Cmw march2015 de

MOLDING A NEW REALITY Trends in machining molds – p34

MARCH 2015 PM 40069240

BUILDING WITH CONFIDENCE Metaline, Toronto, Ontario – p48

PUNCHING OUT PROFITS Strategies for success – p54

TOOLHOLDER TROUBLE Find out how to avoid it! – p78

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New cutting tools and solutions from Sandvik Coromant March 1 marks the launch of the latest innovations from Sandvik Coromant, designed to increase your productivity and help you stay ahead of competition.

SpiroGrooving™ - revolutionizing seal ring groove machining

CoroMill® Plura HD reliable heavy roughing

High quality seal ring grooves in challenging materials such as Inconel 718 and cladded Inconel 625 are critical features for many oil and gas components. There is just no room for inaccuracies. Where conventional

CoroMill Plura Heavy Duty is a new solid end-milling concept, designed to remove large amounts of metal quickly with high process reliability. Use it for heavy roughing operations such as shoulder milling, full slot milling, ramping and helical interpolation in steel, stainless steel, cast iron and heat resistant materials. The

and poor process security, SpiroGrooving produces close tolerance seal ring grooves in a secure and productive way.

SpiroGrooving is programmed in a few easy steps.

It utilizes a spirograph tool path where roughing and with the CoroBore® XL system, SpiroGrooving ensures process security and high output of quality seal ring grooves.

when machining with a large depth of cut. It also prevents re-cutting of chips and sudden tool breakage.

CoroMill® QD - trouble-free groove The main challenge in groove milling is often chip evacuation, which threatens to harm production breakage, (especially when machining narrow and deep four-channel internal coolant and dedicated insert geometries with a narrow shape. The combination results in a reliable solution for secure and trouble-free groove

CoroMill ® Plura HD

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SpiroGrooving ™

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High security groove milling

Clean, high-quality grooves Don’t let chip control issues harm your production efficiency.

When machining narrow and deep grooves, the CoroMill® QD handles chips with ease through optimized geometries and a unique internal coolant solution. CoroMill® QD gives you a reliable solution for trouble-free groove milling and parting off.

Read more at sandvik.coromant.com/coromillqd

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TAKE THE LEAD

IN PUNCHING FLEXIBILITY WITH THE STRIPPIT PX-SERIES

LVD Strippit leads the way in value-added punching with the new Strippit

LASER

PX-Series punch press. Efficiently PUNCH, FORM, BEND and TAP all on a single machine, eliminating secondary operations. This next generation 20-ton punch press can bend flanges up to 3” high, with all tools rotatable to any angle and the

PUNCH

capacity to accept up to 200 tools with modular automation options available;

BEND

the ultimate flexibility and productivity is contained within just one machine.

Learn more about the versatility of the highly capable Strippit PX-Series by

INTEGRATE

visiting www.lvdgroup.com/strippitpx/us or calling 800-828-1527.

LVDGROUP.COM ELLIOTT-MATSUURA CANADA INC. • www.elliottmachinery.com • 905.829.2211

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MARCH 2015 ß VOL. 110 ß NO. 02

www.canadianmetalworking.com

A LOOK INSIDE SPECIAL ISSUE: MOLD TOOL & DIE FEATURES MOLDING A NEW REALITY — 34 Trends in machining molds

THINKING BIG — 38 Rian Solutions, Brantford, Ontario

LOOKING BACK: THE COVER STORY — 44 110 years of Canadian Metalworking

BUILDING WITH CONFIDENCE — 48 Metaline, Toronto, Ontario

COVER STORY — 28 SECTOR REPORT

Tool, Die and Moldmakers leave recession in the dust

PUNCHING OUT PROFITS — 54 How punching strategies bring success

WORKING HAND IN HAND — 60

34

Software and machines advance manufacturing together

CLAMP IT DOWN — 70 Proper fixturing for successful welding

38 54 48

44 www.canadianmetalworking.com

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 MARCH 2015 | 7

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MARCH 2015 ß VOL. 110 ß NO. 02

www.canadianmetalworking.com

A LOOK INSIDE SPECIAL ISSUE: MOLD TOOL & DIE

74

FEATURES (CONT.) INCREASING PRODUCTIVITY AND PROFIT — 74 See what ZOLLER has to say about tool presetters

TOOLHOLDER TROUBLE — 78 How to avoid it!

84

78

TOOL HEAD CARE — 84 Pushing profits with preventive maintenance

LIVING IN A DIGITAL WORLD — 90 Machine tool software makes monitoring so easy

90 DEPARTMENTS VIEW FROM THE FLOOR — 10 NEWS — 12 KEN HURWITZ ON FINANCE — 23 TOOL TECH — 25 BUSINESS MANAGEMENT — 27 CMTS COUNTDOWN — 52 FABRICATING AND WELDING NEWS — 66 TOOL TALK — 86

BY THE NUMBERS — 98

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UPCOMING IN METALWORKING It’s all about energy and resources in our April issue of Canadian Metalworking. The number of pipeline projects in Canada is on the rise with proposals like the TransCanada Nova pipeline expansion and the challenged Keystone XL pipeline. We are exploring topics like milling and grinding, hole making, plasma cutting and arc welding.

We are also pleased to announce the keynote speaker for our Coquitlam Metalworking Manufacturing & Production (MMP) EXPO, Marcus Ewert-Johns, the divisional vice president for the Canadian Manufacturers & Exporters (CME) British Columbia. For all the details about this third-annual event, check out page 16.

For extended coverage of what’s happening in Canada’s metalworking industry visit our website, www.canadianmetalworking.com.

Check out our “Productivity Centre” on the homepage for the latest articles, case studies, products, and more to help enhance productivity on the shop floor.

www.canadianmetalworking.com

15-02-24 10:10 AM

Expand Your Range.

“With the FOM2 RI, we have secured new business while meeting the ever-changing demands of our current customers.”

— Calvin Schmidt, President Schmidt Laserworks

Quickly Change From Flatbed Laser Cutting to Tube in Minutes. No Handling. No Jigs.

No Problem.

Located in Edmonton, Alberta, Schmidt Laserworks has earned a reputation as a single source provider of laser processing and precision metal fabrication.

That reputation was challenged as a growing number of existing customers were sending parts to machine shops to process holes and cutouts in tubes.

To retain current customers while adding capabilities to attract new business, Schmidt Laserworks turned to the technology leader. Amada provided the FOM2 RI laser with an integrated Rotary Index. Calvin Schmidt, President of Schmidt Laserworks, reflects on that investment. “Purchasing a hybrid machine ensures us maximum flexibility. We can go from processing tube, change to cutting flat, and back to tube, with only minutes of setup between jobs. We can also supplement the production of our other flatbed lasers when needed.”

Amada’s FOM2 RI laser with Rotary Index provides: • Process Range Expansion (The FOM2 RI can process round, square, rectangle, C-channel, and angle iron, making it the most versatile Rotary Index laser available).

• Reduced Scrap (The ability to nest parts in 20 ft. lengths has minimized or eliminated scrap — resolving a costly problem associated with processing parts on a bandsaw).

• Maximum Productivity (Previously, holes were drilled or parts were fixed into jigs on a flatbed laser.

One side was processed at a time and parts were turned manually which required running multiple programs.

Reflecting on the decision to choose Amada, Schmidt states, “We’re always looking for a competitive advantage.

Purchasing the FOM2 RI has once again raised the bar, placing Schmidt Laserworks at the forefront of laser cutting solutions and positioning us as a premier, one-stop metal fabrication service provider.”

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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

15-02-23 12:50 PM

VIEW FROM THE FLOOR

CALLS FOR AUTOMATION GET LOUDER

T

Is automation on your horizon? I’d like to hear from those “small” shops planning on making the move. Drop me a line at the email address below.

he digitization of manufacturing continues to roll on and it’s time that machine shops of all sizes stop “thinking” about automating their repeatable processes and begin investigating real solutions.

Everywhere today people in industrial circles are talking about the Internet of Things (IoT), machines talking to machines and in turn communicating to people—if necessary.

This isn’t the future; it’s happening today.

For machine shops, it’s in the ability to track machine tool activity in real time, analyze the results and optimize processes.

Ultimately, improved productivity on shop floors will arrive in the form of robotics. It wasn’t long ago that seeing robotic arms on an automotive assembly line became matter of fact, but automation on the floor of a small machining shop seemed far into the future, but the future is here.

Chatting last fall at our Metalworking Manufacturing and Production Expo in Windsor with automation experts, I came to realize that factory automation systems aren’t only for the large plants. Robotic cells can improve machine tool utilization and productivity for shops of all sizes.

I’ve been surprised when owners of shops with fewer than 20 employees tell me about their plans on installing robotic loading and unloading on their machine tools.

PUBLISHER STEVE DEVONPORT 416.442.5125 ß sdevonport@canadianmetalworking.com

But apparently I shouldn’t be surprised.

A recent report from the Boston Consulting Group predicts that investment in industrial robots is set to grow 10 per cent per year in all major export nations through 2025.

One reason for the growth, robotics are becoming less expensive. According to the report, the cost of robotic spot welding dropped 27 per cent between 2005 and 2014, and it’s forecasted to drop by another 22 per cent by 2025.

Robotics are also a logical solution to overcome the challenge of finding new workers. The report suggests automation is a labour-saving necessity.

“It is becoming increasingly critical that manufacturers rapidly take steps to improve their output per worker to stay competitive,” says Harold Sirkin, co-author of the report.

It’s suggested that these improvements could lure manufacturing back from lower-wage countries.

Of course robotics will not lead to a zero workforce economy, but it will lead to smarter manufacturing. The question owners need to be asking themselves now is not if, but how, to get on the automation train.

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

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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

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Content copyright © 2015 by Annex Publishing & Printing Inc, may not be reprinted without permission.

CM accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue.

DISCLAIMER This publication is for informational purposes only.

The content and “expert” advice presented are not intended as a substitute for informed professional engineering advice. You should not act on information contained in this publication without seeking specific advice from qualified engineering professionals.

PRIVACY NOTICE From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1.800.668.2374 Fax: 416.442.2191 Email: jhunter@businessinformationgroup.ca Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9 Canadian Publications Mail Agreement: 40069240. ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.

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

15-02-24 1:42 PM

Versatility Taken to the Extreme

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Free cutting triple edged indexable inserts with positive cutting geometries and wiper flats with helical cutting edges produce excellent surface finishes at high feed rates. Versatile cutters for face milling,

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IN THE NEWS

CADILLAC INTRODUCES NEW ADVANCED MIXED-MATERIAL MANUFACTURING PHOTO: COURTESY OF GM CORP

Cadillac is known for its sleek-looking luxury vehicles. In order to remain on the cutting edge of technology, the company has developed an advanced mixed-material manufacturing technique for its all-new CT6 sedan.

The CT6, which goes on sale in the fourth quarter of 2015, will be built at the Detroit-Hamtramck Assembly plant. The manufacturing process uses a unique combination of joining techniques. The CT6 will be the first of any General Motors’ model to use these technologies.

“We have invested $300 million in the Detroit-Hamtramck Assembly plant to make this possible,” says Cadillac president Johan de Nysschen.

“These actions will allow us to advance the art of manufacturing and take craftsmanship and manufacturing technology to a new level.”

The facility features a new body shop with new tooling and advanced technologies. The plant also includes 205 robots. The fully automated, roughly 138,000-square-foot, shop 12 | MARCH 2015

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is dedicated to the manufacturing of the high-end luxury sedan.

“For the Cadillac CT6 we have developed additional new body construction techniques and technologies allowing various types of advanced and lightweight materials to be combined within the manufacturing environment like never before,” explains de Nysschen.

Material joining techniques prominent in the body construction of the CT6 include: • Patented aluminum spot welding technology • Aluminum laser welding, which creates a seamless joining of exterior panels • Self-piercing rivets, which are able to join different types of materials together with a clean appearance • Flow drill screws, which are able to join different types of materials used in conjunction with adhesive • Aluminum arc welding and structural adhesive are also separately used for CT6 body assembly.

The combination of these five techniques makes the process unique.

The CT6 engineers determine which of the techniques are best suited depending on the material combinations and body location. This is especially important when it comes to machine equipment access, making the whole process seamless.

How is this done? 28 robots are used to weld both the inner and outer vehicle frames. This is done in two separate framing stations, joining the body-in-white together from all angles. The robots are mounted above and beside the vehicle and can also reach beneath it. Cadillac explains that the two framing processes were choreographed to compensate for different microscopic vibrations.

Once the body construction is complete, a large robotic arm lifts the entire vehicle from one part of the assembly line to an upper-level conveyer. Using this type of automation technique is really pushing the boundaries for a vehicle the size of CT6. www.canadianmetalworking.com

15-02-23 11:24 AM

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IN THE NEWS

SIEMENS HITS MAJOR MILESTONE

PHOTO: COURTESY OF GM CORP

“The manufacturing team has enabled body engineers to optimize the vehicle for mass, safety, stiffness and materials with more precision than ever,” said Travis Hester, CT6 executive chief engineer.

These advanced manufacturing techniques allow for Cadillac to enhance their vehicle build quality, meeting advanced automotive standards. Automakers continue to look for new technologies and techniques to push market standards and vehicle innovations.

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Did you know that the energy production from 1,000 turbine blades generates electricity to power over 230,000 Ontario homes per year?

Well, Siemens’ blade manufacturing facility in Tillsonburg, Ontario has reached this milestone—completing production of its 1,000 th blade.

“We feel an incredible amount of honour and pride in celebrating our 1000 th blade. We’re very proud to be home to Siemens Canada’s wind turbine manufacturing facility and are excited to continue to provide jobs and clean energy to Ontarians,” says Niels Kelter-Wesenberg, plant manager, Tillsonburg Blade Manufacturing Facility.

All Siemens wind turbine blades in Canada are manufactured at the company’s blade facility in Tillsonburg, which is situated on 40 acres of land. Employees manufacture 49-metre blades for the SWT2.3-101 geared-drive platform and 55-metre blades for the SWT-3.2-113 direct-drive platform.

The blades produced at the Tillsonburg facility are installed in Canadian wind farms and abroad.

The Wind Power division of Siemens Canada employs more than 500 people across Canada, the majority work at the 253,000-square-foot facility in Tillsonburg, which has been manufacturing wind turbine blades since 2010.

As the largest employer in Tillsonburg, the factory operates continuously at capacity to support order backlog for the domestic market.

This accelerated production highlights the positive impact that policies like Green Energy Act and the Green Energy Investment Agreement (GEIA) have made on Ontario’s manufacturing sector.

Tillsonburg’s first blade was one of 372 used in the commissioning of South Kent, one of Canada’s largest wind farms.

In addition to manufacturing, Siemens has also established its first Canadian wind turbine Service and Maintenance Distribution Centre in Chatham, Ontario.

The Canadian wind energy market is growing at a rapid rate and is now the ninth largest in the world, with a current installed capacity of approximately 9,700-MW. Siemens Canada is making a significant contribution to this growth, holding a leading position in the Ontario market.

www.canadianmetalworking.com

15-02-23 11:24 AM

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IN THE NEWS

MMP EXPO RETURNS TO COQUITLAM MAY 5 Winnipeg expo, the Coquitlam event will be held on May 5, 2015. This event will be located at the Hard Rock Casino Vancouver Theatre, in Coquitlam, and will run from 10 a.m. to 4 p.m. However, you definitely don’t want to miss the keynote address that begins at 9 a.m.

We are pleased to announce that Marcus EwertJohns (pictured) will be speaking.

Ewert-Johns is the divisional vice president for the Canadian Manufacturers & Exporters (CME) British Columbia. He is responsible for leading the team to advocate for and improve the competitiveness of manufacturers and exporters in the province.

Joining the CME in 2013, Ewert-Johns has a vast background in international S-191 trade, investThe ultimate machining solution… for small precise parts. ment, marketing and export development programs. He is responsible for opening dozens of B.C. Trade and Investment offices in key markets in Asia, Europe and the United States.

Marcus Ewert-Johns’ keynote

Well, we are doing it again! The Metalworking Manufacturing & Production (MMP) Expo will be returning to Coquitlam, B.C. for a third time. After great success at previous shows and enthusiasm from both exhibitors and attendees, it was a no-brainer to return to Western Canada once again. The success of the expo allows us to grow and expand into new locations and reach diverse industries.

Recently, Canadian Metalworking announced the addition of a new show location. On April 7, 2015, the MMP Expo will be in Winnipeg with a keynote address by Don Boitson of Magellan Aerospace. As a national publication, it is important to explore all areas where manufacturing thrives.

Building on the momentum of the

address is titled, “Manufacturing Matters.” He will present an update on the important economic contributions made by manufacturing in B.C., a look ahead and a discussion on the current projects and initiatives the CME and governments are working on to strengthen competitiveness and grow business.

This presentation will shed light on manufacturing in B.C. as well as offer a unique perspective from the CME. Canadian Manufacturers & Exporters is a national trade and industry association serving as the voice of 10,000 leading companies. The British Columbia division chairs the Alliance for Manufacturing in B.C. which is a partnership of more than a dozen manufacturing associations.

The Coquitlam MMP Expo will be co-located with Canadian Metalworking’s sister publication, Design Engineering. This free, oneday table-top show offers visitors a chance to meet face-to-face with industry professionals and gain hands-on knowledge of the latest products and technologies.

The MMP Expo offers regional buying influencers from manufacturers, job shops, maintenance, tool rooms, automotive, aerospace, energy and resources, medical manufacturing, transportation and tool-die moldmaking. This unique experience offers something for everyone, no matter what industry you are in.

The Coquitlam MM&P Expo is sponsored by Sandvik Coromant, Mazak, Elliott Matsuura, TRUMPF, and Renishaw.

For more information about the Coquitlam show or our upcoming events, visit www.mmpshow.com.

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15-02-23 11:25 AM

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IN THE NEWS

MAJOR CHANGES AT BOMBARDIER Over the past several months Bombardier Inc. has been struggling with various aspects of its business, leading to changes at the top. The aerospace division has seen some major setbacks, especially with its C Series delays. Several launch partners have dropped out and the company was forced to restructure. Last month, Bombardier announced they were pausing the Learjet program causing the loss of over 1,000 jobs in the U.S. and Mexico.

However, the company has announced that they are making additional changes.

