Canadian Metalworking February 2012 by Annex Business Media

February 2012 â&#x20AC;˘ www.canadianmetalworking.com

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Contents...

Vol. 107 | No. 1 | February 2012 | www.canadianmetalworking.com

FOCUS ON AEROSPACE HIGHER, FASTER, FARTHER.....................18

A Government review, huge orders and a controversai fighter plane make for interesting times in aerospace

SKY-HIGH IN PEI..................................23

3 Points Machining and Aerospace has set up a new operation in picturesque Charlottetown, PEI ... and reaps multiple rewards.

CAD/CAM TRIPLE PLAY..........................................28 Match machine, control and software

CUTTING TOOLS THE NEED FOR SPEED . ....................... 30 Higher speeds and feeds with lighter cuts

QUALITY

FABRICATING

LET THE GOOD TIMES ROLL................. 45

AUTOMATION AND THE PRESS BRAKE.. 57

Kawasaki uses advanced CMM tech for consistent quality

Evolution towards “hands off” production

WELDING

FINISHING

NEW!

ATTENTION TO DETAIL.........................61

WELDING NEWS............................... 36 EFFICIENT POWER............................... 38 New power sources bring production gains and energy efficiency to the plant

GRINDING TOP GEAR.......................................... 50 Ontario Drive and Gear is a Canadian success story

Optimize the elements of your spray painting system to achieve better efficiency and lower costs

DEPARTMENTS View from the Floor................................... 6 News...................................................... 8 Floor Space........................................... 16 By The Numbers..................................... 64

61 www.canadianmetalworking.com | FEBRUARY 2012 | 5

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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 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.

View From the Floor There is no labour shortage That’s right, you read it here first….there is no shortage of skilled labour in Canada. Need a machinist or toolmaker? CNC programmer? They’re there for the picking…at a price. Willing to pay 40-45 bucks an hour plus benefits? You’ll have all the good hands you need. I know, that’s ridiculous…no one can afford wages like that, which is the real issue the industry faces regarding skilled workers. Here’s how it evolved: Offshoring wiped out the marginal and undercapitalized players in the Canadian industry, which, combined with recession, spiked unemployment in the skilled trades. Young people noticed. Then the surviving metalworking businesses got off the mat and fought back with higher efficiency, quality and speed despite slimmer margins driven by the offshore competition. Smart operations not only bounced back, but used the new flexibility and productivity to chase new markets and look again at growth….until they hit the skilled worker gap. And that gap will continue for one simple reason: Kids are smart. In fact, despite what many in the industry claim about the “new generation” they’re smarter, stronger and faster than we ever were…. and right now they see little future on the shop floor. There are several reasons why. One is the way capitalism has evolved over the last 30 years. The common perception is that winners are wealthy speculators, bankers and lawyers who trade millions at the push of a button. And looking at executive compensation these days, they’re not wrong. How do you move up to the front office if you’re ambitious and smart? How many toolmakers are running Bombardier or SNC Lavalin? The only way off the bench is to go the Frank Stronach route, except that the current level of automation, plus ISO and other certifications makes the cost of entry very high for budding entrepreneurs in the industry….and we know what it’s like trying to raise capital in Canada if you’re a small business. A young MBA with a lousy business plan has a better chance than an expert machinist with a sharp mind and good entrepreneurial instincts. Kids see this and stay away, unless they’re incapable of handling business or law, which is the other problem: we’re still perceived as little more than “grease monkeys”. High school guidance councilors still drive illiterate, innumerate students into the trades, somehow thinking that a useless office worker makes a great machinist or moldmaker. Why? How many guidance councilors are trades people? I know of community colleges here in Toronto that run remedial English and math classes to try to get apprentices up to speed. How much do you want to pay a new hire that can’t read a drawing? And so it goes: in the Twitter age, perception is reality and the perception is that the industry is dirty, demeaning, poorly paid and offers no future for the young. This can be fixed. To start, we need to look at apprenticeship systems like the Germans use. Add continuous education, and provide a route into engineering for bright, ambitious machinists and toolmakers. This would also provide a pool of engineering talent that really understands metalworking. The SME is looking at this right now. Stop throwing financing, taxation and regulation roadblocks in front of young entrepreneurs who want to set up a business and build new markets. Stop the irrational paper trail drowning existing employers who want to hire. And get some sense in income distribution in this country before we completely wipe out the middle class… and condition our youth to admire scheming, speculation and inside dealing while rejecting the real wealth generators in society as idiots. The scary thing is, it would take little to fix this mess and the tools are in Steven Harper’s box. But I’m not holding my breath. JIM ANDERTON, EDITOR

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 6 | FEBRUARY 2012 | www.canadianmetalworking.com

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News FABTECH Canada adds social media, mobile apps On-line excitement builds for FABTECH Canada, the first exclusive fabricating, metal forming and welding event, to be held in Canada in March Show floor exhibits aren’t the only leading edge tools and technologies expected to create a stir at FABTECH Canada, the country’s first exclusive fabricating, metal forming and welding event making its debut at the Toronto Congress Centre March 20-22, 2012. Emerging social media trends and innovative mobile applications will also be in the spotlight as show organizers embrace the latest in communications tools to deliver a state-of-the-art, interactive attendee experience. “Our studies indicate that the more we can immerse show visitors into the overall experience, the more industry knowledge they will take away from FABTECH Canada,” said Janine Saperson, Event Manager with the Society of Manufacturing Engineers (SME), which is hosting the inaugural event together with Fabricators & Manufacturers Association, Intl. (FMA) and American Welding Society (AWS). “By incorporating the hottest trends in mobile devices and social media, we’re making it easier than ever for attendees to contribute ideas, provide feedback, receive up-todate industry education and get the most out of their show floor visit, with the added benefit of keeping our finger on the pulse of our industry at the same time,” she said. FABTECH Canada’s regular on-line Twitter discussions are moderated sessions are intended to engage audiences on key topics in the metal forming, fabricating and welding industries; to access the forum, users sign onto Twitter and enter “#fabtechcanada.” Additional social media outlets used by FABTECH Canada to engage industry members include Facebook, LinkedIn and YouTube. Another innovative technology promising to take FABTECH

Canada Revenue Agency gets failing grades from small business: CFIB Survey

Some say they’re intimidated. Some feel treated as if they’ve done something wrong. Those sentiments reflect the overall consensus from small business owners and their experiences with the Canada Revenue Agency (CRA), according to a report by the Canadian Federation of Independent Business (CFIB) The survey of 10,600 small business owners and tax practitioners were asked to grade the CRA’s overall service to small business. The majority of respondents gave the agency a “C” or lower. Nearly 40 per cent gave them a “D” or “F.” For most, there has been little improvement in service in the last three years. “While CRA has taken steps to improve the way it treats small business owners, those efforts are being drowned out by poor customer service, including audits that some of our members

