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Vol. 107 | No. 3 | APRIL 2012 | www.canadianmetalworking.com
COVER STORY
18
SHOULD I STAY OR SHOULD I GO?..................................... 18
FABRICATING THE MONOLITH WITH A WATERJET..................................... 24 Monolith Precision Machining adds precision and productivity
FIRST IN FIBER. ................................................................... 28 A game-changing laser innovation
CUTTING TOOLS THE CUTTING EDGE. ......................................................... 32 New and productive in insert technology
TURNING
24
TURNING DOWN THE RISK................................................38 Coolant exposure health hazards
PRODUCTION TECHNOLOGY TOOLHOLDING TALK .........................................................44 Experts speak about this crucial technology
LOCK AND GO.................................................................50 Solid workholding has never been more important
QUALITY
44
OUT OF THE LAB, ONTO THE FLOOR..................................48 Precision measuring, down on the line
WELDING CANADA STAYING SAFE WHILE WELDING......................................... 58 Protection for profitability
FINISHING
58
METAL MARKING METHODS. .............................................64 Dot-peening durability
DEPARTMENTS View from the Floor........................................................... 6 News.............................................................................. 8 Floor Space.................................................................... 16 Welding News............................................................... 54 CWA Column................................................................. 56 By The Numbers............................................................. 68
CONTENTS...
Portable and fixed I/M options
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PUBLISHER Steve Devonport 416-442-5125 | SDevonport@canadianmetalworking.com ACCOUNT MANAGER Rob Swan 416-510-5225, cell 416-725-0145 | RSwan@canadianmetalworking.com EDITOR Jim Anderton 416-510-5148 | janderton@canadianmetalworking.com EDITORIAL DIRECTOR Lisa Wichmann 416-442-5600 x 5101 | LWichmann@canadianmanufacturing.com ART DIRECTOR Sheila Wilson 416-442-5600 x 3593 | shwilson@bizinfogroup.ca CIRCULATION MANAGER Selina Rahaman 416-442-5600 x 3528 | SRahaman@bizinfogroup.ca MARKET PRODUCTION MANAGER Barb Vowles 416-510-5103 | vowlesb@bizinfogroup.ca PRINT PRODUCTION MANAGER Phyllis Wright 416-442-6786 | Pwright@bizinfogroup.ca BIG MAGAZINES LP......................................................... PRESIDENT OF BUSINESS INFORMATION GROUP | Bruce Creighton VICE-PRESIDENT OF CANADIAN PUBLISHING | Alex Papanou EXECUTIVE PUBLISHER, MANUFACTURING | Tim Dimopoulos HOW TO REACH US.......................................................... Published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, North York, ON M3B 2S9 Phone: 416-442-5600. Fax: 416-510-5140 CM, established: 1905 is published 7 times per year by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. SUBSCRIPTION RATES Canada $55.00 per year, Outside Canada $90.00 US per year, Single Copy Canada $8.00. RETURN UNDELIVERABLE TO Circulation Department 80 Valleybrook Drive, Toronto, ON M3B 2S9 All rights reserved. Printed in Canada. The contents of the publication may not be reproduction or transmitted in any form, either in part or in full, including photocopying and recording, without the written consent of the copyright owner. Nor may any part of this publication be stored in a retrieval system of any nature without prior written consent. Content copyright ©2012 by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd., may not be reprinted without permission. CM receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. CM, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. CM accepts no responsibility or liability for claims made for any product or service reported or advertised in this issue. DISCLAIMER This publication is for informational purposes only. The content and “expert” advice presented are not intended as a substitute for informed professional engineering advice. You should not act on information contained in this publication without seeking specific advice from qualified engineering professionals. PRIVACY NOTICE From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 Email: jhunter@businessinformationgroup.ca Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9
View From the Floor Don’t blame the CRA There’s an old saying that the only inevitable things in life are death and taxes. While that statement is certainly true, death at least can only happen to you once; taxes, and in this case I’m thinking the Federal kind, can kill you in a multitude of ways. Every business owner in the country decries the Federal income tax burden and urban legends abound about unfair and capricious behavior by the Canada Revenue Agency. The frustration is universal, making the “I got screwed by the CRA” story easy pickings for journalists looking for a big “lead”. Everybody hates the taxman. And everybody is wrong. It’s not the people administering the system who are bleeding Canada’s industrial base white, it’s that major killer of growth, innovation and employment in the nation: the monstrous Income Tax Act. “Big’, doesn’t do this behemoth justice. It’s 2920 pages long. The contents alone consume 29 pages. Printed on standard letter paper this one act forms a pile five inches thick. It’s amended so often that the CRA issues regular bulletins to keep tax professionals on top of the changes. It’s nuts, or at least it’s nuts if you’re part of the real economy. The actual reasons for this juggernaut are two: the first is to conceal the way the tax system works, keeping Canadians in the dark about the vast network of Government subsidies, handouts and market-rigging that drives so much of Canada’s economy. The other is to support a massive welfare system for the legal and accounting professions, while creating the illusion that this sand-in-the-gearsof-Canada’s-economy is somehow good for the creation of wealth. It’s nice work, if you can get it. So what do we do? We blame the CRA, instead of the real culprits, the cabal that sits in the House of Commons. This also serves a purpose, insulating the politicians by allowing the CRA, who are charged with running this insane system, to absorb the public’s frustration. And the worst part is that it’s not even a conspiracy. The Income Tax act grew into a Frankenstein monster slowly, innocently, one amendment at a time as legislators piled tweak on modification, until it evolved into the mess it is today. The sad part is that we’re so used to it, we think it’s normal for a blue-collar worker to need the help of a professional tax preparer to overcome the complexity of even a simple return. For business, it’s an investment-sapping profit killer with no end in sight. And that’s the pity: In an age of fiscal restraint, smaller government and lower tax rates will do nothing to stop this insanity. We need radical tax simplification, not lower rates. We need a three-line postcard tax return, for business and individual Canadians: Gross, Tax and Net. Get subsidies out in the open, not buried in accounting trickery. Do this and we would free capital for investment in new technology and innovation, in manufacturing and beyond. No one in the mainstream however, advocates this. Could it be that most politicians are lawyers, or that the financial industry has too much pull on Parliament Hill? You be the judge. JIM ANDERTON, EDITOR
Canadian publications Mail Sales Product Agreement 40069240 ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.
Do you agree? Let me know, and feel free to drop me a line at the e-mail address below, or buttonhole me at a show or event. I’d love to hear from you! janderton@canadianmetalworking.com
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Inaugural FABTECH Canada a success The inaugural FABTECH Canada, held March 20-22 in Toronto’s Congress Centre, was a resounding success, with attendees viewing 52,000 square feet of floor space with products and services from more than 225 companies from software to saws. The show kicked off with Tuesday’s breakfast keynote speaker, Andrew Comrie-Picard, noted racer and television personality, who spoke about the need to experiment and think “out of the box” for maximum business results. Technical seminars covered advancements in all areas of the fabricating industry from laser welding to brake and punch technology. New products showcased on the floor ranged from major laser and waterjet cutting systems to productivity software to hand tools. Brian Rumsey, Amada software applications support manager said, “It’s been really great. Amada hasn’t been at a Canadian show since 2005, so we came into FABTECH with both feet. The response has been great. I think the FABTECH Show is really going to take off.” A W Miller’s Bill Miller commented from the MAZAK booth: “The show’s been three days of consistent prospects. The fabrication market is alive and strong in Canada. Buyers are concerned about getting maximum use of every hour of the year.” Stefan Schreiber, managing director for Trumpf Canada had a similar experience: “We’re happy and surprised about the attendance. We were busy all three days, including the afternoon of the last day. It was a really good event with quality leads. It was the right decision to join this show.” Pferd’s Canadian general manager, Mark Crump was another exhibitor pleased with the outcome: “It was very worthwhile. We had many leads of decision making quality. We’ve already signed on for the next show.” SME Event manager Janine Saperson, is naturally delighted: “It was better than all expectations. We’ve had nothing but positive feedback and a rebook rate that’s off the charts. There’s great excitement and we can’t wait for the next one.”
8 | APRIL 2012 | www.canadianmetalworking.com
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News Air Canada identifies overhaul companies to replace Aveos work
A
ir Canada has announced its transitional and long-term plans following the closure by Aveos Fleet Performance Inc. of its Canadian-based maintenance, repair and overhaul (MRO) facilities. On a transitional basis, the airline has identified “qualified and government-approved” maintenance facilities in Canada and the U.S. to handle work that was scheduled to be performed by Aveos. The transition to new service providers is already underway: three aircraft scheduled for maintenance this week will go to a Quebec-based maintenance provider currently used by other Canadian and international airlines. In addition, arrangements are being made to complete the maintenance of the three aircraft remaining at Aveos facilities. The airline will continue to source new transitional providers through “industry-standard RFP processes.” “Given the insolvency and unexpected closure of Aveos, we encourage MRO companies from across Canada and around
the world to conduct due diligence and assess which of the former Aveos businesses may be viable in Canada under new ownership,” Alan Butterfield, Air Canada’s vice-president of maintenance and engineering, said in a release. “Air Canada has a strong preference for working with a global MRO which has an interest and ability to provide component, repair and overhaul services in Canada, with particular emphasis given to Montreal, Winnipeg, Vancouver and Toronto,” said Butterfield, who noted that each jurisdiction has a pool of well-trained, qualified and talented skilled workers available for action. Air Canada says it will favour MROs with globally competitive cost structures that have or will establish a portion of their operation in one or more of the cities that Aveos abandoned. Air Canada did not identify how large a commitment to Canadian jurisdictions the winning contract must include.
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News Auto industry subsidies should be contingent on worker pay cuts: IRPP Report
Governments should require competition wages as a condition for subsides and bailouts to the auto sector, according to a new study a study from the Montreal, Que.-based Institute for Research on Public Policy. The Economics of Assisting the Automotive Sector in Canada examines whether auto industry subsidies and bailouts are a cost-effective way of fostering economic development in Canada and the conclusion is that pay concessions by auto-workers would free up a lot of cash and enable the best outcome for the economy. “Despite the relatively minor share of productivity growth that is attributable to labour, workers in the Canadian automotive sector enjoy significantly higher pay than does the average manufacturing worker,” the study explains. “Assembly workers in particular (as opposed to workers in the parts industry) enjoy roughly a $10 hourly premium compared with the average manufacturing wage. Although some of this gap may reflect industry-specific skills, we attribute most of this pay premium to union bargaining power.” Combined, the federal and Ontario provincial governments gave $1.4 billion in subsidies for auto industry projects since 2004. According to the study, it would have been possible to replace the entire value of the subsidies with “relatively modest concessions” in pay, authors Leslie Shiell and Robin Somerville wrote. Pay concessions would not have covered the entire cost of the net cost of $9.5 billion in bailouts handed to General Motors of Canada Ltd., and Chrysler Canada Inc., in 2009, they added. However, $6 billion would have been generated if auto-workers’ wages had been decreased to rates on par with the rest of the manufacturing industry, and would have reduced the burden on government and thus taxpayers — many of whom earn much less than autoworkers — to supply the rest. But overall Shiell and Somerville say the cost of the 2009 bailout was lower than the economic costs that would have resulted without it. If both companies had not been bailed out and closed their
Canadian operations, there would have been immediate losses of about $23 billion in gross domestic product (GDP), with $16 billion being in Ontario. One hundred thousand jobs would have been lost overall, with GM and Chrysler workers accounting for 18,400, while the remaining 81,000 would have been lost elsewhere in the economy. So while the cost was worth it, a better outcome could have been achieved by requiring auto-workers to lose the $10 premium they have over workers in other manufacturing industries. And subsidies are not the most equitable or cost-effective way to attract auto investment to Canada, the authors wrote. However, Jim Stanford of the Canadian Auto Workers says hourly wages of autoworkers in Canada is on par with those in the U.S. and other countries. “The wages are justified because of the worker’s contribution to productivity,” he said. “Trying to cut wages in the name of attracting investment would be self defeating.”
cost method of producing titanium parts for automotive applications through the development of new processes. Replacing steel with titanium alternatives can reduce the weight of a vehicle by 50 percent. Other projects include battery and corrosion research initiatives. Announced by the Government of Canada in April 2009, Automotive Partnership Canada is a five-year, $145-million initiative that supports collaborative R&D and pushes the Canadian automotive industry to greater levels of innovation. As this is an industry-driven initiative, automotive companies provide both financial support and essential in-kind contributions to ensure the research projects’ success. www.apc-pac.ca
January manufacturing sales drop: Stats Can
Digita
Canadian automotive R&D receives $34 million boost
Intended to advance research and development (R&D) in Canada’s automotive industry, six new projects — supported by Automotive Partnership Canada initiative –have been announced at the University of Windsor. These university-industry partnerships will receive approximately $34 million from Automotive Partnership Canada and other industry partners, including Natural Sciences and Engineering Research Council of Canada (NSERC), Canada Foundation for Innovation (CFI), and National Research Council Canada (NRC). The projects include a million-dollar investment to assist in the development of manufacturing processes to produce lighter-weight car parts, headed by Daniel Green, a UWindsor mechanical automotive and materials engineering professor. His project is directed at applying a hybrid electrohydraulic / hydromechanical drawing process to form auto parts — a process that involves discharging a high-voltage current to create a pressure wave in fluid. The wave would then form a sheet metal blank against a die. Dalhousie University received $2.2 million through NSERC to develop a low-
Statistics Canada has reported that manufacturing sales declined 0.9% to $49.6 billion in January, the second decrease in seven months. The decrease partly reflected a drop in production in the aerospace product and parts industry. Lower sales in the primary metals, machinery and other transportation equipment industries also contributed to the overall decline. Excluding the aerospace industry, sales were virtually unchanged from December. Sales decreased in 11 of 21 industries representing approximately 44% of Canadian manufacturing. Sales of durable goods fell 2.4% while those of non-durable goods rose 0.6%. Constant dollar manufacturing sales fell 1.1% in January, reflecting a decrease in the volume of manufactured goods. This was the first decline in constant dollar sales in three months.