“We have one overriding objective at Bombardier: to become a true high performance organization with improved margins and better execution. We are determined and focused on delivering,” said Pierre

Beaudoin, former president and chief executive officer, Bombardier Inc. “We continue to take action to put in place the right conditions to deliver profitable growth. Thanks to the lighter structure implemented in the Aerospace and Transportation business segments, we will fully benefit from the great potential of our new products,” he explained.

After over 50 years at the helm of the corporation, Laurent Beaudoin is retiring as Chairman of the Board of Directors. His son, Pierre Beaudoin, was the CEO but has now been appointed Executive Chairman. The company also announced The best press alternative on the market Alain Bellemare for unitized tools and small die sets. as their new MULTICYL INC President and 640 Hardwick Road, Unit 1, Bolton, ON, Canada L7E 5R1 CEO, effective Tel.: 905-951-0670 - U.S. Toll Free 1-800-388-6359 - Fax : 905- 951-0672 February 13, www.multicyl.com - punch@multicyl.com 2015.

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PHOTO: COURTESY OF BOMBARDIER INC.

“I wish to welcome Alain Bellemare to Bombardier. Alain is an experienced executive who acquired a deep knowledge of the manufacturing sector while assuming leadership positions in various industries,” said Beaudoin.

Bellemare has 18 years of experience at United Technologies Corp., including at the Pratt and Whitney division that makes jet engines for Bombardier and other customers.

“We must improve profitability and realize the true potential of this great organization,” Bellemare said in a statement. “I am thrilled to take on these new responsibilities and to join forces with Pierre Beaudoin and the rest of the senior management team.”

This will be the third time in the company’s history that a non-family CEO takes the helm.

The company does have something to celebrate, though. Bombardier regained its crown as the world’s largest business jet manufacturer.

For the first time in seven quarters, Bombardier was No. 1, shipping 78 planes valued at US$2.7 billion, the General Aviation Manufacturers Association reported. However, when looking at 2014 as a whole, Bombardier lagged behind its U.S. rival, Gulfstream. Bombardier narrowed the gap in 2014 delivering 204 aircraft valued at US$7.56 billion, up from US$6.3 billion in 2013. It shipped 80 large Global aircraft, 90 Challengers and 34 Learjets last year. www.canadianmetalworking.com

15-02-23 11:25 AM

IN THE NEWS

EDC FINANCE DEAL HELPS CONNECT CANADIAN COMPANIES WITH MEXICAN AUTO OEM Export Development Canada (EDC) announced a US$100 million financing deal with Metalsa, S.A de C.V. (Metalsa), a Mexico-based OEM producer of automotive structures such as chassis, suspension, cradles and stamping. Metalsa will use the financing for general corporate purposes, upsizing and extending an existing credit facility the company has with EDC. However, this finance deal was designed to help open doors for Canadian businesses to enter Metalsa’s supply chain. Metalsa has an extensive network as they are the direct suppliers to auto-giants like Toyota, Ford and Chrysler.

Metalsa is currently interested in Canadian companies that could supply tooling, stamping, fixtures and prototyping services for their new projects in Mexico and the U.S. “Our financing for foreign buyers can pay important dividends to Canadian companies,” said Carl Burlock, senior vice-president, Financing and Investment, EDC. “Since we began working with Metalsa more than 15 years ago, we’ve seen their Canadian supply increase by more than 800 per cent.

That, by any standard, is a good return on EDC’s efforts to introduce new suppliers to Metalsa.”

The role of the EDC is to understand the needs of foreign companies and their growth plans and

seek out Canadian companies that can meet their needs. The EDC then connects the foreign and Canadian companies. Mexico is a strategic market for Canada.

Since 2003, EDC has made about $25 billion in loans to more than 200 foreign companies, leading to more than $38 billion in business with about 4,000 Canadian companies.

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MARCH 2015 | 19

15-02-23 11:25 AM

IN THE NEWS

AUTOMAKERS ANNOUNCE MAJOR INVESTMENT IN ONTARIO February was a big month for automakers. Many of the auto giants brought their newest vehicles to the show floor of the Canadian International Auto Show, highlighting the latest and greatest in vehicle prototypes and models. Not only that, two of the key automakers also made major investment announcements.

General Motors of Canada president, Steve Carlisle, announced that GM will invest an additional C$560 million to prepare GM’s CAMI Assembly plant in Ingersoll, Ontario to be a manufacturing location of next generation vehicles. $190 million will be invested directly at CAMI Assembly in manufacturing equipment and tools and $370 million in vendor tooling with suppliers in Canada.

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PHOTO: COURTESY OF FORD MOTOR CO.

“GM is making investments at the award-winning CAMI Assembly plant to enable it to manufacture the next generation Chevrolet Equinox,” said Carlisle.

He continued by explaining, “These investments, which follow planning and study with our partners, are a further vote of confidence in our employees, our business and our future in Ontario and Canada.”

GM’s current investment program at the CAMI Assembly plant rises to more than $800 million.

GM previously announced $250 million for a new body shop and flexible manufacturing equipment and

tooling, converting the manufacturing facility to support future vehicle production. This conversion plan was first announced in March 2013 following GM’s detailed evaluation process.

“This welcomed investment underscores GM’s confidence in Ontario as a global leader in automotive manufacturing, and a great destination for building the next generation Chevrolet Equinox,” said Brad Duguid, Ontario’s Minister of Economic Development, Employment, and Infrastructure.

This wasn’t the only major announcement at the Auto Show.

Ford Motor Company has also decided to invest in Ontario. The company intends to build its new high-performance supercar, the Ford GT, in Ontario in a partnership with Multimatic Inc. Ford Canada president and chief executive Dianne Craig says the automaker has 30 years of experience working with Markham, Ont.based Multimatic.

Though Craig made the announcement at Auto Show in Toronto, she did not provide any details about how many of these vehicles Ford plans to produce in Canada or if any new jobs would be created. Production of the new car is not expected to start until the end of 2016. www.canadianmetalworking.com

15-02-23 11:25 AM

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FINANCE

SECURING FINANCING FOR A NEW MACHINE There are ways to help upgrade old and antiquated equipment to the latest technology

BY KEN HURWITZ

I

n today’s world of manufacturing the competition is fierce, not only is it found from the shop around the corner but also from the shop around the globe, so the best way to maintain an edge is to install the latest and most technologically advanced equipment.

The typical shop owner is usually in the midst of a tough balancing act between trying to keep existing customers and relationships strong, finding new sources of business and revenue as well as ensuring the plant is running smoothly and good parts are being delivered. However the most successful shops are the ones who are continually upgrading old and antiquated equipment to the latest technology.

Almost every owner I come into contact with who has invested in new technology cannot believe they did not do it sooner. This is because of the positive impact the improved efficiency had on the bottom line.

But it is also the unanticipated ancillary benefits of changes to their business. Instead of competing for the same work and getting into the game of who can win the PO, they now go after more complicated work with higher profit margins and much less competition.

The new technology not only increased efficiency and profitably, but it opened doors to more work with existing customers or new work from new customers. Invariably the next move is to secure financing for another new machine.

Now when it comes to getting approved for new equipment, www.canadianmetalworking.com

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without using internal working capital, there are many places to look beyond traditional sources of funding. In cases where a manufacturer cannot get its bank manager to approve a new transaction, I always tell my clients to leverage their own equipment.

A privately owned finance institution, particularly one with expertise in machinery and equipment, can structure and secure transactions by simply using the valuable equipment on a shop floor. These types of institutions know that a good brand named machine tool has a value and, when leveraged, can help secure transaction approvals outside of the credit box of a chartered bank.

It could be as simple as using one piece of equipment as a substitute for a deposit when the financing is approved for less than 100 per cent.

There are other cases where the transaction size is far larger than the equity box of the company, and a few pieces of equipment are used the secure the transaction to lower the potential exposure. For example, securing a $500,000 machine for a company that could only support a transaction of half that size but has three or four pieces on the shop floor worth $250,000.

Other sources of funding that a typical machine shop owner may not be aware of are federal and provincial programs that exist specifically to assist Canadian manufacturers.

The Federal Economic Development Agency for Southern Ontario (FedDev Ontario) is partnering with Canadian Manufacturers & Exporters (CME) on a $20 million program called SMART Advanced Technologies for Global Growth. CME, Canada’s leading trade and industry association, promotes Canadian manufacturers and enables the successful export of Canadian goods and services. The program supports Southern Ontario

manufacturers that are looking to invest in product and process improvements that will increase export opportunities and competiveness. With respect to eligibility it is wide open, applicants must be a small to mid-size manufacturer in Southern Ontario with between 15 to 1,000 employees and are looking to invest in advanced technology assessments and projects.

Another program is the Achieving Innovation and Manufacturing Excellence (AIME) Global initiative.

FedDev Ontario is providing the Yves Landry Foundation (YLF) with up to $9 million to continue delivering this program. YLF was established by leaders in Canada’s manufacturing and business sectors in 1998. This program supports Southern Ontario manufacturers who undertake training activities such as: the development of new engineering skills; training in the use of new software, hardware or other tools necessary to support innovation; and training to adopt and adapt new technologies, new manufacturing methods or any other business area that will make the company more competitive in the global marketplace.

The takeaway from all of this is that there are many different options and programs to finance upgrades to machinery in order to grow your business. The toughest part is taking that first step and committing to improving your business.

Ken Hurwitz is a Senior Account Manager with Blue Chip Leasing Corp., an equipment finance company in Toronto. Ken has years of experience in the machine tool industry and now works to help all types of manufacturers either source or tap into their own capital to optimize their operations. Contact Ken at (416) 614-5878 or via e-mail at ken@bluechipleasing.com.

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TOOL TECH

TRADITIONAL VS. MODERN THINKING IN THE DIE & MOLD INDUSTRY

BY DORON COHEN

T

he die and mold industry dates back to ancient times; one of the first mold making practices was the production of patterns for coins and medals. Today’s mold makers are very qualified and skilled, using a wide variety of techniques and knowledge including metal removal, metallurgy, polymers, plastic flow, EDM and wire cut technology, and in many cases the key personnel in some enterprises will say that since mold or die making is not a mass production process there is no pressure to change tooling and technology.

One of the ways to analyze a mold shop’s technology level is to look at its machining methods and tools.

Many shops are “loyal” to their old instruments. Die and mold machining can be done with a wide range of cutting tools which are selected and optimized in accordance with the process chain, process step specifications, final required geometry and surface integrity, workpiece material and its properties, as well as machine tool specifications and different environmental conditions.

A typical mold shop will still use standard round-shaped milling inserts for its rough milling applications, standard ISO turn inserts for rough turning on a lathe, and HSS (high-speed steel) drill or a tap. A common belief is that mold and die shops only have a specific hole to drill and only one or two threads to tap, so why change to newer tools and add cost. However, in reality, there is a huge difference for shops that do adopt new technology.

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TRADITIONAL ROUGH MILLING WITH ROUND INSERTS For rough milling of a mold cavity or a core, traditionalists believe there is no replacement for the standard round insert geometry; methods of using either an endmill (shank adaptation) or a shell mill (screw + 2 keyways) with round inserts are well known and still widely used. There are many milling applications well suited to this type of tooling such as face milling, shoulder milling, linear and circular ramp milling, and this, in addition to relatively low prices for the cutting inserts, is the main reason for the wide use of the round inserts/tools.

However, while looking at each parameter or application of the whole milling process, and trying to efficiently optimize the common roughing technology, new cutting technologies, tools and methods can dramatically change the manufacturing process.

When approaching the metal, a round-shaped insert creates different approach angles at each depth of cut.

Basically there is a need to change the machining parameters for each depth.

A common method adopted by mold shops is to apply certain consistent machining parameters for all mold parts using the same tool. However, it limits productivity and efficient machining.

An alternative solution developed

by ISCAR, the HELIDO H600 (figure A), enables mold shops to expedite the time on the machine for each part. The approach angle is a linear Figure A

constant 17º or 30º for fast feed (FF) or medium feed (MF) implementation.

For each depth of cut applied the same machining parameters can be used.

ROUGH TURNING WITH ISO STANDARD INSERTS Using ISO standard turning inserts was the only turning method in the market for lathe products.

Rough turning was commonly done with a diamond (80°) shaped insert, clamped with a well-known lever-clamping mechanism.

Under heavy loads, micro lifts of the back of the insert occur and create micro chipping and breakage.

One solution is to use a top clamping mechanism, but only for light depth of cuts due to the fact that large chips can rub the top arm which clamps the insert.

An ISCAR solution is a diamond and trigon-shaped turning line of tools and inserts. At the clamping face there are dovetailed prisms that prevent movement even under extremely high loads and ultimately provide increased tool life (figure B).

Technology in the metalworking industry is constantly being updated and the development of new cutting tools, combined with machining processes and improvements in the complete process chain, are essential for higher productivity and improved performance for the age-old practice of manufacturing dies and molds.

Doron Cohen, industry manager, dies & molds, marketing division, Iscar.

Figure B

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BUSINESS MANAGEMENT

THE 10 COMMANDMENTS IN BUSINESS BANKING

BY ALMA JOHNS

C

anadian banks are among the most heavily regulated institutions in the world and must comply with constantly evolving capital, liquidity and systemic risk regulations. They have fiduciary duties to depositors and shareholders—which includes most Canadians, and to their credit they collectively paid $7.9 billion in taxes and provided financing to 1.6 million SME businesses (CBA, 2013).

•

•

CHALLENGES IMPACTING BUSINESS OWNERS In recent years, the commercial banking industry has shifted its focus from the trusted Advisor model into the sales manager model. This negative development is compounded by the replacement of long-tenured bank managers with short-tenured managers who are typically on the job for an average of only three years.

Akin to “revolving doors”, this trend has engendered a common sentiment among business owners—frustration that their bankers no longer understand their business. A few banks responded to this grievance by introducing industry-specialized managers with some success, but left the core revolving door issue unresolved.

Despite these challenges, following the practical rules below can alleviate frustrations and transform bankers into business partners.

• Keep Financial Statements Up To Date. Bank reporting requirements are typically between 90 and 120 days after fiscal year end. Keep your accountant on track. If there will be a delay inform the banker.

A good accounting system that instantaneously generates year-towww.canadianmetalworking.com

02CMW-BusMgmt.indd 27

•

•

•

date financial statements, A/R, A/P and inventory come in handy.

Keep Business Plan Updated. If a comprehensive plan does not exist, prepare a two- to five-page summary outlining crucial information such as: business history, background of owners and managers, differentiated products and services, industry and competitive landscape, short-term and long-term strategies, marketing plan, etc.

Prepare Financial Projections.

When a business is growing and an additional credit facility may be necessary, always have financial projections ready. Bankers typically like to see monthly projections for the first 12 months, then annual forecasts thereafter. Explain underlying assumptions behind variables.

Maintain Healthy Financial Ratios. Make sure financial ratios are “onside” especially if financial covenants are stipulated in the loan agreement. Banks have different formulae for calculating ratios, and bankers can inadvertently impose covenants that are difficult to adhere to. Understanding those covenants is crucial since any breach can have serious ramifications. First offenses are typically tolerated. Communicate any potential breach immediately and explain workable remedies.

Understand The Financial Statements. This is true both during initial discussions with the bank and annual reviews. If the numbers are not clear, ask your accountant for clarification.

Material Financial Deterioration.

Be forthcoming about any potential financial deterioration. Your banker will likely react more positively the sooner he or she finds out. It demonstrates your genuine concern about protecting the bank’s money and maintaining a good relationship.

This also allows the bank to negotiate mutually acceptable remedies.

When clients suffer severe cash

•

•

•

•

flow issues I recommend deferral of principal payments on term loans.

Be Proactive in Communicating Credit Needs. While imperative to communicate negative developments, it is also advisable to communicate positive developments.

Pick The Battle. A good understanding of “concessions” improves relationships with bankers. Remember that banks work within certain parameters and will determine terms and conditions of financing based on a company’s risk profile, a variable that can change dramatically from year to year especially in a cyclical industry. Expect to pay more if ratios are just above bare minimum, but strong financial ratios can provide flexibility in negotiating interest rates.

Bankers Are In Tough Positions.

Bankers have internal battles to fight, sometimes with underwriters or worse, with credit approvers, also known as Risk or Credit Managers. They are often caught in the middle and if pushed too hard may not be receptive at all.

Hire an Advisor. If your company has no CFO or Controller and your accountant does not provide assistance in dealing with banks or preparing a business plan, hire an external consultant. Not only does this improve the chances of getting approved and improve bargaining power, it gives the bank additional comfort that the business owner is not alone in managing his or her financial matters. Advisors can not only make banks more receptive to a financing request, but also to lower interest rates and a waiver of bank fees.

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.

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BY NATE HENDLEY

I

f you want an example of the optimism that permeates the tool, die and mold-making sector, a good place to start would be Aalbers Tool & Mold, in Oldcastle, Ontario. Founded in 1982, Aalbers is based in Southern Ontario, minutes from Windsor, Canada’s automotive manufacturing epicenter and a region devastated by the recession of 2008 – 2009. Tool, die and mold shops that survived that period are now thriving, unfazed by a sinking dollar, collapsing oil prices, dependence on the auto industry and off-shoring.

Aalbers, in fact, has been on an equipment buying streak—testament to the company’s

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confidence in improved economic conditions.

“We are an injection mold builder. We mainly build the larger range of tools, from 750 tons and up. We service tools as well. In the past two years, we’ve spent $5 million on equipment,” says Aalbers president, Toni Hansen.

Recent equipment acquisitions at Aalbers include two Amera-Seiki A800 palletized high speed machining centers, two Eagle EDM machining centers and one large Promac vertical machine centre for large tooling.

The company, which operates from a 100,000 square foot facility, also owns machine tools from Makino, Okuma and Takumi.

“We’re looking to spend approximately $3 million this year. We are looking at a www.canadianmetalworking.com

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few types of machinery…including a large, five-axis [machining centre], a horizontal pallet machine for small mold component manufacturing, and possibly, a larger EDM [electrical discharge machining] machine as well,” Hansen continues.

Aalbers boasts over 100 employees and its own 3D design department. The company recently expanded operations into new territories, opening a repair and service facility in Queretaro, Mexico.

Other Canadian tool, die and mold firms also report healthy bottom-lines.

In fact, Canadian companies dominated a list of leading North American tool and mold manufacturers published last October in a U.S.www.canadianmetalworking.com

02CMW-CoverStory.indd 29

based plastics industry trade magazine. This annual list ranks companies based on their sales figures. The latest results released to the public were highly gratifying for Canadian patriots with the top five firms of 2013 all based in Canada. From first to fifth place, these companies were, respectively, Husky Injection Molding Systems (a supplier of injection molding equipment with an estimated US$125 million in total sales in 2013), Concours Mold (US$85 million in sales), Integrity Tool & Mold (US$84.4 million), Omega Tool Corp (an estimated US$65 million in sales) and Active Burgess Mould & Design (US$63 million).

