INTERNATIONAL REPUTATION Durose Manufacturing, Guelph, ON — p60
SWISS BLISS Swiss-type turning machines edge toward mainstream — p66
COOLANT CONSIDERATIONS From eco-friendly to productivity enhancing — p78
THE RISE OF VISION SYSTEMS Vision systems provide fast and accurate measurement — p82
FABTECH 2015 PREVIEW OCTOBER 2015 PM 206579
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OCTOBER 2015 ß VOL. 110 ß NO. 08 www.canadianmetalworking.com
A LOOK INSIDE SPECIAL ISSUE: TRANSPORTATION FEATURES LOOKING BACK: TRAIN CAR PRODUCTION — 27 110 years of Canadian Metalworking
FABTECH: BRINGING MORE THAN EVER BEFORE — 34 A look at this year’s FABTECH event in Chicago, IL
GRINDING AWAY — 52 Proper tools necessary for removing material
COVER STORY — 30
A SMALL BIG COMPANY — 56
OEMs making trains, buses and ships are keeping busy
ON THE RIGHT TRACK
ISE Metal Inc., Sherbrooke, QC
AN INTERNATIONAL REPUTATION — 60 Durose Manufacturing, Guelph, ON
THE 3D PRINTING PREDICAMENT — 63 Exploring different types of 3D printing technologies
SWISS BLISS — 66
27
Swiss-type turning machines edge toward mainstream
34
BIG CUTS FOR SMALL SPACES — 70 Cutting tools and toolholders for compact Swiss-type turning centres
63 52 www.canadianmetalworking.com
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OCTOBER 2015 | 7
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OCTOBER 2015 ß VOL. 110 ß NO. 08 www.canadianmetalworking.com
A LOOK INSIDE SPECIAL ISSUE: TRANSPORTATION
78
FEATURES (CONT.) INTRO TO CNC SWISS-TYPE LATHE — 74 JessEm Tool Company, Orillia, ON
74
COOLANT CONSIDERATIONS — 78 From eco-friendly to productivity enhancing
THE RISE OF IMAGE-BASED INSPECTION — 82 Vision systems come in all shapes and sizes but provide fast and accurate measurement
DEPARTMENTS VIEW FROM THE FLOOR — 10 NEWS — 12
82
KEN HURWITZ ON FINANCE — 20 BUSINESS MANAGEMENT — 22 THE BUSINESS OF WELDING — 25 FAB AND WELDING NEWS — 48 TOOL TECH — 88 TOOL TALK — 90 CNC SOLUTIONS — 94 BY THE NUMBERS — 102
8 | OCTOBER 2015
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UPCOMING IN METALWORKING The November issue of Canadian Metalworking will focus on productivity in shops of all sizes, including a look at robotics, maximizing cutting tool speeds and feeds and welding automation. We will also be taking an inside look at the latest in machine tool controls, in-process inspection, and worker safety in metal finishing. Also look for our exclusive round-table coverage on energy efficiency in metalworking operations. And don’t forget to follow along and engage with us on social media – look for us on Twitter, Google+, and Facebook!
www.canadianmetalworking.com
15-10-02 3:23 PM
Amada_10-2015_CM_Aloma_Shim_Layout 1 9/9/15 4:47 PM Page 1
Single-Source Fred Grove, President (left) & Bob Wolpink, Plant Manager of Aloma Shim and Manufacturing.
Leader. “The exceptional ROI and outstanding service on our first purchase made Amada the clear singlesource choice for our next two purchases.” — Fred Grove, President Aloma Shim and Manufacturing
Amada provides the optimal fabricating solutions. Aloma Shim is a leading full-service ISO 9001: 2008 Registered Contract Manufacturing Company. Located in a 98,000 sq. ft. facility in Verona, Pennsylvania, the company specializes in the manufacturing of precision OEM & custom fabricated parts, standard & custom shims, alignment devices and accessories. To maintain a leadership position, the company partnered with Amada and leveraged the latest technologies in fiber laser cutting, tube & angle laser cutting and robotic bending. Aloma Shim’s president, Fred Grove, comments on that decision: “The FOL AJ Fiber Laser with automation improved production efficiency by over 70%... one would think we added two new lasers not just one. We effectively operate the FOL AJ 24 hours a day with one operator and one laborer as opposed to 3 operators and one laborer on our other lasers.” Plant Manager, Bob Wolpink comments on Amada’s robotic bending solution which has made a huge impact on Aloma Shim’s bending production: “The Astro 165W NT with its Automatic Tool Changer has reduced brake setup times by 500% and increased work center output by 150%.” To gain the ability to quickly switch between flat sheet cutting and tube cutting, the company also purchased Amada’s FOM2 RI laser cutting system with an integrated Rotary Index. Bob Wolpink reflects on new levels of speed and efficiency: “The FOM2 RI increased our tubing material utilization by as much as 20% and increased our tube/angle cutting speeds by as much as 40%!”
The FOL 3015 A J Fiber Laser achieves cutting speeds up to 9,400 inches per minute and rapid traverse of over 13,000 inches per minute. ASLUL automation provides high-speed material handling at a rate to match the productivity of the Fiber Laser.
The FOM2 RI’s Rotary Index is located on one of three shuttle pallets — making it extremely easy to switch from f lat sheet cutting to tube or pipe cutting.
Amada’s leading-edge systems and technologies ensure:
The Astro 165W Robotic Bending System provides the ideal high-speed solution for large parts and thick materials.
• Unmatched Productivity (The FOL AJ Fiber Laser provides cutting speeds up to 4 times faster than CO2 laser and a 7/8" rating in steel plate. An ASLUL system maximizes “green-light-on” time by providing high-speed, automated storage and load/unload).
Amada Canada, Ltd. 885 Avenue Georges Cros, Granby, Quebec, Canada J2J 1E8
• The Ultimate Robotic Bending Solution (The Astro 165W NT processes large and heavy parts quickly and safely while outperforming manual operation times by up to 22% and reducing labor costs). • Maximum Versatility (The FOM2 RI can process round, square, rectangle, C-channel, and angle iron — making it the most versatile Rotary Index laser cutting system available. An integrated Rotary Index provides the ability to switch from flat sheet cutting to tube cutting in 2 minutes or less).
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15-10-01 5:05 PM
VIEW FROM THE FLOOR
MOVING TOWARDS ADVANCED MANUFACTURING
T Is your shop embracing automation, incorporating robotics, investigating Industry 4.0? I’d like to know!
he Canadian Manufacturing Technology Show (CMTS) came to close on October 1, and as the lights dimmed on the show floor there was time to reflect on highlights from the four-day event. The opening keynote by Linamar CEO Linda Hasenfratz kicked off on a very positive note, with the head of the global auto parts manufacturing giant applauding the productivity of its Canadian operations and praising Canada’s R&D tax credit system. “We have to be competitive to be prosperous,” says Hasenfratz. This was a great message to hear from the Guelph-based company, and it seems to corroborate the recent Global Competitiveness Report from the World Economic Forum that has Canada moving up two spots to 13th position. The report refers to our “highly efficient labour markets”, yet it also suggests that “Canada should continue to foster innovation at the company level,” noting that our R&D spending ranks 26th overall. At CMTS it was obvious that companies are embracing the next wave of manufacturing. For me, the largest news at the show was a further commitment to metal additive manufacturing in this country. One existing Canadian player, Burloak
PUBLISHER STEVE DEVONPORT 416.543.1641 ß sdevonport@canadianmetalworking.com
Technologies of Dundas, Ontario confirmed its decision to add three more metal 3D printing machines (it already has two), while a new start-up located just north of Toronto, Additive Metal Manufacturing, used the show launch itself into the market. This shop aims share its engineering and product design development skills with customers to ramp up additive metal production in this country. In addition to new processes, the ever-increasing interest in robotics on the show floor reveals demand for automating current machining operations. A new report from the Boston Consulting Group, “Man and Machine in Industry 4.0: How Will Technology Transform the Industrial Workforce Through 2025?” suggests that by installing robotic systems manufacturers will ultimately reduce routine physically demanding jobs, while the number of roles requiring problem solving will increase. “To succeed in their evolving workplace, employees will have to be even more open to change ... and get accustomed to continual interdisciplinary learning,” notes Michael Rußmann, a coauthor of the report. As visitors to CMTS gathered around all of the new technology on the show floor, it was clear that the desire to learn and progress is top of mind. Events like CTMS confirm that Canada’s manufacturing industry is committed to the future.
DOUG PICKLYK, EDITOR dpicklyk@canadianmetalworking.com
ASSOCIATE PUBLISHER ROB SWAN 416.510.5225, cell 416.725.0145 ß rswan@canadianmetalworking.com
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ART DIRECTOR STEWART THOMAS 416-442-5600 x3212 ß sthomas@annexnewcom.ca CIRCULATION MANAGER BEATA OLECHNOWICZ 416.442.5600 x3543 ß bolechnowicz@annexnewcom.ca MARKET PRODUCTION MANAGER BARB VOWLES 416.510.5103 ß bvowles@annexnewcom.ca PRINT PRODUCTION MANAGER PHYLLIS WRIGHT 416.442.6786 ß pwright@annexnewcom.ca PRESIDENT OF ANNEX BUSINESS MEDIA MIKE FREDERICKS VICE-PRESIDENT OF ANNEX BUSINESS MEDIA TIM DIMOPOULOS
10 | OCTOBER 2015
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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: vmoore@annexnewcom.ca Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9 Canadian Publications Mail Agreement: 40065710. ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund of the Department of Canadian Heritage.
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www.canadianmetalworking.com
15-10-02 3:32 PM
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IN THE NEWS
LONG AWAITED SHIPBUILDING BEGINS AT HALIFAX SHIPYARD
Kevin McCoy, President of Irving Shipbuilding and hundreds of employees at the Halifax Shipyard mark the start of production of the first Arctic Offshore Patrol Ship. PHOTO COURTESY CNW GROUP/J.D. IRVING, LIMITED
The beginning of September marked a milestone for Halifax Shipyard, where hundreds of employees gathered to celebrate the start of production of the first Canadian Arctic Offshore Patrol ship (AOPS). The first vessel, the HMCS Harry DeWolf-class ship, is not expected until 2018. “Today is a milestone we have all been anticipating. It is a great day to be a shipbuilder in Nova Scotia as we mark the beginning of this generational opportunity,” said Kevin McCoy, president of Irving Shipbuilding. “We’re doing this with the best team and the largest and most modern shipbuilding facility in North America. Our focus is on delivering the best value to Canada with a growing supply chain from coast to coast to coast.” Two units for the centre section of the ship are the first pieces that workers are beginning production on. The Shipyard is using its new state-of-the-art panel line, and welders, pipefitters, marine fabricators and iron workers are among the trades involved in the process. The ship is the first of up to 21 ves12 | OCTOBER 2015
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sels that will renew Canada’s combatant fleet over the next 30 years under the National Shipbuilding Procurement Strategy. As it stands, Irving Shipbuilding has built more than 80 per cent of Canada’s current combatant ships. All of the employees on the recall list have been contacted. Current direct employment at Marine Fabricators in Dartmouth (where steel is cut) and the Halifax Shipyard is about 900 direct employees (staff and hourly). Over the next two years, the workforce at both sites is expected to rise to 1,600 direct employees with over 1,000 directly employed on AOPS production. In addition, total employment at Irving Shipbuilding
(all operations) is forecasted to rise to over 2,500 direct employees at peak production of the larger Canadian Surface Combatant vessels that will replace Canada’s current fleet of Halifax Class frigates. The modernization at Irving Shipbuilding and the AOPS contract has resulted in over $1 Billion in spending commitments. With projects finally coming to fruition in Halifax, the city’s economic outlook is looking pretty healthy for the next two years.
Centre section component of 1st AOPS ship underway at Halifax Shipyard PHOTO COURTESY CNW GROUP/J.D. IRVING, LIMITED
www.canadianmetalworking.com
15-10-02 3:40 PM
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IN THE NEWS
FORD LOOKING TO LIGHTWEIGHT MORE VEHICLES Ford Motor Company has been consistent in its attempt to lightweight its vehicles. The company recently announced its latest Super Duty trucks, with a fully boxed frame comprised of more than 95 per cent high-strength steel with highstrength, military-grade, aluminum alloy body panels. This new design helps to alleviate 350 pounds from the vehicles weight. Earlier this month, Ford announced that it was partnering with Alcoa to produce next-generation automotive aluminum alloys that are more formable and design-friendly. The companies entered into an agreement to work together on next-gendevelopment. “This eration aluminum Ford’s all-new 2017 Ford collaboration supalloys for automotive F-450 Super Duty Platinum ports our continued parts using Alcoa’s Crew Cab. drive for innovation, Micromill technology. PHOTO COURTESY OF FORD as we research autoThe aluminum alloys motive applications for even greater are slated to be used in multiple light-weighting.” components on the 2016 F-150 truck. Alcoa’s Micromill technology pro‘‘Light-weighting enables us to duces an aluminum alloy that is 40 design vehicles with great customer per cent more formable than current attributes – like the F-150, which automotive aluminum and makes it can tow more, haul more, accelerate easier to shape into intricate forms, quicker and stop faster than the such as the inside panels of automoprevious F-150, and is more fuel-efbile doors and external fenders. ficient than ever,” said Raj Nair, “Alcoa’s breakthrough Micromill Ford group vice president and chief technology offers highly differentiated technical officer, global product
14 | OCTOBER 2015
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Alcoa’s Micromill will be used to produce next-gen aluminum alloys for Ford. PHOTO COURTESY OF ALCOA.
automotive material with strength, weight, formability and surface quality combinations previously impossible,” said Klaus Kleinfeld, Alcoa chairman and chief executive officer. “The door inner is one of the most difficult parts in automotive stamping,” said Peter Friedman, Ford global manager of structures and stamping, research and advanced engineering. “The ability to produce an alloy using Alcoa’s Micromill technology to make that part is a real statement for how this process can benefit the automotive industry and Ford in particular.”
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15-10-02 3:40 PM
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IN THE NEWS
VOLKSWAGEN CEO STEPS DOWN AMID EMISSION SCANDAL Volkswagen CEO Martin Winterkorn stepped down on September 23 over an emission scandal plaguing the German carmaker. The company has admitted to rigging its diesel cars’ emissions to pass U.S. tests. “As CEO I accept responsibility for the irregularities that have been found in diesel engines,” said Winterkorn in a statement before asking the Board to accept his termination request.
“I am doing this in the interests of the company even though I am not aware of any wrong doing on my part,” he continued. “Volkswagen needs a fresh start—also in terms of personnel,” he said. “I am clearing the way for this fresh start with my resignation.” Matthias Mueller, head of the Porsche brand, is taking over as CEO. Winterkorn said Volkswagen must continue the process of “clarification and transparency.”
ISO 9001:2015 FINALLY ARRIVES CMTL May CB 3278 Powerhold.pdf
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2015-09-22
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“This is the only way to win back trust. I am convinced that the Volkswagen Group and its team will overcome this grave crisis,” he added. On September 22, Volkswagen admitted that over 11 million of its vehicles worldwide were affected by the defect device.
changes to the latest version of the management system standards that will affect all businesses using it. One of the major changes will impact top management as Simon Feary, Chief Executive of the CQI, explains, “For the quality profession, whether delivering quality management programmes or auditing against management system standards, it is an opportunity to add greater value to organizations and to develop new skills. The requirements for greater senior management involvement...will put the quality profession in front of senior management like never before.” The business landscape has changed considerably over the past decade. From technological advances to an ever more global economy businesses now work with increasingly complex supply chains. The changes in ISO 9001:2015 intend to reflect these changes and ensure the standard is still relevant today. Those concerned with establishing, implementing and/or managing a QMS based on ISO 9001:2015 or who audit against it will also face new challenges. From looking at risk differently to identifying new evidence sources, ISO 9001:2015 requires auditors to gain new knowledge, skills and understanding to assess a modern Annex SL-based management system. www.canadianmetalworking.com
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IN THE NEWS
WHAT HAPPENED AT CMTS 2015
A brief but dynamic keynote presentation by Linda Hasenfratz, CEO of Guelph-based Linamar, highlighted the $4.2B global company’s continuing expansion into new geographic markets (China and India) and its exploration into new industries including energy and agriculture. Hasenfratz praised the company’s Canadian operations for their leading productivity and Canada as a cost effective manufacturing country.
Industry suppliers were pleased with the traffic and level of conversation over the four-day Canadian Manufacturing Technology Show (CMTS) held September 28 to October 1 at the International Centre in Toronto.
Along with the largest booth space hosting four quadrants of technology from an automated cell to quality, production machining and EDM, Elliott Matsuura Canada also hosted an autograph signing by Maple Leafs legend Darryl Sittler.
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15-10-02 3:40 PM
IN THE NEWS
Peter Adams (right), president of Burloak Technologies in Dundas, Ontario shakes hands with Dafydd Williams, general manager with Renishaw Canada, as Burloak commits to three more Renishaw metal 3D printing machines. Installations will begin this fall and continue through the second quarter of 2016. Burloak currently operates an EOS M290 machine (fall 2014) and a Renishaw AM 250 200w machine (June 2015).
Mazak in cooperation with Sandvik Coromant, was holding lunch and learn programs demonstrating cutting techniques and tools for machining titanium, using a Mazak Variaxis i600 with SmoothX technology to produce a titanium guitar body on the show floor.
FULL RANGE OF PREMIUM WORKHOLDING SOLUTIONS FOR THE OIL INDUSTRY A new company launched at CMTS: Additive Metal Manufacturing in Toronto, with its new EOS machine, is poised to become a metal 3D printing production house and centre of excellence in Canada. The company owners (l-r): Norman Holesh, president/CEO; Nigel Southway, vp engineering; and David Slimowitz, vp sales/marketing.
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OCTOBER 2015 | 19
15-10-02 3:40 PM
FINANCE
EXPLORING ALTERNATIVE FINANCING BY KEN HURWITZ
O
ne of the biggest struggles Canadian manufactures are faced with, particularly successful ones, is managing cash flow. hen business is good and the market is active there are plenty of opportunities to grow your business, whether it is from existing clients or new prospects, but it is managing these opportunities that can create problems. It is almost a “Be careful what you wish for” scenario. A lot of potential clients seek me out because they are looking for ways to put more equipment on their floor without taking funds from their working capital. Bringing on new business, or larger volumes from existing clients, puts pressure on cash flow because of all the additional expenses required to support the new opportunity—this could be anything from needing to purchase more material, increases in tooling, more operators or programmers, and the list goes on—none of which is financeable beyond using a bank operating line, which for most businesses, big or small, is usually very limited in relative terms to what is actually needed. The reason most bank lines are limited is because the security required by any bank, or tier one institution, can be two or three times what they are prepared to put in place. Since the bank is in a very secure position they are able to offer relatively cheap rates for an operation line (normally a couple points above prime), but it’s also the very reason why only a small amount of funds are available. It really isn’t drastically different than a standard mortgage where the
W
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rate is low, again in relative terms, since the lending institution is in an equity position from the onset, and the amount of funds lent are only a percentage of the value of the property. One of the first places a growing company can look to raise working capital is from the equipment currently on their shop floor. Most traditional lenders do not place much value on manufacturing equipment, but an asset-based lender, particularly one who has a background in machinery and equipment, will happily raise money against good used equipment since they understand re-sale values and know where an active market can be found in the unlikely event of a default.
