May 2013 • www.canadianmetalworking.com
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Vol. 108 | No. 4 | MAY 2013 | www.canadianmetalworking.com
20
WESTERN CANADA REPORT................................ 20 WMTS 2013............................................................ 26 The Western Technology and Manufacturing Show is set to take off in Edmonton
TOOLHOLDING TRENDS....................................... 36 Experts look at the costs and benefits
NOTHING RUN OF THE MILL................................. 52 New and improved in work holding
MAJOR LEAGUE MACHINING............................... 56 From the pitcher’s mound to the machine shop
36
OLD WORLD VALUES, NEW WORLD TECHNOLOGY....................................................... 60 Fabcrest Metal Products profits from short runs
A-PLUS LEARNING AT A-LINE............................... 64 A Toronto shop with a unique approach to CAM
SAFE AND SECURE............................................... 70 Access Security bends sheet into safes
WELDING LIGHT ALLOY........................................ 84 Tips and techniques for aluminum
52
MINIATURE MEASURING....................................... 88 Basic tools for measuring simplicity
PRECISION PLATING............................................. 92 Compound Metal Coatings uses green technology
DEPARTMENTS View from the Floor.................................................................6 News.......................................................................................8 The Business of Welding.......................................................17 Tool Talk.................................................................................44 The Cutting Edge..................................................................76 Welding News........................................................................82 Metals Report........................................................................96 By the Numbers....................................................................98
84
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Cover image courtesy Makino
CONTENTS...
COVER STORY:
www.canadianmetalworking.com | MAY 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 may 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 may 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., may not be reprinted without permission. CM receives unsolicited materials (including letters to the editor, press releases, promotional items and images) from time to time. CM, its affiliates and assignees may use, reproduce, publish, 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 may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 Email: jhunter@businessinformationgroup.ca Mail to: Privacy Office, 80 Valleybrook Drive, Toronto, ON M3B 2S9 Canadian publications Mail Sales Product Agreement 40069240 ISSN: 0008-4379 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.
6 | MAY 2013 | www.canadianmetalworking.com
Another cash grab If you are in this business to make things with machinery and equipment in Ontario, things are changing. Effective September 1st, section 12.3 a of the Professional Engineers Act is repealed. The section, commonly called the “machinery/ equipment exception”, allowed small Canadian shops to produce products using production equipment without the necessity of supervision by a professional engineer. The current system has worked for decades. The success stories were many, with toolmakers and machinists starting in garages and basements, then growing into job shops and often manufacturing operations. It’s a proven fact that an outstanding toolmaker that can design and build a progressive die can - and often does - run that die and make money in a safe manufacturing environment. Obviously that success is a hidden profit centre for the licensed engineering community. Excuses for changing the Act listed by the Association of Professional Engineers of Ontario are the standard party line: improve worker safety, reduce costs and standardize regulations across the country. In safety terms, all existing safety regulations still apply, and Ministry inspections are still a fact of life for manufacturers large and small. Neither the worker nor the inspector cares who signed off on a light curtain, or a machine guard, as long as it keeps body parts out of harm’s way. The Association quotes an international labor organization stat that manufacturing is the highest industry sector for on-the-job injury. This is also disingenuous since it compares manufacturing industries with sectors with no potential for harm; stockbrokers rarely lose their fingers. In today’s liability environment, not to mention legal and insurance compliance issues, there is no incentive for small manufacturers to cut corners on machine safety - and with the shop floor head count at an absolute minimum, a time-lost accident could cost a contract, or event bankrupt the business. The cost argument is similarly dubious. The Association assumes that a licensed engineer will always deliver the safer, more productive workplace, a highly questionable assumption. If this were true, there wouldn’t be a need to repeal the exception…the market would drive the demand. The argument that eliminating the exception merely standardizes Acts across the country is true, but misguided. Ontario manufacturers, in our industry especially, are not in competition with the rest of the country, We are up against low-cost U.S. jurisdictions, not to mention low-wage offshore nations. The path to improving manufacturing efficiency and lowering costs lies in reducing the need for expensive, highly skilled staff including professional engineers. It’s not a coincidence that Frank Stronach is not professional engineer. Let’s be clear, manufacturing needs engineers and engineering. Using regulatory capture and a political lobbying effort to go down the road of the medical and the legal professions to line their pockets and bolster the power of their industry association unfortunately isn’t a just a cash grab, it’s the way we do things in this country. Of course, big business will have little trouble or additional cost in compliance….like the hopelessly complex government assistance programs, they have the people and the resources to devote full-time attention to the paperwork. Again, small shop owners will take it in the teeth. Show job shop owners that they can make money by hiring another engineer and they’ll do it in a heartbeat. Force them to do so by legislation and we move another step toward the death of manufacturing in Ontario, and maybe Canada.
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JIM ANDERTON, EDITOR
Do you agree? Let me know, and feel free to drop me a line at the e-mail address below, or buttonhole me at a show or event. I’d love to hear from you! janderton@canadianmetalworking.com
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IN THE NEWS
Wilkinson Steel and Metals sells assets to Samuel, Son & Co.