Aalbers for its part was number 24 on the list with US$24.5 million in sales for 2013.

To compile the list the magazine converted Canadian sales figures into U.S. dollars, based on a near-par 2013 exchange rate in which a Loonie was pegged at 97 cents to a U.S. greenback.

Slightly dated statistics from Industry Canada indicate there were an estimated 464 Canadian establishments with 5,616 employees that made industrial molds in 2012 (the most recent year for which figures are available). This was down significantly from the pre-recession era. In 2005, for example, Industry Canada counted 579 firms making industrial molds.

Industrial mold makers shipped an estimated $959 million of their products in 2012 (down from 2004 when $1.51 billion in shipments were recorded). The United States took in roughly three-quarters of Canadian industrial mold exports in 2012.

One recent bit of bad fiscal news—the sinking Canadian dollar—is widely hailed as a positive development by tool, die and mold makers.

“The Canadian dollar being lower to the U.S. dollar helps us with our American customers,” says Hansen.

“Certainly, from a mold makers perspective, if your customer is American, that gives you a little bit of a competitive advantage,” says David Palmer, sales manager at BuildA-Mold in Windsor, and chairman of CAMM (the Canadian Association of Moldmakers), a trade group also based in Windsor.

Build-A-Mold is listed at number 19 on the Plastics News list, with an estimated US$35 million in sales in 2013.

A Loonie hovering around 80 cents “is sort of ideal, it’s not too low,” echoes Mike Hicks, vice-president of DMS in Oldcastle, Ontario and long-time CAMM board member.

Hicks hopes the Canadian dollar stays near 80 cents. “Our shops don’t like to see a fluctuating situation”—that is, a dollar rapidly MARCH 2015 | 29

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The automotive industry is “probably 85 to 90 per cent of what [moldmakers in Canada] do,” he continues.

Hansen, for her part, estimates that 90 per cent of Aalbers’ work is auto-related, primarily with Ford, GM, Chrysler and Honda.

A total of 2.379 million vehicles were made in Canada in 2013, a drop of 3.4 per cent from the year before. By contrast, 11.066 million vehicles were made in the United States in 2013, an increase of 7.1 per cent.

These figures come from the Paris-based International Organization of Motor Vehicle Manufacturers (known as the “Organisation Internationale des Constructeurs d’Automobiles” or OICA in French).

OICA figures for the first half of 2014 offer much of the same. A total of 1.186 million vehicles were made in Canada during the first six months of 2014, a 1.8 percent dip, while 5.943 million vehicles were made in the same period in the United States, a 4.7 per cent increase.

Pundits say the slight dip in Canadian production is nothing to be feared; production is relatively stable, which is a vast improvement over the recessionary years when vehicle manufacturing bounced wildly up and down (Canadian production in 2008 slid 19.3 percent from the previous year, sank a further 28.4 per cent in 2009 then shot up by 38.8 per cent in 2010, according to the OICA).

Secondly, domestic moldmakers tend to ship their products across the continent. As long as the American auto industry is healthy, all is good in the moldmaking sector.

EMPLOYMENT IN CANADA PPAP terms remain 12,000 the norm for contracts with the Big Three automakers, GM, Ford and Chrysler. Under 10,000 PPAP (which stands for ‘Production Part Approval Process’), all components from 8,000 suppliers must meet exacting standards before being approved for use in an OEM’s production 6,000 line. Suppliers don’t get paid until all their parts are approved, which can take months, even years.

4,000 2010 2011 2012 Some shops have been able to work SOURCE: STATISTICS CANADA

gaining or losing in value against the U.S. dollar within a short period of time.

DMS supplies components to molders, die-casters and mold shops across North America. Because the company ships far and wide, Hicks hails the recent slide in oil prices.

“With Canada being such a big exporter, many of our mold shops rely on transportation to deliver their molds to the United States and/or Mexico…obviously, lower fuel prices are good for our industry…even little things like floor utilities, heating buildings, that type of thing…there’s a savings,” says Hicks.

Low oil prices are also a boon for companies that make plastic car body parts—plastic being a key element in “light-weighting” vehicles for fuel efficiency. Spurred by government fuel economy regulations and consumer demand, light-weighting is an ongoing initiative in automotive circles.

Light-weighting, and growing use of plastic body parts in vehicle manufacture, is a reminder of the close ties between the tool, die and mold sector and the automotive industry. Indeed, on January 6, 2015, CAMM announced it had entered into a “collaborative working relationship” with the Automotive Parts Manufacturers’ Association (APMA).

The two groups will work together on advocacy, trade missions and special events.

“We seem to be very aligned with the successes of the automotive industry ... since 2008/09, there’s been a good resurgence” in auto making, says Palmer.

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“A lot of the Canadian tool shops are being somewhat pressured by the OEMs and tier ones to have capabilities in Mexico,” says Palmer.

Pundits insist that Mexican satellite operations are not an economic threat to tool, die and mold manufacturing in Canada.

“The satellite operations primarily do service, repair, maintenance work—secondary work…most of the new [mold] builds are done in Canada, because that’s where the most sophisticated equipment is … the bulk of the skilled [tool, die and mold] workforce is in Canada,” says Hicks.

“If you have a tool built from the lowest bidder, in any country, you take the risk of a failure occurring in production. We have been building high quality injection tooling for 33 years and will continue to be relied on for this service,” adds Hansen.

Of greater concern is the looming shortage of skilled workers due to a rapidly aging workforce and a lack of replacements.

“I think the average age of a mold maker in Canada is like 50 years-old. We need to rejuvenate our workforce. We’ve worked closely with St. Clair College in Windsor and work very closely with apprenticeship programs” to encourage young people to consider a career in the tool, die and mold sector, says Palmer.

Interestingly enough, Hicks suggests the advent of satellite operations in Mexico might actually “attract young talent to the industry.”

These satellite operations are hungry for workers and offer “a lot of career opportunities” for young Canadians entering the job market, he points out. Young workers might toil a few years in Mexico before moving back to Canada and taking jobs at home.

The notion of building a younger tool, die and mold workforce by opening Mexican operations is an intriguCompact | Quiet | Efficient ing suggestion. This proposal exemplifies the positive outlook the tool, Number One Choice For Oil Mist Removal die and mold sector has embraced.

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“Without any global economic crisis, I think we’re going to be pretty AMT Machine Tools Ltd. 73 Galaxy Blvd. Units 15,16,17, Rexdale, Ont. M9W 5T4 healthy. We’ve come through 2008, Tel: 416-675-7760  Fax: 416-675-6988 so people are not going to forget that. They’re not going to overextend www.amtmachine.com themselves,” echoes Palmer. around PPAP terms, however.

“There’s examples where tier one and tier two suppliers and even OEMs say, ‘I’ll pay you progressively so that you’re not out of pocket for a year-and-a-half,’” says Palmer.

In such a scenario, a shop is paid a percentage of their fee at regular intervals starting shortly after delivery so they don’t have to “wait a year, a year-and-a-half before they get their money” from an OEM, he explains.

Traditional offshoring, in which manufacturers move operations to low-cost countries such as China, doesn’t appear to be the burning issue it used to be.

“They’re still building tools in China, but with the investment in new technology, high speed, lights out operations [in Canada], we’re bringing our costs down. China is essentially raising their prices a little bit. China is not the big pull it once was,” says Palmer.

And of course, some companies were displeased by the poor-quality of tools and molds produced in low-cost locales and have brought operations home.

That said, there’s currently a trend among tool, die and mold shops to open satellite operation in Mexico.

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If 3D printing is viewed as a technology for tomorrow, automation is having an impact right now.

“We’re seeing more and more automation in die-mold. Automation is starting to take hold … I think it helps create a predictable process. It takes some of the guesswork out of what used to be a kind of black art. Now we’ve entered more of an engineering realm,” states Greg Pozzo, vertical machining center application team leader at Makino in Auburn Hills, Michigan.

With that in mind, here’s a look at what’s new and/or noteworthy in terms of machining molds:

OKUMA AMERICA CORP.

BY NATE HENDLEY

I

ndustry experts offer new tools, techniques and strong opinions about industrial molds. According to these pundits, automation is hot while 3D printing is not— at least for the time being.

If 3D printing (also known as additive manufacturing) is used at all in the mold world, it’s to make prototypes, says David Palmer, sales manager at Build-A-Mold in Windsor, Ontario.

“From our business of building molds, it’s not there yet…if you’re going to produce 100,000 parts, you’re certainly not going to go with a 3D printer,” states Palmer.

“We’re a machine company. We really don’t get into additive [manufacturing]. We’re kind of afraid it might dilute our efforts in the machine world, to be honest,” adds Jim Endsley, product specialist for machining centers, at Okuma America Corp., in Charlotte, North Carolina.

That said, Endsley doesn’t dismiss the technology out of hand, “in 15 to 20 years, [3D printing] is probably going to be commonplace” in mold manufacturing, he states.

Toni Hansen, president of Aalbers Tool and Mold in Oldcastle, Ontario says much the same.

“We purchased a 3D printer six months ago. We use this for customers in need of a quick prototype or a few parts for something specific. As this technology progresses, the industry will be able to utilize these parts in more areas. Once mass production is achieved—if that is possible—it will dramatically change the landscape of tool-builders,” states Hansen.

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For die and mold work, Endsley recommends Okuma’s relatively new MU-6300V and MU-500VII vertical five-axis machines.

These machines “are becoming very, very popular with mold shops,” he states.

The MU-6300V offers highly-efficient and productive five-axis, multi-sided machining.

This VMC has a highly rigid and accurate double column structure and can do both heavy duty cutting and high speed finishing.

The MU-6300V has a rapid traverse of 50 m/ min or 1,969 ipm, a magazine capacity of 32 tools (with an option for 48 or 100-tools) and a work envelope measuring 36 inches x 41 inches x 23 inches.

The MU-500VII also boasts a double column structure and full NC five-axis simultaneous control. This machine comes with a high speed, high power, 40 taper 8,000 rpm spindle, high-speed 20-position automatic tool changer and 1,574 ipm rapid traverse.

Okuma’s Five Axis Auto Tuning System, designed to boost five-axis machining accuracy, can be used on both the MU-6300V and the MU-500VII. The Auto Tuning System utilizes a touch probe and datum sphere to measure geometric errors that can negatively impact the machining process. www.okuma.com

MU-500VII boasts a double column structure and full NC five-axis simultaneous control.

www.canadianmetalworking.com

15-02-23 11:47 AM

HAAS Haas Automation of Oxnard, California has a five-axis universal machining center, a powerful new spindle and a chip-clearing system that can all be utilized by moldmakers.

“Our new UMC-750SS five-axis universal machining center, just released for production, is suitable for mold making applications. The The UMC-750SS is a new UMCsuper speed version of 750SS five axis universal our very popular UMCmachining 750. It comes standard center and with a 15,000 rpm inline above, the Through Tool direct-drive spindle, Air Blast (TAB) 1,200 ipm rapids on all system from axes, a high speed sideHaas mount tool changer, and a high-speed, dual-axis trunnion table,” says Scott Rathburn, marketing product manager, Haas.

The 40 taper UMC-750SS has travels of 30 inches x 20 inches x 20 inches and a high speed, 40 + 1 tool side-mount tool changer.

Forty-taper spindles capable of 15,000 rpm, meanwhile, are now standard features on all new Haas VM series machines, says Rathburn.

“Something else we’ve introduced that is applicable to mold making is our Through Tool Air Blast option (TAB), which provides highflow/high pressure air through the tool to clear chips during dry machining,” says Rathburn.

Molds are commonly produced through dry machining methods, making the TAB option, “a good alternative to coolant in mold applications,” adds Bryan O’Fallon, product technical specialist, milling at Haas. www.haascnc.com

MAKINO Makino operates a Die/Mold Technologies Center in Auburn Hills, Michigan. This 40,000 square foot facility is packed with researchers, technicians, sales staff and trainers all devoted to die and mold making. An auditorium offers space for presentations, technical training and seminars when Makino has diemold information it wants to share. www.canadianmetalworking.com

02CMW-MachiningMolds.indd 35

The Technologies Center was deliberately situated close to the twin hubs of automotive manufacturing in Windsor and Detroit, says Pozzo.

“Windsor is a hot-bed of mold activity,” he notes.

In terms of moldmaking gear, Pozzo points to Makino’s F8 and F9 vertical machining centers. The F-Series boast a rigid mechanical structure and is “ideal for precision die mold machining,” according to Makino literature.

To this end, the F8 and F9 models can handle large die/mold components.

The smaller F8 has x, y and z axis travels of 51.2 inches, 31.5 inches and 25.6 inches, a 61 inch by 31.5 inch table and can take a workpiece 61 inches long by 31.5 inches wide by 21.7 inches tall. The larger F9 has x, y and z travels of 63 inches, 31.5 inches and 25.6 inches, a table measuring 72.8 inches by 31.5 inches and can take a workpiece 72.8 inches long by 31.5 inches wide by 21.7 inches tall.

Both the F8 and F9 have a payload capacity of 5,510 pounds and a 30-tool capacity automatic tool changer. The standard spindle configuration is a 49.6 hp, 10,000 rpm, CAT 50 spindle. The two VMCs can be fitted with Super Geometric Intelligence (SGI.4) software, which helps guide high-feedrate and tight-tolerance machining of complex, 3D contoured shapes.

Makino has a few new initia-tives in the die-mold area.

All will be revealed in due course at the Makino Tech Expo, scheduled for September at the Auburn Hills facility, he says. www.makino.com

Makino’s F8 vertical machining center

UNISIG Move over five axis! UNISIG of Menomonee Falls, Wisconsin, a manufacturer of deep-hole drilling systems, has developed a seven-axis deep hole drilling and machining center.

“The seven-axis USC-M38 and USC-M50 deep hole drilling and machining centers are ideal for machining molds with drastically less set-up required”, says Ryan Weister, mechanical design engineer at UNISIG. The larger USC-M50 was the first model to be released. It is now complemented by the release of the smaller USC-M38. The M50 is capable of drilling and machining all four sides of a three meter long workpiece while the M38 is capable of machining all four sides of a two meter long workpiece without repositioning.

MARCH 2015 | 35

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“The ability of the USC-M series machines to utilize two independent spindles, one for gundrilling and BTA drilling, and a second CAT50 machining spindle, greatly increases the capabilities of the M-series machines. When this additional capability is combined with a rotatory workpiece table and programmable headstock, manufacturers are able to combine multiple operations into one machine. The seven axes of control provide 3 + 2 machining to make easy work of deep hole drilling and machining of compound angles,” says Weister.

The seven axis of control are: • b axis:360 degree rotary table • a axis: rotary headstock + 30/- 15 degrees • x axis: standard for the table • y axis: the vertical column • z axis: moves the whole The seven-axis USC-M38 and USC-M50 column back and forth deep hole drilling and machining centers to allow rotation of the are ideal for machining molds. workpiece

• w axis: combined gundrilling and BTA deep hole drilling spindle • u axis: machining axis The USC-M Series machines productively utilize BTA deep hole drilling tooling to drill water line holes at rates five to seven times faster than traditional gundrilling.

The M-series machine was designed to support the large CAT 50 machine quill, making all standard milling functions available within the working envelope of the system.

UNISIG offers a full complement of options to further enhance the milling and machining functions: full enclosure guarding, a high volume mist collector for machining parts with oil on them, a 120 position automatic tool changer, a laser tool pre-setter, and probing.

“The M-series machine will produce more chips, faster, in less floor space with fewer operators,” says Weister. www.unisig.com

METHODS MACHINE TOOLS Methods Machine Tools of Sudbury, Massachusetts offers two new machines from Japanese firm Yasda suitable for mold making.

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cuts. They can be used to machine chalThe Yasda YMC 430 Ver. II is a micro lenging components for plastic injection machining center that is “ideal for the molds and aluminum extrusion dies. ultra-precise manufacturing and high surface finishes required on small, complex The wire EDMs boast a dedicated onboard AgieCharmilles AC CUT HMI (human-mafeatures in components and dies and molds chine interface) designed to reduce setup in industries such as medical and semi-contime and boost productivity. ductor,” says Steve Previti, Yasda product The series includes the CUT 200 mS, manager for Methods.

CUT 200 Sp, CUT 300 The YMC 430 Ver II boasts a high-speed, mS, and the CUT 300 40,000 rpm HSK-E32 spindle and is available The GF AgieCharmilles CUT 200mS wire EDM, part of Sp. in three or five-axis. This micro center has the MoldTech series from GF Machining Solutions x, y, z travels of 16.5 x 11.8 x 9.8 inches with www.gfms.com a work table surface of 23.6 x 13.8 inches. An automatic tool changer holds 32 tools, with a 90-tool option.

Methods recently introduced the Yasda YBM Vi40 five-axis vertical CNC jig boring-milling machine.

“The YBM Vi40 five-axis has many VISIT EMAG impressive features for high accuIN WINNIPEG ON APRIL 7 ! racy, hard milling applications of complex dies, molds and components in industries such as VERTICAL MACHINING: aerospace, defense, autoSAFE AND EFFICIENT motive, medical, electronic and more. It produces surface finishes which meet extremely tight tolerances that in many instances do not require secondary finishing The YASDA YMC 430 operations,” says Ver. II, a new Micro Previti.

Machining Center, The YBM Vi40 sold by Methods Machine Tools features a 24,000 WorkWorkSLHFH š P D[ SLHFH š P D[ rpm, 40-taper 4 in 12 in WorkWorkSLHFH š P D[ Workpiece height Workpiece height SLHFH š P D[ direct-drive P D[ P D[ 8 in 16 in 6 in 10 in spindle and has x, y, z travels of 35.4 Workpiece height Workpiece height P D[ P D[ x 19.7 x 17.7 inches, a vertical rotation 8 in 12 in of 360 degrees and a horizontal rotaTHE NEW EMAG VL-MACHINES tion of +/- 100 degrees. An automatic tool changer holds up to 60 tools with a 100-tool option. www.methodsmachine.com th

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02CMW-MachiningMolds.indd 37

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BUSINESS PROFILE: MACHINING

A SMALL COMPANY THINKING BIG Rian Solutions, Brantford, ON

BY DOUG PICKLYK

A

solid handshake and a pleasant smile is the welcome you receive when meeting the father and son team who manage Rian Solutions in Brantford, Ontario.