Canada to new heights is the ability for audiences to take advantage of an optimized mobile application which can run on any mobile device, including cell phones and tablet PCs, and provides attendees with easy on-line access to the exhibit guide, conference agenda, and more. This application will allow visitors to personalize their trade show experience, receive alerts about conference start times, take notes during sessions and be notified about last minute show changes. A real-time audience response system also enables immediate feedback and can be used to facilitate on-line polls and surveys. “As Canadian manufacturers continue to gain visibility as a critical engine for innovation, technology and economic growth, it makes good sense to foster that growth using the latest in communi cations technology,” said Ed Youdell, FMA President and CEO. “Social media, in particular, is a great way to build a sense of community within our industry,” added Ray Shook, AWS Executive Director. “The more we can get people talking about issues of importance, the more innovation we are likely to see.” Featuring the most comprehensive showcase of the latest industry technologies, tools and trends geared towards the needs of this country’s estimated 1.5 million manufacturing employees, FABTECH Canada is building on the success of the recent FABTECH event, held in Chicago in November, which exceeded expectations with an attendance of more than 35,000. Canada’s premiere industry event will feature an extensive exhibition floor, side-by-side machine evaluations, expert-led educational sessions, Canada’s Best Welder Competition and many other networking opportunities. For more information on FABTECH Canada 2012, visit www.fabtechcanada.com. Show updates are also available on Twitter and LinkedIn.

described as witch hunts,” said Laura Jones, CFIB’s senior vicepresident of research and economics. The survey suggests 28 per cent of Canada’s small businesses were audited in the last three years, 34 per cent of which were in the manufacturing sector. It also found that the more people a company employs increased the likelihood of an audit. Only 20 per cent of companies with one to four employees were audited, while 56 per cent of those with 100 to 499 employees were audited. CFIB outlines a number of recommendations in its report, which include publicly monitoring and reporting the customer service performance of CRA agents. The report also suggests implementing impartial third-party reviews to level the playing field. The full report is available at: http://www.cfib-fcei.ca/ cfib-documents/rr3256.pdf

“The majority of

respondents gave the agency a “C” or lower”

With files from canadianmanufacturing.com

8 | FEBRUARY 2012 | www.canadianmetalworking.com

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The Perfect 90º

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News $18.9 million in Southern Ontario funding assistance available through SMART program

Manufacturers that are exporting, planning to export, or selling into an export supply chain and planning productivity assessments or improvements can apply for the funding provided by the Federal Economic Development Agency for Southern Ontario (FedDev) through CME’s SMART Prosperity Now program. “Two of the largest challenges that companies will face in 2012 are finding new customers and enhancing productivity performance,” said Ian Howcroft, vice-president of CME Ontario. He said funding will help companies commercialize new technologies, enter new domestic and foreign markets, invest in sustainable and green technology, purchase new or upgraded equipment and technology, and implement efficiency improvements. Assessments are eligible for funding of up to half the eligible costs to a maximum of $5,000. Productivity enhancement projects are eligible for up to 33.3% of eligible costs to a maximum of $75,000. Eligible projects under FedDev Ontario’s Prosperity Initiative must: • accelerate the adoption of new technologies, processes and skills;

•d iversify the regional economy by increasing the number of new industries or opportunities that will have a long-term impact on regional economic diversity; and • build a competitive advantage by creating or expanding economic clusters and enhance their global competitiveness. CME said it will be hosting a series of workshops throughout the region in the coming months to help businesses navigate this initiative. For more information go to http://www.cme-smart.ca . With files from PLANT

The indu pro for Aer US October manufacturing tech orders up 80.5% from 2010

LES SUMAB NO CON ING COSTS NN U R O N

■ ■ ■ ■ ■ ■

October U.S. manufacturing technology orders totaled $463.32 million according to AMT-The Association for Manufacturing Technology and AMTDA, the American Machine Tool Distributors’ Association. This total, as reported by companies participating in the USMTO program, was down 22.4% from September but up 20.3% when compared with the total of $385.21 million reported for October 2010. With a year-todate total of $4,529.11 million, 2011 is up 80.5% compared with 2010. These numbers and all data in this report are based on the totals of actual data reported by companies participating in the USMTO program. “Manufacturing technology orders through October had already surpassed the total value accumulated in 2007,” said AMT President Douglas Woods. “The beginning of 2012 will be a little slow as tax incentives pulled some orders back into 2011, which will likely make 2012 growth softer.” The United States Manufacturing Technology Orders (USMTO) report, jointly compiled by the two trade associations representing the production and distribution of manufacturing technology, provides regional and national U.S. orders data of domestic and imported machine tools and related equipment. Analysis of manufacturing technology orders provides a reliable leading economic indicator as manufacturing industries invest in capital metalworking equipment to increase capacity and improve productivity.

10 | FEBRUARY 2012 | www.canadianmetalworking.com

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News U.S. manufacturing technology orders are also reported on a regional basis for five geographic breakdowns of the United States.

Business missing key internal competencies that enhance productivity: global study

ESI International, a global project management training company, has released the findings of a new global study conducted to examine the state of business analysis (BA), a core discipline for translating project objectives into actionable project requirements and deliverables. The study was conducted among both public and private organizations worldwide in September. “The disconnect between those who ultimately sponsor projects and those who execute them was frankly a bit shocking” said Mark Bashrum, Vice President for Corporate Marketing and Strategic Intelligence at ESI. “We were surprised to see how seldom business analysts linked key project success criteria to broader organizational goals.” When business analysts were asked what they thought were the organization’s key project success criteria only 22 percent listed “Organizational Profit Impact” in the top three most important and only 8 percent listed it as the most important criteria in determining project success. The top three responses, were “customer satisfaction”, “on-time completion” and “on-

budget completion” (of the project), clearly indicating a focus on project execution over business impact. “It’s understandable that business analysts are focused on the tactical execution of their projects, however, it’s a bit disappointing that they fail to take the next step and link their project outcomes to obvious organizational goals such as revenue growth or cost reduction,” said Bashrum. These findings strongly indicate that people are missing the big picture in terms of what their overall BA objectives should be, and as a result, organizations are not realizing BA’s full potential in terms of improving efficiencies that increase productivity and profitability, especially important in the current challenging economy. Additionally, key findings show that immaturity in BA organizations may represent an unrecognized deficiency in many of the surveyed organizations. The study, which tracked project outcomes against core BA activities, years of professional experience, BA certifications and a variety of other factors revealed that nearly half of BA practitioners had five or fewer years of experience in the field and that very few respondents possessed any type of BA certification. “Business analysis is obviously recognized as a driver of project success, but organizations and business analysts themselves need to raise the bar in terms of their expectations in order to get the most out of the discipline,” said Glenn R. Brûlé, CBAP, Executive Director of Global Client Solutions, ESI. “This