Wilkinson Steel supplies a number of industries in western Canada.
V
ancouver-based Wilkinson Steel announced it has reached an agreement to sell its assets to Samuel, Son & Co. At the time of press the transaction was expected to close in late April pending regulatory approval. Wilkinson is a steel and metal service centre that supplies the resource based economies in the country’s western provinces. They deal with the forestry, mining, and shipbuilding industries in British Columbia, oil, gas, and mining in Alberta, and agriculture, mining, and oil and gas in Saskatchewan. Wilkinson is currently owned by the international private equity group Nova Capital. Nova Capital acquired the business in 2011 as part of a portfolio of five industrial businesses previously owned by Amalgamated Metal Corporation Plc. Bill Hughes, President of Wilkinson stated, “the acquisition by Samuel provides an excellent strategic and geographic fit
that will best serve the interests of Wilkinson’s existing customers, suppliers and employees, generating new opportunities and profitable growth.” “We are extremely pleased to be acquiring a company with an excellent product offering that is mainly complimentary to Samuel’s product line,” said Wayne K. Bassett, President and CEO of Samuel commented on the deal saying. “The acquisition also adds bars and structurals to Samuel’s current product offering. We are also pleased to be adding a strong team of employees to our Western Canadian Service Center network”. Samuel is the fifth largest processor and distributor of carbon steel, stainless steel, and aluminum in North America, and has over 100 steel service centres and manufacturing facilities. CM
8 | MAY 2013 | www.canadianmetalworking.com
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IN THE NEWS
Canadian auto parts industry on the mend: Scotiabank T
he Canadian auto parts industry outperformed in 2012, with full-year shipments surging 18 per cent to an annualized $23.8 billion, according to the Scotiabank Global Auto Report. “One of the emerging trends in today’s auto industry is that vehicles are increasingly becoming more reliant on electronics,” said Carlos Gomes, Scotiabank’s Senior Economist and Auto Industry Specialist. “We’re also seeing competitive cost challenges dictate that much of the electronics in today’s vehicles is now being imported from low-wage countries.” Global vehicle sales moderated in February, undercut by weak volumes in Western Europe and the impact of the Lunar New Year holidays in China, which distorted purchasing patterns. However, combined results for January and February indicate that car sales in China have advanced 19 per cent so far this year. Outside of China and Western Europe, car sales continued to improve in February, led by a 3.5 per cent year-over-year gain in North America.
A large reason the auto parts industry recovered so nicely was the fact that electronic parts are becoming more and more prevalent in cars. Much of the new technology is found in powertrain management, safety, comfort and entertainment, as well as navigation systems. Estimates also suggest that the use of electronics in vehicles will advance in excess of 7 per cent per annum through the end of the decade. But one trend with electronics in today’s vehicles is that they are imported. North American companies still design semiconductor chips, censors and control devices used in automotive electronics. However, the labour-intensive assembly is increasingly being performed in low-wage countries. Because of this, the segment now accounts for only 4 per cent of overall Canadian auto parts shipments, down from 5 per cent as recently as 2005. However, more traditional parts making methods, such as metal stamping watched sales soar 36 per cent last year. Although even with these gains, the content of Canadianmade parts in each North American-built vehicle only edged up $11 last year to $1,500, and still remains 17 per cent below the $1,800 average of the past decade. Double-digit declines at several automakers also held back overall volumes in Canada last month. Sales improved across most of the industry and are expected to gain momentum during the spring selling season. As a result, Scotiabank still expects full-year sales for 2013 to reach their forecast of 1.69 million units - the second highest on record. CM
New technology could encourage mass production of aluminum intensive vehicles Alcoa has announced that its “Alcoa 951” pre-treatment bonding technology has been licensed to Chemetall in an exclusive distribution agreement. The treatment is an enabler for adhesive bonding of automotive structures and could lead to cars being made with more aluminum parts. It is applied to surfaces with an immersion or spray application, where the organic components bond with oxides on the metal surface. The molecular structure chemically binds aluminum oxide with one end, and adhesive with the other, creating a link at the molecular level and making durable joints for automotive structures. ... continues on page 12
10 | MAY 2013 | www.canadianmetalworking.com
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IN THE NEWS ... from page 10
