THE LATEST IN MACHINE TOOLS, TOOLING, METALWORKING, FORMING, FABRICATING, 3D PRINTING, AUTOMATION, AND DESIGN

VISIT CMTS.CA TO REGISTER NOW! PRODUCED BY

SME-CMTS.indd 1

STRATEGIC EVENT PARTNERS

15-06-05 3:41 PM

THE

BEAUTY OF

A close up of a TIG torch melting the base element and the filler material. PHOTO COURTESY OF MILLER ELECTRIC MFG. CO.

GTAW is the pinnacle of welding BY NESTOR GULA

Proper TIG welding requires skill and patience. PHOTO COURTESY OF THE LINCOLN ELECTRIC COMPANY

78 | JUNE 2015

05CMW-TigWeld.indd 78

f you have ever welded using the TIG welding process you will know of the elegance of the technique. The process involves using a special tungsten needle to focus heat energy onto the work piece while a slender piece of filler metal is dabbed into the weld puddle. It is properly known as Gas Tungsten Arc Welding (GTAW) and colloquially as Tungsten Inert Gas (TIG). “TIG welding is accomplished through constant current power sources that maintain a relatively constant welding output (heat) that is emitted from a tungsten electrode that is contained in a TIG torch connected to the power source,” says Ivan Gracic, product manager – TIG Process Solutions from The Lincoln Electric Company. “DC TIG welding emits a majority of the current away from the tungsten towards the work piece, whereas AC TIG welding applications have the current shift directions during every one cycle of the wave, helping break away surface oxide layers on Aluminum and Magnesium base materials.” It’s a very precise process able to accurately weld tiny and thin objects as well as very large parts. “The TIG welding process is able to

produce the highest quality welds—clean and sound—and it’s also a very versatile process in terms of application because it can be used for virtually any metal and in a range of metal thicknesses, with or without a filler metal,” says Jay Ginder, Sr. application engineer/CWI, CWE at ESAB Welding & Cutting Products. “As a result, TIG welding is used in a broad scope of industries from aerospace to nuclear/power plant construction to automotive for jobs that demand a high integrity weld and/or an aesthetic surface finish that doesn’t need grinding. Aluminum and stainless steel applications are the most common for this process. Because the TIG process gives you more control over the weld, it is also ideal for welding more challenging materials such as titanium and Inconel.” The precision and quality offered by TIG welding is the main reason why a manufacturer would choose to use this process in its facility. “If the application demands the absolute highest degree of weld quality, to be proven through non-destructive evaluation, TIG is often the best choice,” notes Devan www.canadianmetalworking.com

15-06-05 2:51 PM

can be accurately manipulated. “As the operator has a greater degree of control over the weld, precision welding applications that require minimal material distortion, high cosmetic properties, and the elimination of welding spatter, rely upon TIG welding,” says Gracic. “Other processes such as MIG, or even Stick, often can require post welding clean-up and also more challenges with respect to managing heat input in comparison to TIG.” The aesthetics of a finished TIG weld are quite beautiful—as far as welds go. “There is just no mistaking the pleasing uniformity of a well-executed TIG weld,” says DePauw. “This process not only creates the appearance of high weld quality, but also can be used successfully to enhance the visual appeal of a precision part or assembly.” One can use the saying, “if it looks right—it is right” to describe TIG welding in this case. The neat appearance does signify a high quality weld. “The high surface finish that’s achieved with TIG makes it the process of choice for the auto racing industry and for architectural fabrications,” notes Ginder. “Beyond the procedures and codes that dictate using the TIG process, choosing to use this process depends largely on the material you are welding and the speed at which you’re welding.” Generally speaking, TIG is known as a handheld process, with a highly skilled operator working the torch, filler material and foot con-

UNLEASH

DePauw, welding engineer, TIG System Solutions at Miller Electric Mfg. Co. “When equipped with a modern, high-quality TIG power source, an experienced welding operator can work on nearly any weldable metal using only a single variety of tungsten electrode and pure argon as a shielding gas. All they must acquire is the appropriate filler metal.” Suppliers offer a wide variety of filler materials available to them and exotic metal alloys can be welded without too much fuss by an experienced welder by using the base metal as filler. “Another advantage to TIG welding is that it can be accomplished with or without a filler metal (this is known as autogenous welding),” says Ginder. “Autogenous welds melt one part to the other, usually used in thinner materials and for smaller-scale applications (like medical devices, electrical components). “Modern TIG welding machines also take the versatility and capability of TIG a step further, providing more control over weld parameters. Today’s inverter-based TIG machines are lighter and more portable than SCR technology, making them suitable for onsite and offsite use. If the goal is a high quality weld with no contaminant and/or if you have an application that can’t handle any extra oxygen in the weld, then the TIG process is the cleanest process.” The heat input from the welding torch is precisely controlled by the operator, usually using a foot controller that operates like the clutch on a car. Hand controls are also available. The heat and the position of the weld

The NEW Tiger X flap disc raises the bar for professionals who are driven to get the job done right – and done fast. Tiger X holds nothing back with its industry first X3 Technology that combines an advanced grain anchoring system, dual flap design and engineered backing. The result is a disc that delivers the ultimate combination of faster grinding, longer life, and greater versatility. For those who demand uncompromising performance in a disc that doesn’t quit there’s only one choice. Tiger X.

Unleash Tiger X at weilercorp.com/tigerx

The operator focuses on the weld puddle while the welding mask protects them from the spark. PHOTO COURTESY OF MILLER ELECTRIC MFG. CO.

www.canadianmetalworking.com

05CMW-TigWeld.indd 79

800.835.9999 / weilercorp.com JUNE 2015 | 79

15-06-05 2:51 PM

Strong welds on thin material make it perfect for aerospace and car racing applications. PHOTO COURTESY OF THE LINCOLN ELECTRIC COMPANY

The TIG welding operator must balance the use of the torch, filler material and foot control to create a proper weld. PHOTO COURTESY OF ESAB WELDING & CUTTING PRODUCTS

80 | JUNE 2015

05CMW-TigWeld.indd 80

trol in a welding ballet. “The GTAW process has been automated for quite some time,” says Ginder. “Automated TIG welding has received more attention of late because shops are looking for ways to increase productivity and address the shortage of skilled welders. Cold wire TIG—feeding the wire from a wire feeder—is a process that can be semi-automatic (or, handled manually). Recently, we are also seeing more hot wire TIG welding. In this process, the wire is heated before it goes into the weld. This increases productivity because of the higher burn-off rate and subsequent higher speed that can be achieved. Hot wire TIG is usually automated, and the development of automated and specialized equipment for hot wire TIG has helped give it more visibility.” The weld process can be automated using seamers and multiaxis robots. “TIG Welding can be automated, where a robotic arm manages the TIG Torch and a separate wire feeder unit deposits filler metal into the weld puddle,” says Gracic. “This results in increased throughput, while at the same time managing quality standards that are often required when TIG welding.” Manufacturers are crating power sources to adapt to

different types of TIG welding and incorporating features that will make them adaptable to automation. There is a bit of price to pay for having a welding process that is simultaneously of high quality and aesthetically pleasing. A high skill set is needed to consistently lay down proper TIG welds. “TIG has often been known to be considered one of the most challenging welding applications to manage from a skill level perspective,” says Gracic. “It is for this reason, that manufactures often have difficulty finding skilled and experienced TIG welders in industry.” Not just high skill is needed. Proper TIG welding takes time. “The manufacturer integrating TIG welding into his production facility has to know that there is a productivity trade off. The high quality weld that results from TIG welding takes more process time and this impacts the cost of manufacturing,” explains Ginder. “The TIG process is much slower than other welding processes and could even be slower than Stick welding, depending on the stick electrodes.”

