Canadian Metalworking June 2013 by Annex Business Media

June 2013 â&#x20AC;˘ www.canadianmetalworking.com

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A LOOK INSIDE Vol. 108 | No. 5 | JUNE 2013 | www.canadianmetalworking.com

COVER STORY OPEN FOR BUSINESS .............. 22 Mixed economic signals from Canadian shops

FEATURES JOB SHOP SNAPSHOTS: Endeavor Steel Limited ....................................... 21 Straightline Precision Industries.................................... 26 Hansen Industries .............................................. 30 EXEMPT NO MORE ....................................... 34 Ontario shops face new regulation and higher costs

CUTTING IN THE WET ................................... 38

BE FLAT AND HORIZONTAL .......................... 52 Position for top welding efficiency

3D MEASURING SOFTWARE......................... 56 Benefits outweigh the costs

FINE GRINDING ............................................. 60 John Manley on the state of the sector

Set up and monitoring of water jet operations

NO MORE MILLING ABOUT ........................... 64

COQUITLAM HOSTS CANADIAN METALWORKING SHOW ............................... 48

REVVED UP ROUGHING................................ 78

BC biz breaks out with CM’s new tabletop event

What’s new in milling inserts

Build-A-Mold’s fast removal rate solution

21 26

64 78

52 56

38 DEPARTMENTS

View From the Floor ......................................................... 6 News ................................................................................ 8 The Business of Welding ................................................ 17

The Cutting Edge ........................................................... 46 Welding News................................................................. 50 Tool Talk .......................................................................... 72 By The Numbers............................................................. 82

Cover image courtesy Flow International Corp.

www.canadianmetalworking.com | JUNE 2013 | 5

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PUBLISHER Steve Devonport 416-442-5125 | SDevonport@canadianmetalworking.com

View From the Floor

SENIOR ACCOUNT MANAGER Rob Swan 416-510-5225, cell 416-725-0145 | RSwan@canadianmetalworking.com EDITOR Jim Anderton 416-510-5148 | janderton@canadianmetalworking.com ASSISTANT EDITOR Nicholas Healey 416-442-5600 x 3642 | nhealey@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 8 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 JUNE not be reproduced or transmitted in any form, either in part or in full, including photocopying and recording, without the written consent of the copyright owner. Nor JUNE any part of this publication be stored in a retrieval system of any nature without prior written consent. Content copyright ©2013 by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd., JUNE 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 JUNE use, reproduce, publish, republish, 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 JUNE 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

Slow motion nation

s Canadians, we’ve been lucky to escape the worst of the global banking-induced recession. We live in a vast resource warehouse, one that has papered over some ugly realities about the way our economy operates. I write this having averaged 11 km/h during my Toronto morning commute. During that commute, I learned of a Senate expense scandal that will apparently end with no investigation, no criminal charges and a cash bailout by a high-ranking member of Prime Minister Harper’s staff. Here in Ontario, our government will be spending an estimated half a billion dollars to not build a power plant in a hotly contested riding. Here in Toronto, the infrastructure neglect continues with the city Council unable to agree on a simple transit strategy for a traffic-choked city. Federally, our government will spend a quarter of a billion dollars in designing work before metal is cut on our new maritime patrol vessels, ships which are already based on an existing European design. I could go on, but there are too many examples. As a nation, we rest on our laurels, smug in the mistaken assumption that sober common sense has steered us clear of global economic turmoil. It’s far from the truth. The reality is that we avoided the banking crisis by doing nothing, an approach which serves politicians well from coast-to-coast-to-coast. Doing nothing, spending money for nothing, thinking about perception and political electability instead of moving this nation forward in highly competitive world is the way we do business these days. This paralysis, in the form of a nonexistent national industrial strategy, has already damaged the heart of our nation’s GDP earning potential. Governments federal and provincial do pay attention to manufacturing. Unfortunately it’s limited to handing out dollops of taxpayer cash as de facto bribes to corporations willing to expand or at least not relocate their manufacturing operations. Here in Ontario, the upcoming September elimination of the so-called “manufacturing exemption” promises to significantly increase costs for smaller shops at the very time that they face brutal foreign competition and a chronic skilled labour shortage. The corrosive effect of policies like these and a general neglect of industrial policy at both the federal and provincial levels would be considered treason in many societies; here it’s considered good government. Can it be fixed? Yes, but like a fractured casting we have to eliminate the stress riser, not just drill out the crack tip. Want to fix endless procurement crises? Put single officials in charge of each program. Stake their careers or promotions directly on its outcome. Hold contractors to cost estimates and delivery dates, with serious penalties for noncompliance. Tie bonuses and promotions to process simplification at every level of government aiming for one page, plain English forms for everything from training subsidies to personal income tax. And most importantly, start throwing politicians and bureaucrats that defraud the system in jail. If politicians can file fraudulent expense claims and their only sanction is to give the money back, how can we possibly expect good behavior and honest work from the private sector? E-mail or call your MP, MPP or MLA. As the real engines of our economy, if we in industry won’t stand up, who will? JIM ANDERTON, EDITOR

Canadian publications Mail Sales Product Agreement 40069240 ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.

Do you agree? Let me know, and feel free to drop me a line at the e-mail address below, or buttonhole me at a show or event. I’d love to hear from you! janderton@canadianmetalworking.com

6 | JUNE 2013 | www.canadianmetalworking.com

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IN THE NEWS

Toronto-area machine tool dealers host open house Dealers talked with customers about manufacturing solutions and expressed optimism about the industry in Canada going forward

he eighth annual Joint Open House (J.O.H.) for local machine tool dealers was held over two days on April 24th and 25th in the Greater Toronto Area. Five locations across Mississauga and Oakville opened their doors to both shop owners and production staff to show off products and speak with attendees about manufacturing solutions. The participating locations included DMG Canada, EMEC Machine Tools, Single Source Technologies (SST), and Ferro Technique, all based out of Mississauga, as well as Elliott Matsuura Canada, located in Oakville. “I think it’s a fantastic opportunity to bring out the people and showcase the new technologies,” said Daniel Medrea, Managing Director at DMG Canada. “By doing it with the other four partners it’s worthwhile for everyone. We’ve never had so many machines before, four milling machines and four lathes,” he continued. The event was well attended, and much of the discussion

centered around the optimism towards the manufacturing sector in the lead up to the Canadian Manufacturing Technology Show (CMTS) this fall. “We’ll be at CMTS.… It should be a good fourth quarter. I think up to this point (sales) have been spotty. A lot of activity, just hard for customers to release orders … but the third and fourth should be good,” said Brian Donnelly, Vice President at Ferro Technique. “Normally after a down period it goes up, and it goes up quickly.” Tajal Mehta, the Vice President of Operations at EMEC echoed that sentiment. “Canada is on the right track. We’re seeing some (improvement) right now in productivity. The buying cycle’s a little slower than I’d like it to be, however I think 2013 will be a very strong year automotive-wise,” he said. A number of exhibitors also discussed their interest in the ... continues on page 10

8 | MAY 2013 | www.canadianmetalworking.com

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IN THE NEWS ... continued from page 8

All five exhibitors showed multiple machines in a hands-on environment.

manufacturing strength of western Canada and had high hopes for the Western Manufacturing Technology Show (WTMS) this June in Edmonton. “I’m finding that 50, maybe 60 per cent of my business is

coming from western Canada… on the fab side,” said Nigel King, Product Manager for Elliott Matsuura. “We’re going to have a press brake (at CMTS), and we’re also going to have a press brake at the Edmonton show,” he continued. “One thing I find about western Canada, they’re a lot more positive. You drive down the street and you see signs that say ‘welders wanted’, ‘machinists wanted’.” But others commented on the strength of the more traditional Canadian markets as well. “In Montreal and Quebec there’s a lot of aerospace, so titanium, hard metals, things like that we’re working on,” said Peter Sheridan, Application Engineering Technologist, at SST; the distributor for Makino machine tools. “We had a record year in January in machine sales for aerospace machine sales. We sold quite a number of them in the Montreal market.” A number of suppliers were also in attendance at each of the locations to meet potential customers and showcase everything from cutting tools to metrology equipment. Suppliers included Sandvik Coromant, Renishaw and Data Flute, among many others. At each location drinks and lunch were also served over the course of the open house, and prizes, including a trip to Las Vegas, were available to attendees that visited all the locations. CM

SYNERGY MACHINE SALES has hired

Robert Hart, a new sales representative who will cover northern and eastern Ontario. He will be based out of Barrie, Ontario. Hart has 15 years practical CNC machining experience, mostly in the hightech commercial and aerospace fields. He also has experience in supervisory roles, project management, and programming. Hart has five years of experience selling machine tools, and throughout that time maintained a track record as a top performer. “Synergy feels very fortunate to have a person with Rob Hart’s experience and calibre representing our Robert Hart brand,” said Nelson Martins, partner at Synergy Machine Sales Inc. Synergy is based out of its office in Mississauga, Ontario, and also has an Atlantic Canada office in Moncton, New Brunswick. www.synergymachinesales.com 10 | JUNE 2013 | www.canadianmetalworking.com

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IN THE NEWS

Canadian Metalworking hosts tabletop show in Coquitlam Over 400 attendees showed up for the inaugural MMP Show. By Nick Healey

n Tuesday, May 7, Canadian Metalworking magazine held a one-day tabletop show at the Red Robinson Show Theatre in Coquitlam, British Columbia. The Metalworking Manufacturing & Production Expo (MMP Show) was co-hosted with Design Engineering Expo (DEX) and featured 63 displays showcasing products from both the metalworking and design engineering industries. A number of major machine tool, cutting tool, and fabricating companies were on hand to network with local customers and discuss manufacturing solutions. The event was well attended with 400 visitors dropping by throughout the course of the day. The decision by both magazines to hold a show in the Vancouver area was based on the notion that it was underserved for this type of event. “We chose Vancouver because B.C. is a perfect market for a tabletop show – not ready for a large trade show, but has a

good manufacturing base,” said Canadian Metalworking Publisher, Steve Devonport. “This was a part of the country that a lot of our advertisers had a vested interest in exploring, and growing their market share in. We have over 2,000 readers in British Columbia yet there was no show or expo to speak of,” said Rob Swan, Senior Account Manager at Canadian Metalworking. The show also got an excellent response from both exhibitors and attendees. “We didn’t think it’d be as busy — we’ve got some good leads and a lot of test opportunities that we’re going to have. It’s been very worthwhile and we’ll definitely be back,” said Mark Crump, the General Manager of PFERD Canada. Michelle Barry, who works in business development at the Vancouverbased Hansen Industries said, “We go to the EPTECH shows across Canada, but this one’s probably the second busiest show I’ve been to… whatever you guys are doing, you’re doing it well, and I’m so glad you’re out west!” Nigel King, product manager with Elliott Matsuura Canada echoed that sentiment. “We didn’t know, when we came here, what this was going to be… I thought this morning that it would be all students. We’ve had good quality customers here, a lot of interest. So in that respect I think it’s been very good.” There were also multiple draws throughout the day with three attendees taking home an Xbox, an iPad mini, and a new Nikon camera. The show will be returning to the Vancouver area again next year on May 6th. The event was sponsored by Sandvik Coromant, Mazak Canada, Elliott Matsuura Canada, and TRUMPF. CM

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IN THE NEWS

Ontario budget underscores the importance of manufacturing: CME It’s hoped a new youth employment and mentorship fund will help spur young people into manufacturing careers.

he Canadian Manufacturers & Exporters (CME) issued a statement Friday applauding the new Ontario budget, and its potential impact on manufacturing in the province. The lauded it as “a positive step forward in revitalizing the province’s manufacturing sector”, and anticipated it would create jobs and support business growth. The CME, the country’s largest trade and industry association, commended the government for mirroring the federal

decision to extend the accelerated depreciation for manufacturing and processing equipment through 2015. They believed the move will result in $265 million in savings for Ontario companies — as well as the formulation of a new $295 million youth employment and mentorship fund, which could help encourage more youth to explore opportunities in in-demand manufacturing-related careers. “We are pleased to see the government formally recognize the importance of manufacturing to the province’s economy,” stated Ian Howcroft, vice president, CME Ontario. “The success of this entire budget starts with manufacturing, and we will continue to need strong leadership in the coming months from all stakeholders and all parties to implement policies that spur investment and keep us moving forward.” While CME also noted its support for the government’s commitment to reduce the deficit, other moves in the budget received a less favourable response. In particular, the elimination of a threshold exemption for large employers on employee health taxes is expected to drive down competitiveness. The QLC family of chucks is an enviable combination “Overall, this budget is a good signal of proven mechanisms, innovative design, highest that the province wants to work closer quality materials and advanced manufacturing with industry,” said Howcroft. “The rest of Canada and the rest of the techniques. Their lighter weight, high clamping force world won’t wait for us. We need to work and long, reliable service life makes them perfect for together to ensure Ontario is ready to lead practically all turning applications. — in job creation, in investment attraction, in export development – and that growth must start with a vibrant, innovative manufacturing sector.” Recently the CME founded the Ontario Council of Manufacturing Executives (oCME) – a group of senior industry leaders, who have come together to speak about issues impacting the province’s 800-544-3823 sales@forkardt.us manufacturing sector. www.ontariomanufacturing.ca CM

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14 | JUNE 2013 | www.canadianmetalworking.com

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IN THE NEWS A Splashy Canadian Launch for Iscar’s IQ Line By Nate Hendley

sraeli cutting tool giant Iscar hosted a splashy Canadian launch for its IQ line of turning, drilling, gripping and milling tools at the Living Arts Centre in Mississauga, ON, on May 7. A total of 312 people representing Iscar top brass, distributors, machine shops and media registered for the event. The mostly male audience, dressed in business causal, munched on catered meals and packed a Living Arts theatre for the allday presentation. The theme for the launch was “machining intelligently”—an attribute epitomized by the IQ line according to Iscar CEO Jacob Harpaz who led the presentation. Machining intelligently involves non-stop 24-hour cutting, minimum downtime and set-up time, easy cutting, less power consumption, vibration and chatter-free operations, efficient chip evacuation, lower costs and higher productivity, Harpaz explained. Harpaz flashed slides and offered details about tools in the Dove-IQ-Turn Heavy Duty line, Sumo-Cham drill line, Dove-IQGrip Tiger line, Heli-IQ-Mill 390 line, etc. He was interrupted at several points by a trio of young female musicians who shimmied on stage bearing violins and a cello to play music and dazzle.

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David MacNiven, president of E.M. Precise Tool in Stoney Creek, ON, a major ISCAR distributor, was impressed by the day’s proceedings. Iscar “always put on a first-class show” he said, adding, “they’re always coming out with something to machine better and faster.” “This is the biggest investment Iscar has ever had in terms of product introductions,” noted Iscar general manager Ronnie O’Byrne, in a pre-presentation interview. During a break, Harpaz offered a few quick remarks for Canadian Metalworking. He agreed with a suggestion that the lavish launch reflected the return of manufacturing to North America. As for IQ, it’s “a good product line,” said Harpaz. CM

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THE BUSINESS OF WELDING

Potential Energy E

very once in a while I get into a conversation about the future of welding with someone outside our industry, with the conversation always ending up in a discussion around education. Not surprisingly, the outcome always seems to be that there is a need to bring the country as a whole up to speed in terms of trade education, and its support and promotion. What I’m talking about here is not limited to welding; it applies to all skilled trades in general. Sure, there are pockets of progress around Canada on this issue but we still have a long way to go to get us “back to the future” that was in place and promoted when I was going through high school in the ‘80s. At that time almost every high school had one or more shop classes, and they were always full. Looking back, two things come to mind: what happened to the concept of “shop”, and more importantly, where did all that student potential, momentum, and youthful energy go? The key things here are the words “potential” and “energy” - without either we have nothing. If I remember my high school physics, energy cannot be created or destroyed, so in theory what we should now have is a lot of “potential energy” waiting to be released...