However when machinery and equipment is being evaluated for these purposes it is important to understand how a lender looks at values. The exit strategy for any lender would be selling the equipment at auction, so the amount loaned against the equipment will be based on what it is perceived to bring at said sale less any costs associated with getting it picked-up, delivered, cleaned and/or repaired. There is no doubt the healthier the business the better the loan-to-value ratio, but equipment itself may not raise the amount of capital required and other avenues need to be found. Even though this is a great strat-
egy for adding new equipment to the floor, a question I often get is how to raise enough money to purchase an industrial unit or buy a commercial property. As my customers grow and become more successful they look at their monthly rent cost and realize that same money could be used to make a mortgage payment. In this instance another place to look for capital could be the world of private mortgage lending. Private lenders are equity lenders. First they look at the quality of the property and their relative security position on it. Next they look at the borrower’s situation to determine whether or not the individual is someone they want to do business with. Unlike banks who have an application process based on a rigid scoring systems, private lenders adopt a common sense approach to lending. They understand that not all income is verifiable, and sometimes a person’s credit score could have been adversely impacted for justifiable reasons or be non-existent in the case of new immigrants. Private mortgages are filling a growing need as banks are becoming increasing more stringent in their lending criteria, often shutting their doors to self-employed individuals. Private lenders on the other hand create their own lending guidelines, and they often provide a quicker more flexible method of financing. Regardless of whether it is equipment financing or mortgage lending, moving beyond a traditional bank may provide an opportunity which would otherwise be unavailable. Till next month… Ken Hurwitz, Senior Account Manager with Blue Chip Leasing Corp. in Toronto, has years of experience in the machine tool industry and now helps manufacturers of all kinds with their capital needs. Contact Ken at (416) 614-5878 or ken@bluechipleasing.com. www.canadianmetalworking.com
15-10-02 3:34 PM
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BUSINESS MANAGEMENT
ALIGNING YOUR COMPENSATION PLANS TO DRIVE PROFIT BY ANDREW WOOD
I
n a previous Business Management column I discussed “Hiring for Talent” (August, 2015), providing guidelines on how to evaluate individuals with a strong emphasis on their ability to self-manage. This leads to the topic of aligning staff compensation plans in direct support of financial goals established when the company starts its hiring process. When I engage organizations and review compensation plans I’m always amazed that they tend to reward deliverables that I view as subjective, non-quantifiable, or disconnected with the organization’s core goals. I often see bonus plans that reward for the organization’s macro performance, without direct accountability for the managers and employees themselves. I’ve seen capped bonus plans that drive away revenue and talent. But the worst culprits are misaligned plans where pay-out reduces bottom line profits for the company.
CASE IN POINT I performed a turnaround at a national company where a sales team member had just closed a new $600,000 client. This organization made its revenue by charging packaged goods clients for storage and pick-and-pack services in a warehouse environment with an end point of shipping to major retailers. Sales people were compensated on revenue for new business development, warehouse managers were compensated $500/month on hitting a monthly labour-to-revenue ratio. 22 | OCTOBER 2015
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In one case a particular new client was offered free shipping, free on-boarding and setup into the warehouse provider’s physical and electronic environment as part of a deal—a small price to pay to secure such a large and active client. Unfortunately for the warehouse manager, having 15 trailers of goods unexpectedly arrive on the loading dock was not a “planned event”, and with no corresponding revenue, “free on-boarding” was cost without revenue to the warehouse manager and a threat to his monthly bonus. Thus, each day he serviced all revenue-generating clients first, then dealt with the new project only when labour became available. By the third day the new client started to forward service orders to the warehouse customer service reps for required shipments to retailers, but these orders could not be fulfilled as the stock had not been placed nor was it in the electronic inventory yet. Tensions amongst the sales staff, the warehouse manager, customer service rep and the client rose quickly, major retail compliance charges commenced. At no point did the warehouse manager comment that he was protecting his bonus with his inaction, instead a series of excuses were thrown up, only confusing the issue. Senior management’s intervention and a series of conference calls resolved the issue. The company paid fines, lost revenue, and the relationship with a new client suffered. Ironically at month-end the VP of sales celebrated the new business win, and the VP of operations awarded the warehouse manager his bonus.
BUILD A BUSINESS OF BUSINESSES. The above could have been avoided with better communication, or a side
deal with the warehouse manager to ‘back out’ any on-boarding labour expenses. But structurally, the plans were not aligned within the organization’s goals. Ultimately, when it comes to compensation: “Managers and staff will act in their own best interest.” If you accept this to be true, then the formula to better align compensation plans is to ensure that the reward drives behaviour that positively impacts on the P & L, resulting in decision modification. The best organizations structure around a concept I call “Building a Business of Businesses.” In a Business of Businesses, each sub-total on the company’s P& L represents a “bottom line” on each department’s financial report. Each report is structured to capture department metrics that might be altered by their actions, avoiding a clash among department managers.
CHANGES TO BEHAVIOUR When sales persons are compensated on gross profit dollars and not revenue, hunting practices change and business is sought for low season and not low-balled into high season which results in operations incurring overtime labour costs. Commodity selling is reduced as lower pricing reduces commission directly. When sales plans are not capped and previous year’s home runs are not baked into the new baseline then sales plans are not manipulated by the sales team to fit the best case scenario at the expense of the organization. If an organization is structured to increase profitability, the best approach is to construct a Business of Businesses and align all departments, their processes, manager’s discretionary authority and compensation accordingly to support the company’s profit objectives. Andrew Wood has held senior positions in manufacturing, supply chain and other industries and sits on TEC, Canada’s Trusted Advisors Council. andrewjwood@changeagent.ca. www.canadianmetalworking.com
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THE BUSINESS OF WELDING
SKILLS SHORTAGE RETHINK BY IAN CAMPBELL
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ometimes it can be hard to look past the current downturn that is impacting our industry, with all the bad news about layoffs out West and the delay in industry coming back on line in Central Canada, and the times can seem somewhat bleak. But I’ve found that although the economy has stalled on some fronts, talk around skills shortages in this industry has not. At the recent CanWeld15 Conference in St. John’s, NL, a local “skills shortage” debate shifted its focus to the apparent “skills surplus” currently taking place on the island. Is there a surplus of skilled labour in Newfoundland? According to some, it would appear that there is. Talking to local media, industry, and local politicians it would seem that the local schools do a great job generating tradespeople of the hammer wielding, wire stripping and sheet metal bashing persuasion. So, if you are looking to build a wooden structure, the island is well stocked with the required material and people who know what to do with it. From their perspective this qualified, rightly, as a skilled labour surplus. It would appear that welding was not factored in, although no one argues that welding is clearly a skilled trade. We need to rethink the idea of skilled shortages, and how it is portrayed in the media. Is there a skilled trade shortage in Canada? I would say maybe, depending on where you are standing and what you are looking at. If welding is not strongly associated with local building or industry needs, and not supported as an www.canadianmetalworking.com
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career option, it’s likely not going to be factored into any assumptions (or hard facts) relating to the number of “skilled workers” at a given time. With this in mind, simply saying there’s a skills shortage is like looking through the wrong end of a pair of binoculars—you might get the general lay of the land, but not much about what is actually on it. What we should be saying is that there are regional shortages and surpluses of welders. However, and this is an important consideration— where surpluses do exist they will not be that way for long given the age of the average welder. Without a course correction around regional training and welding promotion the compass will start to point towards an every increasing shortage. It’s a simple numbers game: as those on the job move on, or retire, or move out of the area, there is no one training to replace them locally. The key here is to take into account time. We’ve lost a lot of time, and that’s going to be reflected in the size of the available domestic labour pool each and every year starting in the next five to 10 years—regardless of where you start looking. This is our problem to fix. So what can we do? We have two options: train our Canadian youth, or import foreign workers. Lets look at how we can support a Made in Canada solution. Depending on where you look and when, there is (or is going to be) a shortage of welders, regardless of what’s happening in traditional welder-centric regions like Alberta. It’s all about perspective: are there welders in Newfoundland? Absolutely, just like there are welders living and working in all provinces. That said, is there is a focus on creating new welders in Newfoundland? I would say no, at least not in the same way other trades are promoted and taught. For example, we were told that at
the high school level there is only one high school that was set up to teach welding, but no classes had been taught for years. The good news, as announced at CanWeld15, is that through the CWA Foundation this is immediately correctable. The Foundation, alongside the CWB Group and local industry partners, is proactively driving for change, as was reflected in the programs that were announced at CanWeld15 this year. These programs will provide: • Funding for welding-related awareness at all levels across all provinces • Free access to Canada’s new national welding curriculum and assessment tools (in the form of CWBi Acorn) • Financial support for purchasing equipment • Access to local donations of consumables and material These programs will be freely available to any and all high schools in Canada that qualify. Yet, funding and programs can only go so far. It’s people that need to help drive things forward. For example, Newfoundland and other provinces were the hosts of many Mind Over Metal welding camps this year, providing the next generation a first taste of welding in places where such opportunities would not otherwise exist. You can help by pitching in, whether it’s joining the CWA, donating to the Foundation, or helping out at a camp or event. Everything you do helps improve the visibility of welding. If you want to see just how much can be done, join us next year at the CanWeld16 Expo in Edmonton. You may be surprised at what others are doing to improve your industry and job prospects across the country. Ian Campbell is director of marketing and new product development with CWB. OCTOBER 2015 | 25
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LOOKING BACK: TRAIN CAR PRODUCTION I
n our continuing celebration of Canadian Metalworking’s 110th anniversary, in this transportation-themed issue we explore some of the earliest developments in train car manufacturing in Canada. In the June 1905 issue a profile was written on a new train car manufacturing plant that was under construction in Montreal for the new Canada Car Company. And in July 1905 a profile of the Canadian Pacific Railway’s Angus Shops in Montreal provided interesting insights into the manufacturing of locomotives and railway cars at the time. The Angus Shops were originally built in 1904 and named for their founder, Richard Angus. The entire industrial site covered 1,240 acres and consisted of some 66 buildings in total. In 1905, the writer of the profile was very impressed with the size of the operation: “Of necessity, building a locomotive demands a large amount of heavy machine work, where the parts to be machined weigh not only pounds, but, in many cases, tons. … Probably the first impression the visitor receives on entering the machine shops of the Canadian Pacific Railway at Montreal is that of the enormous scale upon which operations are carried out and the ease with which the heavy work is handled.” The Angus Shops built passenger cars, freight cars and locomotives. “The car machine shop takes care of all the work for the erecting shop, the output of which is 30 cars a day. The work done here is of a much lighter nature than that of the locomotive machine shop,” noted the article in 1905. That shop included a complete nickel-plating and oxidizing plant, including plating, buffing and dipping rooms and a brass department. “In the plating plant the metal parts for finishing the passenger and sleeping car interiors are taken care of. The plating and oxidizing are done in separate rooms. The dipping room contains vats of hot and cold water, sawdust, acids, solutions, etc., where all material www.canadianmetalworking.com
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is washed before and after being plated. “The plated articles when polished and washed are lacquered and sent to the drying oven. The brass department looks after all brass works, machining and finishing the hundred and one brass fittings used in modern railway coaches.” Marvelling at the fully-equipped machine shop, the article pointed out particular machining highlights:
Machine bay of the locomotive shop, C.P.R.’s Angus Shops in Montreal (1905).
“One of the features of this shop is the set of 6-spindle Bertram drilling machines with a capacity to drill simultaneously six 1-1/4-inch holes in steel. The distance between the housings is 6 ft. 6 in., and the spindles have a vertical travel of 12 inches and are counter-weighted, while three changes of power feed are provided, also hand adjustment by rack and pinion.” “Four Bertram wheel lathes turn out four pair of 40-inch wheels a day, and one Pond lathe of heavier build turns out six pairs. The Angus Shops’ locomotive building, 1,167feet long by 162-feet wide was divided into three bays, and the part devoted to the machine shop had some 245 machines in operation. The writer of this piece was very impressed with the productivity levels at the shop: OCTOBER 2015 | 27
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from the cross-rail, and the heads can be moved along the cross-rail so that holes may be drilled in any position, while one of the heads swivels for drilling holes at an angle. An unusually large turret lathe, the first of its kind built, is also in operation here.
“Among other economies aimed at is that of getting a maximum output from the machines in operation. This is attained by the expeditious handling of all material with cranes, electric and pneumatic, trucks, hydraulic jacks, the use of highspeed steels in all cases and a highly perfected system of jigs and templets, as well as the latest in pneumatic tools. There is an air of lively industry in evidence here, more so than is usually found in huge manufacturing establishments. Blue chips from the machines are abundant, showing at least that the machines are not running slow speed for the work they are turning out.”
“It is impossible within the scope of this article to enumerate the many specially made high-class machine tools in operation at these shops. Enough has been said to give the reader some idea of the work turned out. These shops are an index to the spirit of the times where manufacturers find it economic, although at increased initial expenditure, to install not only the best tools, The article went on to focus on some particbut the most efficient labor-saving ular machining operations: devices known.” “To handle the locomotive frames The profile on the new train car plant under requires very special machinery, and the construction in Montreal for the Canada Car drill used for these is worthy of attenCo. made note that it was the first all-contion. The frames to be machined consist crete industrial facility of its kind. The of a solid forging 28 feet long and weigh ground was broken in September, 1904, and 3,600 lbs. The drill used is a Nileswas completed by August 1905. Bement-Pond 4-spindle frame drill. The ERI America_CMW_10-15.pdf 1 9/24/2015 4:47:36 PM The plant was designed to manufacture spindles have cross-adjustment to and
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Side view of Canada Car Co.’s plant under construction (1905).
wood-framed freight and passenger cars, with orders on the books expected to keep the facility running for many months after start up. The article noted the state of the art machine tools being ordered to outfit the plant. “In the design and construction of these shops, the point kept in constant consideration was to produce the completed cars with the least possible handling of material.” The facility included a wheel foundry, forging shop and machine shop. “The plant, which is entirely self-contained, will manufacture everything from the raw material, lumber and steel. Its initial capacity will
be about ten passenger cars per month and twenty freight cars per day, with their corresponding trucks. “While wooden cars will be the first product, provision is being made to manufacture composite wood and steel, and all steel cars, pressed steel or structural shapes, street cars and special type of trucks and bolsters, and other specialties used in car building.” By 1909 the Canada Car Company was merged with Dominion Car & Foundry Co. Ltd. of Montreal and Rhodes Curry Co. of Amherst, Nova Scotia, becoming part of Canadian Car & Foundry Co. Ltd. Based in Montreal, it was the largest train-car-building operation in the country. Since C.P.R. was building its own train cars at the Angus Shops it didn’t order cars from Canada Car until around 1920 when the Angus Shops stopped building cars and instead began buying unfinished train cars from Canada Car and would complete the interiors to their liking. Research reveals that the original Canada Car Co. plant was finally closed and sold in 1958, and the new owner sublet sections to a variety of industries.
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OEMs making trains, buses and ships are keeping busy BY NATE HENDLEY
O
Assembly of the new Bombardier low-floor streetcars for Toronto takes place at production facilities in Thunder Bay, Ontario.
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n June 18, Prime Minister Stephen Harper visited Toronto to talk transportation. The occasion was a funding announcement for an ambitious $8 billion public transit project called the SmartTrack Regional Express Rail Line. The latter is a so-called “surface subway” that would see rail vehicles zipping between 22 Toronto-area stations along 53 kilometers of track. The system will primarily use existing track currently utilized by regional GO Trains. Once in place, SmartTrack will reduce commuter times and expand public transit accessibility says Toronto Mayor John Tory, a key supporter of the plan. The Prime Minister promised that Ottawa would pay $2.6 billion, or roughly a third of SmartTrack’s estimated cost. If all goes as
planned, the remaining costs will be borne by the City of Toronto and province of Ontario. “From our country’s earliest days, as a geographically large and internationally open trading economy, mobility has been critical to Canada’s success. Indeed, it has been critical to our existence as a united country. And for that reason, we’ve often made huge investments in the great engineering works that have allowed us to travel more quickly and more conveniently. For example, the Canadian Pacific Railway in the 19th Century and the Trans-Canada highway in the 20th,” noted Harper in his speech. During his appearance, Harper also promoted the new federal Public Transit Fund (PTF). Introduced in the 2015 Budget, the PTF earmarks $750 million in funding for 2017-19, rising to a billion dollars a year thereafter, for worthy public transit projects across Canada. The Canadian government has made good on similar promises in the past; since 2006, Ottawa has committed nearly $5 billion in funding for public transit projects. This includes $265 million for a new light rail and bus rapid transit system in the KitchenerWaterloo-Cambridge, Ontario area, $600 million for light rail in Ottawa and $400 million for light rail in Edmonton, among other projects. Rail isn’t the only transportation segment making news. The city of Montreal is currently looking at new, all-electric buses, a project that might spell big opportunities for suppliers in the near future. Meanwhile, Irving Shipbuilding, based in Halifax, has been so busy the company hosted a job fair in the oil patch. That said, overall revenues have declined in certain transportation segments and some high-profile projects have been endlessly delayed. Still, there’s plenty of opportunity for companies looking to supply OEMS that make trains, buses and ships. If SmartTrack goes forward, it’s not hard to guess which companies might benefit. The most likely beneficiaries will be OEMs that are already involved in Toronto transit. Nippon Sharyo, a division of Sumitomo Corporation of Americas which is based in New York City, manufactured the trains cars used in the newly opened Union Pearson Express train. Said train whisks passengers from downtown to Toronto Pearson International Airport in under 30 minutes. The trains were manufactured in Japan. www.canadianmetalworking.com
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Bombardier of Montreal is also doing several transit projects in Toronto. Bombardier Transportation is building light rail vehicles for the Eglinton Crosstown line, which is supposed to link to the SmartTrack line but otherwise is a separate project. As funded by the province of Ontario, the Eglinton Crosstown line is a $5.3 billion project to build a 19-kilometer light rail transit corridor from east to west Toronto along Eglinton Avenue. Construction began in 2011. When it launches in 2020, the Eglinton Crosstown link is supposed to have two-dozen stops and stations and connections to 54 bus routes, three subway stations and various GO Transit lines. In July 2015, Bombardier Transportation won a $403 million contract to provide three decades worth of maintenance on the Crosstown light rail fleet. The contract was handed out by Crosslinx Transit Solutions Maintenance General Partnership, which is responsible for the Eglinton Crosstown system. The maintenance contract was controversial, given Bombardier is way behind schedule on other Toronto transit projects. In 2009, the Toronto Transit Commission (TTC) paid Bombardier $1.2 billion to build 204 low-floor “Toronto Rocket” streetcars to replace Toronto’s aging streetcar fleet. It was originally anticipated that 60 of these streetcars would be plying Toronto streets by July 2015. By mid-year, however, only a handful of Toronto Rockets had been delivered. Bombardier Transportation—which is building the streetcars at its Thunder Bay, Ontario manufacturing facility—has promised it will deliver all the vehicles by late 2019. Bombardier, it should be noted, is also late in delivering streetcars to New York City, Kansas City and Cincinnati. Bombardier isn’t the only transportation OEM to win big contracts recently. In June 2015, it was announced that National Steel Car, which describes itself as “North America’s leading railroad freight car manufacturer” won a $70 million contract to make 700 new rail cars for Canpotex. Founded in 1912, National Steel Car is based in Hamilton, Ontario. Saskatoon-based Canpotex, short for Canadian Potash Exporters, oversees the marketing and export of potash. To this
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Centre section component of the first Arctic Offshore Patrol ship underway at Irving’s Halifax Shipyard.
end, the 700 new railcars will be customized specifically to transport potash. Since 1999, Canpotex has paid National Steel Car over half-a-billion dollars to manufacture a total of 7,000 railcars. In spite of such big deals, revenues and employment figures are slightly down in the rail sector. According to the Ottawa-based Railway Association of Canada (RAC), in 2013 there were 3,043 locomotives operating on Canadian track (down from 3,234 in 2004) and 59,000 freight cars (down from 99,000 in 2004). The railway industry employed 33,167 people in 2013 (down from 35,736 in 2004). Industry Canada tracks Canadian companies involved in “railroad rolling stock manufacturing”, that is to say, firms “primarily engaged in manufacturing and rebuilding locomotives and railroad cars of any type of gauge, including frames and parts.” There were 53 such operations in Canada as of December 2013, the vast majority in either Ontario (19 establishments) or British Columbia (eight establishments), states Industry Canada. “Total revenues in the railroad rolling stock manufacturing industry have decreased from $2.6 billion in 2004 to $1.6 billion in 2012 or by -6.1 per cent per year on average. In the latest year, total revenues decreased by -3.0 per cent,” adds Industry Canada. In the 2008 budget, Ottawa increased the rate of depreciation for new and rebuilt locomotives from 15 to 30 per cent. Industry associations such as the Ottawa-based Canadian Association of Railway Suppliers (CARS) were hoping to see a similar increase for freight cars but were disappointed. OCTOBER 2015 | 31
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“We did not receive the requested increase to 30 per cent for freight cars in the 2015 budget. Therefore freight cars are currently at 15 per cent,” states Sylvia Newell, executive director of CARS. Newell estimates that “approximately 15 percent” of the organization’s membership consists of manufacturers and machine shops. Rail industry pundits remain pleased, however, with the performance of their sector. “Canada’s railway industry is globally competitive, sustainable and most importantly, safe. Its railways move 75 million people and $250 billion worth of goods in Canada each year,” states Gerald Gauthier, VP of public and corporate affairs at RAC.
