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Vol. 107 | No. 6 | SEPTEMBER 2012 | www.canadianmetalworking.com
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IMTS SHOW ISSUE
WELCOME TO CHICAGO!. .....................................22 Lots to see and do in America’s not-so “second city” IMTS AT A GLANCE...............................................28 Where the show is and how to get there A BRIGHT FUTURE.................................................30 AMT president Doug Woods on the future of manufacturing A SNEAK PEEK AT WHAT’S NEW...............................34 An advance look at IMTS 2012 AUTOMATION FOR EVERYONE. ................................40 Assessing the risk/reward ratio
34
EXACTLY RIGHT....................................................46 Exacta Aerospace machines tough materials for tough applications HOT HANDS......................................................50 Handheld micrometer accuracy is affected by the heat of your hands … but by how much? BEFORE THE WELDING BEGINS.................................56 What you do before you weld is as important as the weld itself THE OTHER EDGE.................................................64 Non-carbide cutting tool options aplenty YOU KNOW THE DRILL...........................................70 New drills, new directions
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LET THERE BE LIGHT...............................................80 Faster, more accurate cutting means higher productivity CUTTING CLEAN.................................................86 Abrasives in handheld tools, more efficient than ever COSTLY CORROSION............................................96 Protect your parts before shipping
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DEPARTMENTS View from the Floor........................................................... 6 News.............................................................................. 8 Floor Space . ................................................................. 16 Welding News............................................................... 54 Tool Talk......................................................................... 76
CONTENTS...
IMTS 2012 CHICAGO ...................................................... 20 North America’s biggest manufacturing show hits the Windy City
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By the Numbers.............................................................. 98 www.canadianmetalworking.com | SEPTEMBER 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 The ugly truth behind the skilled labour shortage In today’s uncertain economic environment a surprising number of non-manufacturing business leaders I encounter are surprised by the problems facing Canada’s metalworking industry, especially the labour issue. The critical shortage of skilled labour has become a preoccupation for most segments of Canada’s metalworking industry and it’s not going away any time soon. The media, industry associations, “think tanks” and all levels of government have branded this as a public relations issue: convince kids that there’s a great career ahead of them in manufacturing and they’ll flood the apprenticeship programs. While there is a pervasive image problem with skilled trades in Canada, in my opinion there are three important factors that you won’t see or hear in the mainstream media: Trades lock bright young people into blue-collar jobs forever. No matter how experienced, a tool and die maker will not become an engineer. In our status and money-driven culture we need to create a career path that allows smart, motivated tradespeople to upgrade skills all the way to professional engineering certification. We can’t blame the engineers. Like other white-collar guilds such as law and medicine, they’ve evolved to selfregulate, tighten qualification and restrict supply, raising effective wages. Not all tradespeople will want to certify, but the option will attract many candidates. Creation of an alternate route to professional qualification would likely require federal and provincial government involvement. Don’t hold your breath. Older journeymen don’t want their children to follow them into the trades. Many skilled workers expect and demand that their children use post-secondary education to earn white-collar positions, even if they pay less. Why? Status and the highly optimistic belief that the easier route to a corner office is through the mail room rather than the tool room. If the children of Canadian tradespeople followed their parents, we wouldn’t have a crisis. No federal ‘Economic Action Plan” can address this. Two-income families restrict labour mobility. Now that both parents must work to support a family, it’s difficult for a skilled worker to relocate unless there are excellent job prospects for their spouse too. A Bay Street office manager married to a welder is going to find few prospects in Fort McMurray. Even if the single skilled wage could replace both incomes, few spouses will torpedo their careers, or relocate school-age children. I don’t blame them. To fix this problem, we have to address the root cause: declining effective middle-class living standards. Jobs are too geographically concentrated in this country, resulting in excessive housing costs. My steelworker grandfather bought a suburban Toronto detached house in the ‘Sixties on his income alone. It sold recently for just under half a million dollars. Try that purchase today on a single income. To fix this, we’ll need to encourage and possibly subsidize relocation of our industrial base away from the major centres either by a Chinese-style command economy or a modern transportation and communication infrastructure driven by a national industrial strategy. Ottawa is going the other way. These issues can be fixed. It will take politicians and business leaders with a longer view than their quarterly statements, or an autocrat at 24 Sussex Drive. Let’s choose the former. 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
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News CWA celebrates 18th Annual Mike Cherry Memorial Golf Tournament
The CWA sponsored, 18th Annual Mike Cherry Memorial Golf Tournament, held August 14th at the Granite Ridge Golf Course in Milton, Ontario. NHL player and ex-Toronto Maple Leaf, John Mitchell (left), was a special guest at the tournament.
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ver 50 golfers representing the spectrum of Canadian welding decision-makers beat the weatherman at the 18th Annual Mike Cherry Memorial Golf Tournament, held August 14th at the Granite Ridge Golf Course in Milton, Ontario. After an initial soaking, the rain stopped after four holes and the Canadian Welding Association event ended in the sun. The Mike Cherry Memorial Tournament is an industry institution, and raises funds for a scholarship fund in Cherry’s name at the University of Waterloo for welding studies. Victor Andrisani, the chair of the CWA’s Toronto chapter was impressed with the turnout. “We were very happy. Even though the weather was bad, everyone still came out and enjoyed themselves and we were really, really pleased with the attendance today … at the end there it was really nice!” In the past, the tournament has raised $2,500 a year for the scholarship fund.
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“Mike was very enthusiastic about the welding industry. What he felt was the welding engineers – there wasn’t enough out there,” Andrisani said. “And he was really trying to promote at the university level to get welding engineers out there.” The tournament featured a best-ball format and dinner and was anchored by a special guest appearance from NHL player and ex-Toronto Maple Leaf, John Mitchell. “I had a great day today. It rained the first four holes but we survived with all pars,” Mitchell said. “Would have been nice if we got a couple birdies but, I enjoyed myself and I got to play with my dad, so that’s always fun.” Mike Cherry was the former president of WPMAC (Welding Product Manufacturers Association of Canada) and former vice-president of Fibre Metal Canada Limited. The scholarship is awarded to a fourth-year student enrolled in the Welding and Joining Specialization in Mechanical and Mechatronics Engineering program at the University of Waterloo. CM
8 | SEPTEMBER 2012 | www.canadianmetalworking.com
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News Renishaw opens new facility in Mississauga
feedback, calibration systems for machine performance analysis, Raman spectroscopy systems, plus new gauging, surveying systems and additive manufacturing equipment. The product demonstrations at the opening included the revolutionary REVO 5-axis scanning system and new PH20 5-axis touch trigger probe for CMMs.
NanoSteel/GM partners; hope to create more fuel-efficient cars
On July 12th Renishaw, opened a brand new facility in Mississauga, Ontario. Ben Taylor, the Renishaw Group’s Assistant Chief Executive, performed the opening and the event included demonstrations of the company’s advanced engineering technologies. Commenting on the new 17,500 square foot facility, Renishaw Canada’s Director & General Manager, Dafydd Williams, said, “This investment marks a further chapter in Renishaw’s on-going commitment to the Canadian market, where we have been successfully trading for more than nine years. With a strong local manufacturing base for automotive and aerospace, there are many opportunities for Renishaw to assist companies that are striving to raise quality and productivity levels.” The new facility is a former film studio and is situated in the heart of the Canadian manufacturing industry. The opening of an updated facility and the convenient location will allow Renishaw to expand its operations to accommodate growing interest in its full range of innovative metrology products. Such products include, co-ordinate measuring machine (CMM) probe systems, touch probes and laser tool setters for CNC machine tools, linear and rotary encoders for position
Rhode Island-based NanoSteel Company has announced that General Motors Ventures LLC has invested in the company because of their advancements in the steel alloy industry. GM Ventures is a subsidiary of its parent company with a mandate to invest in promising automotive technologies. “We are investing in NanoSteel because of the opportunity associated with their new steel alloy technology,” said Jon Lauckner, GM’s chief technology officer, vice president of Global R&D and president of GM Ventures LLC. “Over the next several years, light-weighting of vehicles will be a major focus area to improve fuel economy. NanoSteel’s nano-structured alloys offer unique material characteristics that are not available today, making them a potential game-changer.” Founded in 2002, NanoSteel has created a new class of
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steel called Advanced High Strength Steel (AHSS), which has the ability to drastically reduce the weight of today’s cars. Despite the reduced weight and thinner gauge of the steel, it still maintains the structural integrity needed to meet industry safety standards. The steel is also cold formable, making it easier to process than some other steels. “GM Ventures investment in NanoSteel demonstrates its confidence in our company’s potential to achieve widespread impact on the auto industry through our proprietary steel designs,” said Dave Paratore, president and CEO of NanoSteel. “With the support of General Motors’ automotive expertise and technology leadership, we can accelerate the final phases of development of our nano-structured AHSS in the quest to economically lightweight vehicles.” The unique combination of ductility and strength of AHSS has the potential to allow for steel to take back an industry where aluminum and carbon fibre are starting to become more commonplace. The reduced weight of steel is expected to have significant impact in the auto industry in a number of areas, one of the most important of which is fuel economy. Lighter cars will make it much easier for automotive companies to meet today’s stricter environmental regulatory standards.
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Canadian manufacturers optimistic about future
A new report from KPMG suggests that 85% of Canadian manufacturers are optimistic about the future for their business. The results came by way of KPMG’s Canadian Manufacturing Outlook 2012, which interviewed 150 participants from across Canada. The report found Canadian manufacturers are more confident than last year and optimism had increased by 9% over the previous survey’s results. More importantly, manufacturers have a more positive outlook than that of their global counterparts. “Our survey tells us that Canadian manufacturers are confident in their business strategies, but investing in innovation, increasing efficiencies and managing risk are top-of-mind moving forward,” said Laurent Giguère, National Industry Leader, Industrial Markets, KPMG in Canada. “As smaller, niche players operating with a strong dollar, Canadian companies realize they need to innovate in order to compete with lowercost global producers.” The report made it clear that manufacturers realize the importance innovation can have on their business. More than 60% of Canadian respondents say the next wave of transformational innovation is underway or will be within the next 12 to 24 months. Manufacturers also said striving to increase productivity and manufacture products at the lowest cost continues to be a priority. Half of the respondents said reducing labour costs are the cost control method they expect to be most important over the next 12 to 24 months. The only real concern in the report was that Canadian manufacturers are not doing enough in the area of risk management. The report found that only 5% of Canadian companies use simulations to assess their risk management functions and that 17% of respondents don’t know how they will identify risk in their supply chain in the coming two years. Companies with annual revenues under $100 million made up 62% of the survey’s respondents, while 4% was made up of companies with revenues over $1 billion. The full report is available at: www.kpmg.com
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Fastems, LLC has appointed David Byrne as their Business Development Manager in Canada. “We are very pleased that David has chosen to join the Fastems team,” says Richard Bodine, Fastems’ Vice President – Sales & Marketing. “Canada is a very important market for us. Its manufacturing sector continues to expand, particularly in the aerospace and energy
12 | SEPTEMBER 2012 | www.canadianmetalworking.com
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News sectors, which are two of our biggest markets. David’s extensive machine tool and factory automation experience will serve our customers and prospects well.” Byrne has a background that includes technical sales positions at machine tool distributorships and OEMs. Most recently he was employed by A.W. Miller Technical Sales, Inc. Other machine tool-related companies at which he held
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Global profitability outlook deteriorates in June, Canadian manufacturing bucks trend: study The Conference Board of Canada has released a study, which reports the economies of Europe, the U.S., and China continued to show signs of weaknesses in June as the European debt crisis worsened. However, despite poor performances by other world markets, Canada’s manufacturing sector has remained stable. The report states: Despite several meetings to discuss the problem, European leaders remain unable to agree on the steps needed to resolve the crisis. And the longer it takes them to restore full confidence in European banks, the more likely it is that the world economy will fall back into recession. Given this economic uncertainty, it would not be surprising to see the profitability outlook for Canadian industries deteriorating. The Canadian manufacturing sector, however, has so far proven to be relatively immune to the rise in global economic uncertainty and weaker economic growth worldwide. Despite a decline in The Conference Board of Canada’s Index of Business Confidence in the second quarter of 2012, indicators show that Canadian manufacturing activity continued to grow during that period. Growth in the Canadian manufacturing sector in June resulted in a brighter profit outlook for several manufacturing industries. After four consecutive months of decline, the index of the transport equipment manufacturing
14 | SEPTEMBER 2012 | www.canadianmetalworking.com
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News industry (excluding auto and auto parts) posted the strongest increase of all 49 industries in June, up 1.2 per cent. Along with the transportation equipment manufacturing industries, 10 other industries from the manufacturing sector (out of 17 covered by the index) also recorded an increase in their profitability index—auto manufacturing, auto parts, chemicals products, plastic and rubber products, machinery, food and beverages, non-metallic mineral products, furniture, pharmaceutical products, and even paper products. The full report is available at: www.conferenceboard.ca
Medical manufac turing event to run October 25, 26th SME Canada has announced that in response to the success of MMI Toronto 2010, the Canadian medical industry event returns for its second year at the International Centre in Ontario. MMI 2012 will provide key medical and dental device professionals a platform to meet and learn about the latest technologies, discuss issues and solutions and network with industry peers. The Medical Manufacturing Innovations (MMI) event is a comprehensive, specialized 2-day event focused on and tailored for Medical and dental device manufacturers as well as equipment & contract manufacturers and suppliers. For more information visit: www.mmi.sme.org
The Canadian Welding Association hosts industry’s elite in Quebec The Canadian Welding Association is hosting their third annual conference at the Hilton Hotel in Quebec City September 9-11, in hopes to attract a demographic other than the industry’s engineers, specialists, and professors – the next generation. The average age of a welder is 54-years-old, which means retirement and greener pastures are just around the corner. This means an abundance
of positions within the field are on the horizon. It also means a huge opportunity to help shape the face of the industry and help future generations see its value and potential. The CWA hopes to not only ‘spark’ interest, but also invigorate industry and encourage them to embrace new technology and processes.
Many welding heavyweights are slated to appear and discuss the industry’s latest trends and current advancements in technology as well as crucial elements such as weld quality management. Health and safety is also something of interest as the industry’s standards are always being put under
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Floor Space “Would it help or hurt your business if the Canadian dollar declined to 60 cents against the U.S. dollar?” “A 60 cent Canadian dollar would definitely motivate U.S. and foreign investment in our products, specifically as it relates to the manufacturing sector. This is, of course, based on the assumption the U.S. market starts buying again. For as long as the American consumer remains frugal and limited in spending, improvements will remain limited.”
– Joseph Manzoli, president, Colourfast, Concord, Ontario
“It would not help us with a 60 cent dollar ... we are doing okay where it is.”
– Peter Alden, co-owner, Wessex Precision Machining Limited, Ayr, Ontario
“A decline in the Canadian dollar would very much help our business. At this time, most of our customers are from the U.S. and all of our receivables are in U.S. funds. The weak U.S. dollar has actually been a hindrance to our company for the past few years.”
– Adriano Oppio, vice-president, Classic Tool and Die, Oldcastle, Ontario
“Our company would benefit due to the high percentage of U.S. sales [we make]. We can compete at par but the cost to do business in Canada is much higher than [in the U.S.]. Eighty-five cents would be ideal.”
– Jason Bannerman, president, Xakt Komponets, Brampton, Ontario SumDocHalfPageAd_CanMan9_12_Layout 1 8/3/12 8:06 AM Page 1
“A 60 cent dollar would open the border to our exports all over the world.”
– Marco Gagnon, co-owner, Gagnon Ornamental Works, Grand Falls, New Brunswick
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“I would speculate that we would see an increase in business because conversely, we have seen a decrease from our U.S. customers since the dollar has been so high. I also believe that other business would flow into Canada from other foreign markets as well if the dollar were to drop in value.”
– Gerry Vandersanden, president, Sciens Industries, Peterborough, Ontario
“The dollar at 60 cents [to the U.S. dollar] would mostly be good for us. It would increase the price of imported goods ... but it would reduce the operating costs of our clients, leading to them getting more work and then us getting more work in turn. And more work is what it’s all about.”
– David Foscarini, president, Mecon Industries, Scarborough, Ontario
“A 60 cent dollar would help our company in that our customers would be more competitive stateside but it would increase our cost of production through higher tooling, maintenance and capital equipment costs. A 5 to 10 cent below par dollar would strike a good balance between competitiveness and production costs.”
– George Barnes, president, Foldens Machine Works, Tillsonburg, Ontario
“Canadian dollar at 60 cents again? You bet! Bring it on! Great for growing exports of course ... Canada is in great shape compared to other countries and we are resource rich. So my early guess is, it’s never going to happen.”
– Rob Muru, president, A-Line Precision Tool, Toronto, Ontario
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News a microscope to ensure proper use of equipment and technique. The CWA conference is a unique opportunity for young minds to network, get to know the professionals and learn from the best. To get more information about the conference and to register for an invite you can visit: www.cwaconference.org
RBC purchasing manager’s index climbs as new order growth strengthens to nine-month high June saw a robust improvement in Canadian manufacturing business conditions, according to the RBC Canadian Manufacturing Purchasing Managers IndexTM (RBC PMITM). The monthly survey offers a comprehensive and early indicator of trends in the Canadian manufacturing sector. The RBC PMI is a composite indicator designed to provide a snapshot of the health of the manufacturing sector. The June edition of the report indicated a further improvement in Canadian manufacturing business conditions. Manufacturing employment increased for the fifth successive month in June, while the rate of input price inflation slowed sharply to its weakest pace since data collection began in October 2010. “The strong performance in the manufacturing sector so far this year has been led by medium-sized companies – those with 50 to 199 employees, with more recent improvements also noted for smaller companies,” said Craig Wright, Senior Vice-President and Chief Economist, RBC. “Conditions across the sector are favourable, and we expect that continued gains in employment and an uptick in exports will help contribute to further economic expansion in 2012.” Canadian manufacturers received a larger volume of new orders in June, with greater client demand often cited. Approximately 37 percent of survey respondents reported an increase in new work intakes since May, while 18 percent recorded a decline. Overall, the rate of new order growth was strong and the fastest since last September. While the amount of orders increased in June, so to did input costs for Canadian manufacturing firms. However, the rate of input price inflation was not drastic, and was eased due in part to lower oil prices offsetting the overall rise in cost burdens that month. Manufacturing business conditions improved in all four Canadian regions in June. Quebec posted the strongest improvement, as they have for each of the past three months. Conversely, the slowest expansion of incoming new work was registered in Alberta & British Columbia. “Canada’s manufacturing sector continued to be supported by a strong increase in new orders in June. New export orders were also up, with a solid improvement in Canadian export market conditions reported,” said Cheryl
Paradowski, President and Chief Executive Officer, PMAC. “Manufacturers recorded the weakest increase in input prices since we started collecting data in October 2010.” The full report is available at: www.rbc.com/newsroom/pmi
INDUSTRY ANNOUNCEMENTS: Nick Healey has joined Canadian Metalworking magazine as the new Assistant Editor. Nick has extensive experience working at metal shops in Kingston, ON and Broome, Western Australia and carries a Bachelor’s Degree in Political Science and English from Bishop’s University. “We’re pleased to have Nick aboard. His combination of experience and energy will help us expand our print and on-line platforms for 2012 and beyond”, said Canadian Metalworking Editor Jim Anderton, adding “Nick will join Steve Devonport, Rob Swan and myself on the floor at IMTS and is looking forward to meeting the industry in person.” Nick can be reached at: nhealey@canadianmetalworking.com. Phil Lounsbury has joined Elliott Matsuura Canada Inc., Oakville, ON, as the Regional Sales Manager for Calgary, Alberta South. Phil was working for MTW as an Applications Engineer and has extensive programming experience from his years working at machine shops in the Calgary area.
Alex Moretti has joined Elliott Matsuura Canada Inc., Oakville, ON, as the Regional Sales Manager for Edmonton, Alberta North including Red Deer. Alex comes to Elliott with extensive machine tool experience having worked eight years for MTW selling Mazak machines in Edmonton. Alex also has extensive experience in the industry from managing shops in the Edmonton area.