TAPPING POTENTIAL ENERGY — MOVING DISCUSSIONS INTO ACTIONS As you may know, the Canadian Welding Association (CWA) is involved in many activities tied to improving welder education, training, and general knowledge. Over the past two years we have done a lot of talking and listening and I’m pleased to say the result is action on a number of fronts, from students to teachers to industry suppliers and everyone in between. Lets start with the second annual CWA Educators’ Conference held at the beginning of May. If I had to pick one word to describe this year’s event it would be “success”. Not only was there a record turnout, with educators from a solid cross-section of institutions (high school to university) hailing from a good chunk of the country, there was also action – in the form of some clearly defined objectives, wants, and needs. At a basic level what is being called for is consistency, and access to resources to support it. For example, a national welding strategy for best practices; adoption of apprenticeship program in all provinces; the concept of inter-provincial curriculum; basically a one-system educational approach delivered consistently across the country. What does that mean from an “actions” perspective from the CWA/CWB? It can be summed up be saying: development, funding, and support. There’s

Ian Campbell, Director of Marketing and New Product Development, CWB

something in these actions for everyone, so stay tuned to this column – I will be releasing details relating to each of those words over the next couple of months. Secondly, I would like to mention that the CanWeld Zone at the Gas & Oil Show is sold out from an exhibitor perspective. Truth be told, we have a waiting list, which means things could get bigger and better in upcoming years. All this is good news as it means you will now be able to see a great cross-section of Canada’s welding suppliers in one location, every year. Once again, what started as a discussion resulted in an action – in this case creation of an industry “destination”. Even if you are not involved in the oil & gas industry you should mark June 12th and 13th off on your calendars and plan to attend. While we are talking dates, events, and destinations, you might also want to book off October 28th and 29th for the CanWeld Conference. Information on both events can be found at www.CWAevents.org. follow us on Facebook for weekly updates.

PAT YOURSELF ON THE BACK PROGRAMS Lastly, every industry needs to wave the flag and recognize success. With this in mind I can suggest several programs that do just that. The CWA offers a range of awards specific to our industry. Take the time to read them over and then nominate someone – who knows, next year your name might come up. You can find a full listing of these awards in the latest issue of CWA Engage, which you can access from the CWA site: www.cwa-acs.org. Also, please don’t forget the CWB QualityMark Program. If you are a CWB Certified manufacturer or service provider the QualityMark program is free, and will help you promote your material, products and/or services. Having the QualityMark means you have taken steps to improve your services as well as the safety of Canadians as a whole – that’s something worthy of recognition. Ask your local CWB representative for detail or call 1-800-844-6790. As always, if we can help, let us know.

Canadian Welding Bureau/Canadian Welding Association www.canadianmetalworking.com | JUNE 2013 | 17

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2013 COUNTDOWN

CMTS Returns to the Airport and Offers Visitors a Unique Experience Inside “Terminal 4” S ME, producers of the Canadian Manufacturing Technology Show (CMTS) continue to deliver on their theme “Expect More” for this fall with the announcement of “Terminal 4 – Where Knowledge Takes Flight”, a feature area of the CMTS show floor that will be transformed into an airport terminal. “We had identified this space two years ago as a key networking hub for the floor says CMTS event manager, Julie Pike. Through some great collaboration with a valued client, Sandvik Coromant Canada, we have created an aptly themed airport terminal that will rival any feature we’ve had in the past at CMTS,” Pike added. Excitement abounds on both sides as Sandvik Coromant steps into a key sponsorship role at CMTS with its support of Terminal 4. “We are thrilled to partner with SME in presenting Terminal 4 at CMTS. It’s a natural evolution of our participation at CMTS, as this nexus of the show floor will serve as the key hub for knowledge exchange and networking among manufacturers, suppliers and industry leaders.” says Ross Carpino, General Manager of Sandvik Coromant Canada. Visitors to CMTS will be hard-pressed to miss Terminal 4 — a central point that connects the exhibit halls as they traverse the hundreds of exhibits on display. Highlights of this manufacturing themed airport terminal will include: • An array of “Duty-Free Manufacturing Shops”, offering manufacturing resources and leadership including SME, Tooling U along with other industry partners and media alliances • A glimpse into the future with special displays from the Automotive and Medical industries • A special presentation stage on the luggage carousel • The only dedicated WiFi zone of the five CMTS exhibit halls • An upscale food court experience with reserved dining options A • VIP lounge experience for all CMTS guests to stop

and make a few calls, check email or grab a coffee with a prospect all while looking out to the airport tarmac • Access to the complimentary CMTS shuttle buses to host hotels • Access to the complimentary CMTS shuttle bus to Pearson Airport • Concierge service desk to assist guests including all questions CMTS, restaurant referrals and cell phone charging service “Momentum is building rapidly for CMTS and we’ve still got a few big announcements to make before September, Pike offered. As for Terminal 4 — we’ll let the audience be the judge as to whether we’ve delivered a unique, valuable and rewarding area during their visit to CMTS. We’re working hard to deliver more than ever before to Canada’s National Manufacturing Event and its thousands of loyal supporters.” To learn more about the 2013 edition of CMTS, taking place this September 30-October 3 at The International Centre in Mississauga, ON, visit cmts.ca or call 888322-7333. CM

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Job Shop Snapshot

Endeavor Steel Limited The current home of Endeavor Steel. The shop is full of work (Credit: Jeremy Wiebe) to do, inside and out.

by Jeremy Wiebe

ndeavor Steel Limited specializes in fabrication of structural and miscellaneous steel for commercial and industrial applications. Located in Edmonton, Alberta, the fabrication shop serves the local industry and is growing to accommodate heavier, more industrial work. The business started in 2000 when owner Ken Greenwood started fabricating bollards after hours in his 3-car garage. Soon, the demand for his work had outgrown the garage, so Ken quit his day job and moved operations into the city where Endeavor quickly grew into a 30-employee operation in a 4,000 square-foot shop. After thirteen years in business, the shop is still growing

The interior at Endeavor. Good use is made of limited floor space, but everybody is (Credit: Jeremy Wiebe) looking forward to expanding operations in the new building.

Some of the employees at Endeavor steel with owner Ken Greenwood (center, (Credit: Jeremy Wiebe) glasses.)

HSS grating Endeavor built for trenches in a wash bay. The order called for a much more expensive design, but Endeavor was able to deliver the product for far less.

quickly. Endeavor is building a 10,500 square-foot shop in the city for the operation to move into sometime this year. Already CWB Division 2 certified, Endeavor is in the process of attaining ISO 9001 and 14001 certification as a part of the company’s plan to expand and serve more clients. According to Greenwood, Endeavor is “heavily involved in bringing QA up to industry standards” and is “aggressively pursuing industrial work.” Endeavor is looking at purchasing beamline equipment as well as a plate processor to finish parts faster and take on heavier workloads. “My biggest challenge is people. Finding quality people to do quality work,” says Greenwood. Now, he says, he finally has an “excellent crew” he can depend on. And while the local industry faces frustration with increased out-of-province competition taking over some of the bigger contracts in the area, Endeavor’s lead man stays optimistic. “Although we are in a global, price-sensitive market, more and more clients are concerned with customer service and quality.” The shop’s plans for increased quality certification and further upgrades to equipment put Endeavor well on its way to doing just that.

ESSENTIAL NUMBERS FOUNDED: 2000 by Ken Greenwood OWNERS: Ken and Laurie Greenwood SIZE: 4,000 square feet (upgrading to 10,500 square feet) NUMBER OF EMPLOYEES: 30

SPECIALTIES: Fabrication of structural components for industrial applications. FUTURE PLANS: ISO 9001 and 14001 certification, moving into new building. www.canadianmetalworking.com | JUNE 2013 | 21

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Open for Business Job shops voice guarded optimism in an uncertain market By Jim Anderton, Editor

hese are strange times for Canada’s machining, fabricating and manufacturing sectors. Five years after the historic banking meltdown and in the middle of a pan-European recession, some shops are experiencing strong, even record growth while others are struggling. While commodity prices are flat to slightly down (see the statistics on page 82 of this issue), interest rates are at unprecedented lows, auto sales are strong and new discoveries in US shale-derived energy have not had enough of a downside effect on global oil pricing to counter continued Asian demand. It’s still economically feasible to extract oil from sand and will remain that way for the foreseeable future. The long run is positive, but what about 2013? With over a century of large scale mining operations

and an even longer history in forestry, British Columbia is sensitive to global economic pressures. For Beaver Falls Machining Ltd. in Beaver Falls, (near Trail) the family business with both machining and welding/fab services is affected by uncertainty in global metals pricing. A nearby Teck Resources zinc and lead operation in Trail. is a major customer. “It’s very slow”, states the firm’s Tracey Goldthorpe, adding “Teck is our local customer…they were installing a new furnace and have put it off to 2015. There‘s not much for local people since big components are brought in from outside.” Zinc is a typical case of a metal that’s tied to consumer market volatility. While die casting and alloying demand in specialty applications is steady, the real market is in galvanizing sheet steel which ties the corrosion-resisting

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metal closely to consumer demand for durables such as building materials, appliances, cars and light trucks. The Teck decision to stretch expansion plans until 2015 anticipates flat growth in manufactured goods demand for at least a year, with Asian demand (particularly China) volatile. For the duration for 2013, the local outlook isn’t likely to change: “If anything, I think the market is shrinking” says Goldthorpe. “If Teck were to install that second furnace, they would be using twice the consumables, which would be a good thing for us as well as the trickle-down effect on the local economy. Many of the local lumber companies have established their own machine shops, so there’s less going on. People are still pinching pennies.”

IT’S STILL ABOUT ENERGY In Alberta, it’s still about energy, but delays in the Keystone XL pipeline haven’t made a serious impact on job shops, at least not yet. The economy is robust, but there is a lot of business that isn’t directly tied to the oil sands. At family-owned Aztec Machine Works in Calgary, the order book is filled by a wide variety of jobs. Manager Margaret Bachand declares that, “we’re doing just fine. We’re steady with machining, fabricating and welding”. With years of growth in the oil patch, it’s easy for a shop to evolve into process or downhole specialists, which deepens customer relationships, but carries additional risk. Diversification is a common theme for many Canadian shops this year and businesses that have already secured a broad customer base like Aztec now have added security in a volatile market. In the Calgary region, Bachand notes that “many CNC shops work for two or three customers so if that market goes down they’re in trouble. We don’t depend on the oil patch. In fact, very little of our work is oilfield related. We’re a general service shop and we’re really busy. We have diversified but we do work for the oil sector. It looks steady for the rest of the year.” Many forces affect the market for machining and fabricating services across the country, from the global banking crisis to environmental regulation, but some sectors depend on the most unpredictable factor: weather. In Weyburn, Saskatchewan, Chip 9 Machining does an interesting combination business: machining services and gunsmithing. Chip 9’s Andrew Shanaida serves a market that has been heavily affected by weather. “This year could closely resemble 2011. We had an early slowdown about October of last year and it’s been painful. We had a lot of snow this winter and things are really dragging. In 2011 we had major flooding

and for a major part of our business, which is oil field service including pump jack repair, was a problem. The guys couldn’t get in to the field. We expected a lot of work later, but financially it was like skipping a year. Of course the costs didn’t skip a year. It’s not always easy. 2014? It’s hard to predict. Weather will definitely be a factor. We’re going to tough it out.” And the gunsmithing? ”Guys from the oil patch with money in their pockets come through the shop for parts. We also have a gun shop out front.”

AUTO SALES STRONG Auto sales remain strong, and almost as importantly, higher margin SUV and light truck models underpin the growth, meaning larger tools and more money to pay for them. For Tier One-rich central Canada it’s an opportunity few shops can ignore. Lumar Machining and Manufacturing in St. Thomas, Ontario is located in the heart of OEM supplier country in south west Ontario, an easy day’s drive to Canadian and US automakers and Tier Ones. “It’s been good”, states Lumar’s Ian Wagter. “We had a record year last year…it’s been slower this year, mainly because one of our customers had a hiccup. They have straightened it out and we’ve also been able to find work elsewhere. It’s starting to come up to where we want it.” Lumar uses a wide variety of processes and is also

“People are still pinching pennies” diversified. “Last year half of our business was in the oil and gas sector, for Texas. We are also in the automotive and recreational sectors. It’s varied.” Wagter is understandably bullish on the future: “I’m optimistic. It’s out there but you have to pursue it. We’re looking at expansion so we’re thinking positively.” A full order book is great news, at least until it’s time to build product, when boots on the ground can make the difference between on-time quality delivery and profit-killing excess overtime, or worse. While the labour issue continues to affect the industry and has even grabbed headlines in the mainstream media, solutions like the Federal 5000 dollar subsidized training program will at best take years to produce qualified tradespeople. It’s an issue on the mind of Paul Smith of Tycos Tool and Die in Concord, Ontario. “I’m positive, he states, adding, for us 2013 looks www.canadianmetalworking.com | JUNE 2013 | 23

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“We’re still working and we’re still self-financing, so we can keep going” strong for the latter half of the year. We can only really plan half a year ahead because of the OEM business we do. In general we’re optimistic. We design and build injection molds and dies, but skilled trades are still an issue. We’ve had some success but it’s hard to find the right people. It takes a good fit; it’s necessary to train them directly from school. We do in-house training.” The training issue presents a “Catch 22” scenario for many shops, who will be required to contribute to the shared cost Federal training program, but not see skilled hands until the next business cycle, where demand will be nearly impossible to predict. As Paul Smith notes, it may be necessary to train more personnel than the anticipated need to generate the spectrum of skills adequate for basic machining and fabricating operations as well as close tolerance, precision work.

OFFSHORE IS STILL A THREAT One route to diversification is to run the tooling you build, something Joe Debreczeni’s Moldex Plastics and Tool has been doing in Quebec for over 40 years. Moldex was a pioneer in molded ice skate technology and both builds and runs injection molds along with a range of machining services. For Moldex, offshore competition is keenly felt, on both the manufacturing and moldmaking sides. Regarding 2013, Debreczeni states, “so far it’s lousy. Not as much work as we’re used to. We deal with molds, new products and plastics production. The whole industry is slow, especially the design and building of molds. A lot of business is going to China; they have faster

service than they used to have, and their quality is better. Their prices are now higher, but not as high as here in Canada.” Can Canadian companies compete with improving Asian moldmakers? Debreczeni says we can: “It depends on the quality of the product. They (offshore shops) don’t use the right steel or the right hardness of steel; if the mold runs for only a few hundred thousand units, they just make a new one. Telephone, high-level electronics, those products are more expensive, but if they’re making simple things, China-based shops are much cheaper. Their delivery is fast. They’re working three shifts over there.” The labour cost issue is inescapable: “I’m paying between 25 and 30 dollars an hour and they’re paying 120, 130 dollars a week.” The Moldex formula of building high quality tooling and paying good wages is an example of how the industry should run, and Debreczeni knows the solution is simple. “We have to bring the jobs back to Canada”, he says, adding “I’ve even lost US customers to China. When Obama promoted “Made in the USA” an American customer we’ve known for 30 years took away a product. The whole industry is upside down. Times have changed. Young people don’t make a deal with a handshake like we used to do. I used to order 300,000 dollars’ worth of raw materials at a time. 2.2 million pairs of skates a year. Today very little is made here. We’re still working and we’re still self-financing, so we can keep going.” Coast to coast, there’s no single story that’s common for Canadian job shops. Markets are highly specialized and regional, but if there’s one common thread, it’s that diversification pays dividends in good times and bad. Also noteworthy is the underlying optimism of Canadian shops. Even businesses reporting slow or no growth are staying the course and expect major players to invest some of their record cash reserves once stable global economic growth returns. CM

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Job Shop Snapshot

Straightline Precision Industries L By Nick Healey

ife on Vancouver Island is pretty laid back. With a population of under a million scattered across the temperate island it’s not exactly a hot bed of activity – particularly when it comes to manufacturing. But then again, there are also those who go against the stereotype. Case in point, Straightline Precision Industries. The 6,000 square foot, 10-person shop in Victoria is run by brothers, DJ and Dennis Paulson, where they busily manufacture everything from bike components to aerospace parts. Founded in 1996, along with their father, Mike, the shop grew from a couple of manual lathes into one with over 10 CNC machines who are starting to branch out into the aerospace sector. The company is split into two divisions: Straitline Components, and Straightline Precision Industries. The components division, which they also refer to as their “internal brands” division, is home to their bicycle products. These primarily consist of pedals, stems, and other small components for downhill mountain biking – which makes sense, considering the island’s North Shore is known as one of the Meccas of the sport. But, never ones to be satisfied with their place in the game, the brothers began looking for more. Over the last year and a half they’ve made a conscious effort to

focus on doing more work for the aerospace industry. “We seem to be fairly good at doing complicated, tight tolerance-type parts, and it seemed like a natural fit for us,” says Dennis Paulson. “We like that kind of work. It just seems to be the type of work that works well in our environment.” Not to mention, there’s the added bonus of having a genuine interest in the field. “Growing up my brother and I always had a profound interest in airplanes. I don’t know, Top Gun probably started it,” DJ Paulson says with a laugh. But the brothers realized that if they wanted to do more work in aerospace they would need to make some changes – specifically upgrading their equipment. So they found themselves at IMTS in Chicago this past fall to shop for a new machine that would help them in their quest for tight tolerances and increased productivity. They found one they liked, at the price they liked and bought it on the spot. However, after getting back to Victoria, orders started to roll in, but the machine hadn’t arrived. As it turned out, delivery time for the machine had backed up to the point where it wasn’t going to arrive in time for Straightline to get their orders filled.