ON THE BUS FRONT
Montreal has been a testing ground and will be commissioning its first all-electric NovaBus LFSe models in 2016.
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Nova Bus of St. Eustache, Quebec, is involved in a groundbreaking project with the City of Montreal. The city contracted Nova to manufacture and deliver three fully electric LFSe buses and install two quick-charge stations in Montreal. The quick-charge stations are scheduled to be built in spring 2016 while the all-electric buses will take riders come fall 2016. Representatives from the city and Nova, which is a division of the Volvo Group Global, participated in a demonstration of electric-bus technology in May of this year. While all-electric buses have been tested in Europe, Montreal is the first North American city where Volvo tested all-electric buses. Montreal officials have mused about buying only electric buses by 2025. This possibility opens new vistas for adventurous suppliers. The three electric buses in the initial project were built in St. Eustache. They feature motors designed in Quebec and batteries charged by Quebec hydroelectricity.
In June 2014, Nova Bus announced a contract to make 55 diesel buses for the TTC. These 40-foot buses will be assembled in St. Eustache with a high level of Canadian content. Nova Bus and the Volvo Group “count on more than 65 component manufacturers and suppliers in Ontario” alone. In a similar deal, Nova Bus will manufacture 27 buses for Metrolinx in the Greater Toronto and Hamilton areas. This deal contains an option to purchase up to 188 buses, again with an emphasis on Canadian parts and labour.
FULL STEAM AHEAD According to Industry Canada, there are 568 ship and boat building companies in Canada. The majority are found in B.C. (220), Ontario (135) and Nova Scotia (77). Total revenues in the ship and boat building industry have gone down slightly, from $1.3 billion in 2004 to $1.2 billion in 2012. Some shipbuilders are experiencing a bonanza, however. Irving Shipbuilding of Halifax, has been doing so well it hosted a one-day job fair this July in Fort McMurray, Alberta in an attempt to lure journeymen, welders, pipefitters and fabricators out east. Irving has plenty of work on hand: production in Halifax started in late summer on an Arctic Offshore Patrol ship, the first of 21 combat vessels Irving was contracted to make in October 2011, under the National Shipbuilding Procurement Strategy (NSPS). Vancouver Shipyards was selected to make seven non-combat vessels as part of the NSPS. The total value of the combined Irving/Vancouver Shipyards package has been pegged at $33 billion, with work spanning two to three decades. David Foscarini, president of Mecon Industries Limited in Scarborough, ON, has served as a supplier to transportation OEMs. Mecon worked with Bombardier in 2002 and National Steel Car in 2007 and 2009. “For Bombardier, we’ve built custom press brake tooling and a couple of pieces of coil handling equipment…for National Steel Car, we built heavy duty parts straighteners… we’ve supplied press brake tooling and/or coil handling equipment to a few of their sub-contractors,” states Foscarini. He’s impressed by some Toronto-area transit initiatives: “The Union Pearson Express sounds like a good idea. Anything that adds to our public transportation infrastructure should be a good thing,” states Foscarini. Good for commuters and suppliers alike that is. www.canadianmetalworking.com
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FABTECH 2015 TO OFFER MORE THAN EVER BEFORE I
n early November, Chicago will host North America’s largest metal forming, fabricating, welding and finishing event: FABTECH 2015. And this year’s event promises to offer more than ever before. From November 9-12, 2015, approximately 40,000 attendees are expected to descend on to McCormick Place to see the more than 1,500 exhibitors bring their latest and greatest products and technologies. This year’s show offers an expanded show floor, demonstrating the growth and importance of the metal fabricating and welding industry. “FABTECH is an action-packed, four-day show that’s a must-see event for anyone who wants to take the pulse of manufacturing in the United States,” says John Catalano, show co-manager, FABTECH. “Exhibitors are planning to launch more new products at this year’s show ATTEND FABTECH 2015 than ever before. Attendees will have November 9-12 the unique opportuMcCormick Place, Chicago, IL nity to get a close-up view of all the new Monday, Nov. 9 — 10:00 a.m. – 6:00 p.m. products and techTuesday, Nov. 10 — 9:00 a.m. – 5:00 p.m. nologies, allowing Wednesday, Nov. 11 — 9:00 a.m. – 5:00 p.m. them to create new Thursday, Nov. 12 — 9:00 a.m. – 3:00 p.m. ideas, meet new • 550,000+ square foot trade show floor suppliers and find • 40,000 Attendees cost-saving solutions • 1,500 Exhibitors for working smarter • 100 Conferences and being more competitive in the years to come.” Visit www.fabtechexpo.com One area that is for additional information constantly expand34 | OCTOBER 2015
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ing is this year’s welding hall capacity. There will be over 200,000 square feet of exhibit space in the welding halls, “our largest ever,” says Cindy Weihl, senior manager, public relations, American Welding Society. “Exhibitors will be showcasing the latest welding technology, useful business services and we also have a section for schools to show off their welding programs to target the future leaders of the industry.” In addition to the trade show, FABTECH 2015 will feature an education conference and special events including an opening keynote presentation by NASCAR legend and champion Rusty Wallace. Speakers and expert panel participants will include companies such as Dell, GE Ventures, Siemens, EWI and more. There will also be a large number of networking events, which will allow visitors the opportunity to connect with colleagues. Events include the Women of FABTECH breakfast and the second annual Industry Night party, taking place on Nov. 10 at Lucky Strike in downtown Chicago. “These events are perfect venues for attendees and exhibitors to create a network of contacts they can access year round,” explains Mark Hoper, show co-manager, FABTECH. There are many exciting things happening at this year’s event and the show managers promise it’s going to be bigger and better than ever before. This year both professional and aspiring welders will have a chance to show off their skills in two different competitions: The Professional Welders Competition and the Robotic Welding Competition. www.canadianmetalworking.com
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The Professional Welders Competition is open to any professional welder over the age of 18 who can create a single pass fillet weld on low carbon steel. There’s a $2,500 grand prize, a $1,000 second prize and a $500 third prize that will be awarded. The top 12 competitors win an AWS duffel bag and all participants receive an AWS t-shirt. Participants can register at the show or in advance at http://www.aws.org/events/ detail/professional-welders-competition The Robotic Welding Competition gives contestants the chance to prove their robotic welding prowess in a two-part competition, which includes a hands-on practical test and written examination. Both are timed with the practical exam requiring thorough knowledge of the art of robot programming, safety, and weld inspection. The practical portion will be judged based on speed, accuracy, and quality of the weld. Competitors will be divided into two separate classes: amateur and professional. To register visit: www.aws.org/events/detail/ robotic-welding-competition
FABTECH 2015 promises to offer the latest and greatest technology and products. And if you are a first time visitor, there are some tips to help make for a successful show. “To get the most from attending FABTECH, first-time visitors should have a strategy,” says Catalano. “Knowing what you would like to accomplish before, during, and after the show will help maximize your time.” There’s a lot to see and do so it is important to plan on spending a few days at the show,” adds Hoper. “Make a list of must-see exhibitors and the products and services you need to evaluate, what new products you would like to see and education sessions and special events to attend.” FABTECH 2015 has several ways to make sure you find exactly where you need to be. Using planning tools can make your visit an easy one. The Expo Planner is just one option; you can also download the mobile app to access show info on the go including an exhibitor list, floor plan, agenda planner, and more. However, Catalano offers another important tip, “Pack comfortable shoes, wear business casual clothing, and remember to bring a stack of business of cards.”
FABTECH EXPLORES 3D SCANNING TECHNOLOGIES AT PRE-SHOW
3D scanning technology was highlighted at a FABTECH 2015 pre-show event on the steps of the Art Institute of Chicago. Exact Metrology, a 3D scanning solutions company, used its Surphaser technology to 3D scan the museum’s nine-foot tall south guardian lion, sculpted by Edward L. Kemeys (1843-1907). The iconic guardian lions have flanked the Art Institute’s Michigan Avenue entrance for more than 100 years and have become a symbol of the museum and city. During the event, attendees witnessed the scanning technology firsthand and heard from industry leaders about the process and benefits of 3D scanning and printing. With the scanning portion of the project complete, Met-L-Flo, Inc. will use scan data to print 300 small-scale replicas of the lion, which will be on display and used as giveaways at FABTECH.
www.canadianmetalworking.com
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TECHNOLOGY FOR THE WELDER’S WORLD.
Booth N11045
MORE THAN WELDING. RAB Grip TA & FES-200 W3
Mobile, powerful, and easy to handle! The fume extraction unit FES-200 combined with threaded, low profile fume extraction torches provide the best possible welding fume extraction directly at the source. The W3 is licensed for all CrNi steels!
www.binzel-abicor.com
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BLM GROUP USA Corp — Booth N2000 & N2010
NOVEMBER 9 -12 , 2 0 15 C H I C A G O M C C O R M I C K P L A C E
The company will feature its new LC5 tube and sheet fabricating machine. The compact LC5, equipped with a fiber laser up to 4.5kW is a high production machine with automatic loading and switchunloading that can process both tube and flat sheet in a single machine. Thanks to its design, switch ing from tube to sheet is fast, adding the flexibility fabricators need to expand their laser processing capability. The LC5 can handle bar up to 21 ft. in length and tube to 4.75 in. dia. The processing of sheet metal is fully automatic and allows for sheet up to 5 ft. x 10 ft. The fiber laser is ideal for cutting both mild steel and highly reflective materials such as stainless steel and for aluminum. www.blmgroup.com
Unison LTD — Booth N2055 EvBend greatly reduces the entry costs to precision rotary draw tube bending. It uses manual operations to feed and rotate tubing and apply bending force, but employs smart CNC-controlled braking on the carriage feed, rotation and bend arm axes to ensure part shapes are formed with the highest accuracy. The EvBend 1000 is a simple high precision CNC tube bending solution for small-diameter tubing up to 22 mm, and is currently in use with well over 100 companies from general fabricators to aerospace and motorsports manufacturers. www.unisonltd.com
ABB Inc-Robotics — Booth N6054
ESAB Welding & Cutting Products — Booth N6074
ABB has developed a collaborative, dual arm, small parts assembly robot solution that includes flexible hands, parts feeding systems, camera-based part location and state-of-the-art robot control. YuMi is a vision of the future. YuMi will change the way we think about assembly automation. YuMi is “you and me”, working together to create endless possibilities. ABB dual arm robots have accurate vision, dexterous grippers, sensitive force control feedback, flexible software and built-in safety features that collectively allow for programming through teaching rather than coding. www.abb.com
The Warrior welding system pairs the multi-voltage, multi-process Warrior 400i MV with industry-leading components for a complete industrial welding solution. Warrior 400i MV provides 400 amps at 60 per cent duty cycle and automatically adjusts to primary input power with the flexibility to accept from 220 to 460 VAC 3-phase. Automatic Hot Start/ Variable Arc Control allows the welder to fine-tune the arc to get best possible weld performance and optimize hot start, arc force, and inductance settings with total arc control. www.esabna.com
Koike Aronson Inc — Booth N8008
PFERD — Booth N8025
The KARMAC numerical control with touchscreen interface for all cutting machines uses touch technology to give operators an efficient, easy-to-learn, touchscreen control for plasma, gas, and other cutting systems. Operators don’t need comcom puter or CNC experience— they simply touch the 15” KARMAC monitor to input selections. No keyboard is required, which saves valuable space. KARMAC has CAD import, a library of 50+ shapes, and productivity monitoring. The screen and other components are designed to work in harsh industrial environments. www.koike.com
Produced with advanced ceramic abrasive grain, the new high-performance CO 24 Q bonded grinding wheel is built to tackle the most demanding applications. The new range of wheels delivers unparalleled stock removal rates, long service life and cool cutting action. The self-sharpening action of the ceramic grain delivers fast stock removal with minimal contact pressure, making easy work of even the toughest jobs. For use on steel, stainless steel. www.pferd.com
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www.canadianmetalworking.com
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“We wanted the loading and unloading to be as ergonomic as possible. With the Shear Genius, there is no more shaking out parts, no more loading the sheets by hand. We’ve also eliminated skeletons by taking advantage of common line cutting. We have very rectangular parts, so the right-angle shear was a perfect solution for us. We were able to nest more parts and to achieve better sheet utilization. With our older turret punch press, we were running about 7-8 minutes per sheet compared to the 3-1/2 - 4 minutes with the Prima Power SGe. That’s a 2-to-1 increase in productivity.”
Prima Power o ers the industry’s widest selection of punch/shear and Shear Genius laser/punch combination machines. Prima Power has more than 20 years experience in right angle shear technology combined with proven eld performance in nearly 2,000 applications throughout the world. The bene ts of Shear Genius technology include: Flexible automated fabrication Raw material savings Higher productivity/manufacturing e ciency Reduced manufacturing costs Faster return on investment Reduction/elimination of none value-added tasks The Prima Power laser/punch combination provides punching, forming, tapping, marking, and laser cutting in an integrated machine tool for optimum quality and production speed.
Shear Brilliance
Laser Punch Jacob VandeHei Manufacturing Engineer Unison Comfort Technologies® Minneapolis, MN
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Prima Power Canada Ltd. Tel. 800 344 7143 • www.primapower.com
See us at Booth #S931
15-10-01 5:25 PM
Schwarze-Robitec GmbH — Booth N8103
NOVEMBER 9 -12 , 2 0 15 C H I C A G O M C C O R M I C K P L A C E
The company will present its entire modular, configurable high-performance machines with newly developed CNC systems and innovative axillary programs. The new addition to the bending machine expert’s axillary program is the innovative chopping tool. It reduces the tube waste by up to 90 per cent and shortens the production times considerably. While the previous process required the use of an external shear in order to separate the component from the tensioning or support device after the bending process, this new tool requires only one work step to complete the bending and separation process. www.schwarze-robitec.com
Cincinnati Inc — Booth N9000
Bluco Corp — Booth N11025
BAAM (Big Area Additive Manufacturing) is an industrial sized, additive machine. The machine uses the proven design and technology from a laser platform, including the machine frame, motion system, and control, and has been adapted with an extruder and feeding system. BAAM was designed to allow 3-D printing to be used for production manufacturing. The size and speed allow large parts to be made quickly. The ability to use commodity thermoplastic materials means that the cost per part will be reasonable. By designing a system with an open architecture for material vendors, material costs will be kept lower and with more options. www.e-ci.com
Bluco’s modular fixturing system for welding is the industry gold standard for fixturing low volume/high mix work. With the introduction of the Rollover Positioner and Workstation bases, the benefits of Bluco modular tooling can be extended into even more areas of your manufacturing operations. The rollover positioner provides the ability to rotate parts 360 degrees and still handle unlimited configurations using standard locating and clamping components. Standard models support parts up to 10’ in length and 40” in width. www.bluco.com
Miller Electric Mfg Co — Booth N11037 & N14037 Big Blue 800 Duo Pro SF welder/generator with FieldPRO Smart Feeder is a multipromultiprocess welder/ generator runs conventional stick, TIG, FCAW and MIG welding, as well as advanced Regulated Metal Deposition (RMD) and Pulsed MIG processes with the addition of the FieldPro Smart Feeder. These advanced processes can operate up to 200 feet away from the power source with no control cable, help to reduce weld failures, and can eliminate backing gas on some stainless and chrome-moly pipe welding applications. www.MillerWelds.com
Hobart Brothers — Booth N14032
Bernard — Booth N14037
Hobart will showcase the latest filler metals designed to improve quality and productivity in the fabrication and manufacturing industries while at FABTECH 2015 in Chicago. The company plans to demonstrate its filler metals, including flux-cored wires, metal-cored wires and aluminum products on equipment from Miller Electric Mfg. Co. at booth N14032. Hobart will also have welding specialists available to answer filler metal and process-related questions. www.HobartBrothers.com
Bernard will showcase the latest in its semi-automatic MIG guns, fume extraction guns and consumables. Bernard BTB MIG Guns are a rugged and flexible prodproduct, which allows users to build their ultimate MIG gun by selecting their desired amperage, handle, neck, power cable and more through a convenient online configurator. It builds on the best features from the former Bernard Q-Gun, S-Gun and T-Gun MIG Gun lines, and has been designed to provide industrial-grade performance and reliability. www.bernardwelds.com
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www.canadianmetalworking.com
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LASER SOLUTIONS from ROFIN Standard or Custom Laser Solutions for Marking, Welding and Cutting MARKING; Direct, permanent laser marking
40 YEARS
We Think Laser … and we have
been doing so for 40 years. With 52,000 lasers providing innovative solutions based on our comprehensive range of products and technologies, ROFIN is the world’s leading source of lasers for marking, welding, cutting and surface treatment. Laser sources, customised s o l u t i o n s , o r l a s e r s f o r i n t e g r ation—standard or custom high-speed production systems or desktop units—when it comes to High-Quality Laser Systems, THINK ROFIN Download the new ROFIN APP, a global mobile application that presents you with easy access to ROFIN’s Sales and Support network. Now, easier than ever, you can communicate instantly with our Sales and Service departments directly from your production oor using your smartphone. TAP IT; ZAP IT, SEND IT! www.ROFIN.com/app
WELDING; High-power, high-speed welding
CUTTING; UW-505 Five-Axis Cutting/Welding System NOW with up to 8kW of power
Please call us at 978 635-9100 for a demonstration, or send us your sample parts. Scan matrix code for more information on our full line of laser systems for marking, welding, and cutting.
ROFIN Booth N26036
ROFIN-BAASEL, Canada LTD. 3600(A) Laird Rd., Mississauga ON L5L-6A6. info-canada@rofin-baasel.com
WE THINK LASER Rofin.indd 1
www.rofin.com
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WE BUILD ™
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VIS A T Bo F IT oth AB US N1 TEC 10 H 37
Memories A favorite destination. A treasured moment. Because it’s more than just a day on the lake. It’s a lifetime of reminiscing. On watercraft expertly welded by Louis Graham and the team at Avalon & Tahoe Mfg., Inc. Together, we build memories.
BUILD & WIN! Share what you build — or dream of building — for a chance to win an Avalon pontoon boat!
MillerWelds.com/webuild
The Power of Blue®
15-10-01 5:27 PM
Tregaskiss — Booth N14037
Praxair — Booth N14049
Tregaskiss will feature its robotic MIG guns, peripherals and consumables. TOUGH GUN CA3 Robotic Air-Cooled MIG Guns features a replaceable unicable that offers extended service life to reduce downtime and costs, this gun is a replacement for the TOUGH GUN G1 Series MIG Gun that maintains TCP with minimal or no robotic programming touch ups. The gun has been engineered for precision, durability, and easy maintenance, and also features an improved neck clamp that accidenresists damage due to acciden tal over-torque. www.tregaskiss.com
Praxair’s ProStar PRS900 Robotic Cutting System replaces single purpose machines with a multiple bay system featuring intuitive, integrated controls which requires less shop floor space and provides nearly continuous production. Featuring Hypertherm True Hole Cutting Technology and an industrial Fanuc 9 axis robot, the PRS900 system cuts all four faces of 3D profiles and cuts or bevels flat plate up to 10’ x 24’, bulb flats, I-beams and H-beams up to 65’ feet long, square and rectangular tubing, pipes and domes. www.praxairdirect.com
Walter Surface Technologies — Booth N16106 The SURFOX 304 is a highly effective system for removing heat tint from stainless steel welds (MIG, TIG and spot) without altering the surface of the parent material. The SURFOX 304 removes surface contaminants and promotes the formation of a uniform and durable chromium oxide layer to protect stainless steel against corrosion. Dual inverter board technology makes this unit the most efficient weld cleaning system on the market and ensures that there is no micro pitting on the surface. Two different modes can be utilized; AC mode for cleaning or marking, and DC mode for polishing or etching. www.walter.com
Weiler Corporation — Booth N22025 Vortec Pro Flap Wheels are the smart option for use in low to medium production environments, with a high cut rate at a cost-effective price. Flap Wheels feature a solid hub construction for better balance, reduced chatter and higher RPM ratings and a high quality aluminum oxide cloth. The new .”-20 threaded stem option improves efficiency by elim-
inating the need for special tools to change the flap wheels and is available in 1-in. (30,000 max RPM), 2-in. (25,000 max RPM) and 3-inch (20,000 max RPM) diameters. The new .”-20 threaded stem is available in 60 or 80 grit. The .” stems continue to be available in 60, 80 or 120 grit. www.weilercorp.com
Norton | Saint-Gobain — Booth N24064
Fein Power Tools Inc — Booth N26025
ARKU Coil Systems Inc — Booth S508
Norton Gemini RightCut are new general purpose cut-off wheels. The 100 per cent aluminum oxide abrasive has been infused with a new bond technology and processing for a thinner wheel design and low kerf loss. Operators will appreciate a comfortable cut as it quickly and easily slices through a variety of steels and will appreciate how Norton Gemini Right Cut wheels can cut costs. www.nortonnindustrial.com
The WSG15150PR ErgoGrip is a 6 In. angle grinder with an ergonomic handle to reduce fatigue while increasing efficiency. It offers 1500 watts of power and a soft start with restart and jam protection for increased safety. The WSG15-150PR features a solid metal gear head, a removable, nonslip safety guard, and electronic overload protection. The ErgoGrip performs efficient, reduced-fatigue work with a secure hold and control, even when wearing welder’s gloves. www.feinus.com
EdgeBreaker machines can remove thick slag and heavy burrs up to 3 mm on parts up to 80 mm thick and 1,300 mm wide. The machines can process parts of steel, copper, various alloys, aluminum and titanium. The EdgeBreaker’s oscillating roller self-cleans residue from the grinding belt, while sanding blocks gently round the edges on both sides. www.arku.com
www.canadianmetalworking.com
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Amada America, Inc. — Booth S901
UNLEASH The NEW Tiger X flap disc raises the bar for professionals who are driven to get the job done right – and done fast. Tiger X holds nothing back with its industry first X3 Technology that combines an advanced grain anchoring system, dual flap design and engineered backing. The result is a disc that delivers the ultimate combination of faster grinding, longer life, and greater versatility. For those who demand uncompromising performance in a disc that doesn’t quit there’s only one choice. Tiger X.