The technology can be used for aluminum sheet, extrusion and casting suppliers in the automotive industry. Aluminum is currently the second-most-used material to produce cars and could double in use by 2025 according to automotive OEMs (original equipment manufacturers). To make cars more fuel efficient, many are expanding aluminum use from heat exchangers, wheels, drive shafts, engine blocks, hoods and deck lids to developing aluminum intensive vehicles (AIVs) by converting the body in white, or body structure, to aluminum. “The use of this technology is helping to enable greater use of aluminum throughout the industry and helping make mass-produced aluminum-intensive vehicles possible,” stated Kay Meggers, Executive Vice President and Group President of Alcoa Global Rolled Products. “This, in turn, will drive lighter vehicle weights and enable the integration of sheet, extrusions, and castings to ultimately improve fuel efficiency,” said Dr. Raymond Kilmer, Executive Vice President and Chief Technology Officer at Alcoa. Alcoa 951 technology is being incorporated into the $300 million automotive expansion underway at the company’s Davenport (Iowa) Works facility. It is scheduled for completion by the end of 2013. Chemetall is a German-based company that is one of world’s largest suppliers of surface treatments to the automotive industry. They have over 40 branches worldwide. CM
Suzuki Canada to halt sales after 2014 S
uzuki Canada has announced they will discontinue sales of their cars in the country after 2014. The company made an official announcement on March 26th, where they stated that they will move away from car production to focus solely on their motorcycle, ATV and marine aspects of their business. In a statement the company said it, “concluded that it was no longer feasible for it to produce automobiles for distribution and sale in the Canadian market.” However, earlier this year, parent company Suzuki Motor Corporation of Japan (SMC) confirmed the production and supply of 2014 model year automobiles to Suzuki Canada, and this decision will remain in effect. Last year, the company sold roughly 5,500 units in Canada. On November 5, 2012, the American division of the company announced a similar decision to focus its operations on motorcycle, ATV and marine, while also discontinuing new automobile sales in the country. All of the company’s warranties related to their auto parts and service will remain in effect. — with files from THE CANADIAN PRESS
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IN THE NEWS
Largest wind energy project in Alberta completed
R
enewable Energy Systems Canada (RES Canada), has announced the completion of Halkirk Wind — the largest wind project in Alberta. The $346 million project is located in central Alberta near the town of Halkirk and is expected to provide enough renewable energy to power 50,000 average Alberta homes. Despite the sometimes challenging weather patterns of the prairies, RES Canada completed the project in 14 months, on budget and ahead of schedule. The project employed approximately 360 skilled workers on site for the civil and electrical works. “The province has abundant wind resources, and we look forward to working on other projects like Halkirk, which will drive investment and create jobs,” said Peter Clibbon, Vice President of Development for RES Canada. The electricity generated by the Halkirk Wind project will be sold directly into the Alberta spot market, and the Pacific Gas
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and Electric Company is purchasing renewable energy credits under a 20-year fixed-price agreement. The 150MW project hosts 83 Vestas V90 1.8MW turbines and is owned by Capital Power LP, a subsidiary of Edmontonbased Capital Power Corporation. RES Canada is also undertaking other projects in western Canada, including the MATL (Montana-Alberta Tie-Line), a 345 km high-voltage power line between Lethbridge, AB and Great Falls, MT. The company also has 631MW of wind and 30MW of solar built or under construction in Canada, including the 270MW SouthKent Wind project, Ontario’s largest wind farm. (Photo: Jimmy Jeong/Capital Power LP)
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14 | MAY 2013 | www.canadianmetalworking.com
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IN THE NEWS
Keynote speaker announced for WMTS
T
he Society of Manufacturing Engineers (SME) has announced the keynote speaker for this year’s Western Manufacturing Technology Show (WMTS). Champion rally car driver Andrew Comrie-Picard will speak at the biennial event, which takes place June 4-6, 2013 at the Edmonton EXPO Centre. Comrie-Picard who, in addition to racing, has also appeared as a TV host, will deliver an address to attendees, where he aims to challenge the manufacturing industry to think outside the box. “Growing up in the country, on the farm, it gives you a couple of things,” he says. “You have to figure everything out on your own, which makes you look at things in a different way. It makes you innovative and resourceful.” Comrie-Picard also has a number of interesting experiences of his own from which to draw on. He has performed motorcycle repairs across Africa in the basements of strangers using batteries as welding equipment, and stopped in hills outside of Morocco to repair a Volkswagen minivan using only items on hand — including a stick of chewing gum. “Engineering at its best is really a marrying of the best available technology with the best intuitive, sensible input from humans,” he says. The real message, he says, is to learn to trust intuition when it comes to devising solutions to problems, especially in pressure situations like a tough economy. Comrie-Picard also holds five university degrees, competed in the X Games every year from 2006-2010, and left a high-profile law career in New York City to pursue his racing passion full-time. The show will also feature a Job Shop Night from 4-6pm on June 5, where shop owners and employees can enjoy free beer and food and meet Comrie-Picard. WMTS will also feature an engaging education program on the show floor (free with admission), plenty of opportunities to network with technology companies and industry professionals, and a variety of live machinery and product demonstrations.
WMTS is presented by the Society of Manufacturing Engineers. For more information visit: wmts.ca or call 888-322-7333, ext. 4447.