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DJ Paulson (left) and Dennis Paulson pose in their shop wih their new 5-axis mill.

So, the brothers needed an alternative. Lindsay Harris, a regional sales manager for Elliott Matsuura Canada happened upon the shop in their time of need, and suggested a Matsuura MX520. “I basically did a needs analysis and (it) was, what do you want this 5-axis machine for? Is it for jobbing, or is it for something specific? And that’s when all the conversation started to come out about the aircraft industry,” said Harris. The Paulsons had been considering a Matsuura machine. They’d seen them at IMTS in Chicago and were impressed with the product, but the sticking point had been the price. As a smaller shop, and still looking to grow, they were worried about devoting a lot of money to a machine that was outside their price range. “We probably couldn’t afford it … but the work we

MATSUURA MX520 The Matsuura Machinery Corporation has developed a new 5-axis vertical machining centre using “user friendly” and “safe” concepts. The machine allows for ergonomic operation, because it possesses a front door opening of 805 mm (31.69 in.) and a distance from the operator to the table centre of 385 mm (15.15 in.), thus ensuring an easy facilitation of work setting. The ceiling cover can be quickly opened for the loading of large-sized parts with a crane. The MX520 has been designed with a RAM type structure, giving it a compact & highly rigid machining platform. Design advances have afforded the MX520 a large machining enclosure, within its class. The headstock & trunnion configuration has been designed in such a way as to minimize the possibility of collision, whilst maximizing tool access and reach. The machine can hold workpieces with sizes up to 20.47” in diameter and 13.77” in height. 12,000 RPM spindle speed is standard and available as an option is the 20,000 RPM spindle. The machines functions are controlled by the user friendly Fanuc GTech 31i CNC.

were looking at was really better suited towards that machine,” says Dennis. “There’s a couple customers interested in Straightline doing a lot of work, but it requires a five axis machine… they were sold on the productivity side and also the machine quality side. Plus, we had one in stock, which did help,” Harris adds. It was a particular part – a component for the pilot’s seat on a Twin Otter plane – that required a lot of complicated milling, and undercuts, which was going to make the process labourious enough to begin with. “The particular part we were shooting for had a lot of full five axis milling on it. With the machine – and with 20,000 rpm – it’s going to make the part in a lot less time than (another) would,” said Dennis. “We (thought) that’s what we do really need if we are going to be serious about this, so we decided to just go that extra bit further and just buy the more expensive machine, and so far it’s been amazing for us.” So with their machine concerns now out of the way, the Paulsons can focus on other aspects of their business to help them grow. One of the areas Straightline hopes to get squared away now is their certifications. They are currently a controlled goods certified company, but are striving to get their AS9100 certification – a vital accreditation for any aerospace supplier. “We need that AS9100 because it’s a higher lever of certification and it’s more recognized in the aerospace industry,” says DJ Paulson. “We can approach larger aerospace companies once we have it. It would just give us a broader range, a broader customer base that we could potentially go after.” The brother’s machining processes won’t necessarily change, but this way they’ll be able to sub contract certain processes before giving the part to the customer, then they’ll be able to “just bolt it on the plane and go”. Plus with B.C.’s growing aerospace sector, and companies like Boeing and Avcorp practically in their backyard, mastering the art of aerospace parts means the sky is the limit for the little shop on the island. “We want to be able to say we’re at the top level of manufacturing in this country,” DJ Paulson says. “That’s what we’re pushing for and we’re going to push real hard to do it.” CM

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Job Shop Snapshot

Hansen Industries O n a quiet, leafy street in an industrial area of Richmond, B.C. sits Hansen Industries – a company that’s very much a reflection of the city it resides in. Hansen is home to an ethnically diverse workforce – with employees from over 20 different countries – and much like Vancouver, and the province’s economy, it’s been steadily expanding and changing over the last decade. The shop was originally founded by Bjorn Hansen, a Danish tradesman who came to Canada and started making replacement parts for elevators on a small lathe in 1975. The company took off when they started making dispatch systems for taxi-cabs – a move that necessitated

The ethnically diverse Hansen Industries workforce. Over 20 different countries are represented.

the purchase of two press brakes, and threw them head long into in the sheet metal game. Today it’s owned by Ed Beange, an electrical engineer by trade, who became president after buying a controlling interest of the company in 1991, and four years later became the sole owner. With Beange at the helm, the shop took an aggressive approach to customer service, something he feels is vital to shop’s success, especially as the shop is forced to compete with the likes of China. “We look at what are (China’s) weaknesses? What are they not so good at? And try and compete on those things.” Customer service was the main thing Beange identifies as an area where China can’t keep up with Hansen. “We’ve actually written out in a work instruction what superior customer service means. So for every job description, we lay out our expectations – that’s how long before you return a phone call? From the time you receive an RFQ, how long before you get back to them? “If it’s going to be late we’re telling them. Same with a part, if it’s going to be late we phone them and tell them.” As a result, the ethos of customer service has taken hold of the shop and had a positive effect on the business. “Our on-time delivery last year was 98 per cent right

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Ed Beange, an electrical engineer by trade, who became president after buying a controlling interest of the company in 1991, and four years later became the sole owner.

across the board, and our quality acceptance levels were 99 per cent. So really high quality and on time delivery,” says Beange. Beange also feels it’s important to create a positive workplace for his employees. “I always say, ‘you get the union you deserve’. If you treat your people well, you pay them decently, and show recognition, you’ll probably never have a union. And that’s part of competing with the Chinese – if you have really good employees.” “We have father-son combos – and no one will bring their son in if it’s a lousy place to work.” Currently, the shop still mostly makes metal parts for electronics, but Beange is quick to point out that they’re capable of much more than that. “Our strength is our versatility. The way I try and differentiate ourselves from all the other shops is that we’re in sheet metal, we’re in machining, we’re in waterjet cutting, we’re in metal stamping. We try and do a bunch of different things so that it becomes like one-stop shopping.” The decision to become more versatile was very much a conscious one. After Nortel’s demise at the turn of the century Beange realized the company needed to diversify or it would fail. “What happened in 2001 was (the shop) was all electronics. Then we went, whoa, that hurt (after the Nortel collapse). So anyone that walks in here that doesn’t do electronics, we’re all over them.” Today the company makes everything from bedframes, to parts for orthotics, and as a result they’ve grown stead-

Qualit The E parts, requir full arr capab tight c

ily, and are now up to around $8 million in annual sales, with 65 employees spread across two buildings. Beange also take the approach that you can always be improving their processes, and getting better, and more efficient through automation. “We don’t do R&D, but our equivalent of R&D is to try and add another process,” says Beange. “We bought a robotic welder then spent a year trying to get it to weld aluminum. It’s kind of an art, but once you know how to robotic weld aluminum, you’ve opened things up a lot.” Beange is also quite optimistic about the future – especially as automation helps drive up productivity – and puts the onus for improvement squarely on his own shoulders. “Our five year plan is to always grow, grow, grow. So that’s our plan and we keep adding more equipment and automate everything (we) can. “We’ve had two of our best years ever, and this year is going to be just as good.” CM

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Hydromat’s EPIC R/T provides the ultimate in productivity combined with unparalleled flexibility for cost competitive lean manufacturing. With all the advanced CNC capabilities of Embedded Motion Control coupled with the legendary Hydromat design, don’t you think it’s time you should take a look? AMT in the Toronto, Ontario area, offers new EPIC R/T machine sales, service, and parts and you can rest assured that your needs will always be well attended to. We consider our customers to be our partners, and strive to develop them into long-term business associations. I value these relationships above all else, and I know that our friends at AMT do as well. We stand shoulder to shoulder with our partners. Give AMT a call, we would love to spend a few minutes to discuss the Hydromat EPIC R/T and how it can help you improve your bottom line.

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Exempt No More Ontario’s “industrial exemption” for engineering work on industrial equipment is set to be repealed. Who will be affected? By Jim Anderton, Editor

f you own or work in an Ontario shop, a significant change in the way you do business is coming in the fall. A little known section of Ontario’s Professional Engineers Act, 12.(3)(a), which previously allowed individuals to oversee or carry out some engineering work without having a P.Eng. license, is scheduled to be repealed on September 1st. Affected firms will have a year to become compliant. According to the Professional Engineers of Ontario, the repeal will mean that all engineering work on industrial equipment and machinery will need to be done under the oversight of a licensed professional engineer. Ontario is the only jurisdiction to carry an exemption law and its repeal is expected to affect approximately 1,000 Ontario companies. The PEO’s Marisa Sterling has taken the message about the upcoming changes on the road with a series of information sessions throughout the province. Canadian Metalworking asked Ms. Sterling about the changes:

ees for their employer’s use, to make an end product for that same employer. Based on industry feedback to date, we estimate this change to affect only 1,000 companies. If a manufacturer has their own employees do the engineering design or engineering modifications on their own equipment or machinery, then there would be an effect. However, our estimates suggest that over 80 per cent of manufacturers today either already have engineers on staff to do this work, have their engineering work done by another company or purchase equipment and machinery already designed to their needs. All companies that are impacted, and which inform PEO before September 1, 2013, will have one additional year, until September 1, 2014 to become compliant, four years after the law was originally passed. PEO is offering resources to the sector to help make the transition as seamless as possible, including province wide information sessions, waiving 42 per cent of the licensing fee, onsite review to determine what engineering work is affected, a Compliance Tool Kit and onsite licensing support”

WHY WAS THE EXEMPTION CREATED ORIGINALLY? “Unfortunately there is no clear historical record explaining why the license exception was created. What we do know is that no other province in Canada has adopted the same exception. Only Ontario has this exception. And in the Ontario manufacturing sector, since 1996, we have seen increased rates of workplace fatalities, rates that lead the Canadian averages. The goal with the repeal of the license exception is to help make the manufacturing sector safer for its workers.”

WILL THIS AFFECT TRADESPEOPLE SUCH AS MILLWRIGHTS? “We don’t expect this change to affect trades such as millwrights as they typically are not doing professional engineering work. To help manufacturers better assess what this change will mean to them, PEO has been offering over the past two and a half years to come on site to help identify the professional engineering work that would be affected. PEO has conducted numerous on site visits to date and has helped manufacturers see the very limited scope of this change. Once the scope of engineering work is determined, then a company has three options to comply: including having an existing engineer do or oversee the work, hiring a third party to do the engineering work, or having an existing employee obtain a license. In addition

WHAT PROCESSES AND EQUIPMENT ARE AFFECTED? “The scope of the licensing change is limited to engineering work on machinery and equipment that is done by employ-

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to the P.Eng. license, there is a limited license available to employees who have a minimum three year technology or science diploma or degree and up to 13 years of work experience.” WHY REMOVE THE EXEMPTION NOW? “Ontario has an issue in terms of workplace fatalities in the manufacturing sector that is exceeding the national rate of 2.9 (per 10,000 workers). The government recognizes this and has scheduled the repeal of section 12.(3)(a) of the Professional Engineers Act on September 1, 2013. Ensuring equipment and machinery is designed under the oversight of a licensed professional engineer, who is screened to be competent and is held publicly accountable for the safety of his or her designs, will help to ensure those using this machinery are safe.

“Whether the increased costs for smaller shops will negatively impact their competitiveness will be difficult to measure.” There has been extensive consultation since 2008 and assistance available to the rest of Canada. Repealing the exception in Ontario will be a key step in addressing this issue. Workplace fatalities in Ontario more than doubled from 1996 to 2010, from 1.4 to 3.5 per 10,000 workers, make this transition seamless for those impacted. This change was made law on October 25, 2010 under Bill 68 and we look forward to September 1st when the government has scheduled the proclamation. PEO is sharing the costs of licensing

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and providing a one-year structured transition period under regulations. We are all responsible for making this change happen for the benefit of Ontario’s workers.” WHAT COSTS FOR SMALLER MANUFACTURERS WILL BE ASSOCIATED WITH THE CHANGE? “It will depend on how the manufacturer carries out its engineering work today and whether it has licensed employees on staff. Feedback from industry tells us that of those manufacturers who are affected, on average four employees per company will seek a license under the Professional Engineers Act. The cost to license is $415, after PEO’s 42 per cent price reduction, as compared to the average WSIB claim of $19,000. This is about safety, and we are all responsible for ensuring our workers are protected. We believe that if we save one life with this repeal, it is worth it.” IS THE REPEAL NECESSARY? Safety is a universal goal of all industrial workplace regulation, and the Professional Engineers of Ontario quotes fatalities of slightly over 100 per year, representing half of all manufacturing fatalities in the country. With half of all manufacturing located in Ontario, however, this figure is roughly equal to fatality rates in the rest of Canada, which has no exemption. In Ontario, the Workplace Safety and Insurance Board, the WSIB, breaks out injury claims by industry, figures which show a marked decline in injury rates in manufacturing over the past decade in Ontario with the exemption in place. The new requirements however, won’t replace the network of current regulations and acts governing workplace safety. Since machine guarding and workplace health and safety are already subject to provincial and federal law

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as well as the demands of liability insurance carriers, it’s difficult to measure how a machine or process will be safer under the oversight of a license holder. There are other issues as well. The new scheme will bring engineering technologists, a common qualification for modern tool, die and mold-makers, under the oversight and licensing of the Professional Engineers of Ontario. The PEO will collect licensing fees from technicians and technologists without formal engineering degrees and decide what services limited license holders will be allowed to perform. The issue of conflict of interest has not been clearly addressed, nor has the question of voting rights within the PEO. Will limited license holders have full voting rights within the PEO? Perhaps the most significant issue is cost. Licensing fees are modest, but the lack of clarity about what constitutes “engineering work” will likely have several consequences. One will be increased costs for smaller shops that will be forced to engage expensive consulting engineers to perform tasks formerly done by in-house personnel. Another is the perverse incentive for shops to redefine tasks as non-engineering jobs to avoid the regulation. This may result in a lack of drawings and documentation in machine modification or reconfiguration, as formerly design-rich tasks are rebranded as “maintenance” or “repair” to get around the requirements. This reduced documentation may have the opposite effect of the repeal’s intent by reducing the conventional design/redesign “paper trail” that ensures shop floor accountability. After an accident, who did what may be difficult to determine. Operationally, for smaller shops

without an in-house engineer, the ability to react quickly to changing customer requirements may be negatively affected. Regulatory capture, either by industry or by non-governmental regulator bodies always raises questions - in the case of the repeal of the industrial exemption; whether the increased costs for

smaller shops will negatively impact their competitiveness will be difficult to measure until the changes are well underway. Canadian Metalworking will monitor the industry for further developments. CM www.engineeringinontario.ca www.healthandsafetyontario.ca