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12 | APRIL 2012 | www.canadianmetalworking.com
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News Textron, General Kinetics sign MOU for TAPV project
Dr. Russ King, inservice support program manager of Textron Marine & Land Systems, Charles Williamson, president and CEO of General Kinetics, and Neil Rutter, general manager of Textron Systems Canada, show off the shock absorber that may be used as part of a newly signed memorandum of understanding between the companies at the General Kinetics factory in Brampton, ON. Photo credit: The Canadian Press Images/Salvatore Sacco
T
extron Systems Canada Inc., a Textron Inc. company, has announced that the company has signed a memorandum of understanding (MoU) with General Kinetics for possible work on the Textron Tactical Armoured Patrol Vehicle (TAPV) for the Canadian Forces. Textron has submitted a proposal to supply 500 vehicles to the Canadian Army with an option for up to 100 additional TAPVs, all to be outfitted with shock absorbers designed for military use by General Kinetics, a 100 employee small business in southern Ontario. General Kinetics, for more than 30 years, has designed and manufactured high performance suspension systems and components for the worldwide military vehicle market from its facility in Brampton, Ontario. The Textron TAPV would be equipped with General Kinetics armoured vehicle grade shock absorbers. The MoU represents a substantial opportunity for General Kinetics that would create or maintain employment and have a positive effect on the local economy. “The Government of Canada has stated it wants to procure the best possible equipment for the Canadian Army. We have
engaged great partners like General Kinetics to ensure that the Textron TAPV we propose to deliver will be the best option to protect Canadian soldiers,” said Neil Rutter, general manager of Textron Systems Canada. The Textron TAPV is the most reliable and technologically advanced vehicle of its kind, and it draws on the company’s more than 45 years of experience in the design and production of armoured vehicles. A technology readiness level 8 vehicle, the Textron TAPV will provide the Canadian Forces with the optimal balance of survivability, mobility and versatility, while delivering outstanding performance in the world’s most challenging environments. Extensively tested to confirm ballistic, blast, mobility and reliability levels, the Textron TAPV has been engineered to meet and exceed Canada’s requirements. If awarded the TAPV contact, Textron Systems Canada will become the prime contractor for the program; and through its Industrial and Regional Benefits obligations to Canada, Textron expects to bring new opportunities to other Canadian companies.
14 | APRIL 2012 | www.canadianmetalworking.com
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Floor Space “Have you ever made a major purchase (i.e. a machine tool, cutting tool or something else) for your company over the Internet? If yes, what did you buy?” “Yes. We’ve bought a powdercoating oven and spray booth over the Internet. We’ve bought equipment over the Internet. There is a lot more selection and the pricing is very competitive. For machine tools, however, we need the local support for maintenance and warranty.”
– Renny Husada, vice-president, Yess Products, Surrey, BC
“Over the last year, we have made a couple major purchases over the Internet and other things like custom cutting tools and gauges. The Internet has opened up the opportunity for a small shop to have the kind of resources that a major corporation would have.”
– Chad Plath, shop manager, D-M Precision Products, Dunnville, Ontario
“Like most people, I initially struggled with the thought of making a purchase over the Internet. Sending out my financial information to companies I’ve never heard of or to places I’ve never been was met with a great deal of reluctance. Yet, I find myself becoming more comfortable with it as time goes by. My company started making small purchases several years ago, ordering office supplies, the occasional order of
Feedback: Winnipeg reader Steve Marsden agrees with editor Jim Anderton’s take on the labour shortage from the February “View From the Floor” in Canadian Metalworking: Good morning Jim, I read your article ‘View From the Floor’ this morning from the (February issue-ed) of Canadian Metalworking, and found myself nodding agreement to everything you’ve said. What you’ve articulated is Canadian industry not keeping up with the social changes of Canadian youth. Through my career I’ve seen this with other industries as well. The reason I am sending this email to you is to bring awareness to a local organization here in Manitoba that works to help bridge that gap. I’m sure you will agree, this is not a small gap to bridge either. I invite you to make a quick visit to their website and see for yourself… www.careertrek.ca Darrell Cole is the CEO and founder of the organization. He is a dedicated individual to a mission, and the organization as a whole follows suit. My son was lucky enough to participate in three levels of programming with the organization, which provided the insight he needed to understand himself and figure out what direction he wanted to go with his career. Although you do not know me, trust me, what you will learn about Career Trek will not be a waste of time. Thank you for your time, Jim. Have a great day!
packaging materials, etc. Today, much of what we purchase is done online, from office equipment (like replacement printers, monitors, work stations), right to sandblasting cabinets and powder application equipment for our production in the plant. I find that it’s fast, easy and convenient, and as long as you know who you are dealing with, quite safe.” – Joseph Manzoli, president, Colourfast, Concord, Ontario
“We purchase day-to-day supplies all the time. For major purchases, we find them using the Internet, but purchase them direct.” – Larry Stuyt, president, Ontario Laser Cutting, Tillsonburg, Ontario
“We bought some cutting tools over the Internet, but when it comes to major purchases, we usually do more due diligence on the equipment manufacturer and distributor. After-sale services and support is really important to us and we value the relationship that we have established with distributors and their sales people. Sometimes, a dollar saved is not a dollar earned.” – Marco Gagnon, Gagnon Ornamental Works, Grand Falls, New Brunswick
“Usually, I look at something before I buy it. Especially a machine tool or something. But the day is coming ...” -– Rob Muru, president, A-Line Precision Tool, Toronto
“Answer: not a major piece. Lots of small stuff, up to around $5,000. But I need to talk with a real person and have some real assurances with big purchases.” – Steve Cotton, owner/president, Micro Precision Parts Manufacturing, Vancouver Island, BC
Best Regards, Steve Marsden Inside Sales SYNERGY CONTROLS CORPORATION Jim Anderton replies: Steve, we need more programs like Career Trek, ideally nationally run and Federally-funded. The skilled trades shortage affects multiple industries in Canada….and we need to do our part by creating the kind of growth that makes a career in our sector a life-long one. The recent layoff at Aveos Fleet Performance and the shift of skilled work offshore sends the wrong message. – Jim Anderton
Events: MMTS May 14-16 2012 Place Bonaventure Montreal PQ www.sme.org/mmts/
Mfg4 May 8-10, 2012 Connecticut Convention Centre, Hartford, CT www.mfg4event.com
16 | APRIL 2012 | www.canadianmetalworking.com
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Should I Stay or Should I Go?
New Products Heighten Divide Between Portable and Fixed Position Inspection and Measurement Devices
By Nate Hendley ..................................................................................................................................................
S
hop owners looking to purchase new inspection and measurement devices for quality control purposes are faced with a plethora of choices and one big question: should they buy a portable device such as a measuring arm (compact, flexible and easily transportable) or a stationary device such as a traditional, fixed-position coordinate measuring machine (bulky, immobile and very precise)? Elliott Foster, founder of Canadian Measurement-Metrology, which describes itself as “the largest provider of measuring instruments in Canada” says customers are increasingly embracing portability. “If you’re talking about what are the most popular things [we sell] most of it would be portable metrology ... this could include anything from portable arms, laser trackers and portable scanning devices,” says Foster, whose company is headquartered in Mississauga, ON. In recent years, sales of portable metrology devices have risen from a mere three or four percent of business to 50 to 60 percent, says Foster. Factors goosing sales of portable devices include improved quality and the fact they remain relatively inexpensive compared to CMMs, an important consideration in times of economic turmoil. A used measuring arm at Canadian Measurement-Metrology can be had for $7,000 to $25,000, while used CMMs go for $12,000 to $95,000. New equipment goes for double these rates. In addition to selling equipment, Canadian MeasurementMetrology provides measuring services to manufacturers, machine shops and the like. Five years back, the company did virtually all its measurements on CMMs. Jump forward half-a-decade and the firm finds itself using portable devices for roughly 70 percent of its measuring jobs, says Foster.
Other pundits echo Foster’s opinions. “Certainly there still is a place in the world for fixed CMMs ... but for those times when it’s not practical to move that part to the CMM or you need to do an inspection of machines on the shop floor, portable [is best] ... we do feel like this is the way the wind is blowing these days in terms of metrology and measurement,” says Greg Richards, a public relations supervisor at FARO Technologies, based in Lake Mary, Florida. “Metrology is all about bringing the tool to the job, not taking the job to the device,” adds Foster. “Not so fast”, say CMM proponents. Traditional, fixedposition coordinate measuring machines might be heavy and hard to transport but they offer extremely precise results. “If you’re moving [a measuring device] mechanically by hand, there’s no way it can ever be as accurate as a fixed machine that is using motors,” argues John Lewis, a marketing manager at Carl Zeiss Industrial Metrology of Maple Grove, Minnesota. Even Foster concedes this point, stating, “if we’re talking conventional measurement and precision under 10 microns, then a CMM is king.” Portable CMMs do exist, but they are considered less accurate than their fixed-position counterparts. Fixed CMM’s kept in measurement labs, where temperature and environment are controlled, where dust, grime and dirt from the shop floor kept out are particularly precise, says Lewis. While the initial price tag can be high, fixed-position CMMs are economical in the long run, he insists. Lewis offers a real-life example: say a shop makes 500 identical parts per day and inspects 10 percent of them. Doing such an inspection on an automatic, fixed-position CMM would be a breeze. By contrast, “imagine the cost of having an employee spend
An industry first from VISIONx Inc. VISIONx Inc of Pointe-Claire, Quebec has unveiled a fully automated, part-to-CAD measurement verification system – a metrology industry first. Released in October 2011, VISIONx’s CAD Auto-Align and Auto Pass/Fail software tools are to be used with the company’s VisionGauge Digital Optical Comparator System (patents pending). The Auto Align tool automatically aligns CAD data to a part and produces repeatable and accurate operator independent results. This software program is designed to speed up inspection times and
boost accuracy. The Auto Pass/Fail tool automatically determines in real-time if a part is within tolerance. “We are very excited about the release of these new CAD Auto-Align and Auto Pass-Fail tools to enable the fully automated verification of a part against its CAD data,” said VISIONx president Patrick Beauchemin in a statement. VisionGauge Digital Optical Comparators are distributed throughout North America by Sudbury, MA-based Methods Machine Tools. www.methodsmachine.com
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their entire day measuring parts manually with a mechanical arm,” says Lewis. Lewis and Foster do agree one point: non-contact scanning is gaining in popularity, largely because it’s speedier than contact scanning. “The biggest trend we’ve seen in Canada ... instead of measuring with tactile or a single probe, everyone wants parts scanned ... we’re finding most portable arms are sold with a scanner ... that is total non-contact,” says Foster. As for the future, Foster says, “I see an almost total capitulation of touch on measuring devices ... I think the whole market is going to go to non-contact.” “I think over the next few years we will see an increase in new sensor technologies which allow for faster and more precise measurements. As industries are trying to produce lighter weight components for auto and aerospace industries, new sensors will be developed to deal with the smaller characteristics or lighter forces. Other areas of advancement will be on the software front, where we will see greater capability and more advanced features relating to non-contact systems,” echoes Peter Detmers, a sales manager at Mitutoyo Canada, based in Mississauga, ON. In terms of other scanning technology, expect to see computed tomography (CT) play a more prominent role in metrology. “We’re all familiar with CT in the medical world-for brain scans ... CT is becoming a really big thing for [metrology],” says Lewis. Pundits also predict new metrology devices will become increasingly user-friendly. “More and more metrology functions are being pushed down from the very high level metrologists to the level one operators, the guy on the shop floor who needs to take quick but still accurate measurement,” states Richards. Richards supports the trend towards easy-to-use metrology devices, saying such products will “democratize measurement” and put powerful measurement tools “into the hands of people for everyday use.” Here’s a look at metrology equipment of interest to metalworking shops:
A coordinate measure machine, the Spectrum II unit from Carl Zeiss.
TWO CMMS FROM CARL ZEISS
The Carl Zeiss company has several new offerings of note, including two coordinate measuring machines, the Spectrum II and Micura. “The Spectrum II is an entry-level bridge type machine that measures prismatic parts ... it’s a very affordable machine meant for ‘Mom and Pop’ shops and job shops,” says Lewis.
The Micura unit, a bridge-type CMM. The Micura is ideal for measuring small, intricate parts for optical, electronic, medical, aerospace and telecommunications industries, from Carl Zeiss. www.canadianmetalworking.com | APRIL 2012 | 19
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Priced at $60 to $70,000 with software and accessories, the Spectrum II offers a RDS-C5 articulating probe holder with XDT multi-point sensor or a Renishaw TP20 touch-trigger. It can measure angled features in difficult to reach locations while the articulating probe holder offers plus or minus 180 degrees of bi-directional rotation. The sturdy Spectrum II has a granite machine table and hard-coat aluminum guideway elements which provide hardness and wear resistance, electrical resistance, temperature resistance and a low friction coefficient. The Micura, meanwhile, is a bridge-type CMM with a heftier price tag ($140,000 with all the bells and whistles) that provides sub-micron accuracy. The Micura has a measurement volume of 500 x 500 x 500 mm, 0.9 micron + L/400 accuracy and has a sensor capable of scanning up to 200 points per second. The Micura is ideal for measuring small, intricate parts for optical, electronic, medical, aerospace and telecommunications industries, says its maker. Asked how shop owners can make the most of the Spectrum II or Micura, Lewis says, “It’s all about the software and what you’re able to do with it.” The proprietary software in question is called Calypso and it’s available for both CMMs. This CAD-based software is designed for manual and CNC measurements, is multi-sensor capable and supports all Carl Zeiss sensors.