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News study indicates a relatively high level of satisfaction with BA performance and results, but business analysts have barely scratched the surface providing the enterprise level activities of which they’re capable, and from which organizations will benefit most.” The survey was anonymous unless respondents wanted to receive the results, in which case they had to complete their details.The full study, “Why Good Isn’t Good Enough: The Global State of Business Analysis”, is avaialble at: www.esi-intl.com/BAsurvey

continue to expand our staff to provide sales, service and engineering support for our customers both in the English and French languages. The new facility is located at 6710 Maritz Drive ,Mississauga, Ontario, Unit 4, ands can be reached at (905) 670-8600

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KUKA Robotics Canada opens new facility

KUKA Robotics Canada, a subsidiary of KUKA Roboter GmbH, has announced the opening of their facility in Mississauga, Ontario, Canada. The facility is home to KUKA Robotics Canada’s sales, applications, service and engineering staff to support customers in reviewing applications and applying robotics technologies to improve productivity and quality while reducing costs and ergonomic related injuries. The fully equipped facility includes spare parts, training, and a demonstration area to provide customers with an opportunity for “hands on” experiences with the latest technologies and products. The location is in the heart of one of the largest corporate and industrial sectors in Canada, also home to many major international companies. Five major highways within 10 km and Toronto’s Pearson International Airport within minutes ensure KUKA Robotics can provide quick access to its customers and major markets throughout Canada. KUKA Robotics Canada’s President Chris Claringbold stated, “The location is well suited to KUKA’s needs, allowing our Canadian Team to offer greater support of products and services to KUKA’s growing customer base. We

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www.canadianmetalworking.com | FEBRUARY 2012 | 13

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News New president for the CMTDA

December 1st saw the 69th annual general meeting of the Canadian Machine Tool Distributors’ Association. Held at the Board of Trade Golf and Country Club in Woodbridge, Ontario just north of Toronto, John Manley, outgoing president CMTDA introduced the new president, Frank Haydar. Haydar, (Elliott Matsuura Canada Inc.) reported dramatic increases in orders for both machining and fabricating equipment but also warned about the impact of a rising Canadian dollar: “a low Canadian currency during the past two decades has allowed Canadian manufacturers to make gains internationally without investing in more efficient technology. Now that our dollar hovers around parity with Incoming CMTDA the US dollar, Canadian manufacturing president Frank Haydar companies are struggling to balance the productivity gap between Canada and the US by investing in new machinery-and this is ultimately good for all of us.” Membership in the CMTDA is up from 78 to 82 members over 2010. New member companies are: HUB Sinclair Cockburn, Kennametal Inc., Mitcham Machine tools, Garant

Best selling author Tom Deans makes the case for planning your business exit strategy

Machinery and Zecom Media. Following the membership report from Steven Fitz, a plaque was presented to new members company representatives Robert Dunbar (Ellison Technologies) and Dean Drager (National Leasing). John Manley introduced keynote speaker Tom Deans, author of the bestseller “Every Family’s Business”, who delivered a presentation about protecting wealth within a family business. For more on Canadian machine tool sales expansion, see “By the Numbers” on page 64 www.cmtda.com

14 | FEBRUARY 2012 | www.canadianmetalworking.com

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Floor Space What’s the biggest mistake a new shop owner can make in their first year of business? “The worst decision that a new business owner can make is to overextend themselves financially [so they can’t] compensate for any downturns in the future. I have found that many businesses have failed due to owners purchasing top-of-theline equipment, brand new and financed over long terms. Any minor dry spell—which is bound to happen—will result in disaster [with the shop owner] not being able to make payments on equipment.”

-Adriano Oppio, Vice-President, Classic Tool & Die Inc., Oldcastle, Ontario

“I think the biggest mistake is under estimating the amount of time you need to devote getting the business off the ground. Expect to work long hours for a fraction of what you were getting working for someone else.”

-Peter Alden, co-owner, Wessex Precision Machining Limited, Ayr, Ontario

“There are not as many new start-ups of late in our immediate marketplace, in big part because of the economy and the recent pressures on manufacturing in general. However, there

have been a couple and the common mistake they tend to make is in their pricing. The natural tendency is to undercut their competitor’s right out of the gate, in some cases by significant amounts. They are “buying” new business. From my experience, this is short-sighted and cannot last. Newcomers are trying to compete with companies who have been in the field for 20 – 30 years and have a precise understanding of their costs … [under pricing themselves] is a mistake. Unless they can do so and still generate a profit, it is a useless exercise and will inevitably result in financial losses in their near future. Being competitive is one thing, being silly is altogether another.”

-Joseph Manzoli, president, Colourfast Custom Coatings, Concord, Ontario

“Underestimating the needs of running the business and putting too much faith in one customer. Too many people forget that the cost of opening the doors in the morning plus overhead along with a top heavy organization can kill a company. Startups [sometimes rely] on a relationship with a past customer who feeds them work until an adjustment happens—new overhead costs come in, the customer leaves and the new company is stuck without an anchor customer for its survival.”

-Marco Gagnon, co-owner, Gagnon Ornamental Works, Grand Falls, New Brunswick

“Not having enough credit or cash.”

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Higher, Faster, Far t her A Government review, huge orders and a controversial fighter plane make for interesting times in aerospace By Nate Hendley Canada’s aerospace sector will soon be put under intense government scrutiny and industry leaders couldn’t be happier. The scrutiny comes in the form of a comprehensive policy review, as Ottawa looks for ways to enhance the industry’s competitiveness. Proposed in March 2011 as part of the federal budget, the aerospace policy review is expected to start soon and last a year at least. The proposed review, plus a sunny market outlook courtesy of aviation giant Boeing, has left industry leaders feeling giddy, even in the face of so-so revenues. “We’re pretty optimistic,” says Jim Quick, president and CEO of the Ottawa-based Aerospace Industries Association of Canada (AIAC). Canadian aerospace revenues amounted to $22 billion in 2010 (the last year figures are available), with employment standing around 80,000. Revenues are down slightly from 2009, when they stood at $22.2 billion, with employment at 78,965. Roughly 80 percent of aerospace products in Canada are exported. About 83 percent of the industry’s profits come from civil (commercial) aircraft while 17 percent is from the military sector. AIAC is eagerly awaiting an announcement marking the official launch of the aerospace review. Among other things, the government will examine programs and policies that benefit aerospace. These include SADI (Strategic Aerospace and Defence Initiative), a program launched in 2007 to fund research via repayable government loans to aerospace companies. According to Quick,