A well executed TIG weld is a thing of beauty. PHOTO COURTESY OF ESAB WELDING & CUTTING PRODUCTS

TIG welding is a very specialized process and should be only used where the benefits of this type of welding are appropriate. “Successful implementation of the TIG process requires an understanding of its advantages and limitations. The ideal TIG welding operator will be knowledgeable regarding the many adjustable machine parameters that are within his or her control, especially on modern inverter equipment,” says DePauw. “Of course, a high quality TIG power source is critical, but so too is the Continues on page 82  www.canadianmetalworking.com

15-06-05 2:51 PM

CANWELDCONFERENCE 2015

REGISTER NOW FOR CANWELD 2015! • SEP 13, 2015 • ST. JOHN’S, NL. Canada’s largest welding event, this year in St. John’s, Newfoundland. Hosting some of the welding industry’s most distinguished scholars, who will present fascinating sessions on the technical and practical aspects of welding. CWC 15 will focus on Hydroelectric, Construction, Mining, Shipbuilding and Oil and Gas.

Scan here for more information on CWC 2015. Register today at cwa-acs.org/events

CanWeld Conference 2015

HELP OUR WELDING REPOSITORY

IT’S UP TO US!

The CWA Foundation is facilitating an online donation repository designed to aid the needs of both industry and welding programs in secondary schools across Canada. A repository has been created where industry can donate welding equipment and materials. Donated items will be placed on the CWA Foundation donation site where educators have the opportunity to make selections that improve the quality and delivery of secondary school welding programs. Charitable Registration Number: 83634 0539 RR0001

Scan here to see the repository cwa-foundation.org | 1.800.844.6790

CERTIFICATION QUALITY THE CWB QUALITY MARK If you are looking for a partner with integrity, knowledge and the trust of the industry then look no further than the CWB Group. The CWB Quality Mark is now available for FREE to existing CWB Clients. Scan here to sign up for the quality mark program cwbquality.org | 1.800.844.6790

CWB.indd 1

15-06-05 3:55 PM

 Continued from page 80 quality and integrity of the consumables that are used along with it. Production losses tracing back to a faulty collet or missing O-ring can be costly and frustrating. Providing the appropriate training, when necessary, is also critical.” Due to its process, TIG welding gives the welder the most control over the weld. “Inverter-based welding equipment gives the welder greater control over the process with better control over the AC arc and heat, more programmability through advanced controls, faster travel speeds,” says Ginder. “This translates to more consistent welding results, less time to weld, less weld clean up. Where this is especially impactful is in challenging aluminum welding applications because more capable TIG welding equipment makes it easier and more cost effective to weld aluminum.” The inverter based TIG welding power

sources are more prominent and are the result of higher powered semiconductors. The net result is the power sources have become smaller and quite portable because of the smaller step down transformer needed in these machines. “In the past few years, the industry has witnessed the continued advancement of inverter TIG power sources and peripheral accessories. The best of these power sources offer vast out-of-the-box feature sets, which can include independent adjustment of the AC wave and DC pulsing frequencies up to 5kHz, as well as software that is easily updated and expanded through the use of a common SD card,” said DePauw. “Advances in TIG torch design have also allowed for the manufacture of 375A watercooled torches that are only marginally larger than those rated for only 250 amps, thereby providing optimal cooling for longer, more comfortable welding and increased productivity.”

Control and performance Using inverter technology, the Heliarc delivers increased energy efficiency and functionality in a package that is lighter, smaller, and less expensive than old, less efficient SCR technology machines. Easily set up arc settings are optimized and the pulse current allows for smaller HAZ (Heat Affect Zone), better control of the weld pool, and less plate deformation. Enhanced AC balance controls

provide improved cleaning or penetration compared to conventional AC/DC power sources. Five clear, logical work zones on the control panel setallow the operator to choose the options and set tings needed for fast set up and arc control. The machine’s internal communication is entirely digital for accuracy and repeatability. www.esab.com

Customizing the TIG arc

Capable, powerful and efficient

A good choice for mission critical welds, the Aspect 375 AC/DC TIG welder, features AC Auto-Balance to simplify operations by automatically providing the optimal mix of cleaning and penetration on aluminum. The Intellistart technology provides soft starts on thin materials and hotter starts required on thicker materials. The power source allows the user to manage AC frequency, balance and offset to modify arc profile, cleaning action or penetration. The fast arc response and stability gives smooth and efficient welds, while AC Wave Shape control enables you to customize the arc for critical aluminum welding requiring a higher degree of penetration on thicker materials, increased cleaning action in breaking through heavy oxide layers, or a narrower arc profile enhancing control around corners and other tight configurations. www.lincolnelectric.com

The new Dynasty 280 TIG welder delivers more power and provides the ability to weld metal up to 3/8-inch thick. Intended for industrial manufacturing applications and heavy fabrication, it use less energy than capabilmachines of similar output capabil ities. Weighing just 52 pounds, the Dynasty 280 delivers up to 280 amps of output power and a smooth, stable arc. Pulse control can reduce heat input, increase travel speeds and improve arc techdirectional control. Auto-Line tech nology allows the machine to be hooked up to any input voltage within the specified range. The Dynasty 280 DX model includes additional adjustments for AC balance, waveforms and frequency for precise arc tailoring on aluminum welds. The Pro-Set technology eliminates guesswork by providing pre-set welding parameters. This power source is designed for air-cooled and water-cooled TIG torches. www.willerwelds.com

82 | JUNE 2015

05CMW-TigWeld.indd 82

www.canadianmetalworking.com

15-06-08 11:58 AM

CMY

EMO.indd 1

15-06-05 3:45 PM

Getting the most out of your wire cup brush BY DOUG PICKLYK

hen it comes to cleaning up large metal workpieces without fear of removing any of the base material, operators reach for a wire cup brush. The wire brush is the solution for removing rust, weld splatter, paint or even deburring. But for every application there is an optimal brush for the job. It’s important to know what tools to use and how to get the best results with the least effort. Wire cup brushes are available in two basic styles, either crimped wire for less aggressive applications (especially effective on uneven workpieces) or knotted wire for situations where more aggressive removal is necessary. Yet, within both styles there are also many variations and material considerations to take into account. Selecting of the right type of brush depends as much on the type of finish required (fine or coarse) as the material being cleaned (stainless steel, carbon steel, aluminum, etc.). All models of wire cup brushes are generally available with either carbon steel or stainless steel wire. When cleaning carbon steel, a carbon steel wire wheel is used, and if working on a stainless steel or aluminum surface then a stainless steel wire brush is

PHOTO COURTESY OF WEILER CORP.

84 | JUNE 2015

05CMW-Brushes.indd 84

required. The reason is because carbon steel can leave carbon contaminants on a stainless surface and can cause it to rust and oxidize. The issue of contaminating a workpiece because of using the wrong wire is a common concern, and most vendors are moving towards a more visible solution to help users avoid the problem. “A great advantage of the Norton brushes is, unlike a lot of brushes out there where the hubs are one colour (usually a metallic), Norton brushes are colour-coded: a red hub is a carbon steel brush and a blue hub is a stainless steel brush. So it’s really easy to identify for operators,” says Debbie Gaspich, director product management, North America, Saint-Gobain Abrasives. “Cross contamination is the second biggest complaint in wire cup brushes,” notes Gaspich. “The number one complaint is the throwing, or breakage, of wires.” Pieces of wire often break away from a cup brush due to flex, fatigue and the heat build up on the work surface. And the more pressure an operator uses the more a brush will begin to prematurely wear down. To combat this some brushes are available with a ring around the wires. “Using a wire cup brush with a ring maintains a longer wire length and provides more life,” says Stéphane Drainville, product manager, tooling and power tools, with Walter Surface Technologies. “The ring prevents the cup brush from flaring and it’s a way to reduce significant wire breakage issues under overload circumstances.” The wire deterioration is a problem for the www.canadianmetalworking.com

15-06-05 2:28 PM

IT’S TIME TO CUT THE CORD! ZIPCUTTER

The ONLY Cordless Cutter on the market The ONLY cutter able to power a 6" wheel The ONLY 5.2 Ah /18 V battery – longest lasting & most powerful The ONLY Ventilated Charging System – for faster & safer charging The ONLY rotating battery pack - 270°! The MOST CUTS per charge, guaranteed!