A M s m fi e o
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IMTS 2012 in Chicago
North America’s Bigge Technology Show Hits By Nate Hendley
T
he International Manufacturing Technology Show (IMTS) will be held at McCormick Place in Chicago September 10 – 15, 2012. As sponsored by the Association for Manufacturing Technology (AMT) of McLean, Virginia, IMTS takes place every two years and is one of the largest trade shows of its kind in the world. This year’s event is set to feature over 1,800 exhibitors from the metalworking sector and around 90,000 visitors. Exhibits are organized in pavilions geared towards specific industries, technologies and solutions. There are pavilions
for metal cutting, tooling and workholding systems, metal forming and fabricating/laser processes, etc. IMTS 2012 will also feature a job center, where job seekers can network with potential employers, post resumes and investigate work opportunities. “The show theme for 2012 is ‘Be There’ and is a call to action for the industrial decision makers from all over the world who will attend IMTS to get ideas and find answers to their manufacturing problems and challenges, but most importantly, to stay ahead of their competition,” states John Krisko, Director – Exhibitions for AMT.
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ggest Manufacturing Hits the Windy City Tool manufacturers say much the same. “IMTS has grown into North America’s most important manufacturing technology trade event, rivaled only by EMO in Europe and JIMTOF in Asia. There is a true advantage when manufacturers and engineers can see, touch, and compare potential solutions in machine tools, tooling, software, peripherals and the many other aspects that production operations require,” states Christina Sutter, corporate communication manager for Kennametal in Latrobe, Pennsylvania. “IMTS is significant because it is the single largest show for
manufacturing in North America. IMTS is not just a show, it is an event that provides a great environment for manufacturers such as us to connect with our customer base on a large scale,” says Mark Hemmerling, director of marketing at Walter, USA, the Waukesha, Wisconsin-based branch of a German parent firm. “IMTS is the single biggest event and most important marketing initiative that our company executes ... you may think the Internet allows people to do [product] research, but most people still appreciate face-to-face interaction and the ‘touch and feel’ that a tradeshow provides,” adds Tim Stapula, marketing manager at Big Kaiser Precision Tooling in Hoffman Estates, Illinois. www.canadianmetalworking.com | SEPTEMBER 2012 | 21
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Welcome to Chicago The Windy City serves up great dining, big-league sports and culture to match during IMTS 2012 By Nick Healey, assistant editor
McCormick Place
F
ortunately for the attendees of the International Manufacturing Technology Show (IMTS), it’s located in the heart of one of the greatest cities in North America — Chicago. Meghan Risch, the VP of Communications at Choose Chicago recognizes the value of the show coming to town. “IMTS is one of our largest conventions. This year it’s going to bring about 90,000 attendees from more than 100 countries. They bring more than $200 million in direct expenditures to the city. So this is a welcome piece of business to the city.” When most think of Chicago, there’s a tendency to picture it in the shadow of New York, America’s financial and cultural mecca. But this city has history. Ironically, after much of the city was scorched to the ground in the Great Chicago Fire of 1871, a period of great prosperity began. New buildings shot up, using steel instead of wood, and the city quickly became a massive trade and industry hub. The good times continued to roll right into the roaring ‘20s when Al Capone and his cronies established Chicago as the capital of the bootlegging world during prohibition. Today Chicago continues to grow as one of
Photo courtesy Choose Chicago
the greenest cities in America and is finding innovative ways to incorporate renewable energy despite its hardened industrial past. Fitting logic for the “Windy City”. So clearly being labeled the country’s “second city” is a bit misguided as it’s the gateway to the country’s Midwest and a hotbed of cultural, historical and sports attractions. The city may fly under the radar, but its features are just as impressive, if not more so, than it’s counterparts in New York, Los Angeles, or Toronto.
THE CHICAGO CULTURE CLUB
Some of the finest draws in the city are its cultural ones. “I always recommend to anyone coming for a meeting or a convention to experience our museum campus,” Risch says. “Because if you have some downtime during the show you can walk from McCormick Place, along the lakefront and access the campus. And it’s a beautiful walk, beautiful green space. We’re very fortunate, we’ve taken advantage, we’ve built-up our lakefront and we encourage people to use it.” One such museum, the famous Art Institute of Chicago, is
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DMG_MORI_
Chicago by night.
Home of the original Second City troupe.
Photo courtesy Choose Chicago
home to some of the best pieces by the world’s greatest artists. Works by Jackson Pollock, Picasso, and Claude Monet line the walls of this 19th century Michigan Avenue building. In addition to the Art Institute, there are a slew of great theatres to visit in downtown Chicago, including the Goodman Theatre which is the city’s oldest and largest not-for-profit theatre.
Photo courtesy Choose Chicago
The Lincoln Park Zoo can also claim the mantle of the country’s oldest public zoo, with nearly three million visitors a year making their way to the 35-acre oasis. And the best part? It’s free, thanks to donations from its members. Architectural buffs will also enjoy some of the city’s famous buildings representing the city’s industrial history, including the Willis Tower (formerly known as the Sears Tower), which for many years staked its claim as the world’s tallest structure. Or for less industrial-looking features, the Water Tower is one of Chicago’s most prolific buildings, even managing to withstand the destruction of the Great Fire. Even IMTS itself is an event to behold. Hosted at beautiful McCormick Place with over 2.2 million square feet, the venue is home to the largest amount of exhibition space in North America, so it’s little wonder that so many trade shows find their way there. At some point though, you’re going to need to eat. Chicago is widely considered one of the great culinary cities in the world, and the beauty is that everything from fine dining to comfort food is covered. “We are exploding as what I like to call, an epicurean epicentre,” Risch says. “There are big name chefs. Stephanie Izard, Rick Bayliss, Graham Elliot. They’re not shuttering any restaurants here and going to the coast. They’re opening more restaurants. This is the place to be if you’re looking for a real dining experience.” For those seeking something a little more refined, Chicago has a slew of restaurants to enjoy. Alinea, run by head chef Grant Achatz, features modern dining in the Lincoln Park area
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Photo courtesy Choose Chicago
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COMEDY, DINING AND NIGHTLIFE ABOUND
Of course art galleries and classic theatre can lack the stimulation other attractions provide. For more excitement there are plenty of other options. Second City is the famous Chicago-based comedy troupe, which has produced some of the greatest names the business has ever seen. Names like John Belushi and Bill Murray are synonymous with the outfit as are some iconic Canadians, such as Eugene Levy, John Candy and Martin Short. “Second City is a must! Whether it’s your first time or your tenth time to Chicago,” says Risch. “They have a new comedy club called Up. They have shorter run shows, and they offer food and drink there; where at the original Second City it’s just cocktails. So it’s a different type of experience.”
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Enjoy the cultural experiences of Rush Street. (Left:) The Cubs, White Sox and Photo courtesy Choose Chicago Bears give the sports fan plenty of choices in Chi Town
and is the city’s only restaurant with three Michelin stars for 2012. The list goes on of course, and much like any city, Chicago has its ethnic hotspots to explore, like Greektown, the Ukrainian Village and Little Italy, which make their own contributions to the great dining atmosphere. And keep in mind that to go to Chicago and not indulge in their famous deep-dish style pizza would be a sin. The battle with New York continues to rage over which city can in fact serve the best slice of pie. Plus, owing to Chicago’s heavy eastern European background the city has become famous for its selections of sausages and hot dogs at restaurants like The Weiner Circle – just don’t order ketchup on your dog or you’ll never hear the end of it! And of course, there are plenty of options for the sports fan as well. For the baseball lover, few ballparks in the world match the timeless beauty of Wrigley Field. With its ivy-lined outfield and classic-looking façade, this historic stadium has been home to the Chicago Cubs since 1916 – unfortunately for their fans they’ve been losing there ever since. On the other hand, their crosstown rivals, the White Sox, won the World Series in 2005, so there is good baseball to be seen in the city! Apart from that, the NFL season will be alive and well in Chicago with the beloved Bears plying their trade at Soldier Field through the autumn and winter months. So clearly Chicago has an abundance of features on offer. Whether it’s fine dining, an evening of laughs, or a baseball game there’s so much on offer in Chicago you’ll never have time to get to it all in one trip. But since IMTS is held every second year, at least you know your calendar will be full next time around. CM 26 | SEPTEMBER 2012 | www.canadianmetalworking.com
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IMTS at a glance
McCormick Place building locations and area map.
WHAT’S IMTS?
IMTS, the International Manufacturing and Technology Show, is organized by the Association for Manufacturing Technology (AMT) and is held every second year (on even numbered years), in Chicago at McCormick Place – one of the world’s largest convention centres. The show is typically held in midSeptember with this year’s dates being the 10th-15th. There will be over 1800 exhibitors and over 80,000 visitors.
WHO SHOULD ATTEND?
IMTS is basically a who’s who of manufacturing industry players. Whether you’re the owner of a small machine shop, or the CEO of an international company you can take something useful from the event. Information on the newest and most cutting edge technology in the manufacturing industry is all under one roof. Attending is an effective way to learn a lot in a short amount of time and decide which new products will make sense for your business. According to statistics on the IMTS website, 95 percent are satisfied with exhibit visits, 82 percent are successful in finding specific products or solving manufacturing problems and 62 percent make new business contacts.
GETTING AROUND:
– McCormick Place is located at: 2301 South Lake Shore Drive, Chicago, Illinois. – Trams will be running to and from McCormick Place Monday to Friday, 10:00AM to 6:00PM. – There are shuttle buses as well that run to and from many of the hotels in the city. More info on buses can be found by calling 1-877-214-6065. – Driving yourself is an option. Parking will be available at three main lots in the area. The rates vary between $14 and $32 depending on the lot. Most have no in-and-out privileges.
HELPFUL TIPS AND INFORMATION:
– Get organized! There are a lot of booths spread out over 1.2 million square feet of space, so look online to see which exhibits make the most sense for you to visit and plan accordingly. – Bring an appetite. There are over 45 restaurants at IMTS (some permanent buildings, others portable). Everything from health food to hot dogs and pizza will be on order. – There is a coat ($3) and bag ($4) check available but laptops will not be accepted. CM
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A Bright Future Upbeat Observations on the State of the Manufacturing Sector — Interview with AMT President Doug Woods By Nate Hendley
C
anadian Metalworking recently interviewed Doug Woods, president of the Association for Manufacturing Technology (AMT) based in McLean, Virginia, to get his impressions on the state of the North American manufacturing sector. His prognosis is surprisingly upbeat and strongly optimistic. Woods points to “reshoring” as a positive trend while downplaying the impact of economic turmoil in parts of Europe. While Woods’ primary focus is the United States, much of what he says is very relevant to Canada as well. “Politicians, economists, and the media have continuously predicted the imminent demise of the manufacturing-led recovery. The current recovery celebrated its third year in June and yet very few people even today seem to be ecstatic about the pace or the current outlook. Every quarter there have been warnings that the challenges facing a manufacturing-led recovery would sink the recovery. Stories that a double-dip recession was in the works filtered through the media throughout 2010. Economic experts declared the end of a recovery after the Japanese disasters of March 2011, again during the oil price spikes in late spring 2011 and once more at the beginning of the EU financial crisis in summer 2011. They were wrong,” states Woods.
DURABLE GOODS, MANUFACTURING UP
AMT President Doug Woods
“Two indicators of future trends in manufacturing output or industrial production that are useful are orders for raw materials and manufacturers’ profitability. The demand for primary metals in June was one and one half times what it was in March 2009 and improving. Second, U.S. manufacturers are recording phenomenal profit levels in nominal terms. The previous two peak quarters yielded $115 billion and $134 billion in profits for durable goods manufacturers. The fourth quarter of 2011 netted a whopping $138 billion and expectations are that the first quarter of 2012 will top that when all the tabulations are done and the figures reported,” he continues. Some pundits have predicted that the economic problems besetting parts of Europe will have a shattering impact on North America. Woods begs to differ. “While clearly [Europe] is a big market, people sometimes overestimate what would happen [in North America] if something happened in Spain ... looking at the GDP side, some of these countries we’re talking about, there are U.S. states that are bigger than them,” he states. “Ultimately, the economic conditions in Europe and the rest of the world have an impact on the U.S. No country is wholly insulated from the economic conditions in the rest of the world – not even China. However, it’s important to keep the European situation in perspective. Europe has been challenged since 2008. Their currency instability and debt to GDP ratio is no different than some states here in the U.S. – California for example. Certainly, if countries in Europe go bad it will make our recovery more difficult to sustain, but that alone will not sink our expansion,” Woods continues.
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RESHORING GATHERS SPEED
Woods also has strong opinions about “reshoring”—the phenomenon of North American manufacturers bringing off-shore operations back home. Woods says he’s noticed reshoring for about three years now. The trend is accelerating through a combination of factors, including natural disasters in Japan and elsewhere, armed conflict or the risk of conflict, and manufacturers finally clueing in to the “true cost of ownership.” “Reshoring is building momentum and clearly hasn’t peaked as yet. More work comes back to the U.S. every month. The quality of U.S. work proves more valuable than thought in the off-shoring investment calculation. Companies face increasing costs in logistics issues, with the delivery of components and exportation of completed products to North America. Add to that the rapidly increasing labour costs in traditionally ‘low cost’ labour markets, and the continued decline of labour in the overall share of total production cost, and the reshoring picture becomes clear. When total cost of manufacturing is calculated, the United States is a very favorable environment. This has clearly been identified by foreign manufactures who have increased their investment in U.S. manufacturing facilities by 12 percent over the past year, continuing a growth trend spanning back 2002,” says Woods.
“Reshored manufacturing jobs represented about 10 percent of manufacturing job growth since the low of January 2010. The trend is driven by: past excess offshoring that ignored the total costs and risks involved, rapidly increasing Chinese wages, higher transportation costs and a need to respond faster to market demand. The economic value of manufacturing near the end consumer is valid worldwide, not just in the U.S.,” he continues.
LABOUR COSTS ARE COMPETITIVE
“The Boston Consulting Group in a recent study projects that by around 2015 when higher U.S. worker productivity, supply chain and logistical advantages, and other factors are taken fully into account—it may start to be more economical to manufacture many goods in the U.S,” Woods adds. All of which are points that could apply to Canada as well. Woods is quick to add that the AMT is not opposed to off-shore manufacturing per se. “We have members who we encourage to build plants in different locations around the world, to address the marketplace there,” he states. In other words, if you want to build off-shore plants to produce products for sale overseas, fine. That’s different than setting up manufacturing facilities off-shore with the intended
goal of bringing finished products home and saving a buck. For all his optimism, Woods is no Pollyanna. He notes that skilled trades in North America are still beset with manpower shortages. “There is no quick fix and the job situation remains unresolved, especially considering the projected numbers due to reshoring. Despite the high number of Americans out of work, manufacturing jobs continue to go unfilled. Why? The current factory floor is far different than before. It’s awash with new technologies and processes that require advanced training and adaptable skills. We need a ‘smartforce’ of workers up to the job,” he says.
ADDRESSING THE SKILLS SHORTAGE
The AMT recently partnered with the Cleveland, Ohio-based National Coalition of Advanced Technology Centers (NCATC) which includes more than 160 American institutions of higher education. The AMT’s goal is to create education partnerships and direct top students to MTCareers.org. Run by the AMT, this webpage is designed to connect students and employers with open positions that require filling. Something else: the IMTS show, held every two years in Chicago and organized by AMT, will feature a Job Center for the first time. “We have a lot of unfilled positions. We figured, here’s a good way to get some of those unfilled positions hooked up with people. Get kids involved,” says Woods. As for the future, Woods doesn’t hold back. “Momentum is turning [to North America] as companies reevaluate [true cost of ownership] and the quality and logistical advantages of making products here… more and more foreign companies are expanding or starting manufacturing plants here so it is obviously a trend that will continue with domestic manufacturers,” states Woods. The “new world order” in manufacturing “is going to be much more heavily steeped in data, analytics, software, interoperability and burgeoning advance manufacturing technologies (i.e. additive, micro/nano, high functioning robotics, etc.),” he continues.
“IN GENERAL, THINGS ARE LOOKING UP”
Given North America’s position as a hive of innovation in the technology department, this trend bodes well for both Canada and the United States. “In general, things are looking up for the manufacturing technology market. The market is expected to finish on a nice 10 -15 percent growth in orders for 2012 over 2011. This is phenomenal, taken in perspective. In 2010, the industry realized a 91 percent gain in 2010 over 2009 and another 66 percent last year. Capacity utilization rates for durable manufacturing are near 80 percent with some very important sectors doing much better. The fabricating metal products sector in the U.S. is operating at a near 85 percent rate. The industry that represents more than a third of all orders placed for production equipment in the U.S.—the job shop industry—is a part of this industry group and is expanding capacity at a rapid rate,” says Woods, citing statistics from the U.S. “We are confident that manufacturing will continue to lead the recovery and stay strong in 2013. While not all the indicators are positive, we believe that the positive trends outweigh the negative ones and that manufacturing technology orders will finish up from a very healthy 2011 level,” he adds. CM
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A sneak peek at what’s new
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An advance look at what some exhibiting companies have in store for IMTS 2012
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Mitsui Seiki, USA of Franklin Lake, New Jersey, a branch of a Japanese parent company, will be displaying the HU100A5XL machining center. Designed for a variety of manufacturing sectors such as aerospace, power generation, refrigeration and mould and die, the specific HU100A-5XL at ITMS 2012 features an x, y, z work zone capacity of 2000 mm x 1750 mm x 1400 mm. It can accommodate a weight up to 11,000 pounds (5,000 kilos) and boasts a CAT-50 Tool Taper, dual pallet changer, automatic workpiece/fixture measuring and compensation system, non-contact laser tool setting device, 3D tool compensation and Fanuc 30iM control. IMTS represents “an opportunity for us to educate machine tool buying teams about the differences among machines,” says Scott Walker, president of Mitsui Seiki, USA. “As many of our machines are application and industry-specific, particularly those aimed at difficult to machine materials in aerospace, energy and mould and die, we are hopeful to meet manufacturers who are looking for machining solutions to fill needs in those niches,” adds Walker. www.mitsuiseiki.com
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Walter USA will be showcasing various cutting tool technologies at IMTS 2012. Products to be displayed include Tiger-tec Silver inserts for turning, Walter Titex X-treme Inox solid carbide drills, Walter Prototyp Proto-max Inox solid carbide
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e’re in our 33rd year now and one thing that I have always strived for, that I can happily say I’ve achieved, is longevity. No, not me...the company and our products. Hydromat did it with a philosophy of “Committed to Excellence”. We have kept the solid core of the strong Hydromat rotary transfer machine, while tossing off the old technologies as we replaced them with faster, more accurate systems and components. We never sit idle. It’s been a couple of decades since we introduced our first CNC system, now our flagship product line, the full CNC EPIC R/T, is the standard by which all other rotary transfer systems are judged. All of our EPIC machines feature EMC Technology, Embedded Motion Control, it brought new power to the Hydromat machine’s inherent production capabilities and streamlined the CNC system. Each cutting station has its own control system integrated into each toolspindle unit,
a true plug & play control architecture. These advancements substantially lower re-tooling costs and gives the user superior flexibility. Many EPIC users run par t families with up to 30 par t types in one set-up. Changeover times are generally now only counted in minutes, not hours. The EPIC R/T has proven itself as a lasting valuable asset not only for production. Used EPIC R/T machines are being sold at premium prices these days. With new machine sales, service, and par ts available from AMT in the Toronto, Ontario area, we care for our customers as if they are par tners and neighbors. We consider them as being ‘right down the road’, and for all practical purposes, they are. We don’t let our neighbors down. These are long-term personal relationships that are precious to me, and I am the promise keeper that we exceed your expectations. We’re always here for you, in Toronto, ready to help. Just down the road.
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AMT Machine Tools Ltd.