A young custom machine shop, it was the son, Brian Vaandering who launched Rian Solutions in June 2011 with his father Henry’s support and guidance.

Born and raised in Brantford, Henry is a machinist with over 30 years of experience in the manufacturing business. He was one of the founders of a successful local shop specializing in injection molds. That business grew to 80 staff and a plant of 20,000 sq. ft. Henry was president of the operation when it was sold to an international conglomerate in 2009.

Brian grew up in that machining environment, working on a regular basis from his early teens. It was about three years after graduating from business school at Redeemer University in Ancaster, Ontario, that Brian made the move to start up his business.

Among his first purchases was a coordinated measuring machine (CMM), a CNC lathe, and a CNC mill.

According to both Brian and Henry, the CMM was a critical component and foundational to the business. “What differentiator do you have if you only have a CNC lathe and a CNC mill?” notes Henry. “All you’re selling at that 38 | MARCH 2015

02CMW-Hurco-Rian.indd 38

point is your ability to remove metal. The theory was, if we can measure it, we can make it,” he says.

The idea was that Rian Solutions would be able to validate every product, providing customers with confidence, backed up by data.

Another step to bolster their customers’ confidence and further differentiate their offering was to become ISO 9001 certified, which they accomplished in October 2013.

From day one, Brian began flowcharting every key process in the business. “It’s just good business practice,” he says, adding that going through the certification makes you think your processes through in a logical fashion.

They also knew that their target customers were going to require ISO certification.

The company’s sales approach has also been very deliberate, making efforts to “qualify” the customers they work with. As a solutions provider, they want to be able to partner with clients, inserting their manufacturing knowledge into their clients’ value chain.

“We’re looking for customers that have design, assembly, sales and service,” emphasizes Henry. “What we try to do is develop a plan that’s going to support their manufacturing by producing products they’ve already designed.”

They’re also seeking clients with a similar business philosophy; that is, a company open to a collaborative and creative working partnership. “We’re looking for customers interested in supplier development,” says Brian. www.canadianmetalworking.com

15-02-23 11:46 AM

ENGINEER WHAT YOU ENVISION.

We’re driven to find out what our customers want and committed to make it happen. We concentrate on the applications and what they need to do.

We help engineer the engineering.

To us, perfection is practical. It’s the most productive and efficient way to achieve results, and the only way to turn vision into reality.

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BUSINESS PROFILE: MACHINING As a prime example, the Vaanderings have been working with a customer who has developed new energy-efficient transmission technology, and they are confident the demand for this industrial equipment—which is just hitting the market—will grow and become a significant portion of their business over the next three to five years.

“That’s what we’re hoping for anyway,” says Henry with a measured confidence.

A large portion of Rian Solutions’ current work is in the mold, tool and die sector, with inroads into power generation, agricultural machinery, military, dental and industrial automation. The services they provide include turning, milling and grinding as well as the CMM and reverse engineering.

Since start up the company has installed additional machine tools including three Hurco machines—a fiveaxis mill, four-axis mill and a three-axis lathe. They were drawn to the Hurco products while visiting the IMTS trade show in 2012. “We brought drawings with us to the show,” recalls Henry. “The Hurco demonstrators were able to program the parts at the machine as fast as it would take us to load the drawings into a computer.”

They felt the conversational programming ability for basic machining operations on the Hurco stood out. “It was a clear differentiator for us,” says Henry. “Instead of needing someone working offline, the operators are able to take the drawings and create their own programs at the machine.”

This ability saves valuable time and allows the business to keep its costs down. The Vaanderings also point to the ability of the machines to be programmed and

Brian Vaandering of Rian Solutions with one of the Hurco machine tools on the plant floor.

40 | MARCH 2015

02CMW-Hurco-Rian.indd 40

prepped while they’re running as another key productivity enhancement.

The Hurco installation began in December 2012 and both men comment very favourably about the service and support they’ve received from Elloitt-Matsuura Canada.

“They were able to help us take the steps required to learn the software, and start to offer these additional machining services,” says Henry.

Brian was particularly impressed with the short learning curve. “Our operators who were trained on them had no programming experience whatsoever, and through the training with Elliott and Hurco they became self-sufficient in a very short amount of time.”

Loyalty is a core element to Rian Solutions’ community-minded business approach, so they treat their suppliers the same way they treat their own customers.

“We buy everything from Elliott because of the service and support they provide,” notes Henry. And the company has since purchased a Matsuura 520 five-axis mill to accommodate some larger parts they’re working on.

Going forward, with their eyes on further servicing the medical industry, Rian’s next purchase will likely be a smaller machine for finer small part precision machining.

Built in to their business processes is a commitment to continuous improvement. Part of that includes building strong relationships with its tool suppliers.

“As a custom machine shop, finding quick solutions becomes necessary as our product mix changes frequently,” says Henry. In some cases they may have a short window of time to call on suppliers to get the proper tooling for new machining applications. “We’ve targeted three main distributors of cutting tools to partner with and bring solutions to us,” notes Henry. Again, building relationships built on loyalty and mutual respect.

Looking forward, the company has a five-year business plan, and they know where they want to go and how they want to get there. They’ve been experiencing 15 to 20 per cent growth year over year, and that continues to be their target for the next few years. “We have a pretty good idea that it will happen,” nods Henry.

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BUSINESS PROFILE: MACHINING has been growing ever since. They’re now up to 14 employees, including Brian’s two younger brothers. This past November the business expanded, moving into a vacant nextdoor unit, growing their space to 6,000 sq. ft.

With stable business processes in place, Henry suggests that by 2016 they’ll begin automating aspects of their production. “We have goals that we will automate our milling machines in 2016,” he says, noting that they expect to put System 3R common pallet on their equipment.

They don’t anticipate the company growing much beyond 20 employees, but they will continue adding equipment and automation.

“Can we grow the business using the intellectual power we have and automate what we do?” asks Henry, answering, “That is the goal.”

Both suggest that the biggest obstacles they face are time and resources. “When you’re a small company you have more responsibilities. Time becomes the challenge—time to get everything done that you want to do,” says Brian.

They estimate that 20 per cent of their time is still spent on the shop floor. “You need a careful balance between working on the business and working in the business,” says Henry. “It’s finding that balance so you keep your order book full and you’re keeping to the business plan that you have.”

They admit that machining is a stressful industry with short lead times, where it’s a challenge to meet customer demands.

If something goes wrong during production there is very little time to recover, 42 | MARCH 2015

02CMW-Hurco-Rian.indd 42

or working with an unfamiliar material requires The Zeiss CMM is a dexterity to adapt and cornerstone of the Rian Solutions business. manage the request.

“So many companies talk about trying to exceed customer expectations,” says Henry. “But most people will be very satisfied if you meet their expectations—delivering a quality product, on time, in full.”

In their presentation to prospective customers they spell out how they are “passionate about machining. We love what we do.”

“We love the difficulties, the problem solving,” says Brian.

Collaborating with customers, employees and suppliers, being creative to develop their services and delivering quality products, that’s why they put “Solutions” in their name.

Henry smiles as he retells a very satisfying comment he received from one of their main customers. “You’re a small company that thinks like a big company, and services us like a big company.”

That’s just the way Rian Solutions wants to be seen.

Members of the Rian Solutions team, with Henry Vaandering on the far right.

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15-02-23 11:46 AM

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LOOKING BACK:

THE COVER STORY I

n celebration of this magazine’s 110 th anniversary, this year we’re searching the archives for memorable moments, historical gems and articles of general interest.

In this issue we look at the magazine’s first covers. Originally called Canadian Machinery and Manufacturing News, the first issue was published in January 1905 and ran 68 pages. The colour cover featured an artist’s rendering of a foundry. The first four issues of 1905 all repurposed this same image on the cover.

The May 1905 issue took a fabricating slant, showing workers fabricating an industrial pipe, and then in June a photograph of Niagara Falls graced the cover. The caption under the photo read: Canadian Horse Shoe Falls—The Mighty Source of Electrical Power. 1905 was a watershed moment for the manufacturing industry in Canada and Niagara Falls played a major role in that industrial revolution.

The July and August 1905 covers continued the theme of the Niagara Falls power generation. The July issue featured a photograph showing the machining of one of the castiron sections that was going to be placed at the Electrical Development Company generator. The Electrical Development Company Ltd. (later called the Toronto Power Company) started generating power in 1906.

It was the first Canadian-owned operation to generate electricity at Niagara Falls and it was the largest hydro-electric power system of its kind.

The station operated 11 turbines producing 11,000 horsepower each. Eventually taken over by Ontario Hydro, the station was decommissioned at the end of 1973. The photograph on the July 1905 cover was taken at the Canada Foundry Co., Ltd. where the castings were made and machined.

In August the cover reveals the installation of a turbine set at the power station of the

The fifth issue of Canadian Machinery, May, 1905, a fabricating illustration (left).

The June 1905 issue featured a photo of Niagara Falls “The Mighty Source of Electrical Power”.

44 | MARCH 2015

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15-02-23 11:09 AM

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Ontario Power Co., Niagara Falls. They were the largest capacity horizontal turbines ever built at the time.

The Americanowned Ontario Power Company hydro-electric generating plant opened in 1905.

It was eventually taken over by Ontario Hydro, and in December 1999 the power station was decommissioned from service in order to accommodate the building of Casino Niagara, which is located on the former transformer building site.

The final four covers in 1905 repurposed an artistic etching of a young man stepping into the metalworking labour force.

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The photograph gracing the cover of July, 1905, was taken at the Canada Foundry Co. Ltd., showing the machining of a part headed for the Electrical Development Company hydro-electric generator at Niagara Falls.

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02CMW-100yr.indd 45

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Even in 1905, the call for more young workers in the industry was strong.

This passage from the September 1905 issue describes the message behind the artist’s rendering. … the whole effect lends itself towards bringing forward the central figure, at whose left the picture panel typifies manufacture and industry. He is a man of brawn and muscle, as yet at the bottom of the ladder of progress, but withal resolute and determined. He hears ambition’s call to press forward, and is about to take the step that will lead to the culmination of his present dream—that of becoming a master workman instead of a haphazard laborer of whom nothing is expected. He is typical of the present-day trend of thought, when men are not satisfied with conditions as they find them, but seek self-improvement, and in so doing benefit not only themselves but uplift the standard of mankind.

The Editorial Section of the debut issue explained the demand for and need for a manufacturing magazine in the country. ”Canada has reached the point where indus-

trial expansion is just as vital to her progress as agricultural or commercial development. For nearly a decade manufacturing has been given a great impetus by the happy combination of good crops, a rapidly-increasing population and growth of national sentiment finding expression in wide legislation.”

It also spoke of the pioneering spirit of the country’s growing manufacturing sector and willingness to invest in new process and equipment.

“We would not have attempted to start such a paper if our faith in the future of Canada had been less buoyant or if our confidence in the enterprise of Canadian machinery buyers had been less strong …

“Since the definite announcement of our intention to publish Canadian Machinery and Manufacturing News, we have received most satisfactory encouragement from every part of Canada, and definite support, as will be seen from our advertising columns, by a large proportion of the leading manufacturers of the country.

In fact, so kindly has been the reception of the paper that its success is practically assured from the start.”

It was with such confidence that Canadian Metalworking was launched, and it is with continued conviction and support that the magazine will continue to publish for years to come.

The August, 1905, cover (left) shows a turbine installed at the Ontario Power Co. in Niagara Falls, the largest capacity horizontal turbines in the world at the time.

The artistic etching on the final issues of 1905 represented the forward march of manufacturing in Canada and the aspirations of young adults heading into the profession.

46 | MARCH 2015

02CMW-100yr.indd 46

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Metaline’s business development manager Roman Shimonov with the company’s new Bystronic BySprint fiber laser cutting machine.

BUILDING WITH CONFIDENCE Metaline, Toronto, ON

BY DOUG PICKLYK

T

he line-up of luxury cars, including BMWs, Mercedes, Lexus, Cadillacs, Range Rovers and Hummers—regular and stretch versions—are what you’d expect to see along a red carpet in Beverly Hills, not inside an industrial space in North Toronto. But it’s in this space, where these vehicles are either stretched and customized or armour clad (or both), that an upstart metal fabricating business with high aspirations of its own is equipping itself to become a major player in the fabricating business.

Launched at end of 2012, Metaline is a division of the INKAS group of companies, a privately-held Canadian business specializing in security and protection services. The Metaline division was started up to fabricate sheet metal parts for other divisions of the INKAS group, which include the manufacturing of armoured vehicles, limousines and safes.

Armoured vehicles is the group’s largest division and has been growing for the past five years. “Since 2012 we have doubled our production, right now we produce more than 35 vehicles per month,” says Roman Shimonov, manager business development with INKAS. “And our goal next year is to double our production.”

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The company designs and manufactures heavily armoured personnel carriers for armed forces the world over, as well as retrofitting those luxury cars often seen in presidential cavalcades.

INKAS used to outsource its metal fabricating, but once its volumes began reaching over 30 cars per month, they elected to invest in their own fabricating machinery.

The entire INKAS operation covers about 170,000 sq. ft., with the Metaline business occupying about 70,000 sq. ft. To outfit its metal fabricating business Metaline elected to go with Bystronic technology. “We conducted our research, and in terms of service, quality of products, delivery times and maintenance issues, Bystronic was much better, not only on the laser, but also on the bending machines,” says Shimonov.

The initial technology installed included a Bystronic Bystar 3015 CO2 laser cutter and Xpert 150 press brake, followed by a Bystronic Xpert 650, a 650-ton press brake.

For the armoured vehicles and the safe manufacturing businesses, Metaline works with 5.5- to 8-mm ballistic steels. The ballistic steel is designed to absorb energy and be able to stop bullets. Over time the company has learned how best to handle this special material, bending, cutting and welding it in ways that will not compromise its integrity. They have a local shooting range where products are tested with different calibers, www.canadianmetalworking.com

15-02-23 11:52 AM

BUSINESS PROFILE: FABRICATING

One of the initial installs was a Bystronic Bystar 3015 CO2 laser cutter.

speeds and distances. “We don’t take any risks,” says Shimonov. “Our role is to save lives, and that’s a huge responsibility.”

A walk around the production areas reveals the vertical integration of the INKAS companies’ vehicle production. For every limousine the company manufactures the side panels, doors, roof and floor areas along with the leather seats, along with having a woodworking area where they match the interiors of the luxury vehicles and an entire electronics area to further customize the vehicles.

To keep up with internal production demands the capacity of the Metaline business was further enhanced in early February with the addition of a new Bystronic BySprint Fiber 3015 fiber laser cutter for thin to medium gauge sheet metal and a Bystronic Xcite 80 E electric press brake.

Although in operation for a short period, Shimonov has been impressed with the new additions. “The performance of the 80-ton press brake [Xcite 80 E] has been unbelievable. It’s very fast, and it looks good with its small footprint,” he says.

He’s also been surprised by the speed of the new machine tools. “When you add another machine, logically you think you’re going to increase your production by 100 per cent. But here you increase it by 300 per cent.

On paper it looks nice, but to see it actually cutting the metal, it’s really exciting. You don’t believe it’s metal. It’s like cutting through butter.”

The improved speed helps meet the tight deadline demands of their clients, and the shorter production time also benefits Metaline by reducing the need for www.canadianmetalworking.com

02CMW-Metaline.indd 49

Metaline operator with the company’s new Bystronic Xcite 80 E press brake.

extra work hours.

Shimonov also points to the advantages of the precise laser technology. The clean cuts require less post-process grinding, and with small gaps between the parts combined with efficient nesting programs the amount of sheet metal waste is greatly reduced.

“The technology we’ve purchased allows us to produce much more than we need for our internal use, so we have decided to expand and provide our fabricating services to other companies as well,” he says. Currently about 40 per cent of the Metaline business is dedicated to internal work while 60 per cent is external, servicing clients in various sectors including industrial, retail, medical and automotive. “Our goal is to make the internal usage not more than five per cent,” he says.

He points to a company that INKAS used to outsource to that is now sending work to Metaline because the speed of turnaround allows them to be more competitive.

Metaline has a very aggressive sales structure, and is determined to continue expanding its business. “Within two years we want to more than double our production capabilities,” says Shimonov.

They have already increased their crane capabilities, adding a magnet in order to load larger parts with less worker intervention.

They’ve also engineered and constructed their own heavy duty shelving units to support heavy metal sheets. According to Shimonov they’re able to Roman Shimonov with Metaline’s Bystronic Xpert 650 ton press brake.

MARCH 2015 | 49

15-02-23 11:52 AM

BUSINESS PROFILE: FABRICATING

The INKAS Huron Amoured Personnel Carrier, a 16-person vehicle clad in ballistic steel.

hold three-times more than prior units. He also adds that the company is planning to install a Nitrogen generator, allowing it to produce nitrogen to feed the CO 2 laser.

With all the rapid changes, it’s the area of human resources that is proving to be a limiting factor to Metaline’s growth. The company is actively recruiting people to qualify them or to bring experienced people in and make them even more qualified. “This is the biggest challenge that we have. Because we’re growing fast, we need to have employees whose professional skills grow as fast as we do. We expect to be hiring a lot of people,” says

In the same facility as Metaline’s fabricating business, luxury vehicles are stretched and customized for customers around the world.

50 | MARCH 2015

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Shimonov, noting that they have open positions for mechanical engineers, sales executives, as well as laser and bending operators.

The company is ISO 9001 certified, and places added emphasis on process because of the standards it must meet for its internal clients. “For us, it’s very important to build a structure with extra controls at every stage to ensure all clients are receiving the best quality parts.”

The nature of Metaline’s work allows for no compromise. Safety is also an ongoing process internally, with weekly meetings and a dedicated person in the shop ensuring safety on the floor.

Security is also ingrained through every aspect of the INKAS Group of companies. Metaline has built userfriendly and transparent ordering system that provide visibility from the shop floor to finished products and delivery. And as part of the larger INKAS professional security business, Metaline has developed secure systems to manage their inventories and all client files.

When Shimonov describes the Metaline business, from the design engineering through to the shop floor and the finished products, he’s proud of the blend of technology and craft.

“Our operators and engineers are like artists,” he says.