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The Business of Welding
Time for some news A
s you may know the CWB Group is always looking for ways to improve the quality of welding within Canada. Traditionally this has been through the certification of companies and the qualification of their welders. Over time, it has been expanded to include training of other roles (like welding supervisors), the production of resource material like the CWB Welding Modules and our guide to Red Seal, and most recently courses and course material targeted at training our next-generation welders. All good stuff, some of which you have likely been exposed to of you chose a career in welding. For those who don’t know
the CWB history it’s worth pointing out that training and education for welders has been a cornerstone of the organization since its inception over 65 years ago. What was understood then, and is still in practice today, is that education goes hand-in-hand with safety. A welder without proper training and a firm understanding of the codes and standards that govern welding is an identifiable liability – someone who is putting their life in danger, as well as creating danger for the public at large. On the topics of training and safety, you will see a lot of material from the CWB Group in coming months tied to education, training and safety. The goal is still: better education for better safety and weld quality. Starting with education, the CWA is please to announce that we are partnering with the Gas & Oil Show in Calgary to present the new CWA CanWeld Zone. This is a major move for the Association and represents our commitment to bringing together suppliers and welder for the betterment of the industry. This event happens in June and dovetails with our new CWA CanWeld Conference that will run in the Fall. Where the “Zone” is about having a one-stop location for live demos of new technology and equipment, the “Conference” is all about learning, and the sharing of informa-
tion. This year’s Conference, which will be held in Niagara Fall, ON, will include streams on the “business of welding”, “welding technology” as well as “inspection and NDE”. Both events provide much needed industry “gathering Ian Campbell, Director of Marketing and New Product points” through the year. There Development, CWB will be lot of speakers and suppliers, covering lots of interesting ground, presented in a way that both engages and informs. If you are involved in welding we hope to see you out at both events. For more information check out: www.CWAevents.org and follow us on Facebook, we will be updating weekly so check back often. While we are on the topic of education, there are two more things to mention. First is the upcoming CWA Welding Educator’s Conference. This is a yearly event that brings together welder educators from all over Canada with the goals of sharing knowledge and defining standardized welder training and assessing material. Second I would like to announce that we have released the first of our new welding posters. This one is on Welded Joint and Symbols – ask your local CWB Group rep for a copy next time they visit your location. Finally, on the safety front CWB’s Office of Public Safety is now running free seminars for organizations that want to better understand Canadian Welding Codes and Standards. If you are interested in finding out more then a quick call to the Office will get you set up. This work is being done in conjunction with the newly launched CWB QualityMark program which is all about helping you promote the fact that your business is putting education and safety first by following Canadian Codes and Standards. If you are a CWB Certified company you can now use the QualityMark in your marketing and promotion material, and be included within our soon to be launched public-facing company index/ buyers guide. In closing I would likely you wish you all a great spring, hopefully the warm weather and sunshine are just around the corner. If there’s ever anything the CWA/ CWB can do to help you please let us know – we are Canada-wide and here to help.
Canadian Welding Bureau/Canadian Welding Association www.canadianmetalworking.com | MAY 2013 | 17
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CMTS To Address Major Industry Issues Skilled workforce shortage, cost control, and investing in new equipment top the list of priorities for Canadian manufacturers says a recent CMTS survey
I
n April 2013, Canadian Manufacturing Technology Show (CMTS) producer and organizer, the Society of Manufacturing Engineers (SME) reached out to its past event attendees with a survey to get a pulse check on the Canadian manufacturing landscape in their plans for CMTS this fall. Respondents were quite optimistic about the continued improvement of the economy, growth and expansion, an increase in capital equipment purchases and the return of CMTS to the airport location. “We are extremely encouraged by our findings” says
CMTS event manager, Julie Pike. “We’re busy creating the most significant gathering for manufacturers in Canada this year with CMTS. The survey results dovetail and will be used to further enhance our plans for special events and education programs at the event. As an example, a skilled workforce shortage was cited as the number one challenge Canadian manufacturers are facing today. Many industry media are talking about what Canada needs to do to address this and CMTS will offer solutions, resources and activities on the issues” Pike added.
HIGHLIGHTS FROM THE 415 RESPONDENTS INCLUDE: HOT ISSUES: Skilled workforce shortage (41%), keeping production costs under control (38%) and updating equipment/processes (32%) were the top three challenges facing Canadian manufacturers POSITIVE OUTLOOK: Optimism abounds with 67% of respondents anticipating their business increasing in the next 12-18 months LOOKING TO BUY EQUIPMENT: 74% are looking to spend on equipment in the upcoming year with budgets ranging from less than $50,000 to over $5,000,000. Of those spenders, 84% indicated that
their investment will be the same or greater than what they spent in 2012. WIDE RANGE OF INDUSTRIES & SECTORS REPRESENTED: Automotive led the pack with 32% followed closely by Fabricated Metal/Stamping (20%) and Industrial & Commercial Machinery (20%) with Energy (19%) and Aerospace (18%) rounding out the top five. WHY CMTS MATTERS: 94% indicated that tradeshows are a part of their buying strategy.