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T Emuge
end-mills, the new ValCool VPLFC low-foaming coolant and a new generation of Walter Valenite indexable milling cutters. Tiger-tec Silver coating is designed to offer exceptional resistance to crater and flank wear while reducing machining times and ensuring higher process reliability. Walter Titex X-treme Inox solid carbide drills for stainless steel, meanwhile, offer a new flute profile, point geometry and TTP coating for reduced cutting force and extended tool life. The Prototyp Proto-max Inox solid carbide end mills for stainless steel feature material removal rates up to 50 percent greater than standard solid carbide end mills, claims Walter USA. ValCool VPLFC meanwhile, is a heavy-duty non-chlorinated, semi-synthetic low foaming cutting fluid ideal for high-pressure (1,000 psi and up) applications. “IMTS is a place where vendors and visitors alike achieve a win-win situation. Vendors can attract new customers and strengthen relationships with their existing customers,” notes Hemmerling. www.walter-tools.com/us
Big Kaiser
Booth W-1600
Big Kaiser has quite a bit that’s new. Among other exhibits, Big Kaiser will showcase its series 310 EWD Precision Finish Digital Boring Head, which boasts absolute setting accuracy on a built-in digital display. The measurement system shows precise linear movement of the tool carrier in both directions during adjustments of 0.00005” or 0.001 mm. Meanwhile, Big Daishowa’s newest solution in extended reach arbor technology is called the Smart Damper. The latter features a dynamic damping system designed to eliminate vibration and reduce chatter for higher productivity in deep hole finish boring and extended reach face milling. Big Daishowa also recently introduced the R-Cutter, an ultra high feed front and back radius chamfering mill boasting high rake angles that reduce cutting resistance and minimize burr generation. The radius chamfering mill is offered as a single-insert design and a four-insert design for greater feed rates. “Today’s manufacturing environment is more competitive than it has ever been ... the surveys and reports we have read show a steady correlation between shops that are thriving today and shops that are investing in premium equipment,” notes Stapula. www.bigkaiser.com
Booth W-1536
T P “We will be demonstrating several new taps, thread mills, end mills, toolholders and gauges at the show — a complete lineup of threadmaking tools,” states Peter Matysiak, president of Emuge Corporation, the West Boylston, Massachusetts subsidiary of a German parent company. Prominent displays include a new line of NPT Taper Pipe Taps that boast a newly developed flute form with variable skip tooth geometry. The flute design optimizes chip flow and clearance and lowers tapping torque, making it ideal for materials that produce long, stringy chip formations. Emuge NPT taps are designed to improve chip flow, provide better thread finish and gauging, and boost production rates due to less machine downtime. Other booth highlights include the TiNox-Cut, a new series of end mills “specifically developed to provide exceptional tool life when machining challenging materials,” says Matysiak. “New Emuge TiNox-Cut End Mills offer a dependable cutting solution for nickel alloys like Inconel and Stellite, all grades of titanium and tough stainless steels like Super Duplex — materials used extensively in the aerospace, power generation, medical, chemical and food industries, among others,” he adds. www.emuge.com
Kennametal
Booth W-1522
To
To
Kennametal has introduced a next-generation spindle connection called KM4X for use in machining tough materials such as titanium. KM4X apparently provides three times the bending moment resistance compared to other tool systems. The KM4X offers a combination of high clamping force and controlled interference levels, leading to a robust connection, high stiffness and restrained bending moment for improved
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performance in titanium machining. In practise, this means shops can use their high-performance machining centers to boost speeds and feeds in difficult machining applications, thereby utilizing the machine tool’s full potential. KM4X can also be retrofitted to an existing machine tool, which allows machinists to increase throughput without having to purchase additional capital equipment. “We look forward to a successful IMTS 2012 at a time when manufacturing’s presence and impact in the overall economy is growing ... Kennametal is a pioneer in using and exploring social media, but we’ll always value the face-to-face opportunities events like IMTS provide,” says Sutter. www.kennametal.com
AccuteX EDM
Booth E-5225
AccuteX EDM, a division of Absolute Machine Tools in Mason, Ohio has a slew of new products to display. “AccuteX EDM has a new line of heavy duty die sinker EDMs and a new three axis CNC Wire EDM that will be unveiled in our booth in the EDM Pavilion. Also, at our parent company, Absolute Machine Tools, in booth #S-8536, we will present a new 11 axis three Turret Turning Center called the Tongtai TMV-2000T, a new ultra high speed high performance mould/die machining
center called the Tongtai TMV-1050Q-II, a new graphite machining center called the Tongtai TMV510G, and finally a new nine axis twin spindle multitasking B Axis turning center called the Quicktech TTS-42 and its sibling the seven axis twin spindle multi-tasking B Axis turning center called the Quicktech XTS-42,” says Courtney Ortner, AccuteX EDM marketing director. The three-axis wire EDM is a new EZ-53SA model, with an x, y, z envelope of 19.7 inches x 11.8 inches x 7.1 inches, featuring an automatic wire threader and advanced Windows-based CE control. Asked why IMTS is important, and Ortner replies simply, “exposure ... IMTS allows manufacturers to compare all the machine tool brands under one roof and to shop for the best value or for the machine that best fits their manufacturing needs.” www.accutexedm.com
Iscar
Booth W-1800
Israeli tool giant Iscar will be launching the second-generation Matrix Maxi and Matrix Mini vending and tool management machines and software at IMTS 2012. Ronnie O’Byrne, general manager at Iscar’s Canadian operations in Oakville, Ontario, is tight-lipped about details. He does say Iscar is also launching a marketing campaign at the show: “The new campaign is based on the theme, ‘IQ — are you machining intelligently?’ ... within this campaign will be a host of new products — turning, drilling, milling — that are all designed with advanced technological features. Again, I can’t go further than that right now — all will be revealed at the
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show,” says O’Byrne. What can be revealed are recent products Iscar has already released, including Helitang T490 LNHT 0804PNR RD and T490 LNHT 1306PNTR-RD inserts for ramping down applications and a new extended flute shell mill cutter in the Sumomill T290 line. The T290 SM D050-45-3-22-15 extended flute shell mill cutter can be used with all steel and cast iron materials, as well as stainless steels and difficult to cut materials. Iscar also recently introduced the Helido S890 FSN — a new family of right-hand indexable face mills with an 88 degree cutting edge (two degree lead) and eight helical cutting edges which can be utilized for cuts up to 9 mm deep. Asked why IMTS is important and O’Byrne is quick to answer: “It’s the major show in the North American market and gives Iscar an international audience and exposure,” he says. www.iscar.com
BLM Group USA
Booth E-4694
John Ovsek. The EM80 can handle tube diameters ranging from 10 – 80 mm, wall thickness ranging from 0.8 – 12 mm, solid bars ranging from 10 – 60 mm and bar stock lengths from 2,500 – 120,000 mm. The cutting blade in the machine travels at a speed of 20 m/ minute to 450 m/min. The unit comes equipped with a bundle loader that can handle up to 4,000 kg and can be loaded at any point during operations. BLM Group specializes in tube processing solutions with a product line that includes laser tube cutting, cold sawing, bending, end-forming and wire bending machines. www.blmgroup.com CM
Full Grip Jaws • Aluminum, Steel, or Cast Iron - diameter size range from 6-inch to 36-inch • Jaw heights range: 2-inch, 4-inch, and 6-inch • Close tolerances and concentricity easily maintained. • Allows for complete gripping of the work piece • Special oversized jaws available • Excellent for gripping thin-walled parts without distortion • Machine and tool life extended due to lighter weight jaws, reducing mechanical stress. • Made in the USA
This is the first time that BLM Group USA, which describes itself as “a traditional fabricating equipment manufacturer” will exhibit at IMTS. The Wixom, Minnesota-based company — which has an Italian parent firm — plans to use the occasion to display the EM80, a combined automatic sawing and end machining center for tube and bar processing. “We believe the innovative design of the machine tool, incorporating a cut-off saw with machining capabilities will [generate] vast interest here in North America,” says BLM Group USA president,
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www.canadianmetalworking.com | SEPTEMBER 2012 | 39
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Automation for Everyone Should you move to automated production? There are compelling reasons to make the move, even for traditional job shops By Jim Anderton, Editor...........................................................................................................................................
A twin fully-integrated production cell featuring two High Performance FEELER VMP-580 Vertical Milling Machining Centers being serviced by a single FANUC M20iA robot set-up to process one side of a part in the first machine, and the second side in the other machine. After finishing the machining, the robot processes the parts through a series of ATI brand compliant deburring heads before placing them on the out-feed conveyor. www.methodsmachine.com
T
rue numerical control of machining and manufacturing processes, born in the 1950’s, wasn’t just a new way of making parts, it was a new way of thinking about the partmaking process. Tracing machines based on templates had been used for years, and punched paper tape or cards had been used to automate looms in the 19th century, but in metalworking, The pattern or template, by necessity, was a highly accurate model of the finished part. Numerical control replaced the physical pattern with a virtual one, but flexibility was little better than the original copy lathe of a century ago. Computers changed the game by allowing truly multi-purpose machines. Today, the same principle is taking the CNC machine and adding automation to the cutting tool change and inspection as well as part quality inspection, loading and unloading; removing much of the worker interaction with the production process. While this level of automation improves precision in all manufacturing metrics, the real benefit is lower cost through shorter cycle times.
IS IT WORTH THE COST?
The old adage “it takes money to make money” might have been coined to describe metalworking automation. CNC reduced expensive machinist and toolmaker time, a self-evident cost savings, but an automated cell at first glance replaces much less skilled and lower-cost workers. The business case for high-level automation is less clear for medium and low volume production and job shops. DMG Automation summarizes the profit potential succinctly with a simple graph (see page 42). At first glance the return on investment for the automated process is clear, but as important is the effect on the breakeven point. In the DMG example, two conventional machine tools could be purchased for the price of a single automated system, approximating the profit available soon after breakeven, but the breakeven point occurs much sooner. As the cost/revenue curves diverge post breakeven, even two conventional systems can’t match the overall return on investment represented by the area between the curves. Put simply, the automated system
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FOUR LEVELS OF AUTOMATION
The case for automation is compelling, but is the gold standard, an integrated “lights out” cellular system, the only option? Modern CNC machining centres offer a range of automatic options covering tool change, part holding and bar feeding in turning centres. At the Florence, Kentucky manufacturing plant of Mazak Corporation, extensive automation of machining centres has reduced costs and driven a considerable expansion of the Florence operation, despite perceived cost disadvantages compared with offshore operations. The systems are complex, but George Yamane, marketing manager for Mazak Corporation, describes the basic concept as the “3, 4, 5 Project”, meaning “three levels of controls, four levels of automation and five levels of multitasking.” With automated machine tools literally making other automated machine tools, the Florence lines are complex, but the key concept applicable to job shops everywhere is the clear definition of four discrete levels of automation. Yamane uses a typical horizontal machining centre as an example: “The first level is the bar feeder”, he begins, a basic technology so common many shops wouldn’t consider it ‘automation’ in the usual sense. “The second level are gantry loaders. They’re integrated into the machine; not very flexible, but they allow the machine to operate for many hours unattended.” A gantry-equipped machine not only allows production without the dead time associated with manual loading and unloading, it permits chucking and indexing functions not possible with a simple feeder. With double spindle centres,
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makes money sooner and at a faster rate, with fewer supporting resources such as labour, production floor space, preventative maintenance and machine qualification/documentation. While the benefits of automation are clear for long production runs, job shops that batch-process moderate part volumes also benefit. Reducing the number of part set-ups, and the set-up time is a primary productivity driver, centralizing second or third “op” post-machining processes such as inspection, deburring, marking and labeling into a single process increases single-shift productivity. At lower utilization rates, the automated system boosts throughput without the higher costs and decreased productivity typical of a second shift and when volumes increase, the same technology can allow a second shift supervised by unskilled or semi-skilled labour. (See lower graph page 42.)
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The new DMU 80 eVo with pallet changer has been completely revised and has now been implemented as a gantry machine. The “optimised gantry” provides improved accessibility from the side as well as larger traverse paths and a bigger work area with less space requirements. The concept of the dynamic universal machine also includes the new pallet changer of the DMU 80 eVo. It is optimally integrated into the freely accessible work area, without increasing the machine’s footprint and features a short changeover cycle of just 12 seconds. www.dmg.com www.canadianmetalworking.com | SEPTEMBER 2012 | 41
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Image courtesy DMG Automation
the productivity advantage of a gantry loader machine is even greater. While gantries speed the chucking process and clear the parts efficiently, more complex operations and multiple jobs running on the same centre require a higher level of automation for efficient operation. “The third level is the Palletech (Mazak’s pallet system)”, Yamani explains. Compared to gantry systems, palletized
equipment represents true automation, combining multiple machining tasks with the ability to switch between different jobs, with different lot runs without direct operator intervention. “You can run the machine for long hours, with a very small cost of ownership”, adds Yamane, who notes that palletized systems also allow more in-machine capability, including advanced options such as automatic inspection.
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WHEN NUMBERS MATTER: 6 NEW JOBS. 2 MONTHS TO FULFILL. 1 a51nx HMC.
Making the parts that really matter takes a horizontal machining center that delivers what matters most: faster cycle times, greater reliability and higher-quality results. Which is why a Makino HMC is the only real choice for the production parts that matter most. See the a51nx at work. Book a personal demonstration at IMTS 2012, booth S-8700. makino.com/IMTS Š 2012 Makino
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Are you ready for automated machining? M
any Canadian job shops actively consider automation, but with no hard and fast rule about minimum production volumes for a given ROI target, confusion is common. John Lucier, Automation Manager, Methods Machine Tools, Inc. (www.methodsmachine.com) notes that there is no single “right job” for an automation solution. “ In most cases shops are talking to us about a machine or machines that handle several jobs”, he states, adding, “the question is, does this collection of jobs lend themselves to automation? In this case there are a lot of things to consider. Different parts that require a similar setup are normally good candidates. Lot sizes will also affect the cost of the cell and depending on the long term volumes a shop owner must decide if it’s worth it. Designing a cell to change over quickly may add cost to the cell but this cost will be offset each time the cell is reset.” Lucier notes that typical job shop variability isn’t a obstacle to a properly designed system: “Today’s automation cells allow for one part or multiple parts to be run and will provide unattended operation, opening up valuable resources and saving costs. The high part volume applications have traditionally been the jobs considered for automation, but with a properly designed cell, high mix, low volume end even “job shop” type work can be set-up and run using automation. A popular mindset is that automation is for large volumes but we have successfully designed cells that handle lot sizes of one. Each part coming down the line is slightly different and the cell reacts to that. What’s important is to determine what your needs are and have a cell designed around those needs.” The introduction of robotics to a classic job shop operation inevitably raises questions about the differences in programming compared to straight CNC tool path code. Lucier feels that programing isn’t an obstacle for a shop currently CNCcapable. “While there is a learning curve in anything, we find that someone with a good knowledge of programming CNC machines tends to pick up the articulating robot easily”, he says. “ The programming of a robot is certainly different than a machine tool but the thought process, and flow of the program is similar. In some aspects the programming of the robot is easier. Where the machine tool program needs to control all the machine axes involved, feed rates, spindle speed, and the correlation between each, the robot is basically picking and placing material. The robot does have infinite adjustment in feed but when you are moving material this axis speed becomes a minor consideration. The same holds true with positioning. In the machine tool, axis position is very important, when placing material into a chuck or fixture, the fixture tends to produce and guarantee the accuracy not the placement method.”
For many job shops, this level of automation offers the best price/performance ratio for short to medium-run parts. The next step is towards the ultimate in machining flexibility and performance, says Yamane. “Another formation is customized automation using robots. You can use it for simple loading and unloading or ‘go the whole nine yards’ with conveyors, continuous part feeding, machine vision systems and robots with the ability to change end of arm tooling.” This “Cadillac” level of automation is the ultimate in flexibility and is typically the most expensive, requiring integration of robotics that are frequently outsourced. Shops going the robotic cell route
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1. The Okuma LT-3000EX is the largest in Okuma’s LT-EX series of horizontal lathe machines. The LT-3000EX is available with 16 turret stations to allow for redundant tooling in order to best utilize back-up tooling for lights-out manufacturing or high production runs. The LT-3000EX features automatic part transfer and Okuma’s THINC OSP P300L control. Bar feed systems are available. www.okuma.com. 2. The Makino D300 5-axis vertical machining center is designed specifically for small, complex, 3-D contouring of high-quality part production as typically seen in aerospace, medical, high-end job shop and die/mold applications. The D300 uses Makino’s proprietary Super Geometric Intelligence (SGI.4) software developed specifically for high-feedrate, tight-tolerance machining of complex, 3-D contoured shapes. The machine can be easily upgraded for automation at any time with an automatic pallet changer. www.makino.com 3. The MIKRON HPM 450U milling solution from GF AgieCharmilles boasts a new torque rotary/tilt table for interference-free five-axis machining and spindle options for all machining applications. An internal tool changer, which integrates into the machine’s base, has a storage capacity of up to 60 tools. An external circular magazine increases that capacity to 220 tools. Coupling the external magazine with an optional automatic pallet-changing magazine creates a flexible manufacturing cell capable of unmanned, lights-out production. www.us.gfac.com
have the option of using a third-party integrator who sources machine tools and robotics separately, or purchasing a system from a machine maker who is certified by a robotics supplier to build OEM systems. Both approaches are viable; frequently the decision to use either an independent system integrator or an OEM is based on prior experience with stand-alone machine tools and a good working relationship with their supplier. Yamane’s four stage description of machine tool automation is also a typical incremental pathway for a job shop; few will jump directly to robotic cells without prior experience with in-machine automation. With a mature robotic technology base and an improving price/performance ratio in automated machine tools, Canadian job shops can cost-effectively upgrade to equipment that can allow a small to medium-sized operation to bid on contracts of larger volume and sophistication at lower overall risk. No single article can cover the rapidly advancing state of the art in machine tool automation … look for continuing coverage in Canadian Metalworking. CM
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Exactly Right
Exacta Aerospace uses automation to machine light alloys for important aerospace components
“W
hen you are a supplier to the global aerospace market, you get it right the first time—and every time after. This isn’t just a clever tag line we promote, but a commitment we make to each and every customer,” Ben Voegeli, Exacta Aerospace’s general manager. Exacta Aerospace, Inc. of Wichita, Kan., is a family-run business that was founded in 1978 by current President Randy Voegeli with the assistance of his wife and company CEO, Bonnie Voegeli. Since its inception, the company has grown to become a leader in the manufacture of part components, sheet-metal details, kits and assemblies for the world’s largest aviation manufacturers. The operations of Exacta are shared gs_AugustAd:Layout 1 12-08-13 5:05 PM Page 1
with Randy and Bonnie’s two sons, Ben and Casey. “Experience produces excellence,” said Casey, Exacta’s director of business operations. “For more than 30 years, this company and its highly skilled employees have been delivering the highest quality parts and components for commercial aircraft, military aircraft and business jets. To maintain this competitive position, we’ve invested heavily in machining technologies that can continuously improve accuracy, cycle time and labor.” According to Ben, the company’s current capabilities far exceed those of just under a decade ago. What once was a shop floor full of 3-axis vertical machining centers is now filled with
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COME VISIT US AT IMTS BOOTH W-1485
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t automated cells of 4- and 5-axis machining centers. He attributes this dynamic change to the company’s 2003 investment with a Makino a51 horizontal machining center— its first high-speed horizontal purchase. “When you make investments in machinery, you don’t go cheap. You need something that’s built to last regardless of punishing tasks,” said Ben. “Immediately after installation, we noticed that the volume of work that one a51 could handle was equivalent to three of our verticals, which also translated into the need for only one operator instead of three. Since then, we’ve continued to make incremental investments that would improve our efficiency through automation, 5-axis capabilities and ultimately the capacity to produce full assemblies. Since investing in Makino equipment, our revenue has grown more than 14 times.”
ADDING CAPACITY TO MAXIMIZE PROFITABILITY
Exacta’s investment decisions have been part of a larger strategic plan, Ben explained, which includes building its capacity to produce large, complex assemblies efficiently and maximize the company’s profitability. “Acquiring machines appropriate for all part sizes and geometries is a key factor when working with aerospace assemblies,” he said. With a large majority of the company’s work composed of aluminum, Exacta has focused much of its investments on automated aluminum machining capabilities. Following the success of the initial a51, the company acquired two additional a51s, along with an A77E horizontal machining center. The A77E offered similar capabilities as its a51s, but with a larger work envelope for applications such as hinges and truss ribs. “Aluminum is our bread and butter and has always offered a steady flow of new orders that have enabled us to justify our investments,” said Casey. “Based on market conditions at the time, we were confident www.canadianmetalworking.com | SEPTEMBER 2012 | 47
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“A lot of manufacturers are scared of titanium, and for good reason. It’s tough on tools, machines and ultimately the operators who have to work with them,” explained Ben. “However, these difficulties don’t change the fact that titanium machining capabilities are in high demand. We decided to take up the challenge by investing in a cell featuring a Makino a81M and an a82M horizontal machining center.”
INCREASING THROUGHPUT AND REDUCING MANUAL LABOR
The MAG3EX is very efficient in aerospace machining due to its rigid design, 33,000-rpm spindle and cutting feed rates of 1,000 inches per minute.
that we could win additional orders with more capacity, which led us to continue our investments. Over the next several years, our investments had culminated into two automated cells—one cell featuring four a51s and another with two A77Es and a single a71.” In late 2010, Exacta continued its expansion strategy into the rapidly growing market of titanium machining.