For more information, visit: walter.com/zipcutter or call toll free 1-888-592-5837

Walter Surface.indd 1

15-06-05 3:46 PM

PHOTO COURTESY OF WEILER CORP.

life of the products but it is also a safety issue, as the wire pieces can fly up and into the operator. “Norton has available a line of patented cup brushes with a protective guard,” notes Gaspich. “It’s a cup brush that has plastic flaps on it, and when spinning it opens up into a protective shield and hovers over the work surface. “We call it safety before, during and after work,” says Gaspich, explaining, “Before, because it’s easier to hold the brush and mount it to the grinder without pricking your fingers. During, because it creates a protective shield. And after, because it’s easier to take off of a tool because the guard protects your fingers from the sharp wires.” “The beauty of this product is that you just have to hold it up to somebody and they get it. Safety directors get it right away.” A key solution for cutting down on wire breakage is by having operators reduce the pressure they apply on the brush. “When talking about the proper use of a wire product I always go back to SPOT: speed, pressure, orientation and time. And the big one here is pressure,” says Rick Hopkins, product manager for welding and fabrication with Weiler. An operator’s natural reaction is to lean on a brush if he’s not getting a desired finish, and that leads to breakage. “What’s critical to remember on any wire brush, whether crimped or knotted, is it’s the very tips of the brush that are designed to do the work,” explains Hopkins. “It’s not a scratching or a tearing action, it’s designed to be like a peening action, like thousands of little hammers 86 | JUNE 2015

05CMW-Brushes.indd 86

hitting the surface, that’s what’s doing the cleaning. So you want to maintain as light a pressure as you can in order to do the job.” On the speed side, it’s also important to be using the proper tools when cleaning with a wire cup brush. Drainville from Walter Surface suggests using a variable speed grinder to operate a brush at the safest speed. “Optimal regular mechanical cleaning is between 6,000 to 8,000 rpm, so fixed-rpm grinders at 10,000 rpm for instance will spread more dust and contaminants further, and reduce the life of the brush,” he says. “They also generate a lot more heat inside the material, which is never good.” When selecting a wire cup brush, choose the appropriate diameter for the tool being used, then select the proper trim length and wire gauge for the desired finish. “A thing to remember is the diameters may seem a little bit off,” says Hopkins. “You’re going to use a 2-3/4- or a 3-inch brush on a 4-1/2-inch grinder, and a 6-inch brush on a 7-inch grinder, the reason being that as the grinders get up to speed the wires want to flare out, so the nominal cup size has to be under the size of the tool that’s going to be used.” Wires will gradually wear down over time, and as the trim length gets shorter the wire will become more aggressive. So if the finish is changing it’s time to move to a new brush. If an operator isn’t getting the desired results, Hopkins recommends first moving to a heavier gauge wire, or if necessary move from a crimped brush to a knotted option for more aggressive removal. Among knot-twisted wire cup brushes, which are generally designed for more aggressive removal on flat and large surfaces, a unique solution comes from PFERD with its CombiTwist knot style brush. Every consecutive knot on the brush is twisted in the opposite direction. “The advantage of having the knots twisted in opposite directions is it helps to keep the brush running smoother, so there is less vibration for the operator,” says Imre Karetka, product manager, brushes, with PFERD. This alternate-twisted construction style also offers a more aggressive and effective brushing solution for cleaning and deburring applications suggests Karetka. He explains that it’s the tips of the wire where the cleaning action takes place, so as the brush is spinning and the wires flare out it’s the inside half of the knot that is engaging the material surface. The design of the CombiTwist provides a more even contact www.canadianmetalworking.com

15-06-05 2:29 PM

The Ultimate Solution for Fillet Weld Grinding POLIFAN®-CURVE Flap Discs

New!

6“, 7“ Diameters TRUST BLUE A PFERD innovation that sets a new standard for performance.

www.pferdusa.com/curve

With its special flap disc design, the innovative POLIFAN® CURVE aggressively grinds and finishes fillet welds, leaving a smooth, consistent surface finish. Its unique radial shape allows for grinding with 3 surfaces - the bottom, edge and top of the flap disc. For more information, contact PFERD or your local PFERD distributor today!

www.pferd.com

PFERD CANADA INC., 5570 McAdam Road, Mississauga, ONT L4Z 1P1

Phone: (905) 501-1555 • Toll-Free: (866) 245-1555

PFERD_Canada_POLIFAN-CURVE_Jan2015.indd 1 Pferd.indd 1

1/12/2015 10:57:09 AMPM 15-06-05 3:47

covering a larger footprint than regular knotted brushes. For the most aggressive situations where users are seeking to remove scale, burrs, weld splatters or paint from metal materials, knotted brushes from many vendors are also available in double-row configurations. These

brushes are still designed to remove adherents without removing the base material. From fine-gauge crimped wire brushes to stiff knotted brushes, the options available are varied and they’re all designed to provide the best possible removal solution for users with the least effort required.

Crimped Cup Brush with Ring Walter Surface has a new exclusive crimped wire cup brush with ring in 3-, 4-, and 5-inch diameters. These brushes now double the amount of wires compared with other crimped brushes making for a softer scratch pattern. www.walter.com

Power Brush Cup Brushes

Cup Brushes with Protect Guard Norton wire cup brushes (red caps for carbon, blue for stainless) are available with protective guard, a flexible plastic shield that deflects particles from flying up to the operator. www.nortonindustrial.com

COMBITWIST Knotted Wire Brush PFERD’s COMBITWIST is a variation on knot style wire cup brushes where the knots are alternately twisted to offer improved balance during rotation. It is available in both carbon steel and stainless steel wire. www.pferd.com

88 | JUNE 2015

05CMW-Brushes.indd 88

Weiler’s wire cup brushes, available in a variety of knot wire and crimped wire configurations, are manufactured with individual knot hole and solid ring construction, and are available in heattreated steel, Type 302 stainless steel, and bronze or brass wire. www.weilercorp.com

Scotch-Brite Clean and Strip Cup Wheel Available in 3-, 4- and 6-inch diameters, 3M’s Scotch-Brite Clean and Strip Cup Wheels are suited for removing weld discoloration and splatter. The wheels are unique surface conditioning products with abrasives incorporated into a non-woven fiber matrix. www.3M.com/abrasives

www.canadianmetalworking.com

15-06-05 2:29 PM

WIN THE LEGEND OF YOUR CHOICE! With 3M™ CUBITRON™ II Abrasive Grinding and Cut-Off Wheels 3M™ Cubitron™ II is giving you the chance to WIN either a

2015 Ram 1500 SLT 2015 Harley-Davidson® Fat Boy®

Harley-Davidson Fat Boy motorcycle or a Ram 1500 SLT pickup – you choose. Look for your 6 digit code on every disc and enter online, by selecting the legend of your choice. Three finalists will be offered a VIP experience in Montreal to see Mötley Crüe live in concert, where the winner will be announced. You Grind Like a Legend… Now it’s Time to Ride Like One! ®

• •

Contest runs April 1 - July 31, 2015 For the complete list of qualifying products go to: 3m.ca/Grind2Win

See rules & regulations and value of prizes at 3m.ca/Grind2Win. HARLEY-DAVIDSON, Fat Boy and the motorcycle image are among the trademarks of H-D U.S.A., LLC. and is not affiliated with this Promotion. Ram (a registered trademark of FCA US LLC), the truck image, FCA Canada Inc., Publicis Canada and Mötley Crüe are not affiliated with this Contest. 3M and Cubitron are trademarks of 3M. Used under license in Canada. © 2015, 3M. All rights reserved. 1502-00489 E

3M.indd 1

15-06-05 3:47 PM

Whether you are cutting, bending, stamping, or punching, there are a wide variety of solutions available to make it easier BY LINDSAY LUMINOSO

anufacturers of large parts face a different set of challenges than those shops working with smaller parts. For one thing, the decision to fabricate oversized materials comes with the economic challenge of purchasing a machine that accommodates parts that size. These machines require a significant footprint on the shop floor and demand additional handling accessories to efficiently move objects from one operation to the next. Automation and material handling systems are a great benefit when working with large parts. “The biggest issues that customers face when processing large parts is real estate,” says Brad Williams, national sales manager for Koike. He explains that a typical 10- by 10-foot cutting machine installed properly with efficient safety zones can easily take up a 20- by 20-foot area. “When looking for equipment to cut large parts it’s important to make sure that the machine is built rugged enough to support all tools over a large working span. Is the rail system adequate to support the machine weight and keep it running