Unleash Tiger X at Fabtech by Visiting us at Booth N22025 Mention this ad when you visit our booth for a special gift.
800.835.9999 / weilercorp.com 42 | OCTOBER 2015
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The new HG 1003 ARs utilizes the combined forces of an ultra-precise press brake and a 6-axis robot to achieve maximum productivity. Designed to handle sheets up to 39” x 31” the system’s robot can support loads up to 44 lbs. The 6-axis robot moves on a linear track to provide efficient stage bending with the flexibility to process materials anywhere along the entire length of the machine. www.amada.com
Bystronic Inc — Booth S919 The larger format 4020 (6’ x 12’ material size) of the ByTrans Extended compact material handling system allows for loading and unloading of materials that takes just seventy-five seconds so that the system is always faster than the shortest cutting plan. The short cycle time, which is independent of the thickness of the metal sheet, ensures greater overall throughput. ByTrans Extended offers accessibility and optimum operation in a small, inline footprint and handles all sheet thickness up to 3/4 inch plate. www.bystronicusa.com
Prima Power North America Inc — Booth S931 The new, fully servo-electric Shear Brilliance features linear drive technology for fast sheet positioning and raises manufacturing speed and productivity up to a new level. With long travel of the 4,070 mm coordinate table full 3,100 working area for punching and shearing can be used without repositioning, accurately and at great speed. The sheets are pre-positioned during machine operation which reduces loading time considerably. www.primapower.com
LVD Strippit — Booth S938 The FA-L is the latest in laser cutting automation, designed for flexibility and speed and is available on Sirius Plus and Electra laser cutting machines. This system can handle sheet sizes from 1000x1000mm up to 3050x1525mm. The FA-L unloads a finished sheet and loads the next sheet on the table within 40 seconds and can be fully integrated with an existing warehouse. www.lvdgroup.com
TRUMPF Inc —Booth S1701 With a bending length of 10 feet the TruBend Center 5030 is a thin-sheet processing specialist. In panel bending, the sheet is inserted horizontally and fixed in place while the bending tool moves to form each bend. This system boosts productivity and has ergonomic benefits, especially when processing components with large surface areas. The TruBend Center panel bending technology produces positive and negative bends, folds and circular bends with a variety of radii. www.us.trumpf.com www.canadianmetalworking.com
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MC Machinery Systems Inc — Booth S1719 The new Mitsubishi eX-F Series fiber laser combines the best of both worlds: the top notch construction of the popular eX C02 laser and the power of a fiber resonator. The eX-F is an especially powerful fiber solution for thick-plate processing. For
even faster processing, when turned on, the F-CUT feature can turn the beam on and off without stopping the axis. Non-process times are also shortened by 50 per cent over previous generations with simultaneous nozzle cleaning, height sensor calibration, nozzle changing and gas purge. www.mcmachinery.com
Salvagnini America Inc — Booth S1731
MagaFab-Piranha-WhitneyBertsch — Booth S1737
The B3.ATA press brake automatically adjusts tool length, V-die opening and back gauges to accommodate the next operation or the next part in a kit production sequence. All an operator has to do is to place the blank against the back gauge. The B3.ATA does the rest. The B3.ATA achieves a bending accuracy of ± 2 microns. www.salvagnini.com
The PlateLASER is a fiber laser cutting machine tool 3m x 6m with linear drive motors. This machine is able to laser cut up to 1” thick in carbon steel, and optional plasma cutting head can be used for high speed plasma contour cutting. This machine features pierce, lead-in, and cornering functions and a passthrough pallet design. www.megafab.com
Scotchman — Booth S1923 The GAA-500 90 is a large capacity upcut automatic saw for cutting non-ferrous materials at 90° up to 6” square and round. The saw uses a shuttle feed design with an adjustable vertical and horizontal clamp system to fit almost any profile. Standard features include a 7.5 hp motor that delivers a cutting speed of 3,000 rpm, pneumatic mist coolant system, and a base designed with 2 chip extraction ports. www.scotchman.com
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CPO 350 LT COLD SAW
To find a dealer in Canada, contact: William Brennan Company, 2135 Jetstream Road, London, Ontario N5V 4H7 • Call 519-455-7100 • Fax 519-453-4589 • sales@brennan.ca In the USA Call Toll Free 1-800-843-8844 or Call Direct 605-859-2542 • Fax 1-800-843-5545 or 605-859-2499 • www.scotchman.com • info@scotchman.com • Scotchman Industries Inc., P.O. Box 850, Philip, SD 57567
www.canadianmetalworking.com
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Hougen Manufacturing Inc — Booth S2212
NOVEMBER 9 -12 , 2 0 15 C H I C A G O M C C O R M I C K P L A C E
AKS Cutting Systems Inc — Booth S2714 The “water-kut” X3 is a mid-level production machine specifically designed with an open layout for easy load/ unload for fabrication shops. The X3 is the most popular “waterkut” model with work envelope sizes ranging from 4’x5’ to 6’x36’ and cutting pressures from 55,000psi to 90,000psi. Options include the TCS - Taper Control System, GRS - Garnet Removal System and CLS - Closed Loop System. www.akscutting.com
JMT USA — Booth S3114 JMT’s new HDF(L) model fiber lasers incorporate the latest advances in cutting technology. With power output available from 1 kW to 6kW, this system can cut thin gauge sheets or thick metal plates up to 1”. A state-of-the-art linear drive system delivers faster processing cycle times. Lantek CAD/CAM software makes it easy to draw and nest parts. JMT can configure a complete work flow solution integrates an automated material handling system with the laser control so you can queue several sheets of material by pressing one single button. www.jmtusa.com
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The new power feed HMD927 magnetic drill offers a major performance improvement to the mid-range line of Hougen magnetic drills. The HMD927 fills the gap with great power to weight ratio by giving steel fabricators more strength and torque while still maintaining the small lightweight footprint. New features include magnetic drill pilot light for low light or no light operation, Hougen two speed motor, improved arbor system for quicker change out of accessories, hex wrench holder, two stage magnet, and the Hougen operator safety system, with a hole capacity up to 1-5/8” dia. and 2” deep. www.hougen.com
OMAX Corp — Booth S2767 The 80X JetMachining Center processes large, complex components or multiple parts from various materials and thicknesses with speed and precision. This comes from the Intelli-MAX Software Suite and EnduroMAX pump design. The intuitive software optimizes the machine’s tool path for consistent quality and repeatable results, while the efficient EnduroMAX pump provides faster cutting speeds per unit of input than intensifier designs. OMAX will pair the 80X with the new 100-hp EnduroMAX Pump, which operates at 85 per cent efficiency as opposed to the 60 to 70 per cent range of intensifier pumps. www.omax.com
Mazak Optonics Corp — Booth S3101 The Mazak Optonics booth will showcase four fiber generator laser machines. One of the highlights will be the launch of the OPTIPLEX NEXUS 3015 Fiber. This durable 26,000 pound machine incorporates a helical rack and pinion positioning system that features solid throughput and high accuracy. This laser has been engineered to be utilized with Mazak’s extensive range of automated material handling systems. The OPTIPLEX NEXUS 3015 Fiber is a 2D system that utilizes rugged construction and an innovative design to deliver high performance for fabrication job shops and production environments. www.mazakoptonics.com
Gravotech Inc — Booth S3216
Hypertherm Inc — Booth S3340
Technifor F-Series Laser Solution are compact and robust, and fully PPC (program-to-program communication) compatible to easily integrate marking requirements in your production process. The Fiber Solutions are available in a range of powers to obtain various laser effects on most materials: F10 for Surface Coloring; F20 for Flexible Solution; F30 for High Speed Marking; and F50 for Deep marking and engraving. www.gravotech.us
The new Powermax30 AIR is a portable air plasma system and internal compressor in one. With the built in compressor and the ability to operate on both 120 or 240 volt lines, the Powermax30 AIR is a highly versatile system that enables metal cutting just about anywhere. Weighing only 13.5 kg the Powermax30 AIR provides 30 amps of output. With a recommended cut capacity of 8 mm and a severance capacity of 16 mm the system can easily and quickly cut a variety of metal types and thicknesses. www.hypertherm.com www.canadianmetalworking.com
15-10-02 3:34 PM
FIBER OR We’ll help you decide. When it comes to laser technology, both fiber and CO2 are good for business, from fiber’s low cost of operation to the powerhouse performance and versatility of CO2. So whether you’re looking to upgrade, expand or rethink your technology, make sure you talk to the one source with endless expertise.
Experience the difference: mills designed with fab shops in mind With 30 years experience delivering sophisticated solutions for a variety of shops, we know what fabricators need in a mill. From versatile, cost-efficient models to sophisticated 5-axis machines—we’ve built a line to meet your needs. Partner with us, and leverage a single source provider with expertise in shop floor integration, automation, and the industry’s leading service and support network.
To learn more about our full line of CO2 lasers, fiber lasers and mills, visit MCMachinery.com.
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15-10-02 3:20 PM
Marvel Manufacturing Co. — Booth S3907
NOVEMBER 9 -12 , 2 0 15 C H I C A G O M C C O R M I C K P L A C E
The V600 Bundle Saw provides detailed performance metrics, and the PC3.1 control captures detailed saw utilization and performance measurements. These metrics are captured for each shift, day, week, month and year. The V600 also provides the option of a 48” servo controlled axis. This shuttle resides at the discharge end of the saw table and substitutes as the second machine vise. Once the material being fed into the saw with the infeed shuttle is not long enough to be fed any further into the saw, then the remnant reduction shuttle will pull the remaining material, allowing complete material consumption. www.marvelsaws.com
Ficep Corporation — Booth S3942
Logopress3/Accurate Die Design Inc— Booth S4124
Big Ass Solutions — Booth S4179
The Vanguard drill lines from Ficep with their ball screw feed and 5,000 RPM are compatible with all types of tooling. Some can even achieve feed rates up to 10 times faster than hydraulic drill lines using HSS tooling. www.ficepcorp.com
Logopress3 NESTING starts with either a multibody part file (either created with SOLIDWORKS or imported from a different CAD system) or with individual part files that are in an assembly. www.logopress3.com
Designed with versatility in mind, Black Jack’s 6.5-ft (2-m) frame fits through standard interior doorways and plugs into any 110V power supply, drawing less power than a toaster—only 7 amps at top speed. It moves air up to 36.5 meters www.bigsolutions.com
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Coe Press Equipment — Booth S4722 COE’s Work Roll Advisor takes the guesswork out of setting up. Roll depth setting is calculated and automatically set. Work Roll Compensation feature automatically compensates the straightener roll depth settings as the coil OD depletes to compensate for changes the amount of coil set in the material. www.coepress.com
Keyence Corp of America — Booth S4840 The IM Series Instant Measurement system measures and programs in seconds, and solves your top-lighting applications automatically. This contact height measurement unit reduces the time spent using separate measuring instruments for different measurement points. www.keyence.com www.canadianmetalworking.com
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FABRICATING & WELDING NEWS
LVD EXPANDS TUBE CUTTING MACHINE PORTFOLIO LVD Company has announced that it has entered into an operational merger with AltaMAR, a tube cutting machine manufacturer. The operational merger of the companies will combine sales, service, production and research and development facilities. The agreement will expand the product offerings and market reach of both companies and will create one of the industry’s largest sheet metalworking equipment manufacturers with manufacturing facilities in Belgium, Central Europe, the U.S. and China, providing representation in over 50 countries worldwide including 20 direct sales and service subsidiaries. Under the agreement each company will maintain their independent corporate identity but will combine key operations in the areas of sales, ser-
vice, proproduction and engineering development. All AltaMAR tube laser cutcut ting machines will be manufactured by Strippit Inc. at its Akron, NY manufacturing plant for the world market and will collaborate with AltaMAR on research and developdevelop ment efforts for future tube cutting products and technology. The complete range of AltaMAR tube cutting machines will be added to LVD’s existing product portfolio. The result will be the industry’s most comprehensive product offering with
a broad range of capabili-capabili ties and an extensive line of automated systems. LVD and AltaMAR sales and service operations will be merged to provide an integrated sales and service network for LVD and AltaMAR customers alike. www.lvdgroup.com
CWA AND MARINUCCI FOUNDATIONS ANNOUNCE $500,000 SECONDARY SCHOOL DONATION High school welding programs across the country received a healthy boost
John Marinucci, founder and chairman of the Marinucci Family Foundation, announces the launch of a generous funding program at CanWeld 2015.
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when it was announced at the recent CanWeld Conference in St. John’s, NL, that the CWA Foundation and the Marinucci Family Foundation (MFF) have partnered to provide $500,000 in funding for 10 Canadian programs. Each school will receive $5,000 annually over 10 years. “Through the generous gift of the MFF, we are able to offer 10 secondary schools across the country with the funds to provide their students with a better quality learning experience within their welding programs,” said Deborah Mates, executive director of the CWA Foundation. The selected schools, chosen based on program history, student success and recommendations from welding education experts, will begin receiving funding Jan. 1, 2016. The schools receiving funding include: Grande Cashe Community H.S.,
Grande Cashe, Alta.; St. Joseph’s H.S., Edmonton; West Central H.S. Fabrication, Rocky Mountain House, Alta.; Sardis Secondary School, Chilliwack, B.C.; Lord Selkirk Comprehensive School, Selkirk, Man.; Oromocto H.S., Oromocto, N.B.; Diamond Jenness H.S. in Hay River, N.W.T.; Ottawa Technical Secondary School, Ottawa; Pontiac H.S., Shawville, Que.; and Albert E. Peacock Collegiate, Moose Jaw, Sask. “We are excited to partner with the CWA Foundation to significantly enhance secondary school welding programs across Canada,” said John Marinucci, founder of the MFF and retired former president/CEO of New Flyer. The CWA Foundation is also working to establish a secondary school welding program in Newfoundland within the next two years. www.canadianmetalworking.com
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FABRICATING & WELDING NEWS Exceptional TIG and stick performance
NEW SALES VP FOR MATE Mate Precision Tooling has named Michael Brown to the position of vice president international sales. A seasoned sales veteran with more than 20 years of experience, Brown will be responsible for planning and managing all of Mate’s international sales activities. With significant experience in managing key accounts and a thorough knowledge of selling via dealers, Brown’s focus will include developing strategies and team capabilities to further strengthen customer relationships. “Michael brings a wealth of strategic insight and international sales experience to our senior leadership team,” said Kevin Nicholson, Mate president. “We look forward to his contributions to expand our strong international presence and introduce our proven tooling solutions to more companies around the world.” Prior to joining Mate, Brown was international sales manager at Andersen Windows, where he had a 21-year career. He earned a Bachelor of Arts degree in International Management from Gustavus Adolphus College and an MBA from the University of St. Thomas. His global sales experience makes him well-versed in the international market place. www.mate.com
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The DC TIG/stick-capable Maxstar 210 replaces the recent Maxstar 200 model and welds up to 1/4-inch steel in a single pass. Offering class-leading portability, each stand-alone power source weighs 50 pounds or less and features dual carry handles and a carrying strap for easy transport. Base models of the new power sources provide operator-friendly, menu-driven features and improve performance on low-amperage applications. The Maxstar 210 STR model now features digital meters and dual welding memories for faster and more consistent process setup. www.MillerWelds.com.
Allowing operators deeper cutting depth Walter Surface Technologies extended its product portfolio of exclusive narrow-crown patented technology to all 4½” and 5” ZIPCUT, ZIP+, ZIP Stainless and ZIP ALU cutting wheels. The Type 27 narrow crown patented technology incorporates an improved, refined metal cladding in the center hub which maximizes on safety and allows operators deeper cutting depth. The new technology extends the life of the cutting wheel, allowing for more cuts per unit. With the new Type 27 narrow crown technology, operators benefit from the best performance available. The narrow crown combines the extended life of a flat Type 1 wheel, with the extra stiffness of a depressed center cutting wheel. The metal cladding also maximizes safety by preventing contact with the work piece which increases worker’s safety when cutting into metal applications. The Type 27 narrow crown technology is available now for all 4½” and 5” ZIPCUT/ZIPWHEEL, ZIP+, ZIP Stainless and ZIP ALU cutting wheels. www.walter.com
New line of electric servo pumps TECHNI Waterjet announces the launch of its second line of electric servo pumps (ESPs). The ESPs were designed to address the requirements of today’s competitive manufacturing industry. This line introduces a “Value Range” to Quantum ESP’s. There are three models currently available: VP 10/60, capable of running a 0.007” orifice at 60,000psi, VP 15/52, capable of running a 0.010” orifice at 52,000psi, and the VP 20/55 capable of running a 0.011” orifice at 55,000psi. With one of the smallest footprints in the waterjet industry, the Quantum VP’s are just 54” x 21” x 42” and weighs 990 lbs. They can also be operated off single or 3 phase 200 – 480V and only require a 30A supply. As with all of TECHNI’s Quantum Electric Servo Pumps, the Quantum VP is less than 68 dBA, compared to an old fashioned hydraulic intensifier pump at 80 dBA, making the innovative Quantum VP’s 10 times quieter than the standard hydraulic pump. www.techniwaterjet.com. www.canadianmetalworking.com
15-10-02 3:34 PM
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Proper tools necessary for removing material BY NESTOR GULA
A
ngle grinders are simple tools. On the surface it is just a motor, a transfer case and grinding disk or cut-off wheel. These simple machines have been around for ages and can be picked up at the local hardware store very inexpensively. A proper and well-designed angle grinder is not such a simple machine. “A high-end grinder should be extremely durable, high performance, safe and ergonomic,” says Randy McDonald national sales manager at Fein Canadian Power Tool Company. “It should be designed for continuous use, even in the toughest of applications. High-end grinders feature higher motor outputs, which means constant speed and torque which leads to higher productivity. They are typically more energy efficient as well.” Having steel gears in the nose of the grinder results in a durable unit. “These units may be a higher cost initially but will pay for themselves in terms of not having to be replaced as
quickly,” says Keith Potts, national trainer for Milwaukee Electric Tool. “Electronics that shut the unit down if jammed into material to protects it. Electronic clutches that work in a similar fashion, and also CPT, or Constant Power Technology, electronics that keep the same RPMs in any materials, which is critical in cutting and polishing operations when using flap wheels and wire cups etc. is also helpful when using grinding wheels where long consistent performance is required. Angle grinders work under considerable load so “maintaining a constant RPM is a critical factor,” according to Max Bezner, national sales manager with Metabo Canada. But anyone who has used an inexpensive angle grinder for an extended period of time, even 10 minutes, will tell you that the vibrations of such a machine has caused a considerable amount of discomfort in their hands, wrist and elbows at the very least. “Disorders like hand-arm vibration syndrome can be a side effect of too much vibration,” notes Steve Wilcox, group marketing manager at Robert Bosch Tool Corp. It is essential to get a properly engineered and balanced tool because prolonged use of an angle grinder can lead to health issues including white finger syndrome and tendonitis. “Using an unbalanced grinder is simply not efficient; there is a lower removal rate and a short life span of the consumables being used,” says Stephane Drainville, product manager at Walter Surface Technologies. “A grinding wheel will generate a lot more dust and it will disintegrate faster than it should. There is also a very important issue concerning safety: vibration while cutting with a thin cutting wheel is more vulnerable to breakage. You don’t want breakage.” Worker fatigue due to excessive vibration is a serious issue as it affects productivity. “The worker can become tired, stressed and even weak when faced with using tools that have high vibration levels,” says McDonald. “This translates into less productivity, possible time off, and potential compensation implications.” High-end grinder manufacturers engineer and design their tools to eliminate unwanted vibration. “When the armature of the angle grinder is built, it goes into an automated balancing machine,” explains Drainville. “This Proper ergonomics makes work easier. IMAGE COURTESY OF METABO CANADA
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www.canadianmetalworking.com
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machine will spin the armature at a regular usage level and will automatically detect which side of the armature is unbalanced. Then, a small grinding wheel will remove the unnecessary material. It will start spinning again and continue the same process to be sure the operation was performed well.” The easiest way for users to minimize vibration is to choose tools that have documented vibration emission values that meet national or international standards criteria. “High-end manufacturers have this information available either in the manuals that come with the tools or on their websites” says McDonald. “Another option is vibration-dampening gloves or vibration dampening handles (if required). But in the end, using tools that significantly reduce vibration in the first place is the best solution.”