Ottawa will continue to fund SADI during the course of the policy review. The proposed review was one of the main topics of discussion at the First Canadian Aerospace Summit, an industry event hosted by AIAC in Ottawa last November. The summit attracted hundreds of people including federal Industry Minister Christian Paradis, who gave a keynote luncheon address. The summit was intended to covey a simple message, namely the importance of aerospace to Canada’s economy. “The reality of our industry is that we generate high-quality, high-paying jobs,” notes Quick. To a large extent, these high-paying jobs are dependent on the actions of major aerospace OEMs such as Boeing and Airbus. Chicago-based Boeing reported 778 net orders for new planes through December 20 last year. This is up from 530 net orders in 2010 and a vast improvement over 2009 when only 142 net orders were recorded. Airbus (which is headquartered in France and controlled by parent company European Aeronautic Defence and Space

18 | FEBRUARY 2012 | www.canadianmetalworking.com

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Co.) reported 1,378 net orders for 2011, as of November 30. This is a large gain from 2010 when 574 net orders were made and 2009 when only 271 were recorded. Each year, Boeing issues a report, called Current Market Outlook, which offers an overview of industry conditions and a peak into the future. The most recent report, called Current Market Outlook 2011 - 2030, predicts heady times ahead. “Passenger air travel rose eight percent in 2010, after declining about two percent in 2009. The persistent resilience of air travel is expected to sustain six percent growth in 2011 and keep the growth rate at or above the historical trend through the middle of the decade,” states the report. Current Market Outlook 2011 - 2030 is equally bullish on new plane orders: “The long-range forecast for 2011 anticipates delivery of 33,500 new airplanes over the next 20 years, valued at more than $4.0 trillion ... single aisle airplanes account for the majority of deliveries over the next 20 years-70 percent of the airplanes and 48 percent of the value. Rapidly expanding air service within China and other emerging economies and the spread of low-cost business models

throughout the world, drive this market segment.” The report breaks down demand by region. It predicts Asia will require 11,450 planes, at a value of $1.51 trillion over the next two decades. Demand in Europe will stand at 7,550 planes (worth $880 billion) while North American demand will come to 7,530 planes (worth $760 billion) in the same time period. “Worldwide economic activity is the most powerful driver of growth in commercial air transport and the resulting demand for airplanes. The global gross domestic product (GDP) is projected to grow at an average of 3.3 percent per year for the next 20 years. Reflecting this economic growth, worldwide passenger traffic will average 5.1 percent growth and cargo traffic will average 5.6 percent growth over the forecast period,” states the Boeing report. Rival firm Airbus also has its own report, Global Market Forecast 2011 - 2030, which differs slightly from the Boeing document but still predicts massive growth ahead. Airbus pegs global demand for aircraft over the next two decades at 26,921 aircraft with a value of $3.2 trillion.

Closer to home, major Canadian aerospace players report healthy revenues. Montreal-based CAE, which makes flight training simulators, announced a slew of contracts last year. In the second half of 2011 alone, the company recorded roughly C$400 million worth of new business with military and civilian sources. The aerospace segment of Longueuil, Quebec-based Heroux-Devtek received a seven year contract from Bombardier Aerospace (third largest civil aircraft manufacturer in the world) in February 2011. Heroux-Devtek will make over 300 different structural components, including wing spars, wing ribs, fuselage frames and other parts for Bombardier, which is headquartered in Montreal. The deal is worth around $175 million. For its part, Bombardier continues to work on the CSeries family of passenger jets. Launched in July 2008, the CSeries consists of 110 and 130-seat commercial aircraft scheduled to enter service next year. At present, some 2,100 Bombardier Aerospace workers are labouring on the planes, in Canada, Northern Ireland and China. The CSeries, which features heavy use of composites and advanced aluminum alloy, is being billed as eco-friendly. Bombardier promises that the CSeries “will be the greenest single-aisle aircraft in its class” when it finally enters service. The company claims the plane will emit 20 percent less carbon

“Canada’s aerospace sector

will soon be put under intense government scrutiny and industry leaders couldn’t be happier.” dioxide and 50 percent less mono-nitrogen oxide, fly four times quieter and burn 20 percent less fuel than other similarly sized jets. While the true environmental value of the CSeries has yet to be determined, the plane does represent a huge opportunity for Canadian firms. Final assembly will take place at Bombardier facilities in the Montreal area, which will mean a bonanza for domestic aerospace suppliers. The Joint Strike Fighter (JSF) program meanwhile, continues to attract suppliers and generate controversy. The JSF initiative is a multi-billion dollar, multi-decade, American-led program to build F-35 state-of-the-art fighter planes. Canada signed onto JSF in 1997. In July 2010, the Canadian government announced it would acquire 65 F-35 Lightning II Joint Strike Fighter planes for C$9 billion, with maintenance and support costs of C$250 - 300 million. The JSF initiative has come in for some tough criticism, however. In March 2011, the office of the Parliamentary Budget Officer released a damning report, blasting the JSF project for massive cost overruns and production delays. The AIAC are still strongly supportive of the initiative, www.canadianmetalworking.com | FEBRUARY 2012 | 19

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Case Study

Boeing’s ongoing FA-18E/F Super Hornet programme includes landing gear assemblies manufactured by Messier-Dowty Inc. in a contract valued at nearly US$200 million. The contract also includes gear assemblies for EA-18G Growler aircraft. Messier-Dowty will manufacture the assemblies at its production facility in Ajax, Ontario near Toronto.

however. According to Quick, about 60 Canadian firms have gotten JSF contracts to date, at a cumulative value of over $800 million. One of those firms was A-Line Precision Tool, a Toronto shop that counts on aerospace for about threequarters of its business, according to President Rob Muru. A-Line’s experience underscores the profits and pitfalls of working in the aerospace sector. A-Line picked up a JSF contract to work on a General Electric/Rolls Royce F136 engine. The latter was intended to be an alternate engine for the F-35 if for some reason the original engine, which is being manufactured by Pratt & Whitney, didn’t work out. “We made the main titanium engine struts in the front of the engine. Seventeen per engine. These would be the first line of defence when hitting Canada geese or incurring FOD (foreign object damage). We also did speciality EDM work as well as five-axis machining. One casting that we machined had 2,500 plus machining features ... that’s a lot of features and a lot of G-code,” says Muru. For a variety of reasons, however, the F136 initiative lost the vital support of the U.S. government. In early December 2011, GE and Rolls Royce cancelled the F136 project, which meant no more work for suppliers. “We did all the development and were basically set up for production when the plug was pulled. So we took a bath on that one ... that’s the nature of these super programs ... you suck it up, have a beer, a little cry, tell your wife and kids your summer vacation will involve domestic car travel and you move on,” says Muru, philosophically. Indeed, despite the F136 fiasco, Muru remains buoyantly optimistic. “The past few years have been up and down. The last six months have been great! I am expecting [business] to ramp up in the next few years,” he states. CM www.canadianmetalworking.com | FEBRUARY 2012 | 21

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Sky-high in PEI 3 Points Machining and Aerospace has set up a new operation in picturesque Charlottetown, PEI...and reaps multiple rewards By Jim Anderton, Editor .........................................................................................................................................