90 | JUNE 2015

05CMW-LargePartFab.indd 90

www.canadianmetalworking.com

15-06-08 12:01 PM

true over the entire length of the rail system, and most importantly, does the manufacturer have a strong track record for building and supplying large format cutting systems?” Another major factor when dealing with large part fabrication is operator efficiency and productivity, “especially when bending. As the operator becomes fatigued, there is a natural drop off in production,” says Brian Welz, product group manager for TRUMPF. Maximizing productivity is important for any shop, so finding solutions to deal with this common problem is important. “Bending aids are an excellent feature to be added directly to the machine. Bending aids are designed to minimize the fatigue for the operator while a full automation solution like the BendMaster eliminates operator fatigue completely.” There are many technical elements to consider when working with oversize sheets or plates. “It’s important to consider distortion and/or plate movement. When cutting large parts, especially multi-pass beveled parts, it’s critical to choose the right process and plan the cutting sequence. “In tank and vessel manufacturing, for instance, having the ability to cut the long seams simultaneously can significantly increase production output and help keep distortion in check,” says Douglas Shuda, director of marketing, global cutting technologies for ESAB Welding & Cutting Products. There is quite a difference fabricating a large part versus large sheets. Putting a large part on a large sheet is not a problem, according to Timothy Brady, punching and combi product manager for Amada America. “However, using “large sheets” to nest many smaller and/or medium size parts is a much more efficient use of the machine and can also result in much better utilization of material (i.e. less scrap), so this might be a factor that would push manufacturers to want to be able handle large sheets,” he explains. What is considered a large part? This is very application specific but the experts agree; there is virtually no limit to a machine’s length capacity. Amada offers an automatic repositioning, which is “available to extend to maximum length (not width) of the sheet that can be processed. When using this feature, additional support tables must be added to the machines and additional clearances for the material movement to and from the machine may be required,” says Brady. When it comes to width, the size of the machine generally dictates this feature. www.canadianmetalworking.com

05CMW-LargePartFab.indd 91

PHOTO COURTESY OF ESAB

PHOTO COURTESY OF MACRODYNE

JUNE 2015 | 91

15-06-05 3:58 PM

Experts all agree that the size restrictions are almost always predicated on the machine process (bending, stamping, cutting, etc.) as well as application. For optimal results, large part fabricating demands that equipment and cutting processes be defined based on the application requirements, explains Shuda. Considerations such as plate size and material thickness are necessary to consider when exploring large part fabricationg. “Most machines are application specific as well; steel service centers, heavy equipment manufacturers, shipyards, railcar manufacturers and agricultural equipment manufacturers all typically look for large part capacity cutting systems,” says Williams. One thing that is certain, job shops like flexibility. The ability to offer customers large part fabrication services can enahnce business. “[Shops] want to be able to support any job that comes their way and so large part fabrication is a part of this mix,” explains Welz. In addition to job shops, there are some industry specific needs. “In the Mid-West, for example, there tends to be more of the larger-format equipment. There are plenty of job shops, but also customers in or directly supporting the agriculture industry which tend to have larger parts. In Canada, the transportation industry also drives the need for larger format machines, especially where bus frames and similar products are manufactured.” The machines themselves are not the only consideration when taking on the processing of oversize materials. Adding accessories and equipment to enhance large part fabricating can be just as important as choosing a quality machine. “The larger the part, the more difficult and time-consuming manual handling becomes, and the greater the safety risks as well,” says Tobias Reuther, product manager automation group for TRUMPF. Reuther explains that due to the part size, there are many cases in which two people are required to handle one part together. This drives up labor costs and reduces efficiency dramatically. Automation is one solution for this challenge. Additional equipment and accessories may also need to be added to the shop floor in order to accommodate large raw material sheets, store finished products, and increase productivity. Brady states that forklifts would be a standard means of moving pallets of large (and small) material. However, if you are working with extremely large and 92 | JUNE 2015

05CMW-LargePartFab.indd 92

heavy products, another option is an overhead crane system. “Overhead cranes are vital for moving large cut parts,” reiterates Williams. “Crane accessories include sling chains, magnets, plate clamps and vacuum lifting devices depending on the size, weight and material to be handled.” There are some strong reasons for exploring the ability to process larger parts/sheets. “The added expense and square footage required by the larger machines can be a deterrent,” explains Brady. However, offering customers the ability to cut, bend, stamp, and fabricate a wide range of sizes and materials can provide a competitive advantage. The availability of raw materials, the ability to store large sheets, material handling capabilities and general movement of large parts on the shop floor are all factors to consider when exploring large part fabricating. There are a wide range of solutions available to make large part fabricating an efficient part of your portfolio. Following are some of the latest products:

HEAVY PLATE FABRICATION The Impuls flying optics laser systems address heavy plate fabrication requirements with an extremely large sheet carrying capacity. These high performance systems feature a table width capacity of three meters and can handle several 3 x 1.5 meter sheets, providing increased capacity and productivity for heavy plate fabrication. The ability to load multiple workpieces increases cutting time and reduces time spent handling material. Using larger material sizes also improves sheet utilization and nesting efficiency. The Impuls 6530 handles sheets up to 6.5 x 3 meters. The Impuls 8030 accommodates workpieces up to 8 x 3 meters. The Impuls 12530 features a work area of 12.5 x 3 meters. These Impuls lasers process flat plate up to 25 mm mild steel and provide a fully programmable Z-axis with travel up to 280 mm for processing pre-formed parts. High performance features assure high quality cutting, optimum cutting speeds, and ease of use. Some of the

www.canadianmetalworking.com

15-06-05 3:58 PM

Ferric.indd 1

15-06-05 3:51 PM

key options include a plasma detection feature, the choice of 4, 5, or 6 kW laser sources, and CADMAN-L 3D offline software. There are six different models in this series. www.lvdgroup.com

INTELLIGENT SOLUTION FOR THE LOADING/ UNLOADING OF LASER CUTTING SYSTEMS The ByTrans and ByTrans Extended from Bystronic offer a solution for material handling of large sheets on laser cutting systems. Automatic loading and unloading decreases set-up times and allows for fast job processing. Investing in this system allows for much higher machine utilization and increased productivity. The ByTrans Extended design has not just one but two cassettes,

thereby making the machine system even more autonomous. These flexible systems are not just for storage/return transfer but also for large part removal as well as the preparation of plastic protective separators, which are placed between the metal sheets by the system. This system allows for entry into lightly-manned parts production. ByTrans Extended is optionally available in 3 × 1.5 meters and 4 × 2 meters, ByAutonom 4020 + ByTrans 4020 Extended. www.bystronic.com

Powerful

Pipe Benders

Benders • Tooling • Parts • Service | tel 253/922-7433 | fax 253/922-2536 |

Featuring: • CNC Pipe Benders up to 10” • BendPro CNC • Overhead Clamp • In-House Tooling • Made in the USA

8” 20D!

94 | JUNE 2015

05CMW-LargePartFab.indd 94

www.JesseEngineering.com “Click on Pipe Benders”

12” 3D!