“To the outside world metal fabricating looks like a very industrial sector, but when you have the right machines combined with the right knowledge and experience, it’s not so industrial but more of a high technology business.” www.canadianmetalworking.com

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

SEPTEMBER 28 – OCTOBER 1, 2015

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L

et the countdown begin to the Canadian manufacturing industry’s 2015 event of the year—the Canadian Manufacturing Technology Show. Returning this fall to newly-upgraded International Centre (conveniently located just minutes from Toronto’s Pearson International Airport) the event will run from September 28 to October 1, 2015, and this year CMTS promises to support Canadian manufacturers as they “Manufacture the Future.”

“For CMTS 2015, one of the major changes we undertook was to further organize the exhibit halls and related technologies so that visitors can more easily source the equipment and solutions they are seeking,” says event manager, Julie Pike. The show will be held in Halls 1 to 4 with a focus on Advanced Manufacturing in Hall 1, including the debut of the Rapid Canada Pavilion showcasing the latest advancements in additive manufacturing, 3D printing and scanning. Halls 2, 3 and 4 will be dedicated to machine tools, tooling and metalworking technologies.

“Another new concept we’re introducing in 2015 is ‘The Tech Shop’, an interactive learning and lounging area right on the show floor,” adds Pike. “Visitors will be able to take in complimentary ‘tech talks’, where they will hear about and see some of manufacturing’s latest advancements.”

At its core, the show brings together more than 8,000 manufacturing professionals over four days to source the latest advancements in technologies and solutions in the machine tool, tooling and workholding, metal forming

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and fabricating, advanced manufacturing (including 3D printing/additive manufacturing), automation and robotics, and design engineering. The event also draws a growing national and international audience from major industries including automotive, aerospace, medical and energy, among others.

MANUFACTURE THE FUTURE CMTS is viewed as a leading-edge event that offers the Canadian manufacturing community the most comprehensive display of cutting-edge technologies and solutions under one roof. Coupled with credible industry resources and timely conference tracks, this year’s tagline “Manufacture the Future” promises Canadian manufacturers the support to grow and evolve their operations.

“We believe that CMTS, with all the leading innovative brands that manufacturers know and trust, is an event that offers unparalleled opportunities to discover the solutions for what tomorrow’s manufacturing possibilities can be,” says Pike.

Watch for regular updates in Canadian Metalworking as we ‘countdown’ to CMTS and share exciting announcements and highlights in future issues and online. For the latest event news, or to find information on exhibiting, attending or sponsoring at CMTS, visit the re-launched CMTS website, www.cmts.ca or contact Julie Pike, event manager at jpike@ sme.org or 888-322-7333, ext. 4471.

To learn more about SME, the producers of CMTS, please visit www.sme.org www.canadianmetalworking.com

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Various punching strategies can bring success to your business

BY NESTOR GULA

W

The Amada EM 3612 ZRT offers features like punching drive with energy recovery capabilities, dual AC servo drives, and a high-speed automatic tool changer.

WWW.AMADA.CA

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hile new technologies are regularly introduced in order to speed up manufacturing processes, making them simpler and more productive, punching remains the most efficient and least expensive method for putting holes into sheet metal.

But making simple holes in sheet metal parts is only one of the processes modern punching machines can perform, as the capabilities of automated systems begin to integrate multiple applications to increase the functionality of these tools.

“With the latest technologies, punch machines can

complete far more operations on the machine, eliminating second handling of parts,” says Dan Caprio, punching sales manager for LVD Strippit Inc, who explains that these operations include formings, louvers, knockouts, tapping, shear cut edges, deburred edges, bending flanges up to one-inch high and much more.

MANY PUNCHES To add flexibility many high-end automated machines switch their dies to apply more than one procedure, be it punching a hole, making a louver or bending the sheet metal. These machines can, in most instances, replace some stamping machines. “Stamping presses use very expensive and often complicated dies to stamp out a part in one cycle of the press, or in the case of a progressive die, perhaps several cycles of the ram. Once in operation, a stamping press basically makes a complete part with every cycle of the ram,” explains Timothy Brady, punching and combi product manager for Amada America, Inc. Stamping presses can make dozens or even hundreds of parts per minute. Yet, tooling can be very expensive due www.canadianmetalworking.com

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“The E6x allowed us to produce all the louvers inhouse, saving us nearly $1-million. It also allowed us to decrease our prototyping time.

We were sold on the servoelectric design and speed of the E6x. The machine was also competitively priced, and we liked the fact of the proximity of the service technicians.The

PRIMA POWER has a 15-year history in the development of servo-electric turret punch presses. Our productive and flexible machines have made such terms as auto-index, Multi-Tool, and upforming popular in the sheet metal fabrication industry. Our new generation of servo-operated turret punch presses offer versatile punching, nibbling, forming, and bending capacity on a single machine tool.

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E6x also gave us flexibility in how we choose to manage our inventory. We can reduce our inventory from three months to three weeks.The Prima Power equipment has brought Jamco into the 21st century.

The servo-electric turret punch press and press brake have increased our productivity, flexibility, and accuracy. Prima Power has helped bring Jamco to the next level.”

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LVD’s VX-Series combines a 20 metric ton hydraulic ram with a large 48-station turret.

This system comes in two models, VX-Series 1225 and VX-Series 1525.

WWW.LVDGROUP.COM

to the complexity of the design and can take some time to build. Brady says that tooling can range from as low as $10,000 to upwards of $100,000. What is more, the tooling requires a fairly high degree of skill to set up in the press. “On the other hand, a turret punch press uses a multitude of standard tools [in the turret] which are rapidly selected and used to ‘nibble’ complete parts out of a large sheet.” Turret punch presses range in terms of how long they take to produce a part, anywhere from several seconds to several minutes per part.

The turret punch press offers several advantages, but one of its greatest features is its versatility. Brady explains that it is its ability to make an unlimited number of different parts using the same set of tools that sets the turret punch press apart. What is more, the press

offers the ability for quick and easy changing of tools using relatively unskilled operators.

Modern CAD/CAM systems can allow rapid programming of parts making it possible to design, program, and produce parts in a very short time. “[It can be as quick as] same day or same hour,” says Brady. “Design updates or part rev changes are not a problem, and the ability to economically make small quantities of parts to meet ‘just-in-time’ demands

TRUMPF’s TruMatic 7000 gives you the best of both worlds. Offering scratch-free punching and high speed laser processing, the TruMatic 7000 features a 4kW laser and a punching head with a max stroke rate of 1200 1/min in the medium format.

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are the forte of the turret punch press.”

The tool storage capacity in a turret-style punching machine gives it great flexibility. “Most turret tools do not require specialized measurements and data entry by the operator,” says LVD’s Caprio. “Tools for several different jobs remain in the turret for reduced set up for job changeover. Very rugged, mechanically simple designs are possible since tooling remains held and fully guided within the turrets.”

Although turret punches are one way to have multiple punching tools on hand, not all manufacturers chose this system to bring many tools into play. “TRUMPF offers punching machines with a single head punch technology system which allows for auto tool rotation of all tools, less wearable components, faster tooling set up times, and tooling rail changeover times in www.JesseEngineering.com “Click on Pipe Benders” less than three minutes,” says Mike Kroll, TruPunch product manager 12” 3D! for TRUMPF. He explains that this equates to an average machine uptime (the time the machine is actually punching) of 70 per cent, compared to 35 per cent uptime seen in the latest turret machines offered.

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MATERIALIZING VISIONS

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SINGLE PUNCH SOLUTION There is still a place for simple punch systems for shops requiring a dedicated punching tool to perform specific functions. “They are small and compact. They are less expensive. And furthermore, for the right type of application, medium sized light gauge runs, they do as good or better job,” says Todd Bryson, vice president of operations for Multicyl Inc. The company manufactures air over oil presses used in punching applications among others. “So when you get into very high volume runs, or heavy stuff, ours might not be the right ones suited for it. But if you have medium volumes, light duty, there are all kinds of advantages to it. Ours would be good for long runs only if it is dedicated.

With volumes you are not going to do 10,000 parts a day, or two shifts per day with our punching machines. It is great for short runs because it is small and compact and inexpensive, so you’re not tying up a large expensive press.”

The punching tool in the punches can be changed to suit the part being manufactured.

“It depends on what type of die you are using for your applications,” he says. “We certainly do have an option for quick changing. If we use unitized tooling for example. If you have a C-frame styled tooling, that can be changed out. That is the most common type tooling.”

The tools held in these systems can be standard or customized as the application calls for. The amount of tools held varies by manufacturer giving virtually unlimited capabilities to these punching systems.

PUNCHING PLUS A relatively new aspect in the manufacturing world is the combination of a punching system with a laser cutting machine. “Combining a laser with a turret creates the ultimate fabricating machine with the ability economically punch and form parts while having the lasers ability to cut unlimited shapes with excellent edge quality,” says Brady. Adding a punch machine to a laser there can give a manufacturer several benefits.

Space limitation is just one example of why a combination system would beneficial. Having limited space, having a separate punch and

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laser machine might not be possible. “This [is when a] combination [system] will work well,” says Kroll. He explains, “the part geometry can allow for internal punched holes and form, but the outside edge may have contours not suitable for punching, or laser cut quality of the edge is needed. If automation is being used, part separation and sorting can save hours of sorting time with a combination machine.”

However, these benefits come at a price.

According to Brady, adding laser capabilities to a turret can nearly double the cost of the turret punch press. “It’s a no-brainer that a combo machine will have an advantage over a punch only machine, but budgetary considerations often rule it out,” he says.

There is a challenge when it comes to combination machines. In the industry, there is an ongoing conversation over efficiency.

Combining a turret punch press with a laser results can mean that half the machine is idle while the other half is working.

According to Brady, “having a separate turret punch press and laser machine means they both can be 100 per cent utilized.” This is only a real problem when parts must be produced that require both punch and laser

www.canadianmetalworking.com

02CMW-Punching.indd 59

features. “Programming and coordinating these parts to run through two machines is much more difficult and problematic.”

CAPABILITIES Systems are limited by the thickness of material that can be punched. However, modern punches can perform many functions in one machine that used to be done in multiple stations. “A turret punch system can do forming and special shapes, rolling, ribbing, offset, cutting, pincher wheel, and tapping,” says Caprio.

It’s all in the value added features, explains Brady. “Besides just punching and nibbling of flat parts out of sheet metal, the turret punch press is capable of producing many… features in sheet metal parts such as, part marking [logos and lettering], embossments, extrusions and tapping of holes, louvers and much, much more.”

Combining four technologies in one package (punching, forming, marking, and laser cutting), Prima Power’s LPef laser punch series offers versatility.

WWW.PRIMAPOWER.COM

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Software and machines work together to bring advances to manufacturing

BY NESTOR GULA

T

he evolution of the modern fabrication plant has progressed along two parallel lines: the machines have become more sophisticated, faster, and more accurate; while the software that drives this machinery has become more powerful, elegant and user friendly. It can be argued that advancements in both hardware and software are required to drive each other forward.

“They have to work hand in hand,” says Mark Szczepanski, vice president of customer service for Shop Data Systems Inc., a software developer for the metal fabrication industry. “You have partners, machine builders and software developers, and when they partner up together the software enhances the capability of the machinery.

All machines have a finite capability and they are designed to do a certain function, and what we do is enhance the machine’s

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capability and optimize the machine productivity.”

As software is nearly infinitely expandable, this allows developers of fabricating machinery to add more functionality to the machines. “As with anything else it is always the software technology that takes advantage of the hardware capabilities. Software has become more automated just as machines have become more automated,” says Frank Arteaga, head of product marketing, NAFTA region, for Bystronic Inc. Both software and the machines need to evolve together.

Software advances create new opportunities for hardware innovations.

Automation, which is made possible by software, combined with machine functionality is introducing improved productivity, speeding processes, time savings and expanded profit margins. “Functions such as auto focus, torch and nozzle changers, and automatic ‘blue flame’ are now standard on www.canadianmetalworking.com

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The vFACTORY from Amada is a system that monitors each part, each job and each department.

The software monitors machine and tooling maintenance schedules and can automatically send alerts via e-mail or cell phone.

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Mazak laser machines,” says Tim O’Donnell, software supervisor for Mazak Optonics Corp. “The software’s ability to generate NC code controlling this functionality has allowed these once manual operations to instead become automated procedures, minimizing operator work load and machine down time.”

The improved technology of the manufacturing machines could not take place without the advances in upfront software engineering. One area that this can clearly be seen is through the development of sheet metal manufacturing, says Dave Hartman, laser product specialist at LVD Strippit.

“Developments such as automation, continuous monitoring of the KPI resulting quality, rise in productivity and CAD software solutions for part preparation.”

Much of the software advancements have also come about as a result in the exponential leaps in computer processing power. “Thanks to semiconductor advancements, technology has made the limitations of the past disappear. Just look at iPhones and other similar devices that have a thousand times more computation power than desktop computers did in the 1980s and 90s,” says Jonathan Kim, division manager, software operation with Amada America Inc. “The most important manufacturing software actually resides inside the machine’s controller. If you look at the machine controller today, you have access to USB imports, you have the Internet, you have great computation power, and you even have the ability to render 3D models. This really allows the machine controller software to process complex data.”

The computer software and hardware are not the only new technologies that have increased the functionality of today’s manufacturing machines.

“You are seeing more advanced sensor technology trickling down,” says Kim.

Amada’s Dr.ABE_Blank can create CAM data quickly, producing intelligent part nesting with a company’s own parameter settings.

WWW.AMADA.CA

“Like ‘smart home’ devices, what you will see is a smart factory, with smart fabrifabri cating machines with built-in controllers running the latest software innovations. I think we will see is this innovainnova tion start, because the barrier of cost from having expensive computer and expensive sensors is decreasing considerably. The latest Amada machinery that incorporates the smart features will be able to actually monitor, record and notify. This is all being fuelled by software.”

EASE OF USE To address the lack of experienced operators entering the industry, manufacturing software is being designed to bridge the skills gap. One of the features that address this issue is a complete touch screen interface for the latest CNC controls. This allows for all possible functions to be available on each screen with no large quantities of hard push buttons on the control panel, explains Arteaga. “With today’s modern touch screens, if you can operate a smart phone you can learn how to operate a machine control,” he says.

The digitization of the entire manufacturing flow, from product design to the shop floor tools, is simplifying the process.

“The ability to have the software take raw CAD data and use automated processes to quickly and easily generate program data for the machine tool is just the first step,” says O’Donnell. “The ability of today’s laser machines to utilize things such as built-in cutting table data, automatic torch and nozzle changers, as well as auto focusing, has allowed for greater reliability and consistency of the cutting process, all while helping to greatly minimize the demands placed upon the machine operator.”

Getting operators up to speed supplier training programs are also being adopted to “While having experience is beneficial, it isn’t always a necessity. For 2D programming, a basic knowledge of computers and Windows is a good starting point. For 3D programming, having experience with a 3D CAD package www.canadianmetalworking.com

15-02-23 11:39 AM

like SolidWorks or Pro-E can be beneficial,” says O’Donnell. “That said, with our many years of training experience, we have successfully trained personnel with a wide spectrum of knowledge and capabilities.”

For Shop Data Systems, they are always looking for customers that have a desire to learn and really be involved in the manufacturing process. Szczepanski explains that operators need want to do a better job than the one they are currently doing, that’s where the software comes in. Shop Data Systems offers comprehensive on-site training as well as in-site training with their experts, providing customers with the tools and knowledge to run even the most complicated of machines.

Most, if not all, parts are designed on a CAD system, which are then read by the software on the machines. CAD systems are user-friendly and allow each drawing to be created in a digital format. Software

Mazak Optonic’s e-Soft gathers, stores, and distributes manufacturing information allowing factory staff and management to view machine activity in real time and respond WWW.MAZAKOPTONICS.COM

made the machines more efficient and increased throughput,” says Hartman. These software systems in turn can then instruct the employee how to create the part using the machine if manual input is needed in any step of the procedure. “Systems like LVD’s Easy-Form allow inexperienced brake users to get the right part every time.”

As technology advances there will be a lot more features in the software and in the machines, but the software itself will make the machines simpler to use. “You can employ anybody with a bit of computer skills to operate the software,” says Kim. “If you are looking at implementation of the software, you do need expertise, because you are optimizing it for the environment and your requirements. For this you will need experts to fine tune the software, but once it is finetuned, then the people are basically data entry. They are software operators.” www.canadianmetalworking.com

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Training sessions depend on the industry and the machinery in question. “The OEMs might spend a day training on the software and then we will spend quite a good amount of remote assistance through the computer,” says Szczepanski. Some industries may require more hours or days of training than others. Generally training can take four to five days. However, something like plasma bevelling might take up to a week and a half to train,” explains Szczepanski.

Having experience working and knowing the non-computer concon trolled machinery still helps on the job floor. “It eliminates having to learn the why aspect of what you are learning. The application of bending is already known, it is only the process that needs to be learned,” says Arteaga. Training experienced workers is well worth the investment because of the rewards this will bring to the company.

“When you have someone who is familiar with the machinery and then you add the soft-

Simplifying the laser cutting process, the Touch-L from LVD uses intuitive graphical icons and visual indicators to display and control functions.

WWW.LVDGROUP.COM

With a 22-inch touch screen, ByVision Control from Bystronic lets users maneuver through screen selections for easy setup and operation.

WWW.BYSTRONICUSA.COM

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Shop Data’s Basic Parts software combines a built-in drawing and importing feature, flexible automatic and interactive tooling, and interactive nesting.

ware to it, they become supercharged because they know the machine, they know the machine capability, so now they have a new tool, the software, and will do nothing but increase their productivity,” says Szczepanski.

WWW.SHOPDATA.COM

One of the reasons for the efficiency of the new fabricating machinery is that you can program and load part orders in offline, while the machine is working on another job. The offline programming makes the machines easier to run. “It used to be that someone had to stand in front of the machine’s controller and program the machine. Generally the machines require minimal interaction in a fully automated environment,” says Kim. “The more there is interaction on the shop floor level with the machines this basically causes the machines to be on standby and idling. So that reduces production capacity.”

The more work done offline by the engineering departments will result in greater production capacity from the shop floor.

“Offline part programming is best suited as it enables the machine operator to run the machine versus spending time to program,” says Arteaga. Most of the CAD design is set up offline by a manufacturing engineer.

OFF-LINE OPERATION

“The designer imports a two or three dimensional part, goes through the unfolding function, and once this is finished, the designer will work on nesting the parts on the sheet,” says Hartman. The operator runs the machine and keep it running, while making the necessary tool changes when needed and running the program generated by the CAD/CAM software. In this way, a single operator can take care of more than one machine. “Especially in today’s manufacturing plant, automation has allowed for greater flexibility and efficiency,” he says.