SME will look to incorporate many of these findings and industry issues at CMTS being held September 30–October 3, 2013.
www.canadianmetalworking.com | MAY 2013 | 19
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CANADA’S NEW ECONOMIC ENGINE
20 | MAY 2013 | www.canadianmetalworking.com
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Western Canada takes over as the driver of national economic growth By Jim Anderton, Editor
I
s this the decade of the Canadian West? Strong global demand for commodities, combined with a growing manufacturing base west of the Ontario/Manitoba border points to a shift in the centre of gravity away from central Canada. Four years after the shock of the 2008 crisis, how is Western Canada doing?
BRITISH COLUMBIA Real estate in the Greater Vancouver region dominates the mainstream media, but there’s much more to the story in our westernmost province. British Columbia limped into 2013 with a fall in employment between October 2012 in January 2013. Retail sales, manufacturing shipments, home resale, and resident of construction were flat to down. Royal Bank of Canada research however, suggests that housing resale activity is now stable and with new motor vehicle sales picking up in January followed by employment British Columbia is poised for a better 2013. Investment in the province is shifting from residential to nonresidential projects aided by US recovery and increasing demand for BC lumber production. Politically, austerity is the watchword in British Columbia and with provincial revenues from natural gas royalties down and a commitment to balance the books by 2014, the provincial government intends to flatline spending, raise taxes and sell assets. While austerity in a recession is a very controversial strategy, provincial elections are scheduled for May 14, so pump-priming by way of infrastructure spending may be in the cards for 2013.
SASKATCHEWAN Petroleum and potash are positive factors for Saskatchewan in 2013 According to the Conference Board of Canada, Saskatchewan’s economy is set to grow at a compounded annual average rate of 2.4 per cent over the years 2012-25. This relatively stable, sustainable growth will be fed by a strong fertility rate and robust international migration, softening the impact of retiring baby-boomers on the labour force. In the short term, CIBC World markets projects three percent growth in 2013, behind only Alberta at 3.2 percent. Potash extraction will drive the non-metal mining sector to annualized compound growth of 5.3 per cent over 2012–35. Saskatchewan sits atop one of the most talked about oil formations on the continent, the Bakken Formation. Conventional oil in place is estimated by the provincial government to be 45.6 billion barrels. In 2011, 158 million barrels of oil were produced worth about 13 billion dollars; Saskatchewan is also Canada’s third largest producer of natural gas. Oil and gas revenues to the province were 1.7 billion dollars in 2011-2012; petroleum is fast becoming as important to Saskatchewan’s economy as it is in Alberta. In comparison, mineral output was valued at 8.1 billion dollars with potash and uranium major resources. A major growth area is potash, with over 13 billion dollars in planned expansion on the books through 2020. Overall stats are positive: International exports were up 10.3 per cent to $26.5 billion
ALBERTA Predictably, it’s still about petroleum in Alberta, although manufacturing and heavy construction in support of the industry is building a significant technological base for the future, if skills shortages can be addressed. The outlook for Alberta is again positive, with record crude oil production despite the delay of Keystone XL pipeline approval and the resulting difficulty in shipping product to market. While increasing US petroleum production and downward pressure on global oil prices have dampened enthusiasm for future oil sands megaprojects, the prospect of Keystone XL approval and increasing Asian demand as their economies recover will drive a projected 3% growth in real GDP for the province, according to RBC Capital Markets, who predict Keystone XL pipeline approval with a 75% probability in 2013. www.canadianmetalworking.com | MAY 2013 | 21
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in the first 10 months of 2012, manufacturing shipments increased 13.1 per cent to $11.9 billion in the first 10 months of last year and employment growth was up 2.1 percent in the first 11 months of 2012, second-highest among all provinces.
MANUFACTURING SALES BY PROVINCE
MANITOBA Manitoba will experience slow growth in 2013, as a Government of Manitoba forecast predict 1.9 percent GDP growth in 2013 improving to 2.3 percent the following year. This is well ahead of the Canadian average of 1.1 percent over the last five years. Unemployment is third lowest of all provinces at 5.0 percent for the first quarter of 2013. Manufacturing sales slipped 0.4 percent in 2013 to date, sixth among all provinces and the same as the national decrease. Machinery and aerospace track above the trend, while fabricated metals and transportation equipment lag growth. The aerospace sector is increasing in importance in Manitoba with the sector now
On the manufacturing side, Alberta maintains its leadership position among Western provinces, with approximately $6 billion in shipments in February 2013. British Columbia follows with some $3 billion in sales. The combined manufacturing output of four Prairie provinces approximately equal Québec and replace them together in a tie for second behind only Ontario in the Atlantic provinces, the New Brunswick comes close with some $1.7 billion in sales in the same time period. StatsCan www.5.statcan.gc.ca
accounting for 8 percent of total manufacturing sales in the province at over 1 billion dollars.