MATERIAL HANDLING ON BENDING MACHINES Flexible support brackets and bending tools contribute a great deal to setting up a productive bending process. Ergonomics increases productivity and reduces parts costs. Support brackets make it easier to work with parts providing the ability to set parts down to rotate them or turn them over between bends. The heavy load support bracket carries up to 550 lbs. simplifying the bending of large, heavy and awkward parts. Extensive accessories, like extensions and front stops, offer additional convenience and support for material handling. www.us.trumpf.com

RUGGED 3D PRECISION FOR TUBE AND STRUCTURAL APPLICATIONS Mazak Optonic’s 3D FABRI GEAR 400 II machine excels for an expanded range of laser-cut tube, pipe and structural applications. Available with a 2.5kW or 4.0kW resonator, the 3D FABRI GEAR 400 II cuts a wide www.canadianmetalworking.com

15-06-05 2:39 PM

COMBINATION MACHINE MAXIMIZES PRODUCTIVITY

variety of tubes and pipes including round, square, rectangular and triangular. It can also process I and H beams, C-channel, angle iron and additional user-defined shapes from mild or stainless steel. This extensive range of capabilities makes the machine ideal for many industries and applications. Featuring a powerful, high-precision 6-axis laser, the 3D FABRI GEAR 400 II can handle larger, longer, thicker and heavier material than similar machines due to its rigid workpiece handling system incorporating a four chuck design. It also has improved processing speeds, tighter tolerances and can be used for drilling and tapping. The 3D FABRI GEAR 220 II model can process a round pipe diameter of up to 8.6 inches at a rapid traverse rate of 3,937 IPM. For large material jobs, the 3D FABRI GEAR 400 II can process a round pipe diameter of up to a 16â&#x20AC;?. www.mazakoptonics.com

www.canadianmetalworking.com

05CMW-LargePartFab.indd 95

Amadaâ&#x20AC;&#x2122;s LC 2515 C1 AJ is engineered for high-speed productivity and combines the forces of a 22-ton turret punch press with the flexibility of a 2kW fiber laser. To maximize punching productivity in conjunction with laser cutting, the C1 AJ features a 49-station MPT (Multi-Purpose Turret). In addition to ensuring maximum speed, the highly efficient fiber laser uses approximately a third of the electricity when compared to a CO2 system. The laser head moves in the Y-axis via a direct drive servomechanism for maximum speed and accuracy and is isolated from punching vibration to help maintain beam integrity and cut quality. Reliability is further enhanced by a gap near the laser axis which is engineered to allow cutting gas and slag to escape without impacting

JUNE 2015 | 95

15-06-05 2:39 PM

processing. A cartridge-type lens provides for simple and fast lens changes. In addition, the use of non-contact sensor technology ensures that the laser beam remains focused on the sheet, thereby guaranteeing maximum quality and consistent cutting operations. Unique features of the MPT include four tapping tool stations and three innovative die lift stations. The die stations automatically lift to facilitate upward forms while reducing material scratches and preventing downward forms from hitting the forming dies during sheet movements. www.amada.com

EASY OPERATION CAPABILITIES THAT ALLOWS FOR INTEGRATION WITH OTHER EQUIPMENT Koike Aronson’s Klean Sweep optimizes production by automatically removing slag and scrap during cutting operations, interrupeliminating interrup tion and labor costs. The chain drive operation and simple design ensures reliability and minimizes maintenance costs. Depending on the application, the exhaust channel ducts for fume extraction can be external or internal, and cutting widths range from 5 to 24 feet. Klean Sweep can be used with various laser, oxy-fuel, and plasma cutting machines, including Koike’s highly accurate thermal cutting system, the Versagraph Extreme. The Koike Versagraph Extreme offers reliability and precision, allowing the user to cut tons of plates ranging from 96 to 228 inches quickly and accurately. The larger and stiffer main beam means less plasma Z deflection and greater load capacities. The Versagraph Extreme allows for easier operation capabilities that allows for integration with other equipment without making major changes. www.koike.com

CUTTING AND WELDING OF LARGE WORKPIECES OPTIMO is the laser machine by Prima Power for the high precision cutting and welding of large and very large three-dimensional parts. Its wide work volume, over 11 cubic meters, sets no limits to the size of the components which can be processed. OPTIMO is suitable for a variety of cutting and welding applications, thanks to the wide range of laser sources available and to the fast 96 | JUNE 2015

05CMW-LargePartFab.indd 96

tool change system. Its design allows easy access to the work area and the integration with a wide range of solutions for workpiece support and handling. The OPTIMO offers an optimal floor space/work area ratio, using less factory space. This machine allows for the processing of very large components without repositioning. www.primapower.com

THE ABILITY TO PRODUCE PARTICULARLY LARGE PANELS The P4Xe Panel Bender by Salvagnini is an extraordinarily high-throughput machine and is characterized by simple, intuitive programming and agile, precise sheet handling. It can be set up in a variety of ways for different production needs. The various configurations will depend on the user’s preferences in terms of loading/unloading solutions and on the model of machine. The Salvagnini range of Panel Benders incorporates different models, split into two families, which together cover countless production requirements. The more compact version that bends up to 2,180 mm; the XXL model that produces panels up to 4 m long; a machine that makes bends up to 165 mm high; and another capable of making bends up to 254

mm high on mild steel up to 3.2 mm thick. The P4Xe3816 model meets the needs of companies that produce particularly large panels, such as those in the industrial and commercial air-conditioning and the refrigeration sectors. This machine is especially suitable for processing large sheets of thin material, because the parts are handled www.canadianmetalworking.com

15-06-05 2:39 PM

and rotated automatically on a surface and supported throughout the entire work cycle. www.salvagnini.com

TRIPLE OR QUADRUPLE THE AMOUNT OF SETUPS PERFORMED EACH DAY Fabricators are confronted with the demand for a wide variety of parts and the associated short runs. Amada provides a solution to meet this challenge with the HG 1003 press brake equipped with an Automatic Tool Changer (ATC). The HG 1003 press brake is an ultra-precise, high-speed bending solution. An innovative hybrid drive system achieves extremely fast approach, bending and return speeds, resulting in faster cycle times and more parts per hour. The ATC combines outstanding versatility with enormous capacity by providing 18 magazines for dies and 15 for punches. Each magazine can accommodate tool

bending aid relieves the operator when handling very heavy parts. When working with large, thin materials, counter-bends must be avoided. The CNC synchronized bending tool supports the part over a large surface. The extension and widening options are extremely flexible and when the bending aid isnâ&#x20AC;&#x2122;t needed, it can be put in the park position. www.us.trumpf.com

ACHIEVING COMPLETE LIGHTS OUT OPERATION The KOIKE designed Lasertex uses a patented process in which the resonator is mounted to the main beam cross carriage. This then moves with the cutting/focus head. The laser beam is reflected by stationary mirrors inside an air purged Sigma box. The laser beam never changes. This allows for capabilities of 20-feet cutting width to over 200-feet of cutting length. Complete lights out operation can be achieved, which saves

lengths up to 31.5 inches (800 mm). A highly rigid frame design features a larger open height. The increased distance between tooling and greater stroke length produces a larger processing area, providing process range expansion by enabling deep box bending while making part extraction faster and easier. www.amada.com

BEND EVEN LARGER PARTS WITH BENDING AIDS With bending aids, even large parts can be fabricated with one operator instead of two. A

The best press alternative on the market for unitized tools and small die sets. MULTICYL INC

640 Hardwick Road, Unit 1, Bolton, ON, Canada L7E 5R1 Tel.: 905-951-0670 - U.S. Toll Free 1-800-388-6359 - Fax : 905- 951-0672 www.multicyl.com - punch@multicyl.com

www.canadianmetalworking.com

05CMW-LargePartFab.indd 97

JUNE 2015 | 97

15-06-05 2:39 PM

on energy costs and man power. Laser cutting has a very low heat affected zone and can maintain tight part tolerances versus an oxy-fuel or plasma cuts. The 4kW Laser has a cutting capacity up to 3/4 -inch mild steel and 1/2 -inch stainless steel. The 6kW Laser has a cutting capacity up to 1-inch mild steel and 3/4 -inch stainless steel. www.koike.com

cutting. This enables parts to be finished in one set-up with no jigging or work holding devices necessary. The K5000 allows for large part cutting widths up to 4.3 meters and 6 meters or longer length capabilities. www.kineticusa.com PHOTO COURTESY OF ESAB

SUPPORTING LARGE WORKPIECES AT A LOW COST

Mitsubishi’s RX Laser is designed to handle large workpieces, up to 4 x 2 meters. The evolution of jet pierce technology takes center stage on this machine. High Peak Pierce (HPP) can drastically change piercing times in mild steel. Some studies have shown a reduction up to 80 per cent. FAB control is another new feature which improves cutting ability, and allows more stability across the cutting area. And new M-Cut technology, also called Motion Cut, affords the ability to move through thin materials at greater speeds. This series offers superior edge quality and processing consistency over an entire work area. www.mcmachinery.com