THE CONSUMABLE FACTOR Using proper consumables, grinding disks or cut-off wheels, will also reduce vibration and unnecessary strain on operators. “Operators will not only have a better balanced angle grinder, but switching to a more durable abrasive they will also significantly reduce their labor costs,” says Drainville. “The Walter Documented Cost Savings program was designed to demonstrate how using our products can assist in lowering long-term expenses. We encourage abrasives users to download the online white paper.” A good quality consumable provides the user with the best performance since they offer better removal rates; while at the same time have longer product life. “Users are more productive since they dramatically reduce the amount of wheel changeovers,” he adds. “Normally, poor quality consumables are very low priced but they cost you more at the end of the day since you are consuming more wheels and take more time to get the job done. At the end, users who buy quality are saving time and money.” In addition, quality consumables, made with premium materials (resin, grains, and reinforcements) will effect the grinder performance. “Just like high-end tool manufacturers, high-end abrasive manufacturers produce wheels to the highest of safety standards,” says McDonald. “High performance wheels are balanced to ensure that they run straight and smooth. Choosing the correct wheel for the material and application is critical for the performance of an angle grinder. But most of all it is critical for the safety of the operator.” www.canadianmetalworking.com
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GOING WIRELESS Most angle grinders are wired, but with the advent of more powerful and longer lasting batteries cordless angle grinders are becoming more accepted in industrial applications. “Brushless units have similar performance to corded units now. 18-volt units used to be categorized as cutting units only until recently, now with FUEL brushless technology the units can serve as cutter and grinder,” says Potts. “The new brushless tools with LiHD high density lithium battery packs are making
Cut off wheels are great for cutting awkward objects. IMAGE COURTESY OF MILWAUKEE ELECTRIC TOOL CORPORATION
The best press alternative on the market for unitized tools and small die sets. MULTICYL INC
640 Hardwick Road, Unit 1, Bolton, ON, Canada L7E 5R1 Tel.: 905-951-0670 - U.S. Toll Free 1-800-388-6359 - Fax : 905- 951-0672 www.multicyl.com - punch@multicyl.com
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A slim body makes gripping a grinder easier. IMAGE COURTESY OF ROBERT BOSCH TOOL CORPORATION
cordless grinding a viable option without sacrificing performance,” says Bezner. “The weight of the cordless angle grinder is similar to that of the corded version, although there is a medium-sized and heavy battery attached to the grinder,” says Wilcox. “A good cordless grinder requires that balance be accurately equalized across the entire width of the tool while the user is grinding. So the ergonomics of a cordless grinder are similar to what’s required in a corded grinder. As with weight, ergonomics need to be well optimized considering the attached battery adds a little bulk-
iness. As a general rule, ergonomic designs usually have additional slimness at the center of the grinder handle.” The design of cordless angle grinders differs from their corded cousins as they have permanent magnets in them, which can cause problems. “Grinding, sanding and cutting applications will generate dust that must at all cost never enter inside the cordless grinder,” says Drainville. “All particles that will be sucked inside the cordless tool will be attracted by the permanent magnet, and you won’t be able to remove it even using an air gun. That’s why cordless grinders without a dust guard protection have a very poor life, being short-circuited by the accumulated dust.” As the technology evolves cordless angle grinders will become more ubiquitous in industrial applications.
Pferd high torque grinder With a maximum tool diameter up to five inches, the Pferd UWER 15/100 features a stepless rpm adjustment and its high torque provides high-speed stability. An electronic shutdown device deactivates the motor in cases of extreme overload. www.pferdcanada.ca
Small and powerful
Walter puts the Zip to the cut
With a fourpole motor the Bosch CAG180B 18V Lithium-Ion 4-1/2” Small Angle Grinder features a low-profile gear design and electronic motor protection. Ergonomically designed with soft grip surfaces, it weighs only slightly more than five pounds. It has overload protection and a lifetime brush design that results in a long motor life. www.boschtools.com
The Zip cutter is a cordless angle cutter able to power a 6-inch cutting wheel. Paired with an 18V/5.2 Ah battery pack, it features a fast charging ventilated charging system. It has an electronic RPM control to protect from overloading and overheating and easy access to the internal carbon brushes. It’s available in 4-1/2” and a 6” versions. www.walter.com
Grind and brake Milwaukee Tool introduced of the first cordless braking grinder solution which stops accessories in under two seconds and delivers up to 10-times longer tool life. The M18 FUEL Braking Grinder includes an anti-vibration handle and a well balanced thin body design. Its tool-free design allows adjusting the guard or replacing accessories without a wrench. www.milwaukeetool.com 54 | OCTOBER 2015
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Comfort in a tat-tail grinder With enhanced grinding ergonomics, the narrow handle that extends toward the rear of the FEIN ErgoGrip grinder makes it more fatigue-free, enabling continuous work. The grinders are suitable for heavy grinding and cutting applications. Vibration is reduced because the angle grinder is not held around the motor housing www.fein.ca
Slim grinder The slim design of Metabo‘s W 18 LTX 115 18-volt cordless angle grinder is suitable for prolonged comfort when working overhead or in areas with limited space. The motor overs long service while the tool-free adjustable guard makes for easy usability. The battery pack can be swivelled, while the detachable dust filter protects the motor from coarse particles. www.metabo.ca www.canadianmetalworking.com
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N EW !
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TRUST BLUE PFERD launches new TOOL MANUAL 22, the full-line product resource guide at FABTECH 2015. With improved navigation, simplified text and hundreds of new metal finishing solutions, this new resource is the most advanced metal finishing guide available. At FABTECH, see new product demonstrations from a range of more than 600 new additions to the TOOL MANUAL. Among the new products are trimmable flap discs, premium ceramic grinding wheels, new high-performance carbide burs optimized for Steel and Cast Iron, and a new series of products designed for long-reach applications.
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15-10-01 5:33 8/27/2015 1:27:29 PMPM
BUSINESS PROFILE: FABRICATING
A SMALL BIG COMPANY ISE Metal Inc., Sherbrooke, QC BY NESTOR GULA
I
t is always fascinating what goes on behind closed doors. Quebec’s ISE Metal Inc. is a very interesting family-owned company. Founded in 1934 as a single factory, its name was synonymous with its function, Industrial Stamping Enterprise (ISE). The company’s main products were stamped components for the auto and appliance industries. According to ISE’s business development/ sales manager, Jared Henderson, his father Robert bought the company in 1992. “He was a businessman/ entrepreneur, and prior to acquiring this business he had no history with metal fabrication.” The company was still stamping out parts for cars and appliances, but in the late 1990s those industries started to disappear from Quebec and the business had to reinvent itself. “That is why we began laser cutting. In the mid 2000s we got our first laser cutter, a TRUMPF laser,” says Henderson. The 35-year-old joined the family firm in 2006. “I studied business and marketing at Bishops University, and when I graduated I wanted to get into the family business. I started in a sales position, and I wanted to increase the gross sales, however we were not very developed at that point as a true laser cutting company,” he says. “We were doing mainly skate blades for Easton, CCM and Nike. We were basically making skate blades for all these companies, and the lasers were running long runs.” But as it happens the lucrative skate blade making contracts dried up when the skate manufacturing businesses moved overseas. “The skate blades production is now done overseas except for the Bauer replacement blades. And we do packaging for them as well,” notes Henderson. “Skate blades are a very small part of the business now. We were forced to react quickly.” They now supply parts
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for machinery in the food processing, agriculture and lighting industries. “The latter is interesting because we can cut very thin gauge material quickly,” he explains. While managing change for a small company is difficult, the effort at ISE Metal Inc. was enormous because although its offices are located in a relatively modest 45,000 square foot industrial building not too far from the centre of Sherbrooke, Quebec, the setting does not convey the magnitude of the whole ISE operation. This is a large company with nine plants. Six are located in the Sherbrooke area, there is one in Cambridge, ON, one in Piqua, OH and one in Saltillo, Mexico. Managing change of such a large and diverse company takes a great deal of work. “The transition from long runs of making skate blades to short runs has been a long process. It means getting the team coordinated and working toward a common goal,” says Henderson. “We are now light years ahead of where we were even a year or two ago. What has been crucial to achieving this progress is stronger management and leadership in the company.” The original plant in Sherbrooke is still stamping some parts for the automotive sector. “Electrolux and Bombardier are some of the customers, but there is much
The bending machine area in ISE’s Plant 2. PHOTO: NESTOR GULA
www.canadianmetalworking.com
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The modest headquarters and Plant 2 of ISE Metal Inc. PHOTO: NESTOR GULA
less work now than there used to be,” he says. The company’s headquarters is Plant 2, which houses four laser cutting systems, two brake presses and a plating line. The 30,000 square foot Plant 3 is the Lennox assembly plant for machinery used in the pulp and paper industry. It is here that they also process and package the skate blades. The nearby town of Waterville is the home of the 15,000
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square foot Plant 4 that houses an assembly shop and a conventional machine shop. Plant 5 in Sherbrooke is a machine shop with CNC machines and is about 5,000 square feet. The 50,000 square foot Plant 6 in Magog is an assembly plant. “It assembles one of our own products, the Aquanox water slide-gates. We sell these to different communities that need to regulate water flow and water levels,” explains Henderson. Plant 7 in Cambridge services the area west of Toronto, and it’s a laser cutting shop that also does some assembly for the forestry sector. The Mexican Plant 8 performs stamping for the auto industry, while at the Piqua location, Plant 9 is a production plant that also makes parts for the auto industry. “It is a massive amount of management,” says Henderson. “All the plants came as a way of acquisition to add value for the customer. If you could laser cut a part and then add value with additional services such as machining and assembly, service purchasers, and serve other businesses by providing a turn-key operation.” It seems ISE Metal is always working to expand and innovate. “The goal is to start creating end-user products
HELP OUR WELDING STUDENTS Have surplus equipment, material or supplies? Donate it to local secondary schools in need through our new online repository. Visit cwa-foundation.org/donations for more information.
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weldquality.org | 1.800.844.6790
www.canadianmetalworking.com
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cwa-foundation.org | 1.800.844.6790
OCTOBER 2015 | 57
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BUSINESS PROFILE: FABRICATING Jared Henderson in front of a TRUMPF Laser in the 45,000 square foot Plant 2. PHOTO: NESTOR GULA
and generate our own demand,” says Henderson. Besides their Aquanox business (www.iseaquanox.com) they have just recently embarked on a new venture of designing and building storage lockers that will fit in the parking spaces of condominium dwellers.
ADVERTISERS INDEX ADVERTISER 3M Canada ABICOR BINZEL Amada Canada, Ltd. AMT Machine Tools Ltd. Blaser Swisslube Inc. Bohler-Uddeholm Limited Can Weld Creaform 3D CWB Group Dipaolo Machine Tools Elliott Matsuura Canada Inc. EMAG L.L.C. ERI America Inc. ESAB FANUC Canada, Ltd. FARO Technologies Inc. Gullco International Haas Automation Inc. Haimer USA Hexagon Metrology, Inc. HORN USA, Inc Hurco USA IESO ifm efector Index Traub Ingersoll Cutting Tools Iscar Tools Inc. ITI Tooling Company Inc. Jesse Engineering Kinetic Cutting Systems Inc. Kyocera Precision Tools Inc. Lincoln Electric Company of Canada Longterm Technology Services LVD Strippit Mascoutech Inc. Mazak Corporation Canada MC Machinery Megatel Inc. Miller Electric Mitcham Machine Tools Mitutoyo Canada Inc. Motoman Robotics Multicyl Inc. Okuma PFERD Powerhold Inc. PRAB Prima Renishaw (Canada) Ltd. Rofin-Baasel Samchully Workholding, Inc. Sandvik Scotchman Industries, Inc. SGS Tool Company SME FABTECH Starrag USA, Inc. TRUMPF Inc. Tungaloy America Inc. Vargus USA Walter Surface Technologies Walter USA, LLC Weiler Corporation
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PAGE# 26 35 9 18 80 79 95 84 57 13 6 90 28 24 59 85 14 89 71 17 11 IFC 65 87 21 23 OBC, 92 91 46 62 93 49 29 6 29 69 45 75 40 21 83 47 53 33 55 16 15 37 77 39 19 4,5 43 67 98 28 IBC 3 81 51, 86 73 42
“Aquanox was released two years ago. This is the first ISE-owned product. We were approached by two people with this business opportunity,” he says. The locker idea was his. “I lived in a condo and came up with the idea because storage in a condo is always a problem. Called Consto (www.consto.ca) this unit has a price point of about $2,000 and is more cost effective and convenient than renting a storage space.” “One of the biggest challenges in this business is filling up all your capacity and that is my job,” he says. Depending on the demand, they will run up to three shifts at their nine plants. “When we reach 100 per cent capacity we’ll buy more TRUMPF lasers,” he says with a laugh. Henderson says that they are quite up to date on their lasers. He notes that all the lasers and brake presses are TRUMPF except for one. “We are very happy with the machines and the service,” he says. “The fiber laser allows us to cut twice as fast. If you invest in your company and as a result you are able to achieve almost double the output, it helps serve our customers. Slow production just doesn’t cut it,” he quips. He says that keeping up with the technology is important because the speed and accuracy improvements can make a big difference to the bottom line. “We have some older machines that were purchased 10 years ago, but now technology does develop so fast there is a wide gap in terms of cutting speeds that effects production in laser cutting.” He recognizes that there is a noticeable speed difference when cutting thin gauge on the older lasers and the newer ones. “There is less of a difference when you are cutting thicker material, but there is a big difference when you are cutting very thin gauge.” He says they frequently cut 18- to 22-gauge material. They will also cut up to one inch on the lasers. Henderson says that it takes a great deal of foresight to stay competitive. “We remain a service-oriented company. We are willing to work with our customers in achieving their goals. We develop relationships which increases customer loyalty.” He is bullish on the robustness of the Canadian economy. “I believe that on the whole manufacturing can bounce back given the recent changes in the exchange rate, and that allows us to compete a lot more for the U.S. demand,” he says. “Foreign competition does exist, but the quality issue still exists and you don’t have the same relationships with your suppliers as you do over here.” www.canadianmetalworking.com
15-10-06 10:29 AM
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BUSINESS PROFILE: FABRICATING
AN INTERNATIONAL REPUTATION Large parts cut from sheets on Durose’s LVD Strippit Impuls 8030 6kW laser.
Angelo Maggiolo, owner.
Durose Manufacturing, Guelph, Ontario BY DOUG PICKLYK
F
rom New York City landmarks and NFL stadiums to forestry and mining machinery, Guelph, Ontario’s Durose Manufacturing Limited has cut, formed, rolled and welded steel that keeps buildings up and helps industries dig deep. A longstanding fixture in Guelph, Durose had been in business since 1944, still located on the same street where it was founded. The business was originally started by Sid Durose as a small one-man welding shop. For health reasons Durose had to sell the business in the early 1950s, and despite two changes in ownership since he sold the business, the Durose name has endured. The company’s current owner, Angelo Maggiolo, joined the business in May of 1962 as a 21-year-old shortly after
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arriving in Canada from Italy. Maggiolo had minimal welding experience, but he understood the process and was a skilled layout man. He recalls his first visit to the shop—it was very small and had no indoor plumbing. The only other workers were two brothers who were partners in the business, so Maggiolo was the first employee. He was offered $1.25-an-hour to start, and that was more than he was being offered by a competing business down the road, so he stayed, and he has never regretted that decision. As the business grew through the ‘60s Durose began working on more complex, large-scale, projects. “Because I knew layout, people came to know by word of mouth that we could handle the complex projects,” says Maggiolo. He pulls out a photo album showing projects from the early ‘70s, including a massive metal elbow for an intake shaft destined for a nuclear plant that was used to draw in water from Lake Erie to cool the facility. The company has also fabricated air intakes for the Rogers Pass in B.C., as well as major projects across the U.S., South America and in Europe. Maggiolo took over the business in 1974, changing the company name from Durose Welding to Durose Manufacturing to better reflect the broader range of www.canadianmetalworking.com
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fabricating services the company offers. Durose has experienced continuous growth, adding floor space and people over the years, even though that was never Maggiolo’s primary goal. “I’ve never believed in being big, because I don’t think that’s the answer,” he says. “But every time work slowed down we would put on a little addition to the facility, often just to keep our good workers busy.” Today the plant covers close to 140,000 sq, ft. and the company’s services range from cutting, rolling, bending, drilling, tapping, machining and welding, to a paint shop and engineering services. Maggiolo endorses continuous improvement in the shop and the adoption of new technologies. “Without the new technology we wouldn’t even be here,” he says. “Not only us, but everybody else as well. Without the new technology you’re not going anywhere. That’s what’s replacing the know-how of the skilled trades people.” Like all manufacturing businesses, the challenge of finding skilled workers leads to incorporating more automation and sophisticated machinery on the shop floor. Some of the company’s more recent installations include an LVD Strippit PPEB-H 640 CNC hydraulic press brake, adding a new level of precision and process automation to their operation. The brake has over a 640 ton pressing force and 20-foot
www.canadianmetalworking.com
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VTEC double column machining center for drilling and machining.
long working length, and its Touch-B control simplifies the operating process. Durose also has an LVD Strippit Impuls 8030 6kW laser that it’s had for a number of years. Capable of cutting plate up to 1” thick on a 10- x 24-foot bed, it’s used for the more precise cutting work at the plant. With clients demanding higher tolerances these days, the necessity of installing more automated and higher precision technology is a must. “Customers today build a wheelbarrow with the spec of an airplane,” laughs Maggiolo. “It’s too bad, because there’s a cost to keep
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BUSINESS PROFILE: FABRICATING
Touch-screen control on their new LVD Strippit PPEB-H 640 CNC hydraulic press brake.
that tight of a tolerance, but that’s what they want.” To meet these increasing demands, Durose has also installed a VTEC double column machining center for drilling and some machining. Maggiolo’s son Martino explains that for some of the intensive high-volume work they’re doing they have to hit tolerances of 25 microns.“It couldn’t be done without a machine like this,” he says pointing to the VTEC. “It’s very accurate, very precise.” The machining center has been operating for just over a year and a half, and initially the company had a challenge maintaining accuracy due to temperature swings in the plant from the morning to the afternoon. “The machine was moving 100 microns,” says Martino. “So we had to place sensors all over it, and now it’s constantly measuring the temperature of the part, temperature of the air and making adjustments to the machine.” In order to keep the business growing the company has learned the necessity to diversify, servicing multiple industry sectors in various geographical markets. The company’s specialties range from architectural fabrication to heavy-duty fabricated parts including attachments for industrial equipment for many Fortune 500 companies around the world. Projects have included very recognizable sites including the Home Depot center in Los Angeles, where the LA Galaxy soccer club plays. “Every piece of steel came from our shop,” says Martino. “We sent 80 trucks from Guelph to L.A.” Durose also supplied the tubular steel supports for the roof of the Georgia Dome, home of the Atlanta Falcons in the NFL, and a lot of work in New York City, including curved circular staircase sections for the iconic Rockefeller Center. Closer to home, the company also provides custom large part metal rolling for hundreds of local shops. Growing the business has never been limited because of their location, notes Maggiolo. For him the key to sustain62 | OCTOBER 2015
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ing a viable business lies in the company’s capabilities and its integrity. “We just happen to be in Guelph, but that has never been a problem. Tell the truth and do what you say you’re going to do,” he says, “and don’t be afraid to tell someone if something can’t be done.” There have been some bumps along the way, and he clearly remembers the tragedy of September 11 as a shock to the company. They were working on a variety of projects at the time, including a job for the Pentagon, work in Pennsylvania, projects with the aerospace industry and also work at the World Trade Center. “We were affected very hard,” he says. He also notes that they’re still recovering from the recession of 2008 as well. “It’s coming around, but it’s taken a little longer for us because we got caught—we had a lot of business in the U.S., and we had companies in our own backyard who didn’t even know who we were. We had to change that, and in order to do that we hired sales people to spread the news that we are here.” He notes that competition is stiff everywhere, and with the Internet clients can get competitive bids from around the world with the push of a button. Looking forward, he does anticipate the business will continue to grow, especially as the U.S. market picks up steam. “We’re going to get bigger,” he says with confidence. “This shop can handle 130 to 140 people, and right now we’re at about 100 employees.” There’s room to expand their existing location if necessary, but he says they won’t add space until the company is running closer to full capacity. “You have to be running three shifts these days before you start expanding, because the margins aren’t there to support an empty building.” Durose has already secured approvals to expand if necessary, and for Maggiolo, who at 74 years old still comes into the office regularly, the prospect of adding more space seems almost inevitable. After all of these years he claims that he’s been very fortunate with the decisions he’s made, but it’s also been a strong work ethic and his business integrity that has built Durose into a metal fabrication shop that is recognized locally and around the world for the work it does.