Different manufactures have different needs and set up their shops to run as efficiently as they see fit. The software needs to be flexible to take all options into account.

O’Donnell explains that customer preferences vary, some like to have engineers do the programming so operator requirements are reduced. Others prefer to have the engineer provide the CAD data only, requiring the operator to generate the NC programs on the system on the floor. “With the capability of the Mazak software and machine tools, we are able to offer customers the flexibility to designate their work flow in the manner best for them,” he says.

Manufacturers need to ask themselves what the best way to run their company is and what software enhances this vision.

Szczepanski outlines the questions that should be asked, “Does he want the machine operator to be the programmer and be in 100 per cent control, or does the owner of the company want the programmer in the office doing all the programming work so he can have anyone at the machine pushing the green button? We (software designers) have to adapt to either scenario.”

TruTops Fab software from TRUMPF is easy to adapt to any fabrication needs. Its Quickjob basic module enables users to check and control all aspects of machine orders and monitor machines in real time.

WWW.US.TRUMPF.COM

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www.canadianmetalworking.com

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15-02-23 1:14 PM

FABRICATING & WELDING NEWS

CHECK OUT THE WELDING SPECIALIST MARK (WSM) PROGRAM In March 2014, the Office of Public Safety (OPS), a division of the Canadian Welding Bureau (CWB) launched the CWB Welding Specialist Mark (WSM) Program.

The program was developed for welding professionals and since its launch has acquired 190 members.

The program allows successful candidates to identify themselves as individuals with recognized knowledge of welding.

Candidates can apply online, while meeting eligibility requirements, in order to be considered for the program. The program does not have any fees.

Upon successful completion of the examination process, candidates will be provided with a unique QualityMark number and access to the Mark logo.

“One of the most significant mandates of the OPS is to ensure that

public safety is front of mind. With the WSM we are able to identify individuals based on their knowledge of welding fundamentals and CSA welding standards,” says Cristian Zanfir, assistant manager, standards. “We are able to provide welding specialists with a visible identifier that recognizes their achievements and dedication to excellence in welding standards knowledge and their commitment to upholding public safety as it is related to welded structures.”

The goal of this program is to generate awareness about the relationship between welding professionals and their knowledge of building codes at the National and Provincial levels, and CSA design and product standards. The WSM program will create a better understanding of CSA welding certification programs available in Canada and amalgamate welding specialists with earned recognition.

For further information and to apply to the CWB Welding Specialist Mark Program visit weldquality.org.

LINCOLN ELECTRIC CANADA USHERS IN NEW LEADERSHIP Lincoln Electric Canada has announced the departure of its longtime president and CEO, Joseph Doria, effective December 31, 2014, and taking over the role of president is Mike Whitehead.

After spending over 42 years with the company, Doria elected to retire.

Over the years he has served as a corporate vice president and officer of Lincoln Electric Holdings, Inc., and held the position of president and CEO of Lincoln Electric Canada and Indalco since 2002. Doria joined Lincoln Electric 42 years ago as a technical sales representative and held various positions working

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his way up in North America and Europe, including assistant to the president and COO of the Canadian Company, and president of Lincoln Electric Europe, before being promoted to president of Lincoln Electric Canada in 1991.

Whitehead took over for Doria as of January 1. He joined Lincoln Electric in 2005 as chief counsel, intellectual property and has served as director, new product development in consumables R&D since 2011. He earned a Bachelor’s of Science degree from Ohio State University and a Juris Doctor degree from New Hampshire

University School of Law. Whitehead Mike also completed Whitehead, the the Advanced new CEO of Executive Program Lincoln Electric Canada at Kellogg School of Management at Northwestern.

“Mike joins Lincoln Electric Canada as a well-respected leader within the organization. His decisive leadership style, his consistent focus on innovation, and broad experience across our organization will be invaluable as he builds upon the strong foundation that Joe has built,” says George D. Blankenship.

www.canadianmetalworking.com

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FABRICATING & WELDING NEWS

AWARDS PROGRAM REWARDS CANADIAN WELDING STUDENTS CWA Foundation has introduced the Post-Secondary School Awards Program. This new program rewards deserving Canadian welding students.

32 successful applicants from post-secondary welding programs across Canada were selected to receive scholarships of $2,500.

Candidates submitted applications in late 2014 and those selected for the scholarship were notified in early January 2015.

“It is a fundamental principle of the CWA Foundation to encourage welding students and promote the industry to Canadian youth,” says Deborah Mates, executive director of the CWA Foundation. “We are thrilled at the success of the CWA Foundation’s Post-Secondary School Awards Program. It was great to see so many students applying. It

validated the need for this type of scholarship program in Canada.”

Travis Pines, a student from Conestoga College, Ontario, recognizes the value of entering into the Canadian welding industry. “I chose this career path because it was something I knew would be valuable for my future. I worked hard within the welding engineering technician program and have decided to continue my education into welding inspection. The scholarship I received from the CWA Foundation made me realize that I have chosen the right career path in an industry that is well supported.”

The CWA Foundation was founded in 2013 and has since continued to engage various Canadian youth demographics in education and promotion of welding.

CANWELD PUTS OUT A CALL FOR PAPERS The CanWeld Conference is looking for speaker abstracts for those who want to present during the 2015 CanWeld Conference, to be held in St. John’s, NL on September 13-15, 2015.

The conference themes are focused on the practical side of the welding and metal fabrication industry, specifically the application of welding skills and technology to solve common fabrication and repair problems; ways of improving efficiency and quality; and the adoption of new ideas and technology with respect to managing staff, the shop floor and business in general.

Topics to consider include: • Practical advances in welding technology and or techniques • Practical/interesting application of welding technology and/or techniques • Best practices around welding sup68 | MARCH 2015

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ply chain management (materials, consumables, testing, etc.)

• Welding site/shop logistics: Estimating, staging jobs, scheduling, manufacturing line logistics • Real world welding/welder productivity, including robotics/ automation • Welding quality control and inspection • Welder training, recruitment and retention • Adoption and/or going on management of industry standards, including welding as well as ISO/ industry specific and LEAN • Managing other business factors that directly impact the welding industry.

Last date for Abstract submissions is March 31, 2015. If you are interested in participating in the CanWeld event, visit www.cwa-acs.org.

JMT USA WELCOMES NEW PRESIDENT Congratulations to Jared Peterson, the new president of JMT USA division.

The Board of Directors for Jorgenson Industrial Companies announced the new appointment following the departure of Kyle Jorgenson.

For the past 11 years, Peterson has worked as the service and operations manager at JMT. In that position he worked closely with both JMT customers and machine tool suppliers.

Peterson has been in this industry for over 20 years and has built a solid reputation.

“We are excited to announce Jared’s appointment and are completely confident in his abilities to assume leadership of our JMT USA division.

He’s well respected throughout the machine tool industry and the entire Jorgenson organization. His extensive knowledge of the industry, his hands-on machine tool application experience and his commitment to our organization, staff, vendors and customers will help the company move forward.” says company co-owner, Dustin Jorgenson.

For the past five years JMT has been on a strong growth trajectory, expanding from a regional to a national supplier. Best known for sheet metal equipment with a focus on press brakes and plate rolls, JMT has expanded its product line to include fiber lasers and structural drill lines.

Assisting Peterson in the day-today operations will be Rob Yorgason, who was named general manager of JMT in September, 2014.

“JMT has a bright future with both the people and the resources to continue growing in the machine tool industry,” says Jorgenson. www.canadianmetalworking.com

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FABRICATING & WELDING NEWS Powerful, lightweight MIG welder The Eastwood MIG 250 Welder is designed for fabrication shops, as well as DIY fabricators. The MIG 250 operates on 120v or 240v and offers adjustable 30-250 amp welding range. Featuring inverter technology, the MIG 250 can be run off of a generator and weighs half as much as other comparable machines.

The Eastwood MIG 250 Welder is easy to set up and accepts 4" and 8" diameter wire spools of .023" to .045".

With infinitely adjustable controls.

It can weld 18 gauge up to 1/2" steel, and aluminum up to 1 /2" thick, with the optional spool gun.

It offers a 60 per cent duty cycle at 250 amp setting. www.eastwood.com

A new cordless cutter The ZIPCUTTER by Walter Surface Technologies is a powerful tool and is uniquely able to use a 6” cutting wheel. This product is designed for metal workers who are consistently on location without access to a power supply.

Using the latest battery technology, the ZIPCUTTER features an exclusive Ventilated Charging System. The system comprises an 18V/5.2Ah battery allowing workers to perform more cuts between charges. In addition, the ventilated charging station quickly charges the battery while also extending its life by keeping it cool during the charging process.

This new product offers the latest in Walter Surface technologies including DYNAMAX electronics for RPM control and consistent speed under load, bevelled gears to reduce noise, and a front retaining plate and rear bushing to prevent misalignment and reduce vibration.

The ZIPCUTTER is designed to be used with Walter’s ZIP family of cutting wheels. By combining both products together, users have capable cutting technology in hand.

The ZIPCUTTER cordless cutter is available in 4-1/2" / 5" and 6" diameters. With a 270º rotating battery pack and countless other features, the ZIPCUTTER gets an extensive number of cuts per charge. www.walter.com

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MARCH 2015 | 69

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Proper fixturing is critical for successful welding

BY NESTOR GULA

T

A solid base and good clamping gear will bring success to any welding operation.

PHOTO COURTESY OF STRONG HAND TOOLS

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here is no escaping it— solidly clamping parts that you need to weld will ensure that these parts will not move unintentionally and be properly welded. Having pieces of metal move while heat is being applied is a recipe for disaster. Proper hold down of parts to be welded means they can be positioned accurately to make the weld successful.

“A proper fixture should stop and locate stock at accurate angles while allowing adequate space for the welder to operate comfortably and efficiently,“ says Pam Farley, marketing manager for Strong Hand Tools.

“A fixture can also elevate stock to create additional welding clearance, and set the structure at a uniform, level height. Fixtures should be designed with possible heat distortion problems in mind and work to minimize those effects. A fixture should be designed, at the outset, with a plan for the removal of the welded piece.

Clamps, and clamping elements, should be able to easily swing out of the way for easy welded part removal by sliding off the table or lift-

ing from the top of the work surface.”

Keeping the gap between the pieces to be welded consistent is also critical to completing a successful weld. “Fixturing is used primarily to minimize the gaps to improve the final welding quality,” says Reg Kelley president at Easom Automation Systems Inc. Controlling or minimizing gaps ensures the welding process is not being asked to fill large voids or gaps, notes Kelley.

MODULAR OR CUSTOMIZED When choosing an approach to fixturing there are basically two streams one can choose, modular or customized. In a nutshell, modular lets you adapt standard fixturing tools to suit any situation. Customized is a set fixturing solution that will be excellent for one part and that part only.

“The positive attributes modular fixturing brings to any welding operation is adaptability and repeatability. Adaptability enables a shop to take on a wide variety of jobs without having to create a specialized jig every time,” says Farley. “This is especially useful for short production runs or prototyping jobs where a dedicated jig and fixture will be quickly rendered obsolete by a design change. Repeatability refers to the basic requirements of any jig and fixture to hold work in a consistent and repeatable www.canadianmetalworking.com

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The 6.5-foot BuildPro table can hold parts up to 4,000 pounds.

PHOTO COURTESY OF STRONG HAND TOOLS

manner piece after piece. A modular fixturing system allows the welder to react quickly for customer retention, and modular fixturing provides the means to continue generating revenue from the one investment in the fixturing system. Also, the universal system can be torn down and stored away when not in use, freeing up valuable work space in the shop.”

When making many thousands of the same part, or if it’s a very complex part, sometimes a customized fixturing solution will make the most sense. “Custom fixturing works best to fit any unusual structural shapes,” says Kelley, noting that custom solutions

are often used for curves or different shapes.

In an operation that produces continuous production runs of oversized, heavy, bulky, specialty structures that cannot be fixtured using off-the-shelf universal components a custom fixture is the only solusolu tion. Dedicated fixturing may be the best option for long-term contract engiwork, in which engi infreneering changes are infre quent and tight tolerances are required.

Modular fixturing is built to high tolerances to provide accurate holding in any posiposi tion. “A modular fixturing system, such as the BuildPro Modular Welding Table line, is composed of reusable components so indithe user does not have to fabricate indi vidual fixture elements every time,” says Farley. “These modular components are adjustable and universal. A good modular system includes the table, with a tabletop surface of highly accurate CNC machined holes (mounting holes), in a dimensionally accurate grid pattern, for the setup of clamps and components at any point along the tabletop to accurately hold stock. The modular BuildPro tables feature plates that can be added or repositioned to reconfigure the table length or width for odd shaped or oversized weldments.”

FIXTURING FOR AUTOMATION When working with an automated or robotic welding setup, accurate positioning is even more critical. “Automation requires very precise

The BuildPro tables from Strong Hand Tools can successfully hold many welding scenarios.

PHOTO COURTESY OF STRONG HAND TOOLS

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www.canadianmetalworking.com

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placement of parts, so that the welding robot or the torch is going to come to the same spot every time with a controlled arc, with wire position and wire angle,” says Kelley. “A manual welding situation where a human is manually adjusting things and is more flexible. Manual positioners do not have to be as precise as ones used for automation.”

There are specific issues regarding fixturing for automated and robotic welding stations. “Automation often requires lower profile fixtures for better robot arm access.

Automation also comes with a different mindset where the weldments are often smaller, and a desire to decrease cycle times requires fitting several parts onto the table at once. This means that fixtures need to be more compact in their design,” says Farley.

“Modular systems can be integrated into automated welding processes, but the recommendation with higher-volume production is to use the modular fixture system as the physical framework for custom fixtures. For example, custom pins can fit into right angle brackets to hold punched sheet goods using indexing holes already designed from previous manufacturing processes.

02CMW-WeldPosition.indd 73

A lot of shops considering automation already have ready access to CNC cutting machines and simple drilling or turning capabilities. In these cases modular fixturing simplifies the fixture design and fabrication process because fixtures do not need to be built from the ground up. Each custom part tends to be smaller and requires less machining because the modular fixture already addresses one or more dimensions requiring adjustability or flatness.”

Solid clamping ensures parts will not move when welded.

PHOTO COURTESY OF STRONG HAND TOOLS

15-02-23 12:01 PM

TOOL PRESETTERS

INCREASE PRODUCTIVITY W

hen it comes to tool room quality and management, presetting is one way to increase profit and boost productivity.

Manufacturers are constantly trying to improve cycle times, lessen down times, and enhance the production process. One of the first thoughts is often the need to upgrade existing equipment. However, purchasing a presetter machine can make a difference, and is often the less expensive option to streamline the manufacturing process.

Canadian Metalworking spoke with ZOLLER, a German-based manufacturer of inspection and measuring technology, to find out what presetting can do to maximize quality control.

Top right: Tool presetters can allow contactless cutting edge inspection for checking tool cutting edges in incident light.

PHOTO: ZOLLER

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What are questions to help choose the right presetter for the tool room?

There are several important specifications to remember when choosing a new piece of equipment. It helps if you ask yourself important questions that can determine the best options for your needs.

What kind of tools are in use in your production? Are you a tool manufacturer or do you want to preset your machining tools?

Do your tools have special geometries which need to be measured, for example hob cutters, helical tools or shrink fit tools?

Do you need a presetter placed right next to your CNC machine or do you have a climate measuring chamber? Do you need to manually measure the most important functions only (e.g. measuring of length, diameter) or is there the need for a fully automatic solution which fulfills all manufacturing needs?

What are the advantages of having a tool presetter?

Primarily, you are faster. Your tools are set

and measured while your machine is producing without any downtime. Furthermore, you decrease your waste. Due to correct presetting, you produce 100 per cent correct parts.

In summary, precisely measured tools, optimized machine uptimes and longer tool service lives make sound financial sense.

What factors affect measurement accuracy on a presetter?

Of course, a high-quality spindle is of high importance. If a tool is not clamped correctly, this causes measuring errors and leads to inaccurate presetting and increased waste. Moreover, brand name products, special cameras for the measurement in incident, and transmitted light are crucial for the measuring success as well as an intelligent vision system. The combination of brand products, a stable housing, the spindle and of course a correct calibration by the assemblyman is the basis for quality in presetting.

What are key features of the presetter?

There are several important features to look for when purchasing a presetter. Here are things to explore: • Stable housing • Image processing technology • Spindle for tool clamping • Z and X direction drives • Incident and transmitted lights What comes standard on your tool presetter? What are additional options?

Generally, we offer a broad range of tool presetter and measuring machines from the entry-level class »smile/pilot 2 mT« for a professional start to cost-effective tool www.canadianmetalworking.com

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The ZOLLER »smile« universal tool presetter and measuring machine is designed specifically for measuring tools for manufacturing production and are equipped with »pilot« image processing software.

PHOTO: ZOLLER

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measurement, univerup to the univer sal inspection and measuring machine »titan« for all precision tools.

All presetter and measuring machines are equipped with the unique ZOLLER image processing technology.

Depending on the customer’s requirements, tool presetters are available with different operating technologies: »pilot 2 mT« with up-to-date touch-screen technology and individually configurable interface. »pilot 3.0« offers high functionality and flexibility.

Features such as the graphical user interface, the dynamic crosshair and photo real input dialogs have set the standard for userfriendly and intuitive metrology. »pilot 3.0« provides complex measurements on a single user interface. Also the image processing is modular expandable.

ZOLLER presetters are based on a compact, specially alloyed and thermally optimized design, which is robust and work-shop compatible. As already mentioned, also brand products and high-precision spindles are standard on ZOLLER tool presetters.

The main ergonomic features are the adjustable control unit »cockpit« for flexible positioning around the spindle and tool, the one-hand control handle for quick and simultaneous slide adjustment in Z and X direction. Unique features that come standard include the image processing technology with intuitive user interface and the 180-degrees accessibility for highprecision spindle.

Standard measuring methods are the cutting edge inspection and the measurement of length, diameter, radius and angles. Every device can be optionally operated with a CNC control unit. The range of optional measuring methods varies from device to device.

The options of measuring methods include, for example, center height measuring, swiveling tool inspection, measuring probe or

CNC swiveling optics carrier.

Every presetter is equipped with a SK50 spindle. Spindle options are vacuum clamping, the power-operated »ace« high-precision spindle for maximum precision and quick changes, autofocus, third axis with rotational encoder and the »asza« adjusting device for automatic adjustment of your tools directly on the presetter.