COMBINATION DRILLIN G AND CUTTING The Kinetic K5000 offers a 48HP, Cat 50, machining spindle with through spindle coolant for heavy duty drilling applications and machining operations. The gantry type machine offers Hypertherm high definition plasma cutting and beveling along with traditradi tional oxy fuel. This machine is designed for doing machining operations and precipreci sion plasma or flame 98 | JUNE 2015

05CMW-LargePartFab.indd 98

EXCELLENT U-GROOVE EDGE PREPARATION Many weldments require back gouging to meet code requirements, and air-carbon arc gouging is one of the most widely accepted and most productive processes for metal removal. The Arcair-Matic N7500 from Arcair, an ESAB brand, gouges with carbons up to 3/4” in diameter at 1600 amps at 100 per cent duty cycle. It also gouges with an accuracy of 0.025”, and more accurate gouging reduces filler metal and consumable use, as well as cycle times. The N7500 gouging system produces excellent U-groove edge preparation with less edge distortion than flame cutting. It can bevel a 1” (25.4mm) J-groove about 50 per cent faster than an automatic flame torch, and since a J-groove requires less fill metal than a conventional V bevel, welding is completed about 150 per cent faster. It can be used on almost all metals, including stainless steel, carbon, manganese and chromemoly steels. www.esabna.com www.canadianmetalworking.com

15-06-05 2:39 PM

Bring us your toughest tooling problems. Our experts welcome the challenge of working with our customers to help them make quality parts in an ongoing, predictable and consistent manner. Take one of the variables out of your manufacturing process and choose one of our high performance specialty steels for your application. Bรถhler-Uddeholm your one stop for steel, heat treatment, coatings machining services and technical support.

Bร HLER-UDDEHOLM - CANADA www.bucanada.ca Tel.: 1-800-665-8335

Bohler.indd 1

MATERIALIZING VISIONS 15-06-05 3:51 PM

STAMPING SEES

MARKET UPSWING A conversation with Macrodyne Technologies of Toronto. BY LINDSAY LUMINOSO

acrodyne Technologies Inc. is a privately-held company located in the north end of Toronto. The company’s specialized manufacturing facility produces heavy-duty hydraulic press machinery up to 10,000+ tons. “We have supplied hundreds of customized hydraulic presses for many industries, some of which include automotive, heavy truck and off-road vehicles, aerospace, construction, medical equipment, military, appliance, cookware, oil and gas, pulp and paper and a wide variety of other consumer and industrial product areas,” says Jeremy Neil, business development manager for Macrodyne. The company predominantly supplies some of the world’s largest Tier 1 and 2 auto parts manufacturers. “Many of the vehicles currently on the road in North America include components that were produced in Macrodyne hydraulic presses,” says Neil. The company’s presses are used by automotive parts manufacturers to produce body components, structural components, engine and driveline components and a variety of interior components. According to Neil, this is a really great time for stamping manufacturers. “We have

PHOTO COURTESY OF MACRODYNE

100 | JUNE 2015

05CMW-LargePartFab.indd 100

been experiencing a very high demand for stamping presses for the last two years, and all indications lead to a continuation of this trend for the near term at least,” he says. “A major source of the current demand for our presses is in the automotive sector.” In the world of metalforming, the company supplies presses for general metalforming and stamping applications (punching, bending, notching, etc.) and has special lines of presses for other metalforming processes including forging, deep draw, hot stamping, embossing, extrusion, elastoforming and super plastic forming (SPF) in addition to a variety of other processes. When it comes to stamping, Macrodyne knows its stuff. “One notable advancement [in stamping technology] is the proliferation of systems for the manufacture of lightweight and high strength components with processes such as press hardening (hot stamping) producing high performance steels,” says Neil. He explains that hydraulic presses remain prominent in manufacturing across Canada. In addition to hydraulic presses, Macrodyne supplies fully-automated hydraulic press lines and automated (hydraulic press based) manufacturing cells, and die handling equipment (fully automated die storage and retrieval systems, die carts, T tables, die elevators, die openers, rolling bolsters, die storage racks, etc.). “We also have extensive experience in the supply of repair, rebuild & upgrade services. We routinely retrofit existing hydraulic presses of all makes for our customers,” explains Neil. Retrofits consist of repairs or replacement of damaged components, modernization or complete replacement of hydraulic systems and/or electrical/control systems. Macrodyne also offers modifications to increase performance characteristics, and to facilitate alternate manufacturing processes. www.macrodynepress.com www.canadianmetalworking.com

15-06-05 3:57 PM

TAKE FLIGHT WITH CANADA’S LEADING METALWORKING MAGAZINE.

 Nine issues  CMTS & WMTS show guides  CMTDA directory  100+ e-newsletters  Metalworking Marketplace product newsletters & whitepapers  E-blasts  Direct mail  Vancouver & Winnipeg table top shows

CONTACT Steve Devonport

Rob Swan

Nicholas Healey

Doug Picklyk

Lindsay Luminoso

Publisher Associate Publisher Account Manager Editor Associate/Web Editor t: 416-543-1641 t: 416-510-5225 t: 416-442-5600 x3642 t: 416-510-5206 t: 416-442-5600 x3645 e: sdevonport@ e: rswan@ e: nhealey@ e: dpicklyk@ e: lluminoso@ canadianmetalworking.com canadianmetalworking.com canadianmetalworking.com canadianmetalworking.com canadianmetalworking.com

HouseAd-TakeFlight.indd 1

15-06-05 3:53 PM

PRODUCTS & SERVICES

Introducing an opportunity for small-space and classified advertising in Canadian Metalworking

For a quote on any size ad, contact: STEVE DEVONPORT, Publisher 416-543-1641 sdevonport@canadianmetalworking.com

Metalworking Marketplace will be available in all nine issues of Canadian Metalworking, and provides the opportunity to run small space advertising and classified ads at low cost. There are two main parts to Marketplace, Listings for Products and Services, and Classified for Machine Tool and Fabricating Equipment. ROB SWAN, Associate Publisher 416-510-5225 cell 416-725-0145 rswan@canadianmetalworking.com

ADDITIVE MANUFACTURING RENISHAW (CANADA) LIMITED. Renishaw laser melting system is a pioneering process capable of producing fully dense metal parts direct from 3D CAD. From tooling inserts featuring conformal cooling, to lightweight structures for aerospace & high technology applications, laser melting gives designers more freedom. Find out more at www.renishaw.com/additive. T: 1 905 828 5519 E: Canada@renishaw.com www.renishaw.com

ASSOCIATIONS CANADIAN MACHINE TOOL DISTRIBUTORS’ ASSOCIATION (CMTDA) The CMTDA is a trade association dedicated to the marketing of machine tools and services in Canada through distributors. For more information about CMTDA or our members products and services, contact us at: T: 519 599 2803 E: info@cmtda.com www.cmtda.com

CUTTING TOOLS HORN USA, INC. HORN is the technology leader of indexable cutting tools with experience in over 100,000 custom application solutions and engineering expertise applied to more than 17,000 standardized turning and milling tools. T: 888 818 4676 E: info@hornusa.com www.hornusa.com ISCAR TOOLS INC. ISCAR provides industries machine tools, carbide cutting tools, engineering and manufacturing solutions for a wide range of metal cutting applications, including innovative products, designed specifically for customer increased productivity requirements globally. T: 905-829-9000 www.iscar.ca SANDVIK COROMANT (Cutting tools for turning, milling and drilling, modular tooling systems for lathes and machining centres. Direct sales personnel and specialists in more than 60 countries plus authorised distributors and 20 Productivity Centres worldwide providing training in tooling solutions for increased productivity) T: 905 826 8900/800 268 0703 E: coromant.ca@sandvik.com www.sandvik.coromant.com SGS TOOL COMPANY. SGS is a privately-held, ISO-certified leader of round solid carbide cutting tool technology providing value at the spindle for the aerospace, medical, power generation, and automotive industries. T: 330-688-6667 E: sales@sgstool.com www.sgstool.com TUNGALOY. Tungaloy has supplied carbide cutting tools for over 70 years. Supported by our sophisticated materials technology and state-of-theart processing technology, Tungaloy is committed to quality. For more information on our extensive range of products contact us at: T: 888 886 4256 www.tungaloy.co.jp.ca WALTER TOOLS. The five competence brands of Walter, Walter Titex, Walter Prototyp, Walter Valenite and Walter Multiply, are united under one umbrella. With a product range of around 49,000 catalogue tools for milling, drilling, turning and threading. Walter is a complete service provider for the metalworking industry. T: 800 945-5554 E: service.ca@walter-tools.com www.walter-tools.com/us

102 | JUNE 2015

05CMW-Marketplace.indd 102

NICHOLAS HEALEY, Account Manager 416-442-5600 x3642 nhealey@canadianmetalworking.com

EMPLOYMENT OPPORTUNITIES

Campbell Morden specializes in recruiting full-time staff for a broad range of industries, such as aerospace, automotive, CNC Machine Builders, and system integrators. Positions include: technical sales, CNC machining, applications engineers, manufacturing management, and field service technicians – among others.