PRAIRIE CITIES LEAD THE NATION IN GROWTH Saskatoon and Regina will be the fastest growing metropolitan economies in the country this year. Calgary and Edmonton are also forecast to have some of the strongest growth rates in the country, but neither are “booming” like they were prior to the 2008-09 recession. The sunny
PERCENT CHANGE IN TRADE EMPLOYMENT
In trades employment terms, employment of national was a modest 1.9% compared to the previous reporting year, 2011. British Columbia reported drop in trades employment and that figure at -0.4% is within statistical error. Manitoba showed essentially flat tray deployment while sketcher one was slightly above the national average. Alberta is the real star in trades employment with a whopping 7.4% increase year-over-year.
Prairie urban outlook is the result of the Conference Board of Canada’s Metropolitan Outlook-Winter 2013, the Board’s forecast for 28 Canadian census metropolitan areas. A thriving job market is attracting newcomers in droves to Saskatoon, which helps everything in the economy from housing starts to retail trade. The Saskatoon CMA’s real gross domestic product (GDP) is expected to grow by 3.7 per cent this year, number one in the country, and is expected to have the strongest growth rate over the 2014-2017 period as well. Regina’s economy is slowing by its own recent standards, from real GDP growth of 4.2 per cent in 2012 to 3.5 per cent in 2013, but growth remains robust. The Regina CMA is effectively at full employment, but jobs continue to be created – employment is expected to grow by 3.5 per cent this year. Regina’s population has grown by about two per cent for four straight years, providing support to the area`s services-producing industries and housing market. “Both Regina and Saskatoon attracted record numbers of newcomers in 2012. Migration is arguably one of the greatest success stories for these cities, with more and more Canadians choosing to call them home,” said Mario Lefebvre, Director, Centre for Municipal Studies.
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H F G
TRADES EMPLOYMENT
In thousands.
Real GDP in Calgary grew by 3.3 per cent in 2012, and is forecast to grow at a similar pace in 2013. Calgary continues to benefit from its role as services hub for Alberta’s growing energy industry. There is, however, a heightened risk of slower growth in the outlook, as a result of the unusual amount of uncertainty in the energy sector. The “bitumen bubble” (price discount between Alberta’s oil and world prices), along with lower natural gas prices, pose downside risks to the forecast. Edmonton led the country in real GDP growth in both 2011 and 2012, at 6.6 per cent and 4.4 per cent, respectively. However, growth is forecast to moderate starting in 2013, when it is projected to reach 3.2 per cent. In addition, if pipelines are not built to meet rising oil sands production, Edmonton’s mediumterm outlook could be trimmed. Vancouver’s economic growth is expected to accelerate slightly from 2.5 per cent last year to 2.9 per cent in 2013. The medium term outlook sees growth averaging three per cent annually through 2016. The CMA’s housing market is slightly overbuilt at present, which will slow residential construction in 2013 and 2104. Employment in the AbbotsfordMission CMA grew by 5.3 per cent in 2012, its biggest jump in 10 years. Although job growth will slow
Source: StatsCan www.5.statcan.gc.ca
in 2013, real GDP will grow by 2.7 per cent in both 2013 and 2014, a slight acceleration over the 2.4 per cent average growth recorded over the previous two years. Signs of life in the U.S. housing market will boost the outlook for the area`s wood products manufacturing sector. Still in the west, Winnipeg’s econo my will be held to two per cent growth in 2013. Growth in the manufacturing sector — thanks to higher demand for bus transportation — and an improving services sector will be partly offset by a weaker construction outlook. Outside of Western Canada, Toronto is expected to have the fastest-growing economy in 2013 (at 2.8 per cent), and over the next four years (2.7 per cent per year on average from 2014 to 2017). Kitchener-Cambridge-Waterloo and Oshawa are expected to post economic growth of 2.7 per cent and 2.6 per cent respectively, this year. Moncton is forecast to boast the strongest growth rate in Atlantic Canada at 2.5 per cent, followed closely by Halifax and St. John’s. Quebec City is expected to lead the five major cities in Quebec with economic growth of 2.1 per cent in 2013. The construction of a new NHL-sized arena is providing a boost to the economy. Elsewhere in Quebec a slight malaise seems to
be permeating Montreal’s economy. After real GDP growth of just 0.8 per cent in 2012, Montreal’s economy is expected to expand by 1.7 per cent. Trois-Rivieres is the only Canadian city whose economy is expected to contract this year, in part because of the recent announcement to close the Gentilly 2 nuclear power plant. Regardless of the province, sus tainable Western growth will be driven by resource exports in the short to medium term, exports which are challenged by weak commodity prices, skilled labour shortages and difficulty in getting product to market, particularly oil due to the delays in the Keystone XL project. Scotiabank research suggests that by mid-century, emerging markets will account for 70 percent of global trade, while currently trade with those markets account for less than 12 percent of Canada’s exports. Addressing serous infrastructure shortages that inhibit export, particularly to Asia, combined with long term demographic challenges as Baby boomers retire will be challenged by strong demand for western resources. The population issue will not be solved entirely by interprovincial migration; immigration policy will have to fill the gap to keep Western Canada’s hot streak alive for the foreseeable future. CM