When it comes to data transfer, there are several options. For example, you can choose data communication via „Network“, manual or automatic tool identification or a bar code reader. Customers can choose the data transfer option which fits best in their production process.

How does a presetter enhance productivity?

There are so many benefits to introducing a presetter onto the shop floor or in a tool room setting. You benefit from: • less machine down-time • reduced scrap rates • more efficient processes • higher process reliability • better production quality • overall increased productivity What are advantages or disadvantages of contact versus non-contact presetters?

The big advantage of non-contact presetters is the ability to bypass the damaging of the measured tool. If you use contact presetters, you may damage the cutting edges, resulting in increased waste and decreased productivity in your production process.

The display of measurement results is much clearer and easier to understand with optical measurement than the display of tactile measurement. The ZOLLER image processing technology for example provides intuitive and easy to operate user interfaces with self-explanatory task buttons. Even untrained employees can do that measuring and setting of standard tools easily.

When looking towards the future, 3D scanning opens new perspectives for the three-dimensional digitalization of workpieces and tools of all kinds and materials. The six axis ZOLLER »3dCheck« CNC machine combines the benefits of optical detection by a 3D sensor with high precision CNC control and fully automated incident light image processing.

What makes your offering unique?

We develop systems with high automation www.canadianmetalworking.com

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content, with a clear operating structure, which can communicate with other systems via interfaces so operating errors, and thus downtimes, can be avoided.

Example 1: Tool measurement with »elephant« technology Standard tools can be measured with »elephant« technology by ZOLLER without data entry and previous knowledge. This technology allows you to measures tools without prior data entry fast, contact-free and with a choice of up to 52 parameters. No training, no previous knowledge required, making this a simple solution.

Example 2: »tool realityCheck« A typical example is the measurement program specially developed for tool and mold making »tool realityCheck«. Collisions of the tool in the machine lead to expensive and costly production downtime. To avoid this, one uses the known and for a long time proven instrument of the simulation. If, however, the used tools do not correspond to the reality, the simulation is “just a gimmick.” The in-house developed ZOLLER measuring program »tool realityCheck« provides just the right solution for this case.

In the automotive industry adjustable reamers are highly productive, however very demanding tools to be set. ZOLLER provides a user-independent, fully automatic and micron-precision measuring process that guarantees exact accuracy for over 20 years. Different setting procedures are possible.

The danger of cutting damage is completely eliminated since the measurement process run without any contact.

tem, so it’s open to all the options available through further development. From entry-level to professional tool presetting and measurement for small companies up to comprehensive and complex measuring requirements, whether single-component or volume production, ZOLLER solutions are complementary and can be interconnected by means of a central tool database. That enables you, whenever new requirements arise, to expand, modify and upgrade whenever you wish to do so.

WINNIPEG APRIL 7, 2015 Victoria Inn and Conference Centre

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Any final thoughts?

With all of these solutions, the user is equipped to meet future requirements.

ZOLLER products are not restricted to standalone solutions. Instead, the focus is on optimization of production processes. These products can already contend today with the increasingly stringent requirements with respect to process reliability, documentation and traceability.

Even the entry-level model »smile« can be extended by fitting the TMS Tool Management Solutions syswww.canadianmetalworking.com

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TOOLHOLDER

TROUBLE AND HOW TO AVOID IT

BY NATE HENDLEY

W

ant to avoid toolholder trouble? The first step is recognizing the importance of toolholders in the manufacturing process. While toolholders are the vital link between machine and cutting tool, they are all too often overlooked and abused.

“Here’s a scenario: I’m buying a new machine tool. I spend a lot of time with the machine builder looking at different designs.

I pick out the one that has the best criteria within my affordability. I make the choice of that machine. And I’ve already had a lot of time spent looking into what types of cutting tools I buy … but when the machine’s on its way in, that’s when all of a sudden I think, ‘Oh, I’ve got to get some new toolholders.’ Or maybe I just find some lying around. [The toolholder] becomes the afterthought,” says Dave Hartman, senior product manager rotating products, Parlec in Fairport, New York.

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02CMW-ToolHolders.indd 78

elements. It’s important to make sure that the toolholder is seen as importantly as the other two elements,” Hartman continues.

“A lot of time and effort is spent specifying high dollar machine tools and the vital toolholder and workholding systems which we outfit these precision machines with are often forgotten,” agrees Matt Panosh, group manager tooling at Schunk in Morrisville, North Carolina.

“In most cases, the toolholder is the most critical part of the system … a cheap toolholder gives you cheap results,” echoes David McHenry, engineering and technical manager at REGO-FIX Tool Corp. in Indianapolis, Indiana.

“You buy a half-million dollar machine. You put a junk holder on it. The holder falls apart and breaks the turret,” adds Leigh Bickham, general manager at ITI Group in Ramsey, New Jersey.

Hartman cites another scenario in which a machinist tests a brand-new, expensive cutting tool. A salesperson has promised definitive results. When the machinist puts the www.canadianmetalworking.com

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ings,” says Panosh.

Other important characteristics include vibration dampening, increased radial stiffness, length adjustment or adjustable run-out, he adds.

This list comes with a caveat: “Depending on the job you’re doing, one of these features will be more important. So, for me to say concentricity is the most important, that’s true if you’re doing high speed machining of a relatively fine nature—meaning a precision, high-speed machining job. But if you’re doing a big piece of titanium air frame, you really need rigidity and non-pullout capability. So, all of [the features cited] are important, but everybody’s level of imporSchunk’s TENDO tance changes based on what they’re doing,” Aviation combines the strengths of explains Hartman. hydraulic A best practice is to “look at the application expansion as a whole” before selecting a toolholder, technology with those of Weldon says Panosh. shanks. Integrated “What is the capability of my machining anti pull-out locking center? How am I processing the part? What mechanism prevents micro creep is my application: milling, drilling, reaming movements of the or threading? Have you considered cleartool and damage to ance? The toolholder profile is critical when the workpiece. working with five-axis machines or millturns. All of these things come into play. In addition, a job shop may look at part processing differently than an OEM,” he states.

Serving the Acquiring a decent toolholder is Automotive Parts only the first step, however, in the Manufacturing proper care and handling of such Industry for devices. Even if a machinist avoids 55 years the temptation of purchasing bargain basement toolholders, rough handling and improper cleaning can Engineered also spell disaster.

Solutions for Machinists see toolholders “as High Production something that lasts forever. And Manufacturing how long does a toolholder last?

Well, it depends. If you’re routing a piece of sheet metal, the tool may be in the spindle for eight hours and you may only do one of those Exclusive North American Dealer for Manufacturer of parts a week. You may have a total Custom Designed Chucks and Fixtures Gamet DELTA Series Jaw Chucks of one tool change per week and [the for High Volume CNC Turning Collet, Diaphragm, Offset and toolholder] could last forever. But if Bruckner Live and Dead Centers, and Face Drivers Many Other Chuck Designs you’re using a much smaller workpiece, doing six parts per minute, and you might have a tool change 30 times a day, that’s going to wear out [the toolholder] much quicker,” says Hartman.

Old Indian Trail, Middlefield, CT 06455 USA | T: 860-349-1044 | F: 860-349-1815 “A lot of times what happens, the end-users forget what it takes to WWW.POWERHOLDINC.COM maintain the tooling … a lot of the cutting tool to the test, however, he grabs the first toolholder he can find, regardless of how old, worn or cheap it is. The machinist is disappointed with the results of his test and blames the cutting tool, rather than the toolholder. This outcome could have been avoided had the cutting tool been matched with a better toolholder in the first place.

So, with all this in mind, what characteristics should you look for in a toolholder?

“There are three key components you should always consider when choosing a toolholder. A toolholder should have good run-out/repeatability, good balance qualities and be easy to use. These three key components are the gateway to increasing toolholder knowledge and cost sav-

THE WORKHOLDING ENGINEERS

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www.canadianmetalworking.com

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Precision balanced and certified for high speed operations, Parlec’s ERos is a simplistic, precise, extreme performance toolholding system.

times the clean cleaning aspect is very much forgotten about because they need that tool, they need it now and don’t have time to clean it. They might grab a rag out of their pocket, wipe [the toolholder] off, put it back together. Then they wonder, ‘What happened? Why am I getting bad results?’ If you want to hold a tool to tenths or microns of run-out, you have to clean it,” adds McHenry.

That said, neglectful toolholder maintenance is sometimes simply the end-result of running full-out operations.

“Most of the time, the plant manager looks at a down machine as losing money. To put a machine [off-line] to take the toolholder out to inspect it and rebuilt it, is very rare [in my experience],” says Bickham.

Over-torqueing retention knobs is another common mistake.

“Over tightening of the retention knob can affect the performance of a toolholder. We have inspected toolholders for run-out or vibration only to find that the retention knob has been over tightened and deformed the taper,” says Panosh.

“The other issue is doing the same thing to a collet chuck. If you overtorque a retention knob on a steep taper you can swell the nose of your toolholder … because of the risk of something coming loose—which would be catastrophic—you get people using the adage, ‘Tight is good, tighter is better.’ What we recommend is not to over-tighten them but to use a serviceable thread lock … that will allow it not to come loose,” says Hartman.

Other pointers: the type of cutting tool being used will determine the type of toolholder that should be www.canadianmetalworking.com

02CMW-ToolHolders.indd 81

matched with it.

“If I have a jobber high speed steel drill, I’m going to use a standard collet system. If I have a $300 G drill, I’m going to use a high performance, high precision holding system.

If I’m using a high speed steel end-mill with a Weldon flat, I’m going to use a Weldon toolholder. If I’m using a high helix carbide solid carbide round tool, I’m going to use a high performance, high precision holding system … the cutting tool should define the type of toolholder system you use,” says Hartman.

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New versions of the REGO-FIX secuRgrip anti-pullout tool holding system can be used in any ER collet system as well as applied in REGO-FIX milling chucks.

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The material being worked on can also influence toolholder preference.

“As far as the actual material you’re cutting, sometimes the easiest tools to machine are the worst for the toolholder. For instance, when you’re machining aluminum, it’s soft, but it can turn the coolant into mud [which] can get lodged in all sorts of places. With a hardened steel ... you don’t get it muddymuddy ing the coolant as much,” says Hartman.

In terms of the type of material being worked on, “again, you have to look at the application and process as a whole. I may choose a different toolholder to cut a material on a high speed machine than I would on a machine with a lot of horsepower.

A vertical machining center may have different toolholder requirerequire ments than a horizontal. For example, a horizontal may require a minimum gage length of six inches just to reach the part. In this scenario, due to the length, in a rough milling application you’re going to want [a toolholder] with good radial stiffness as well as good clamping force. A balance of them both,” adds Panosh.

Experts cite other important toolholder characteristics: “in general, most customers want rigidity. They don’t want the tool to deflect. When they go to setup and optimize their process, they know what that toolholder can give them. If you can find a toolholder that is rigid and has some vibration dampening to it at the same time, it’s golden,” says McHenry.

Anti-pullout capability is a popular feature on some new toolholding systems. At IMTS 2014 in Chicago, for example, REGO-FIX rolled out a new version of its secuRgrip anti-pullout toolholding system that can be used with the company’s ER collets and milling chucks. The secuRgrip system locks collet and cutter to the body of the toolholder via a proprietary method involving a profiled locking key insert that fits into a tool’s standard Weldon endmill flat. When the insert is put into the tool flat, screwing the tool into a collet or milling chuck with a matching internal diameter profile locks the two together in a highly secure fashion.

“The big advantage we have in the

secuRgrip system is that it uses a standard Weldon flat cutting tool. It doesn’t require any special groove or grinding to be done to the cutting tool. We try to make it nice and easy for the customer,” says McHenry.

Schunk’s recently released Tendo Aviation toolholder system also has prominent anti-pullout characteristics. The Tendo Aviation toolholder is designed to ensure secure, form-fit tool clamping with a standard Weldon shank. Machinists can maximize efficiency with their tools and machines while incurring minimal material wear. Advantages include boosted process reliability and the elimination of the need for time-wasting tool shank modifications.

“Anti-pullout is for expensive parts where you absolutely cannot have any risk of tool creepage. You have a solidified process; you just need that added protection with giving consideration to tool life, because tool life is very important. You’re using expensive tools on an expensive part,” explains Panosh.

Parlec, for its part, also introduced some new products at IMTS 2014 including the ERos high performance toolholder.

“It’s an extremely high speed, high concentricity toolholder with good grip force. When you are trying to get a perfectly sized hole using a reamer, or trying to get a high metal removal rate, or high precision drilling and milling, or something where you’re doing a finish pass and you want maximum tool life … the ERos is based on a collet system, there’s no high start-up cost. You just need a wrench and the chuck and collet. It gives you that level of performance with low start-up costs,” says Hartman The discussion of new and/or newly improved toolholder systems leads back to the original point: treat your toolholder with respect. Don’t buy a toolholder solely because of its price, match it with an appropriate cutting tool and be sure to take care of the toolholder once it’s in your possession through proper storage and cleaning.

“As cutting tools become more capable and machine tools become more capable, then the [toolholding] itself has to become more capable as well,” says Hartman.

Single Source Technologies offers MST’s new Slimline Curve shrink-fit tool-holder systems for “2+3” and simultaneous 5-axis machining applications.

www.canadianmetalworking.com

15-02-23 11:55 AM

HEAVY DUTY

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• X-axis travel • Y-axis travel • Z-axis travel • W-axis travel (Quill extension) • Table working surface • Table loading capacity • Spindle speed • Tool storage capacity • Optional

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15-02-23 1:19 PM

BY NICHOLAS BERGMANN, GENERAL MANAGER AT EXSYS TOOL, INC.

S

hops that regularly inspect and maintain their live tool heads can achieve up to five times more service life and lower overall toolholder costs than those that do not. A live tool system preventive maintenance (PM) program ensures part accuracy, increased cutting tool life, reduced scrap, improved reliability and overall confidence in lightsout operations. Furthermore, such a program dovetails with OEE and Six Sigma practices

that focus on the effectiveness and efficiency of a manufacturing facility.

Tool system suppliers often come in contact with shops that have two completely different viewpoints when it comes to live tool heads, either they are considered perishable items or everlasting solutions. Unfortunately, both of these perspectives lead to a costly mistake and one that can be avoided with the implementation of a simple PM plan.

It is difficult to quantify the exact maintenance intervals and service life for a live tool head because every shop has its own unique manufacturing methods. Plus, several application variables must be taken into consideration. These can include everything from workpiece material type, to cycle times, to coolant condition. Consider that two hours machining titanium, for example, is much harder on a live tool head than 10 hours of cutting graphite.

FIVE-POINT PM INSPECTION Proper coolant care is probably the only controllable variable, amongst all manufacturing facilities, in increasing live tool head service life. However, there is a general fivepoint PM inspection that EXSYS/Eppinger suggests shops perform at least every three months. And while these are just recommendations, machine operators will have to make the judgment call for exactly how often the inspections are needed based on the variables of the particular mill/ turn operations at hand.

INSPECTION POINT #1 First, measure spindle runout.

Operators can determine runout by simply resting a dial test indicator tip on the inner surface of the collet pocket and rotating the live tool head.

The maximum runout for live tools is around five microns in the collet pocket. Excessive runout in the spindle puts an additional load on the bearings, decreasing overall service life.

INSPECTION POINT #2 While the dial test indicator is in the collet pocket, it is also possible to simultaneously check for radial play, the second inspection point. If movement shows up on the indicator when you toggle the spindle, then there is some sort of problem that can be anything from a bent spindle to a bad bearing.

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INSPECTION POINT #3 Ease of rotation marks the third inspection point. Live tool heads should rotate smoothly, be free of any binding, and should have no real audible noise coming from the bearings while spinning the tool.

INSPECTION POINT #4 The fourth inspection point involves a visual inspection of the live tool head, with a particular focus on the collet pocket and the system’s drive connection, to check for any damage, wear or rust.

When properly cared for, live tool heads can deliver high value and production accuracy over a long service life—making a PM program much more important.

INSPECTION POINT #5 If the live tool holder has an easily accessible cover plate, the operator should remove it and inspect for coolant contamination. But remember, if a live tool head is still under warranty, it should not be disassembled completely.

AFTER PM INSPECTION A down machine is an unproductive machine, and it takes little time to perform the five-point inspection that could prevent such a scenario.

In fact, once an operator gets acclimated to the process, it should only take a few minutes.

It is best for operators to create and make entries in a maintenance log.

Over time, operators will be able to tell when they should remove a live tool head for routine service as well as establish an accurate maintenance budget.

This log should also include information about coolant maintenance to give an idea of when the system requires cleaning.

Live heads with minor problems, such as those requiring seal and bearing replacements, should be sent out for service as many times as possible before being discarded. Keep in mind that if a live head suffers a catastrophic crash, it is most likely past the point of inspection.

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CONCLUSION While live tool heads only represent a small portion of the overall machining process, they are a big contributor to improving machine tool efficiency. Therefore, shops should never view them as perishable items. www.canadianmetalworking.com

02CMW-PMlive.indd 85

www.sgstool.com 330-686-5700

Manufactured in the USA

MARCH 2015 | 85

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TOOL TALK

CELEBRATING 25 YEARS IN NORTH AMERICA This year marks the 25th year of North American operations BIG Kaiser Precision Tooling Inc. In spring of 1990, the company was incorporated under the name Kaiser Precision Tooling (KPT), the subsidiary of Swiss-based Heinz Kaiser AG. Establishing its home in Elk Grove Village, IL, KPT officially opened its doors on August 1, 1990.

“We set out to be driven first by our engineering capabilities,” recalls Jack Burley, VP, sales and engineering, and with the company from the beginning. “We had an expression, ‘give us your toughest boring problem.’ We’ve always believed if we can’t solve it, there probably isn’t anyone else who can.”

A major catalyst of the company’s growth came in 2003 when KPT formed an alliance with BIG

Daishowa Seiki, a Japanese manufacturer and a worldwide leader in tool holders, cutting tools and measuring accessories.

Eventually, KPT changed its name to BIG Kaiser Precision Tooling Inc. In 2009, BIG Kaiser made the move to a new 33,000 square-foot facility in Hoffman Estates, IL. The facility is three times larger than their previous headquarters and made room for a growing team and features a state-ofthe-art showroom, high-tech training auditorium, larger shipping warehouse space, as well as a repair center to save customers time and money

instead of sending tools overseas.