Email: bp@campbellmorden.com Call Brian Pho at 905-482-0636

EXCITING SALES CAREER OPPORTUNITY As a result of a recent promotion, we are seeking an individual to ﬁll an inside sales position selling new Metal Forming Machinery. This is a developmental position that will lead to an exciting career in outside sales with excellent earning potential. Requirements for this position include previous sales experience, strong mechanical aptitude, technical trade school/college diploma or apprenticeship and above all, enthusiasm. For more details about this Inside Sales Professional role, please visit the careers section of our website: http://westwaymachinery.com/inside-sales-professional. Send Resume to: careers@westwaymachinery.com

EVENTS – TRADE SHOWS FABTECH CANADA. March 22-24, 2016 Toronto Congress Centre, FABTECH Canada is Canada’s largest one-stop, all-encompassing venue for the latest technologies and trends in fabricating, welding, metal forming, stamping, coating and finishing. With an unmatched reputation in the industry, FABTECH is the largest event in this sector in North America. For more information contact us at: T: 1 888 322 7333 E: jsaperson@sme.org www.fabtechcanada.com WESTERN MANUFACTURING TECHNOLOGY SHOW (WMTS). June 1517 2015, Edmonton EXPO Centre. Evaluate and compare cutting-edge manufacturing equipment, advanced technologies, new products & applications, and services at Western Canada’s largest manufacturing technology event. For more information contact us at: T: 1 888 322 7333 E: jsaperson@SME.org www.wmts.ca

www.canadianmetalworking.com

15-06-05 2:40 PM

PRODUCTS & SERVICES

CANADIAN MANUFACTURING TECHNOLOGY SHOW (CMTS). Sept 28 – Oct 1 2015, The International Centre, Mississauga. Canada’s largest display of manufacturing equipment and technology attended by over 8,000 professionals. Connect with over 700 suppliers under one roof demonstrating live, working equipment. For more information contact us at: T: 1 888 322 7333 E: jpike@sme.org www.cmts.ca

FABRICATING MACHINERY AMADA CANADA, LTD. Since 1987, Amada has provided the Canadian industry with innovative sheet metal fabrication equipment including: CNC turret punch presses, lasers, punch/laser combination machines, press brakes, automated systems, tooling and software. Peter Burell T: 905 858 4496 pburell@amada.ca www.amada.ca TRUMPF INC. TRUMPF Inc. is the largest manufacturer of sheet metal fabrication equipment and industrial lasers in North America. Our Farmington, CT facility produces precision laser cutting machines, punching machines and CO2 and solid-state lasers. T: 860 255 6000 E: info@us.trumpf.com www.us.trumpf.com

LASERS ROFIN-BAASEL, CANADA LTD. A Canadian division of the laser industry leader ROFIN-SINAR, provides applications, sales and a sophisticated service/technical support network for our vast line of lasers for marking, welding, cutting, and surface treatment. For more information contact us at: T: 905 607-0400 E: Info-canada@rofin-inc.com www.rofin.com

MAZAK CORPORATION. Mazak is a leader in the design, manufacture and support of advanced technology solutions, including Multi-Tasking, 5-axis, milling, turning, CNC controls and automation, for all metal working industry segments. T: 859 342 1700 E: triddell@mazakcorp.com www.mazakusa.com MITCHAM MACHINE TOOLS INC. Mitcham Machine Tools Inc. are Canadian distributors of CNC and manual Machine Tools. With our extensive product line from manufactures around the world, we will work with you to find you the right machine for your needs, both on time, and within budget. T: 416-458-7994. E: sales@mitchammachinetools.com www.mitchammachinetools.com TOS TRADE CANADA Inc. is a subsidiary of TOS Varnsdorf, the established manufacturer of a broad range of quality horizontal boring mills. Over 1000 boring mills installed within past 25 years. T: 905-878-0888 E: info@tostrade.com www.tostrade.com

MACHINERY ELLIOTT MATSUURA CANADA INC. Elliott Matsuura Canada Inc. is an industry-leading supplier of quality machine tools coast to coast in Canada. Since 1950, Elliott has provided complex metal cutting solutions to meet the challenges of aerospace, automotive, medical, energy, and other industries. T: 905-829-2211 E: info@elliottmachinery.com www.elliottmachinery.com

MACHINE TOOLS AMT MACHINE TOOLS LTD. AMT specializes in Sales & Service of: Star CNC Swiss Style Automatic Lathes and Hydromat Transfer Machines. We also have a complete line of filtration products including Filtermist Oil-Mist collectors. T 416-675-7760 E: sales@amtmachine.com www.amtmachine.com

BERTHIEZ VTL with milling

DIPAOLO MACHINE TOOLS. DiPaolo Machine Tools is the one stop shop for all of your machine tool needs. We’ll source the equipment, rebuild it, retrofit it, calibrate and service it. For more information contact us at: T: 905 676-9265 E: sales@dipaolocnc.com www.dipaolocnc.com HAAS AUTOMATION, INC. Haas Automation, Inc. – America’s leading machine tool builder – manufactures a full line of CNC vertical machining centers, CNC horizontal machining centers, CNC lathes, 5-axis machining centers, and rotary products. T: 805 278 1800/Toll Free: 800-331-6746 E: haascnc@haascnc.com www.HaasCNC.com HURCO COMPANIES, INC. Hurco invents CNC technology that makes our customers more profitable. We design and manufacture more than 60 models of CNC machines with the most versatile control in the industry— equally powerful for NC and conversational programming. T: 1-800-634-2416 E: info@hurco.com www.hurco.com MAKINO, INC. Makino is a world leader in advanced CNC machining centers for today’s most complex metalworking applications. With a wide range of high-precision metal-cutting and EDM machinery, we help our customers make what matters. T: 513-573-7200 E: webmaster@makino.com www.makino.com

www.canadianmetalworking.com

05CMW-Marketplace.indd 103

GENERAL TECHNICAL SPECIFICATION Table Diameter Maximum Swing Height Under Rail Maximum Machining Height Vertical travel of ram Table speeds Spindle drive motor Maximum part weight Feed rate X&Z Rapid traverse X&Z C-Axis indexing C-Axis traverse Serial No.