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Kelly Eilerts, Exacta’s 4- and 5-axis manager, asserted that some of the most dynamic changes to the company’s shop floor can be attributed to the integration of fully automated pallet handling systems. “Since integrating our machines into Makino’s MMC2 cells, we’ve more than quadrupled our capacity,” he said. “We’re burning through parts, running lights out 24 hours a day, seven days a week, and maintaining an average spindle utilization of 90 percent.” According to Eilerts, the a51 cell is currently the most productive piece of equipment on the shop floor, producing thousands of parts per year. In a typical week, the cell can be loaded with more than 20 jobs and have them machined complete and ready for on-time delivery. “By combining the efficiency of automation with Makino’s high-performance machining capabilities, we’re running parts at higher efficiencies than ever,” he said. “In one application transferred to the a51 cell from our previous equipment, cycle times have been reduced by 30 percent.” Because Exacta works with high volumes of parts and more than 1,500 different part varieties, Eilerts emphasizes the importance of accurate inventory tracking and efficient part distribution. “Through the MMC2’s MAS-A5 controller, we’re able to pull up part programs on the fly and adjust scheduling based on customer demands,” he said. “The system is highly user-friendly and
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Exacta’s aerospace customers demand light alloy parts of increasing complexity.
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representative, Mark Rehwinkel, is always available when we have questions and concerns, and, even if he can’t answer a question directly, he calls someone who can answer right on the spot.” Business partners like Makino enable Exacta to focus more on the future, explains Casey. Instead of dealing with day-to-day worries of inconsistent performance and costly downtimes, the company can work toward optimizing its processes and further expanding upon capacity and capabilities. Courtesy, Makino Inc.
Exacta Aerospace, Inc. – www.exactaaerospace.com Makino’s M-package machines are built specifically for hardened materials, such as titanium alloys. Their integral drive spindles offer significantly higher torque (1,009 Nm) at lower rpm.
Makino, Inc. – www.makino.com Single Source Technologies-Canada ULC www.singlesourcetech.com
intelligent, prompting us to run parts in a specific order to gain the highest efficiency. Its one-button access to highly accurate time studies saves us a great deal of time compared to the manual labor-intensive paperwork previously required. Altogether, this system allows us to manage six machines with only one operator.”
FOCUSING ON THE FUTURE
Exacta attributes much of its success to Makino’s support and its willingness to change processes and adapt to more efficient machining standards. “Makino has provided us with much more than just the machines,” said Ben. “Makino’s sales force has the knowledge and materials to support customers far past the date of sale. Our local
parts of
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Hot Hands Handheld micrometer accuracy is affected by the heat of your hands…but by how much? By Jim Anderton, editor...........................................................................................................................................
H
andheld precision measuring instruments like the c-frame micrometer are the first purchase for every machining apprentice. Accurate, precise, low in cost and versatile, “mikes” fit nicely in a pocket or the palm of your hand — warm places that have an effect on the instrument. But how much? Mitutoyo has performed extensive research on the effects of body heat from the hands on accuracy and the results dispel plenty of toolroom mythology about the correct use of micrometers. Figure 1 shows typical effects of micrometer frame expansion due to heat transfer from hand to frame when the frame is held in the bare hand. As can be seen, this may result in a significant measurement error due to temperature-induced expansion. If the micrometer must be held by hand during measurement then try to minimize contact time. A heat insulator will reduce this effect considerably if fitted. Gloves may also be worn to reduce the effect.
Figure 1: Micrometer expansion due to holding frame with bare hand
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Figure 2: Length standard expansion with change of temperature (for 200mm bar initially at 20°C)
Figure 3: Difference in thermal expansion between micrometer and length standard
The above experimental graph (Figure 2), shows how a particular micrometer standard expanded with time as people whose hand temperatures were different (as shown) held the end of it at a room temperature of 20°C. This graph shows it is important not to set a micrometer while directly holding the micrometer standard but to make adjustments only while wearing gloves or lightly supporting the length standard by its heat insulators. When performing a measurement, note that it takes time until the expanded micrometer standard returns to the original length. (Note: the graph values are experimental, not certified values)
In the above experiment, (Figure 3), after the micrometer and its standard were left at a room temperature of 20°C for about 24 hours for temperature stabilization, the start point was adjusted using the micrometer standard. Then, the micrometer, with its standard, was left at the temperatures of 0°C and 10°C for about the same period of time, and the start point was tested for shift. The above graph shows the results for each of the sizes from 125 through 525mm at each temperature. This graph shows that both the micrometer and its standard must be left at the same location for at least several hours before adjusting the start point. (Note: the graph values are experimental, not certified values)
Coolant proof micrometers like this Mitutoyo 293-233 survive the harsh conditions of a machine shop or tool room. The frame is insulated to minimize the effect of hand heat, but good handling practice is still essential for accurate, repeatable measurement.
The Mitutoyo research clearly shows that ambient temperature changes and the heat from the hands do noticeably affect measurement accuracy, both in the instrument and on production and calibration standards. The use of stands and temperature-controlled environments are ideal, but the results show that even insulating the hands
from the micrometer with gloves helps, as does a few hours of equilibration time when moving the instrument into a different environment. Many shops have a significant temperature difference between the front office, QC department and shop floor. Here are some tips for getting the best precision and accuracy out of handheld micrometers: www.canadianmetalworking.com | SEPTEMBER 2012 | 51
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GENERAL NOTES ON MICROMETER USE: 1. Carefully check the type, measuring range, accuracy, and other specifications to select the appropriate model for your application.
7. When attaching the micrometer onto a micrometer stand, the stand should clamp the center of the micrometer frame. Do not clamp it too tightly.
2. Leave the micrometer and workpiece at room temperature long enough for their temperatures to equalize before making a measurement.
8. Be careful not to drop or bump the micrometer on anything. Do not rotate the micrometer thimble using excessive force. If you believe a micrometer may have been damaged due to accidental mishandling, ensure that it is inspected for accuracy before further use.
3. L ook directly at the fiducial line when taking a reading against the thimble graduations. If the graduation lines are viewed from an angle, the correct alignment position of the lines cannot be read due to parallax error. 4. W ipe off the measuring faces of both the anvil and spindle with lint-free paper set the start (zero) point before measuring. 5. Wipe away any dust, chips and other debris from the circumference and measuring face of the spindle as part of daily maintenance. In addition, sufficiently wipe off any stains and fingerprints on each part with dry cloth. 6. Use the constant-force device correctly so that measurements are performed with the correct measuring force.
9. After a long storage period or when there is no protective oil film visible, lightly apply anti-corrosion oil to the micrometer by wiping with a cloth soaked in it. 10. Notes on storage: Avoid storing the micrometer in direct sunlight. Store the micrometer in a ventilated place with low humidity. Store the micrometer in a place with little dust. Store the micrometer in a case or other container, which should not be kept on the floor. When storing the micrometer, always leave a gap of 0.1 to 1 mm between the measuring faces. Do not store the micrometer in a clamped state.
Adapted from Mitutoyo’s “Quick Guide to Precision Measuring Instruments”. For more information, visit www.mitutoyo.ca
There’s a right way and a wrong way to use a micrometer stand. The correct frame depth gives support without distortion
Thermal expansion effects are magnified with large diameter micrometers. In use, however a stand is often impractial.
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Welding News DO-IT-ALL COMBO
With multi-mode welders all the rage now Lincoln Electric has bundled two powerful welders in one package. The company’s Precision TIG 225/Power MIG 140C One-Pak includes everything needed to perform MIG, TIG and stick welding. A wire feed welding mounting bracket attaches a Power MIG 140C on top of a Precision TIG 225. The 140C MIG unit plugs into the Precision TIG 225’s 120V 20amp auxiliary receptacle for full power. A dual cylinder cart can holds a bottle of 75/75 gas for MIG welding and a second bottle of argon for TIG welding. The setup takes up minimum floor space and is easy to move. The package combines Lincoln’s Microstart II and Diamond Core technology, delivering stable low amperage starting, welding and cratering for AC and DC welding. Diamond Core One powerful do-it-all package technology features a wide voltage sweet spot, low spatter and is well suited for aluminum and stainless steel welding. The package is suitable for general fabrication, automotive/motorsports, vocational schools, serious hobby work, farm and small shop welding and sheet metal. This complete package has a Lincoln Electric part number of K2680-1 and comes with the Precision TIG 225 Ready-Pak, the Power MIG 140C, small wire feeder welder mounting bracket, the dual cylinder cart and stick electrode holder and cable. www.lincolnelectric.ca
HALF MASK RESPIRATOR HAS LOW PROFILE
With an exclusive patented low profile design to fit under most welding helmets, the new LPR-100 Half Mask is part of Miller Electric’s line of Arc Armor welding protective products. The mask is a National Institute for Occupational Safety and Health (NIOSH) certified design that filters out 99.97 percent of airborne particles and oil aerosols. It features an Assigned Protection Factor (APF) of 10, and is meant to provide comfort for the user. A four-point head strap adjustment allows the mask to be customized to most head shapes and sizes, and a large non-return exhaust valve further reduces heat build-up and user fatigue. The mask protects the user while providing a wide Half mask has many uses field of vision and an unobstructed view for optimal safety and productivity. The pleated filter is replaceable and provides a larger surface area that reduces breathing resistance and extends filter life. The lightweight mask is constructed of medical-grade material that is odour, latex and silicone free. While designed for welders, the mask provides appropriate respiratory protection in any industrial or manufacturing setting as well as small shop or home applications when breathing protection is needed. www.millerwelds.com
ARC ARMOR HELMETS GET AN UPGRADE
New digital controls on Miller Electric Mfg. Co. Arc Armor Digital Elite, Digital Performance and Digital Pro-Hobby Series auto-darkening welding helmets make it easier for the welder to adjust shade, delay and sensitivity, even when wearing gloves, compared to previous digital and analog designs. The new headgear is designed to increase comfort and is substantially easier to adjust to personal preferences than previous models. The headgear offers more flexibility with six points of adjustment and has an integrated comfort cushion mounted on the back of the headgear to further ensure a secure and sturdy fit. The The Digital Elite Fury helmet from Miller updates to this helmet line also include the unveiling of two new female-inspired graphic designs: Fury and Illusion. The full line of Arc Armor digital helmets comes with a three-year warranty. www.millerwelds.com
ESAB GOES FOR NEW GAS PRODUCTS
Featuring quality, performance and durability, the new Purox Elite Series and Oxweld Elite Series gas apparatus products from ESAB have been improved upon from when they were originally introduced in 1912. The new line of products will be assembled at the Global Center of Excellence for Gas Apparatus in Florence, South Carolina. The Purox Elite Series and Oxweld Elite Series product lines include welding handles, cutting attachments, hand cutting torches, regulators and complete outfits. The products will be launched initially in North America, England and South Africa, followed by release to all global markets. All products sold in North America are backed by ESAB’s 100 percent satisfaction guarantee for the first 100 days of ownership and ESAB’s Lifetime Warranty. www.esabna.com
VICTOR TECHNOLOGIES ACQUIRES CNC CONTROLLER DEVELOPER ROBOTRONIC OY AND PROMOTION CONTROLS
Victor Technologies has taken another step into the automation world with the acquisition of ProMotion Controls and Robotronic Oy. ProMotion specializes in PC-based shapecutting controls, nesting software, torch height controls and associated products for new and retrofit cutting systems that use plasma, oxy-fuel, laser, water-jet or router technology. Victor Technologies announced that it has acquired all of the capital stock of Robotronic Oy, the parent company of ProMotion Controls, Inc. “This acquisition delivers on our promise to offer end users the industry’s most innovative cutting technology,” said Martin Quinn, ProMotion control panel CEO of Victor Technologies. “As a fully integrated system provider, Thermal Dynamics will continue to design and develop automated solutions that optimize cutting performance and reduce operating costs.” www.victortechnologies.com
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The same grit blasting process used for paint prep also removes mill scale and oils from the joint
BEFORE THE WELDING BEGINS What you do before you weld is important to the weld itself
By Nestor Gula...................................................................................................................................................... 56 | SEPTEMBER 2012 | www.canadianmetalworking.com
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A cutoff wheel and steady hands can produce a good bevel. Note how the surface has been cleaned to bare metal well back of the joint
I
n an era of speed and efficiency sometimes essential work steps get neglected. Preparing the work surfaces of metal is an area frequently glossed over on the shop floor. Who really wants to spend all that time doing preparatory work when the job is actually welding two or more pieces of metal together?
PROPER SURFACE PREPARATION
Proper surface preparation plays as much of a role in the quality of the weld as the quality of the weld bead. “There are three primary considerations for weld preparation: cleanliness, joint preparation and fit-up. Each of these plays an important role in ensuring the quality of the final weld,” said Ken Puls, welding engineer for Miller Electric Mfg. Co. “In terms of cleanliness, any paint, oils or materials left on the base metal will work itself through the weld during the process and may create inclusions or flaws within the weld, which may harm the integrity of the joint and cause it to fail. In proper joint preparation (beveled, grooved, notched, etc.) the joint design will be dictated by a prequalified procedure or one that has been tested to ensure proper weld characteristics are met. Using an incorrect joint or angle for the weld process can lead to lack of penetration at the root of the weld. Similarly, proper part fit-up — making sure that the weld joint is set uniformly from the start of the joint to the end — will ensure weld consistency throughout the part.” The joint, or the part that should be welded, must be as clean as possible. “While some welding processes and materials may be more forgiving to the inclusions of oil, mill scale or paint, a welder should always assume that any foreign material in the weld may cause problems for the weld,” said Puls. Welding on
garbage will give you a garbage weld, so it is always necessary to clean the joint and not just by haphazardly rubbing a welding brush over the area. “This will go a long way in eliminating problems associated with foreign material in the weld,” he said. “Ensure that the joint has been prepared properly, according to the qualified welding process. Set the part with a uniform gap from beginning to end. Inconsistent fit-up can affect weld quality and consistency of the weld. Also, if you notice inconsistencies in the fit-up caused by the manufacturing process, it’s important to address that with downstream processes because welding will not fix manufacturing problems.”
DEALING WITH MOISTURE
While cleaning the metal with a brush or angle grinder will remove most, if not all, foreign matter from the metal there is one thing that still needs to be dealt with — moisture. “Ensuring that there is no moisture in the metals is also very important in the preparation. We never want to have moisture in the material when we weld it. Otherwise you can get into hydrogen cracking — which comes from H2O,” said Jim Byall an application engineer with Lincoln Electric. “Primarily, if you are working outside on just even steel, which is most common. People will go and begin their job and there is moisture in the material. It is just there either from the dew or from rain. We always recommend that you sweat it out before welding. That means we take a torch and remove excess moisture that is in the steel or on the steel. Even regular welding you should bring it up to 100 degrees Fahrenheit to sweat it out. That is not hot. You should just use a torch to get the moisture out and then begin welding.”
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THE CONSEQUENCES OF POOR WELD PREP
Besides hydrogen cracking there are other consequences of skipping or doing sloppy weld preparation. “Weld failure and poor aesthetics — as we mentioned, some materials and/or weld processes are more tolerant, but welders should not approach a weld and say, ‘I’m welding with the flux cored process, which is more forgiving, so I don’t need to clean this joint as well.’ As with many things, prevention is often the best medicine,” said Puls. “Proper weld preparation in all welding processes will help ensure
“Proper part fit-up will
ensure weld consistency throughout the part.” the integrity of your weld. Having said that, common problems due to poor preparation include porosity, lack of fusion, inclusions, burn-through and inadequate penetration.” As more and more welding jobs are being done with automated systems more care must be taken when positioning
Simple hand tools like this file are adequate for small beveling jobs
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(Left) These pipe segments are pre-beveled for line work. The proper bevel is essential for the critical root pass in safety and high-pressure applications. (Below) Thin wall, clean material in non-critical applications may be welded without metal removal if full penetration can be achieved in a single pass. Often it still makes sense to grind to ensure even fit-up pre-welding.
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the parts to be welded. “Part fit-up and joint geometry are even more important because, in many cases, an automated system cannot react in the same way a human welder can react to inconsistencies,” said Puls. “It’s also important that your downstream processes are extremely consistent because an automated welding system, designed for repeatability, will not provide the result you are looking for if every piece is different. To achieve repeatability at fast rates, the parts must be consistent.”
you’ll need to remove the oxide with a dedicated stainless steel wire brush, then use a standard weld cleaner to wipe down the joint. The dedicated stainless steel wire brush will ensure other contaminants don’t enter the weld. In stainless steel, cleanliness is the most important factor for successful welds and a proper weld-cleaning agent should be used. Cast iron is a more porous material that is particularly vulnerable to foreign material like oils or humidity. Because it is porous, grinding can actually smear these materials into the part. Weld preparations for cast steel should be done with a machine or a saw to prevent further dispersal of contaminants throughout the material.
aration include porosity, lack of fusion, inclusions, burn-through and inadequate penetration.”
WORK HOLDING METHODS
The primary method of work holding in automated welding is fixturing and it is critical to get this right. “The primary difference with automated welding will be your fixturing, because when you program a robot, and you tell it to go to a point in space. It will go to that point in space every single time,” said Byall. “So if your fixturing is off this will in turn cause the steel not to be in the same place, where the robot expects it to be, every time. It is critical that the machining and the fixturing puts that material in exactly the same place every time.” Preparation is similar for most metals but there are variables with each the welder has to watch out for. In mild steel, mill scale is a common cause for weld defects. Proper cleaning should remove this. Cleanliness with aluminum is critical, so
KEEPING THE WORK AREA CLEAN
Cleanliness and good weld preparation is important regardless of weld process. “While some processes, such as flux cored and stick may be more forgiving due to various elements added to the various filler metals, a clean joint will help ensure an optimal weld in all processes,” said Puls. “For stick welding with certain electrodes, proper filler metal storage is important, as exposure to moisture can have a negative affect on weld performance. Similarly, MIG and flux cored wires should be kept shielded from the elements and clean. And, in may cases, TIG filler metal may benefit from being wiped with a cleaning agent prior to use to ensure optimal performance.” CM
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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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The Business of Welding
1,2,3 – Public Safety, Knowledge and the value of getting connected F
or the past 65 years the Canadian Welding Bureau has been quietly making sure that the welded parts of Canadian buildings, bridges as well as a lot of other steel and aluminum structural stuff that we all take for granted is safely constructed. As a not-for-profit what we do has always been for a greater good. We help ensure the quality of welding and by extension help companies build safer structures. It’s a bit of a complement that, for most of the public who use these structures, our work goes un-noticed. You might say people don’t know who we are because we do such a good job. Which brings me to my first point: Public Safety. First off I would like to announce the creation of a new group within the CWB: the Public Safety Department. I can hear you asking, ”why create a new department for something you already do”. Well, the answer is that we want to do more, and to make the public aware of the importance of safe welding in their day-to-day lives. Think about it, almost everything has a weld or two in it. Welding is one of those technologies that helps everything stay together, something we all take for granted when we enter a building, drive over a bridge or even ride a bike. This brings me to my second point: Making you - a welder or supplier or manufacturer of welded products - aware that we will be reaching out to you too. In support of the Public Safety Department we will be offering you a number of public safety related programs that will help you let the public know that you are also looking out for their safety. What we want you to know is that our new public safety programs, and the department that will be administering them are focused around a single principle; ensuring the safety of Canadians and the integrity of the Canadian welding codes that helps keep them that way. Simply put: We believe in Canadian codes for Canadian safety. So here’s what we are doing about it. Our goal is to create a
Ian Campbell, Director of Marketing and New Product Development, CWB
range of not-for-profit non-mandated programs that are available to all welding related companies who want to participate. What are these programs? Well, they cover a lot of ground - public facing advertising, industry events, welding related education, government outreach, social media, as well as a company marking and branding program to help show your commitment to adhering and upholding Canadian welding codes. The underlying purpose here is to educate the public on what to look for and then help them with any questions they might have. These “public” programs will dovetail with other programs geared specifically to supporting you and the industry. Some of these relate to helping you source “code compliant” work/ workers, educating your work force so they understand Canadian codes & standards, as well as the co-promotion of your products and services within the marketplace. If you are “pro-Canadian codes” then we will help you get the facts out about your products to the marketplace. Does any of this sound interesting? If so then it’s time to talk about the last point I want to make – Getting Connected. For those of you who are already CWB clients and/or CWA members these new programs will just be an extension of the services we currently offer, and you will be hearing more about them from us very soon. If you are not a CWA/ CWB client then we hope that you will see the new Public Safety Department and their programs as a good reason to connect with us so we can help you too.