“Say you’ve got a part you want to measure and you have the CAD drawing of it ... you would load that CAD drawing into our Calypso software and from there, you would then measure on the machine and do your comparisons against that CAD drawing in the callouts,” explains Lewis. www.zeiss.ca
MITUTOYO RELEASES A WORLD’S FIRST
Last year, Mitutoyo introduced the High-Accuracy Digimatic Micrometer (the world’s first 0.1µm hand-held micrometer). This portable device is “very user friendly. Anyone who uses or has used a micrometer can use it with no need for special training,” says Detmers. “We feel the target market is any manufacturer of high accuracy shafts or pins which require high accuracy measurement capability. We also see a very good potential for gauge control or gauge calibration departments who wish to perform their own calibration on pin gauges or plug gauges,” he continues. The High-Accuracy Digimatic Micrometer “utilizes Mitutoyo’s innovative 0.1µm resolution ABS (Absolute) rotary sensor and high-accuracy screw machining technology to reduce the instrumental error to plus or minus 0.5 µm ... with no overspeed errors, the High-Accuracy Digimatic Micrometer (available with 0 - 1 inch/0-25 mm measuring range) delivers a higher level of
“Suppliers that have proven over the longer term to be the most profitable are those that adapt systems and technologies that allow them to be more efficient overall.”
– Steve Rodgers, president, Automotive Parts Manufacturers’ Association
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/
The moment a measuring instrument simplifies more than just your measurements. This is the moment we work for.
// CONTURA G2 MAde By CARl Zeiss
Getting a lot of data from a CMM is one thing. Trusting in the technology to gather the right information and help make sense of it is another. Maybe that’s why so many manufacturers have our systems, sensors and metrology software as a critical part of their production process. www.elliottmachinery.com (905) 829-1188
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reliability and offers several features to enable flexible measurement, including switchable resolution (.00005 inch/.00002 inch, 0.0001 mm/0.0005 mm), function lock and preset,” explains the company. This micrometer also comes with a highly-rigid frame to enable stable measurement and a removable heat shield to minimize the impact of body heat when making measurements by hand. www.mitutoyo.com
GEORGE PRODUCTS COMPANY REFINES THE OASIS
2012 has already been a busy year for George Products Company of Middletown, DE, with two big announcements. Since the New Year, George Products Company has upgraded its OASIS line of fast, full-featured, non-contact vision inspection machines and introduced a newcomer to the OASIS family called the CoreX2. The OASIS line consists of portable metrology devices that can measure multiple part dimensions simultaneously to an accuracy of plus or minus 0.0001 inches. The system works with a shadow (profile view) of the part and takes measurements COREX2 sample part status bar. at the rate of 10-times
precise rays through a series of specially designed diffusers and lenses that shine across the part to be inspected. That image is then captured by a very specific telecentric optical lens, which results in a perfect monochrome profile of the inspected part. The part profile is then digitally captured with a specifically designed camera system and transferred to the custom onboard computer where the software does the rest,” explains Palmer. George Products claim the OASIS line is “the industry’s fastest inspection system” and that’s no empty boast: “What would take a QC inspector five to six minutes to do using conventional methods, OASIS can do in five or six seconds,” says Palmer. The new Core X2, meanwhile, offers a field of view of 3.4 inches x 2.8 inches which means users can measure parts up to 33⁄8 inches in length and 23⁄4 inches in diameter, with an accuracy of plus or minus 0.0002 inches. Working again with a shadow, measurements can be taken on the Core X2 at a rate of six times per second. www.georgeproducts.com
FARO GETS EDGY
COREX2 unit.
per second. For the recent upgrade, George Products added a Manual Rotary Stage to the line so parts can be rotated 360-degrees for more complete measurements. “The target end-user for OASIS COREX2 sample part. are Swiss machine shops, screw makers and in general, manufacturers of parts 6.5 inches and under for their inspections, be it first-article, in-process or final. OASIS can be used directly on a shop floor or in a QC (Quality Control) lab. Our customers come from a variety of industries including, but not limited to aerospace, automotive, defence, fasteners and medical implants and devices,” says Jeff Palmer, a sales manager at George Products Company. “OASIS devices utilize an LED light source to collimate
FARO proudly describes the Edge as “the world’s most innovative measuring arm”. Released last year, the Edge is a good fit for machine shops, given that it’s portable, accurate and easy to master, says Richards. “For a metalworking facility ... to really ensure the quality of parts and compare them, the Edge arm is the ideal solution. It has touch screen indicator lights, simple quick measurement buttons ... it’s a lot like using a smart phone. We’ve made it really simple to use,” he states. The new Edge measuring arm has enhanced connectivity (Bluetooth, WiFi, USB and Ethernet-ready), smart sensor technology (improved sensors offer warnings when external loads are too excessive, correct for thermal variation and even detect potential setup problems) and a built-in touch screen. Shops can use the Edge to verify product quality through inspections, tool certifications, CAD-to-part analysis and reverse engineering via hard probing and non-contact laser scanning. A Laser Line Probe can be added to the arm, increasing scan coverage without impacting accuracy while variable capture rates can produce more than 45,000 points per second. http://www.faro.com CM
22 | APRIL 2012 | www.canadianmetalworking.com
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The Monolith
Monolith Precision Machining moves to waterjet cutting for prescision and productivity
By Nestor Gula . ...................................................................................................................................................
I
was reminded of the U2 song, “Where the streets have no name” as I drove from Toronto to Milton to visit Monolith Precision Machining Inc. The owner’s words rang in my memory, “Just follow the directions I give you, our street is new and it’s not on GPS yet.” The area of Milton where Monolith is located is in the midst of a mini building boom where new industrial subdivisions are everywhere. The street does not appear on GPS. Not on Google Maps. Nor on MapQuest. The Canadian Post office did not have a listing for it on their website before I ventured out to this city west of Toronto. But the street did have a name.
Although not a large company, the presence of Monolith in Ontario’s economy signals that the manufacturing sector is not in a death spiral. There have been some tough times but with hard work, innovation, a skilled workforce and management, business can succeed on a world scale. Monolith’s owner, Vojislav Tasic, was a trained as a machinist in his native Serbia. He came to Canada 22 years ago as a young man of 25 with a good base of machining knowledge gained and several years of work experience. Like many immigrants, he went to work immediately, working as a machinist for various companies in Toronto. He eventually
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Vojislav Tasic with his Maxiem 2040
th and a waterjet started running a small machining company due to the owner’s illness. “I was running everything, ordering materials, doing all sorts of stuff,” he said. “After three and a half years I had enough.” A hobby of his was the spark for him to start Monolith. “I’m a diver, and I machine my own equipment,” said Tasic. “A fellow diver, Rob Gillis, asked me if I can make some alignment tools for his company and I made these tools for him. And he suggested that I start a business making things for them. So that is how I started.” While working for other companies as a machinist, Tasic started making small equipment for different customers working on the side. “I was working in two jobs. The nightshift as a machinist in a company and during the day I was running my own business. It sounds strange now,” he exclaims. At that
time his shop was located on Torbram Avenue in Mississauga, Ontario. He moved the shop several times and then finally three years ago, moved to Milton. The name “Monolith” comes from the 1968 film 2001: A Space Odyssey. “I am a science fiction freak,” admits the 48 year-old Tasic. When he needed a name for his company he thought of the monolith in the film. “It was perfectly flat. All the angles were perfect. The dimensions were perfect,’” he reminisces. “What a better name for a machining company than having it named after something so perfectly made.” The company employs five workers, mostly on contract. He said that it fluctuates as work orders increase. Tasic says that the key to his success now, is his purchase of the Maxiem 2040 Waterjet. This abrasive jet system can cut all types of materials accurately, quickly and dependably.
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This waterjet is about one year old and he proudly states would be moving and there was a lot of scrap involved.” Tasic that it has already more than paid for itself. and Monolith had enough of shipping out parts to subconThe road to acquiring this Maxiem was long and fraught tractors and acquired a water jet. with errors. “Before we used to cut with a laser cutter,” he said. “Maxiem might be the introductory line for the OMAX When he started Monolith he subcontracted the cutting to a water jet range but we can still do plus, minus one-thousandth different company. “Because of the temperatures involved we of an inch. This is amazing,” exclaims Tasic. He has high had quality issues. The metal would expand a lot. If you are praise for the machine. “Omax is one of the really rare cutting 140 inches long then you have an expansion of about American companies which gives you a product that is really 3/8ths of an inch when using a laser,” he explains. “If you are precise and will last for a long time. With this machine you putting holes in the barely have to do any metal as well, you are I’m a diver, and I machine my own equipment, said Tasic. maintenance on it. You way out of tolerance.” can run the water and Tasic said that since sand and cut forever. A fellow diver, Rob Gillis, asked me if I can make some the parts for laser maintenance alignment tools for his company and I made these tools for Regular cutting were shipped for the pump comes him. And he suggested that I start a business making things at 500 hours, until out, on occasion they would come back then, you don’t have for them. So that is how I started. with major defects: to touch the machine “The parts would be at all. Other things you scrapped. They were need to change are the not usable,” he said. “You had to cut first, let it cool down and nozzles at about 100 hours, but these are regular items. The then you could drill holes.” machine is designed so simply and works so well.” After working through a lot of quality control issues, he Tasic praises it for its efficiency. “This waterjet is cleaner decided to employ a water jet. Water jet cutting was specified and does not produce lots of debris (sand) on the shop floor. on some of the contracts he has bidding for at that time. The shop is clean,” he said. He trusts the machine completely “With the water jet there is no pressure involved. The water is and can let it run on its own. cold and there is no heat in the environment,” he said. Tasic has a camera that monitors the machine as it runs, so Monolith, at first, would send parts to have them cut by he can do other work in the office, while it cuts. “You can have water jet but, “there were lots of mistakes,” said Tasic. “Not the machine running and do other jobs,” he said. “This water just in the cutting, but in the programming and the lack of jet lets me do that. The other machines don’t even come close.” knowledge of clamping parts on the machines. The parts He explains that even having a great water jet like the
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Maxiem 2040 is not enough in the manufacturing sector these days. “Some people, even with the good machines, cannot give you a good product. Because they do not know how to run the machine,” Tasic notes pointing out the problems he had when contracting out. “Most people do not know how to run the machine. When you do the first cut you have to stop and measure and make adjustments as needed. Some people they will just push the button and cut. What comes out, comes out. Besides having a good machine you have to have the knowledge of how to use it. You have to have an understanding of the materials. The German industry is known for being the best, not because they have the best machines. They are the best in the world for only one reason, the technology of how they develop materials – nobody can touch them. Nobody in the world has what they have.” CM
For more on waterjet technology, check out the May issue of Canadian Metalworking
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First to Fiber Fiber lasers are a relatively new technology which has rapidly carved a major share of the market for high-speed sheet metal processing By Ricky Hansson, VP Applications & Project Management, Salvagnini America, Inc. . ..................................................
I
n the winter of 2007 to 2008, Salvagnini began investigating the potential of applying fiber laser technology to cutting sheet metal. The company, like many others, had been heavily invested in the manufacture and marketing of CO2 laser cutting machines, but management recognized that as a product category, CO2 lasers were approaching the mature product stage, with any advances in technology being few in number and incremental in nature. In fact, much of the company’s success in laser sales stemmed as much from its expertise in automating the laser cutting process with products like its parts picker/sorter/stacker — the industry’s first — as it did for the laser itself. Salvagnini thought the market wanted something new, something better, and the more the company’s R&D team members dug into the Fiber Project, the more excited they became. Initial research using an IPG Photonic fiber laser demonstrated unprecedented speeds when cutting thinner materials, and at least comparable speeds when cutting thicker materials. CO2 lasers continued to perform best on the thickest materials, but for the bulk of the sheet metal fabrication market, fiber
laser technology seemed to be well suited. In addition to speed, the cost of operation was as much as five times lower than CO2 lasers, which meant the payback time was reduced and ROI would be greater for owners of fiber laser cutters. When the initial studies were complete, the future was clear — Salvagnini would go with fiber lasers.
THE WORLD’S FIRST FIBER LASER CUTTER
During the first part of 2008, company engineers designed and assembled the company’s first fiber laser cutter using an IPG fiber laser source based on the architecture of its L1 CO2 laser system. The result was a machine that required no warm-up, no laser gases, no mirror realignments, but owing to its 1µm wavelength, it was capable of cutting highly reflective materials such as copper, brass, aluminum, and galvanized steel. With test results in hand that proved a 2kW fiber laser could outperform a 4kW CO2 laser in almost every category, the designers and engineers set about building a commercial fiber laser cutter. The L1Xe fiber laser was introduced to the world at
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“Management recognized that as a product category, CO2 lasers were approaching the mature product stage, with any advances in technology being few in number and incremental in nature.” EuroBech in October 2008 and to the US market at FabTech 2009. Salvagnini shipped its first fiber laser cutter in March 2009 and over the course of the following 2½ years has created a base of over 130 installed machines around the world. In 2010, the company introduced a second generation of laser systems at 2 and 3kW that were not based on an earlier CO2 chassis, but one designed to accommodate the specifics and take full advantage of the technology.
THE 70% SOLUTION
Ever since lasers were introduced for cutting sheet metal, CO2 lasers have occupied the lion’s share of the market. However, fiber lasers have captured an increasingly large share of new sales. The simplicity of a fiber laser versus a CO2 laser can be seen with the naked eye; the machine footprint of a fiber laser is smaller. The laser source and chiller are smaller. Laser gas lines have disappeared, and there are no mirrors to align. And yet a 2 kW or 3 kW fiber laser source can do the same amount of work as a 4 kW or 6 kW CO2 laser, and do it faster with less energy consumption and with less environmental impact. The key lies with the laser source. A CO2 laser source requires a lot of power to excite N2 molecules in order to create collisions with CO2 molecules (the laser gas), causing them to emit photons which are ultimately focused to form a laser beam capable of cutting through metal. Stimulating molecules in the resonator releases heat as well as light, which requires a chiller to cool off the laser gases. That means more power is consumed in the cooling process and a further reduction in efficiency. Fiber lasers, on the other hand, employ solid-state diodes to pump molecules that are captured in an optical active double clad fiber with an ytterbium-doped core. The pumped light excites the core and the light exits the module via a transport optical fiber that carries the beam to the focusing
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head where cutting takes place. The need for laser gas is eliminated as all collisions between molecules take place within the optical fiber, which in turn requires far less energy — about one-third that of a comparable CO2 laser. And because less heat is generated, the size of the chiller is proportionally reduced. In general, overall energy consumption is 70% less than a CO2 laser performing the same task.