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CUTTING IN THE WET Setting up and monitoring water jet operations

By Nestor Gula

ne of the nice things about abrasive water jets is that they are the one tool that cuts it all. Steel, aluminium, titanium, plastic, glass — all succumb to the high-pressure stream of abrasive and water. The evolution of these versatile machines has been swift. Modern computer control has taken a lot of guesswork out of running water jets. “It is very easy to set them up,” said Laird Parry, Senior Applications Engineer for Omax. “Most companies will use the same set-up - the same nozzle, same pressure, same abrasive flow, same machine for everything. And then what happens is, because of the relatively new PC based control systems, the control system will automatically maximize the average speed. You can vary it for the given material.” This PC control has made the water jets very productive in the shop. “Maximum productivity is achieved when the operator can simply load the material, press go, unload material. Repeat,” said Daniel Austin, Sales and Marketing Manager at MultiCam Canada. “Typically a water jet can be left unattended for extended periods of time although like any automated operation having an operator periodically check the machine is recommended. There really is no closed loop monitoring of the machine on an ongoing basis.” A common problem users encounter with their water

jets is self-inflicted because they chose a water pump that is too small to handle the job. “Typically customers are driven by low costs and they undersize their pump,” said Bradley Schwartz, Regional Manager for Jet Edge, Inc. “What happens is with most water jets and when they get into 3-, 4- or 5-inch material and if they do not have the right kind of pump and they do not have enough horse power then they can still cut it but it costs them a lot of money to cut. They are not doing it efficiently. 30 hp is fine for up to an inch on a single head. Anything beyond that is price prohibitive in terms of operating costs. If they start with 50 horsepower you can cut with two small heads or one large head. For production shops and high volume shops, cutting with many heads you need 150 to 200 horsepower.” RIGHT FROM THE START: SET-UP A proper set-up is crucial to proper cutting. Due to automation and the ease of use of water jet cutting machines, operators sometimes do not take proper care when setting up to run a job. “The first step in setting up a job involves getting the material on the cutting surface. The operator has to either square the material to the machine movement, or on more sophisticated machines they can reverse that process and

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make sure that the part program is lined up with the material,” said Brody Fanning, VP Sales for Bystronic. “This can be helpful when you are cutting very thick or heavy materials that are challenging to get square to the machine. Once the alignment is set in the X and Y dimensions, the operator now has to concern himself with the vertical Z axis.” Depending on whether the machine has active height sensing for the cutting head or not, the operator must determine the standoff distance between the cutting nozzle and the workpiece manually. “First the standoff distance is a critical factor in the kerf width and the amount of taper in the cut. There is an ideal standoff (of about .060-inch), and if the cutting head gets closer or farther away from this ideal distance, the cutting performance diminishes,” said Fanning. “Because material from the mill is rarely flat enough to set the head once at .060-inch above the material and leave it alone, operators tend to set the standoff distance higher and run at slower, less efficient - yet safer for them - speed.” Since many water jets on the market offer submerged cutting it makes it difficult to see the standoff distance when setting the Z-axis manually. “Operators compensate for this by setting the standoff even higher, resulting in slower speeds and more kerf

width and taper issues,” he said. “On machines that do come equipped with active height sensing, the set-up phase becomes much simpler. Put the material in place, line up the start position in X and Y and they are ready to cut. The Z axis is always correct, during piercing and cutting, regardless whether the workpiece can be seen or not.” When setting up the operating parameters of the machine to match the material being cut, a few variables

The Permalign Edge technology available in some of Jet Edge’s water jet machines allows for beveling up to 55 degrees per side to producing weld bevels, chamfers, or three dimensional parts.

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resonant frequency that might be there. I have seen more parts scrapped because of that than from any other thing.” To get the maximum productivity out of a water jet machine, the whole table should be used said Steve Szczesniak, National Waterjet Product Manager with MC Machinery/Mitsubishi Waterjet. “On the Mitsubishi water jet we can store up to 97 work offset locations. So obviously utilizing the whole table. Most people only use the lower left had corner that is convenient to the operator. They do not realise that they can set up multiple pieces at one time, even different thicknesses.” A Multi Cam 3000 installed at Mariner Forge in Dartmouth, NB

must be set for type of materials, orifice diameter, flow rate, the nozzle diameter (typically 3 times the orifice diameter), pressure, the type and amount of abrasive, and feed rate. “Most premier machines available in the marketplace today allow the operator to pick the material type and thickness being cut from a database on the controller and the machine will automatically set the parameters to match his machine capabilities,” said Fanning. BAD VIBRATIONS There is a great temptation to just simply place the material on the table and have the water jet do its work. Materials on a water jet table should be secured before cuts are made. Even though the force from a water jet is very small. “Even though there is high pressure, the fact is that the cutting force is relatively small,” said Laird Parry, Senior Applications Engineer with OMAX. “People think they can take a piece of, say a 1-inch piece of steel, and plunk it down on a machine and know that it will not go anywhere because there is not a lot of forces on it. What you get

is you get an upwelling of water and that, combined with the cutting, means you can get a resonant vibration going horizontally. And it will result in a rough cut. So it is a simple thing, of not securing the material, the raw stock that you are cutting, from keeping it from vibrating horizontally. It is not anything to do with the machine, it is more to do with the mechanical setup prior to cutting the parts. I have seen a piece of 2-inch Inconel basically move around even though it weighed many pounds, just because you get this vibration going. And that makes for a very rough cut. Anytime we see a person having an issue with a part that has nice smooth edges but one edge in one direction is rough, it is often because of this horizontal vibration.” The material does not need to be clamped down hard like you would when cutting by hand with an angle grinder, but it has to be secured so that it does not move horizontally. “So that it can’t vibrate across the slats,” he said. “It doesn’t take much force, just enough to keep it from vibrating, to get rid of any

THE RIGHT ABRASIVE Improper usage of abrasives still increases the cost of running water jets. “Too often jobs get set-up to run using more abrasive than that material really requires,” said Fanning. “Sometimes this can be the fault of the machine because it does not have accurate or CNC control of the abrasive flow rate, and sometimes this is just due to inattention to the abrasive flow rate on the machine. Most of the time owners or operators want the machine set-up for the quickest processing time possible. When cutting metals, this usually means running the biggest orifice nozzle combination and the most abrasive the machine can handle. A typical metal cutting set-up might be a .014-inch orifice and a .040inch nozzle running 1.0 pound per minute of 80 mesh abrasive if the machine has a 50 HP pump. However if the application calls for a finer edge finish, or smaller features to be cut, the operator can adjust these parameters. For instance, if the part being cut were a small decorative type piece of polished stainless or glass, the setup might be a .010-inch orifice and a, .030inch nozzle using 0.6 or 0.7 pounds per minute of 120 mesh abrasive.”

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Monitoring the cutting process has become automated although it still requires an attentive operator. “I have customers with five machines and one operator will run three machines,” said Schwartz. To maximize productivity the operator must be looking at the pressure and the abrasive flow and making sure that the machine is still running. They also must monitor the abrasive usage and the amount of abrasives left. “What we are seeing now is a computer-based monitoring system that is not only monitoring how the machine is performing right now but also what is coming down the road,” said Parry. “For example, you may have a good abrasive flow rate and good pressure, and things are going fine, but it has a sensor in the abrasive feed hopper that is saying that in half an hour you will run out of abrasive. “And so what the control system can do is to send a warning to the operator, this can be sent as a text message or email, and then it will look for a pause point. It will pause at a suitable traverse area so there will be no damage done to the part. It will then wait till the operator loads up the abrasive hopper. So it is doing proactive stuff. It means that a single operator can monitor a whole bunch of machines operating at the same time.”

GOING SLOW SAVES MONEY The concept on productivity and efficiency in manufacturing occasionally gets confused with speed. Getting parts made faster. To get a clean accurate cut, in a water jet or any other process for the matter, speed is a killer. “Cutting speed indicates the cut edge quality,” said Austin. “The slower the cutting speed the higher the edge quality. It is always a balance between obtaining the best cut edge, while maintaining maximum cutting speeds.” If you do not need absolute accuracy or if there is a wider tolerance allowance than setting a higher speed will make production more efficient. “One of the things you do is when it is programmed, is the designer can specify the quality of cut or as some people call it percentage of maximum speed,” said Parry. “How smooth you want the cut to be. If, for example you know that you will be tapping some holes, you might make those holes with a smoother finish and what will happen is that the computer will automatically slow down in those areas.” Most machines have several different cut qualities, and you can choose them based on accuracy and the surface finish that is required. “The slower you go the more accurate you will be and the better finish you will have,” said Szczesniak. CM

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42 | JUNE 2013 | www.canadianmetalworking.com

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MULTICAM 3000 SERIES

OMAX 5555 JETMACHINING CENTER The compact 5555 JetMachining Center from OMAX is a cantilever-style abrasive water jet machine that can handle a wide range of production runs. It can cut complex parts up to 1.2 meters by 1.2 meters in size from a variety of materials and thickness, including traditional metals, advanced composites, exotic alloys and even rubber. Equipped with the company’s Intelli-MAX Software Suite that runs on the Windows operating system, it precisely calculates the velocity of a tool path at over 2,000 points per inch, allowing for complete control over the machines motion.

An affordable, easy-to-use, production cutting solution, the MultiCam 3000 Series Waterjet cutting system is designed for manufacturers that want to cut a wide variety of materials. These cutting machines have an all steel, stress-relieved, integral water tank design, three (3) side cutting tank access for easy load and unload, integrated fork lift tubes for easy machine positioning and increased machine rigidity, heavy C channel guttering for water run-off and significantly increased machine rigidity and a moving gantry with dual-side, brushless digital AC servo drives. Control is through the MultiCam EZ Control and EZ Suite software and they have standard Ethernet interface with DNC file system. The MultiCam EZ Control features an advanced CNC interface that is both powerful and easy-to-use. The system has 1,000 line look ahead and built in self-testing and voltage protection and can accept unlimited file-size transfers.

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Can RET BYJET SMART 3015 With two fully automatic CNC-controlled and monitored cutting heads the ByJet Smart 3015 ensures short throughput times, high efficiency of the pump and long service intervals to keep operating costs low and a minimal set-up space due to integrated components as well as good accessibility from several sides. The machine features a system that automatically monitors and adjusts the distance between the work piece and the cutting head for precise cut quality. There is also an automatic control system built into the CNC system to accurately feed the abrasive while cutting.

JET EDGE MID RAIL GANTRY Capable of cutting complex parts from virtually any material, the Mid Rail Gantry water jet cutting machine utilizes the AquaVision Di industrial PC controller. Designed to provide years of dependable service in harsh industrial environments, its design separates the motion system from the catcher tank, eliminating vibration and ensuring maximum part quality. It is ball-screw driven for optimal precision and features directcouple AC brushless digital servomotors and single or double carriages. Critical bearing components are protected with heavy metal covers with brush seals and positive air pressure. Available in many sizes, from 5’x5’ (1500mm x 1500mm) to 24’x13’ (7300mm x 4000mm), the Mid Rail Gantry supports multiple cutting heads to maximize productivity.

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Combining speed and precision for shops looking for accuracy and reliability the MWX4 from Mitsubishi takes leap in precision water jet technology. It is a servo motor-driven system with greater A Axis tilt angle and unlimited rotating angle C Axis to allow for straighter parts in thicker material. It features the Mitsubishi M730 CNC controller with 3-Axis joystick positioning and full keyboard, and a standard Garnet Removal System. The MWX4 machines are available in multiple sizes and pumps are available in 60 horsepower and 90,000 psi. as standard and an optional 125 horsepower at 125,000 psi. CM

44 | JUNE 2013 | www.canadianmetalworking.com

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CANADIAN MANUFACTURING TECHNOLOGY SHOW THE INTERNATIONAL CENTRE – MISSISSAUGA, ONTARIO SEPTEMBER 30 – OCTOBER 3, 2013

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CUTTING EDGE Technifor marking system for heavy equipment manufacturing Technifor, a business entity of Gravotech, Inc., has released their new XF530 micro-percussion machine for identification and traceability demands. The XF530 is one of Technifor’s versatile, portable direct part marking systems. This system marks all types of metal components and offers a large marking area (7.87”x 1.96”/ 200x50mm), with large character marks penetrating as deep as .016”/.4mm. This capability makes the XF530 capable of marking before/after painting and before part treatment. The adjustable, V-shaped universal feet stabilize the XF530 (40lbs/18k) for marking on any flat and curved surface. The included balancer, when coupled with the

ergonomic handles (with built-in start buttons) makes marking in a vertical position as easy as marking horizontally. The controller, with its graphical interface offers fast creation of marking files thanks to the integrated, intuitive and user-friendly software. Operating with or without a computer, marking data can be entered via keyboard, USB, bar code reader or via Ethernet connection. A universal power supply means the XF530 will operate in any country. A manufacturer of micro-percussion, scribing and laser direct part marking solutions for identification and traceability To learn more visit www.technifor.us.

TRUMPF releases new TruDiode lasers TRUMPF Inc. has introduced the next generation of TruDiode lasers complete with the latest developments in diode module technology. The TruDiode 151 and TruDiode 301 are more powerful and efficient, but smaller than previous TruDiode lasers, and are ideal for plastic or thin gauge metal welding. The two newest additions to TRUMPF’s diode laser product line are the TruDiode 151, a 150 watt fiber-coupled laser and the TruDiode 301 which supplies 300 watts of laser power to the work piece. Wavelength range is between 920 – 970nm with CW or modulated CW up to 3kHz. Both lasers feature a 150μm core diameter TRUMPF

LLK but are available with LLK core diameters of up to 600 μm. The two output external beam switch with a single safety circuit is also an option. In addition, customers may choose between a 19 inch rack mount laser unit or 19 inch rack cabinet with central power distribution and self contained chiller. TruDiode lasers are produced with the integrated TruControl 1000 which offers a simple, yet extensive operator interface to control power levels, pulse shapes, PFO, the dual channel E-stop circuit and more. TruControl also supports standard interfaces such as parallel I/O, DeviceNet, Profitbus and others. www.trumpf.com

Flow adds Dynamic Waterjet capability to Mach 2c system High-speed, accurate cutting is now achievable on an affordable waterjet system. The Mach2c, the newest member of the Flow Mach Series waterjet line, is now available with Dynamic Waterjet taper compensation. Dynamic Waterjet was previously only available on Flow’s advanced Mach 3 and Mach 4 waterjet systems. Dynamic Waterjet produces faster, more accurate parts by adjusting taper angle with speed. Stream lag and taper are inherent issues in all waterjet cutting, previously only minimized by reducing cut speed.