C g R g
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of welding and by extension help companies build safer structures.”
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T p e a b
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PUROX
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The new and improved PUROX Elite Series gas apparatus offers top-of-the-line safety, durability, and performance, no matter your welding or cutting application. All PUROX Elite Series regulators feature ESAB’s encapsulated valve design and patented regulator burnout (RBO) protection. And torches are compatible with any fuel gas, thanks to our revolutionary universal swirl injector. Plus, most PUROX Elite Series products are backed by ESAB’s industry-leading Lifetime Warranty and 100% Satisfaction Guarantee. ®
To learn more about PUROX Elite Series, visit esabna.com/gasapparatus, scan the QR code with your mobile device, or talk to your local distributor.
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Visit us at IMTS booth N-6129.
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F t m n c u a t S y W t
The Other Edge Carbides have been a cutting tool standard for decades, but modern non-carbide products offer definite advantages By Irwin Rapopport................................................................................................................................................
C
arbide inserts have been a mainstay of the machining industry for decades. Constant improvements in carbide formulations have improved performance significantly, but to attain high material removal rates and to deal with advanced, tough materials, non-carbide inserts are an excellent
solution. New ceramic, CBN and diamond chemistries offer longer tool life, higher removal rates and in many cases are the only cost-effective route to a producible and profitable job. Here is a selection of non-carbide inserts poised to allow for more efficient operations that can improve profitability.
SECO CBN060K
Seco’s Secoma CBN060K inserts combine a variety of new technologies and unique concepts that the company says, “offers a whole new level of product performance. [It] has been designed specifically for turning case-hardened steels within the application area of H10 – H20.” The advantages of the CBN060K grade are many. One such advantage is the multi-layer K coating (patent pending) that enhances performance. “The multi-layer coating, coupled with optimized pre-treatments and PVD deposition techniques,
Seco’s Secoma CBN060K inserts in action and singular.
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From complex micro-machining to cutting exotic, difficult-tomachine materials and creating new technology, Seco partners closely with manufacturers to understand the challenges you face and develop innovative solutions to meet your needs – we call this Secovation. At IMTS 2012, bring your challenges to us in Booth W-1564 to experience the solutions that will redefine your operations.
SECOVATION [see-koh’-vey-shun’n] noun: A productivity enhancing, profitability boosting, process redefining technological innovation developed as a direct result of Seco’s close relationships with its customers.
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improves adhesion and reduces friction for increased wear resistance and reduced temperature.” Furthermore, micron-sized CBN particles enhance surface finish and increase tool life. “A carefully tailored substrate comprised of these CBN particles and unique particle distribution result in increased tool life and consistency and superb part surface finishes.” Finally, a superalloy binder is used to improve the material’s mechanical properties. “This unique and special binder includes both the superalloy and TiCN, which dramatically improves the material’s mechanical properties without compromising wear resistance, while the toughness from a superalloy binder provides greater cutting edge reliability and tool life as well as the ability to machine at higher cutting speeds.” www.secotools .com
ISCAR IW7
ISCAR has developed a new line of ceramic turning inserts — the IW7 series – described in a release as, “tough enough to tackle interrupted-cut finish turning of superalloys, as well as roughing of hard castings and hardened steel … thus they extend the known benefits of ceramic machining to applications involving higher shock and impact loads and machining with coolant.” The IW7 is available in round, square and rhombic formats. The inserts feature an improved alumina substrate with SiC whisker reinforcement. Tests involving roughing and interrupted-cut finishing, sometimes under coolant, boast improved removal rates eight- to ten-fold compared with carbide. “Comparing it with other ceramics,” it adds, “turbomachinery manufacturers report substantial improvements with the IW7 for machining Inconel 718 and Waspalloy, Stellite and Rene.” The IW7 product include an extra hard (Hv 2,100) substrate that “provides extreme wear resistance in hard materials, and the SiC whiskers add shock resistance which can withstand machining heat; well enough to last at speeds that soften the metal being cut.” Iscar notes, “the new insert works best when clamped with ISCAR’s T-clamp toolholders” and “to reduce cutting forces and impact loads in roughing work, [it] recommends 15 or 45° lead angles.” www.iscar.ca
HORN USA, INC. — CVD THICK-FILM DIAMOND TOOLS
Earlier this year Horn USA, Inc. released its CVD thick-film diamond tools, based on a “material harder than PCD and twice as wear-resistant.” The CVD, adds the press release, “delivers various benefits when milling and turning — from rough machining to micro milling — of long-chipping aluminum and magnesium alloys,
high-silica aluminum as well as of precious metal alloys, plastics with abrasive fillers, tungsten carbide and ceramic green compacts. “The extremely long tool life of diamond tools combined with the new Horn chip breaker on the CVD diamond cutter,” it explains, “can increase machining productivity by up to 35 percent and reduce processing costs by up to 80 percent. Various inserts have been developed with wiper geometry for high-performance machining with continuous turning.” Horn’s ISO inserts come in types C, D and V and will be equipped with the CVD thick film. Custom-made tools are also available. The CVD’s “innovative undulating chip breaker reduces contact of the chip with the insert surface, which considerably reduces heat formation and energy consumption. The extreme chip angle of up to 25° produces a soft cut and reduces burr formation to a minimum. This increases tool life compared to PCD cutters.” www.hornusa.com
SANDVIK COROMANT — COROTURN TR
Sandvik Coromant’s line of CoroTurn TR inserts with CBN tips bolsters the company’s contribution to hard part machining. “The unique iLock T-rail insert interface provides the stability essential for this demanding application area,” says a release. “These inserts offer outstanding performance in profiling due to maximum insert stability in the tool holder, as well as repeatable insert indexing providing closer tolerances and high-quality surfaces. “The inserts are available in D & V style insert shapes which offer customers the choice of strength or accessibility for their profiling needs and they come in two CBN grades – the CB7015, a low content CBN grade offering high cutting speeds and long tool life in finishing applications, and the CB7025, a medium content CBN grade capable of handling higher feed rates and light interrupted cuts. Both grades are optimized to give the highest possible productivity and process security. Sandvik has found that many shops are switching from grinding to turning hardened surfaces with cubic boron nitride (CBN) inserts due to significant savings, both economical and environmental. “On profiled surfaces where complex grinding wheels and expensive grinding equipment are normally required,” states the release, “the new Coroturn TR CBN tipped inserts are the perfect solution.” www.coromant.sandvik.com/ca
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WALTER VALENITE — WIS10 AND WWS20
Walter Valenite’s new WIS10 and WWS20 new ceramic cutting tool materials were designed to meet the special requirements involved in machining high-temperature alloys, states a release. According to a company statement, “WIS10 is suitable for all high-temperature alloys. Because of its high level of chemical stability, it offers excellent notch wear resistance. WWS20 has a higher level of toughness, and is ideal for nickel-based alloys and difficult conditions, e.g. for forged parts with changing cutting depths, but also for hard machining of steel materials”. Their overall applications features include: “machining high-temperature alloys such as Inconel, Waspaloy, and Stellite in forged, cast or pre-machined condition; aerospace components; power engineering components, and highly corrosion-resistant components for oil, petrochemical and medical applications”. Among the WIS10’s (ISO S10) features are, “maximum chemical resistance and outstanding shear wear resistance, and can be used for any type of high-temperature alloy”. Aspects of the WWS20 (ISO S20) include: “silicon carbide whisker reinforced aluminum oxide ceramic with higher toughness than WIS10, and is used primarily for machining Ni-based high temperature alloys in unfavorable machining conditions, for example roughing forged surfaces with a fluctuating depth of cut”. www.walter-tools.com
TUNGALOY AMERICA — BXM10 AND BXM20
Tungaloy’s Cubic Boron Nitride (CBN) is “a man-made diamond product, designed to work at high speeds in harden ferrous applications, cast iron, powdered metal and super alloys [and] is quickly replacing grinding applications, since it is fast, economical and versatile. Rather than grind, your hardened parts can easily be done on your CNC lathe.” It was also noted that Tungaloy is one of the few manufacturers of CBNs, and its two latest products are the BXM10 and BXM20. States a release: “Both of these grades offer multiple coated layers on CBN substrates. BXM10 is designed for semi-finishing to finishing application, [and] is capable of handling light interrupted cuts, while BXM 20 is capable of more severe interruptions.” Both grades offer a new substrate that reduces wear, with three coatings applied to the CBN. “The first coating offers excellent adhesion,” states the release. “The second layer produces exceptional wear resistance, while the top layer offers a smooth surface to prevent built up edge and makes tool wear easily identifiable.” The new CBN inserts are available in standard ISO sizes, and other CBN grades considered to be the smallest sizes in the world — these small inserts are capable of producing bores as small as 4.5mm. www.tungaloyamerica.com
SUMITOMO ELECTRIC CARBIDE INC. — SN2000K AND SN2100K
Sumitomo Electric Carbide Inc.’s SN2000K and SN2100K, its new ceramic grades, “emphasize a dynamic balance between wear resistance and toughness in rough turning and milling of cast iron,” states a release. “Developed using a patented microwave sintering process, [both] excel in machining a broad range of cast iron materials. These ceramic grades exhibit the ideal amount of wear resistance and toughness to produce elite grades for cast iron turning and milling.” The manufacturer also stresses that “the new SN2000K grade is excellent for high-speed general turning and finishing applications in cast iron,” and that “this grade promotes long tool life and exceptional wear resistance through its hardness and increased toughness.” Due to the SN2000K and SN2100K’s high shock and impact resistance, the SN2100K “is perfect for rough turning and milling of gray cast iron applications,” while “the SN2100K is ideal when extraordinary toughness is required.” www.sumicarbide .com
INGERSOLL CUTTING TOOLS — TC430
Ingersoll’s TC430 is a newly developed SiC whisker reinforced ceramic grade for machining high-strength and hightemperature alloys. “[It] has been developed for machining super alloys at high cutting speeds,” says a release. “With a composition of alumina (Al2O3) matrix and a strong oxidation resistance with its silicon carbide (SiC) whiskers, the new grade offers exceptional toughness. “TC430 can be applied to high-speed cutting conditions due to its combination of micro-structural and chemical advantages that deliver excellent toughness and hardness levels when compared to other alumina-based and silicon nitride-based ceramics,” it adds. “These features enable the TC430 grade to machine exotic materials such as Inconel, Stellite, nickel and cobalt-based alloys as well as hardened steel and cast irons at very high cutting speeds.” CM www.ingersoll-imc.com
WAL
Wal N22 Wau 800 serv
www
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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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You Know the Drill Cutting tool companies offer new drills and new directions in drilling By Nate Hendley...................................................................................................................................................
A
layna Roberts, an applications engineer with Big Kaiser Precision Tooling based in Hoffman Estates, Illinois, has strong opinions about emerging trends in drilling tools and technique. “Five years ago, gun drills were used for deep hole drilling. Today, the deep hole drilling process is done with carbide drills ... and coolant. Combining this with the capabilities of CNC machines leads to higher productivity,” says Roberts. She also has some helpful tips on getting the most out of your drill. “Making sure you have the correct point geometry for the application and workpiece material is key. This will reduce the cutting forces on the drill, thus minimizing drill walking. Drill size is also something to take into consideration. The smaller the drill is, the more important tool holding becomes: Collet chucks have proven to be advantageous because of the even gripping surface the collet has on the drill shank,” states Roberts. “Monitoring chip evacuation is also important. When first drilling, it is best to start with conservative feed rates, and more peck cycles to get a feel for the performance of the drill. After positive results are achieved, it’s acceptable to start working on the application aggressively. Finally, coating tools increases
lubricity and reduces friction, thus resulting in faster chip evacuation,” she continues. Here’s a look at what’s new and/or notable from cutting tool companies in drills:
BIG KAISER – POWER-PHOENIX DRILLS
Big Kaiser introduced the PowerPhoenix extra-long high-performance drill series to the North American market earlier this year. Made by Swiss firm Sphinx, this series is designed for deep hole applications in steel, stainless steel, cast iron, aluminum and titanium. “The most notable feature about the Power-Phoenix is the optimal performance in deep-hole applications reaching up to 30xD, as well as the large variety of materials that can be drilled. It is successful in these kinds of operations for several reasons: it has a unique point grind and polished flutes for quick chip
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evacuation; a four margin geometry that ensures straightness; and Helica coating for tool wear resistance. The Power-Phoenix is designed to run with moderate coolant pressures as low as 290 PSI, and even in vertical orientations, will have exceptional chip evacuation,” states Roberts. This heavy-duty, solid carbide drill is designed to machine hard-to-cut materials. Big Kaiser also recently released another Sphinx product— the Spotting/Chamfering Twist Drill, Art. 50818. “This uncoated carbide drill has a unique point geometry: it has an ideal 142 degree tip along with a 90 degree step for a chamfer on the outside of a hole,” says Roberts. www.bigkaiser.com
ISCAR – SUMOCHAM DRILLS Israeli tool giant Iscar has expanded its Sumocham drill family. The latter now includes drills with a 12xD depth to diameter ratio, in a diameter range of 12 – 25.9 mm and cylindrical shanks (which enable the drill to be clamped in hydraulic toolholders). Iscar describes the Sumocham family as an
“advanced evolution” from the existing Chamdrill and Chamdrilljet drill families. Asked about maximizing drill performance, and David Vetrecin, holemaking product manager for Iscar Canada based in Oakville, Ontario, says, “I always promote spindle coolant with high pressure—that’s the best way to get the best performance out of the Iscar drills ... and when using long drills, always pre-drill with a short drill to start.” Iscar has other new drilling products in the pipeline, but Vetrecin is hesitant to offer any details, citing company secrecy before the IMTS show in Chicago this September. www.iscar.com
TUNGALOY – TUNGSIX-DRILL
WORDS CANNOT BEGIN TO DESCRIBE THE SGS DIFFERENCE. BUT RESULTS CAN.*
Booth W-2217
Our high performance solutions offer patented geometries extending tool life, reducing chatter, and cutting cycle times. Even in the most demanding applications, our industry-leading products offer precision, speed and savings. And that’s the SGS difference. *2012 ISA American Eagle Award Winner www.sgstool.com 330-686-5700 Manufactured in the USA
Tungaloy has introduced the new TungSix-Drill, the “first indexable drill in the world with double-sided inserts with six cutting edges,” boasts Alex Livingston, product manager for Tungaloy Canada, the Brantford, Ontario-based domestic division of a Japanese parent firm. The TungSix-Drill “also has twisted coolant holes, which allows for deeper flutes creating excellent chip evacuation,” says Livingston. The TungSix-Drill features a diameter range of 28-54 mm, in 1 mm increments. The company claims it can boost tool life by one and a half times compared to inserts with four cutting edges, while delivering similar rates of speed and feed.
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“With an optimized cutting balance between the central and peripheral cutting edges in combination with twisted oil holes and Tungaloy’s revolutionary new AH9030 grade, the new TungSix-Drill is the ideal solution for steel, stainless steel and cast iron drilling,” states Tungaloy. According to Livingston, “TungSix opens up the application range for indexable drilling.” The AH9030 grade that has PVD coating provides enhanced wear and oxidation resistance. www.tungaloyamerica.com
SECO – CROWNLOC PLUS
existing DP2000 grade, the new grade is suitable for most materials and applications. Scott Turner, drilling product manager at Seco’s North American division, based in Troy, Michigan, says “reliability” is another important attribute about the DP3000 grade. “In indexable drilling predictable and reliable tool life is very important because an insert failure can result in irreparable drill body damage. This leads to tooling expense, downtime and scrapped parts. The DP3000 grade is very tough and reliable, which drastically reduces the risk of drill body damage,” says Turner. www.secotools.com/us
Back in January 2012, Swedish firm Seco released a new generation of Crownloc Plus exchangeable tip drills. Seco says the drills will yield high quality holes with less tool inventory and no regrinding or resetting costs, thus saving users money. New optimized geometry featuring TiAIN coating offers improved chip evacuation and increased wear resistance. Crownloc Plus drills boast a polished drill body design with deep and wide flutes and a highstrength locking interface. Seco has also introduced DP3000, a new range of indexable insert drills for fast speeds and feeds that boast high-end wear resistance and edge toughness. Designed to complement the
WALTER USA – X-TREME INOX
Walter USA of Waukesha, Wisconsin, recently introduced the Walter Titex X-treme Inox, a high-performance solid carbide drill that features internal coolant and special coating. The drill is designed to handle stainless steel and other high-alloy ISO M materials. The X-treme Inox boasts a multilayer TiAIN tip coating to
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 | SEPTEMBER 2012 | 73
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and precision shank, designed for low runout. The VariDrill can be used with a variety of materials, including steels, stainless steels, cast irons, non-ferrous materials and high-temperature alloys. The point and flute design of the VariDrill are intended to let chips roll smoothly and evacuate easily, resulting in less friction, heat, jamming and scratching. Minimizing such drilling issues means users can anticipate an optimum surface finish on each hole across various work materials without the fear of catastrophic failure thanks to chip jamming, says the company. “The VariDrill portfolio features 3xD, 5xD and 8xD lengths, as well as coolant-through and solid options. The drills can be reconditioned, further extending tool life and adding tool value for general engineering users,” states Widia. www.widia.com maximize tool life and minimize adhesion. Process stability is ensured thanks to the stability of the Inox’s main cutting edges and the drill’s new flute profile. Coordinated margins are designed to minimize friction against the hole wall while an internal coolant supply ensures correct operating temperature. The Inox drill is available in 3 to 20 mm in standard lengths up to 5xD. Additional lengths of up to 12xD and stepped tools are available as options. Walter has also expanded its line of Titex X-treme deep hole micro drills with three new high-performance variants. These are the X-treme M, X-treme DM8 and the X-treme DM12 (M is for “micro” while D is for “deep”). X-treme M can manage drilling depths up to 5xD while the DM8 and DM12 can handle depths of up to 8xD and 12xD respectively. These solid carbide drills have diameters ranges from 2.0 to 2.95 mm and have been optimized to ensure a high degree of process reliability. The drills also boast AITiN-based coating, to maximize cutting performance and tool life. www.walter-tools.com/us
SANDVIK COROMANT – CORODRILL
WIDIA – VARIDRILL
Widia, which is run by Kennametal of Latrobe, Pennsylvania, has released the VariDrill, a multi-application drill with advanced VDS point geometry (to reduce chipping on the cutting edge)
On March 1, 2012, Sandvik Coromant of Sweden launched the CoroDrill 860 — the fastest solid carbide drill available for steel drilling on the market, according to the company. CoroDrill 860 is a “top performer” for conventional drilling, chamfered holes, inclined surfaces, cross holes, stack drilling and convex/concave surfaces, says Sandvik. It boasts premium chip evacuation control and a new unique geometry which, combined with the new flute shape, offers highly efficient chip clearance even at increased penetration rates. CoroDrill comes in standard lengths of 3 – 8xD. The same day the CoroDrill 860 was unveiled Sandvik Coromant also launched the CoroDrill 870, a new type of exchangeable tip drill. The CoroDrill 870 features a secure interface between drill body and tip, to ensure a high degree of reliability and precision. Tips are easily changed, thus maximizing machining time. Other features include a new cutting-edge geometry (for safe cutting) with optimized chip control, high penetration rates and a long tool life. The CoroDrill 870 is available in diameter ranges of 12 – 20.99 mm (0.472 – 0.826 inch) and 3 and 5 x hole diameter as standard. www.sandvik.coromant.com/ca CM
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Tool Talk NAKAMURA-TOME SUPER NTMX
Wall System, that has a double wall foam-filled aluminum slat design that increases door strength. The new aluminum slat design lowers door weight and makes it easy for operators to open and close the door. The Technician Series of tool storage boxes on display feature drawers with full extension and a 440-pound capacity. www.listaintl.com
HOBART WELDING PRODUCTS STICKMATE LX 300 AC/200 DC
Nakamura-Tome’s new Super NTMX is breaking ground as the first lathe system to have two 24-tool automatic tool change (ATC) magazines – each located on the left and right sides. Because of this new feature, and the lathe’s 5-axis milling capabilities, jobs can be drastically simplified while maintaining a high degree of precision. Plus, tools can be changed in and out faster and inserts can be changed without stopping the machine, allowing for increased productivity. www.elliottmachinery.com
LISTA MINI MEZZANINE
Hobart Welding Products has introduced a new AC/DC stick welder that provides up to 300 amps of weld power. The new Stickmate LX 300 AC/200 DC stick welder allows users to choose between 200 amps of DC output, to reduce arc outages and minimize spatter, or 300 amps of AC output to produce less arc blow. This AC/DC output enables the use of specialty electrodes for a wide range of metals, including mild steel, cast iron, and aluminum. It is ideal for big jobs on the farm or ranch, maintenance repairs, hobbyist applications and more. The Stickmate LX 300 AC/200 DC power source also features Accu-Set, which allows the user to fine tune the arc in one amp increments. This stick welder also allows a higher duty cycle when amperages decrease to give more arc time when welding thinner materials. www.hobartwelders.com
EMUGE TOP CUT CARBIDE END MILLS
Lista International Corporation announced that it will showcase a lineup of new and improved tool storage solutions at this year’s International Manufacturing and Technology Show (IMTS). On display will be: Lista’s Mini Mezzanine, a box that maximizes usable storage footprint, a Storage Wall System featuring an entirely new aluminum slat tambour door, double bank Technician Series toolboxes, and Align adjustable-height workstations with the Nexus system of above-work surface accessories and modular components. Lista’s Mini Mezzanine takes advantage of all available height in a storage area and is an alternative to building an additional floor or adding square footage. Comprised of stacked Lista high-density storage cabinets, it able to store everything from maintenance and repair parts and supplies to perishable tooling and CNC tooling. Also released is the new tambour door for the Lista Storage
Emuge Corp. has introduced Top Cut, a new series of high performance carbide end mills. Top Cut is offered in a wide range of sizes and styles to provide maximum versatility in milling a wide array of materials, including hard steel at up to 55 HRC. Ideal for mold and die, or general milling applications, Emuge’s Top Cut end mills feature a new variable helix flute technology and a variant of the high heat resistant TiAlN coating. These features, in addition to internal coolant capabilities, enable highly efficient material removal with minimal vibration and wear. Speaking to their versatility, the mills are made of micro-grain carbide, featuring proprietary relief ground cutting edges, making Top Cut capable of performing roughing as well as finishing cutting operations. “Our new Top Cut End Mills are a superb alternative for shops seeking an affordable high performance end mill choice
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PORTABLE SURFACE ROUGHNESS TESTERS The evolution continues.