Seven and a half years ago, Tom Considine and John Druken had no intention to start an aviation machine shop. In fact 3 Points Aviation began at the exact opposite end of the aviation parts life cycle: dismantling old aircraft. “Our focus was in the regional aircraft parts business, declares Tom Considine. “We buy aircraft, dismantle them and then have those components rebuilt and recertified before selling them to airlines worldwide. We focus on Bombardier products; we have dealt in Fokker and ATR, but our real core aircraft is the DeHavilland Dash 8. We also buy inventories of airlines who find the Dash 8 no longer fits their fleet. If they’re not leased we try to buy the airplanes. We want ‘run out’ aircraft, as well as low time aircraft. They’re expensive; we go after the components, expendables, engines and landing gear.” 3 Points still operates a substantial Toronto-based parts trading operation, but chose to expand into part machining and fabrication by launching 3 Points Machining and Aerospace, Inc. That considerable change in the business model was driven by

the repair/overhaul operations the firm was subcontracting to outside machining operations. “We do a lot of component exchange”, says Considine, adding, “they give us back a core. But they don’t want to stock inventory. We were charging them a fee, taking their core and sending it out to a shop for overhaul. We billed it back, but figured that there was a lot of money that we could capture if we had our own shop. That’s what drew us into the business. The manufacturing side of it supports the repairs, but our end users ask for remanufacturing plus reverse engineering. Some parts we can manufacture a good deal cheaper than the repair would cost. It’s another opportunity. And of course, some parts aren’t repairable.” Machining and fabricating for overhaul is a different paradigm from the extensive support needed to actually manufacture replacement parts. Many would simply buy an existing business, but 3 Points’ machining operation is a clean sheet startup. “We were looking for existing shops but found so many www.canadianmetalworking.com | FEBRUARY 2012 | 23

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issues in fixing them, we thought it would be better to start from scratch”, states Considine, adding “it’s all integrated, built all at once. We’ve worked very closely with Elliott Matsuura Canada.” One of the benefits of building a custom shop from the ground up is the ability to choose the best location....and 3 Points chose one that seems improbable: Charlottetown, Prince Edward Island. Co-owner John Druken was the driving force behind the decision to set up in PEI, says Considine: “John is from Newfoundland; he explored all over Canada and the US and he knows people in PEI from the aviation business who set up in Charlottetown. The government here focuses on the aerospace sector. They want to grow that sector on the island and have various incentive programs. We were also looking for a skilled workforce. Charlottetown was the ‘right place’”. The Government of Canada, through the Atlantic Canada Opportunities Agency, invested $500,000 towards equipment purchase and the Government of Prince Edward Island supported the project through their Department of Innovation and Advanced Learning with a $1.9 million secured, repayable loan. Although 3 Points isn’t immune to the skilled labour shortage, there is an aero base on the island, with majors like Honeywell well established. And the natural benefits of PEI are there: affordable housing, natural beauty and the island lifestyle. Considine has not had difficulty with employee relocation: “We’ve had people relocate from Ontario and Alberta as well as some that wanted to come back East.” 3 Points Machining and Aerospace operates both a repair/ overhaul service and aerospace manufacturing. Unlike most

Part complexity, extensive certification/approval processes and serious quality assurance are a given in th

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y assurance are a given in the aerospace sector.

metalworking segments, finished and remanufactured parts require extensive lot traceability and inspection by certified personnel. On site Transport Canada approved engineering staff brings the entire process under one roof. Certifications are key in this industry, and 3 Points carries ISO 9001-2008, AS9120 and has recently earned EASA Part-145 Approval. Certification is an ongoing process with updates and new approvals always in process. The business has developed a specialty in what Considine describes as ‘legacy product”, especially the deHavilland (now Bombardier) Dash 8. The Dash 8 is in many ways the ideal product for 3 Points’ business model: used globally, with a large fleet of aging aircraft (the aircraft was introduced in 1984), operating costs efficient enough to keep the small turboprop economically viable for many operators and perhaps most importantly, an OE manufacturer interested in avoiding the high cost of supporting the Dash 8 fleet. And the cost for an aerospace heavyweight like Bombardier is significant, with the need to inventory potentially slow turning parts which must be approved and shipped globally, often to small operators. That’s where the ability to cut metal gives 3 Points an advantage: “We can turn things quickly”, Considine states. “For new product, there are often long lead times. Look at the Joint Strike Fighter; they keep pushing it back year after year...you have equipment sitting there. With legacy support the customer needs it now. In fact, they need it yesterday. It’s ‘can you do this for us?’ ” What the legacy Dash 8 operators want 3 Points to do is supply a wide variety of parts from seat frames to engine parts. The Dash 8 is a common aircraft for smaller regional and

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ints facility. All inent in the 3 Po ikron unit is prom processes are multi-axis M GF s ile rm This AgieCha d machining ment is new an production equip

non-scheduled operators, meaning single aircraft and small fleets which mean customers who won’t inventory parts and need as little as a single repair component, fast. 3 Points uses modern equipment to fill the gap. It’s about smaller quantities. We’re using today’s technology to build yesterday’s parts”. 3 Points also supports airframes from ATR, Fokker and the Canadair Regional BCP_QT_PAGE_AD_FINAL_RESIZED.pdf 1 10/17/11 12:30 PM Jet. And Considine won’t rule out new part production in the

future. “There are a number of major airframe manufacturers we’re talking to as well...Boeing, Airbus, Agusta Westland, Bell, Pratt and Whitney. They’re interested. Boeing has looked at our operation. Others are coming to look. Our goal is to work closely with the OEM’s.” With aerospace machining, there isn’t much carbon steel on the shop floor. There are traditional aero aluminum alloys like 7075 and 6061 in heat treatments from T3 to T6. Adding processing heat to a heat treated alloy destroys the mechanical properties of the material, so cutting processes are an important consideration. Water jet cutting is one solution but in many cases the part must be post machining heat treated to the proper state before approval. 3 Points also works with titanium, Inconel, some stainless and difficult to machine tungsten. Regardless of the material, speed is crucial to a low inventory business model and customers who can’t afford aircraft downtime. 3 Points can scan and create CAD files to generate tool paths that flow directly to the shop floor with very little interruption or tool setup. Jobs are not palletized, although equipment like the Nakamura-Tome Super NTX Max does auto feed. The ability to approve and certify to Transport Canada and FAA standards in house closes the loop and gives 3 Points a definite advantage where speed matters...and in the airline industry, it usually does. “We can do ‘one off’s’ to thousands”, says Considine. “That’s where to auto feed comes in. It’s by demand. Some parts we make and consign to end users...as they use them we replenish their stock. For spares on site they might order two a year...if it’s a retrofit to address a corrosion issue and a fleet might be 85 aircraft, with 14-15 rails per aircraft, it’s a production run.