Large part welding at Durose Manufacturing.
www.canadianmetalworking.com
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BY ROBIN WESTON
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n an industry report published in 2014, PricewaterhouseCoopers surveyed 100 industrial manufacturers of all sizes to better grasp their views on 3D printing. The results showed that two thirds of manufacturers were already implementing the technology in some way—from experimenting with how it could be used within their operations to employing it for prototypes or even final part production. Furthermore, one in four manufacturers surveyed said they planned to adopt 3D printing at some point in the future. These results reflect the progress our company (Renishaw) has seen in recent years in its additive manufacturing (metal 3D printing) business. We’re being approached by more and more companies from different manufacturing sectors, keen to find out exactly what benefits 3D printing could offer. This is probably the best attitude when it comes to any new technology: explore its www.canadianmetalworking.com
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capabilities and understand how it can benefit you before making a purchasing decision. 3D printing has masses of potential but it’s not the quick fix some would have you believe. Even though global 3D printing revenues have grown three fold since 2009, when it comes to adoption for direct part manufacturing, the technology is still comparatively underutilised.
DIFFERENT TECHNOLOGIES It’s important to distinguish among different types of 3D printing technologies. For example, we specialize in metal powder bed fusion, a metal 3D printing process capable of producing fully dense parts directly from 3D computer aided designs (CAD). Our laser melting process uses a high powered ytterbium fibre laser to fuse fine metallic powders together and form functional three dimensional parts. The beam is focused to less than the diameter of a human hair, creating temperatures high enough to fully weld the materials. OCTOBER 2015 | 63
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Our AM250 machine is already used in medical applications, including orthopaedics and dental, aerospace and industrial part production. Currently, the most common uses of additive manufacturing are prototype creation, the manufacturing of complex geometries and low volume manufacturing of elaborate metal parts in specialist materials. The main advantages of additive manufacturing across industry sectors are optimized part design, customization and the ability to produce highly complex geometries, without additional cost.
ESTABLISH POTENTIAL In November 2013, The Institution of Engineering and Technology, based in the UK, named 3D printing (additive manufacturing) as one of the key technologies it expects to deliver economic growth in a report entitled ‘Ones to Watch’. In that report, Dr Phil Reeves, then managing director of specialist 3D printing consultancy Econolyst, explained, “At the moment, about 80 per cent of the machines in existence are used for prototyping and 20 per cent for production. However, that 20 per cent of machines on the shop floor are in constant use.” Our company is confident that the figure of 20 per cent for production applications is set to increase as more and more manufacturing companies unlock the benefits of the technology for direct part manufacturing. It’s important to keep in mind that not all products designed for traditional manufacturmanufactur ing methods suitwill be suit able for additive manufacturing, redebut when a rede sign is possible, the end product is usually lighter, stronger and requires fewer components. Simple, straight-forstraight-for ward parts like bearings and bolts or larger cabiparts like cabi nets and panels are rarely suitable for additive manufacturing. Yes, they can be 64 | OCTOBER 2015
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produced using the technology, but it’s often more economic to employ traditional manufacturing methods. To see the real benefits of additive manufacturing, companies should evaluate it on a product whose design can be improved in some way. Tooling inserts featuring conformal cooling channels, lightweight structures for aerospace or medical devices that improve patient care—this is where the design freedom of additive manufacturing becomes invaluable. Adopting 3D printing for manufacturing requires careful planning and research. It is important to keep in mind the challenges you might face; additive manufacturing is still limited in terms of the materials it uses and the size of the parts it can produce. Furthermore, the technology’s new found design freedom also means a company needs to have CAD skills and a willingness to design for the process. Often, employees need to be trained and educated before they can unlock the true benefits. As with all manufacturing technologies, standards play an integral part of the adoption process. The fact that additive manufacturing standards are still at the incipient stage can result in lengthier quality and inspection processes, with the additional risk that non-uniform practices and customs develop causing uncertainty about the ‘right’ approach. Although we have seen some very encouraging signs from ISO and the American Society for Testing and Materials (ASTM) F42 committee, it could take a number of years to compile satisfactory harmonized standards. It’s probably fair to say 3D printing is not the universal panacea some in the wider media have been expounding. However, industry predictions show the adoption of additive manufacturing technology is building momentum. Since 2009 the industry has tripled to $3 billion and is tipped to be a $20 billion industry by 2020. The wisest decision manufacturers can make at this stage is to investigate exactly what advantages additive manufacturing could bring to their company. If it looks promising, the next step would be to get in touch with a specialist and arrange a trial for the technology. Additive manufacturing is, without question, a technology to watch in 2016 and beyond, just as the IET suggests. Robin Weston, Marketing Manager for Renishaw’s Additive Manufacturing Products Division www.canadianmetalworking.com
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Swiss-type turning machines edge towards the mainstream BY NATE HENDLEY
S
wiss-type turning centers were originally created to serve Switzerland’s watch-making industry where tiny, complex, parts were the norm. Swiss-type turning was then taken up by manufacturers and machine shops supplying the medical and electronics sectors (where parts are also small and complex). Since then, Swiss-type turning has spread to a wider range of fields. “Now we have many other types of work [besides medical and electronics] transferring to the Swiss machines. A big one would be the arms manufacturing industry,” says Douglas Paoletta, president and owner, Encompass Swiss Consulting in Richmond Heights, Ohio, a consultancy that offers companies on-site training in Swiss-type machining. “A lot of gun parts are now being produced on Swiss machines,” says Paoletta. “We have customers in aerospace/defense, medical, dental, electronics, hydraulics and commercial industries just to name a few.” Swiss-type turning is still popular for making medical parts. Some analysts suggest
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this ability might further expand the reach of Swiss-type machines, as the baby boomer population ages and the demand for medical parts increases. In a conventional lathe, the part is fixed while the tool moves. On a Swiss-type turning center, this is reversed: the part moves (in a Z axis) while the tool remains stationary. The machine holds the bar stock, which is then put through a guide bushing. Bar stock is machined by stationary tools as it exits the bushing. The segment being machined is the only part of the stock exposed from the guide bushing. Material can be held tightly, which reduces deflection while boosting accuracy. The Y axis is capable of full milling, a feature which saves time and is lacking on the majority of conventional CNC lathes. “The [sliding] headstock and the guide bushing are the key elements” of a Swisstype turning center, says Tim Duffy, president of the Cleveland Industrial Training Center, a leading training facility for Swisstype turning based in Cleveland, Ohio. “Swiss-type turning has many advantages over conventional turning machines. The main advantage is the guide bushing. By keeping the cutting tool next to the support (guide bushing), we keep tool deflection and vibration to a minimum. This rigidity gives us the ability to turn very small diameters over a long area, even holding diameters into the millionths of an inch. Another big advantage would be the ability to have several tools in a cut simultaneously … some models can even machine several different threads, I.D. and O.D., metric and standard, simultaneously,” says Paoletta. “The advantage of Swiss is that you have the ability to drop parts complete; there’s no secondary [work]. You can reduce labour and you can also control the quality,” adds Chuck Austerberry, applications manager at Dynamic Machine of Detroit, a Michiganbased distributor. As far as Duffy is concerned, the main advantage of Swiss-type turning centers is speed and “accuracy into the tenths on very small diameters. You cannot turn very, very small diameters on a conventional lathe accurately.” Swiss-type turning centers are not without their flaws, however. “The greatest advantage of the Swiss machine is also its Achilles heel. The guide bushing has a normal surface area or land length of around 19 mm (.750 thousandths). Because of this land length, we normally do www.canadianmetalworking.com
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not rough turn the O.D. of parts. If we pull the bar stock back too far and it falls out of the guide bushing, we lose all concentricity and in most cases we have to scrap the part, change the program and start again. Because of this ‘max’ pull back value, we have to look at segmenting the parts into sections for processing, guaranteeing we never fully retract out of the guide bushing, thus keeping our concentricity good,” says Paoletta. Swiss-type turning machines are produced by a handful of OEMs. “I do not have hard facts to prove the numbers, but Citizen is rumoured to have over 50 per cent of global Swiss machine sales annually. The big three Swiss machine makers are Citizen, Star and Tsugami. They have the lion’s share of the market with other manufacturers like Nexturn, Nomura, Hanwha, Yama Seiki and the rest sharing the balance. I have tried to get sales numbers and geographical sales and distribution without success,” says Paoletta. Marubeni Citizen-Cincom was formed in 1984 to service Citizen’s Cincom family of Swiss-type turning centers. The new company is an amalgamation of two big Japanese firms, Marubeni Corporation and Citizen Watch Company. Cincom machines are used extensively in the medical instruments, electronics, fiber optics, automotive, business machine, aerospace, defense, firearms, tool and fasteners sectors, among others. Dynamic Machine of Detroit is a key distributors of Marubeni Citizen-Cincom machines in the U.S. The company operates a branch office in Burlington, Ontario called Dynamic Machine/Canada to serve the Canadian market. Given the uniqueness of the
SW-20 Swiss-type automatic lathe from Star
machines, is it challenging for opera-tors to learn? “They are not difficult to master, though there is a long learning curve. Programming is just one
The S206 CNC Lathe from Tsugami.
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The XD38HII Swiss-type turning center from Hanwha.
aspect of that curve. Some people do not realize that Swiss machines are two or three channel control. Meaning that there are mini-protwo or three mini-pro grams running simultaneously, tied together with synchronization and/ or wait commands,” says Paoletta.”Each one of these mini-programs control a certain segment of the machine or set of tool numbers. By editing one channel, the change could be adversely affecting another channel, causing needed editing on other channels. “One of the first problems conventional lathe personnel usually have is adjusting to the thought: ‘the tools are fixed and the stock does the moving’. This confuses people who are not used to seeing the machines work. On some Swiss machines, the axes are the reverse of conventional lathes. This also causes puzzled looks when making an offset on a tool. “They also do not grasp the significance of the guide bushing. The guide bushing is the heart of the machine. If the guide bushing is not adjusted correctly, problems leading to catastrophic crashes can and do occur,” he adds. The Cleveland Industrial Training Center has offered CNC training for 24 years and Swiss training for roughly six. The Center currently runs a five-week 80-hour course, or compressed one-week, 36-hour course, in Swisstype training. The Cleveland Center works closely with a machine shop called Borman Enterprises to offer students shop-floor training opportunities. In total, Duffy figures he’s trained 150 students in Swiss-type turning techniques. The Center is one of few facilities in North America that currently offers intensive, hands-on training in Swiss-type turning. Duffy was asked what he considers the most difficult aspect of Swiss-type turning to teach. “I would say, getting acclimated to small diameters and the intricacy of dealing with tolerances that are in the 10 thousandths as opposed to the thousandths. Everything is smaller, everything is faster. Which means parts can be made faster but mistakes are also magnified,” he replies. Asked about best practices, pundits point to ground bar stock. “All Swiss machine manufacturers rec68 | OCTOBER 2015
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ommend ground bar stock. Swiss machines cannot make a bent bar straight nor an ‘outof-round’ bar round … we generally have the 60 per cent rule. We can control roundness to 60 per cent of the raw bar stock. If you are trying to hold an O.D to +/- .005mm (.0002 ten thousandths), and your bar stock is out of round by .025mm (.001 thousands), generally we will get a .015mm (.0006 ten thousandths) out of round condition. Which means your part will be ‘out-of-round’ more times than not with that specific bar stock,” says Paoletta. While Swiss is becoming more popular, will go mainstream? “I think it’s going to become more mainstream, because of the ability to have parts drop complete. With a job shop, let’s say their lot sizes are 1,500 pieces. A lot of times, right now they might blank it out on a lathe, then move to a mill or drill press … now they have the ability to job complete off the machine. You have much more versatility. Swiss machines excel in long-term diameter ratios, five to one, six to one, ten to one. It excels there, but it also does smaller parts extremely well. Let’s say you have a 20 mm machine—it can do literally anything as long as you can fit the part in that 20 mm envelope,” echoes Austerberry. “I think the Swiss machining industry will continue to grow by leaps and bounds as long as we get the personnel to man the machines,” notes Paoletta. Scott Laprade, marketing manager of Genevieve Swiss Industries, based in Westfield, Mass. echoes this sentiment. A Swiss-type turning center is “a very capable piece of equipment. It’s pretty versatile when you get the right guy in front of it.”
SD series Swiss-type turning machine from Goodway.
www.canadianmetalworking.com
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Cutting Tools and toolholders for compact Swiss-type turning centers. BY NATE HENDLEY
A
s Swiss-type turning edges towards the mainstream, cutting tool companies continue to provide a steady stream of appropriate tools. Such tools have to be able to function in the confined work envelope characteristic of Swiss-type machines. “There are many tools that were designed with the Swiss machine in mind, due to the limited tooling space and stations,” says Douglas Paoletta, president and owner, Encompass Swiss Consulting in Richmond Heights, Ohio. “Iscar’s Pentacut insert, which is a five-sided indexable tool, is one. One of the first ‘back turning’ tools, and still one of the best, is the Kyocera ABS/ABW series tool. Kennametal has one of the best ‘quick change series’ tools called the KM-Micro,” adds Paoletta, whose company offers on-site training for shops and manufacturers interested in Swiss-type machining. “Manufacturers have really paid attention to the growing market and needs of the Swiss turn industry, so there really is a lot avail70 | OCTOBER 2015
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able [that meets] the needs of the Swiss-type turn shops,” he continues. “Considerations in tooling must also be made in relation to the geometry of the part and a possible non-standard program format to create certain part features. Some Swiss machines are limited on stick tool stations. There are many new tools out there that combine several things like face, turn, groove for the O.D. or drill, bore, and thread for the I.D. By using these combinations we can free up tool stations allowing us to machine more complex or tooling intensive parts with the limited stations.” “Maximizing the envelope is crucial given the tooling requirement to complete a part versus space provided,” adds Jim Garfield, regional sales manager, at Horn USA. “Swiss type multi-function tools can reduce the number of tools/holders required as well as reduce cycle times. Quick-change Swiss holders can reduce downtime when changeover is necessary due to tool wear or new part set up. Repeatability of center height when changing insert/tools is of utmost importance,” he adds. Horn, among other cutting tool companies, has new offerings for the Swiss-type turning sector. “Although Horn has traditionally been oriented towards small part Swiss type machining, we have introduced new tooling dedicated to Swiss-type turning grooving and milling applications. A recent introduction to our existing 274 line was the System 274 ‘µ’ finish for micro turning, grooving and back turning. In addition, our Graf line of Swiss tooling offer numerous options for holding with round shank holders and height adjustable quick change holders for most Swiss type machines, i.e. Star, Miyano and Citizen,” says Garfield. Exsys Tool places its expertise with tooling
Iscar’s Pentacut insert
www.canadianmetalworking.com
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for Swiss-type machines front and center. The company highlights its Decoflex tooling system for interchangeable tools. “Decoflex is a modular tooling system specifically designed for Swiss turning head stock machines…we have introduced a multi-headed collet chuck that will work in both Kyocera sub-spindle tools directions of the spindle simultaneously,” says Scott Leitch, marketing manager with Exsys. Rego-Fix Tool, meanwhile, recently expanded its retrofit reCool coolant through system. Previously matched with live tooling on CNC lathes, the system can be now be used with static toolholders on Swiss automatic machines. “Most Swiss machines just use flood coolant [and have] a little stick out there shooting the oil where you’re cutting. That may or may not be an accurate way of getting [coolant] there. [The reCool system] brings the coolant in through the nut, and now you can go through your cutting tool, something that’s always been hard to do with a Swiss machine,” says David McHenry, engineering and technical manager at Rego-Fix Tool. There’s a general consensus that when it comes to designing tooling for Swiss-type turning, coolant through is preferable to flood coolant. Coolant through tools utilize high pressure (H.P.) for delivery. “In Swiss applications where the parts and work Kennametal envelope are generally smaller, through coolant when KM-Micro systems and where available is always a better option than relying on flood coolant,” says Garfield. “When turning the O.D. of a part, H.P. coolant pays big dividends on gummy/hard materials or long cuts where stringy chips are a problem,” says Paoletta. “The H.P increases the tool life and reduces the need for intervention by the operator for chips wrapping on a part. “On the I.D, using coolant-through drills for instance, can gain you a 2x feedrate over a standard carbide drill or 3x to 4x a cobalt drill, while you can also increase your SFM for the tool,” he explains. The new Walter Cut G1011-P grooving tool from Walter USA, which can be used in Swiss-type turning, is internally cooled. “The G1011-P is designed so
The Original The only true solution for roughing and trochoidal milling operations in the industry.
WORKHOLDING FOR SWISS TYPES “Swiss machines have three work holding devices in them if you don’t include the bar feed collets. The headstock collet, the guide bushing (which is what the stock feeds through during the cutting and is used for support), and the pickoff or sub-spindle collet which takes a parted-off work piece and can hold it for secondary operations on the sub spindle side of the machine.
www.canadianmetalworking.com
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“Each of these devices can be ordered with special options that might pertain to the application being performed. Special ID tolerances, extended nose lengths, extended land surface, over gripping geometry, or special ID shapes are all things that can be modified on a guide bushing or pickoff collet,” says Scott Laprade, marketing manager, Genevieve Swiss Industries, Inc.