SJ-210
SJ-310
SJ-411
Mitutoyoâ&#x20AC;&#x2122;s newest line-up of portable surface roughness testers combine added functions with intuitive controls for advanced operability. A rich choice of options provide easier, smoother and more accurate measurements. Call your nearest Mitutoyo ofďŹ ce for a demonstration.
Precision is our profession.
cmw sept 2012 Tool Talk pg 76-79.indd 77
Mitutoyo Canada Inc. Toronto (905) 821-1261 Montreal (514) 337-5994 www.mitutoyo.ca info@mitutoyo.ca
12-08-22 8:01 AM
Tool Talk to apply across multiple materials, cutting applications and operations, without the need for expensive tool changes,” said Mr. Peter Matysiak, President of Emuge Corp. Emuge Top Cut End Mills are available in a full range of inch and metric sizes, lengths, and in various types–over 600 new items in total, with most tools available for immediate delivery from stock at Emuge’s North American headquarters in West Boylston, MA, U.S.A. www.emuge.com
SULLAIR COMPRESSOR
EXSYS BOLT-ON PRECI-FLEX SYSTEM FOR NAKAMURA MACHINES
Several machine tool manufacturers, including Nakamura, are transitioning over to bolt-on style turrets for their horizontal lathes because these solutions are easier to use than VDI designs.
NOW iN PROmOTiON
N ke H EW yl igh P tit ess pr RO an c ec DU iu hu isi CT m ck on ja s w w it s. h
Compressor manufacturer Sullair has introduced a new line of 230 Volt VSD S-energy lubricated rotary screw air compressors. This expanded line of compressors now includes Models 1100e, 1500e, 1800e, 1800, 2200, 3000P, 3700 and 4500, all of which are available with variable speed drive. These models range from 15 to 60 horsepower, with capacities from 46.4 to 222 cfm and pressures ranging from 100 to 175 psig. Energy costs continue to escalate—frequently representing as much as 82 percent of the total operating expense of a compressed air system. Energy-saving features provided by Sullair Variable Speed Drive compressors include a variable speed drive motor to match rising and falling air demand. When a compressed air system operates at less than 100 percent load,
variable speed drive allows the compressor to consume less electrical power than any other motor control method. By adapting speed to output, Sullair VSD compressors keep working at maximum efficiency. This is one of the most effective ways to minimize energy consumption and conserve costs. Contributing to these energy savings is Sullair’s air-end design with low restriction inlet valve for superior CFM performance, the new low-pressure drop air-fluid separation system to prevent energy loss, and a high-efficiency cooling fan. The Sullair S-energy compressor package also includes a variety of design features that simplify maintenance, improve reliability and extend service life. www.sullair.com
Drill chucks & power tool accessories manufacturer since 1936!!
• High torque / high precision self-tightening keyless chuck with titanium jaws. • All components are heat treated and ground. • The high-tech titanium increases the grip and wear resistance of the jaws. • Maximum run-out: 0.04 mm or 0.001576. Extremely accurate and precise for CNC machines and machine centres. • Supplied with spanner wrench for supplementary gripping torque. Excellent quality – High technology Precision tested and certified – Innovative
1-800-442-2535 sales@mascoutech.com www.mascoutech.com 78 | SEPTEMBER 2012 | www.canadianmetalworking.com
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Tool Talk To compliment this, EXSYS Tool, Inc. is introducing a new bolt-on mounting PRECI-FLEX Modular Tooling System for most Nakamura machines equipped with bolt-on style turrets. This includes the models: TW-10, WT-20 II M-MY, WT-150, WT-250, TW-20, WT-300, Super NTX, WTW-150, Super NTJ and more. EXSYS/EPPINGER manufactures its tool holders to meet rigid construction standards for handling deep feeds at high rates of speed. Because these tool holders feature a double-tapered roller bearing configuration they are able to handle greater loads than tool holders with conventional ball bearings. “Our quality construction standards and better bearings enable our customers to achieve longer tool life and a better return on their overall investment,” says Scott Leitch, sales manager for EXSYS. The system’s compact design ensures maximum torque transmission and rigidity, resulting in increased machining accuracy and improved productivity. The system goes a long way in eliminating machine downtime, and allows tooling adapters to be interchanged between fixed and rotary base holders for fast, economical machining. www.exsys-tool.com
expanding its selection of high-performance controls into the mill-turn market, and this model will be offered with optional turning functions. With the TNC 640 control, turning operations can now be enabled on a milling machine allowing the operator to transition from milling to turning cycles in the same program. The turning operations can be programmed in plain text, just like the familiar milling operations. Comprehensive turning cycles are available for frequently repeated operations, such as roughing, finishing recessing and thread cutting. The TNC 640 is based on HSCI (Heidenhain Serial Controller Interface), the new and completely digital interface hardware platform. This significantly reduces cabling during set-up. Also, the new ergonomic design of the 19” screen gives the TNC 640 a more user-friendly appearance. The TNC 640 also incorporates a new stainless steel control design, a specially prepared keyboard surface and screen frame to eliminate fingerprints.
GIBBSCAM SOFTWARE FOR CNC MACHINE TOOLS
The Huron K3X 8 Five high performance machines are suited to roughing and finishing work in five simultaneous axes and on five faces and meets all the technical and economic challenges facing engineering companies in the Aeronautics, Automotive, Medical and Energy sectors with regard to reducing process times and cutting manufacturing costs. Performance levels in roughing, finishing and precision work enable the toughest productivity targets to be met in terms of machining complex parts, such as injection moulds, aeronautical components or parts used in precision mechanics. The architecture of the K3X 8 Five highspeed 5-axis milling centre consists of a fixed gantry and bed and a 500 mm diameter table that rotates (C-axis, 360°) and tilts (A-axis, –30°/+180°) and can take up to 250 kg. It is therefore capable of machining in five continuous axes on five faces. As the table on this new generation “8 Five” is inclined in a 55° plane (instead of 45°), negative machining angles of up to –20° can be reached. Consequently, the angle of the spindle axis in relation to the table ranges from 0 to 110° compared with 90° for the previous generation. The combination of dynamics and precision on this machine results in the production of high-quality surface finishes. With its standard spindle reaching a speed of 24,000 rpm with a torque of 40 Nm for 25 kW, it has a high maximum chip-forming capacity. This milling centre also offers the advantage of great accessibility with good visibility of the work area. www.huron.fr
Gibbs and Associates, developer of GibbsCAM software for programming CNC machine tools, has announced it will be demonstrating the next generation of its MTM programming solution and automated programming capabilities at IMTS 2012 (Booth # E-3310). The next generation of GibbsCAM’s MTM solution helps utilize the full capabilities of complex MTM machines, including 5-axis rotary head and Swiss-style machines. MTM machines pose special challenges to users, including programming machines with multiple spindles and turrets, which allow multiple parts to be cut simultaneously. GibbsCAM’s interface helps walk the user through more complex part programming with graphics that demonstrate an accurate simulation of what is being machined. By providing full visualization of errors before the part gets to the shop floor, it can help prevent costly mistakes (like tool interference and gouges). Also highlighted at IMTS will be GibbsCAM’s improvements in automated programming, including the introduction of “smart features”. This will help users program parts faster by retaining data about the feature itself, including depths, clearances and feature types (pocket, boss, slot, etc.). Customers can create automatic processes for different features, which will quickly and automatically create programs to customer specifications.
HEIDENHAIN TNC 640 CONTROL FOR MILLING AND TURNING MACHINES
Heidenhain’s new milling machine control, the TNC 640, will be unveiled at IMTS 2012. With this control, Heidenhain is
HURON K3X 8 FIVE MILLING CENTRE
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Let There Be Light Faster, more accurate cutting with less downtime mean higher productivity for both gas and fibre By Irwin Rapopport................................................................................................................................................
W
ith greater demands being placed on the performance of laser cutters, manufacturers are developing and producing new machines to better meet the demands of an industry that is seeking devices which deliver more power and improved productivity, and lower operating costs. There is also a growing request for fiber lasers, which is also being met with a variety of models. This product review brings together nine products from well-known laser cutter manufacturers, be they traditional laser cutting systems (gas) or fiber. Bottom-line demands also include reduced downtime for maintenance, cleaner and precise cutting, quickening cutting times, the ability to cut various ferrous and non-ferrous metals, faster feed rates, and improved software and user-friendly screens to maximize operations. And of course, safety is an ongoing concern and software is making great strides in this field. Some of the products are new to the market, while others are
more advanced versions of metalworking industry standards that bring together the tried and true and the latest technological advances. Many of our readers have seen these products at recent trade shows and we hope that this review will better help those responsible for equipment purchases to make the best possible selections.
SALVAGNINI L5 FIBER LASER CUTTER
Salvagnini’s (www.salvagnini.com) L5 Laser Cutter, is “the first laser designed from the ground up to harness the power an efficiency of fiber optic technology – and the only one to incorporate the patented, rotary motor driven compass head positioner for unmatched speed, accuracy, reliability, energy conservation and performance”, according to a press release. “Running costs are only one-third that of a 4kW CO2 laser with chiller,” states the release. “There is virtually zero maintenance. There are no mirrors to align. And, no laser gas is
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required. The result is a machine with a payback that is typically only 70 percent of that of a CO2 laser – and that means leaner, more efficient, more profitable production.” The versatile L5 can handle many configurations for feeding blanks, picking up and stacking finished parts, and unloading skeletons. It’s new all-electric pallet changer “is unique in the industry, with the processed piece always passing beneath the work table, thereby eliminating any risk of cut parts or scrap falling onto the incoming blank.”
TRUMPF TRULASER 5030 FIBER
TRUMPF’s TruLaser 5030 fiber (www.us.trumpf.com), says the company, “significantly lowers cost of cutting thin sheet material with its fiber-guided TruDisk solid-state laser , achieving very high cutting speeds for the cost-effective production.” It cuts stainless steel up to 0.16 in. thick (4 mm), and ferrous metals such as copper and brass with feed rates up to three times faster than the CO2 version, “reducing table time up to 45 percent and significantly decreasing cost per part,” states the release. The solid-state laser with 2D laser cutting system can process sheets measuring 10 ft. x 5 ft. (3,000 mm x 1,500 mm).
The laser can be placed independently of the machine and because both are manufactured by TRUMPF they are optimally integrated for production. “The TruLaser 5030 fiber can cut the same sheet thicknesses as its CO2 counterpart,” states the release, “however, the 1.03m wavelength of the solid-state laser makes it possible to cut thin sheet more quickly and with the same high part quality. When cutting mild steel with oxygen, there are no decisive differences over the range of thicknesses between the two laser technologies.”
MAZAK OPTONICS OPTIPLEX 2 PALLET CHANGER JOB SHOP LASER
Mazak (www.mazakoptonics.com), which offers 50 laser cutting systems, launched its OPTIPLEX 2 Pallet Changer Job Shop Laser at the latest Fabtech Canada event, with a focus on automation. “The 2D laser-cutting system has been specifically designed to integrate ‘intelligent’ automation features with superior cutting speeds,” states a press release. “Typically, laser
Machitech is a Canadian manufacturer of industrial equipment for the metal cutting markets. We offer complete installation and training packages that are tailored to the customer’s needs and experience. Our technicians are highly trained to trouble shoot any situation encountered. Machitech’s extensive knowledge in CNC Plasma, Water Jet and Laser technology is what makes them the leader in the Canadian Market
the innovative manufacturer of Plasma, Waterjet and laser cutting equiPment “Productive cutting system and excellent service’’ D.Martin Welding and Fabricating inc Inverary Ontario
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operations that accommodate varied workpiece materials and thicknesses are automated by compromising cutting parameters such as nozzle diameters and condition. This can significantly affect the productivity and cost of operation especially with today’s focus on smaller batch sizes. Mazak has developed a series of automated setup functions called AO5 that enable optimized cutting even during extended unattended operation.” The OPTIPLEX includes a new PreView 2 control with a 15” touch screen and a straight forward user interface which simplifies machine operations. Additionally, a new 4,000 watt Type 10 resonator improves operating efficiency and lowers operating costs. It also has a 5’x10’ table and can process from the thinnest steel up to 1” mild steel.
CINCINNATI CL-900 SERIES FIBER LASER SYSTEM
Cincinnati Incorporated (www.e-ci.com) recently launched its CL-900 laser cutting system, combining a fiber laser with the company’s 12,000 ipm linear-motor drive (combined X & Y axis speed) to increase productivity and lower operating costs. The most productive, economical and easy-to-use laser cutting system for sheet metal processing, the CL-900 series cuts thin steel two to three times faster than similar wattage CO2 lasers, with reduced operating costs. The solid-state fiber laser simplifies maintenance by eliminating laser gas, internal optics, glassware, blowers and vacuum pumps. The beam is delivered via flexible glass fiber, eliminating external mirrors, bellows, and beam purge gas. Fiber lasers deliver power efficiency greater than 30 percent, roughly three times higher than CO2 systems. Ideal for highvolume cutting of intricate shapes and part designs, fiber lasers concentrate more energy into the cutting spot, for faster cutting of thin material. Available with 5 ft. x 10 ft., 6 ft. x 12 ft, and 8 ft. x 20 ft beds, CL-900 systems include the PC-based HMI control and Cincinnati’s Programming and Nesting Software. A web cam for monitoring is available.
HYPERTHERM HYINTESNITY FIBER LASER SYSTEMS – HFL020 AND HFL010
Last January Hypertherm (www.fiberlasercutting.com) released two new HyIntensity Fiber Laser systems—the two kilowatt HFL020 and the one kilowatt HFL010. “These two new systems join a 1.5 kilowatt system unveiled in 2010 as the first fully-integrated fiber laser systems designed
specifically for cutting applications, including marking and finefeature cutting,” states a company press release. “The powerful systems deliver a number of advantages, including: performance on a wide range of applications and consistent cut quality across a number of material types including brass and copper and thicknesses up to 16mm (5/8”) on mild steel; higher cut speeds, lower operating costs, and higher productivity than CO2 laser or plasma on material thicknesses below 6mm (1/4”); superior cut quality and tolerances for fine-feature cutting on materials from gauge to plate; [and] easy integration and installation onto existing cutting tables, even tables that already have a plasma torch.” Hypertherm fiber laser is considered so advanced that engineers at NASA Tech Briefs honoured it as Product of the Year for 2011. Hypertherm develops and manufactures its HyIntensity systems in the United States.
ROFIN FL 030 C FIBER LASER FL 030 C
The ROFIN Macro Group’s (www.rofin.com) FL 030 C, a compact fiber laser, “has been specially developed for direct integration into existing machine concepts,” states a press release. “With an output power of 3,000 W, the FL 030 C is available as a multi-mode laser with a 50 µm or 100 µm fiber. With beam qualities in the range of 2 up to 4 mm x mrad and a modular and robust design, the FL 030 C is the ideal tool for laser cutting and for laser welding applications.” By utilizing the different diameters of the process fiber, “the laser’s beam quality, the focus diameter, as well as the Rayleigh length, can be ideally adapted to the specific application task.” The compact version of the FL Series is offered with 500, 750, 1,000 and 2,000 W output power options. “This covers the complete range of applications for processing thin materials,” states the release. “ROFIN fiber lasers are extremely compact, robust, highly-efficient, and meet the requirements of harsh industrial environments thanks to the modular and robust design.”
MITSUBISHI EX LASER CUTTER
Mitsubishi’s (www.mitsubishi-world.com) eX Laser Cutter replaces its former LVP series and is the fifth generation in a line of powerful 2D lasers. It delivers low running costs and eco-friendly features for power and gas consumption, and stable operation for up to 1.4 times greater productivity. “The eco mode cuts running costs by up to 90 percent during standby,” states a press release. “Carbon dioxide emissions are reduced by around 30 percent compared to competitor machines. [Its] new compact design provides a small footprint without reducing table size [and] standard on the eX is its magnetic head, which protects from catastrophic crashes and allows for easy recovery.” Mitsubishi’s patented three-axis, cross-flow resonator design delivers “the highest cutting power per watt available [and its]
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simplified resonator design eliminates the need for expensive quartz tubes and turbine blower systems, optimizes cutting power and requires 2-5 times less maintenance than other laser equipment on the market.” Mitsubishi’s National Product Manager, Jeff Hahn, stresses that the “eX series combines ease of operability, faster cutting, upgradable automation, and eco-friendly, cost-saving features — it’s a smart choice for small job shops or high volume production facilities.”
PRIMA POWER PLATINO FIBER LASER
According to Prima Power( www.primapower.com ), its Platino Fiber Laser “is a highly flexible and reliable laser cutting machine” and “uses of all state-of-the-art laser technologies on hand to meet the needs of high quality sheet metal manufacturing.” The laser is available for sheet size 1,500 x 3,000 mm and with a laser power ranging from 2,000 W up to 3,000 W, handles a wide range of applications. “The unique architecture of Platino fiber allows full accessibility to the working area from three sides,” states a release. “This open structure makes it easy to integrate the system, at any time, with the wide range of modular automation solutions by Prima
Power, from simple pallet changer to the most complete system with automatic handling and storage of the material.” Its features include a unique machine design using a synthetic granite frame to offer the best thermal stability and vibration damping; a safe impact protection system for the protection of the machine head against collision with fixtures or workpieces; and the manual loading/unloading of sheets without using the automatic pallet changer.
AMADA FOL-AJ
Amada Canada’s (www.amada.ca) FOL3015AJ fiber laser is engineered to produce high-quality parts at very fast speeds while reducing operating costs and environmental waste. The FOL-AJ is the world’s first 4000 W production fiber laser specifically designed for cutting. Key features include faster cutting of thin material (two to three times that of a comparable 4000 W CO2 laser), superior speed and edge quality in material thicknesses up to 7/8˝ compared to other solid-state systems and process range expansion by providing the ability to cut copper, brass and titanium.
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The system’s resonator produces a beam with a wavelength that is approximately a tenth of that emitted by a conventional gas laser, allowing for materials that CO2 lasers could not process to be easily cut. There are also environmental benefits. “Solid-state technology does not require laser gas to generate the laser beam — thereby reducing environmentally harmful emissions,” states Amada. “In addition, the power requirements for Amada’s FOL-AJ is less than its CO2 counterpart. Since there are no optics to keep cool, a smaller, more efficient chiller further enhances cost savings.”