This Jet Edge waterjet machine allows clean, efficient cuts, important when the raw material can cost several thousand dollars per billet

The airlines more and more order parts that they need today... everything is critical. They don’t want to stock inventory, so if you have one ready to go, you get the sale.” 3 Points has a solid business model and lots of experience with the Dash 8, but the firm isn’t stopping there. Other aircraft types, from small feeder liners to 737’s are aging and there is new work surfacing in pilotless UAV’s from manufacturers like Grumman, BAE and General Atomics. Combined with contract non-destructive testing and growing East Coast markets like the offshore oil industry, 3 Points’ operation is poised for growth. Nothing is off the table for the firm, including new part design and manufacturing. “It’s something we’re exploring”, says Considine, a pilot himself. “How do you eat an elephant? One bite at a time.” CM

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26 | FEBRUARY 2012 | www.canadianmetalworking.com

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Triple Play Match machine, control and CAM software for hyper-productive high speed machining By Jim Anderton, Editor ......................................................................................................................................... Modern CNC machine tools are capable of cutting fees and speeds that were considered impossible only a decade ago… yet many shops fail to take advantage of the full performance available to them. There are several reasons, from physical limitations in the machine tool to the code created to control tool motion. Mark Sully, Account Manager – Central Ontario for Delcam International presented a comprehensive overview of the productivity problem at Canadian Metalworking’s 2011 Future of Metalcutting Fabricating Conference and has several tips to win back that lost time and money. Sully describes the problem as three-sided: “The trend is toward a ‘triple paradigm’:

According to Sully, to manufacture in ‘high cost’ regions and make a profit, businesses must: • Get the maximum output from machine tools • Minimise unskilled labour content • Minimise quality costs How? Sully states: “by implementing the latest manufacturing methods to achieve fast, robust, automated, and productive machining processes.” The future is clearly in high speed machining, involving very fast tool feeds and speeds. The key is to ensure that the machine, machine control and software are all state-of-the-art; saving money on any link in the chain

THE TRENDS – “THE TRIPLE PARADIGM” Part Side Increased Complexity Smaller Lot Sizes Shorter Lead Times

Engineering Side More Capable Machines 3D vs 2D Design • Paperless Manufacturing • Solid Modeling

Personnel Side Skill levels are harder to find

“The future is clearly in high speed machining, involving very fast tool feeds and speeds. The key is to ensure that the machine, machine control and software are all state-of-the-art; saving money on any link in the chain compromises the strength of the system.”

28 | FEBRUARY 2012 | www.canadianmetalworking.com

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compromises the strength of the system. From a machine standpoint, Sully advises these basic parameters:

‰ Spindle speed range up to 80,000 rpm ‰ Spindle power better than 22 kW ‰ Programmed feed rate up to 60 m/min ‰ Rapid traverse up to 90 m/min ‰ Axis deceleration/acceleration of at least 2.5g (faster w. linear motors) ‰ High thermal stability ‰ Air blast/cutting fluid through spindle ‰ High frame rigidity and mechanical precision

And for the control:

‰ Fast block processing speed (0.5 – 2 milliseconds) ‰ Fast data flow via Ethernet/data server ‰ Handle extremely small, increments point-to-point. ‰ Different error compensations –temperature, quadrant, ball screw ‰ Advanced smoothing/look ahead (HSM functions) ‰ Support probing and tool setting cycles

processing to minimize down time. ‰ HSM Strategies e.g. raceline, spiral, arc fitting ‰ Powerful editing to optimise toolpaths. ‰ Gouge prevention and holder collision checking. ‰ Advanced entry/exit moves – reduce wear and dwell marks. ‰ Machine tool simulation and collision verification ‰ Customizable with macros, Visual Basic**.

There is much more to process optimization in high speed machining than can be covered in any one article….watch Canadian Metalworking for more coverage of this high-productivity, high profit process. CM

To maximise machine tool productivity, NC programs must be produced using a “state-of-the-art” CAD-CAM software. Sully advises the following features:

‰ Support for 64 Bit Windows ‰ Multi-threaded algorithms to make use of multiple CPUs. ‰ Fast Toolpath calculation and background

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Delcam has launched a new web site for its FeatureCAM feature-based CAM system – www. featurecam.com. Visitors to the site can also see video demonstrations of key improvements to the latest version of the software, FeatureCAM 2012, to enable faster and easier programming, and generate more efficient toolpaths to give greater machine productivity. Enhancements include greater use of keyboard shortcuts, easier toolpath editing, new strategies such as back boring and spiral roughing, increased use of stock models, and the ability to have a negative leave allowance (such as a fitting allowance) for turning or wire EDM. The new website features a modern, easy-to-navigate interface to allow visitors to find information relevant to their industry and machining application. www.delcam.com

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A Need for Speed Still faster feeds and speeds with lighter cuts By Nate Hendley .................................................................................................................................................. When it comes to ongoing milling trends, experts point to the need for speed. “I think that the trend will continue towards faster milling as customers seek to reduce cycle time. The machines and tools will be the only limiting factors. We will have to make tools that can work at higher speeds and the machines will need to be able to perform as well,” says Todd White, national sales manager, Scientific Cutting Tools, Simi Valley, California. “Higher milling speeds and feeds with a lighter depth of cut will continue to grow as more and more customers upgrade their milling machines,” agrees Duane Drape, national sales manager for Horn USA, based in Franklin, Tennessee. “People want to run faster and faster and faster.” Thomas Hagan, milling product manager at Iscar Canada, based in Oakville, Ontario, sees plunge milling to machine deep cavities as another growing trend. “Plunge milling is very effective and productive in machining deep cavities and walls,” he states, pointing to Iscar’s Helitang – FTP line of cutters. “This family of cutters is capable of straight plunge side plunging, boring and face machining with ramping at high feed rates at shallow depth of cuts. The inserts are double-sided with four cutting edges that are tangentially clamped,” continues Hagan. Drape suggests CVD (Chemical Vapour Deposition) diamond tipped tools, used to cut hard, non-ferrous materials, will become increasingly popular. “A CVD diamond tip is where we see the future ... the cost for the tool is 30–50 percent more than a polycrystalline (PCD) diamond for the overall manufacturing process ... but the hardness of the CVD diamond is equal to natural diamond, so it’s 30–40 percent harder than polycrystalline diamond,” says Drape. Here’s a look at what’s new and/or noteworthy in cutting tools:

ISCAR – EFP LINE

Israeli tool giant Iscar offers a new family of EFP Solid Carbide Endmills. The EFP line blends features from Iscar’s Feedmill, Chip Splitter and Chatterfree endmills. EFP Endmills can be used for slotting, pocketing, helical interpolation and contouring. “The Feedmill bottom utilizes a large radius cutting edge configuration that allows for greater increase of feed rates—up to 0.5 mm/tooth at 0.3 to 1.0 mm depth of cut. The results are higher productivity in the application of pocketing into the mould. The Chip Splitter edge is able to break up the chips and reduce the cutting forces. The Chatterfree helix has variable pitch which is excellent in dampening the vibration, especially in long overhangs,” states Thomas Hagan, milling product manager at Iscar Canada, based in Oakville, Ontario.

EFP Endmills come with either four or five flutes and can machine hardened steel, cast iron, stainless steel, titanium and high temperature alloys. The series is also designed to reduce cycle time and boost productivity. http://www.iscar.com

KENNAMETAL GOES BEYOND

Kennametal presents the BEYOND KCPM20 indexable milling grade. “KCPM20 is a micro-engineered milling grade featuring a CVD coating process with special surface treatments. KCPM20 is targeted as a best in class grade for high-speed dry milling capability, under stable conditions, in plain and alloyed steel,” says Scott Etling, a manager of global indexable milling at Kennametal, which is headquartered in Latrobe, Pennsylvania. In terms of secondary applications, Etling says KCPM20 is “an ideal optimization grade for stainless steel machining applications where coolant is not used and optimal wear resistance required.” www.kennametal.com

NEW SHOULDER MILL FROM SUMITOMO

Sumitomo Electric Carbide, the Illinois-based branch of the Japanese parent company, released their WFX series of shoulder milling cutters just before Christmas. The high-precision body on the WFX Series includes a cutter containing a 90-degree lead angle, and is optimal for shoulder milling. The WFX offers high accuracy which translates to exceptional part squareness.

30 | FEBRUARY 2012 | www.canadianmetalworking.com

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The high-precision body on the WFX Series includes a cutter containing a 90-degree lead angle, and is optimal for shoulder milling

“The WFX inserts’ convex cutting edge provides extreme toughness and features an integrated wiper that delivers an excellent surface finish. The Series includes coarse, fine and super fine pitch cutter bodies. Coarse and fine pitch versions range from 2 to 8 inch diameters, while super fine pitch bodies are available in 2 to 5 inch diameters,” according to the company. Cutters in the WFX series feature a newly developed, multilayer Super ZX coating which strengthens fracture and adhesion resistance and lengthens tool life, says Sumitomo. www.sumicarbide.com

WALTER – NEW MILLING CUTTER

German tool giant Walter Tools recently introduced the F4050 Milling Cutter with polycrystalline diamond (PCD) cartridges. “Key features are adjustability of run-out to improve finish, flexibility of different cartridges for specific applications, large selection of geometries for universal use,” says Thomas Benjamin, a marketing manager for Walter USA, which is based in Waukesha, Wisconsin. The cutter uses high-tensile steel cartridges with brazed PCD drill points. An adjusting key results in a micro-precise run-out of the cartridges. Settings are effected by clamping screws, which are tightened with defined torques to allow for high limiting speeds. Fine balancing screws ensure a high balance class as

well. Tool bodies are available in diameters ranging from 80 to 200 mm. The F4050 mill is designed for machining non-ferrous materials. www.walter-tools.com

SGS TOOL COMPANY – EXPANDED Z-CARB-AP VARIABLE RAKE ENDMILLS

Late last year, SGS Tool Company of Munroe Falls, Ohio, expanded their line of Z-Carb-AP Variable Rake End Mills to include smaller sizes for a fuller offering. The company’s flagship endmill product, the Z-Carb-AP features enhanced corner geometry with a tighter tolerance corner radius for more accurate machining, unequal flute spacing, and unequal helix design. The Z-Carb-AP’s geometry is designed with chatter suppression in mind. This year, SGS will be releasing a multiple flute end mill for finishing applications. Said mill will be “primarily geared towards aerospace and medical materials like titanium, stainless steels, those types of materials,” says SGS product manager, Jason Wells. www.sgstool.com

Th an M

32 | FEBRUARY 2012 | www.canadianmetalworking.com

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MMTS_gu

Montréal Manufacturing Technology Show 2012

Official Show Guide

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Canadian Metalworking has been chosen by SME to produce the official 2012 MMTS Showguide.

2012 MMTS Show Guide Rates 2 page

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$1,800

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MMTS, May 14 to May 16, 2012 is the largest and most important event serving the Quebec Francophone market.

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Steve Devonport, Publisher 416-543-1641 SDevonport@ canadianmetalworking.com

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SCIENTIFIC CUTTING TOOLS – COMPLETE LINE OF ACME AND STUB ACME THREAD MILLS

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Scientific Cutting Tools of Simi Valley, California released a complete line of Acme and Stub Acme Thread Milling Cutters a little over a year ago. Now a standard item, these mills had been previously manufactured as special tools. The line offers thread sizes from 1¼ - 5 inches and micro grain carbide uncoated and TiALN (titanium aluminum nitride) coated tools. These thread mills produce small chips which can be controlled with flood coolant. Tools cut both left and right hand threads. The line is designed to ensure speedy thread cutting and cost-savings, compared to tapping. www.sct-usa.com

HORN USA — SMALL DIAMETER CARBIDE TOOLS

Last year, Horn USA introduced their DC line of Solid Carbide Cutting Tools for machining grooves, threads and chamfers. “These tools are for diameters smaller than our Mini-Milling replaceable insert product line,” explains Duane Drape, national sales manager of Horn USA. Horn also offers a threadmilling line featuring multiple flute tools. “We stay with our preferred method of only one level of cutting edges. Most of our competitors have multiple levels of cutting edges and a reduced number of flutes. Our approach results in the customer being able to feed the tools substantially faster and if the thread is not perfect, he can rerun by changing an offset diameter. The multiple level cutters potentially leave a slightly tapered thread,” adds Drape, speaking of the threadmilling line. www.hornusa.com 34 | FEBRUARY 2012 | www.canadianmetalworking.com