24 | MAY 2013 | www.canadianmetalworking.com
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WMTS 2013 The Western Manufacturing Technology Show brings high-tech to the fastest growing manufacturing region in the country By Jim Anderton, Editor
W
ith Western Canada driving the Canadian economy forward, the Western manufacturing Technology show brings the expertise needed in a fast-changing sector right to the source: Edmonton, Alberta. Scheduled for June 4-6th at the Edmonton EXPO Centre, the event will showcase leading-edge machine tools, tooling and accessories, fabrication, design, automation, process control, and plant main tenance equipment all under one roof. Information sharing will extend beyond equipment, with a notable industry keynote, an interactive town hall panel and multiple opportunities to network and share ideas with colleagues and customers in Western Canada. “For manufacturers, WMTS is the place to learn, evaluate and compare technologies and solutions on a one-on-one basis. All under one roof, over three days,” says Janine Saperson, event manager. More than 2,000 attendees are expected to attend the biennial event. KEYNOTE ADDRESS Champion racecar driver Andrew Comrie-Picard will deliver the keynote address to WMTS and is expected to again entertain with his multiple adventures in international motorsport. Comrie-Picard works full-time as a top rally car driver, precision driver, auto journalist, and television host. At WMTS he aims to challenge the manufacturing industry to think outside the box by sharing his own insights and experiences. “Growing up in the country, on the farm, it gives you a couple of things,” Andrew says. “…you have to figure everything out on your own, which makes you look at things in a different way. It makes you innovative and resourceful.” Picard is certainly re sourceful, having perKeynote speaker Andrew Comrie-Picard formed motorcycle repairs
Edmonton art piece “Immense Mode” stands tall.
©
City of Edmonton.
across Africa in the basements of strangers using batteries as welding equipment, and repairing a Volkswagen minivan in the hills outside Morocco with a stick of chewing gum. “Engineering at its best is really a marrying of the best available technology with the best intuitive, sensible input from humans,” says ComriePicard, who holds five university degrees, competed in the X Games every year from 2006-2010, and left a high-profile law career in New York City to pursue his racing passion full-time. His keynote will encourage the manufacturing industry to think outside of the box, a skill he relies on whether he’s trying to come first in a rally race or attempting to turn a car into an airplane in three days on a television series. The real message, he says, is to learn to trust intuition when it comes to devising
26 | MAY 2013 | www.canadianmetalworking.com
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WMTS SUPPORTS CANADIAN ARTIST Artwork for this year’s WMTS is by Edmonton-based artist Jason Carter, one of Canada’s most exciting and accomplished contemporary Aboriginal visual artists, celebrated for both his paintings and his carvings. He was the only artist in Alberta to have had a feature showing at Alberta House on Alberta Day at the Vancouver 2010 Winter Olympics, his work has been acquired into dozens of private collections (The City Of Edmonton, AFA, Rogers Media, The Regional Municipality of Wood Buffalo to name a few) as well, he has had several exciting public shows, including the Royal Alberta Museum and the Indian and Northern Affairs Public Art Display in Ottawa, Ontario. Jason has had seven solo shows in the past three years and has been commissioned by the Art Gallery of Alberta, The Society of Manufacturing Engineers of Canada, Winter Light Festival, The Works International Visual Arts Society, The Edmonton Arts Council, The Alberta Foundation of the Arts, The Canada Council for the Arts, The Government of Canada and most recently, The Edmonton International Airport to create a 100ft x 7ft permanent installation/mural for the new Edmonton International Airport which opened Summer 2012, with an expected viewing of over 1 million people per year. Jason Carter is currently represented by The Bearclaw Gallery in Edmonton, The Town Square Gallery in Oakville Ontario and this past year, opened his own gallery, The Carter-Ryan Gallery in Canmore Alberta. Jason is member of the Little Red River Cree Nation and he paints and/or carves seven days a week. For more information, visit jasoncarter.ca
solutions to problems, especially in pressure situations like a tough economy. JOB SHOP NIGHT AT THE SHOW Job shop owners and employees can enjoy free beer and food and meet Comrie-Picard at Job Shop Night on June 5, from 4:00-6:00 PM. WMTS will also feature
FAST FACTS What: Western Manufacturing Technology Show When: June 4th-6th, 2013 Where: Edmonton EXPO Centre, Northlands 7515-118 Avenue Edmonton, Alberta Contact: Chris Raso, Customer Service at craso@sme.org or by phone at 1-888-322-7333 ex. 4447 Internet: www.wmts.ca
EXHIBIT HALL HOURS Tuesday, June 4 — 10:00 a.m. to 5:00 p.m. Wednesday, June 5 — 10:00 a.m. to 6:00 p.m. Thursday, June 6 — 10:00 a.m. to 4:00 p.m.