LVD ORION 3015
LVD has redesigned its Orion 3015 Plus CO2 laser cutting system and has added a 19” touch screen graphical user interface to improve machine setup and ease of use. LVD’s Orion 3015 provides cost-efficient processing of a range of materials in sheet sizes up to 1500 x 3000 mm. The redesigned hybrid-style system now features LVD’s latest Touch-L graphical user interface technology, allowing both routine and complex operations to be quickly and efficiently completed with minimal operator input. Touch-L simplifies the laser cutting process through use of intuitive graphical icons and visual indicators to display and control functions. Touch-L also performs automatic nesting and job generation. It provides the user flexibility to easily change cutting qualities, position and type of lead-in, and add or relocate micro joints for all online-generated jobs. The addition of the Touch-L interface to the redesigned Orion simplifies setup and operation of the system, making the laser cutting system ideal for entry-level users. The Orion 3015 Plus also features automatic cutting gas selection, automatic focal positioning and automatic cutting gas pressure control with servo valve to further
aid in machine set-up and operation. The laser cutting system is equipped as standard with Process Control, which automatically senses piercing times and detects and controls plasma when cutting stainless steel and aluminum. This feature maximizes processing time and minimizes part damage due to loss of cut. Orion 3015 Plus employs the reliable Fanuc RF excited fast axial flow CO2 laser. The laser, CNC control, drives and motors are fully integrated, providing superior processing speed, high reliability, and low operating and maintenance costs. Automation options are also available. The laser cutting machine can be equipped or retrofitted with an automatic load/ unload unit or a Compact Tower (CT-L) warehouse system. CM
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HyIntensity™ Fiber Laser Laser cutting made easy by the experts in metal cutting
Introducing simple, efficient, reliable fiber laser cutting from Hypertherm HyIntensity Fiber Laser is the first fully-integrated system optimized for metal cutting. With multiple power levels available, this low maintenance, easy to integrate, efficient system makes it easy to produce great results across a wide range of materials and thicknesses. Visit www.FiberLaserCutting.com to learn about the benefits of fiber laser technology or request a demo.
ManuaL PLasMa I MecHanIzed PLasMa I autoMatIon I Laser I consuMabLes I soFtWare www.canadianmetalworking.com | SEPTEMBER 2012 | 85
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Cutting Clean Abrasives in handheld tools are a time-honoured way to clean and dress metals, and new technology makes them more efficient than ever By: Irwin Rapopport ..............................................................................................................................................
Few tools are as widespread in Canadian metalworking shops than the humble angle grinder and belt sander. Whether itâ&#x20AC;&#x2122;s prepping joints for pipeline welding or descaling hot-rolled stock prior to finishing, abrasives in a handheld tool are a well-known quantityâ&#x20AC;Śor are they? There is a surprising amount of technology embedded in discs and belts, with opportunities
to pick-up efficiency and productivity with the right product choice. When choosing belts, Mike Radaelli, senior product manager with Norton Abrasives, says there are three main types of minerals that are commonly used today in the coated abrasive belt, which allows for the removal of excess metal by grinding
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off-hand or using pressure assisted equipment in preparing these items for consumer use. They are: aluminum oxide, “a utility grade mineral that provides a good cut and consistent finish on metals such as carbon steel, bronze and wood which require fast penetration of the metal or wood without breaking down”; alumina zirconia, “a mineral that is tougher than aluminum oxide or silicon carbide and has a unique self-sharping characteristic, which provides long life on rugged stock removal operations on aluminum, titanium and stainless steels”; and ceramic alumina, “a mineral with the greatest toughness and hardness that is generally used on high-pressure grinding applications that use super-alloy metals such as aero-space alloys, nickel-based alloys, and some stainless steels.” He adds that the ceramic alumina mineral is the most expensive to manufacture and that in “today’s economy it is important to make sure that you are using the most cost-effective coated abrasive product.” Coated belt products, explains Radaelli, are made up of three basic components - a flexible or semi-rigid backing, abrasive grains (minerals), and adhesive that bonds the other two components together. “Selecting the proper abrasive grade is very important in achieving the optimal cut rate and desired surface finish,” he says. “The backing on a coated abrasive
belt must be smooth enough for uniform coating and grain adhesion, strong enough to withstand grinding pressures, and flexible enough to conform to contours of the work piece and the grinding machine. Ounce for ounce, a polyester backing is stronger than cotton backing, and polyester offers better tear and puncture resistance than cotton. A cotton back is more flexible and can allow the operator to grind in shapes and flex the belt more easily.” He notes that there are seven factors to consider when choosing a coated abrasive belt: 1. Type of grinding – Roughing – 36-80 grit; Intermediate – 100-180 grit; Finishing – 220-240 grit 2. Type of grinding machine – Off-hand, pressure assist, centerless, automatic 3. Pressure applied – Heavy/severe, moderate, light 4. Shape of part – Flat, medium contours, severe contours, gate removal 5. Contact wheel or belt support system – Steel, rubber platen, slack-of-belt 6. Type of metal being ground – Stainless steel, titanium, aluminum, carbon steel 7. Specification – Size of belt, grit size In terms of a formula for determining the best choice, contionued on page 90
WALTER - ENDURO-FLEX
Walter Surface Technologies International recently launched ENDURO-FLEX finishing disc for metal finishing applications, a product billed with “an improved longer life [that is] a remarkable trail-blazing product,” says company president and COO Timothy Houghton. “The improved ENDUROFLEX disc features a totally new design and flap configuration with an exclusive cloth and abrasive composition. Patented backing can be trimmed down adding total longevity to the product. “This breakthrough innovation offers a more consistent surface finish,” he adds, “and most importantly, removes more material. A 5-inch disc with Grit 40 Date: removes up to 2,500 grams over its lifespan – performance is comparable in other th 15 March 2012 disc sizes and different grit sizes.” Author: High performance combined with longevity, and cost reductions are principles of the Florian Pottrick new disc. “Overall this results in less disc changeovers as well as less waste over the long-term, making it the ideal ® solution for finishing steel and stainless steel, aluminum, and other Flap discalloys,” POLIFAN -STRONG-FREEZE says Houghton. www.walter.com Grinding ice-cold with maximum aggressiveness and tool life
PFERD - POLIFAN-STRONG-FREEZE
Pferd Canada’s Polifan-Strong-Freeze flap disc, states in a press release that its product, “offers an innovative flap disc with a cool grind that is particularly advantageous when working with poor heat-conducting materials such as stainless steel (INOX). The unique ceramic grit abrasive reduces the usual sparking to a minimum. This means that damage to other stainless steel work pieces caused by glowing sparks is almost eliminated. The surface temperature during the grinding process is reduced by about 30%, resulting in low heat build-up, distortion, and thermal damage to the structure of the work piece.” Compared to conventional flap discs, Polifan-Strong-Freeze discs reveal an unusual initial wear pattern. The highly effective fillers form a shining cooling film on the disc (not ‘glazed over’). This film is the basis for the excellent cooling, aggressiveness and tool life. www.pferd.ca 88 | SEPTEMBER 2012 | www.canadianmetalworking.com
With the innovation POLIFAN®-STRONG-FREEZE, PFERD is offering a flap disc with a cool grind unrivalled anywhere in the world. This is particularly advantageous when working poorly heat-conducting materials such as stainless steel (INOX). Thanks to the innovative design of the ceramic grit abrasive, the cmw sept 2012 abrasives pg 86-91 88 usual sparking is reduced to a minimum. This means that damage to other
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3M – CUBITRON II FIBRE DISCS
3M Cubitron II Fibre Discs, a recently launched product line, offer a “new range of fibre discs which are set to revolutionize productivity, throughput, comfort and grinding speed in a range of abrasive applications,” states a release. “[The] discs use innovative 3M precision-shaped ceramic grain technology, with ultra-sharp fast-cutting points,” it adds, “which wear evenly and run cooler than alternative products, with optimized mineral breakdown to maximize disc life. Each disc features triangular precisionshaped grain, electrostatically oriented to form sharp peaks which slice through metal, wearing evenly and providing long life and consistency at any grinding pressure.” Moreover, “The range comprises 987C discs for stainless steel and 982C for carbon and mild steel,” with discs available in 36+, 60+ and 80+ grades that provide “a complete solution for removal of weld, mill scale, surface imperfection, beveling and edge chamfering.” The diameters range from 4” up to 9 1/8”. According to 3M’s workplace research, “the discs last at least twice as long as conventional ceramic products, and up to five times as long in some applications [and] cut rates are faster too, more than twice those of some other fibre discs.” www.3MCubitron2.com
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contionued from page 88 Radaelli says: “The best product for cleaning/finishing can be determined by the actual cost/part including labour and overhead. To quickly figure cost/part use this formulation: abrasive cost + (labour + overhead) = grinding cost per part.” Kate Ouellette, Rex-Cut’s marketing manager, stresses that when selecting abrasive products, the application is the key. “If you are working on a soft metal, you will want a disc that will not load up, one that constantly reveals new grain, such as our Type 27 Non-Woven Cotton Fiber products,” she says. “This disc is designed to minimize the amount of steps the user must take to reach a desired finish. The composition of this disc enables grinding and finishing in one operation. This disc has consistently reduced finishing steps from two or three to one, which in turn lowers the cost of grinding metal.” Ouellette continues, “If you are working on something such as handrails or small TIG welds where finishes really matter, our fusion flap disc leaves a number four finish.” She adds, “Flap discs are typically selected because they are less expensive, but our premium high-end product conforms to the metal, avoiding flat spot on tubes and rails while leaving an improved surface finish.” Ouellette notes, “Sigma Green is another option if you are looking to take a weld down quickly without chattering or surface staining.” Ross Paterson, the marketing manager for 3M Canada’s Abrasive Systems Division, commenting on the question of using flap discs versus fibre discs, says that customers should ponder the process. Using a right angle grinder to take down welds, isn’t rocket science. What is the substrate? What kind of process steps are you performing? How do you judge if the finish on the part is acceptable? Are you looking at ways to increase productivity?” The choice does matter and when considered, Paterson states, “you can determine the best disc for the job. If life of the disc is important to you, then flap discs would be your choice. Then ask yourself if the application is low, medium or high pressure and that will determine the disc choice. If low pressure, 3M
546D would be the choice, if medium or general purpose, use 3M 566A, or if high pressure, then the 3M 577F flap disc. If the substrate is stainless steel, 3M 747D is the your choice regardless of pressures.” Should speed and cut be key aspects, “we suggest fibre discs. Determine the substrate and that will determine the disc to use. 3M 501C or 3M 988C for carbon steel or 3M 785C or 3M 985C for stainless are your best choices.” And if speed and life issues are paramount, he suggests “ 3M’s revolutionary precision shaped grain,” with Cubitron II Fibre Discs, 982C or the 987F. “While you won’t get the overall life of a flap disc,” says Paterson, you will in fact get closer to the life and a substantial increase in life versus other fibre discs.” On the issue of metal removal rates via its abrasive products, Patrick Lapointe, vice president, marketing of WALTER Surface Technologies International, says that its Enduro-Flex finishing disc is a good example of how its products meet more demanding industry benchmarks because it “removes more material than any other product on the market” and that a “five-inch disc with Grit 40 removes up to 2,500 grams over its lifespan, with a performance that is comparable in other WALTER disc sizes and different grit sizes.” Lapointe stresses that his company’s latest disc products help firms lower the cost of grinding because of their durability and resulting in fewer downtimes to change discs, which disrupt the rhythm of the work day. “Our discs last longer, which helps the bottom line,” he says, “and in today’s competitive market, every advantage is critical to achieve efficiency and maximize production.” He adds that improving the quality of the finish is a given, pointing out that WALTER abrasive products ensure “smooth handling and our vibration-free tools allow workers to achieve a very high quality finish while work comfortably. Improving the work experience for those using our products is important to us and the feedback we receive from our customers in turns helps us design better products that meet their criteria.”
ABTEX CORPORATION - ABRASIVE FILAMENT DISC BRUSHING TOOLS
Abtex Corporation’s abrasive filament disc brushing tools are “designed for manual and automated finishing machinery used in extrusion, automotive and appliance plants, as well as fineblankers and other industrial applications,” says a release. “[Our] unique anchoring system embeds the fibers in a resin body, increasing the durability of the tool without compromising its integrity when finishing soft materials.” The tools come in standard diameters ranging from 3” to 16”, with a wide choice of grits. “However,” states the release, “Abtex’s flexible manufacturing process allows products to be customized for a wide range of applications. The standard grit is silicon carbide, but ceramic is offered as an option. Other options include custom arbor holes, ‘hook and loop’ backing, special diameters, nylon-only filaments and special trim heights.” www.abtex.com
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REX-CUT ABRASIVES – FUSION FLAP DISC AND TYPE 27 COTTON FIBER GRINDING WHEELS
Two of Rex-Cut’s products are the FUSION Flap Disc and the Type 27 Cotton Fiber Grinding Wheels. “The FUSION Flap Disc has an interleaf construction that lets users grind and finish stainless steel handrails, vessels, and other structures in one operation using a standard right angle grinder,” states a release. “The disc features a premium coated abrasive layer and a surface conditioning layer that leave a smooth finish.” The Type 27 Cotton Fiber Grinding Wheels are designed for grinding and blending small welds. “They feature multiple layers of condensed non-woven cotton, impregnated with aluminum oxide or silicon carbide abrasives,” says a release. “[Our] Fiber abrasive products do not load up when working on softer metals and do not back transfer on harder alloys. Other products created with the Cotton Fiber Abrasive material include, Type 1 wheels, mounted points, quick change discs, and sticks.” www.rexcut.com
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MMi is the MEdiCAl ANd dENtAl MANufACturiNg industry event of 2012 www.canadianmetalworking.com | SEPTEMBER 2012 | 91
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i meTalworking markeTplace producT previews The new exchangeable Tip drill – corodrill 870 The CoroDrill 870, can save time and reduce hole costs. CoroDrill 870 can be tailored to optimize applications through diameter range, steps and length possibilities. A highly secure interface between drill body and tip ensures reliability and precision, while the quick and easy tip change procedure helps to maximize active machining time. The cutting edge geometry provides a safe cutting process with optimized chip control, and long dependable tool life. www.sandvik.coromanT.com IMTS BooTh #: W-1500 laser marking soluTions TRUMPF will show a wide range of laser marking solutions at IMTS – from processing small components with the air-cooled TruMark 3020 and TruMark Station 1000 (D) to deep engraving metal components with the TruMark 6030 – all with exceptional mark quality. Also on display is the TruMark 5020, a fiber laser marker for high quality, customized marking or engraving with short processing times on metals and plastics. www.us.Trumpf.com IMTS BooTh #: N-6223 cusTom workholding engineers on hand aT imTs booTh s-8148 Hardinge Inc. (Elmira, NY) manufactures workholding products to grip parts to be turned, milled, ground, welded, assembled and positioned in the small-to-medium parts machining industry. Hardinge has completed over 200,000 custom workholding designs, while offering over 40,000 standard products. Common gripping problems involve odd shapes, part slippage, thin and delicate materials, scratching, threading, or lack of gripping surface. Drawings and sample parts can be emailed to orders@hardinge.com; or faxed to 607-737-0090. www.hardinge.com IMTS BooTh #: S-8148 Technifor xf520cp Fast, accurate marks can be placed anywhere identification is needed with Technifor’s XF520Cp. This handheld, micro percussion marking dynamo may weigh only 5 lbs., but it packs the power needed to mark any type of surface (raw, painted and machined) most materials (metals, alloys, plastics) and many shapes (flat, convex, concave). The easy to operate software offers icons, pop up help and graphic preview. www.Technifor.us IMTS BooTh #: N-6146 mulTi-carb high performance The Multi-Carb high performance finishing end mill from SGS Tool Company incorporates a large number of flutes for stability and high feed finishing capabilities in applications where surface finish and tolerance are critical factors. Available with 7, 9 or 11 flutes, the odd number of cutting flutes control natural harmonics, staggering entry and exit of the cutting edges allowing smoother performance and increased tool life. Exclusively coated with Ti-NAMITE-A®. www.sgsTool.com IMTS BooTh #: W-2217 scoTchman® cpo 350 circular cold saw Scotchman Industries’ American-made CPO 350 Circular Cold Saw features a double clamping, self-centering vise that provides burr-free, high quality parts and a chip drawer. This saw has 135º mitering ability and a miter-locking device that automatically stops at 45° left, 90° straight, and 45° right, a double reduction gearbox, a two-speed motor which utilizes up to a 14” diameter blade giving it a 4-7/8” OD round capacity and a 3-Year Warranty.. www.scoTchman.com IMTS BooTh #: N-6417 Toshiba machine To feaTure bTh-130.r24 horizonTal boring & milling machine aT imTs 2012 At IMTS 2012, Toshiba Machine will be featuring their BTH-130.R24 Horizontal Boring & Milling Machine. With a large work envelope and the ability to hold workpieces up to 20 metric tons (44,000 lbs.), the BTH-130.R24 is ideal for a variety of energy-related machining applications including wind turbine components, turbine casings, natural gas fracturing (fracking) components and oilfield and mining equipment. www.Toshibamachine.ca IMTS BooTh #: S-9436 mazak inTegrex i-100sT mulTi-Tasking machine Ideal for small high-precision part applications, the compact INTEGREX i-100ST Multi-Tasking machine employs two turning spindles, a milling spindle and lower turret for processing first and second operations simultaneously or performing required sequential operations on a single workpiece. It also executes full, simultaneous 5-axis machining for handling all processes from raw material input through final machining on one machine, reducing production lead times, improving machining accuracy and lowering operating expenses. www.mazak.com IMTS BooTh #: S-8300
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imTs chicago 2012 meTalworking markeTplace producT previews seco double ocTomill – 05 face milling cuTTer The Double Octomill - 05 face milling cutter, available in diameters ranging from 1” to 5”, provides optimal performance in applications requiring a maximum 0.118” depth of cut. The cutter’s insert pockets incorporate a strong center lock screw and hardened HSS insert locating pins. The pockets also feature an 8-degree negative angle to allow for double sided inserts, while the inserts themselves are positive, creating a positive cutting rake to minimize power consumption. Four insert geometries are available to accommodate various materials. www.secoTools.com IMTS BooTh #: S-8300 licon Tripod powerflex CON Technologies will premiere a revolution in precision metal cutting, the ICON Tripod 700S Powerflex, a modular 6-Axis PKM Machining Center of advanced design in terms of automation, dexterity, and accuracy. The PKM design results in high structural stiffness and the capability of performing extremely high-speed motions. The Tripod Powerflex models feature 40 or 80 pocket tool changers. The rotary table is a large 800mm and features a zero point clamping system.” icon.hydromaT.com IMTS BooTh #: S-8348 powerful Turning capabiliTies The Okuma VTM-1200YB 5-axis vertical multitasking machine combines powerful turning capabilities with 5-sided machining and face milling into one robust machine. Designed to reduce setup and change-overs, minimizing non-cutting time and increasing productivity, this machine has fast axis feeds and short ATC times to ensure highly efficient cutting. Built on Okuma’s Thermo-Friendly Concept, the machine can be run from a cold start because it resists thermal deformation, minimizing thermal growth. www.okuma.com IMTS BooTh #: S-8500 dmu 85 monoblock® nexT generaTion wiTh mill Turn (fd) Complete machining for maximum precision with minimum cycle time The DMU 85 monoBLOCK® FD is based on 12 years experience in mill turn technology (FD) and over 800 installed FD machines. This machine achieves up to 300% more productivity than conventional machines, with less floor space and lower investment. Multitasking through milling and turning in one setup increases accuracy and minimises cycle time. www.ca-en.dmg.com IMTS BooTh #: S-8900 miTuToyo releases new porTable surface roughness TesTer. Mitutoyo has released its new SJ-310 series of surface roughness testers. The key features include a large color LCD touch panel with improved clarity and readability in low light. The testers are powered by either a Ni-MH rechargeable battery, or an AC adapter and include an optional SD memory card that can store measurement results. In addition to data storage it also features a high-speed thermal printer to create hard copies of results. www.miTuToyo.ca IMTS BooTh #: E-5214 miTuToyo unveils new cnc 3d measuremenT sysTem Mitutoyo has announced the introduction of Ko-ga-me, a new 3D CNC measurement system offering flexible configuration that allows for optimum versatility. The Ko-ga-me 3D CNC measuring head can be installed to a base unit for high-accuracy and high-speed inspection results when measuring. Available in 40mm, 80mm and 120mm stroke types, Ko-ga-me is designed as a 3 axis or 2 axis measurement system and is available in either horizontal or vertical models. www.miTuToyo.ca IMTS BooTh #: E-5214 solid carbide high-performance drill FWalter Titex X·treme Inox, is a solid carbide high-performance drill suited for use in ISO M machining operations. A tip geometry, which has been specially adapted to these materials, reduces the cutting forces and significantly reduces burr formation on entry and exit. The TTP coating allows for maximum increase in productivity. The X·treme drill is available in a diameter range of 3 to 20 mm, and standard lengths up to 5 x D. www.walTer-Tools.com/us IMTS BooTh #: W-1700 chip conTrol inserT for small diameTer boring in demanding maTerials. The SCT Advantage Chip Control insert, is the latest addition to the Advantage Boring Bar System. The SCT Advantage Chip Control Inserts address the challenges accompanied with boring applications in some of today’s demanding materials including High temperature alloys, low carbon steel, stainless steel, chip packing, marred surface finishes, poor tool life and premature tool holder failure, to bring extra value and increased productivity in demanding boring applications. A proprietary precision ground chip former and lapped surface finish coupled with a sub-micrograin carbide substrate and the latest in ALTiN coating technology. www.scT-usa.com IMTS BooTh #: W-2258