Dynamic Waterjet with Active Tolerance Control counters taper and stream lag using advanced SmartStream mathematical models. More than just a tilting cutting head, SmartStream technology changes the angle dynamically, based on cut speed, producing a better part in less time. Released in 2011, the Mach 2c Waterjet system is available with multiple cutting head options including; pure waterjet, standard abrasive waterjet, and now Dynamic Waterjet. www.FlowWaterJet.com

46 | JUNE 2013 | www.canadianmetalworking.com

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Coquitlam hosts Canadian Metalworking tabletop show

By Nick Healey

azing out the window of a Vancouver-bound plane and crossing the endless range of snow-capped peaks somehow reinforces the idea that Canada’s west is still very isolated. Its almost as though the Rockies are some great veil, shrouding the west from the rest of Canada, as though it’s some sort of hidden secret. The reality though is that’s not the case – or at least it shouldn’t be. The greater Vancouver area is home to just over two million – a good enough size for a proper hockey riot – and is the third largest metropolitan area in the country. With vibrant shipbuilding and tech industries, the lower mainland is just as industrious as many other parts of Canada – it just doesn’t grab the same headlines. It was for this very reason Canadian Metalworking chose to bring a tabletop show to the B.C.’s lower main-

Dan Cormier of Data Flute talks with a customer.

land. The idea behind the Metalworking Manufacturing and Production Show was to give the area an event that catered to the province’s growing metalworking and manufacturing industries. This burgeoning scene in B.C. is something many eastern Canadians may not be familiar with. But the reality is the industrial make-up of the left coast has been steadily changing over the last decade or so. Ever since the days of the softwood lumber dispute with the U.S., Canadians have identified the province as a forestry powerhouse. But over time, the area has diversified and new industries have entered the fray. Part of this diversification rose out of necessity. Wood products manufacturing, which made up the lion’s share of the province’s manufacturing sales, eventually started to take a nosedive. Throughout the 90’s and early 2000’s the industry hovered around $10-$11 billion in annual sales, but by the late 2000’s the industry had been cut in half, dropping to between $4-$6 billion by the end of the decade. David Lowey is local sales consultant for the company Machine Toolworks, a distributor of Mazak machine tools in the province. “When I first came to B.C. everybody that did anything with manufacturing did it with pulp mills,” he says, adding, “so when the wood industry died, everybody sat around and said, ‘oh it’ll get better’ – well it didn’t. So the guys that went out and got new work, like aerospace, they’re good. Now what’s happening is a lot of people are buying bigger machines and going after work in the oil patch. Previously, B.C. didn’t do that.”

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The numbers would suggest the same. According to statistics from NAICS (North American Industry Classification System) fabricated metal product manufacturing in the province has seen steady growth since the early 1990s. Valued at around $1 billion in annual sales in 1992, the industry more than doubled by 2006, where it was pegged at $2.2 billion in sales. Other manufacturing industries have experienced the boom as well. Machinery manufacturing hovered around $2 billion annually for the past five years – up from roughly $700 million in 1992. Aerospace is another example of an industry that has grown in B.C, going from around $100 million in annual sales in the early 1990s to approximately $300 million through the later stages of the 2000’s. David Coyle, a productivity specialist for the cutting tool giant Sandvik Coromant, is another local who echoed that sentiment: “B.C. is a very diverse market. Traditionally we were a forestry market, but it’s sort of halved itself over the last 10 years, so we’ve had to diversify.” “Most of the traditional jobbing shops have converted their business from forestry to oil and gas,” Coyle says. As the oil and gas industry expands in neighbouring Alberta, B.C. stands to reap some of the benefits , especailly if a west coast pipeline can be negotiated successfully. Indeed, while sales for mining/oil and gas machinery manufacturing hovered around $45 million throughout the late 90s, by 2006, the number had tripled, to just under $150 million. “What we see lately is pretty good activity in western Canada, in particular in B.C. People are busy, the fantasy is back... so for them the glass is half full right now,” says Stefan Schreiber, the managing director at TRUMPF Canada, a supplier of fabricating equipment. “A lot of our customers do work for the oil and gas, and same for the shipbuilding. We’re quite happy with how things are going right now.” Of course, the diversification of B.C.’s industrial sector didn’t come overnight and most of this growth was slow, but now, as other metalworking and manufacturing industries mature, so do the shops that service them. And one of the hallmarks of a maturing industry is the need for more sophisticated equipment purchases. “What I’ve noticed of late is now manufacturers (in western Canada) are seeing the advantage of automation,” says Frank Bolieiro, Vice-President of Sales and Marketing at Elliott Matsuura Canada. “Not only do they want to buy lathes and mills that are multi-tasking, that are more state of the art, they’re also asking questions like ‘how do I automate?’ ‘How do I minimize my changeover from this type of component to this type of component?’

Canadian Metalworking Senior Account Manager Rob Swan (L) and Design Engineering Publisher Alan MacPherson (R) present draw winner Mike Nell (centre) with a Nikon camera as his prize.

“And whether it’s a robot, whether it’s a palletized system, or whether it’s an inline system. Those are all questions that customers have been asking the last while that they weren’t five years ago,” he continues. Indeed, even more equipment purchases could happen in the coming months, as the provincial government recently created a sales tax exemption for the purchase of production machinery and equipment. So as the industry begins to expand and change, equipment dealers are beginning to understand the importance of being on the ground with a local presence. “We certainly see the advantage of having local representation to be able to support the local customers – and specifically out west, where they sometimes feel isolated from the rest of the country,” says Bolieiro. “We had one person here covering western Canada, covering all four provinces, and we knew already some years ago that we needed to change that.” Bolieiro also stressed the need to speak the “language” of local areas, and as a result the company now has four new salespeople spread across the western provinces. Coyle, a veteran of the local scene, notes the differences. “I think it’s a little smaller scale working in B.C. I’ve made calls in Ontario. They’re very business-like. Here we’re a little more small scale, a little more personable,” he says with a smile. But he’s quick to add that despite the smaller size, there is real room for growth in the province. “These owners of smaller shops, they still have a real thirst for knowledge and new innovation, even though it’s on a smaller scale. I think the show did a good job bringing some of that,” Coyle says. Certainly, attendees of the MMP Show did repeat that refrain – there’s work to being done, and opportunities to be had out in the province. So now, with the cat out of the bag, no longer is B.C. a secret, but a bonafide player in the country’s manufacturing scene. CM www.canadianmetalworking.com | JUNE 2013 | 49

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WHAT’S NEW IN WELDING FLAMEMASTER LETS YOU MASTER THE FLAME

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The latest in the Purox Elite Gas Apparatus product line, the FlameMaster is ready to cut up to 4 inches this kit heats up to 44,000 btu/hr. using 30 cfh of acetylene. Optional heating tips offer up to 294,000 btu/hr. using 200 cfh of acetylene and allow cutting up to 8 inches. This kit comes with the Purox Elite WH-4200 welding handle, the CA-4200 cutting attachment, 1/2-inch, 1-1/2-inch, and 4-inch acetylene cutting tips, and the #30 Rosebud Jr. acetylene heating head. It does not come with regulators or hoses and so is a suitable conversion kit for operators who already have those supplies. The ESAB universal injector offers flexibility in gas use while the CA-4200 cutting attachment’s patented Swirl Injector creates a superior homogenous mix of preheat gas and preheat oxygen in the entrainment zone to increase efficiency and deliver optimum performance not possible with equal pressure or tip mixers. www.esabna.com/gasapparatus

FUSION GUNS HELP FUSE METAL

With an ergonomic handle and a simple but rugged design the Tweco Fusion series odf MIG guns come standard on all Victor Technology 3-in-1 welders but and now feature Tweco’s new Velocity MIG consumables platform. The non-threaded, “drop-in” style contact tip eliminates the need to use vice-grips or other tools to remove the tip, even if the wire burns back and fuses inside the tip. The Velocity consumables design integrates the gas diffuser into the conductor tube creating an improved all-copper conductor path that provides better electrical conductivity and transfers heat more efficiently away from the tip. As a result, the arc becomes more stable and predictable. The design also eliminates the insulator found on other MIG guns. Suitable for light to medium gauge work in auto-body, agriculture, architectural, general light fabrication, production welding, RV/Campers and Farm Equipment, operate up to 250 Amps @ 80% duty cycle. www.victortechnologies.com/tweco

HARD-HAT AIR PURIFYING RESPIRATORS

Many work areas require hard hats to be worn so it is natural that Miller Electric Mfg. Co. has added a hard hat option to its current Powered Air Purifying Respirator (PAPR) line. Paired with the Titanium Series auto-darkening welding helmets the PAPRs provide respiratory protection from hazardous welding fumes, such as hexavalent chromium, zinc, aluminum and manganese, found in some welding environments. This system features a lightweight blower unit, as well as load-bearing shoulder straps that evenly distribute the system’s weight for optimal PAPR blower respirator system is made for jobs where wearing a hard comfort. Dual air speeds allow hat and welding helmet is necessary. users to adjust the volume of air to maximize comfort. Additional blower unit benefits include audible and vibrating alarms (to alert users to low battery or restricted airflow), a lightweight lithium battery that provides eight hours of use, and a low profile design that helps

New consumable system makes it easy to swap tips even when burnt

reduce interference. A high efficiency particulate air (HEPA) filter captures airborne particles as small as 0.3 microns, protecting users from the hazardous dust, metal fumes and mists that are common in welding environments. These units have an Assigned Protection Factor of 25 and are NIOSH 42 CFR 85 certified. The new hard hat head assembly is ANSI Z89.1 2009 certified, Type 1, Class C or G. The hard hat addition is suitable for welding applications in construction, manufacturing, oil/gas, shipbuilding and other industries where hard hat use is required. Head assemblies available include the Titanium 9400 Helmet, Titanium 9400i Helmet, Hard Hat with no helmet, Hard Hat with Titanium 9400 Helmet and Hard Hat with Titanium 9400i Helmet. The Titanium Series welding helmets feature a large viewing area (9.22 square inches), aluminium heat shield that protects the lens in high amperage welding applications and a silver shell that reflects radiant heat. All head assemblies feature a flame-resistant head seal and cinch closure to keep welding fumes out of the breathing zone. www.millerwelds.com

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To be flat and horizontal Proper positioning parts when welding is crucial for quality and efficiency By Nestor Gula

oo often we see the image of a welder on television and in the movies. Standing splay legged, holding the welding torch above his head in a a dramatic, even heroic, image. The only thing that is real about that image is that the weld, more often than naught, will not be a proper weld. Proper welds are made with the joint to be welded lying flat and the weld torch, or stick, moving in a horizontally plane. All other welds are called out of position welds and are trickier to do and require an operator with considerable skill and experience to complete properly. “The welding position affects everything about the weld: penetration, speed, tie-in at the toes of the weld, spatter, torch angle, work angle, volts, amps and wire feed speed, said Kevin Summers, commercial business manager for Miller Welding Automation. “Welding in a flat or horizontal position, the puddle can be very fluid and still remain in the joint. When those same conditions are used in the vertical position, the weld will literally run out of the joint. As the operator turns down the voltage, current, wire feed speed and travel speed to create a colder, less fluid puddle, the penetration goes down.” For a welder, the horizontal position of welding is the easiest, most ergonomic and safest. “It is a lot easier if we can position the weld in front of the welder. It will be much easier for them to get access to the joint. They’ll be able to see the joint and see what they are doing,” said Mike Morgan, General Manager, Automation for Lincoln Electric. A horizontal weld is the easiest to weld adds Jeff Chittim, application specialist for ESAB Welding & Cutting Products. “It is what people always

This Rapol BP-150 is a small benchtop positioner with a load capacity of 150 lbs. with a 1/8 hp motor that provides a rotation speed of 0.2 to 10 RPM.

Always weld flat and horizontal — even on round parts.

try to weld in. The biggest thing that is against out of position welding is gravity. When you are welding you have molten material and so it is liquid. When you are out of position it wants to run out of the weld and it just wants to flow wherever gravity takes it. When you are welding vertically up or overhead, there is nothing there to support the weld metal so that is when welding gets a little bit more tricky.” Welding out of position is a slower procedure and uses more resources to accomplish the same quality of weld. This flat horizontal position allows for the maximum travel speed. “You can have a very hot/fluid puddle that stays in the joint and gain faster travel speeds. Welding out of position is slow,” said Summers. “You have to dial everything back to keep the puddle from dripping. You also have to manipulate the puddle more when welding out of position, which takes more time and ultimately cost you travel speeds. You can do upside down welding, it is just that you have to slow down and be very careful because the weld material has a tendency to work with gravity and drop on you,” said Morgan. “You have to place very small passes down, stringer passes so you put in very low deposition it is a very difficult weld to make, even in automation.” Not all welders have the skill to perform proper out of position welding. “Out of position welding takes a little bit more time and it also takes a higher skill level to do,” said Chittim. “That’s one of the reasons people would rather weld in the flat horizontal position especially

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right now with the shortage in the skill trades labour.” Welding in the proper flat position applies to both manual welding and robotic welding. “The weld is the weld,” states Morgan. “You are working against gravity. You will have to work welding up, otherwise you do not get enough penetration if you work welding down on anything more than 5/16” thick material. You weld vertical up. You stack the bead so you are welding on the weld below and that supports it. Otherwise you can use a special flux cored wire which the flux is able to support the freezing weld metal below it.” Poor penetration and improper welds result when welding at the speeds used horizontally or flat. Automated robotic welding takes the operator’s skill out of the equasion when welding out of position. The weld programming can be set so that some parameters, like gas flow, wire speed, spark settings and amperage can be adjusted so that proper weld penetration occurs in the joint. “If welding in position is still is not feasible, in that situation the robot will change parameters,” said Chittim. “It can’t change the wire on the fly, but it can change to a different set of parameters that might be lower and the weld puddle is not so hot so it won’t run away and then it can do the out of position welding.” The net result is still slower welding with more consumables

With a 2,000 lbs. capacity, the P2000 has two 1hp motors (one for rotationa nd one for tilt) that run on standard 115V power. Tilt range is from 0 to 90 degrees. Rapol Inc.

being used. “When welding out of position, your robotic MIG gun angles have to radically change, not to mention most of the time you have to create a weave to get the weld to tie-in at the toes,” said Summers. “This action takes extra programming and extra time. Use technology built into the robotic welding equipment to allow deeper penetration at the weld root and cooler penetration at the toes to avoid dripping. Use weld parameters synchronized with weave patterns.” A lot of out of position welding is performed on site,

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Able to handle pipes from 2- to 16-inches in diameter, the TR-15 has a speed range of 5 to 50 IPM. It can handle a work weight of 1,500 pounds. Rapol Inc.

doing structural work or pipelines. “Usually if you are doing a vertical up you might need to increase your gas flow a little bit just to ensure that you have proper coverage. Typically it is not a real big issue. If you are overhead the gases are actually being trapped in the joint above you,” said Chittim. “But then again most of out of position welding is being done on structural or bridge is outside so then you will be having increased

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flow rates already.” Welding overhead is the worst case scenario for most welders. If you can’t do anything and you have to weld overhead using a flux-coed wire is a good option suggests Morgan. “One thing people will look at is using a flux-cored wire because it is certainly a lot easier to use a flux cored wire overhead than it is a solid wire because it is able to help the weldment to freeze. What precautions you do use is to use smaller beads so you will have to do a multipass weld. It will take a lot more time and it will not look as pretty.” Pipelines welding use stick or flux cored wire because they can’t escape from welding upside down, he adds. “If you use a solid wire you will have to weave a lot more and weld to the sides of the joint to try and dissipate the heat a lot more than you would with the flux cored,” said Morgan. If you must use a solid wire, “you tend to get a better freezing action the more argon you put in. The more CO2 you put in the more fluid it becomes. So it is easier to weld out of position with a mixed gas.” POSITIONING FOR THE PERFECT WELD When welding small and lightweight objects, there really is no reason why a welder cannot move the object to suit the preferred flat and horizontal welding position. Where things get interesting is when automated robotic welding comes into play. For this there are positioners that can be programmed, like the robotic welders to rotate and move the object being welded to the right position. “Positioning equipment on robotic work cells help with the return on investment (ROI),” says Summers. “By repositioning the weld or using coordinated motion with a positioner and the robot, you can maximize your welding speed, which helps increase productivity and profit.” Positioners come in a variety of sizes from units that can handle about 50 kilos to ones that manipulate more than ten tons. From simple table like machines and some that resemble forklifts, the positioners are designed to always present the weld in the flat and horizontal plane to make welding easier for both automation and hand. Paul Raczynski, Director of Operations at Rapol Inc., a Woodstock, Ontario based manufacturer of positioners, remembers visiting a trailer factory where a whole trailer was suspended by chains from cranes. It was lifted up, rotated a bit, set down, a joint welded (in a horizontal and flat position), and then the procedure was repeated. This situation could be easily made efficient using a headstock/tailstock system that can be described as something similar to a rotisserie system. Morgan said, “if you are going to spend the money on a robot, on a track to go up and down the length of a trailer, you might as well put in a headstock/tailstock system as well and integrate the whole thing and always present the weld in the best position.” CM