“Quality, innovation and performance—it’s always been about that,” BIG Kaiser president and CEO Chris Kaiser says. “That’s gotten us to where we are today and it will not change. Whether it’s when we walk in to the office tomorrow or we’re looking towards the next 25 years, we’re not going to stray away from those things.” www.bigkaiser.com

CLAMP. DONE. RUN. Introducing FCS clamping system from SST. It’s that fast.

Learn how moving clamping setup time to the CAD/CAM stage can drastically reduce downtime at the point of production. Talk to your SST representative about the latest innovations from FCS clamping system.

Learn more at singlesourcetech.com/FCS

© 2015 Single Source Technologies.

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www.canadianmetalworking.com

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TOOL TALK

KOMET OF AMERICA EXPANDING N.A. REACH

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“I’m really excited about working with KOMET. Combining Razor Tool’s capabilities with KOMET’s knowledge and support will result in better service, more technical options, and lower costs for our customers in New England,” says Tony

Madiros, president of Razor Tool, Inc. of Stoneham, Mass.

Users of industrial cutting tools are able to reach out and try any of the 10 KOMET SERVICE Partners located across North America. www.komet.com

NEW INNOVATIONS in Steel Turning

CA5 Series G r a d e s

P Series C h i p b r e a k e r s Wear Resistance

KOMET of America is off to a great start in 2015. The company has signed three new partners for its KOMET SERVICE network this January.

The addition of three new Partners represents a 40 per cent increase in the size of the network in North America.

KOMET now has 10 service partners.

The new additions include: Cutting Tool Engineers, of Pelham, Ala.; Breckers Cutting Tools, based in Roseville, Mich.; and Razor Tool, Inc. in Stoneham, Mass.

The KOMET SERVICE is working with all of these Partners to train them in the quality control practices and state-of-the-art engineering and tool grinding for which KOMET is known. Each of the new Partners will also receive training in best practices for marketing, as well as a complete marketing and branding package.

“I cannot overstate how exciting this is for all of us,” said Tom Whennen, manager, KOMET SERVICE North America.

“We look forward to being partners with a global tool company,” said Nate Anderson, general manager of cutting tool engineers in Pelham, Ala. “The ability for a regional company to have access to the newest advances in tooling technology and tooling support is a great advantage for us.”

Chelsey Gumro, CMO at Breckers Cutting Tools, was quick to point out the potential for customers, stating, “Our decision to partner with KOMET was based on the fact that our company and their company hold themselves to the highest standards in the marketplace.”

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MARCH 2015 | 87

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TOOL TALK

REGO-FIX PARTNERS WITH BELDER TOOL SOLUTIONS REGO-FIX Tool Corp. has partnered with Belder Tool Solutions Inc., a firm of manufacturers’ represen-

tatives in Hamilton.

This will allow REGO-FIX to extend its reach throughout the area. Belder will help support REGO-FIX’s local distributors in offering the full breadth of the REGO-FIX product line, including its new reCool system,

High performance 2D Measurement Systems

QM & LH Linear Height

For simple or sophisticated linear height applications

powRgrip system and SwissQuick ER-to-ER adaptor products.

Founded by John Belder (pictured) in 2001, Belder Tool Solutions has 35 years of industrial sales experience.

“We are partnering with Belder Tool because they are deeply committed to meeting their customers’ toolholding needs,” says Jeff Schemel, North American sales manager for REGO-FIX. “They pride themselves on being extremely responsive and having the technical expertise required to provide the best solutions.” www.beldertool.com

WILSON TOOL’S NEW DIRECTOR OF SALES FOR NORTH AMERICA

Call to book your personal demonstration

2D Linear Height Features: • Best-in-class accuracy: LH-600: ±(1.1+0.6L/600)μm, QM-Height: ±(2.4+2.1L/600)μm • Built-in air bearings for smooth movement along the surface plate • Easy-to-view, simple control panel allows performance of main measurements with a single key • Full range of options, including a variety of probes, as well as USB Input Tool Direct which allows output to a PC

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Mitutoyo Canada Inc. Toronto (905) 821-1261 Montréal (514) 337-5994 www.mitutoyo.ca

Precision is our profession

Wilson Tool International announced the return of Ron Palick as the organization’s new director of sales for North America.

“We’re proud to welcome Ron back to the Wilson Tool family,” says Brian Robinson, CEO of Wilson Tool.

In his new position, Palick will be responsible for building and leading Wilson Tool’s industry presence through strategic sales development initiatives throughout North America.

Palick began his sales career with Wilson Tool 20 years ago as a national sales manager. He previously served as Wilson Tool’s vice president of sales and marketing from 2000-2006, and then held executive positions at Prima Finn-Power and Haco/Atlantic before returning to Wilson Tool this year. www.wilsontool.com www.canadianmetalworking.com

15-02-23 11:59 AM

TOOL TALK

DOOSAN APPOINTS NEW CEO Doosan Infracore America Machine has announced that they have appointed a new chief executive officer, Mr. Hee Eun Ahn.

Mr. Ahn has been with Doosan for more than 12 years, holding several different positions.

“I’m excited to be joining Doosan Infracore America Machine Tools at a time when manufacturing is returning to North America in a big

way. Doosan is well positioned to support this growth with our mature management team and sales channel, along with a reputation for providing superior support to our customers,” notes Mr. Ahn. www.doosanmachinetools.com

PERCEPTRON ACQUIRES TWO METROLOGY COMPANIES Perceptron of Plymouth, MI, acquired two European metrology companies: Coord3 Industries and Next Metrology Software (NMS).

Coord3 Industries is based in Turin, Italy and is a mid-market designer and builder of CMMs. Next Metrology Software, of Prague, Czech Republic, specialspecial izes in CMM software.

The total value of the transactions is $15.9 million.

Jeffrey M. Armstrong, CEO of Perceptron, said, “The acquisitions of Coord3 and Next Metrology illustrate the progress we are making to implement our strategic plan. These transactions expand and diversify our offerings in the industrial metrology market, and particularly in the scanning CMM market...

According to Frost & Sullivan, global CMM sales are estimated to exceed $1.8 billion in 2015, with automotive CMM sales at approximately $625 million and aerospace CMM sales at approximately $350 million. By offering a compelling solution in this marketplace, we believe we can help expand the overall market.” www.perceptron.com www.canadianmetalworking.com

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keeping things open to the customer so they can do what they would like to do with the intelligence inside the machine.

SPEAKING ONE COMMON LANGUAGE

Machine monitoring is not new but enhanced capabilities make it so easy

BY LINDSAY LUMINOSO

O

ne of the biggest things Neil Desrosiers hears when he lectures on machine monitoring and MTConnect is that “monitoring isn’t new, don’t sell monitoring as being new because it’s been around for 30 years now.”

Although this is true, Desrosiers, who is the application engineer/developer MTConnect specialist for Mazak, usually responds by explaining that the features and capabilities are expanding which makes monitoring so much easier and accessible.

In the past several years, technological advances have pushed forward the manufacturing industry both in terms of new product development as well as advanced production processes. Machine tool OEMs provide customers with a wide range of hardware options. However, developing cutting-edge controls and software are now very much in the spotlight.

“Our whole industrial group, we are at the beginning stages, the infancy, of intelligent programming. We know that it is going to enhance the ability to get data quicker and faster for better decision making, but we really don’t know beyond that where it’s going,” says Jeff Estes, director of Partners in THINC at Okuma America Corp. New technology is enabling customers to customize their machines in new and exciting ways.

As technology advances, machine controls and software are becoming highly sophisticated. Machine tool builders are tasked with

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This is where MTConnect really comes into play. Although this technology was developed and announced in 2008, many shop floors really haven’t had the opportunity to use the capabilities. MTConnect is an open, royalty free protocol with its own data dictionary. It was created through a collaborative effort between many machining companies and organizations through the MTConnect Institute and is continually being expanded. It is a way of communicating data in manufacturing. If all machines on the shop floor are MTConnect compliant, the data tags or information collected will all use the same terminology. What this means is that spindle speed on one machine will mean the same as spindle speed on another.

“One thing we are very cautious about at the Institute is where the boundaries are. We don’t want to delegate or dictate to the applications developers that you have to do this or you have to do that,” explains Desrosiers.

“We don’t do calculations. MTConnect doesn’t calculate anything for you. It’s up to the end users to glean the data.”

The protocol requires that shop floor devices have an adapter, which enables the machine “to speak MTConnect.” Many of the new machines being built come with the option of being MTConnect capable. As this technology advances and more customers see the value in shop floor monitoring, MTConnect will eventually become a standard on all machines going forward. One of the challenges has been getting older models connected, which is done through adapters.

Adam South, staff engineer for the Innovation Ventures Group at Kennametal explains that, “We work with our partner company, System Insights, and machine tool builders like Mazak and Okuma, to develop and provide the MTConnect adapters to collect this data.”

Many machine tool builders have gone back and developed adapters to MTConnectenable their older devices. Mazak went back as far as their 1998 controls in order to meet the growing demand to connect all machines on the shop floor. The collaborative effort by industry leaders is expanding MTConnect and allowing customers to reap the benefits of data collection. www.canadianmetalworking.com

15-02-23 11:49 AM

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On April 28-30, 2015, the Institute is hosting its [MC]2 Conference in Chicago. This conference offers a unique glimpse into how the digital age is transforming manufacturing and how companies are adjusting to the times. Adam South will speak about optimizing manufacturing processes using MTConnect. This year’s event is titled “Digital Manufacturing and the Industrial Internet of Things (IIoT) will transform your business.” The support that MTConnect receives from the industry is really driving the technology forward.

ENHANCING PRODUCTIVITY One of the questions that generally arises is now that machines are MTConnect capable, what do I do with all this data? Because this protocol only enables the machines to speak the same language, machine tool manufacturers created their own agents, which allow MTConnect messages and data files to be transmitted across a network to MTConnect-compatible applications.

However, one of the great things about the protocol is that it is an open source, which makes it possible for experienced soft-

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ware writers to create an adapter for any machine they want. The agent is simply a software program, much like the adapter, which takes over after the data has been “adapted.” Generally, the agent can take advantage of the existing network connection of a machine. However, one of the real challenges is leveraging the data.

South explains that Kennametal’s software turns the data into actionable information because, “users don’t want to analyze data, they want to know how their data can drive productivity improvements.”

Many companies offer a standard dashboard control that allows for basic monitoring and are developing sophisticated software that goes beyond the basic data collection. One way that Kennametal is doing this is through its NOVO Optimize software.

“It is collecting real-world data from machine tools. Actual speeds and feeds for all tools are measured from the shop floor, and then through the analytics it finds the best practices,” South explains. “NOVO Optimize identifies the most productive set of conditions historically used in the shop on similar processes. It then recommends them back to the user and quantifies expected cycle time reductions if these best practices are applied on other parts that use the same tool and process.”

Because MTConnect is an open protocol, customers can use any software developed based on their individual needs to monitor their system. Prior to this advancement, machines could only be monitored with software designed for the proprietary protocol of that machine. “Now, it doesn’t matter what brand machine tool you have, if you make them MTConnect compliant you can use one system, one protocol, to monitor everything,” says Desrosiers.

Many machine tool companies and organizations are working beyond the MTConnect Institute to bring actionable solutions to their customers. The Okuma America Corporation has created the Partners in THINC program that brings together competing companies in a partnership in order to solve problems and explore new productivity ideas for manufacturers. Partners in THINC uses a wide range of expertise to provide integrated solutions to the end-user.

What does this mean actually on the shop floor, though? Estes explains that machine shops are challenged with enhancing productivity and bringing high-quality parts to customers. The monitoring software that is www.canadianmetalworking.com

15-02-23 11:50 AM

being developed is not only collecting the data but is offering intuitive solutions. “Immediate feedback from the machine and gauging systems allow the machine to respond and adapt in milliseconds, 5-10 milliseconds, to what’s happening on the shop floor and the cutting process, to hold that dimension correctly. That ability to respond quickly in changing conditions, in realtime conditions, is a real key. Linking those devices together is what is making it possible.”

For Desrosiers, one of the greatest productivity enhancers is this idea that you can monitor really whatever you want, at the same time, real-time. You can have software that’s monitoring the machines for utilization, telling you what your uptime is and what your downtime is and how much you are utilizing the equipment. Side by side, running parallel, you could have another piece of software that is oriented around maintenance, querying the same machines to get just the maintenance data or the health conditions of the machines. “The ability to get information off the factory floor, or do these different decisions, or targeting improvements on the factory floor, or just even understanding what’s taking place, it becomes very easy,” says Desrosiers.

WHERE DO WE GO FROM HERE? For South, one of the directions forward is expanding into enhancing machine uptime.

“Where does a user go once downtimes have been minimized? We are leveraging MTConnect data to help users decrease cycle times and produce more pieces in the same amount of time,” says South. This is where Kennametal software development is going, beyond mere process monitoring but with decisive real-time adjustments to increase uptime productivity.

Another area that is being developed is with apps. In August 2014, Okuma launched its App Store that offers approximately 30 www.canadianmetalworking.com

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unique free apps to users. “It can be one of our distributors or Okuma developed...

You can control certain single-functionality of the machine and get that information by writing a simple app,” states Estes. “It’s PC talking to PC, and that’s where apps are really exciting.”

Apps are an extension of MTConnect and provide bi-directional communication.

Machine tool manufacturers are working together through developmental groups at the MTConnect Institute to bring machine monitoring to new levels. Software like Kennametal’s NOVO Optimize or Okuma’s partnership program, allow for companies to leverage the MTConnect protocol and bring real-time, actionable monitoring to customers. Apps are a fairly new advancement in the machine tool world; however, it’s an exciting new area that is being developed.

“I would say apps are a key way that [Okuma] wants to go with software in the future, to keep things open to the customer so they can do what they would like to do with the intelligence inside the machine,” says Estes.

That’s really what MTConnect and trajectory software is all about, bringing the intelligence inside of the machine to end-users so that they can make the best decisions possible for their business. What is more, machines can make intelligent adjustments based on the data to allow corrective practices in real-time, reducing scrap and enhancing productivity.

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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

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

SETUP, OPERATOR & SUPERVISOR

NEEDED

We are seeking a CNC Trumpf Brake Press – Supervisor to oversee all production jobs in our CNC Trumpf Brake Department. Requirements for this position include a min. of 5 years setup and operational experience, as well as the ability to program off line with related software. A min. of three years in a supervisory role in the custom metal fabrication environment is also required. F/T $27/hr. Trumpf experience is a definite asset. Please send your resume via email to careers@marfabmetal.com.

Marfab Metal Products Inc. Concord, ON www.marfabmetal.com

EVENTS – TABLE-TOP SHOWS

April 7, 2015 Winnipeg MB May 5, 2015 Coquitlam BC CONTACT: 416-510-5225 www.mmpshow.com

Sponsored by:

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

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www.canadianmetalworking.com

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PRODUCTS & SERVICES

EVENTS – TRADE SHOWS

MACHINE TOOLS

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 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

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 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 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

ADVERTISERS INDEX ADVERTISER

PAGE#

ADVERTISER

Amada Canada, Ltd. AMT Machine Tools Ltd. Blaser Swisslube Inc. Bohler-Uddeholm Ltd. CWB Group Data Flute Delcam Dipaolo Machine Tools Dormer Pramet E.M.A.G. L.L.C. Elliott Matsuura Canada ERI America Inc. Forkardt Gullco International Haas Automation Inc. HORN USA, Inc Hurco Ingersoll Iscar Tools Inc.

9 32 81 57 71,73 33 92 13 17 37 6 36 84 14 91 11 IFC 15 OBC, 79

ITI Tooling Jesse Engineering Kinetic Cutting Systems Inc. Kyocera Precision Tools Inc. Lincoln Electric Company of Canada LVD Strippit Mascoutech Megatel Inc. Methods Machine Tools Micro 100 Tool Corporation Mighty USA, Inc. Miller Electric Mitcham Machine Tools Mitutoyo Canada Inc. Multicyl Inc. PFERD Powerhold Inc. PRAB Prima Power

www.canadianmetalworking.com

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PAGE# 89 56 59 87 67 6 36 31 26 20 21 22 21 88 18 47 80 41 55

ADVERTISER Renishaw (Canada) Ltd. Samchully Workholding, Inc. Sandvik Schunk Intec Corp Scotchman Industries, Inc. Seco Cutting Tools SGS Tool Company Shop Data Systems SME CMTS SME WMTS SST Canada Starrag USA, Inc. Toshiba Machine Co. of Canada TRUMPF Inc. Tungaloy America Inc. Walter Surface Technologies Walter USA Weiler Corporation

PAGE# 24 19 4,5 53 69 43 85 61 65 75 86 16 83 IBC 3 51 39 45

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PRODUCTS & SERVICES

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

MARKING

METALS

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 in 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

Alro Steel

Metals Industrial Supplies Plastics

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

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888-888-ALRO 2 5 7 6

alro.com

www.canadianmetalworking.com

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PRODUCTS & SERVICES

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

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

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

IN STOCK American Standards and specials.

Japanese Standards - inch or metric.

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

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

USED MACHINE TOOLS

BERTHIEZ VTL with milling

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

www.canadianmetalworking.com

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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

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BY THE NUMBERS

49.6

%

40.7%

EM DISPLOY

BY TRIB MEN AG U T T E ION

25–44 years

8.1% 45–64 years

1.6% 15–24 years 65 years and over

There are •

2012 estimated N.A. auto OEM tooling expenses:

2000-3000 tools used to make a vehicle •

Tools range from $5,000

to $1 million

68.2% 17.9

%

Highschool

Less than high-school

•

spent approx.

$9.25 billion

At 2012 vehicle volumes, N.A. vendors spent

$550 per car on average, on tooling content

Souce: Harbour Results, Inc.

EM

BY PLOY L E ME VE N LO TD F E IS T D U R IB CA U T TIO IO N N

Bachelors degree

2.2%

Source: Statistics Canada

11.7%

Postsecondary

AU T TO O OL FA IN CT G S

Auto OEMs

•

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ISCAR's High Productivity Machining Solutions for the Automotive Industry Indexable drilling heads for high productivity and extended tool life

Dovetail clamped milling insert with 8 edges, for less power consumption and smooth finish

Unique 5 cornered insert for larger parting diameter and deeper grooving capacities

Interchangeable solid carbide reaming head system for accuracy and high productivity

Machining Intelligently

ISCAR HIGH GH Q LINES

Iscar.indd 1

Wide range of ISOTURN small sized inserts for increased profitability

www.iscar.ca

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