Tooling Technology Shrinking Technology Balancing Technology
Measuring Instruments
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GenSwiss Ti-Loc system
Walter Cut G1011-P
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the coolant stream is released very close to the cutting edge, guaranteeing the best possible effect of the coolant, no matter what the supply pressure is,” says Kurt Ludeking, product manager of turning at Walter USA. “Compared to an external coolant supply, this ensures coolant at the cutting edge throughout the cut, especially important in deep, narrow grooves and parting operations “Coolant delivery can be the key to success and direct delivery via coolant nozzles built into the tools can have benefits of better chip control and cooling of the component and chips,” says Kevin Burton, product specialist at Sandvik Coromant in Mississauga, Ontario. When the question is about the best kind of coatings on Swiss-type turn tooling, there’s further consensus. “Typically PVD coatings or uncoated tools are used for Swiss-type turning operations,” says Ludeking. “These provide the sharpest cutting edges, thereby reducing forces on the small workpieces. Also, these tools have higher edge toughness that helps them withstand the high forces generated when cutting at low speeds often encountered in small diameter components. Because CVD coatings require somewhat larger edge-rounding (hones), they tend to generate higher cutting forces that are detrimental to small components. On the positive side, new CVD coating technology is enabling smaller hones, making them good choices for higher speed operations or very abrasive alloys,” he adds. “PVD coatings are most common due to the reduced heat factor in small part machining—small contact diameter, lighter feeds and good cooling. The required sharper cutting edges also dictate that PVD be used,” echoes Burton. “At GenSwiss we recommend micro-thin PVD coatings that don’t change the edge conditions
of the cutting tools when applied to them,” adds Scott Laprade, marketing manager, Genevieve Swiss Industries, Inc. (GenSwiss). “When working with small diameter parts you want the edges to remain as sharp as possible to prevent pressure build up which can lead to deflection of the work piece. Some coatings and processes deposit a ‘bead’ of coating on the edge of the insert which can round it off by up to a thousandth of an inch.” GenSwiss’ recently released its Ti-Loc SwissClamp System “for rotary tooling in Swiss machines … it can be used for milling and slitting operations that utilize ER collets for tool holding,” explains Laprade. Industry experts were also asked about grades and geometries for Swiss-type turning tools. “A grade specifically for use in Swiss-type turning is WSM21, a mono-layer PVD coating that is designed to withstand the low cutting speeds often encountered with small diameter components. Grades with thinner PVD coatings and sharp edges are generally best,” says Ludeking. “Although there aren’t any specific Swiss-turning geometries, those with aggressive chip control for light feed rates and depth-of-cut are often best for Swiss-type operations.” Insert shape also plays a big role in Swisstype turning “since we normally do not rough and finish turn parts. Parts that have undercuts, larger grooves, angles into smaller diameters, and other features like that, are studied to see if a different tool can provide the entire profile in one turn. If not then we have to look at segmenting the part into sections to process,” says Paoletta. To sum up, Laprade cites an old retail truism. “Swiss tooling is a very ‘get what you pay for’ type of product. When you’re trying to continuously ‘split tenths’ you want something that is high quality and more importantly, repeats each time a job is set up or when a tool is changed. A good tool or tooling system will eliminate the need for an operator to chase a tolerance because the tooling wasn’t intended for it or is poor quality,” notes Laprade. Horn System 274µ
www.canadianmetalworking.com
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BUSINESS PROFILE: MACHINING JessEm Tool Company’s new Star SR-32J CNC Swiss-Type Automatic Lathe.
INTRO TO CNC SWISS-TYPE LATHE JessEm Tool Company, Orillia, ON BY NATE HENDLEY
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his spring, the JessEm Tool Company of Orillia, Ontario, acquired its first Swiss-type machine tool. More specifically, the company bought an SR-32J CNC Swiss-Type Automatic Lathe from AMT Machine Tools of Toronto. The Automatic Lathe was manufactured by Star CNC Machine Tool Corp., a division of Star Micronics Co., Ltd. of Japan. JessEm (which was founded in 1999 and named after president Darrin Smith’s twin daughters, Jessica and Emily) makes its own line of woodworking tools and accessories, such as router tables. The company has 20 employees working in a 27,000 square foot facility with 10 machine tools and other equipment, including the Star SR-32J. JessEm’s customers include woodworking tool stores across North America, Asia and Europe. “We have other CNC lathes with automatic bar feeders but this was the first lathe that will allow us to do secondary operations in the same process,” states Smith. “We have a lot of parts we used to make on our other lathes that have to go in the mills after for drilled crossholes and things like that … I didn’t want to be using more labour to do that. I wanted to get a machine to do it automatically.” Smith did extensive online research before making his purchase. He selected AMT in large part because of the complementary training and service offered by the company. In addition to being JessEm’s first Swiss-type CNC lathe, this was also the first Star machine tool the firm ever purchased.
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The Star SR-32J boasts a six-station tool holder, revolving guide bush unit, four-spindle sleeve holder, C-axis control unit, FANUC CNC unit and a rapid feed rate of 24 m/min on the X, Y, Z, ZB and XB axis. The company took delivery of the new machine tool this past April. “What I refer to as installation took two days, from unload to running the first customer part,” says AMT president Keith Crowther. “The machine actually came in at 8:30 am on the 17th and we left that night at 9 pm ready to hand the machine over to my application engineer for set-up and training,” he says. The application engineer stuck around JessEm for several days after the SR-32J was put in place, training company personnel on how to use the machine. The same engineer has returned to JessEm a few times since installation to check in and offer additional insights. “Swiss style machines usually take a little longer for training due to the Swiss concept and number of axis,” notes Crowther. “Even how you machine the parts is a little different [on a Swiss-type lathe]. Because the part runs in a guide bushing, the material actually moves back and forth instead of the tool moving back and forth. Your order of operations as you machine the part is a little bit different. You have to get your head around that and [the fact] it actually runs two programs at the same time,” states Smith. “We’re in pretty good shape now. The first few set-ups were a little rough. [AMT] were always there to help. That’s really the reason I bought from them. I felt most comfortable that they would get us up to speed. That was pretty important because it is a pretty fair learning curve, but between the manual and AMT’s training, it www.canadianmetalworking.com
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BUSINESS PROFILE: MACHINING
The interior of JessEm Tool Company.
hasn’t been too bad at all. I thought it would be a little worse than it was,” he adds. In addition to the Star SR-32J Swiss-type CNC lathe, JessEm’s current equipment inventory includes five Haas VF-2 CNC milling centres, one Haas VF-5 milling centre, one Haas SL-20 lathe with a bar feeder, one Haas ST-20 lathe with a bar feeder, one Hydmech H10 automatic saw, one Elumatec automatic non-ferrous saw, one Abtex semi-automatic deburring machine, and various other small manual machines. All told, the SR-32J came to roughly quarter-of-a-million dollars, more than double the cost of JessEm’s Haas CNCs, and according to Smith, the expense was well worth it. “We did increase our run size for the Swiss lathe because it does take longer to set-up. We typically did runs of 200 to 500 parts at a time on our other lathes. Now any of the parts we do on the Swiss lathe, we run between 3,000 to 10,000 parts. This spreads the set-up time over a greater number of parts and is less demanding on our manpower. “We knew it would take a while before we really saw any benefit. We’re starting to see the benefit of it now. It does do the parts a lot faster. Probably in half the time it was taking before,” he states. JessEm is also using the SR-32J to produce components for a new product called the Wood Sabre Marking Gauge. The gauge boasts a long shaft with a series of grooves on it, and according to Smith it would have been very difficult to make with the company’s other CNC equipment. Crowther offers some straight-forward suggestions on using the SR-32J. “Like any new machine, my idea of best 76 | OCTOBER 2015
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JessEm president Darrin Smith and his new Star Swiss-Type automatic lathe.
practice is to look after the equipment. Don’t abuse it and it will serve you well,” he states. For his part, Smith hopes his new machine tool purchase marks a return to pre-recession levels of productivity. Before the 2008 downturn, JessEm was based in Barrie, Ontario and had 50 employees, 21 machine tools and a second plant in Tennessee. That plant was sold off and both staff and machines scaled back. The company moved to Orillia a year-and-a-half ago. At present, JessEm’s annual revenues stand at about $4 million, roughly half of what they were prior to the recession. In recent years, the company has enjoyed a flourishing 20 per cent annual growth rate. Smith says he can “definitely” see JessEm acquiring more Swiss-type CNC lathes—“as long as the economy stays good and we keep growing.” www.canadianmetalworking.com
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From eco-friendly to productivity enhancing, get the most out of your cutting fluids. BY DOUG PICKLYK
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or effective metal cutting there is no escaping the use of machine tool coolants, and as an essential element in a metalworking process it’s necessary to maximize the efficiency of the fluids while also maintaining a healthy work environment for machine operators. Metalworking fluids typically fulfill two important cutting functions, cooling and lubrication. The cooling effect is necessary to remove heat from the tool, chip, and workpiece. It ultimately helps to extend cutting tool life while also helping keep the metal part thermally stable. Of course coolant also flushes away chips from the tool and cutting zone, and with such large volumes of liquid sloshing around it’s advisable to ensure that it’s safe to be around. “Most people want to give their employees something that is safe,” says Brett Reynolds, senior applications engineer with Blaser Swisslube. “But I think “THE BIGGEST STEP A SHOP CAN as people are becoming TAKE IS TO CHECK ITS COOLANT more aware that metalCONCENTRATION, THAT’S A KEY working fluid costs keep FACTOR IN METALWORKING going up. They’re becomFLUIDS SUCCESS” ing even more conscious that they should be taking better care of the fluids they have so they can get the most out of them.” When it comes to making productivity enhancements through the use of coolant, some fluid companies are promoting vegetable-emulsion coolants as a solution over traditional mineral oil based fluids. “We’ve actually been marketing vegetable-based metalworking fluids as long as I’ve 78 | OCTOBER 2015
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been associated with Blaser (as far back as 1999),” says Reynolds. “We’ve gone to market with these products, not so much from an environmental aspect, but because performance aspects of those fluids are substantially higher when compared to traditional metalworking fluids,” he explains. Blaser’s vegetable ester-based products include its Vasco series. “Once people understand how that base oil interacts with the metal surface and delivers the additives more effectively, then they realize that it makes sense to move to a more expensive fluid that’s ester based because of the performance.” Condat Corporation recently released its new MECAGREEN product line made with a blend of synthetic vegetable esters. In promoting the products, Condat points to benefits including extended tool life (as much as 20 per cent), reduced consumption (as high as 30 to 40 per cent compared with mineral-based coolants), improved cleanliness with less residue left on parts, tool holders and windows, and overall improved operator friendliness with no skin sensitivity issues. The knock on vegetable-based products in the past has been the unpredictable bio-stability of the fluid, because it is essentially biodegradable and bacteria feed off of the base oil in the product. But as is the case with the Condat product, today companies are using synthetic esters. The early natural ester-based fluids didn’t last long and smelled bad, giving the products a bad reputation. “In my opinion that’s a moot point now,” says Reynolds, explaining that because the natural esters are now chemically altered it’s a lot harder for bacteria to break them down, making the new synthetic esters essentially bio-resistant. While the upfront price of ester-based fluid will usually be higher than mineral-based products, according to Reynolds price has little to do with the overall cost of a metalworking fluid. “What you pay for and what it costs you to use it are two different things,” he says. “A lot of people only look at up-front price. The benefits of using ester-based metalworking fluids include the run-off rate which is substantially higher, so you actually use less product, and a lot of times the decreased usage offsets the higher price.” From a health and safety point of view, he points to the problems of misting or fumes that are also greatly reduced with the use of the ester-based fluids. For shops locked into using mineral-based www.canadianmetalworking.com
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coolants there may be an environmental change coming very soon anyway. Unless legislators in the U.S. have a change of heart, the Environmental Protection Agency (EPA) is banning the use of medium- and longchain chlorinated paraffins in metalworking cutting fluids beginning in May, 2016. Already, even in Canada, some fluid suppliers are encouraging shops to switch to chlorine-free solutions. According to Barry Gothard, sales representative with Fuchs Lubricants in Canada, word has come down from the top to begin educating metalworking customers about the change. “We’re here to help customers When the coolant becomes a liquid tool. becomescomply,” When the coolant a liquid tool. says Gothard. “We want to be looked at as the chlorine-free alternative,” he says. Unlike the chlorine in a swimming pool, the use of chlorinated paraffins in coolant has nothing to do with controlling bacteria. Instead, the chlorinated paraffin is an extreme pressure (EP) additive that is carried by the oil and interacts with a metal surface forming a metal chloride under heat and pressure. This bond provides a lubricating film that can withstand higher temperatures than mineral-based oil on its own, so in essence, the chlorinated paraffins provide lubrication to protect cutting tools when working at higher temperatures. “They’re extremely effective on stainless steel and nickel-based alloys, just because of the way they interact with the surface of the metal,” says Reynolds. There are EP additive alternatives to chlorine, namely sulphur or phosphorous, but one of the reasons chlorine has been favoured is because it is the least expensive Metalworking fluids to option of the three. So according to optimize productivty, Gothard there will be an incremental economic efficiency increase in the purchase price of the and machining quality. chlorine-free fluids. There are still other ways to improve coolant productivity in a shop and keep an environmentally-sensitive approach. A common Our specialists support you to get the best out of your machines and tools with the refrain from all the coolant suppliers Liquid Tool. Please contact us for your local distributor. is that as metalworking fluids continue to increase in price companies will become more proactive in recycling their fluids. Looking to extend Blaser Swisslube Inc. Goshen, New York Phone 845-294-3200 mailboxusa@blaser.com www.blaser.com the longevity of coolants through proper filtration and incorporating 80 | OCTOBER 2015
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www.canadianmetalworking.com
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maintenance procedures, shops will be able to reduce their costs. “The biggest step a shop can take is to check its coolant concentration, that’s a key factor in metalworking fluids success,” says Reynolds. Gothard agrees, noticing that some customers will try to push their concentrations lower and lower to save on fluids. “But if they run only water they’ll have rusty parts, rusty machinery and broken tools, so they need to keep the concentrations between five and 10 per cent,” suggests Gothard, insisting that chemists formulate their products to work best at a certain percentage, and it’s up to the customers to run it at those percentages. The productivity benefits in production will outperform the savings from skimping on fluids. There are many companies on the market that are promoting or selling coolant recycling systems, including PRAB, Eriez or Custom Coolant Equipment of Lynden, Ontario. These suppliers are all helping shops maintain their systems and reduce their costs. PRAB for example recently introduced a new feature for monitoring and controlling coolant concentration within its Guardian coolant recycling system. The Automatic Coolant Concentration Control (AC3), continually monitors coolant concentration levels and adjusts automatically to maintain ratios within a plus/minus 0.5 per cent accuracy. The monitoring system takes continuous measurements using an automatic refractometer. The readings are analyzed and the system automatically determines action; opening and closing valves, and turning on and off a pump delivery system. “The industry has long sought an economical solution for automatic concentration control. We developed the AC3 for those customers seeking to improve the performance of their coolant chemicals, which in turn improves tool life and lowers operational costs,” states Tim Hanna, managing director of PRAB’s fluid filtration division in a company release. Their company’s coolant recycling system uses a coalescing filtration www.canadianmetalworking.com
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process removing mechanically dispersed tramp oils to 0.1 per cent or less, and according to the company has demonstrated a reduction in haul-away costs by 90 per cent, and has lowered new coolant purchase up to 75 per cent, noting that payback on the equipment is typically six to nine months. From vegetable-based options to recycling systems with automated concentration options, there are many ways shops can be improving their operations with new coolant solutions.
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Vision systems come in all shapes and sizes but provide fast and accurate measurement BY LINDSAY LUMINOSO
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s technology advances, new and sophisticated means for part inspection are being made readily available. Vision inspection technology allows for industries to replace manual inspection with a high speed, high accuracy option. According to the AIA, a global association for vision information, North American sales for machine vision systems and components grew 16 per cent to US$1.2 billion in the first half of 2015, setting an all-time high. “We’re happy to see the machine vision market continue its expansion in 2015,” says Jeff Burnstein, AIA president. “We’re seeing a wide variety of companies in all industries realize the benefits of implementing machine vision in their operations.” Vision systems encompass a wide range of product styles and configurations. “Traditionally, vision systems were a vertical style machine, with the camera positioned above the part,” explains John Wybenga, product specialist – metrology, The L.S. 82 | OCTOBER 2015
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Starrett Co. of Canada. “The part itself would be on a glass plate.” These systems still exist and are useful for the inspection of smaller and low volume parts. However, as the production environment changes, inspection and quality requirements also change, which in turn has advanced vision systems to fit a wider range of applications. “When used in the production environment, [vision systems] can provide instant information regarding part quality and feature sizes so production can react,” adds Peter Detmers, vice president, sales, Mitutoyo Canada Inc.
WHY CHOOSE VISION INSPECTION? For the most part, vision measuring systems are used for difficult to measure parts, specifically parts that are hard to measure with touch-based methods. “All manufacturers of small parts, where many small features can be measured optically, are candidates for a vision system,” explains Dragos Leu, sales associate, Canadian Measurement-Metrology. “Also some small part or small opening that cannot be probed with a contact probe will absolutely require a non-contact measurement [solution].” “They are also used because optical measurements, when suited to the type of feature being measured, are most often much quicker than other methods of measurement,” says Detmers. However, he adds that it is really a case of suiting the device to the application. Wybenga adds that any company currently using a CMM, optical projector or microscope can benefit from the capabilities of www.canadianmetalworking.com
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a vision system. Whether medical device manufacturing, automotive and aerospace manufacturing or fastener manufacturing, a vision system can enhance production and provide valuable data required for the successful completion of products. “[Vision systems] are not suited for every application and potential users need to ensure they challenge the seller to show why the vision system best suits their need over other instruments,” explains Detmers.
system works well when palletizing multiple parts, explains Wybenga. Manual systems tend to be much lower costs than the CNC systems, yet they are typically slower, adds Detmers. “A CNC [vision] machine will surely increase the throughput if multiple parts need to be checked and also off-line programming can be an advantage,” adds Leu.
EXPERT TECH TIPS Environment: “The vision systems work both
HARDWARE There are so many different configurations and features for vision systems depending on the application. Whether it is tabletop, in-machine, or ceiling mounted, each system provides fast and accurate measurement. For the most part, the primary function of a vision system is for inspection and gauging. A part is placed within the field-of-view of a vision system, which takes measurement of features. However, machine vision systems add the ability for the system to cover more than just these two applications. Mounting cameras in a production environment and creating an intuitive system, something Cognex specializes in, is a great way to add robotic guidance and part identification to your abilities. “[Machine vision systems] tend to work for companies that do larger production runs, something repeatable,” says Sean Lett, regional sales manager for Canada, Cognex. “You don’t traditionally see machine
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Quick Image Features: vision in custom manufacturing facilities. This vision system is very good at what it does but you do have to tell it what to do.” This can be a challenge for a company constantly manufacturing different parts. A manual machine is a great option for low volume parts, whereas a CNC www.canadianmetalworking.com
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• The ultimate in simple operation with one-click instant measurement • Telecentric optical system with large focal depth and field of view • Quick GO/NG judgment for efficient quality control inspection • Available in sizes (X,Y): 100x100, 200x100, 200x170, 300x170, 400x200mm, with view field of 32x24mm or 12.8 x 9.6mm
Mitutoyo Canada Inc. Toronto (905) 821-1261 Montréal (514) 337-5994 www.mitutoyo.ca
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in lab and shop floor environment—optical machine lenses need to kept clean,” says Leu. “The thing to remember is that the main purpose of the vision machine is to optically measure features, which requires a higher level of part cleanliness,” says Detmers. Lighting Conditions “Be aware of the environment,” says Lett. “Most people don’t think of how ambient light affects what the vision system/camera sees. “ ‘Keep in mind that light control also includes the ambient light conditions,” says Detmers, “so if the machine is being programmed in the day time, in a room where there are windows with lots of natural light, the machine may perform differently in evening or on a cloudy day, because of the ambient conditions. “ Ease of Use: “Look for a system where the user interface is simple to use—fewer icons often means more [ease of use], more productivity and less time searching,” says Wybenga. “A less complicated looking screen [tends to be] more intuitive, resulting in users of different skill levels being able to use the machine.”
VISION SYSTEMS TRENDS Conventional optical vision tended to be slow for certain types of measurement required by customers, so Mitutoyo has explored different options for advancing the speed and adding sensor types to the system. Some other features that are new for these systems include LED illumination, off-line programming to CAD, larger measuring range lasers which replaces contact scanning with a point laser. For machine vision, 3D displacement is beginning to become popular. “Most machine vision system cameras are area scanner, 2D cameras,” says Lett. “Now with the technology of lasers and imagers working together you can bounce a laser off the part, the laser bounces off into an imager and it builds a 3D profile of the part, one pixel at a time.” This creates a full 3D rendering. Overall, vision systems encompass an array of products and can include many different features. Finding the right solution can make quality assurance easy. Using imaging-based inspection and measurement is a rapid and highly accurate way to ensure that your customers are receiving quality parts.