WHERE DO FIBER LASERS FIT INTO A MODERN SHOP?
Fiber lasers are very versatile, efficient machine tools that shops of all sizes and levels of sophistication are finding to be one of their most valuable assets. For those cutting a variety of materials and thicknesses, Salvagnini L3 and L5 machines are
capable of cutting steel up to 0.70 inches thick, stainless up to 0.394”, aluminum to 0.315”, and copper and brass to 0.197” with no lens change. For those companies that value speed, fiber lasers have no equal at thicknesses higher than 7 to 12 gauge. For example, On 20 to 22 gauge mild steel, the fiber laser travels twice as fast as a CO2 laser, and with the L5’s patented Compass focusing head positioner, it functions with a high degree of quiet and smoothness. For materials thicker than 7 to 12 gauge, the speed advantage begins to dissipate until the cutting speed becomes comparable to that of a CO2 machine, although the fiber laser still maintains operating cost savings. Speed and versatility are vital in a manufacturing
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“Fiber lasers, on the other hand,
employ solid-state diodes to pump molecules that are captured in an optical active double clad fiber with an ytterbium-doped core.” environment because work-in-process adds cost to the final product. But there are other costs that factor into the profitability equation. For example, total operating costs for a Salvagnini fiber laser cutter are about 56 cents an hour compared to $3.19 an hour for a typical CO2 laser. What’s more, with no mirrors to keep in alignment, no blowers to replace, no resonators to tune, and no laser gas to replace, maintenance costs are negligible or non-existent. And with a laser source that is predicted to last 100,000 hours — 5 times longer than a CO2 resonator — both replacement costs and the cost of downtime are eliminated. All things considered, a fiber laser can cut twice as fast at one-sixth the cost, with a typical payback period that is only 70% of that of a CO2 laser. Last, but not least, part quality benefits from a very stable beam platform that remains constant and maintains cut quality, even if there is variation in the distance between the nozzle and the sheet being cut, owing to any unevenness in the surface of the metal. And because of the fiber laser’s small spot size and
narrow kerf width, high speed cutting is achieved without sacrificing high cut quality. That means reduced scrap and superior quality finished parts. In 2008, very few companies saw the potential of fiber laser cutting (or were unwilling to admit it), but since then most major systems manufacturers have developed some form of fiber laser cutter. But as history reminds us, technology never stands still. Solid-state diode sources are scalable, and power packages as massive as 50 kW have already been assembled for other applications, although that would obviously be overkill for sheet metal cutting. So power is not a problem. Others are working on improved optics that will enable the cutting of greater thicknesses. Until recently, cutting through film has been difficult, but the solution to that problem has been proposed, and success is imminent. As improvements are implemented and capacity is increased, it becomes only a matter of time until fiber lasers may challenge CO2 lasers in annual sales. www.salvagnini.com CM
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The Cutting Edge New and Noteworthy in Cutting Tool Inserts By Nate Hendley ..................................................................................................................................................
Sandvik Coromant’s new Spectrum range of turning inserts
C
ontrolling chips, combating “bird nests” and multiple corners are top-of-mind among industry experts looking at cutting tool inserts. “As the manufacturing sector continues to recover, machine shops are focused quite intently on the value that their tooling brings to operations. For inserts, this translates into a greater willingness to try new products than has been the case over the last several years. And this willingness to try new products has been matched by a greater willingness to adopt those that cut costs, especially when the new technology improves cycle time along with increased tool life. Chip control has become a more important factor in insert decisions. There is much less tolerance for uncontrolled chips that create difficulties for the operator and lead to safety issues,” says Kurt Ludeking, product manager, turning, for Walter USA, the Waukesha, Wisconsinbased branch of German giant, Walter AG. “Many shops are also taking on work in alloys that they have less experience with: higher strength steels, corrosion resistant and high temperature alloys. In order to handle the wider range of materials, customers are looking for products that can handle
a wider variety of materials and machining conditions,” adds Ludeking. Pundits were also quizzed on trends in the cutting tool insert sector. “The industry trend that will dominate the cutting tool segment will be multiple corners on an insert. Traditionally, to enjoy the economy of an eight sided insert on a square geometry required a “negative” insert. A negative insert, while providing additional rigidity and corner strength would draw excessive amounts of horse power. Negative geometries would put excess pressure into the part and not always allow for a good surface finish. As CNC machines became lighter and faster, the industry moved to “positive” geometry, which meant that same square insert would only have four corner edges. However it drew much less horsepower and enabled lighter CNC machines to produce quality parts,” says John Mitchell, general manager with Tungaloy America, the Arlington Heights, Illinois-based division of a Japanese parent company. Bill Alexander, senior product manager for Kennametal’s Global Turning Team in Latrobe, Pennsylvania, identifies
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“productivity” as the dominant trend in the sector. “Greater performance that either increases production efficiencies, extends tool life, or a combination of the two, holds the key to realizing improved economies for manufacturers. Greater performance is achieved in a variety of ways—stronger substrates, new geometries, advanced coating technologies, and new post-coat treatments. Such advances are not a case of technology for technology’s sake. [Rather] they are carefully engineered and tested to deliver value, whether measured in delivering parts faster or producing more parts per cutting edge,” states Alexander. “I feel that in 2012 there will continue to be a big focus in the industry on cost reduction through productivity gains ... cycle
time reduction through increased cutting data will be a big push for customers looking to reduce machining time, overhead and overall costs of production,” echoes David Andrews, product and application specialist for turning products with Sandvik Coromant Canada, based in Mississauga, ON. Here’s a look at what’s new and/or noteworthy when it comes to cutting tool inserts:
WALTER- A NEW BENCHMARK PRODUCT?
Does Walter’s line of Tiger-tec Silver inserts have “all the characteristics of a benchmark product,” as the company immodestly claims? Time will tell for this indexable insert range, which can boost the productivity of steel turning applications by 75 percent, according to its maker. “The Tiger-tec Silver advantage begins with a newly formulated aluminum oxide coating with an optimized microstructure that delivers superior resistance to crater wear and flank wear as well as to plastic deformation, considerably reducing
IRONICALLY, REDUCING CHATTER GIVES US A LOT TO TALK ABOUT. We’ve evolved from a tool supplier to a provider of cutting tool solutions, and our tools have evolved a long way too. Our patented geometry and specialty tool coatings for high performance applications help suppress chatter, promote longer tool life and ultimately improve your bottom line. Now that’s really something to talk about.
www.sgstool.com 330-686-5700 Manufactured in the USA
machining times. A new coating posttreatment boosts coating toughness and ensures higher process reliability in mass production. The inserts also feature a new silver flank face for easier wear detection. In addition, the insert seating surface is ground after coating to ensure optimum seating in the toolholder,” says Ludeking. Tiger-tec Silver inserts boast extremely stable cutting edges for a high degree of process reliability and smooth rake face for excellent tribo-chemical wear resistance. These inserts can be used for dry and wet machining in automotive engineering and railway vehicle manufacturing, power engineering, toolmaking, aerospace engineering, etc. www.walter-tools.com
SANDVIK COROMANT – TURN, TURN, TURN
Swedish tooling giant could have been designed with the adage “keep it simple” in mind. “The new Spectrum turning range provides customers a simplified choice of inserts designed to efficiently machine different materials under various cutting conditions. So whether external or internal machining, rough turning or finishing, machining continuously or with interrupted
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cuts, these inserts have been designed to be as versatile as possible, yet deliver high performance output in terms of reliability, tool life and chip control,” explains Andrews. “The new Spectrum turning line can offer customers a two pronged approach to cost savings: we can help them to reduce insert inventory through a simplified choice of inserts and we can also deliver high performance in terms of cutting data and productivity. Those customers after the highest possible productivity can continue to utilize our proven material specific grade and geometry combinations,” he continues. Spectrum turning inserts can be used in turning operations with steel, stainless steel, HRSA, cast iron, titanium and nonferrous materials. Within the Spectrum range, the GC15 grade blends high strength micro-grain cemented carbide with a thin, PVD coating to add strength and wear resistance while the GC30 grade has high bulk toughness with a gradient cemented carbide substrate and a highly wear and heat resistant CVD coating. www.sandvik.coromant.com
Kennametal PCBN inserts with chip breakers also boast PVD (physical vapour deposition) coating and new braze technology for boosted braze joint strength.
KENNAMETAL – A HARD TURN
Kennametal believes that hard turning, which the company defines as “the use of high-hardness polycrystalline cubic boron nitride (PCBN) inserts for machining hardened ferrous or super alloy materials” is going to become increasingly popular in manufacturing circles. For machining bearings, CV joints, transmission components and other parts, hard turning can eliminate grinding, which in turn lowers manufacturing costs and speeds output. Problem is, in continuous-cut operations chip control becomes an issue. Hard inserts produce chip ribbons which
can turn into “bird nests”—a colourful term for a mess that can damage a part’s surface finish and slow down the machining process. Fear not, says Kennametal—the company has integrated chip-breaking geometries into two of their hardest PCBN grades, KB5610 and KB5625. Kennametal PCBN inserts with chip breakers also boast PVD (physical vapour deposition) coating and new braze technology for boosted braze joint strength. Grades KCU10 and KCU25 in Kennametal’s new “Beyond” line also have PVD coating, to improve machining performance with
THE CUTTING EDGE We use Premium Micro grain solid carbide for longer tool life and increased feeds and speeds. Tools are stocked uncoated and ALTiN coated. Designs for threading, grooving, PCD, and CBN-tipped inserts
Solid carbide grooving, boring and threading tools.
Set includes boring bar, 5 inserts, 5 screws, and a torx plus key
Threadmills
Available in coated AlTiN or uncoated sub micrograin carbide
Port tools
Hardened steel head features proprietary mechanical attachment... no annealing from brazing heat Pocket keeps chips away from machined surface Fits into SCI standard QHC coolant tool holders Inserts lapped and ground to fine finish for maximum chip flow Available in right-hand and left-hand versions Bars stocked with or without locating flat... Low profile screw keeps chips flowing
SCIENTIFIC CUTTING TOOLS, INC. 110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com www.canadianmetalworking.com | APRIL 2012 | 35
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high temperature materials. KCU10 offers a material removal rate (MRR) of up to 20 percent, plus notable abrasion and crater-wear resistance for high-speed machining of steels and cast irons. KCU25, meanwhile, also offers a 20 percent or higher MRR, plus 30 percent extended tool life and a high degree of reliability in steels, stainless steels and cast irons. www.kennametal.com
GROOVING, PARTING AND TURNING WITH 4 CUTTING EDGES WITH CHIP FORMER
Ingersoll has introduced Gold-Flex, a new product line that features a 4-edged insert for multifunctional operations. Suitable for grooving, parting, lateral turning and chamfer machining, Gold-Flex provides “excellent performance, repeatability and economy” according to the company. Gold-Flex inserts feature a high-positive chip former that enables machining in multiple applications while providing excellent chip control in plunging and lateral turning operations. This improves surface finish as the chips are broken and moved away from the work piece. The clamping system features a side Torx screw and 3 contact points for stability and durability; insert indexing and changing is simple and accurate. The clamping design also protects the cutting edges that are not in use. If one or more of the edges are broken, the insert can simply be indexed to a new edge without adversely affecting the insert seating position. Gold-Flex is available in widths from .020” to .125” (.5mm 3.18mm). Lead angles and full radius inserts are also available as standard items. All inserts are available in grade TT9080, a versatile grade suitable for machining a wide variety of materials.
NEW GENERATION INSERT-TYPE THREAD MILLING
Over the last 15-20 years, two threading methods have been primarily used on cnc machining centers to produce internal threads 1.00 or M24 and above. The most widely used has been machine cutting taps made of high speed steel, and secondly, thread milling cutters with pitch specific multi-tooth carbide inserts. Each threading method offered its own benefits, but both were also subject to causing frequent problems in the areas of thread quality, high operating costs, and scraped parts. To address
the shortcomings of these traditional threading methods and maximize the advancements made in cnc machine tools, a new generation of insert type thread milling technology was developed by Emuge Corp. for 8 UN and API ¾ inch-per-ft. taper thread forms to revolutionize the production of large threads. This new family of indexable insert thread milling cutters was developed to economically and efficiently produce large and deep threads on modern cnc machines. The program is designed in five different bar sizes, with the target of achieving the best possible stability of the tools and, consequently, trouble-free thread production. This aim is achieved by a choice of different cutter diameters, number of inserts and bar lengths. Advanced partial-profile insert technology further enhances the versatility, security, and economy of the system. With only 2 inserts per bar size, multiple thread diameters and pitches of UN, UNC, UNF, UNEF, UNJF, M , MF, and MJ can be produced. The insert is made of submicron carbide, precision ground with advanced cutting geometry, and PVD coated for long tool life. Additionally, each insert has 4 useable cutting edges and fast edge indexing can be easily accomplished at the machine. When compared to full form multi-tooth inserts, up to 4x more tool life can be realized. The performance of the system is further enhanced with internal coolant supply exiting radially at the insert cutting edge optimizing cooling, chip evacuation and thread surface finish.
NEW TURNING GRADE FROM ISCAR
ISCAR is introducing the IC806 - a new complementary SUMO TEC PVD coated grade for machining high temperature alloys, especially Inconel 718. This material is widely used in the aerospace industry for components which are placed in the hot section of the engine; and in additional sectors of the oil industry. The major problems encountered when machining Inconel 718 are characterized by very high temperatures on the cutting edge of the insert due to the abrasive elements in the material composition (high nickel content of 50-55% and chrome 17-21%) which causes high wear rates, chipping, notching and insert breakage. These factors contribute to reduced tool life and high deformation of the cutting edge even at low cutting speeds. ISCAR’s aim is to effectively machine this unique material, and has therefore successfully developed the IC806, which is a submicron grade with superior wear resistant properties and advanced PVD TiAlN. IC806 has a hard submicron substrate with PVD coaing and a special post coating treatment which provides substantially improved tool life and better reliability. CM
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Fully
integrated performance
NEW
Tiger·tec® Silver ISO P Generation: By combining new grades and new geometries, Walter Valenite has created a new generation of steel turning inserts. We paired our unique Tiger·tec® Silver CVD coating with a newly developed universal geometry range for turning steel. That’s what we call pure performance – fully integrated into the processes of our customers.