62” 75” 43.4” 31.5” 31.5” 3.2 to 400 RPM 125 HP 22,000 lbs. 0.004 TO 78.7 IPM 472 IPM 0.001 degrees (360,000 positions) 5 RPM 4162

EQUIPPED WITH: * Fanuc 15 TB CNC control * 20 Position automatic tool charger * Coolant through spindle * 62” face plate with 4-Jaws * Approx. 15 tool blocks * Tool and part probes * Chip conveyor and full enclosure

For more information on this or our 50 plus used machines contact T 905 676 9265 E Sales@dipaolocnc.com www.dipaolocnc.com

JUNE 2015 | 103

15-06-05 2:40 PM

PRODUCTS & SERVICES

MARKING GRAVOTECH, INC. Gravotech are global leaders in the design, manufacturing, sales, and support of innovative solutions for engraving, marking and artistic modeling. As a global leader in durable marking technologies such as engraving, laser, micro-percussion and scribing, we utilize our expertise to develop and market equipment, software and consumables for every application. T 800-843-7637 E: sales@us..gravotech.com www.gravotech.us

MATERIAL HANDLING PRAB. A global manufacturer of material handling equipment for scrap metal and coolant recycling. A broad line of conveyors, wringers, crushers, briquetters, and fluid filtration and recycling equipment will automate scrap processing while maximizing production and improving safety and environmental compliance. Robert Webb Authorized PRAB Sales Representative T: 905-296-2039 E: robert@rgwsalescanada.com

METAL FINISHING PFERD. The PFERD brand name is synonymous with outstanding premium-quality tools and abrasives. Today, we manufacture more than 7,500 PFERD brand grinding, cutting and surface finishing tools. And a complete range of ADVANCE BRUSH power and maintenance brushes. T: 905-501-1555 E: sales@pferdcanada.ca www.pferdcanada.ca

WALTER SURFACE TECHNOLOGIES. Walter Surface Technologies has been a leader inÂ surface treatment technologies for more than 60 years, and has been providing high productivity abrasives, power tools, tooling, chemical solutions and environmental solutions for the metal working industry. T: 1-888-592-5837 E: csr@walter.com www.walter.com

METALS BĂ&#x2013;HLER-UDDEHOLM CANADA is a leading manufacturer of high quality tool steel, high speed steel, powder metallurgical steels, stainless steels, and specialty alloys. Products and conveniently located facilities are supported by a highly trained technical sales force and by a local and international metallurgical support staff. For more information contact: 1-800-665-8335 or www.bucanada.ca/contact_us.htm

QUALITY CONTROL RENISHAW (CANADA) LIMITED. Introducing a unique versatile gauging system. Equator, an alternative to custom gauging, offers inspection of an unprecedented variety of manufactured parts. Proven and Developed on the shop floor with industry leading gauging users in a variety of industries and applications. For more contact us at www.renishaw.com/gauging. T: 1 905 828 0104 E: Canada@renishaw.com www.renishaw.com

Alro Steel

Metals Industrial Supplies Plastics

Your One Stop Shop for cut-to-size Metals & Plastics with daily deliveries to Ontario, Canada Since 1948

104 | JUNE 2015

05CMW-Marketplace.indd 104

888-888-ALRO 2 5 7 6

alro.com

www.canadianmetalworking.com

15-06-05 2:40 PM

PRODUCTS & SERVICES

RETENTION KNOBS

WELDING SUPPLIES LINCOLN ELECTRIC COMPANY OF CANADA. Lincoln Electric is the world leader in the design, development and manufacture of arc welding products, robotic arc welding systems, plasma and oxyfuel cutting equipment and brazing and soldering alloys. For more information contact us at: T 905 565 5600 www.lincolnelectric.ca

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

WORKHOLDING SAMCHULLY WORKHOLDING, INC. Samchully Workholding leverages a broad range of complementary products to provide full turn-key custom solutions. The ability to single source the solutions ensures customers optimal compatibility and unsurpassed quality control. T 949-727-3001/1-877-750-4747 E info@samchullyworkholding.com www.samchully.com

FOR FAST DELIVERY: Contact your local tooling dealer or order direct.

TEL 937-686-6405  FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O.Box 61 Bellefontaine, OH43311

ADVERTISERS INDEX ADVERTISER

PAGE#

3M Canada 89 Allied Machine & Engineering Corp. 67 Alro Steel 104 Amada Canada, Ltd. 9 AMT Machine Tools Ltd. 16, 39 Benz Inc. 66 Blaser Swisslube Inc. 64 Bohler-Uddeholm Ltd. 99 Brother 6 Compumachine 42 Creaform 3D 59 CWB Group 81 Dipaolo Machine Tools 13 Dormer Pramet 55 Elliott Matsuura Canada Inc. 6 EMAG L.L.C. 35 EMO MILANO 2015 83 ERI America Inc. 66 Eriez Magnetics 30 Ferric Machinery 96 Forkardt Workholding 31 GMN USA 34 Gullco International 14 Haas Automation Inc. 27 Hainbuch America 49 HORN USA, Inc 11 Hurco USA IFC Hydromat Inc. 39 IESO 75 Ingersoll 24 Iscar Tools Inc. OBC, 53 ITI Tooling 33 Jesse Engineering 94

www.canadianmetalworking.com

05CMW-Marketplace.indd 105

ADVERTISER

PAGE#

Kinetic Cutting Systems Inc. 95 Kyocera Precision Tools Inc. 51 Lincoln Electric Company of Canada 73 Makino (SST Canada) 48 Makino Inc. 41 Mapal Inc. 29 Mazak Corporation Canada 37 Megatel Inc. 47 Mitcham Machine Tools 20 Multicyl Inc. 97 Oerlikon Balzers 57 Okuma 43 PFERD 87 Powerhold Inc. 18 PRAB 22 Renishaw (Canada) Ltd. 61 Samchully Workholding, Inc. 19 Sandvik 4,5 Schunk Intec Corp. 15 Scientific Cutting Tools 65 Seco Cutting Tools 17 SGS Tool Company 47 Sirco Machinery 27 SME CMTS 77 SST 48 Starrag USA, Inc. 62 Thomas Skinner 27 TRUMPF Inc. IBC Tungaloy America Inc. 3 Walter Surface Technologies 85 Walter USA, LLC 63 Weiler Corporation 79

Canada’s leading source for metalworking news and information www.canadianmetalworking.com

JUNE 2015 | 105

15-06-05 2:40 PM

BY THE NUMBERS

VEHICLE PRODUCTION AROUND

GLOBAL MOTOR VEHICLE PRODUCTION* 2013 637,000 45.8 M 19.9 M 4.6 M 16.5 M

Africa Asia/Oceana Europe South America NAFTA

2014 708,000 47.4 M 20.4 M 3. 8 M 17.4 M

Change +11.3% +3.4% +2.3% -16.5% +5.6%

NAFTA MOTOR VEHICLE PRODUCTION* Canada Mexico U.S.

2013 2.38 M 3.1 M 11.1 M

2014 2.39 M 3.4 M 11.7 M

Change +0.6% +10.2% +5.4%

5 . & CLOSE TO 3 N 9 . O S I R 9 8 L HOME YEA 74 MIL 1 THE WORLD

ge a r e Av ge a a of ian d na * Ca icle.* h ve

a te r e rags per s e v e t e A hicl itan h T ve ab of inh the % 00 nd 21 10 arou up * – 5 r ld 2 0 0 o w nce si

CANADIAN MOTOR VEHICLE PRODUCTION

TRUCKS

[Thousands of Units (January-March)]***

CARS * International Organization of Motor Vehicle Manufacturers/Organisation Internationale des Constructeurs d’Automobiles ** Automotive Industries Association of Canada *** Scotiabank Global Auto Report (Ward’s Automotive Data)

106 | JUNE 2015

05CMW-Numbers.indd 106

Chrysler GM Honda Toyota

d ce u – d ro 014 p lese in 2013, c i h d .* 2 Ve ldwi rom 005 2 r %f wo 3 ince up % s 34 up

Q1-2014 56.5 68.5 49.1 49.2

Q1-2015 64.7 59.0 42.9 56.6

(Light, Medium & Heavy Trucks) Q1-2014 Q1-2015 Chrysler 82.1 51.2 Ford 53.2 24.6 GM 88.2 98.5 Honda 52.8 48.7 Toyota 61.9 85.3 Others 2.7 3.2

www.canadianmetalworking.com

15-06-09 10:12 AM

Trumpf.indd 1

15-06-05 3:12 PM

ISCAR's High Productivity Machining

Solutions for the Oil and Gas Industry 350 LINE

Integral shank, TANG-GRIP parting and grooving toolholders with 4 pockets

PIPE THREADING LINE

Oilfield Threading

High Feed Turning

8 Cutting Edges

Machining Intelligently

ISCAR HIGH GH Q LINES Iscar.indd 1

Indexable Drills