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3D point cloud data can be generated by touch probes, lasers or white light scanners

3D Measuring Software The benefits outweigh the cost By Jeremy Wiebe

ompared to the tools of yesteryear, todayâ&#x20AC;&#x2122;s most sophisticated measuring solutions can look like something straight out of Star Trek. Laser scanners, infrared cameras and touch probes are becoming ever more popular in quality control environments and even making their way into the everyday workplace. Scanning a part and rendering it as a three-dimensional model is impressive, but does it serve a purpose beyond the wow factor? 3D measuring software is already being utilized in a huge variety of applications. From extensive use in restoration projects like the rebuilding of the Kasubi Tombs in Uganda to more complete analysis of CT scans in the medical field, 3D measuring is now becoming a large part of metalworking as well. While it may seem overwhelming at first glance, 3D part measuring software has developed in leaps and bounds alongside the industry, improving in both functionality and accessibility. 3D measuring is quickly becoming the most accurate way to maintain a dependable quality control operation. By measuring an object

directly, a well-maintained 3D scanning system removes any margin of error caused by faulty tools or inevitable, slight variations in measurements taken manually. CMM AT THE HEART OF 3D 3D measuring works by collecting coordinate data from a part and using that data to render a 3D image that can be manipulated, measured and compared with existing information. This data can be collected in a number of ways, the most common of which include optical scanning and physical probe data. Some coordinate measuring machines (CMMs) gather part coordinates by checking the part with a physical probe. The machine is equipped with a mechanical probe that it draws across the part and takes readings at preset intervals. This is an effective way to provide excellent part readings fairly quickly. More advanced CMMs replace the mechanical probe with optical scanners. This can be done in a few different ways. Some setups use laser beams set at various points around the part and use cameras to

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triangulate the location of the part. It’s also possible to shine a beam directly at the part and gauge the amount of time it takes to bounce back. Some systems even use a white light and watch the different wavelengths bouncing off the part to record coordinates. Other data gathering methods, such as stereoscopic video systems that view parts from two separate cameras and analyze depth the same way our eyes do, or systems that use varying intensities of light and shadow to interpret measurement data have been used in some instances. There are also scanners that work by shining a shifting light on a part and record data by watching for reflections as the light changes. Some even use a specific light pattern and analyze the way the shape changes when it hits the part. All of these tools would be useless without a strong software suite to analyze the data and output it as something that’s easy to work with. Existing 3D measurement software has become extremely robust and can compare the rendered image with the original CAD model, as well as comparing numerous measured parts with one another to single out variations in the manufacturing process. LASERS AND SOFTWARE WORKING TOGETHER Depending on the measurement techniques used, measured parts can be rendered to almost perfect detail. Time-of-flight laser scans measure the amount of time it takes for the beam to reflect off the part and come back. These are fast and extend to long distances, but only report coordinates within a millimeter, though some systems modulate beam power for higher accuracy. These scans are usually better suited for large objects and can even be used to provide scans of buildings. Time-of-flight systems use mirrors and only require one laser for 360 degree scans. Laser triangulation,

while limited in reach, can provide readings to less than a micrometer. When a group of researchers from Stanford University used a laser triangulation system to scan Michelangelo’s David statue in 1999, the results were accurate enough to show chisel marks on the 3D part. Measurement software has become very versatile and can ren-

der point cloud data in a variety of ways. Data can be displayed in two- or three-dimensions and can take a few different forms. Simpler shapes might be better represented as polygonal models while extra complex parts can be rendered as solid objects in full detail. Some applications display as a layered series of two-dimensional images.

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While reliable, the most accurate scans can be very time consuming and it isn’t always practical to bring a workpiece to the machine. Portable CCMs can be used to measure parts in the workplace. Handheld touch probes and articulated arms provide coordinate data for the measurement software with respectable accuracy. If a probe isn’t going to work, a hand-held laser scanner can be used to triangulate on the part in much the same way a full sized CMM would. The laser tracker records its position relative to the part with infrared. Instead of rendering a full, solid model, measurement software will just record whichever points are being measured by the handheld tools, eliminating unnecessary information from the measuring process. LASER LIMITATIONS There are some problems with optical measuring that software can’t overlook. Overly reflective part surfaces can return faulty data because the light didn’t reflect back as expected. This is especially problematic with time-of-flight systems since the laser might not come back as directly as it should. Physical probes might work better on such parts, since feedback comes from direct contact with the object. Complex profiles, especially in highly reflective material, would react better to a probe than an optical scan. Though they may be effective, 3D scanning systems are still time-consuming and best used in a quality control scenario. By scanning a selection of parts and ensuring they adhere to established parameters, the manufacturing process can stay within its guidelines without spending too much time measuring. More efficient software helps improve that process, but hasn’t eliminated it altogether. Despite a few inevitable hurdles, 3D measurement software provides the user with absolute flexibility when measuring a scanned object. The part can be fully manipulated and measured from every angle, making larger parts much easier to look over. Detailed pieces with profiles that would be otherwise hard to reach can now be easily measured without worrying about measuring tools that can’t fit into such small spaces. Comparing the scanned workpiece with the original CAD model gives the designer options he may not otherwise have had. To help highlight areas that need improvement, some software even colour codes points exceeding set tolerances. A part might look perfect when it’s designed, but the manufacturing process has drawbacks and certain details might not meet the desired result. By comparing models, the original can be revised to meet specifications without expecting the impossible from outside the engineer’s office.

Sometimes, the original CAD model is outdated. Changes may have been made on the fly without first being updated in a CAD program. By scanning the improved part into the system, it’s possible to introduce that update without wasting time measuring and trying to recreate the part artificially. This reverse engineering is also incredibly useful when duplicating existing parts that haven’t been previously drawn. For example, if a customer wants a change made quickly and it’s easier to make the change manually, the modification can be done and scanned in later when time allows. Using software provides the user with a certain degree of autonomous quality control. Macros can be implemented that measure the part after it gets scanned without much human interaction. Data can also be exported to a spreadsheet for later analysis. These features simplify the quality control process significantly, eliminating the need for almost all direct human interaction. Newer measurement software even has the added benefit of remote access. Some software suites now include mobile apps for smartphones and tablets so the user can remotely measure and read data from anywhere. CONSISTENCY AND CONTROL Spotting inconsistencies in manufacturing also becomes much easier with 3D software. Multiple scanned parts can be compared with one another and trends can be identified. This not only allows the engineering process to become more refined, but it provides information on which manufacturing elements to improve. If a lot of parts in a production run begin to exhibit the same flaws, a machinist can take that into account and adjust his program to correct it. Or, if the raw material has flaws, it can be replaced by a more stable material before the full product run is finished. Like any computerized technology, 3D measuring is a quickly evolving field. What was next to impossible ten years ago is commonplace now. Not only is it now possible to get an accurate reading of a part, but that reading can be converted into a solid model and compared to another model. And through recent advancements, all of this can be done wirelessly. There’s no doubt the future of manufacturing has a large spot open for further advancement in this field. 3D measuring software can be an incredibly valuable asset to any quality control system. For companies looking to improve product quality and rate of production, a system like this will prove invaluable. By providing detailed part measurement and analysis of problem processes, this software takes almost all of the margin of error out of measuring and provides even more control over the entire manufacturing process. CM

58 | JUNE 2013 | www.canadianmetalworking.com

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Fine Grinding John Manley on the state of the sector By Nate Hendley

achine Tool Systems Inc. of Toronto claims to be Canada’s first speciality distributorship focused on grinding and finishing equipment. The company was founded in 1998 by John Manley, a University of Toronto engineering graduate and former salesman for United Grinding, one of the biggest names in the business. Manley also served as president of the Canadian Machine Tool Distributors Association (CMTDA) from early 2008 to late 2011. MTS offers camshaft & crankshaft, centerless, cylindrical, creep feed, gear, optical, profile, punch, surface and tool & cutter grinders and carries machines from Wasino, Schaudt, Blohm, Kapp Niles, Studer and Walter, among others. The company also sells turnkey abrasive and filtration solutions. Canadian Metalworking recently sat down with Manley to get his sense on the state of the grinding machine industry.

of the particulate in the air. The only way to do that is to fully enclose the machine and ventilate it. When you have a manual machine, the second you try to enclose it, the operator can’t see the process as well. More importantly, he can’t hear the process, because in grinding, when the grinding wheel approaches the workpiece ... you need to look at the sparks, need to hear the contact. [Grinding requires] constant monitoring of the process. You can almost call it closed loop machining. To do that, you need an operator who is looking and listening to the process. So what do we do on a CNC when we enclose it? We put in acoustical sensors like a man’s ears ... you partner that with a probing system

WHAT TRENDS HAVE YOU NOTICED IN THE GRINDING MACHINE SECTOR? One of the big things is automation. Everybody’s seeing that. That’s why they’re buying CNC machines. The most important thing is what I refer to as asset utilization. You go out and spend a quarter or half or a million dollars on a machine tool and that quarter-million dollar asset better not sit idle after you leave at five o’clock at night until you come in at eight in the morning. I think grinding was the last frontier for automation. People used to buy a surface grinder, run it when they needed to. Might only be a couple hours a day ... now they realize that [grinder] can’t sit idle. Automation has to be user-friendly. You want to have a variety of employees that can walk up [to the grinder] and the man-machine interface is easy enough for them to use. IS THE WHOLE GRINDING INDUSTRY MOVING TO A CNC MODEL? Personal safety regulations in Canada are almost forcing people to leave manual ... what parts are being ground? Carbide, nickel alloys—nasty heavy metals. You don’t want to breathe that as an operator. As a director of the company, do you want to have [your employees] breathing in carcinogens? Now you’ve got to process the coolant, got to process the mist, get rid

Machine Tool Systems Inc.’s founder, John Manley.

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[for the visual aspect]. So really today, we’re able to do closed loop grinding. This is what I offer to clients when they’re evaluating different brands of grinders. I tell them, don’t get overwhelmed by the software, the pictures, the graphics, the mechanics of the machine. All of that is for nought if you don’t have a closed loop system.

“It’s not hard to see a half-a-million to a million dollar investment. That’s becoming more of a trend—more sophisticated machines.”

WILL THERE STILL BE A NEED FOR MANUAL GRINDING IN THE NEAR FUTURE? The need is [based on] grandfathered operations. You’ve got a machine that’s 40 – 50 years old. I’ve got an operator who has 40 years experience under his belt. There’s no way I can teach an old dog new tricks. Trouble comes when you have to move that machine to a kaizen cell or somewhere else in the plant. Or if you build a new plant or did an upgrade to your plant. Anything that’s changed in the process, you are legally bound to do a health and safety review on it. I had a client last week who had two older machines ... that didn’t pass health and safety anymore. So they looked at upgrading them. By the time they evaluated everything necessary they just said, this isn’t worth it. So they just bought two new machines from me for a quarter-million dollars each, surface grinders. Not only

are they going to be up to code now, they’re going to be way more productive. Four or five operators can now run [the grinder] because it’s not dependant on one old man’s skill set. ARE YOU CONCERNED GRINDING OPERATIONS WILL GO OFF-SHORE? THAT MANUFACTURERS WILL FARM OUT GRINDING WORK TO CHINA OR ELSEWHERE? Your magazine interviewed me [back in 1998]. We had an article on ‘Why are you specializing in grinding?’ because I had a background in EDM and mill/turn as well. But I saw a real niche, a trend in the industry that’s really come to fruition. And the trend is, when you look at raw parts, castings and stampings, one of the differentiators on where you make that part globally isn’t necessarily skill, because it’s just a casting or a forging or a stamping, it’s

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to some of these Third World countries. They get there and all of a sudden they have a wake-up call. I [have] a million dollar machine but how am I going to support it? And that becomes a big issue.

“I think grinding was the last frontier for automation.” the labour content. Do you make the part in Canada or Scandinavia where you have some of the highest labour costs in the world or do you pour that casting or forge that part in the lowest labour cost [countries] of the world, where ever they happen to be? When I was interviewed [in 1998] it was Korea. Now it’s China. Tomorrow it may be somewhere in Africa. It’s just a matter of where is the lowest labour content in the world? And that’s quickly changing in China. Over the last decade, labour costs [in China have] tripled. If you take China out of the equation, we’re still going to be facing, whether it’s South America or the Caribbean, somewhere else in the world [that has lower cost labour than Canada]. [Complex parts and processes] are just not being done in third world countries. You need highly skilled operators, highly skilled management and a highly skilled supply base [when] you’re bringing higher precision parts to the table. This is what’s happened with people who have gone

IS THERE A TREND TOWARDS MULTIPLE-AXIS GRINDERS? Absolutely. I’m already seeing that myself. I look at the machines I was selling 10 years ago— let’s take a surface grinder as an example. I could bring in a basic $60 – 80,000 surface grinder and we’d do okay with those ... today I don’t even have a grinder at that price in my mix. Let’s take a Wasino CNC surface grinder—we’re starting at maybe mid-100s for that. When you get into more sophisticated grinders, where you get fifth-axis capability, pallet changers, tool changers, automatic wheel changers, it’s not hard to see a half-a-million to a million dollar investment. That’s becoming more of a trend—more sophisticated machines. As they get more sophisticated ... you have a machine that you don’t just use two hours a day or eight hours a day. You might be able to put different parts through the same machine and it’s also more automated. You can [use it for] three shifts seven days a week. So if you spend twice as much on a machine, who cares?

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IN OTHER WORDS, THE LIGHT’S OUT MODEL IS GOING TO BECOME MORE COMMON? Absolutely. In the old days, you would run [a grinder] for 10 – 20 years until its death. You can still do that, but the utilization of it is going to change in years three to five, because the software and more so, the hardware that runs the software, the computers, are changing so fast and the whole man-machine interface is changing so fast, and the requirement of the machine is changing so fast ... in years three to five, you’re doing moderate utilization of the machine’s capabilities, but in years five to 10, you’re going to really scale back what you’re using it for in the shop. So in the case of tool grinding, if you have a seven or eight year old Walter grinder, today you’re probably just using it to make basic end mills and drills and resharps and that’s okay. It’s still giving you a long payback on the machine. But if you’re getting into the more complex form tools and variable geometry tools, you’re probably going to use a newer model machine to do that. So, you have to get your payback faster ... hence, you’re going to automate the machine and run it in multiple shifts.

WHERE DO YOU SEE THE GRINDING MACHINE SECTOR IN THE NEXT COUPLE YEARS? It’s going to continue to get more and more sophisticated ... abrasives are getting highly sophisticated as well. We’ve moved from what used to be conventional abrasives—aluminum oxide wheels like a nail file—to super abrasive wheels where you have vitrified CBN and vitrified diamond.

IS THERE ANY PARTICULAR GRINDER THAT’S ‘HOT’ RIGHT NOW, IN TERMS OF SALES? I would say the Studer CNC cylindrical grinder is very popular and the Walter CNC tool grinder.