Remarkable increase in performance: Competition Tiger·tec® Silver WPP10S
+ 75 %
See the product video: Scan the QR code or go to http://goo.gl/frwc2
WALTER NORTH AMERICA Walter USA, LLC N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.us@walter-tools.com
Walter Canada N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.ca@walter-tools.com
Walter Tools S.A. de C.V. Boulevard Louis Donaldo Colosio 2255 2do Piso, Colonia San Patricio 25204 Saltillo, Coahuila, Mexico +52 (844) 450-3500 service.mx@walter-tools.com
www.walter-tools.com/us
www.youtube.com/waltertools
www.facebook.com/waltertools
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Turning down the risk Wet turning delivers high productivity and quality…but workers need to avoid metalworking fluids as much as possible By Jim Anderton, Editor .........................................................................................................................................
L
et’s face it: nobody likes cutting metal with coolant. Turning with cutting fluids is at best a mess and at worst, a significant health and environmental issue. At modern feeds and speeds, however, cooling the tool/part interface is essential to keep the tool alive and maintain productivity. Fluid cooling is the original high production technique, but the fluids have undergone intensive scrutiny from a health and safety standpoint. The Canadian Centre for Occupational Health and Safety maintains a website with extensive information about metalworking fluids and their health effects. The potential for toxicity doesn’t end there. When stored, nitrosamines (90 percent of which are carcinogens) can form while the fluid is stored for long periods of time. Nitrosamines form slowly in the water-based fluids and may be the result of
interaction of nitrites in the fluid, lining of the cans used for storage, or from nitrogen oxides in air. Recycling of fluids can increase the problem if more reactants are added. When water based formulas are used, a primary concern is the presence of contaminants that encourage the growth of bacteria and fungi. The bacteria can degrade the emulsions that keep the lubricant and additive package in suspension in the water carrier, degrading the properties of the fluid. While biocides are added to reduce the amount of microbial growth, the biocide products themselves have hazardous properties. Other sources of contamination include “tramp” oils (oils used by equipment, including hydraulic oil, gear box oil, and grease). Tramp oils that leak into the metalworking fluids can also contribute to microbial growth. Even if the fluids can be kept microbe-free without
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Through-tool cooling, like this Sandvik Coromant setup, is not only more effective, it lessens worker exposure to fluids
excessively toxic biocides, they are also contaminated by fines, chips or swarf that the fluid is intended to flush from the tool-work interface during machining. While ferrous materials like carbon steel have low toxicity, alloys containing nickel, cobalt and chromium are a known hazard. Without lab analysis, it’s impossible to determine the metal loading fraction. Many shops assume that water-based fluids are a disposal non-issue, but fines that stay in suspension could render the fluid toxic waste, making fine filtration a worthwhile investment. The fluid can also chemically change due to temperature rise in the cut, although studies have not clearly defined the issue: there is the potential for straight oils to be heated during use to a temperature high enough to cause the formation of polynuclear hydrocarbons (or polyaromatic hydrocarbons, PAHs), known and dangerous carcinogens. Another source of uncontrolled chemical changes to the fluid is contamination. Water, cleaning products used for routine housekeeping, or improper recycling of materials (or the addition of unspecified fluids such as old lubricating oils) to the fluid will also change its composition.
HOW DO METALWORKING FLUIDS ENTER THE BODY?
Metalworking fluids can enter the body when the mist, aerosol, or vapour is inhaled. Exposure will depend on what kind of turning is being done, how the fluid is applied (e.g., manually with an oil can; flooded through a hose or pipe, or mist-sprayed where the tool contacts the work piece), and the extent of machine enclosure and ventilation. Higher exposures happen when the operator works close to the machine, the operations involve high-speed tools or deep
cuts, enclosure is poor or non-existent and ventilation is inadequate. Ingestion is possible when operators eat, drink or smoke at the workstation or without washing hands first. The most common route is through contact with the skin, especially if there are cuts, rashes, abrasions or other breaks in the skin common in shop environments. Hands and arms are most at risk if adequate precautions are not taken. Fluids can splash onto the skin during machining, and can also occur when preparing or draining the fluids, handling work pieces, changing or setting tools, and during maintenance or cleaning operations. Rags or clothes soaked with fluids that are in constant contact with the skin are also a source.
HEALTH ISSUES
While worst-case scenarios involving cancers are dire, the most common consequences of exposure are skin irritation and respiratory issues. Contact dermatitis is the most common skin condition reported which can result in burning, itching, and blistery skin while breathing in the mists may cause asthma and lung irritation (hypersensitivity pneumonitis), chronic bronchitis, and impaired lung function. There is also evidence that some metal working fluids are associated with an increase risk of certain cancers such as larynx, rectum, pancreas, skin, scrotum, and bladder, but the good news is the time between exposure and the development of the disease is often more than 20 years. Today’s fluids and turning operations are significantly safer than those used in the ‘80’s, and most of this risk is thought to be from fluids used in the mid 1970s or earlier. In general, the type and
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BASIC FLUID TYPES: Straight Oil: Also called “cutting” or “neat” oils. This type is made up of petroleum, animal, marine, vegetable or synthetic oils. Today, the mineral oils are “severely solvent refined” or “severely hydro treated”. These terms refer to refining processes that help reduce the amount of polynuclear aromatic hydrocarbons (PAHs). Straight oils are not diluted with water but other additives may be present. Soluble Oil: This category contains 30 to 85 percent severely refined petroleum oils, as well as emulsifiers to disperse the oil in water. Semi-synthetic fluids contain 5 to 30 percent severely refined petroleum oils, 30 to 50 percent water and a number of additives. Synthetic fluids do not contain petroleum oils. Instead, they use detergent-like components and other additives to help “wet” the work piece. There are three primary reasons to flood or spray the tool while turning: Lubrication, cooling and chip removal. At low feeds and speeds, ambient air is sufficient, but high productivity turning requires fluids that can withstand extreme pressures and temperatures, requiring a wide variety of chemical additives to improve performance and extend fluid life.
Toolroom and maintenance operations often neglect lathe safety. The back shield contains coolant spatter, but the swarf and fines will keep the bed wet and exposure to fluids likely.
severity of the health problem depends on the fluid formulation, contamination and how long the worker is exposed to the fluid.
EXPOSURE CONTROL: MACHINE OR WORKER?
While controlling exposure to cutting fluids by engineering the supply system at the machine is the best solution, where contact or ingestion is still probable, the next line of defense is personal protective clothing.
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IN
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The other health and safety approach besides exposure control is to choose coolants with lower toxicity. This Henkel Multan fluid inhibits bacterial growth but uses no bactericides
While it’s a given that employers should provide and require protective wear in areas of potential exposure to known hazards, metalworking fluids are rarely thought of in the same class as solvents, acids or alkalis. Hands are a special problem in turning and milling operations. Gloves can create a significant entanglement hazard if used around spinning tools and workpieces, leaving barrier creams as the only safe option, and creams are never 100 percent effective. Similarly, eyewear that’s chemical-resistant plus impact proof is rarely practical. Aerosols are a special problem. According to the Canadian Centre for Occupational Health and Safety, respiratory protection that is classified
ADDITIVES MAKE FLUID FORMULAS COMPLEX Even simple water-soluble or mineral oil formulations can contain multiple compounds of varying toxicity: Á sulfurized or chlorinated compounds, Á corrosion inhibitors (e.g., calcium sulfonate, sodium sulfonates, fatty acid soaps, amines, boric acid), Á extreme pressure additives (e.g., sulfurized fatty materials, chlorinated paraffins, phosphorus derivatives), Á anti-mist agents (e.g., polyisobutylene polymer) Á emulsifiers (e.g., triethanolamine, sodium petroleum sulphonates, salts of fatty acids and non-ionic surfactants), Á alkanolamines, Á biocides (e.g., triazine compounds, oxazolidine compounds), Á stabilizers, Á dispersants, Á defoamers, Á colourants or dyes Á deodourants, and/or fragrances
as “resistant to oil” (class R) or oil proof (class P) should be selected where appropriate. Depending on the level of airborne contaminants, the correct level of protection is an air-purifying, half mask respirator (with HEPA filter) including disposable (P- or R-series) (for oil mists less than 50 mg/m3), or any powered, air-purifying respirator equipped with hood or helmet and HEPA filter (for oil mists less than 125 mg/m3). The cost, complexity and bookkeeping needed to run a safety protocol like this can be prohibitive; it’s a good reason to invest in tight machine enclosures and proper ventilation.
MINIMIZING THE RISK
Reducing the risk of health issues caused by metalworking fluids involves three elements: the fluid, application to the turning or machining process and personnel exposure. Choosing fluids with low toxicity is obvious, but less accepted is the availability of compounds that perform as well or better than older formulations…it’s not a given that old sulfurized or chlorinated fluids perform better. While the MSDS describes the exact breakdown of the fluid, its data is often too difficult to decipher; consult the supplier for more information. While most turning and machining centres are enclosed, excess pressures and flow rates can leave fluid draining and dripping over operators during part loading and unloading. Fluid handling during tank cleaning and replenishment is another contact source, which can be minimized with proper transfer pumping equipment and tightly enclosed tanks and reservoirs. Shop personnel should maintain good hygiene and housekeeping procedures, use protective equipment wherever possible and eliminate persistent contact through wet clothes and cleaning wipers. Modern dry or near dry machining techniques are the ultimate risk reduction strategy, with cost savings and productivity gains, too. Watch Canadian Metalworking for future coverage of these and other turning and machining issues. For more details on the health effects of metalworking fluids, visit the Canadian Centre for Occupational Health and Safety’s metalworking fluid page at: www.ccohs.ca CM
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Toolholding Talk Experts reply to questions posed by our author By Nate Hendley .................................................................................................................................................. We recently ran some questions by a collection of toolholding experts. Our first question was straight-forward: what are the most important factors to consider when purchasing a toolholder? Our second question was more open-ended: do you think people are too causal when it comes to picking out toolholders? Both questions generated vigorous responses. “Factors that need to be considered are run-out accuracy, vibration dampening, balance quality and flexibility. All are dependent on the specific application and process. When we design a toolholder each criteria is very important which is why we always focus on run-out accuracy, vibration dampening, balance quality and flexibility. In today’s world everything is getting more and more complex and machines evolve with greater spindle speeds, feeds etc. so tooling is a critical component in the machining process,” says Mike Roy, general manager at the Mississauga, Ontario-based division of German company, Schunk. “If you have a complete package, then you’re going to make better parts. So if your machine tool is good, and you’ve got a good spindle, got a good set of tooling and got a good tool on the end of that, that’s the trifecta that’s going to give you high productivity and have less hassles,” adds Mike Smith, a product manager for the toolholder line at Seco, in Troy, Michigan. Experts also had a lot to say about our second question. The general consensus was yes, for many people getting a toolholder is treated as an afterthought. “We see that quite a bit. A guy goes and buys a $500,000 machine and he’s looking to put a five dollar toolholder on it … I think a lot of people think of a toolholder as a commodity type product. It’s holding your tools and your tools could be very expensive, so you don’t want to get a five dollar tool holder that isn’t very accurate, isn’t very strong or isn’t made out of very good material,” says Smith. Scott Leitch, sales manager of Florida distributor Exsys, says buying a tool and a corresponding toolholder is like “buying a car then buying a set of tires and rims.” While it’s tempting to go with cut-price wheels after making a big auto purchase, you risk a blowout by taking the cheap route. “In most cases customers are too casual when selecting toolholders. You can buy the fastest and most accurate machine on the market but if you select poor toolholding technologies the performance of the machine will never achieve its full capabilities. It is a necessity to investigate and research tooling and workholding solutions as these components are in direct contact with the workpiece,” echoes Roy. Roy offers some advice: “Our recommendation is to budget 15 percent of the machine purchase for tooling and workholding solutions. It may seem like a lot of money but if you can get 50 percent more tool life and/or change your setups or machining time in half what is that worth? Most customers spend a lot of time researching the machine that suits them best. They need to invest time in how to grip, clamp and process their parts as well,” he states.
We also asked our pundits what’s new and/or noteworthy in their sector. Here’s what they had to say:
SCHUNK
Schunk recently released the TENDOzero hydraulic expansion toolholder. “It was designed for mainly light machining applications where quality and accuracy is critical. It’s ideal for drilling, reaming and finishing applications for perfect concentricity. What’s unique with TENDOzero over other adjustable holders is you can use intermediate sleeves and still adjust the run-out to 0.000 mm. This is done in a matter of seconds. Simply adjust the four set screws to desired accuracy and lock in the actuation screw to clamp the cutting tool and you’re done. Combined with the vibration dampening from TENDO technology you will also see up to 50 percent longer tool life,” says Roy. “Another new release for SCHUNK is TENDO E Compact (TENDO EC). I refer to it as our ‘all-in-one-holder’. It is capable of
I
y y
TENDOzero hydraulic expansion toolholder.
44 | APRIL 2012 | www.canadianmetalworking.com
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Iscar’s stationary toolholder for turn-mill machines — the shank size HSK A100WH.