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Cognex’s In-Sight 7010C
Nikon’s CMM-Manager 3.5 for iNexiv
In-Sight 7010C is an entry-level color vision system that can distinguish parts by color. The system features 24-bit color resolution that accurately identifies 16 million color variations. Ease-of-use is the core of In-Sight vision systems starting with smart vision tools that automatically select features, set parameters and operate in real world conditions without adjustment. The EasyBuilder software interface offers everything required to easily set up reliable applications. www.cognex.com
The CMM-Manager 3.5 for Nikon’s iNexiv vision measuring equipment offers a powerful and user-friendly interface. CMM-Manager 3.5 works with vision measuring, autofocus laser scanning, rotary indexing, and touch probing to provide a true 3D multi-sensor system for both physical products and 3D CAD models. Historically, vision hardware technology has outpaced software development. The latest CMM-Manager can import 3D CAD models and pick features to create automatic probe paths for both vision and tactile measuring. www.nikonmetrology.com
Starrett’s AVR300 CNC vision system The AVR300 CNC vision system offers 12” x 8” x 8” travel, Z-axis measuring, a powerful MetLogix software control system, 6.5:1 (optional 12:1) zoom optics and several LED illumination options. These systems are general-purpose CNC video-based measurement systems, ideal for quality assurance, inspection labs, manufacturing, assembly and research facilities. A precision mechanical bearing X-Y-Z stage and column translates data accurately and repeatably to the MetLogix software. www.starrett.com
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Mitutoyo’s Quick Image series The Quick Image series 2-D vision measuring system now includes “One-click” measuring functionality. Quick Image Telecentric lens offers a wide field of view and depth of focus, enabling easy measurements on workpieces with multiple heights. A new one-click measurement function enables measurement and tolerance judgment with a single mouse click. This function enables automatic detection of a workpiece position and inclination, and batch measurement of multiple parts with the same shape, up to a maximum of 1,000 workpieces at one setting. Measurement results are displayed in real time directly on the video image, which enables tolerance judgments to be seen at a glance. www.mitutoyo.ca
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TOOL TECH
EFFICIENT BLISKS PRODUCTION BY ANDREI PETRILIN
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blisk (bladed disk) is an aero-engine component consisting of a rotor disk and multiple blades in a single part. Since their introduction in the mid-eighties, the use of blisks continues to grow in popularity. Also known as integrally bladed rotors (IBR’s), blisks are usually machined from a solid piece of material. The use of blisks in the compressors and fans of modern turbojet engines not only leads to gains in performance, it negates the need to assemble the rotor disk and blades and also allows the vital component to be produced in a single setup on the same machine tool. Due to their complicated shapes, the machining of blisks requires the use of multiaxis machine tools and advanced CNC software. Naturally, such machining demands effective and reliable cutting tools. As the majority of blisk machining consists of milling, the quality of the milling cutters used is of paramount importance. Usually, blisks are produced from titanium (Ti) or nickel-based alloys (Ni-alloys), therefore the milling cutters used need to meet the stringent productive and fail-safe machining requirements of these hard-to-cut materials. Major cutting tool suppliers to the global aerospace manufacturing industry develop a wide range of milling cutters to ensure the premium quality of blisks and also boost users’ productivity. 88 | OCTOBER 2015
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An Iscar solution for the efficient production of blisks is provided by its coated solid carbide endmills and its MULTI-MASTER tools. Using premium submicron and ultra-fine carbide substrates, which in combination with nano-layer PVD coating technology and post-coating SUMO TEC treatment, improve the tools’ impact strength and wear resistance, resulting in longer tool life and enhanced working characteristics. As the milling of blisks begins with rough slot milling, solid carbide endmills are specifically designed for this demanding operation. MULTI-MASTER end milling tools consist of a shank interchangecarrying interchange able solid carbide cutting heads that are treaded to allow a quick-change connection with the shank. These tools are preferred where a slot to be milled is deep and narrow, and they are also ideal for milling fillet areas. The benefits of a flexible system like this include minimum setup time and the ability to configure the system in more than 15,000 ways from standard shanks and heads. If necessary, the assembly can be extended by the use of extensions.
A range of shanks are available and are made from steel for general-duty applications, tungsten carbide with greater rigidity and heavy-metal for increased vibration resistance. In some blisk rough slot milling situations, such as the machining of Ni-alloys, the trochoidal technique is the most productive machining method, therefore, a trochoidal tool path is highly recommended. For these applications, solid carbide endmills with multiple flutes with different helix angles, like Iscar’s Chatterfree tools, enable high stock removal rates. When finish milling of blisks, a high-quality surface finish and predictable long tool life are vital. The cutting tool often works with a high overhang that raises the requirement of the tool’s stability. For these situations, it’s recommended to use solid carbide tapered ball nose endmills, which are characterized by different helix angles of the endmill flutes. Productive milling of blisks is based on three pillars: a high-velocity multi-axis machine tool, advanced CNC and CAD/CAM software, and not least efficient milling cutters, all working in concert to achieve considerably reduced cost per unit (CPU). Andrei Petrilin is application/ project engineer, milling manager, with Iscar. www.canadianmetalworking.com
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TOOL TALK
MAKINO HOSTS DIE/MOLD TECHNOLOGY DAYS With a focus on automation, simplified controls and advanced functionality, Makino welcomed over 400 customers to its Die/Mold and EDM Technology Center in Auburn Hills, Michigan September 16 and 17 for its latest Technology Expo.
More than 20 machines were running and visitors experienced non-stop demonstrations by Makino application specialists along with a day-long line-up of educational sessions. The first day included an industry outlook by Laurie Harbour, president
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and CEO of Harbour Results Inc. Keeping a close eye on the automotive market, Harbour noted that die/ mold shops “are running very busy,” right now as auto sales are riding high and the OEMs are driving to introduce more complexity and customized models to their lineups. She did warn that car makers may begin scaling back on tooling if their profitability begins to dip, but some of that slack could be taken up by new automotive R&D projects taking place in North America.
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Among the technologies on display was an automated cell with integrated quality control, and a highlight was Makino’s new Professional 6 (Pro 6) controller, being demonstrated on a V56i vertical machining centre and a five-axis D800Z. The new Pro 6 control offers a larger touch screen and streamlined screen layouts, operator guidance and assistance, and new machine functionality with a focus on enhancing productivity while also ensuring safety. For complex molds and dies, Makino was also highlighting its new SGI.5 (super geometric intelligence) advanced motion control designed to optimize every move and cut on the machine tool. Part of the new Pro 6, SGI.5 reduces CAM processing time, allows for faster feed rates while still delivering improved surface finish. Also on display were new advances in EDM technology including the company’s new Hyper i control for both wire and sinker EDM machines. www.canadianmetalworking.com
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TOOL TALK
CANADIAN MEASUREMENT-METROLOGY ANNOUNCES KNOWLEDGE TOUR as WLS qFlash Compact White Light Measurement System, Leica Absolute Tracker AT960, Leica Absolute Tracker AT402, Renishaw Equator, Renishaw Revo, and the Romer
Absolute 7 Axis SI Portable Arm. CMM’s PC-DMIS Professor will be available for one-on-one sessions. Visit cmmxyz.com to for more information and to register.
Canadian Measurement-Metrology (CMM) will be hosting its popular Knowledge Tour at its headquarters in Mississauga on November 3rd and 4th from 9am to 4pm. “This year’s version of our very popular Knowledge Tour provides the latest in metrology innovation,” says Elliott Foster, owner of Canadian Measurement-Metrology. “Our customers get a chance to speak to the experts and have all their questions answered as well as practical demonstrations.” The company will be hosting a PC-DMIS Product Forum, which highlights the latest features and improvements in PC-DMIS. The event will also showcases various technologies such
CTMA HOSTS AGM The Canadian Tooling and Machining Association (CTMA) hosted its Annual General Meeting on September 16th in Ingersoll, ON. The AGM saw the appointment of the new 2015-16 Board of Directors (pictured) as well as a small ceremony awarding apprentice bursaries and the Trades Ambassador of the Year, which was presented to Igor Babmov, Advanced Machining Services Inc. The CTMA welcomed Major-General (retired) David Fraser to speak about the unique work being done at INKAS Armoured Manufacturing Ltd. After the meeting, guests were welcomed to dinner and cocktails and a chance to speak with colleagues and friends.
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TOOL TALK Enhancements for increased productivity CGTech announced the next major release of its VERICUT CNC simulation software product, used world-wide to simulate of all types of CNC machines including leading brands such as Mazak, DMG MORI, Makino, Matsuura, Okuma, Haas, and Heller. In addition to new features designed to make NC programmers’ jobs easier, nearly 500 customer-driven
Solution for demanding workholding scenarios Two additions to the 138 series make it a more versatile workholding solution. The ESM 138 Turbo and the ERGO 138 fundashare the same funda mental body dimensions including diameter, bolt hole pattern, open port orientation, knob type, etc., making them direct swaps for the ESM 138. The new models include Unilock’s core features including quick/easy setup and loading, self-guided top-side mounting and zero-point clamping. www.bigkaiser.com
enhancements and software change requests have been completed in version 7.4. These updates utilize the latest technologies to enable faster processing speeds, longer tool life and increased part quality. Added features to the user interface simplify the most common user actions and significant developer hours have been invested to increase simulation speed by more thoroughly taking advantage of multiple processors and background processing. www.cgtech.com
SMALLER AND
JUST AS FIERCE
MFH-RAPT R Enhanced Multi-purpose Geometry The new Universal Drill from Niagara Cutter will soon hit the market. The solid-carbide drill combines a special multi-purpose geometry with advanced coating technology to provide reliable, predictable tool life and the lowest cost per hole, especially in high-volume production environments. The Universal Drill’s rigid four-facet point geometry provides excellent centering capability, maintains an IT8/9 hole tolerance and is easy to regrind. A polished AlCrN coating gives the drill high abrasion resistance, toughness and good chip evacuation capabilities. www.secotools.com www.canadianmetalworking.com
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High Fe e d End M ills Experience the newest addition to the popular MFH-Raptor high feed milling cutter family. The MFH-Mini high feed end mills are available in diameters from 0.625” to 1.250” for small machining centers. Boost productivity and reduce machining costs with the MFH-Mini’s economical double-sided 4-edge inserts. Covering such a broad spectrum of machining operations, the MFH-Mini is an essential part to any machine shop’s cutting tool arsenal.
Face Milling & Shouldering
Slotting
Ramping
Helical Milling
Pocketing
Contouring
Check out: KyoceraPrecisionTools.com/Raptor-Mini for more information! KYOCERA Precision Tools, Inc.
/
800.823.7284
/
cuttingtools@kyocera.com
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CNC SOLUTIONS
WIRE EDM MAINTENANCE: TRUE OPERATIONAL IMPACT BY BRIAN PFLUGER, EDM PRODUCT LINE MANAGER AT MAKINO
O
n a wire EDM machine both the mechanical components that drive and apply tension to the machining wire and the electrical components that deliver precise power to this wire during machining must work together for optimum results. On any type of machine components wear over time and require proper intervals of maintenance to stay productive. But on a wire EDM machine, maintenance is especially critical for reliable operations. If maintenance is neglected, it will result in a loss of valuable machining time and in operational issues including wire breaks, slow cutting speeds, poor accuracy and unreliable automatic wire threading. Any one of these can decrease 94 | OCTOBER 2015
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efficiency on its own, but when the issues are combined they rob a shop of productive unattended machining time. This concept of regular EDM maintenance is more intensive than most other machines on the shop floor and should be performed proactively at set intervals.
WIRE EDM MAINTENANCE ITEMS While the type and interval of maintenance varies by the make and model of a machine, there are many common wire EDM maintenance items that need to be performed. Exchanging the wire spool seems intuitive because it is required for normal WEDM operation. The spool supplies and renews the cutting tool that performs the work, and the wire collection bin that holds the used wire must be emptied at regular intervals. Since coated wires are dirtier, they require the machine to be maintained more frequently. True to its name, the automatic wire threading unit performs the automatic threading of the wire. This unit is the single-most-important
automated feature on the machine and allows for reliable unattended machining. Maintenance of this unit consists of simple cleaning. There are two electrical contacts that deliver the machining power to the wire. The contacts will wear over time and require indexing and eventual replacement. As the contacts are depleted the machining speed is significantly decreased. Indexing the energizer plates involves moving the contact by a specific measured amount, and it is performed between every 60 to 80 hours. The wire guides provide the precision alignment of the wire within the machine and can become dirty and build up debris to the point of clogging. Round wire guides are the most common, and they should be removed for cleaning. It’s also important not to forget to perform vertical alignment calibration after each cleaning. There are several rollers that support and drive the wire that become dirty. If wire drive rollers are not properly cleaned, the wire may slip across the rollers, affecting part accuracy and surface finish and increasing the probability of wire breaks. The three most important rollers making up the wire transport system are the clutch roller, which controls tension; the 90 pivot roller, which is located in the lower head; and the pinch rollers, which pull the used wire in the back of the machine and into the collection bin. The main water filters purify the water and remove the debris that is created during machining to maintain stable EDM production. There are four different filter types which are determined by the direction of water flow. Inside-out filters are larger in size and sit inside the machine. These are usually quicker with less mess, but they require the water to be evacuated from the machine first. Outside-in filtration can be a bit messier and is located in a pressurized canister on the machine. Paper media provides adequate performance with lower www.canadianmetalworking.com
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Canada’s premier event for welding, metal fabricating and finishing
October 4 & 5, 2016 | Edmonton, Alberta | Edmonton EXPO Centre | Halls F, G, H
Join the only Canadian-made welding, fabricating and metal forming event that brings the whole industry together under one roof. QUICK FACTS •
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CWC is Canada’s Largest Welding and Joining Conference. 15-10-01 5:53 PM
CNC SOLUTIONS Performing general maintenance will extend the life of consumable components.
cost, while synthetic media provides longer filter life and enhanced filter performance at a higher cost. Deionization resin (di-resin) is necessary to control the conductivity of the water for stable EDM machining; if the water level becomes too high the EDM machining becomes unstable as the dielectric is too conductive and can’t act as an insulator. The water reservoir must also be maintained. Finally, general cleaning is probably the most overlooked item of wire EDM maintenance. This entails the simple washing of the work tank area, work table and seal plate. It’s important to remember that EDM debris consists of very fine, abrasive particles that build up and create a hard scale over time. Specially designed EDM acid cleaners are used for general cleaning. Be sure to use these proper/approved chemical cleaners, and don’t spray them directly into the machine.
Some of the short-term maintenance items include the wire spool, energizer plates, automated wire threading unit and general cleaning. Long-term items include wire guide cleaning, wire drive rollers, filters, di-resin and general cleaning. Machine maintenance costs typically include the consumable parts costs and the direct labor, but actual total cost of maintenance should include the lost billable machine hours that occur while the machine is not in operation. To save on these maintenance costs, it’s important to choose a high-performance machine that eliminates as much maintenance and wear to parts as possible. Look for time-saving measures such as: • a simplified wire threading unit
with fewer components for easy, reliable, performance • fast and easy indexing of the energizer plates through a tool-less system with a one-click index • development of long-life energizer plate to improve the service life of the contacts and also lower consumables costs • wire guide design requiring minimal wire guide maintenance • filter air purge function drains excess water from the filters to reduce filter weight and prevent spills • intelligent on-machine maintenance tracking to track the health of all items on the machine
KEEP THE PARTS FLOWING As mentioned, there are many items that must be properly addressed to keep a wire EDM machine in top operating order. Reviewing these on a regular basis ensures that all proper maintenance procedures are being performed on the machine. For best productivity and reliability, it is critical that machine maintenance disciplines are handled as a proactive preventive measure. Brian Pfluger, EDM Product Line Manager at Makino.
MAINTENANCE INTERVALS AND COSTS Performing these general maintenance items will extend the life of the consumable components. While timing will vary between machines, wire EDM maintenance is typically performed using short-term (weekly) and long-term (monthly) strategies. General cleaning, including washing of the work tank area, is probably the most overlooked item of wire EDM maintenance.
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Canada’s only dedicated Fabricating & Welding publication 8 issues in 2016 MMTS Show Guide/Special Quebec Industrial preview issue CMTDA Directory www.canadianfabweld.com Online Directory *new for 2016* Weekly Fabricating & Welding e-newsletters Product newsletters Whitepaper mailings Targeted e-blasts Top 20 under 40 Winnipeg, Vancouver, and Halifax Table Top Expos
CONTACT Steve Devonport
Rob Swan
Nicholas Healey
Rob Colman
Lindsay Luminoso
Publisher t: 416-543-1641 e: sdevonport@ canadianfabweld.com
Associate Publisher t: 416-510-5225 e: rswan@ canadianfabweld.com
Account Manager t: 416-510-5232 e: nhealey@ canadianfabweld.com
Editor t: 905-726-4656 e: rcolman@ canadianfabweld.com
Associate/Web Editor t: 416-510-5233 e: lluminoso@ canadianfabweld.com
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March 22 - 24, 2016 Toronto Congress Centre Canada’s ONLY exclusive fabricating, welding, metal forming and finishing event.
If your company provides services for manufacturing then FABTECH Canada is for you!
3 DAYS ONLY > Discover new products in the marketplace > See live machinery demonstrations > Network with industry peers
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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 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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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
POSITION: SALES REPRESENTATIVE One of the fastest growing abrasive’s company in Canada is looking for a dynamic and technically strong sales person. We are looking for a highly motivated sales professional to join our team to see, promote and demonstrate PFRED products in the Eastern Quebec territory. Qualifications: Knowledge of the Welding and Industrial markets at both Distributor and End User levels. This position required a minimum (2) years’ experience in outside sales. Valid driver’s license and ability to travel
Additional Skill and Knowledge Requirements: • Negotiation and presentation skills required • Excellent time management skills • Proficient in Microsoft Office applications • Fluent in French and English • Must be proactive, self-disciplined, and be able to demonstrate solutions for customers
If you are looking for a great opportunity, need a challenge in a global company, please send cover letter and CV to: Mcrump@pferdca.com, Fax: 905-501-1554
SEEKING
REPRESENTATIVES Royal Products, a leading U.S. manufacturer of machine tool performance accessories, is seeking independent manufacturer’s representatives for all Canadian provinces. For further information, please contact Brian Mecca at bmecca@royalprod.com
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PRODUCTS & SERVICES
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
EVENTS – TRADE SHOWS
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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 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
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
MACHINE TOOLS AMT MACHINE TOOLS LTD. AMT specializes in Sales & Service of: Star CNC Swiss Style Automatic Lathes and Hydromat Transfer Machines. We also have a complete line of filtration products including Filtermist Oil-Mist collectors.
Alro Steel
Metals Industrial Supplies Plastics
Your One Stop Shop for cut-to-size Metals & Plastics with daily deliveries to Ontario, Canada Since 1948 100 | OCTOBER 2015
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888-888-ALRO 2 5 7 6
alro.com www.canadianmetalworking.com
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PRODUCTS & SERVICES
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 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 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
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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
METALS BÖHLER-UDDEHOLM CANADA is a leading manufacturer of high quality tool steel, high speed steel, powder metallurgical steels, stainless steels, and specialty alloys. Products and conveniently located facilities are supported by a highly trained technical sales force and by a local and international metallurgical support staff. For more information contact: 1-800-665-8335 or www.bucanada.ca/contact_us.htm
QUALITY CONTROL RENISHAW (CANADA) LIMITED. Introducing a unique versatile gauging system. Equator, an alternative to custom gauging, offers inspection of an unprecedented variety of manufactured parts. Proven and Developed on the shop floor with industry leading gauging users in a variety of industries and applications. For more contact us at www.renishaw.com/gauging. T: 1 905 828 0104 E: Canada@renishaw.com www.renishaw.com
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
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
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BY THE NUMBERS
RAIL, SHIP&
Heavy Load Transport 568
TRUCK Canada supports a healthy transportation sector on the road with heavy trucking and buses, by rail (both intermodal freight and transit) and by sea. According to Industry Canada there are some 3,405 transportation-related equipment manufacturers in Canada (including automotive) employing approx. 180,000 people. This sector has been stimulated by both domestic and global economic growth, and in 2014 national initiatives to improve safety and security across all modes of transportation led to additional work to be done. Here is a snapshot of Canada’s transportation industry…
SHIP AND BOAT BUILDING ESTABLISHMENTS (2013).
53 RAILROAD ROLLING STOCK MANUFACTURING ESTABLISHMENTS (2013). •
Includes all facets of locomotive and railroad car manufacturing, rapid transit cars, rail layers and railway track maintenance equipment
56 HEAVY-DUTY TRUCK MANUFACTURING ESTABLISHMENTS (2013)
Canada’s transportation industry
$83 billion CANADA’S TRANSPORTATION EQUIPMENT MANUFACTURING EXPORTS (2014)
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567 PORT FACILITIES IN CANADA
45,742 route-km CANADA’S RAIL SYSTEM
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