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i makino a51nx: producTiviTy and reliabiliTy ThaT maTTers When it comes to making the parts that matter most, Makino’s new a51nx horizontal machining center provides the reliability, stability and precision to help you succeed. Its enhanced spindle power and axis speeds slash cycle times for high-quality parts at a lower cost. To find out more, visit booth S-8700 at IMTS and witness true next-generation performance that matters. www.makino.com/imTs IMTS BooTh #: S-8700 bohler-uddeholm, a leading supplier of special sTeel will be at booth 1685 in the west hall to talk about how to lower manufacturing costs through the application of special At IMTS, Bohler-Uddeholm will feature our full range of products including steel technology: • High Speed Steel • Powder Metallurgy Steel • Tool Steel • Specialty Alloys. For more information about the show or if you would like to schedule a meeting with one of our representatives call us toll free at 1-800-638-2520. websiTe: www.bucanada.ca IMTS BooTh #: W-1685 The mosT advanced faro laser Tracker ever FARO’s newest breakthrough, the Vantage, is also the most advanced FARO Laser Tracker ever. Dramatic reductions in size and weight make the Vantage supremely portable. Plus, new features like SmartFind and MultiView enable operators to make multiple measurements of even very large parts, quickly. This, along with increased range and the accuracy that has made FARO the trusted name in laser trackers, makes the Vantage a true no-compromise solution for the customer. www.faro.com/laser-Tracker IMTS BooTh #: E-5504 sumiTomo elecTric carbide sTrenghThens iTs drilling lineup wiTh The wdx large diameTer expansion. Sumitomo offers an expanded cutting edge WDX drilling series, highlighted by the new large diameter drills. Providing additional drilling solutions, the WDX advancement is comprised of diameters ranging from 0.5625” – 2.625” in 2XD, 3XD, 4XD and 5XD drill body lengths. All WDX diameters utilize the same four-cornered indexable insert for the outer and inner pocket to provide a cost effective drilling solution and easy tool management. The DL1500 (Diamond-Like Carbon coating) insert grade is available for non-ferrous materials to increase insert toughness. The trusted series uses two inserts per drill, regardless of diameter size.’ www.sumicarbide.com IMTS BooTh #: W-2422 new offerings in The feeler producT line include The all box way fT series laThes. A push toward larger parts in the oil and other energy fields has increased demand for larger horizontal Lathes. The Feeler FT Series feature all box way design and large 110mm (4.3”) rotating tail stock quills to handle heavier cuts than other linear guide machines. For more information on Feeler products and technology from Methods, visit www.meThodsmachine.com IMTS BooTh #: S-9119 new mobile sumpdoc™ Eriez new mobile SumpDoc™ provides “inline” fluid recycling that cleans and rejuvenates coolant while machine tools continuously produce parts. Use the SumpDoc as a faster and cheaper way to maintain cutting fluids – roll the SumpDoc next to the dirty sump, drop in the hoses and let it cycle through, removing solids, chips and tramp oils while evaluating and replenishing the coolant. For more information on Eriez equipment, visit www.hydroflow.eriez.com IMTS BooTh #: N-7353 fagor To inTroduce new nano-meTric resoluTion precision linear encoders aT imTs 2012 The all new Fagor GZ and SZ series precision high performance linear encoders will offer maximum performance resolutions up to 50 nano-meter. Nano-metric resolution ensures highest quality part finish by providing maximum positional accuracy. Accuracy will be guaranteed up to 3 microns per meter. The SZ series will be offered in travel lengths of up to 2040 mm and the GZ series in lengths up to 3040 mm. www.fagorauTomaTion.com IMTS BooTh #: E-5230
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imTs chicago 2012 meTalworking markeTplace producT previews gs angle heads GS Tooling is introducing a new line of Italian made ATC Series Angle Heads. With superior design featuring Gleason ground spiral bevel gears as well as class ABE7/9 precision bearings and solid (or integral) shaft and shank makes these heads stand above the rest. These heads and much more will be on display at IMTS. Call today for your brochure or visit our website to download. www.sowaTool.com IMTBooTh #: W-1485
s s
maTsuura 5-axis offers larger working envelope As with all Matsuura 5 axis products, the MAM72-100H is designed to function best with flexible multiple setups, process a wide array of materials in a multitude of industries, & offer users advanced, proven & extended unmanned operation. Process integration & high-precision complex “one hit” operation come as standard. Matsuura has developed the MAM72-100H following many requests from existing MAM72 users for a machine with a larger working envelope & processing capacity. www.ellioTTmachinery.com IMTS BooTh #: S-9119 nakamura-Tome super nTmx offers a world firsT The Super NTMX is the world’s first system to offer dual 24-tool ATC magazines, a unique design to simplify complex multitasking machining. Full 5-axis milling capability via a Fanuc 31iA5 Control provides high precision and accuracy for manufacturing complex contoured components, including medical, aerospace and more, in large or small volume production. Manufacturers looking for a simple, high performance 5-axis multitasking solution, with the flexibility of 2-ATC magazines, must consider the Super NTMX solution from Nakamura-Tome. www.ellioTTmachinery.com IMTS BooTh #: S-9119 sTrong, free-cuTTing buTTon face mills Ingersoll Cutting Tools is pleased to introduce the new Form-MasterShear line of button face mills. This new line currently offers face mills from 2 inch through 6 inch diameters. The round button inserts offer eight indexes and are available in 12mm & 16mm IC sizes. Four different standard edge preps available in all popular Ingersoll grades. Form-MasterShear features an insert clamping system that keeps the insert from rotating in the insert pocket during milling operations. This new offering combines performance and economy. Application flexibility will be an added benefit when considering all of the different edge preps and grade combinations that are available. www.ingersoll-imc.com IMTS BooTh #: W-1822 lincoln elecTric exTends and enhances magnum® pro semiauTomaTic and roboTic gun offering Lincoln Electric’s Magnum® PRO welding gun line has been extended and enhanced to add greater flxibility and convenience for fabrication owners and operators. The Magnum® PRO product family includes semiautomatic MIG/flux-cored guns with barrel style or Curve™ handles; dedicated self-shielded flux-cored K126™ guns; and Magnum® PRO Thru-Arm and External-Dress torches for robotic applications. Magnum® PRO guns use the same interchangeable Copper Plus™ contact tips, nozzels and diffusers with AntiSeize™ thread design. www.lincolnelecTric.com/en-us/equipmenT/guns/pages/magnum-pro.aspx IMTS BooTh #: N-6618
. er
emuge inTroduces new modular Tap holders for machines wiTh synchronous spindles. Emuge Corp., the leader in thread cutting technology, introduced a series of tool holders with variable exchangeable transfer elements and length adjustment screws. Designed for machines with synchronous spindles, the new Softsynchro® HD and MQL Modular System makes it possible for the same tool holder body to be used for minimal quantity lubricant (MQL) or HSK coolant applications. www.emuge.com IMTS BooTh #: W-1536 helido s890 new economical high efficiency soluTion for face milling HELIDO S890 FSN is a new family of right-hand indexable face mills with an 88º cutting edge angle (2° lead) with 8 helical cutting edges. Designed for rough to semi-finish, high-efficiency face milling, the face mills carry square-shaped inserts: S890 SNMU 1305 PN… with 8 helical cutting edges. Every cutter body features coolant holes directed to the insert cutting edges. The inserts feature an advanced cutting geometry with positive rake, that ensures smooth milling with soft entry to and exit from material. www.iscar.ca IMTS BooTh #: W-1800
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Costly Corrosion If your process requires the shipping of bare metal parts, corrosion control is essential By Fernando Longinotti, Armor Protective Packaging .................................................................................................
A
s heat and humidity increase during the warm months, delivering rust-free parts, especially metal parts shipped internationally, is nearly impossible. For those in the metal and automotive industry, ocean shipments are a “black box of mystery” where corrosion damage often seems unpredictable. If you are in the metal part manufacturing business, you are used to dealing with processing variables like coolant flow, pressure and tool breakage among many others. Unfortunately, the worst variables rest outside of your plant, like the position of the pallet (cargo) inside the container or the position on the ship. They are hard to predict or control. As a metal part nears completion, mistakes are more expensive as more time and energy has been invested in that piece of metal. If corrosion ruins the part in shipment, the ROI (return on investment) will be zero! Rust on metal parts is a major source of dissatisfaction for the end user, but it also represents wasted resources for the manufacturer. Ferrous corrosion, or rust, is the chemical reaction between iron and oxygen in the presence of water. Rust progresses moderately under these conditions, but can form much faster if chemical catalysts are present. When shipping metal parts, it is likely that iron, oxygen and water (whether in liquid or vapor form) will be present in the shipping container; ideal conditions for corrosion. Corrosion damage is accentuated by temperature fluctuations. For example, when a shipping or storage container cools down after a hot day in the sun condensation can occur. There is a maximum amount of moisture that air at a particular temperature can hold. If the temperature drops enough, condensation will occur. The metal surface usually cools the fastest and will therefore attract moisture. The study titled “Temperature & Humidity in Ocean Containers” by David Leinberger, CPP, CPLP, Senior Packaging Engineer for Xerox Corporation, looked at typical ocean shipments and divided them into three stages: land-water-land. The recorded data shows that the highest risk of corrosion damage occurs on land before or after the ocean freight voyage. This is because the inner temperature of the packaging and the air contained will follow
the same pattern of fluctuations as the surrounding environment. The air inside, will be cold and saturated during night hours, and hot and humid during day hours. For years, it was falsely believed that ocean shipments were more susceptible to corrosion than ground transportation, but this study shows that the opposite can be true.
EFFECT OF POSITION ON SHIP:
Usually, this is how metal parts are shipped overseas. (See picture). As part of the study, the conditions in multiple ocean containers traveling on the same ship were measured. Clear differences in temperature were found between the ocean containers located in different parts of the boat. The below figure shows how container #2 had a gradual temperature variation along the ocean journey. Container #1 shows a much larger variation each day. This container was loaded above deck where the sunlight could affect the container temperature, while container #2 was covered by other containers and it seems the shadow has moderated it naturally. The position on the ship is probably one of the toughest variables, because it is almost impossible to control, and it does play a role in the final outcome. This is not great news, but it is better to be aware than ignore it. These records also explain why some ground shipments present more rust issues than ocean shipments. A container on truck gets as much sunlight as the one that goes on top of the pile on a ship.
EFFECT OF POSITION WITHIN CONTAINER:
A controlled experiment was done with data recorders at various positions within a partially filled ocean container. The below figure details the recorder position along with the temperature profiles over a three-day period. The temperature recorded at the top of the ocean container was over 35° F [19° C] higher during the afternoon than the temperature recorded near the bottom. This can be explained due to the fact that the roof
96 | SEPTEMBER 2012 | www.canadianmetalworking.com
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ADVERTISERS INDEX ADVERTISER . . . . . . . . . . . . . . PAGE
ADVERTISER . . . . . . . . . . . . .
American Torch Tip . . . . . . . . . . . . . . . . . . . 61 AMT Machine Tools Ltd. . . . . . . . . . . 29,35,38 Benz Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Bohler-Uddeholm Limited . . . . . . . . . . . . . . . 53 Canadian Measurement-Metrology . . . . . . . 14 Cincinnati Incorporated . . . . . . . . . . . . . . . . 4 CWB Group . . . . . . . . . . . . . . . . . . . . . . . 59 Data Flute . . . . . . . . . . . . . . . . . . . . . . . . . 71 Diapaolo CNC Retrofit Ltd. . . . . . . . . . . . . . 11 Dillon Manufacturing, Inc. . . . . . . . . . . . . . . 39 DMG Canada, Inc. . . . . . . . . . . . . . . . . . . 25 DMG/Mori Seiki USA . . . . . . . . . . . . . . . . 31 Eclipse Tools North America Inc. . . . . . . . . . 10 Elliott Matsuura Canada Inc. . . . . . . . . . . . . . 4 Emec Machine Tools Inc. . . . . . . . . . . . . . . . 27 Eriez Magnetics . . . . . . . . . . . . . . . . . . . . . 16 ESAB Canada . . . . . . . . . . . . . . . . . . . . . . 63 Fagor Automation Canada . . . . . . . . . . . . . 13 Fein Power Tool Company . . . . . . . . . . . . . .34 Gibbs & Associates . . . . . . . . . . . . . . . . . . 15 Hardinge Inc. . . . . . . . . . . . . . . . . . . . . . . . 41 Horn USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . 7 Hurco USA . . . . . . . . . . . . . . . . . . . . . . . . IFC Hydromat Inc. . . . . . . . . . . . . . . . . . . . . . . 35 Hypertherm Inc. . . . . . . . . . . . . . . . . . . . . . 85 Ingersoll . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Iscar . . . . . . . . . . . . . . . . . . . . . . . . . . . . OBC Jarvis Cutting Tools, Inc. . . . . . . . . . . . . . . . 48 Lincoln Electric Company of Canada . . . . . . 55
Lubricor Inc. . . . . . . . . . . . . . . . . . . . . . . . . 17 Machitech Automation . . . . . . . . . . . . . . . . 81 Makino Inc. . . . . . . . . . . . . . . . . . . . . . . . . 43 Mascoutech Inc. . . . . . . . . . . . . . . . . . . . . . 78 Mazak Corporation . . . . . . . . . . . . . . . . . . 19 Megatel Inc. . . . . . . . . . . . . . . . . . . . . . . . 49 Methods Machine Tools, Inc. . . . . . . . . . . 23,45 Mitutoyo Canada, Inc. . . . . . . . . . . . . . . . . 77 Okuma . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Renishaw Canada Ltd. . . . . . . . . . . . . . . . . 33 Retention Knob Supply & Mfg. Co. Inc. . . . . 97 Sandvik . . . . . . . . . . . . . . . . . . . front flap & 67 Schunk Intec Corp. . . . . . . . . . . . . . . . . . . . 78 Scientific Cutting Tools . . . . . . . . . . . . . . . . 73 Scotchman Industries, Inc. . . . . . . . . . . . . . . 84 Seco Tools Inc. . . . . . . . . . . . . . . . . . . . . . . 65 SGS Tool Company . . . . . . . . . . . . . . . . . . 72 Society of Manufacturing Engineers . . . . . . . 91 Sowa Tool & Machine Co. Ltd. . . . . . . . . . . 46 Star CNC Machine Tool Co. . . . . . . . . . . . 29 Sumitomo Electric Carbide . . . . . . . . . . . . . . 9 Technifor . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Toshiba Machine Company of Canada Ltd. . 37 TRUMPF Inc. . . . . . . . . . . . . . . . . . . . . . . . IBC Tungaloy America Inc. . . . . . . . . . . . . . . . . . 3 Victor Technologies . . . . . . . . . . . . . . . . . . . 57 Walter Surface Technologies . . . . . . . . . . . . 89 Walter USA, LLC . . . . . . . . . . . . . . . . . . . . 69
PAGE
8CMM20186
01/07/2008
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IN STOCK American Standards and specials. Japanese Standards inch or metric.
FOR FAST DELIVERY: Contact your local tooling dealer or order direct. TEL 937-686-6405 FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O. Box 61 Bellefontaine, OH 43311
TYPICAL CORROSION VARIABLES Heat Corrosion happens twice as fast for every 50°F rise in temperature.
usually receives more direct sun rays than the walls and it is usually the hottest part of the container. It can also explain why, sometimes, rusty metal parts are located in the upper pallets or near the door.
Moisture Allows flow of the electrolytic corrosion current. Pollutants Increases the electrolytic corrosion current.
EFFECT OF CONTAINER CONTENTS:
Porous materials present in the packaging, such as corrugated boxes, paper and wooden skids, slowly absorb the moisture from the air prevent ing condensation at the lower ocean temperatures. This event usually happens during night hours. The below figure shows the simulated container with the fiberboard boxes had a much lower relative humidity.
This reveals why many auto-parts manufacturers’ condensation and corrosion issues occurred when they switched from corrugated boxes to returnable plastic containers. Reusable plastic trays are a well-known source of contamination and won’t absorb moisture. CM Fernando Longinotti International Sales Manager of Armor Protective Packaging, an international company that provides corrosion management systems for metal products. www.armorvci.com www.canadianmetalworking.com | SEPTEMBER 2012 | 97
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By The NUMBERS UPSTAIRS, DOWNSTAIRS The U.S. is our largest trading partner … is it really recovering?
N
ew analysis from the International Monetary Fund suggests that the U.S. recovery is progressing slowly, but not steadily. According to the conclusion to the IMF 2012 Article IV Mission the United States, The U.S. recovery remains tepid. After rebounding in the second half of 2011, growth slowed to around two percent in the first half of this year. Strong headwinds persist on private consumption, as households continue to deleverage. Residential investment has picked
up and house prices have stabilized recently, but remain at depressed levels. Job creation has slowed since early 2012, and the employment-to-population ratio remains substantially below pre-recession levels. Exports have been a bright spot in the recovery but have recently been hampered by some slowdown in foreign demand, particularly in Europe. Growth is likely to remain modest in the next two years, constrained by household deleveraging, fiscal restraint, and subpar global demand.
UNITED STATES: SELECTED ECONOMIC INDICATORS (annual change in percent, unless otherwise indicated)
2007
2008
2009
2010
2011
2012
2013
–3.5
3.0
1.7
2.0
2.3
National production and income Real GDP
1.9
Net exports (base:1)
0.6
1.2
1.1
–0.5
0.0
–0.1
–0.2
Total domestic demand
1.2
–1.5
–4.4
3.4
1.6
2.0
2.3
–0.2
–0.5
–0.8
1.6
–0.2
0.2
0.1
Unemployment rate
4.6
5.8
9.3
9.6
9.0
8.2
7.9
CPI inflation
2.9
3.8
–0.3
1.6
3.1
2.2
1.7
Change in private inventories
Merchandise trade balance (billions of dollars)
–819
–0.3
–830
–506
–645
–738
–769
–817
Sources: Haver Analytics and IMF staff estimates
ANALYSIS:
Risks surrounding this forecast are tilted to the downside. The United States remains vulnerable to contagion from an intensification of the euro area debt crisis. U.S. financial institutions have limited direct claims on the euro area periphery, but strong financial linkages with the core euro area. On the domestic front, failure to reach an agreement on near-term tax and spending policies would trigger a severe fiscal tightening in 2013, threatening the recovery. A fiscal consolidation of around four percent of GDP in 2013 (in line with current law) could reduce annual growth to well below one percent, with negative growth early next year and significant negative repercussions on an already fragile world economy. Meanwhile,
the federal debt ceiling will need to be raised in early 2013, bringing back the risk of heightened uncertainty and financial market disruption. There are also upside risks, however. Capital investment may turn out to be stronger than in staff’s forecast (particularly in a less uncertain environment), given the strong balance sheets of non-financial corporations. A more positive outlook for the housing market can also be envisaged, with a faster-than-expected recovery in housing starts associated with pent-up demand. The recovery could also strengthen if the policy measures aimed at a faster resolution of the housing crisis gain traction. Finally, a slower fiscal withdrawal than built in our forecast would help lift growth. Source: IMF, www.imf.org
98 | SEPTEMBER 2012 | www.canadianmetalworking.com
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ISCAR is About to Upgrade the World of Metal Cutting
w w w. i s c a r. c a
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