Shunk’s TENDOzero tool holder.
precision drilling, reaming and finishing with <.003 run-out but also the heaviest of roughing applications can be achieved with this holder as well. With 900Nm of clamping torque it is more rigid then heat shrink and milling chucks and has excellent vibration dampening due to TENDO Technology. The versatility is a major benefit as you can use intermediate sleeves to clamp various sizes with one holder,” he continues. Finally, we asked Roy if he had any tips on how shops can get the most out of their Schunk toolholders. “In all of our TENDO holders, we have a dead stop so there is no guessing how much pressure to apply, no cheater bars etc. Simply use a hex key and with 6 - 7 revolutions, the actuation screw will come to a dead stop and then you are 100 percent certain you are at max torque and don’t risk over torquing or questioning if the tool is clamped securely,” says Roy. http://www.schunk.com/schunk/index.html?country=CAN
ISCAR
Shortly after the New Year, Israeli tool-giant Iscar expanded its line of stationary toolholders for turn-mill machines with shank size HSK A100WH. “The new toolholders are for square shank and boring bars. The target market would be customers with large spindle machines that require large shanks and bar sizes,” explains Thomas Hagan, milling product manager at Iscar’s Canadian operations, in Oakville, ON. “Iscar also recently introduced a new line of stationary and rotating tool holders for use on MAZAK Integrex 300/400 Series items, including C4, C5 and C10 shanks with longer extensions than the present tools … due to a growing demand from various industries and since there are many face mills with coolant holes available in the market, ISCAR is expanding the range of holders for face milling cutters with cooling holes by adding internal coolant DIN69871 40 & 50 and BT 40 & 50 holders,” continues Hagan. Finally, we asked Hagan what Iscar toolholder he would recommend for high-speed and heavy machining applications. “A shop doing high-speed machining is inclined to be using
solid carbide tools. I would recommend a shrink system for their needs. This would give the best TIR (total indicator runout). Using a shrink system, the toolholder is heated for a few seconds and the tool is inserted. Once the toolholders cool down, the toolholders and tool become one piece. This lets you have incredible concentricity and rigidity of the tool in the holder,” says Hagan. http://www.iscar.com/
SECO
Seco’s EasyShrink15 toolholding system is a compact update of the EasyShrink20 system. The EasyShrink15 borrows the high-performance heating technology of its predecessor, including automatic recognition of the toolholder for optimized heating. The compact system offers one heating and two air cooling stations. It’s designed for a wide range of diameters (Ø3-32mm), all back taper sizes (SA30-SA50, HSK32-HSK100, C3-C8), Carbide and HSS shanks and tool height up to 400 mm. Displacement of the toolholder from the heating slot to the cooling slots is achieved by sliding, which means an operator doesn’t have to touch the hot toolholder. Seco also offers the 5675 ER collet chuck system, which replaces the 5875 ER chuck. With new ER collets and nuts for maximum precision, the 5675 system has a run-out quality of 10μm, versus 40μm for the 5875 system. “The new ER system now reaches accuracy levels that were only possible with specialized, much higher cost collet systems in the past. This makes precision machining a very beneficial reality for most applications and leads to better component quality,” states the company. http://www.secotools.com/
EXSYS TOOL
Exsys Tool, a toolholder distributor in San Antonio, Florida, is selling new adapters for the Preci-Flex interchange tooling system. Preci-Flex (the name is blend of the words “precise and flexible,” says Leitch) is made by German tooling firm, Eppinger. Described as “the most unique adapter system available in the global market” in Exsys/Eppinger literature, the Preci-Flex modular toolholder offers a single base holder and multiple tooling adapters that utilize the ER collet pocket. The system is designed to cut setup time, speed up machining time, increase tool life and lower tool cost. Preci-Flex can be used by “everybody” says Leitch, who
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lists aerospace, oil, energy and medical as sectors that could benefit from the toolholder. In January 2012, Type 02 extended adapters and Shrink-Fit adapters were added to the Preci-Flex line. “Type 02 extended adapters within the Preci-Flex system feature extended collet chucks that allow tooling to be positioned closer into a machine spindle or chuck; because of their extended lengths, the adapters eliminate any tool interference issues,” explains Exsys/Eppinger. The new Shrink-Fit adapters meanwhile, are designed to “deliver 100 percent clamping and connectivity around a tool’s entire shank diameter while providing the holding power, rigidity and accuracy associated with shrink-fit tooling,” adds Exsys/Eppinger. The new additions “broaden the machining capabilities” of the system, explains Leitch. http://exsys-tool.com/
EMUGE
Emuge, of West Boylston, MA, offers the PGR Clamping system, suitable for “a wide range of applications,” in the words of David Ridenour, OEM sales manager. “System size PGR 10 is a perfect solution for Mini-Micro applications … typical customers would be the medical industry, with tool diameters of 0.0078 inches. On the other end of the scale is the system size PGR 32. This size is suitable for heavy duty applications. With this size, our customers are able to run a one inch solid carbide end mill in a heavy roughing operation. PGR 32 offers the highest clamping forces and transferable torques,” explains Ridenour.
Emuge’s PGR clamping system.
The PGR clamping system consists of the toolholder, the high-precision collet and a compact clamping unit. “The collet is pressed into the tool holder with a force of 90 kN, the maximum torque to be transferred and the holding power of the clamping system PGR are higher than those of shrink-fit chucks. In addition, PGR permits the safe clamping of very small tool diameters,” says Ridenour. CM www.emuge.com
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www.canadianmetalworking.com | APRIL 2012 | 47 VERO-S_86x124_CA_0811.indd 1
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Equator has overcome difficulties of gauging a conical hole on a motor crank arm
Out of the lab, onto the floor
Spanish auto parts maker Esponsa uses software-driven gauging to bring in-process monitoring directly to production machines
E
ponsa, a manufacturer of automotive components located near Barcelona, Spain, has purchased a versatile and innovative shop-floor comparative gauge, the new Renishaw Equator, to check the quality of stamped parts and assemblies. This will reduce non-productive waiting times to a fraction of the time taken now, while maintaining the high quality and manufacturing efficiencies that are critical for the success of an automotive subcontractor. Other advantages for Eponsa are that Equator can scan the form of part features with its SP25 probe and change styli with the stylus change rack, included as standard, to check a large variety of parts. According to the firm, “Equator could reduce or eliminate quality room waiting times. This is because Equator can be used on the shop floor, alongside the machines producing the parts, and with the low purchase cost we can have several Equators positioned where we need them. We plan to have Equators alongside the stamping area and in the area for assembling mechanisms, where they will be particularly important. The speed of operation and measurement capability of Equator will ensure rapid, comprehensive and fully automated gauging.”
followed by dimensional measurements with hand instruments like calipers and plug gauges. Because the stamping processes are automated, making them very consistent and reducing the chances of human error, operators can usually detect potential problems before scrap parts are made, to ensure 100% good parts. However measurement with hand gauges is time consuming, repetitive and all down to the skill of the operator - there is more chance of the inspection process being wrong than the manufacturing process. Equator’s repeatability is set to change all that. Equator is an independent and traceable test of part quality, with the difference that all the operators can use it rather than just quality staff – currently a quality inspector walks around the plant constantly checking that procedures are being followed and parts are good. This is done with a visual check followed by taking the last part in every batch and performing a full inspection in the quality room. Experience has shown that if the last part is good then the whole batch is good, but this still means a long line up at the quality room.
AUTOMATED SHOP-FLOOR GAUGING
The Equator system includes easy to use graphical software called MODUS Organiser, which is designed for shop floor operators to activate checks, with just a few minutes of training. This software is vital to the operation of Equator: “MODUS Organiser is the perfect way to run Equator on the shop floor, it is so simple and useful. The operators are able to choose
Eponsa believes that Equator will be welcomed on the shop floor since it will reduce the workload considerably. Eponsa operators are inspecting thousands of parts every day, using documented procedures. Visual checks are done to ensure holes are present and that there are no cracks in the material,
EASY SHOP FLOOR USE
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An Eponsa engineer loads a wiper mechanism part onto Equator ready for gauging.
programs and start checking the parts in a few seconds, with an immediate view of how long the check will take on a countdown timer. Once the check is complete the operator sees a clear indication of whether a part has passed or failed – in the quality department we then only have to deal with any suspicious parts, instead of every part. This is reducing the load on the quality department considerably.”
RESTRICTED ACCESS TO PROGRAMS
The gauging programs are written using Renishaw MODUS software, but use of this is access-controlled. As Eponsa says “It is a very good idea that only programmers can create and change programs, we can then set up the Equators knowing that the programs are running correctly and operators will not be making any changes. We make it easy for the operators to find the right program in MODUS Organiser by including photos of the part, which also shows them how the part is placed on the fixture. The intention is to use as few fixtures as possible, with many parts using each configuration.”
GAUGING REPEATABILITY THROUGH MASTERING
Equator uses a comparison method of mastering and measuring that will be very familiar to any existing users of dedicated gauging systems. A master component with features of known dimensions is used to ‘zero’ the system, with all subsequent measurements compared to this part. The key to the Equator system is a highly repeatable and radically different metrology mechanism based on a structure known as parallel kinematics. This mechanism is lightweight, allowing
rapid motion, yet very stiff during comparison measurement of features, with repeatability of less than ±2 µm. This has been proven on a wide variety of both prismatic and free-form features.
MANUFACTURING AT EPONSA
80% of Eponsa’s business is producing automotive components, the other 20% is general subcontract stamping, welding and assembly work. Designing and commissioning all their quality and manufacturing processes themselves is a big advantage, allowing them total control. This includes design of the stamping tools and welding/assembly jigs. Eponsa is certified to ISO-TS16949, a specific standard for the automotive industry and ISO14001. It directly supplies factories around the world in Mexico, South Africa, Germany, Hungary, China and Korea.
EQUATOR HELPS EPONSA TO IMPROVE EFFICIENCY AND REDUCE COSTS
Eponsa produce all the stamped parts for windscreen wiper mechanisms.
The pressure on automotive subcontractors to reduce costs while simultaneously improving efficiency and quality might seem to be at odds with each other, but Eponsa firmly believe that Equator technology is the break-through they need to help them achieve this. CM www.renishaw.com www.canadianmetalworking.com | APRIL 2012 | 49
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Mitee-Bite’s Pitbull:10 parts on a rotary table
Load and Go
Proper fixturing is essential to quality and productivity
By Nestor Gula ....................................................................................................................................................
M
ost companies see the financial advantages of investing the right amount of money in proper equipment to enhance accuracy, quality and productivity. This concern for buying the best tool to do a top-notch job, on occasion does not translate into work holding equipment. “Often I am speaking to customers and asking them what they are using for fixturing,” said Bob Ellig, president of Bluco Corp. “There is a pause and then I ask – am I standing on it? They chuckle a bit and then say yes, they are using the floors. You might not know much about floors but they are never flat, they are never square, they are never parallel or rectangular.” When welding or machining, holding the part down securely is essential to a quality job. “If we are considering tools that are used strictly for simple hold down purposes, to apply downward pressure and hold stock in a positive location while processes are applied to it, (such as cutting and grinding) then proper tools are needed to make sure stock doesn’t shift out of position for reasons such as safety, accuracy, and job quality,” said Pamela Farley, Marketing Manager for Strong Hand Tools. “Quite often in fixturing, hold down tools are used to provide several different functions: to apply clamping pressure, locate a part, set stock at a specific angle, or hold one or more pieces of stock in position to be joined by tack welding. For safety, accuracy, and repeatability, it is necessary to use proper hold down tools that will assure the stock is set at accurate angles, set at a precise location, and can hold stock securely in the correct position for welding, brazing, and soldering.” In the modern manufacturing environment, you need to be able to reproduce your parts to the same specification each
time. “You need to be able to reproduce the parts that you make. If you are making a series of parts, you have to make the first one look exactly like the last one,” said Ellig. “The cheapest in terms of what it costs to get into, but the most expensive in terms of what it truly costs, is having no fixturing at all. Framing squares, chalk, piano wire, plumb bob, tape measure.” This is not acceptable in modern manufacturing. “Here you are using multimillion dollar equipment to make quality parts, and once they come out of the machine you put them in a rough and tumble surface where the flatness is questionable,” he adds. “Some companies have taken it another step further and made some sawhorses and made the feet with adjusting screws. Well, because they are not tied to the floor, they can slide around and as soon as you move it, your level is gone.” When considering the proper clamps to use, one must consider the secure and positive clamping pressure, rapid release, adequate clearance, and resistance to damage from weld spatter. “A fixture can be thought of as a ‘positioner’. The job of an accurate fixture is to set-up materials at accurate angles, in a convenient, accessible position for the welder,” said Farley. “Proper fixturing is worth the time and effort it takes for the initial set-up, to achieve repeatability, a key element in production, to ensure that each weldment set-up in the fixture will be dimensionally accurate, every time. A fixture should be custom built around the work piece; it should locate, clamp the stock to prepare for assembly, tack welding, and finally, welding.” When proper fixturing is used, the welder can begin working, knowing that the angles and positioning is accurate; the clearances are correct; there is adequate access to the seams