DO YOU HAVE ANY ADVICE FOR YOUNG MACHINISTS? I would say for young machinists, look at grinding. The challenge is, where do you find it? The schools aren’t teaching grinding ... how are we going to graduate kids with experience with grinding if they don’t get their hands dirty? www.machinetoolsystems.com

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No Milling About: New in Milling Inserts Tougher, harder cutting edges for better productivity By Nate Hendley

arbide-content and multiple-edges are two growing trends when it comes to milling inserts, say industry experts. “There’s a trend towards carbide substrate/coating combinations that exhibit properties of both increased toughness and hardness,” says Thomas Benjamin, in the marketing department at Walter USA, the Waukesha, Wisconsin-based branch of a German parent company. “In order to reduce machine time, specialized tools with multiple levels of carbide inserts that produce more than one feature are increasingly becoming popular ... [these tools are also] environmentally sound in the reduction of energy usage,” adds Jason Farthing, technical sales and marketing at Horn USA, the Franklin, Tennessee based subsidiary of a German parent company. Kevin Burton, product specialist at the Canadian branch of Swedish tool giant, Sandvik Coromant, in

Mississauga, Ontario, agrees there is a trend towards multiple-edges, but is quick to qualify his remarks. “Multiple edges can of course be economic, but the reality is, the more edges you put on an insert, the larger it has to be to accommodate the number of edges and also they tend to be capable of less of a depth of cut,” says Burton. As for advice on using milling inserts, Dale Hill, applications engineer at Greenleaf, based in Saegertown, Pennsylvania, takes the broad view. “Milling is a very intricate kind of thing ... a lot of people don’t pay close attention to it ... the most common mistake I see in milling is underfeeding ... [there’s] usually too low of a feed rate ... and basically you end up just rubbing the inserts to death,” says Hill. Here’s a look at what’s new and/or noteworthy in milling inserts:

TUNGALOY Tungaloy’s brand new Tungalu inserts are made from uncoated, highly polished carbide and boast a helical cutting edge and high positive rake angle. “The inserts have a wiper edge on them so it leaves a highquality surface on the bottom, due to the wiper edge,” says Alex Livingston, product manager at Tungaloy, which is based in Brantford, Ontario, with a Japanese parent company. The inserts’ V-shaped bottoms, meanwhile, “prevent the insert from shifting, due to centrifugal force ... it relieves the stress on the screws, so it’s not just the screw holding the insert in the pocket,” he continues. Tungalu inserts are “capable of all types of milling, shoulder milling, pocket milling, slotting, ramping, helically ramping, etc,” Livingston adds. Tungaloy also recently expanded the DoFeedSeries of mills and introduced a new grade: AH3035. AH3035 “offers higher impact resistance compared to the current grades for machining steels ... if you’re milling through a lot of interruptions, [AH3035] would be a better grade than our current grades,” says Livingston.

AH3035 is a good grade for overhang conditions “because the cutting edge is more chipping and fracture resistant” than older grades, he adds. The new grade was developed with machining carbon steels, alloy steels, pre-hardened and hardened tool steels up to 60 Rc in mind. AH3035 has a thick, PVD coating plus PremiumTec, Tungaloy’s special surface post-coat treatment. www.tungaloy.co.jp/us/

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WALTER USA “Walter just introduced an expansion of our Tiger-tec Silver PVD-coated grades WSM35S and WSP45S. The expansion covers about six milling product families,” says Benjamin. WSM35S and WSP45S boast PVD aluminum oxide coating and optimum cutting tool material toughness due to minimal thermal loads in the coating process. The grades feature an extremely smooth rake face (ensuring low-friction machining) and are intended primarily for machining stainless steel and materials with difficult cutting properties. WSM35 is also suitable for use in aircraft and automotive production. Walter USA will be expanding its line of Blaxx milling cutters and inserts this fall, adds Benjamin. www.walter-tools.com

Walter USA’s new WSM35S and WSP45S grades

HORN USA

Horn USA’s new DAH62 insert.

Horn USA recently expanded its DAH range of high feed milling cutters and inserts. The new DAH62 insert features a SC6A coating and supports cutting depth of up to 2.1 mm at feed rates of up to 3 mm per tooth. The CVD applied ultra smooth TiAIN based coating enhances chip evacuation and heat dispersal and is designed to extend tool life when doing rough machining. The insert itself is 14.8 mm thick, nearly twice the thickness of the existing DAH37 insert. “The 6-edge DAH62 insert is part of an expansion to the 3-edge DAH37 product line. The addition of the DAH62 enhances an already strong product,” says Farthing. www.hornusa.com

Horn USA’s new DAH37 insert.

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

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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 | JUNE 2013 | 65

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SANDVIK COROMANT Earlier this year, Sandvik Coromant unveiled CoroPak 13.1, a package of new products that included several inserts. Inserts for the CoroMill 419 high feed milling cutter boast five cutting edges and a range of grades. Face milling inserts for the CoroMill 419 feature geometries of

419R-1405E-MM, 419R-1405M-PM and 419R-1405M-PH while face and profile milling inserts for this cutter have geometries of 419N-1405E-SM and 419N-1405M-KH. The insert clamping system for the CoroMill 357 multi-edge rough face milling cutter, meanwhile, is designed for fast and simple insert indexing

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and insert changing. Inserts for the CoroMill 357 are pentagonal in shape and double-sided with shim protection and geometries of 357N-2408M-PM and 357N-2408M-KH. The CoroMill 345 high performance face mill uses double-sided, precisionground inserts with eight cutting edges and one geometry for both ISO P and ISO K materials. Wiper inserts are also available for the CoroMill 345. New ceramic inserts for the CoroMill 490 face and shoulder mill have four edges and can be used with ISO K and 1SO H materials, particularly in automotive and general engineering. According to Sandvik Coromant, these inserts offer up to three time’s greater productivity than cemented carbide. As for the future, Burton says there will be no new milling grades in the upcoming CoroPak 13.2, “but there will be some extensions in some products ... I cannot say for sure at this point what they will be.” www.sandvik.coromant.com

ISCAR

Composite cutting tools from SGS Tool Company. SGS is proud to introduce a line of Composite solutions specific to the unique qualities of machining this complex material. We know composites can be challenging and that’s why we designed new cutting tool technologies that provide the optimal combination of substrate, geometry, edge preparation, and our proprietary Di-NAMITE Solid Carbide Tools coating for maximum performance. Delivering performance by design. Contact your local SGS distributor for details. www.sgstool.com | 330-686-5700 | Manufactured in the USA

Israeli-tool giant Iscar held a major product launch in Toronto this May that featured a slew of new tools and inserts. Developed for the HeliIQmill 390 line of cutters, the HM390 TPKT 1003PDR insert boasts a .315 inch maximum depth of cut while the HM390 TDKT Iscar’s new Helido H606 1505PDR insert RXCU ACT insert boasts a .512 inch maximum depth of cut. The advanced cutting geometries of these inserts reduce cutting forces and power consumption. These inserts are also appropriate for milling high temperature, super alloys of the kind used in the aerospace industry. The Helido H690 tool family, meanwhile, uses double-sided triangular

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inserts with six helical cutting edges. “The Helido H690 helical design of the triangular insert, coupled with a rigid pocket design, provides extremely high durability and very stable performance,” states Iscar literature. Iscar’s new T465 FLN D...22ST face Iscar’s new HelilQ 390 mills feature tangentially clamped inserts insert with four cutting edges and a .750 inch maximum depth of cut. These inserts also have a high positive rake cutting angle (for a light cut) and a positive axial angle (R.H. helix) for a soft entry and exit from a workpiece. These inserts also feature a .10 inch flat wiper for premium quality surface finish. Inserts with chip splitting grooves, to boost

performance in rough milling are also available. The H606 RXCU line of double-sided profiling inserts have six 6 mm corner radii and 90 degree cutting edge arcs while the T490 LNMT 0804PNR-CS insert has four .315 inch cutting edges. The new Heli2000 chatterfree insert, meanwhile, “features asymmetrical design with two different cutting edges … reduced chatter, which increases tool life … ground cutting edges [which provide] more accurate perpendicularity, special edge preparation, 10 percent less power consumption versus a regular insert and improved chip evacuation due to unique axial variable cutting edges. [The insert is] most efficient on even number flute milling tools ... [and is] available in Sumo Tec carbide grades, IC380 and IC830,” states Iscar. www.iscar.com

GREENLEAF Last year, Greenleaf introduced G-9120, a heavy milling grade for forged steels with PVD coating that offers longer tool life than its predecessor, G-955. “Traditionally, PVD coatings are relatively thin ... [nanolayering] allowed Greenleaf to build a thicker coating structure than what they traditionally do,” says Hill. www.greenleafcorporation.com

Greenleaf’s G-910 heavy milling grade

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BIG KAISER Big Kaiser Precision Tooling, based in Hoffman Estates, Illinois with a Swiss parent company, has just released a major indexable cutting tools catalogue that apparently sets some world records. One of the new offerings is the R-Cutter ultra high feed front and back radius chamfering mill. The mill is available in singleinsert format with a four-insert design for higher feed rates. Coated carbide inserts allow for four indexes and are effective on all steels (including stainless), cast iron and aluminum. High rake angle minimizes cutting resistance and reduces the generation of burrs.

Big Kaiser’s Speed Finisher face mill inserts.

“A variety of R-cutter types are available, including a single insert front chamfering-only design with shank diameters of Ø16 and Ø20 mm and front-and-back combination chamfering

Big Kaiser’s C-Cutter mini inserts.

models with cutting shank diameters of Ø10, Ø16, Ø32 mm. Each model featuring a single insert design allows for cutting in the tightest of spaces,” reads Big Kaiser literature. The C-Cutter chamfer mill meanwhile, has double-screw indexable inserts that are parallelogram-shaped and designed to enhance cutting performance for chamfering. The C-Cutter has a double-screw construction for reliable clamping. The CCutter mini, meanwhile, boasts the world’s tiniest square insert (according to Big Kaiser). Each of insert’s four cutting edges comes in at .197 inches. The Big Kaiser’s R-Cutter chamfering mill C-Cutter mini takes four of these inserts. miniature inserts in total. The Speed Finisher face mill, meanwhile, is designed for machining aluminium and cast-iron. The Speed Finisher can carry CBN inserts. “[The insert’s] newly designed CBN sintered body with high content rate of CBN improves toughness and thermal conductivity,” reads Big Kaiser’s C-Cutter chamfering mill Big Kaiser literature. inserts. www.bigkaiser.com

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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

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THE BUSINESS OF METALWORKING

Downsize your turning inserts M

any machine shops today are machining with inserts much larger than are required. There are two trends in the machining industry today that influence the decision to consider downsizing your insert’s size. The first is that the raw materials (tungsten and cobalt) used to produce carbide inserts are dramatically increasing in price. The second is that manufacturing technology is advancing and parts to be machined are considered “near net”. That means the unmachined part is near its net size or there is little material to be removed. Over 75 per cent of the turning market takes depth of cuts of 3mm (0.117-inch) or less. Yet many machine shops insist on using large size inserts. The most common turning insert sold in North America today is a CNMG 432. This insert is capable of almost 0.250-inch depth of cut. Yet, as mentioned earlier, over 75 per cent of the machining industry takes cuts of less than half of that depth. This seems wasteful. In order to maintain the same performance, integrity, and fracture resistance of the tool, the smaller insert should have a thickness close to that of the large inserts. The insert numbering system or “nomenclature” indicates the size of the insert. The first number specifies the size of the inscribed circle of that particular

John Mitchell, General Manager of Tungaloy Canada

insert geometry. In the case of a CNMG 432, the 4 would translate to 4/8 or ½ inch inscribed circle. The second number points to the thickness of the insert. In

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“fit” loose. This may cause the insert to move while in cut leading to shorter tool life and slower performance resulting in catastrophic failure. It is sensible to change your holder often as it will help maintain high productivity and extend tool life. Trying to save a few dollars by extending the life of an $85.00 tool holder generally ends up costing much more in the long run. CM Many shops tend to push the life of a tool holder without realizing the consquences.

this case a 3/16 thick insert. The last number indicates the radius of the insert. So if you are using a CNMG 432 insert, you can simply downsize to a CNMG 332 insert. Since the insert thickness is the same, the chipbreaker and grade are also the same and the performance will be equal. However the price will be 20 per cent lower. Some shops are reluctant to change, since they consider they have made an investment in the tool holder. A typical holder for a CNMG 432 would be an ACLNR 16-4, which would typically list for $85.00. A CNMG 432 insert typically has a list price of about $11.25 whereas a smaller CNMG 332 would typically have a list price 20 per cent lower or about $9.00. By downsizing your insert the break-even on the tool holder would occur after using only 38 inserts. A typical tool holder is capable of lasting several hundred inserts. Similarly, this is only an extra cost on the first replacement as all tool holders eventually will wear out and need replacing. Of course there is no extra cost involved if the shop simply waits until the holder wears out and replaces it. However this is not recommended as the shop would be spending too much money on larger inserts. This leads to another topic: tool holders. Many shops tend to push the life of the tool holder without realizing the negative consequences. Tool holders are subjected to intense pressure, heat, and abuse. Over time, the pocket in a tool holder will “coin” or deform making the insert www.canadianmetalworking.com | JUNE 2013 | 71

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TOOL TALK

Horn’s CVD thick-film diamond tools Special chip-breakers for long-chipping types of aluminum

orn has expanded its product program to include CVD thick-film tools. The CVD cutting material is harder than PCD and twice as wear-resistant. Because of this and its other properties, CVD delivers various benefits when milling and turning — from rough machining to micro-milling — of longchipping 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 long life of diamond tools combined with an optimized chip-breaker on the CVD diamond cutter can increase machining productivity by up to 35 per cent and reduce processing costs by up to 80 per cent. For high performance machining and continuous turning applications, various inserts with wiper geometries were developed. Laser equipment is used to cut out the segments from the CVD-D blanks; these are then attached to the one-cutter inserts or milling cutters by brazing under vacuum. The chip-breakers and cutting edges are also laser-formed.

The undulating chipbreaker 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 degrees produces a soft cut and reduces burr formation to a minimum. This increases tool life compared to PCD cutters. In addition the controlled chip-break guarantees process reliability, and the reduced cutting force protects the spindle allowing the narrowest of tolerances even with delicate components. The sharp blade offers special advantages in processing CFRP, GFR, and their composites. In the first expansion phases, ISO inserts in types C, D, and V, along with different types of milling cutters, were equipped with the CVD thick film. The next phase will include Supermini and Mini tool systems. For more information: www.hornusa.com CM

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72 | JUNE 2013 | www.canadianmetalworking.com

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TOOL TALK

Makino hosts aerospace event 37 machines on display, with eight units cutting aerospace parts on the floor

akino hosted their aerospace structural day on April 30 showcasing the machine tool maker’s light alloy and titanium capabilities. Over 150 attendees watched structural part-machining demonstrations and technical sessions at Makino’s Mason, Ohio North American headquarters.

Attendees watch a demonstration taking place at Makino’s headquarters in Mason, Ohio.

There were 37 machines on display, with eight units cutting aerospace parts on the floor. Technical sessions highlighted close tolerance and large part-machining, including engine casings and wing box components.

event was held on May 8th focussing on auto parts production. For more information visit: www.makino.com CM

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The M-Four and M-Six Milling Cutters are now available as part of the Kyocera Milling Kit Sale. View details on our promotions page at www.kyocera.com/cuttingtools K y o c e r a I n d u s t r i a l C e r a mi c s C o r p . C u t t i n g T o o l s D i v i s i o n 8 0 0 . 8 2 3 . 7 2 8 4 � c u t t i n g t o o l s @ ky o c e r a . c o m w w w . ky o c e r a . c o m/ c u t t i n g t o o l s

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TOOL TALK

DMG Mori Seiki holds tech event

DMG Mori Seiki USA’s Innovation Days event brought a large group of attendees to view 44 machines, including 5 new premiers.

hicago-based DMG Mori Seiki USA kicked off the firm’s Innovation Days event on May 7 with a large group of attendees viewing 44 machines, including 5 new premieres.

DMG Mori Seiki USA’s new Milltap 30-taper vertical.

Over 40 suppliers were also on the floor with tabletop displays and technical personnel touting accessories and software ranging from tools and tool-holding to quality and machine financing.

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Repair/Service for GMN & most other makes and models Spindle support systems Manufacturing & servicing spindles for over 85 years

Design • Engineer • Manufacture • Support

www.slatertools.com Ph: 586.465.5000 74 | JUNE 2013 | www.canadianmetalworking.com

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TOOL TALK

Behind every great tool there’s a great idea The tool:

KOMET KUB® Quatron hi.feed High-performance milling cutter

Event attendees walk the floor at DMG Mori Seiki’s facility in Chicago.