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EC-H mills come in two family types: cylindrical and relieved shank endmills. Endmills in both families offer a 6 – 25 mm diameter range, while all have corner radii. Improved dampening performance will prolong tool life up to 25 percent, says Iscar. These mills reduce the cutting forces and power consumption of the machine and provide improved chip evacuation. CM

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NIAGARA CUTTER INTRODUCES NEW THREAD MILLS

Niagara Cutter of Amherst, New York has introduced a new line of High Performance Carbide Thread Mills, designed to ramp up productivity, quality and performance consistency. Said mills come in a variety of thread sizes and diameters. Options include AlCrN (aluminum chromium nitride-based) coating and extended reach. www.niagaracutter.com

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WALTER USA NEW FOR HARD MACHINING

Another new offering from Walter is the Proto-max Ultra, a ball-nose, solid carbide endmill designed for hard material machining. These new mills come in two different diameter ranges: the standard version offers a 3 – 12 mm diameter while the mini version offers diameter ranges as low as 0.1 – 2.5 mm. Main applications for the Proto-max Ultra line include hardened materials up to 70 HRC in die and mouldmaking and similar operations in general machining and heavy construction. In addition to semifinishing and fine finishing, the Proto-max Ultra can be used for semi-roughing and roughing.

ISCAR IMPROVED DAMPING PERFORMANCE Iscar also recently introduced a line of new EC-H endmills, with a four flute, variable pitch and different helix flute angles: two 35 degree helix flutes and two 37 degree helix flutes. The

Visit HydroFlow.Eriez.com or Call 888.300.ERIEZ www.canadianmetalworking.com | FEBRUARY 2012 | 35

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Welding News PORTABLE WELDING SOLUTIONS FROM SEMIAUTOMATIC WIRE FEEDER

Designed for use in shipbuilding, offshore, construction or pipe welding operations, the Lincoln Electric’s portable Active8 wire feeder is small enough to fit through ship manways. It’s modular designed is light enough to carry around the site. The Activ8 is capable of feeding self-shielded FCAW or FCAW-G and GMAW (MIG) gas-shielded wires at 50–800 IPM (1.3–20.3 m/min). The unit will handle GMAW wires .023–.052 in. (0.6–1.3 mm) in diameter and FCAW wires of .035–5/64 in. (0.9–2.0 mm) in diameter. The portable wire feeder is rated at 330 amps at 60 percent duty cycle and weighs in at only 27 lbs. (12.2 kg). This modular unit is designed specifically for 8 in. (200 mm) spools, is compatible with any DC CV and/or CC power source, boasts simple controls including front WFS knob and internal booted cold feed and/ gas purges, trigger interlock Lincoln’s Activ8 is a tough durable portable and CV/CC switches. The wire feeder. unit is enclosed in a tough plastic case molded from high-impact, flame-retardant material and features the MAXTRAC Drive System with dual gear-driven drive ensuring positive feeding performance, a patented wire drive with tool-less drive roller and wire guide changes for quick spool replacement. A tachometer-controlled motor powers drive rolls for smooth, steady feeding without wire slippage. www.lincolnelectric.ca

AWS BRINGS AUTOMATED WELDING TO ORLANDO

Orlando, Florida will be the scene of the American Welding Societies’ (AWS) Conference on Automated Welding. Held on March 6 and 7, 2012, the conference will feature talks on a variety of topics, including tandem arc welding, hybrid welding, several hot wire processes, Computer-Controlled Hot Wire Tig Welding and Cladding of Land-Based Gas Turbines, the new SAT process from Sweden, as well as presentations on the latest in networking, laser welding, welding of aluminum, robotic inspection, and friction stir welding. Speakers on U.S. Army challenges, such as GMA welding of titanium and the welding of ballistic steels will also be on the agenda. www.aws.org/conferences/2012automated.html

HOBART BROTHERS OFFERS FILLER METALS FOR DEMAND CRITICAL SEISMIC APPLICATIONS

16 metal-cored and flux-cored (gas- and self-shielded) wires that meet the AWS D1.8/D1.8M, Structural Welding Code-Seismic Supplement for Demand Critical welds in seismic moment frame welded connections are being offered by Hobart Brothers. These filler metals have all been three-lot tested in accordance with AWS D1.8/D1.8M:2009 testing requirements and meet the requirements specific for their diameter and shielding Hobart Brothers now offers sixteen gas (where applicable). As a flux-cored and metal-cored wires, including its popular Fabshield XLR-8 result, they are considered wire, that meet the D1.8 Seismic pre-qualified for seismic Code requirements for Demand applications and can be used by Critical Seismic applications contractors without additional

filler metal testing. The additional testing also ensures that the deposited weld metal has adequate strength and toughness at the specified heat input envelope for the low and high heat inputs according to individual diameter sizes. Included in the company’s offering for D1.8 Seismic filler metals are the popular Hobart Fabshield XLR-8 self-shielded flux-cored wire, the Tri-Mark Metalloy Vantage metal-cored wire and the Hobart FabCO Hornet gas-shielded flux-cored wire. www.hobartbrothers.com

LINCOLN EXTENDS MONEY MATTERS REBATE PROGRAM

Lincoln Electric’s successful Money Matters rebate program has been extended until Feb. 29, 2012. The company has expanded the program to include additional products like the Power MIG 180 Dual and the new Power MIG. Rebates on the new additions are $100 for the Power MIG 180 Dual and $200 for the Power MIG 256. Lincoln has also bundled its Tomahawk 625 plasma cutting system with a Torchmate(r) 2x2 CNC plasma cutting table, offered with a $300 rebate. The existing offer are: Power MIG 140C - $75 rebate, Power MIG 180C - $75 rebate, Power MIG 180 Dual - $100 rebate, Power MIG 216 - $125 rebate, Square Wave(tm) TIG 175 - $150 rebate, Outback 145 Engine-driven welder/generator - $150 rebate, and the Ranger 225 Engine-driven welder/generator - $200 rebate. www.lincolnelectric.ca

HYPERTHERM CUTTING INSTITUTE NOW ONLINE

Hypertherm has unveiled an enhanced Hypertherm Cutting Institute, an online training community that offers a number of resources for people who work with or want to learn more about cutting metal. Key features found on the online site are video tutorials providing thorough step-by-step instruction, interactive e-learning courses on everything from consumable care and optimization to gouging and cutting technique, discussion forums and blogs where metal fabricators and hobbyists can talk about their current products, troubleshoot issues and share ideas. An added bonus: Hypertherm experts like Jim Colt will drop by from time to time to offer advice and answer questions. The idea section, called My Hypertherm Voice, is designed for visitors who want to offer suggestions for future metal working products and then vote on their favourite ideas. www.hyperthermcuttinginstitute.com

36 | FEBRUARY 2012 | www.canadianmetalworking.com

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