50 | APRIL 2012 | www.canadianmetalworking.com
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and joints and the parts will not move. This not only saves time and improves accuracy, but also builds confidence in the welder. “The fixture should be designed for minimal handling and re-positioning of the weldment during all of the processes that are applied to it, for cost savings, for the safety of the welder, and to decrease potential damage to the weldment,” said Farley. “Proper fixturing will also ensure against distortion as the fixture Mitee-Bite fixturing in action cools after welding. Proper fixturing, in combination with a properly air cooled work environment, should be an adequate defence against distortion. Proper fixturing will allow a finished weldment to be completed right the first time, efficiently, with less scrap, thereby increasing production, quality and cutting costs.” There is always a debate around modular fixtures and dedicated fixtures. “They essentially work the same, provided the dedicated fixture is done properly,” said Ellig. “The dedicated fixture and the modular fixture will do the same thing, except that in one area of the shop, we have a modular
Detail of a setup on Stronghand’s BuildPro Table
fixture with thousands of part numbers. The same, thousands of part numbers, in a dedicated fixturing system, will require a great deal of investment in the tooling and storing and in maintenance and upkeep.” “The benefits of modular fixturing can be expressed in one word: adaptability,” notes Farley. “In modular fixturing, the work surface, clamps and components used can be configured and reconfigured as needed to create a wide variety of fixtures, and to create weldments of varying sizes and types. In a shop that takes on a wide variety of jobs, a modular fixturing system gives the shop the ability to adapt to each new project.” Modular fixturing systems resemble large Meccano sets said Ellig. “You can build it and take it apart,” he said. “In the most general terms, the “heart” of a MF system should be described as the capability to set-up fixtures at any point on the table, and at any configuration, as dictated by the fixturing requirements of the users,” said Farley. “The “heart” of the system will be unique to the MF system, and may be unique to the company that utilizes that system. The “heart” of the BuildPro Table, is the unique plate, slot and hole system, which allows for the setup of clamps and modular fixturing components, at any point on the tabletop,
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52 | APRIL 2012 | www.canadianmetalworking.com
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by using the 5/8” holes set in a 2” grid “Many customers have told us pattern on the tabletop.” they assumed custom workholding Modular fixturing can be expanded products would be too expensive, or and contracted, handling anything from thought they could make something small parts like phones to large rail in-house to solve their gripping locomotives. problem. Later they realize that they’ve “An extremely large fixture is very compromised the part quality and/or A setup of Stronghand’s BuildPro Table very expensive. If you have a 73-foot they’ve created a situation with added fixture to hold, the relationship between the front end and the setup and changeover time.” back end of the locomotive engine, means you need a 73-foot Handing over to experts in the field, in these cases, is fixture. Now what kind of machine do you need to machine that essential according to Levanduski. “Compromising the quality thing?,” asks Ellig. “In our case we have an incremental approach of the gripping device and increasing the cost of the part could to it. We have a rail system where you lag it to the floor. It has cost you an important customer”. CM a pattern of bores in the rail surface that matches the pattern of bores in our components. It is laser levelled and the pattern of bores carries from one end to the other. The relationship of the pattern of bores from one end to the other end is held.” A benefit of a modular fixturing system is that it can be easily adapted to mid-production run changes. “Typically modular systems are used for short runs, but we have had customers who used our modular system for long runs. They use it for two years and then can reclaim all the components,” said Ellig. “One customer was running it this way, when in the middle of the run, the engineers came out with an emergency change order. A dedicated fixture would have cost quite a bit of money and in our case they made adapter block, put it back together and they were back in production two days later.” Fixturing for machining is a little different because you have a block and you know where the forces are going to be. Unlike weld fixturing that typically works on a part-by-part basis, machining can produce multiple parts in one go. “What we try to do is to focus on productivity to get as many pieces on the worktable,” said David Bishop, General Manager with Mitee-Bite Products LLC. “It’s what we term as high density workholding.” This is to maximize the utility of the machining process. “This way you can build two identical fixtures; so while the machine is running, the operator can load and unload the pallet offline, and as soon as the machine stops, they swap pallets so the machine never stops to wait for the operator.” Mitee-Bite products are built for automation and tackling difficult applications. The engineers at Mitee-Bite work with the customers to design specific fixturing solutions. A rigorous procedure of testing follows to ensure accuracy and quality. “We always prove out a solution before going into production.” For turning solutions there isn’t a shop worldwide that can say they’ve never had a problem gripping a part. “It’s an odd shape, it’s slipping, it’s too delicate, it’s getting scratched, there is not enough gripping surface, or it’s threaded,” said Mike Levanduski, Sales Director at Hardinge Workholding. www.canadianmetalworking.com | APRIL 2012 | 53
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Welding News LINCOLN ELECTRIC INTRODUCES NEW HYDROGUARD BENCH ROD OVEN
Stick electrodes can be damaging through moisture pickup. This is a major contributor to potential weld cracking and porosity. The new Bench 350 model holds up 350 lbs. (159 kg) of stick electrode up to 18 in. (46 cm) in length, enough for multiple operators in almost any fabrication shop or maintenance operation. Key features of the HydroGuard Bench 350 Rod Oven include: a circular shape that evenly directs airflow, moisture vent at top of the door to allow moisture to escape, adjustable thermostat that regulates temperature from 100°–550°F (38°–228°C), Protecting your welding sticks in this oven flexible interior configuration with removable shelves for pre- or post-heating of welded parts, top mounted shelf that provides a surface to take notes, store documentation or necessary tools, an optional Thermometer Kit to monitor actual temperature, a Data Logger Kit Capability to record time and temperature for compliance with certain code requirements. www.lincolnelectric.com
NEW DURA-FLUX SELF-SHIELDED FLUX-CORED GUN EASES MAINTENANCE
Bernard has introduced its new Dura-Flux Gun with replaceable power cable liner. This self-shielded flux-cored arc welding (FCAW-S) gun allows quick and easy power cable maintenance, and provides operators with 350 amps of welding capability at 60 percent duty cycle. The Dura-Flux Gun with replaceable liner features an advanced handle design that helps reduce downtime associated with operator fatigue and it is available with an optional dual schedule switch. The dual schedule switch allows for easy wire feed speed adjustment while welding and is integrated into the handle to protect it from weld spatter. The gun’s trigger is sealed to protect from outside contaminants and has been designed for simple replacement should it become damaged. The trigger also absorbs less heat than a traditional metal trigger to increase arc-on time, lower heat input and extend component life. The Dura-Flux Gun with replaceable liner can be configured with a variety of cable length and neck options. It is also adaptable for use with multiple styles of wire feeders from The new Dura-Flux Gun major manufacturers. with replaceable power cable liner has www.bernardwelds.com been designed to allow quick and easy maintenance and reduce downtime.
ESAB CANADA OFFERS SCHOLARSHIP AWARDS
ESAB Group Canada is now taking applications for the 2012-2013 ESAB Scholarship Awards. Scholarships are offered in two areas: post-secondary education and high school. The ESAB Post-Secondary Scholarship Award was established to support students who choose careers in welding and welding technology. The award is available to applicants who are in a post-secondary education program in the welding or welding technology fields. The $1,000 scholarship is awarded to a single recipient based on academic achievement, a demonstrated interest in welding and welding technology and their potential contributions to the industry in the future. The program was established to support high schools offering courses in welding and welding technology that inspire students to choose a career in the metalworking industry. The top 3 high schools will be awarded ESAB equipment packages in 3 categories: first prize valued at $2,000.00, second prize valued at $800.00, third prize valued at $300.00. Selection is based on the school’s demonstrated interest in the welding and welding technologies industries. www.esab.ca
LINCOLN ANNOUNCES NEW MONEY MATTERS REBATE PROGRAM
Lincoln Electric is offering rebates and incentives on most of its products from March 1, 2012 to June 30, 2012. The company’s successful Money Matters rebate includes products like the Power MIG 180 Dual, $100 rebate or a traditional welding gear Ready-Pak valued at over $250, the Power Mig 180 C with a $75 rebate or a Viking 1849 Autodarkening helmet valued at over $180. The Square Wave TIG 175, and Outback 145 both carry a $150 rebate or the Traditional welding gear Ready-Pak. The Power The Square Wave TIG 175 has a rebate of MIG 256 has a $200 rebate or the Traditional $150 until June 30, 2012 welding gear Ready-Pak while the Ranger 225 also has a $200 rebate or a traditional welding gear Ready-Pak but has a canvas cover thrown in. For this program, Lincoln has bundled its Tomahawk 625 One-Pak plasma cutting system with a Torchmate Growth Series 2x2 CNC plasma cutting table with a free 2X2 Water Table. www.lincolnelectric.ca
54 | APRIL 2012 | www.canadianmetalworking.com
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Your association, your voice T
here comes a time in every industry where hard business or government decision need to be made that can have a ripple effect for years to follow. Sometime what is needed is a solid sense of direction to at least help you plan for and hopefully ride out the storms. As a welder, welding professional, or business owner you may have felt a bit lost with respect to finding the information and resources needed to help you weather the storm. Banks, unions and even the government all have their own mandates, in support of their specific goals, and it can be hard sometimes telling the friends from the foes. Foreign welding associations like the AWS and regional welding associations and organizations like ISQ in Quebec may provide some help, but they also have they have their own agendas which are not necessary in the best interest of all Canadians... nor will they have an intimate understanding of the needs of the industry here in Canada. The CWA is focused on helping the Canadian welding industry and the people employed in it. Membership fees paid by our members directly support the activities of the CWA and, in turn, help support both Canadians and Canadian industry – the same cannot be said for foreign associations. Dues paid to AWS go directly across the border and helps to fund programs for welders in the US, as well as assisting in the marketing of US-based welding standards, which in turn erode our own national standards. Within Canada, ISQ provides their services only within Quebec and only in French, which is little value if you happen to be in Alberta. On the other hand the CWA, as Canada’s only national welding association, acts as both the voice of all Canadian welders as well as providing a trusted resource for information and support in both official languages. For those who don’t know the CWA, it is not a union, a government agency or a standards body; the CWA doesn’t write or sell codes and standards, sell equipment, test welders, or support the interests of people or industries operating outside
Astr
Birm
of Canada. At over 19,000 members and 22 chapters across Canada, the CWA has grown into a leadership roll in the welding industry from a humble beginning dating back to the 1920’s. Why do we need a national welding association? In two words: “Creating solutions”. At its core, the CWA is about bring in people together to discuss and solve issues. Issues like education, employment, on-going skills development, government funding, and industry growth cut across all industries as well as schools, colleges, test centres and unions that support them. Putting this into a national perspective, welding issues that impact the oil and gas industry in Alberta also are felt by the automotive industry in Ontario, and will be felt on both coasts when the shipyards start lying keels. In support of this, the CWA runs several conferences a year (this year in Quebec City and Halifax) and run special focus events like the Welder Educator Conference with the goal of bringing the best and brightest together. CWA also operates Canada’s largest Advanced Welding Technology Centre, available to members who want to learn about the latest advances in welding technology. Working with it’s parent company, the Canadian Welding Bureau (CWB Group), it is actively involved in promoting welding training, the promotion of welding as a career and government legislation with respect to welders and the welding industry. Regardless of where you work, the type of welding you do or what you call yourself – a welding shop owner, pipefitter, boilermaker, steelworker, welding inspector or custom car fabricator the CWA is here to help. As a not-for-profit association, membership for individual welders is free at the basic level, with a professional and corporate option available for those who want CM to help out with funding services and programs. Ian Campbell is director of marketing for the Canadian Welding Association. For more information, visit: www.cwa-acs.org
This space provided to the Canadian Welding Bureau by Canadian Metalworking magazine. All opinions are those of the CWB and not necessarily those of Canadian Metalworking magazine
56 | APRIL 2012 | www.canadianmetalworking.com
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Astralloy Saves Big Using New PHD System From ATTC Astralloy Steel Products Inc. is a steel service center Birmingham Alabama. “We are cutting steel .75 inches and above. To do
John Mattocks Branch Manager Astralloy Steel Products
and the ability to cut thicker plate,” said Mattocks, “we considered purchasing new CNC plasma cutting not an option.”
“The new torches have increased productivity by about 25% due to an increase in speed and longer consumable life.” Instead, the company purchased four plasma conversion systems* from ATTC to be used for specialty cutting work. Changing over the torches took 15 minutes and changing the consumables was quick and easy. With the conversion, Astralloy improved cutting capacity and reduced the rework.
PHD 2000 PLASMA HIGH DENSITY
plasma system to a high density cut quality without a big capital investment. and longer consumable life. Now, there is very little grinding time needed to remove slag and dross. Grinding time was reduced by 75%, from eight hours to two,” said Mattocks.
“All in all it was a good investment.” ®
www.BetterPlasmaCuts.com/now * Our Plasma PHD kit turns standard plasma into plasma high density
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Staying safe while welding Welding safety increases productivity and profit By Nestor Gula . ...................................................................................................................................................