The idea: Extending the technology behind the proven KUB Quatron® drills to a milling cutter.

Why it’s great: • Removes large quantities of material at high feed rates. • Plunge milling of deep grooves and large cavities. • Utilizes same 4-effective inserts as our KUB Quatron® drills. Learn more about this and other great ideas. Event attendees walk the floor at DMG Mori Seiki’s facility in Chicago.

According to Randy Harland, Executive Vice President of DMG Mori Seiki USA, “It’s about innovation and new ideas. We challenge ourselves constantly in terms of process engineering and sophistication of the equipment. We want customers to come every year; the event is gaining more and more popularity with customers throughout North America. “We’re constantly offering new product, for example our new Milltap 30-taper vertical. It bridges the gap between a drilling and tapping machine and a 40-taper vertical machining centre. “It’s a big event; we bring in literally thousands of visitors to this event.” CM

Go to www.komet.com/greatideas or scan this QR code.

Visit us in BOOTH #6604

www.komet.com 905-954-0466 www.canadianmetalworking.com | JUNE 2013 | 75

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Auto Mold Shop Revs Roughing Ops With Advanced Tooling Fast removal rates are critical at Build-A-Mold

n mold production, rough machining operations can prove just as critical as the final surface finishing processes. Out of all the material needing to be machined from a typical mold cavity, approximately 70 per cent of it will be removed during the roughing operation. So, the faster a mold shop can run its roughing cutters, the more it can shorten overall part cycle times and increase machine tool throughput and, thus, the quicker it can deliver molds. One mold shop that realizes the benefits of achieving the fastest rough machining speeds as possible is Build-A-Mold. With a simple switch in tooling, the Windsor, Ontario, shop was able to supercharge the rough machining performance of its older boring mills and gantry-style mills. Build-A-Mold not only doubled, and in some cases even tripled, metal removal rates with the new tooling, but also gained significant increases in roughing tool life as well. In business for 34 years, Build-A-Moldâ&#x20AC;&#x2122;s major focus is plastic injection molds for automotive exterior (painted) and interior components, in addition to intake manifolds and other engine components. Of all the molds it produces, 95 per cent are for the automotive industry, while the other five per cent are molds for

plastic bins and other such storage components. The shop employs 120 people and is a Tier One supplier to practically all the major automakers, including Honda, Toyota, General Motors, Chrysler and Kia. As such, it is continuously challenged with providing lower cost molds delivered in the shortest times possible. And on top of that, customers continue to demand molds with higher levels of quality and tighter tolerances. Average mold sizes vary from 5,000 lbs. to as much as 80,000 lbs. Most are multi-cavity, and many of the bigger molds have been for automotive interior quarter panels and exterior rocker panels. Mold components are made from tool steel, and the shopâ&#x20AC;&#x2122;s cutters can range from 0.020 inch diameter ball nose cutters to inserted milling cutters 6 inch in diameter. Tool lengths are as short as 0.125 or as long as 15 with the combination of cutters and holders. Practically all the mold tooling Build-A-Mold machines is high tolerance. For example, tolerances for the intake manifold molds must be held to within 0.0001 inch so that basically the molded product is perfect. The shop produces between 150 and 200 molds per year and does all the machining required for its molds â&#x20AC;&#x201D; going from design to finished product. Its processes

76 | JUNE 2013 | www.canadianmetalworking.com

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E-Z setup

Super-Speed milling

Vertical Edition

Repeat (max profit)

VF-2SS | Super-Speed Vertical | Affordable Haas price. Simple. Innovation.

Find your local Canadian Haas Factor y Outlet: 800.331.6746 â&#x20AC;˘ find them online @ www.HaasCNC.com

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Stack molds add complexity and cost but are highly productive.

include engineering, CNC machining and EDM, as well as mold finishing, spotting and repairing. Build-A-Mold’s mantra for success and exceeding customer needs over the past year or so has been “push product as fast as possible, make it as accurate as possible, and do so while keeping production costs in check.” In line with this goal, the faster the shop can rough cut a mold, the more it increases machining capacity without having to take on additional machine tools or labour. Plus, the reduced amount of time spent on a mold, the more profitability is gained. As part of the shop’s overall production initiative, BuildA-Mold’s CNC supervisor Joe Hindi and moldmaker manager Rob Caixeiro, together with company vice president of tooling Tony Romanello, turned their attention to shop’s rough machining operations on its 3-axis gantry- style and boring mill machines. The trio then worked closely with applications experts Ken Adair from Seco Tools and Frank Palombo of WFS Ltd., a Seco Tools distributor in Windsor. Hindi and Caixeiro first tested Seco’s Square 6 highfeed shoulder milling cutters. The 2 inch diameter cutters immediately allowed feedrates to advance from 145 ipm to over 500 ipm for high-feed rough milling pockets. And while these results are significant on their own, what makes the situation even more incredible is that it was accomplished on significantly older machines. Square 6 cutters incorporate trigonal inserts with six cutting edges for increased productivity and lower cost per edge. The tool offers three different insert geometries and three different pitches, enabling it to provide reliable, high productivity in face milling, contouring,

plunging, slotting and square shoulder milling. Square 6 inserts can be set to true 90 degree cutting angles to create clean 90 degree walls and eliminate secondary operations. Inserts lock into place via a strong center screw placed in the same direction as cutting forces, and wiper flats optimize surface finishes. Square 6 inserts can be indexed 2x3 times for a total of six cutting edges. “No one ever associates high-feed milling with older machines,” pointed out Caixeiro. “Prior to the Seco tools, we had maxed out the machines’ capabilities and looked for other avenues to increase output, mainly through tooling. The old machines provide the necessary rigidity for high-feed cutting and now run at maximum speeds and feeds with the Square 6 cutters. Yes, we’re running the machines at their limits, but we aren’t destroying them. Plus, we get longer tool life as well as the increased output.” With one of its 2 inch Square 6 cutters, the shop takes 0.040 inch depths of cut at 900 to 1,200 rpm spindle speeds and feeding at 250 ipm. These speeds and feeds are the maximum for that particular older milling machine. And what’s amazing is that the shop is confident it could run the Seco cutter at 500 ipm if the machine was capable. It is this reason that Build-A-Mold is in the process of acquiring newer faster equipment. After implementing the Square 6 cutters, Build-A-Mold brought in Seco’s Double Octomill face milling cutter. And according to Hindi, like the Square 6 cutters, the Double Octomills provide longer tool life and increased throughput. The Octomills are used for backwork — squaring up and/or side milling — components such

78 | JUNE 2013 | www.canadianmetalworking.com

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as mold cavity blocks on two of the shop’s horizontal boring mills. Build-A-Mold’s Double Octomills are 6 inch in diameter and have 10 insert pockets with inserts that provide a total of 16 cutting edges. In current operations, the shop runs the cutter at 0.125 inch step downs and full cutter diameter for maximum metal removal. For high versatility, cost effectiveness and productivity, Double Oc-

tomills work for both roughing and finishing operations. Additionally, Seco designed the Double Octomills in a range of three different pitches: Normal, Normal+ and Close pitch. This allows shops such as Build-AMold to match the right cutter pitch to specific machine power and speed capabilities to optimize productivity for different machines and materials. For both its Double Octomill and Square 6 cutters, Build-A-Mold uses

Jawnuts and Keys • Made from 4140 steel

• Always in stock

• Competitively Priced

• Made in the USA

ISO 9000 Certied QMS

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inserts coated with Seco’s Duratomic technology. The coating process produces a durable coating by arranging the aluminum and oxygen atoms in a special way to provide increased toughness and abrasion resistance. The cumulative result is improved mechanical and thermal properties together with toughness, far beyond that of any existing insert grades. “Before the Seco cutters, we’d just hog out material as best we could for our roughing operations,” explained Caixeiro. “We’d use 2 inch and 4 inch cutters with standard rounded inserts as well as button cutters together with multiple machine passes. Now, when machining molds, such as a big one we do for producing ATV hoods, we use the Seco Square 6 in a ramping technique to rough pockets in one pass as opposed to the two or three passes required with our previous cutters. And with the Double Octomills, we now take up to 0.200 inch depths of cut at full cutter diameter. Our previous cutters handled only 0.100 inch depths of cut.” Build-A-Mold’s boring mills are 50 hp machines, and its gantry mills are 25 hp. Maximum spindle speeds for the machines used for roughing vary from 1,600 rpm to 3,000 rpm, and according to Jeff Bailey, a programmer at Build-A-Mold, rough machining parameters, prior to

incorporating the Seco tooling, were all over the place. Machining times for components varied from one machine and machinist to the next. There was definitely a lack of consistency, said Bailey. So along with adding the Seco tooling, the shop standardized from one machine to the next. Now everyone runs the same program, takes the same depths of cut and at the same speeds and feeds. The shop also made its own pallets and tombstones for a standardizing of fixturing and pallet systems. Additionally, the shop uses a special in-house developed tracking system to optimize production. Employees on the shop floor input data into the system for keeping track of machine up and down times, programming time and unattended operation time. For workflow, the shop’s master scheduler will use the system and a timing system to break down a job by hours and by processes. Then feeding that information to each department that, in turn, tracks what has been listed for them to ensure that process due dates are met. On the programming side, Build-A-Mold streamlines part programming with one programmer developing programs for all the boring mills and gantry machines. This person knows the shop’s surface finish require-

LEADING THE WAY SINCE 1905 | www.canadianmetalworking.com

WWW.CANADIANMETALWORKING.COM INTRODUCING Canada’s LEADING metalworking

website, from Canada’s LEADING metalworking magazine.

80 | JUNE 2013 | www.canadianmetalworking.com

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ments and all the machine speed and feed parameters that should be used. Programs are developed in one office, and then get posted out to the machines. As far as tooling is concerned, Hindi and Caixeiro are now focusing on the shop’s drilling operations. They plan to incorporate more inserted drills that will eliminate

ADVERTISERS INDEX ADVERTISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PAGE

the need for resharpening standard twist drills. Plus, in addition to drilling operations, Seco tooling is also being considered for mold finishing operations. Standardization, along with a highly skilled team, quality work and quick deliveries, are what Hindi and Caixeiro both agree sets Build-A-Mold apart from its competition. The incorporation of the Seco tooling is a part of that drive to standardization, and the shop is making sure the cutters are always used to their maximum capacity. As opposed to individual machinists each determining what parameters they think the cutters should be run at. “For us, standardization is setting the process,” explained Hindi. “This is how it should be set up, how it should be programmed, what cutters should be used and at what speeds and feeds they should run. And these parameters will be used every time and by everyone involved. With the Seco cutters, we handed them to our machinists, and instructed them as to what speeds and feeds to run the cutters. And Seco played a key role in instructing us, then once the machinists saw the cutters perform at those increased speeds and feeds Seco said they would, the confidence was level of our machinists was solidified.” Build-A-Mold must be on the right path because it successfully implemented Lean and 5S techniques and tactics. But most importantly, in 2012, business grew by 15 percent. Both Hindi and Caixeiro realize there is a lot of knowledge and expertise at the shop, and they will continue to finesse and optimize this talent as well as bring in some new processes and technologies to further strengthen the shop’s business. CM

AME Abrasive Belt Machinery & Equip. Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 AMT Machine Tools Ltd.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Bohler-Uddeholm Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Brubaker Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Canadian Measurement-Metrology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Cecor Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 CWB Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Data Flute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Dillon Manufacturing, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Dipaolo CNC Retrofit Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Doosan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Elliott Matsuura Canada Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 EMO 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Eriez . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Exsys Tool, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Fastcut Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Fastems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Fein . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Ferric Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Ferro Technique Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Forkardt Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 GMN USA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 H&R Mfg. & Supply, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Haas Automation Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 HORN USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Hurco USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC Hydromat Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Hypertherm Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37 Ingersoll Cutting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Iscar Tools Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .OBC ITI Tooling Company Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Jet Edge, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Komet Canada . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Kyocera Industrial Ceramics Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 8CMM20186 01/07/2008 08:19 AM Lincoln Electric Company of Canada . . . . . . . .49 Lyndex-Nikken Inc. . . . . . . . . . . . . . . . . . . . . .62 Machitech Automation . . . . . . . . . . . . . . . . . . .39 Megatel Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . .36 Muticyl Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Nederman Canada Ltd. . . . . . . . . . . . . . . . . . .52 PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Renishaw (Canada) Ltd. . . . . . . . . . . . . . . . . . .57 Retention Knob Suppy & Mfg. Co. Inc. . . . . . . .81 Sandvik . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Schunk Intec Corp.. . . . . . . . . . . . . . . . . . . . . .68 IN STOCK Scientific Cutting Tools. . . . . . . . . . . . . . . . . . .65 American Standards Scotchman Industries, Inc.. . . . . . . . . . . . . . . .42 and specials. Seco Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Japanese Standards SGS Tool Company. . . . . . . . . . . . . . . . . . . . . .66 inch or metric. Slater Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .74 SME - CMTS . . . . . . . . . . . . . . . . . . . . . . . . . .45 FOR FAST DELIVERY: Sumitomo . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Contact your local tooling dealer or TE-CO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 order direct. TRUMPF Inc. . . . . . . . . . . . . . . . . . . . . . . . . . IBC TEL 937-686-6405 Tungaloy America Inc. . . . . . . . . . . . . . . . . . . . .3 FAX 937-686-4125 United Grinding . . . . . . . . . . . . . . . . . . . . . . . .25 www.retentionknobsupply.com US Shop Tools . . . . . . . . . . . . . . . . . . . . . . . . .67 Retention Knob Supply Company Victor Technologies . . . . . . . . . . . . . . . . . . . . .53 P.O. Box 61 Bellefontaine, OH 43311 Walter Surface Technologies . . . . . . . . . . . . . .41 Walter USA, LLC. . . . . . . . . . . . . . . . . . . . . . . .69 Weldon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Feature courtesy SECO

Page 1

Filter coolant faster, easier, cleaner and save! The power of CECOR high suction lift cleans sumps down to the bare metal in minutes.

CECOR Sump Cleaners pick up everything in the sump - coolant, chips and swarf. Filter separates solids from the coolant.

www.cecor.net 1-800-356-9042 www.canadianmetalworking.com | JUNE 2013 | 81

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By The NUMBERS Commodity Pricing: Energy Effects? Commodity Price Index: Energy

Commodity Price Index: Minerals & Forestry

2000 1000 1500 800 1000 600 500 400 0 2006 2007

2008 Total

2009

2010

Excluding Energy

2011

2012

Energy

200 2006 2007

2008 Total

2009

2010

Metals & Minerals

2011

2012

Forestry

1972=100 Adapted for Bank of Canada statistics. www.bankofcanada.ca

he Bank of Canada (BoC) compiles many useful statistics frequently used by economists and market analysts to predict the short-term outlook for the Canadian economy. We’re a resource driven economy, so commodity price indices are more important than in most developed nations. These graphs, derived for the BoC’s commodity price data, reveal some interesting trends in the economy. The energy chart on the left shows how much energy pricing affects the Canadian economy as a whole. With energy excluded, commodity pricing was and is stable, with little downward pressure during the post-2007 crisis,

but aggregated with the energy sector, price swings are very significant. If you’re building for the mining or forestry industries, the impact of the energy sector skews the outlook for the other, more stable sectors. The right-hand graph, showing mineral and forestry pricing, shows how the minerals and metals sector is softening slightly into 2013, as European recession fears deepen and Asian growth slows. Forestry however, is stable, reflecting already suppressed commodity pricing for much of the decade. If you’re looking to diversify from oil-patch work, mining and forestry look less volatile.

82 | JUNE 2013 | www.canadianmetalworking.com

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Why Pay More?

Improved Productivity and Tool Life for Less Money with

CTIVE E F F E COST ROACH APP

ECO THICKER INSERT

TURNING LINE

CNMG 0904.. (33...)

CNMG 1204.. (43...)

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