The Tigerhood series of welding helmets from Honeywell’s FibreMetal
I
f you could transport a factory worker from half a century ago to today’s factory setting they would be amazed. Not only due to the modern machinery but also due to the cleanliness and safety awareness of the modern manufacturing process. While it is true that not all shops are as obsessively clean and organized as a Formula One racing operaton, the difference in the shop floor from even a few decades ago to now is quite impressive. Welding is still perceived to be a dirty industry. There are heat, fumes and smoke. This old perception is no longer based on reality as anybody who has attended a modern manufacturing trade show can attest; there is welding going on, but there is a definite lack of fumes or smoke at the welder. The most ubiquitous welding safety device is the helmet. “From a productivity and safety standpoint we are seeing a trend moving towards auto-darkening helmets,” said Kristy Giebe, Welding Products Manager for Kimberly-Clark Professional. Prices for these helmets are coming down and within the reach of most, if not all shops and manufacturers. “It is like any other electronic device, when you first bought your VCR you paid a heck of a lot of money for it but as technology advances the price goes down so that’s the same that has
happened to auto-darkening helmets,” explains Giebe. “The price has gone down to a reasonable price where people can easily see a return on the investment.” Auto darkening helmets have a benefit to productivity besides keeping the welder safe. “When you have a passive welding helmet the reason you have to lift it and then lower it, using that welder’s nod, is that you cannot see the work that you are trying to do. You cannot see the spot you are trying to weld. If you have an auto-darkening helmet, you have a clear view of the seam that you are trying to weld together, allowing you to leave your helmet in the down position,” said Giebe. “Kimberley-Clark has actually done studies that proves the validity of the enhancement of productivity. We have a calculator on our website that any company can go to and do the calculation for yourself.” www.kcprofessional.com
AUTO-DARKENING HELMETS
When choosing an auto-darkening helmet there are several things to consider. One of these is whether the auto-darkening feature is powered by a battery or by solar power cells. “The solar auto-darkening helmets have a solar cell to charge a lithium battery so you don’t have to constantly change the
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standard battery. The solar helmets do need to be recharged by the sun,” said Elaine Slatter the Country Manager/Director of Marketing Administration for Thermadyne Welding Products Canada Ltd. “Battery operated helmets mean if you haven’t checked your batteries, the helmet could malfunction in the middle of a job. If you don’t have the correct replacement batteries on hand, then the welder could lose time on the job until he finds some.” “All 3M helmets have batteries in them so they are replaceable,” said Carrie Mailloux the Product Marketer — Protective Eyewear and Welding Solutions for 3M Occupational Health & Environmental Safety. “The real cost of a welding helmet is the ADF (auto darkening filter) so if you are able to replace the batteries it’s easy to continue on with it. But if you have to dispose of the helmet and purchase another one because all you have is solar power, then that is a disatvantage. Even if the battery wasn’t working you are still protected because there is an IR film that is protecting you whether the battery is working or not working. You would know because when turning on the ADF it is not coming on or flashing.” “If used properly, the ADF should not Miller’s Automation Hood works well for robotic welding applications where consistent and thorough fume extraction is demanded. wear out and should last a long time, said Katie Twist-Rowlinson, Product Manager — Welding Helmets & Hard Hats,
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2012
for Honeywell Safety Products. “Most high-quality ADF manufacturers offer a two-year warranty.” Most manufacturers offer protective shields over the lens as protection from weld splatter. “Components such as front cover plates are replaced often,” said TwistRowlinson. “Many manufacturers offer replacement suspensions, sweatbands and other accessories to keep the helmets comfortable and working at their optimum performance level.” There are a myriad of other options available. Many manufacturers have come out with larger lenses to give the welder a better viewing area. “When you have a larger viewing area then you have to be careful that the darkening intesity is the same throughout the field so that is not lighter here and darker there,” commented Bruce Clark, Director, Marketing & Export Sales for Lincoln Electric. Other options are
Keep cool under your lid. The Miller Coolband removes stagnant air and can keep the temperature up to 8°F cooler under the welding helmet
respirators that shield the workers from harmful fumes, hardhat adaptors, like Fibre-Metal’s QuickSwitch System (which allows the worker to use their hard hat as the foundation of their eye and face protection and quickly and easily connect a welding helmet or faceshield) or even Miller’s innovative CoolBand that is an integrated headgear cooling system that fits exclusively into most Miller Arc Armor helmets providing up to six hours of continuous cooling on one battery charge. www.millerwelds.com
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Welding Canada
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60 | APRIL 2012 | www.canadianmetalworking.com
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FUMES AWAY
When dealing with fumes associated with welding the best place to start is to minimize them. “Try to fix the process first, and eliminate as much fume generation with different consumables or different weld processes, meaning short circuiting, spray transfer pulse welding — those kind of processes,” said Allan Hilbert, Product Manager with Miller Electric who specializes in fume extraction equipment. “You can reduce fume generation by changing to a different process or changing the parameters in that process to reduce fumes. Different consumables can reduce fumes, like going from a self shielding wire to a solid wire. Stick and self shielding wires produce lots of fumes.” “Welding generates gases and fumes. Fumes consist of particles of different sizes, some of these particles are very small and particles smaller than .5 micron will be inhaled to the deepest part of the lung,” said Guy Shelverton the Global Product Manager, PPE — Welding, Enterprise Product Group for ESAB Group (UK) Ltd. “Gas Welding and gas cutting may generate Comfort and safety with Lincoln’s Red Line safety apparel high levels of nitrogen dioxide (NO2), and this emerges from the nitrogen and the oxygen in the zinc coated steel, or galvanised steel, will cause a fever, which air. Inhaling high levels of this will cause pulmonary edema, is called “zinc fume fever”. It is also associated with coronary which is a very serious condition affecting the blood plasma in heart disease. Stainless steel welding generates hexavalent the body/lungs. Electric arc welding will also generate particles chromium. This has been known to cause asthma & lung cancer. that are different sizes. These particles will cause a chronic There are other types of exposure that may cause asthma, in cough that is also known as chronic bronchitis. Welding in
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ESAB fire resistant fabric jacket.
particular welding polyurethane coated steel or pipes coated with polyurethane foam. There are some metals that are neurotoxic like aluminium, lead & manganese. It’s easy to get intoxicated when cutting lead and steel. Manganese in high levels may cause a disease similar to Parkison’s.” As for shielding gas Shelverton said, “Argon is an inert gas, so isn’t harmful in itself. However, it is an asphyxiant, which means it will, in sufficient concentration, displace the oxygen in the air, which will kill you. All you have to do is ensure that it can’t concentrate.” Proper ventilation is necessary. According to OSHA (Occupational Health and Safety Administration) in the US, the most recommended way to capture fumes is to do source capture or local exhaust ventilation. “That is capturing the exhaust at the source before it reaches the workers breathing zone,” said Hilbert. “So if a guy is welding, you want to have some kind of a source extraction hood or arm or some type of ductwork with a fan device that can pull the fumes away from the workers breathing zone. To capture it right at the source, have it within 12 and 18 inches from the source.” Eradicating welding fumes in a manufacturing facility is one of the most difficult things to address effectively. “Every job will be different when it comes to fume extraction,” said Clark. “There are very sophisticated hoods with an incredible system for drawing fumes up and around the perimeter of the hood and red plastic sheets that hang down to contain the fumes on a custom robotic cell. When these red plastic strips that are hanging down don’t capture everything, you have fumes escaping into the general atmosphere around the shop. Then you put in something like the Circulator. It drives the air in a circular pattern up so many feet and by making the air move it, actually has to go by a capture hood that grabs the fumes which are taken down through a set of filters and to a gathering drum. Then they can then be disposed of with an environmentally responsible method.” Ambient or general ventilation is whole building ventilation that moves large quantities of air and removes contaminants. “There is a drawback to that because it still does not protect the worker itself although the air in the plant is cleaner in general,” said Hilbert. “It protects all the other workers who are not welding; it does a decent job keeping the air in the plant clean.”
WEAR IT WELL
Welding clothes have come a long way as well. In an industry that was dominates with drab heavy leather clothing new lighter, and dare we say, fashionable, clothing is emerging. “Clothing for welders is changing,” said Shelverton. “The need for heavy duty leather jackets, aprons and sleeves is still a demand and always will be (until there is a suitable man made substitute for leather). There has been an influx of more fabric based garments, names like Nomex and Proban, which are inherently fire resistant, without chemicals that can be washed out of the garment. These inherently fire resistant products are generally more expensive than a treated cotton garment. Although they offer more comfort in terms of weight, they do not protect to the level of a full leather jacket, so when using a fire resistant fabric jacket, we always train our welders to where additional layers of personal protective equipment, like a leather welding sleeve to protect the arm from spatter burns, or a full length apron to protect the mid section.” CM 62 | APRIL 2012 | www.canadianmetalworking.com
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Metal Marking Methods Technifor’s Andy Wellons describes a technique that uses impact marking with a high-tech twist By Jim Anderton, Editor .........................................................................................................................................
A
s an industry, we cut, machine and fabricate metal parts and assemblies….but a major part of the real value of the parts we make is tied to the information attached to them. Part numbers, lot traceability, serial and revision numbers, date stamping and internal production coding are all essential for any modern ISO/Lean/Zero Defects operation. Getting data onto metal parts with fast, durable marking is no longer just a paper tag and Sharpie operation. Durability is essential, whether it’s for lot traceability in production parts or tracking an expensive machined die block at the heat treater, but cost is always a factor. For many small to medium size shops, metal marking isn’t as thoroughly researched as other production processes. “That’s exactly it”, says Andy Wellons, sales engineer, Technifor Inc. (Mississauga, Ontario). “There are many options. Hand stamping is an obvious one, then there’s vibra pen, CNC marking and chemical etching. More sophisticated options are laser marking and dot peen technology.”
The Lasertop etching system.
Dot peen technology used for QR codes and part codes.
Hand stamping is cheap and quick, but there are risks in impacting metal, especially a dimensionally sensitive or case-hardened part, with what is essentially a hammer and chisel. Carbide-tipped vibrating engravers are also low cost, but time consuming to use and inconsistent, as well as producing marks limited to hand-drawn letters and numbers. Why not just use your machining centre? In a word, “time”. Using six-figure equipment to simply mark a production part is frequently the least productive tool path written into the code…a little like cracking a walnut with a punch press. With CNC programmers working hard to shave seconds from cycle times, carving a part number at the end of the machining process is often a time waster. According to Wellons, “we still have companies out there that do it, based on the utilization of their CNC equipment. Some are lucky enough to have spare machine capacity, but it’s not the best utilization of the equipment. It’s a solution that you use because you don’t want to invest in new equipment.” What abut chemical etching? “It’s an inexpensive technology”, declares Wellons, adding, “you can buy a kit for about a thousand dollars. The downside is that it’s tedious, you need a template, it’s time consuming to do the prep work and there are environmental concerns with the
64 | APRIL 2012 | www.canadianmetalworking.com
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Dot peen technology leaves a highly legible and machine readable mark on metal surfaces.
chemicals. It’s also tricky. At times you can get blurry marks if you don’t get it just right. It’s possible to get a good laser-like mark if it’s done properly, but for volume production it’s just not practical. And the safety and environmental issues can’t be ignored.” Laser is a option, especially for high-volume production, and produces excellent results, although the up front cost of laser marking equipment can price the technology out of lower volume applications. Where materials are very hard, like carbides and some aerospace alloys, it’s the best solution. For the majority of ferrous and non-ferrous part marking , however, Wellons describes another approach: dot peening. Dot peening, or “micropercussion’ uses a series of tiny pin-prick like dimples on the part surface to draw curves and line segments to form images. “It uses a stylus that moves in an
Technifor’s XF500 Tagfeeder.
x-y plane in a head using an electric solenoid or pneumatics...it drives the tip very fast to make line segments. It’s not an impact like a hand stamp. The average pressure is about 5 pounds. The advantage is that the systems are fully programmable. You can mark logos, bar and QR codes. That’s why micropercussion is so widely used. You can mark flat and we have rotary devices that can turn a cylindrical part to mark around the circumference. It’s accurate and repeatable.” Where hardened parts and tool steels are in play, the laser/ dot peening choice boils down to Rockwell numbers. Post-heattreatment marking needs careful testing, according to Wellons: “No more than 62Rc. If you want to mark after hardening, laser comes into play. The challenge there is the initial investment, which is about four times the price of micro percussion, but it’s still cheaper than outsourcing the marking process. A lot of companies go straight from hand stamping straight into micro percussion. It’s a good solution for a small shop that wants a complete system without a large investment.” Why switch to high-tech marking systems? Ultimately it’s about control. Outsourcing, shipping to assembly operations, inventory control and quality assurance programs all need reliable data built into (or onto) metallic parts. Even smaller job shops can lose a critical part at a heat treater, or confuse two similar mold or die components if the marking technology is a Sharpie or paper tag... and carving numbers into a part with half a million dollar’s worth of CNC technology can be too expensive. It’s worth exploring the options. CM www.technifor.com www.canadianmetalworking.com | APRIL 2012 | 65
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ADVERTISERS INDEX ADVERTISER . . . . . . . . . . . . . . PAGE
ADVERTISER . . . . . . . . . . . . . . PAGE
American Torch Tip . . . . . . . . . . . . . . . . . . . 57
Machitech Automation . . . . . . . . . . . . . . . . 30
AMT Machine Tools Ltd. . . . . . . . . . . . . . . . 41
Mate Precision Tooling . . . . . . . . . . . . . . . . 31
Benz Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Bohler-Uddeholm Limited . . . . . . . . . . . . . . . 11 Carl Zeiss IMT Corp. . . . . . . . . . . . . . . . . . 21 CPB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Diapaolo CNC Retrofit . . . . . . . . . . . . . . . . 15
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Nederman Canada Inc. . . . . . . . . . . . . . . . 61 Renishaw Canada Ltd. . . . . . . . . . . . . . . . . 23 Retention Knob Supply & Mfg. Co. Inc. . . . . 67 Sandvik . . . . . . . . . . . . . . . . . . . . front flap, 33
Eclipse Tools North America . . . . . . . . . . . . 52
Schunk Intec Corp. . . . . . . . . . . . . . . . . . . . 47
Elliott Matsura . . . . . . . . . . . . . . . . . . 4,21,43
Scientific Cutting Tools . . . . . . . . . . . . . . . . 35
Eriez Magnetics . . . . . . . . . . . . . . . . . . . . . 29
SGS Tool Company . . . . . . . . . . . . . . . . . . 34
Fagor Automation Canada . . . . . . . . . . . . . 13
SME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ferro Technique Ltd. . . . . . . . . . . . . . . . . . . 17
Sumitomo Electric Carbide . . . . . . . . . . . . . . . 9
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Hilco Industrial, LLC . . . . . . . . . . . . . . . . . . 52 Horn USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 7 Hurco USA . . . . . . . . . . . . . . . . . . . . . . . . IFC Ingersoll Cutting Tools . . . . . . . . . . . . . . . . . 39 Iscar Tolls Inc. . . . . . . . . . . . . . . . . . . . . . . OBC
Page 1
IN STOCK American Standards and specials. Japanese Standards inch or metric.
Thermadyne Industries, Inc. . . . . . . . . . . . . . 63 TRUMPF Inc. . . . . . . . . . . . . . . . . . . . . . . . IBC Tsugami . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Jet Edge, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tungaloy America, Inc. . . . . . . . . . . . . . . . . . . 3
KMT Waterjet Systems, Inc. . . . . . . . . . . . . . 26
Walter USA, LLC . . . . . . . . . . . . . . . . . . . . 37
Lincoln Electric Company of Canada . . . . . . 55
Walter Surface Technologies . . . . . . . . . . . . 59
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www.canadianmetalworking.com | APRIL 2012 | 67
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Metal...Works By The NUMBERS Post-recovery private sector employment recovery: A comparison of the last three recessions
The 2008–2009 recession was less severe for private sector employment than the 1981–1982 and 1990–1992 recessions. Small businesses, although losing the most jobs during the last recession, quickly regained jobs and recently surpassed pre-recessionary employment levels. Year-over-year employment in Canada increased by 1.3 percent (191 849 jobs) in the third quarter of 2011. Small business employment grew by 0.5 percent, contributing 28 777 jobs.
Key performance indicators for small business, 2000-2009
Trends in operating profit margins and return on equity indicate that performance among small businesses increased steadily from 2002 to 2006. Since then, these ratios have been stable, with slight declines occurring during the 2008–2009 economic recession. On average, Canada’s top 200 fastest growing businesses grew by 1464 percent in terms of revenues between 2005 and 2010. Of these high-growth companies, 95 percent were small and medium-sized enterprises. Small businesses are defined as having fewer than 100 employees, medium-sized businesses having 100 to 499 employees and large businesses having 500 or more employees. Source: Industry Canada Small Business Quarterly, www.ic.gc.ca/SMEquarterly
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