an engaging education program on the show floor (free with admission), plenty of opportunities to network with technology companies and industry professionals, and a variety of live machinery and product demonstrations. A Tech Bar on the show floor will offer live, interactive education right in the heart of the action, and a comprehensive lineup of seminar speakers covering topics as diverse as Lean Implementation to welding and cutting technologies. Opening day Tuesday June 4th will feature six seminars and wraps with a 4:00PM networking reception for attendees, suppliers and industry experts. The Wednesday schedule is just as informative, and begins with a town hall panel discussion on resources for manufacturers in Alberta, moderated by Dr. John Wolodko, portfolio manager, advanced materials at Alberta Innovates Technology Futures (AITF). Wednesday evening concludes with Job Shop Night, featuring keynote speaker Andrew Comrie-Picard. Thursday’s lineup spans business analytics, continuous improvement and a don’t miss session on doing business with the Federal Government and the Canadian Innovation Commercialization Program. WMTS, presented by the Society of Manufacturing Engineers, is at the Edmonton EXPO Centre (7515-118 Ave) from June 4 to 6, 2013. More than 2,000 attendees are expected to attend. To learn more about WMTS, visit www.wmts.ca or call 888-322-7333, ext. 4447. CM
28 | MAY 2013 | www.canadianmetalworking.com
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On the Floor at WMTS W ith hundreds of exhibiting companies show casing new products (with many running live demonstrations) there is lots to see whether
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you’re in machining, fabricating, engineering or manufacturing services. Here’s a small sample of the machinery and equipment you’ll see at WMTS.
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KOMET GROUP KOMET will be introducing their MicroKom BluFlex fine boring system at the Western Manufacturing Technology Show (WMTS) in Edmonton, Alberta between June 4th-6th. By incorporating Bluetooth wireless technology to the MicroKom BluFlex fine boring system, tool developers at KOMET GROUP have created a safer, easier to use, and more convenient to read tool. When dialing-in the micro-adjustable head with the adjustment key, the operator can affix the magnetic, external display unit anywhere within the field of view, outside of the machine tool. The data on the tool position is sent wirelessly to the display, and the illuminated screen and oversized numerals make reading easier. The system can switch between mm and inches, and allows for adjustment in increments of 2µ or 0.00008-inch. KOMET will be showcasing their products at booth #1437 at WMTS 2013. www.komet.com
ELLIOTT MATSUURA CANADA INC Matsuura MX520 Booth #1121,1020,1026 The MX520 is a high rigidity machine equipped with the Fanuc31i CNC control and 12K rpm spindle as standard (20K rpm Optional). Matsuura Machinery Corp. has developed a 5-Axes Vertical Machining Center using “User Friendly” and “Safe” concepts. The MX520 is a high rigidity machine equipped with the Fanuc31i CNC control and 12K rpm spindle as standard (20K rpm Optional). The newest model Matsuura machines are the VX 1000 and VX1500 VMC 3-Axes machining centers.
P
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First time shown in Western Canada Come and see technology at its best from EMEC Machine Tools Inc Visit us at Booth# 1421
GROB 5-axis Universal Machining Center
The smallest package of pure technology
X/Y/Z travels 31.49”/ 37.40” / 40.15”
A-axis travel of 240 degrees
Available direct drive table for turning applications
GROB G550
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Travel: 40” x 21” x 21” (X/Y/Z)
Spindle: 10,000 RPM
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Windsor Office Tel. 519-222-8716 Fax. 905-565-3580
Western Canada Suite 900,10665 Jasper Avenue, Edmonton, Alberta T5J 3S9 Tel. 780-953-3570 Fax. 780-421-8400
Providing Tomorrow’s Manufacturing Solutions Today www.emecmt.com
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ELLISON TECHNOLOGIES/MORI SEIKI Mori Seiki NLX4000AY/750 Booth #1331 Ellison Technologies, Booth #1331, will feature the latest model in Mori Seiki’s X-class series of CNC turning centres - the Mori Seiki NLX4000AY/750. The NEW Mori Seiki NLX4000AY/750, with up to 400 mm turning diameter, is designed for manufacturing large parts in multiple industries including: aerospace, oil & gas, medical, and automotive. It has the aptitude of large turning with extremely high precision, offering first-class machining capabilities. The NLX4000 is recognized as one of the highest performing horizontal turning centres on the market with superior rigidity, accuracy, and operability. It also has the broadest slideways and through spindle hole diameter in its class. In addition, the energy saving NLX4000AY/750 comes equipped with a world class Built-in Motor Turret (BMT), top-of-the-line MAPPS IV operating system, and extensive specification options. The robust construction of the NLX4000 allows for heavy duty machining that complies with safety standards and precision requirements.
EMEC MACHINE TOOLS INC Grob 550 5-axis Universal Machining Center Booth #1421 The Grob G550 machining center is characterized by its compact design with best machine accessibility to the work area. Built for speed, accuracy and regidity the 550 can handle a multitude of workpieces. Travels: XYZ 31.4” / 37.4” / 40.1” Spindle speeds: 10,000 RPM / 12,000 RPM / 16,000 RPM / 18,000 RPM
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32 | MAY 2013 | www.canadianmetalworking.com Linearmill_114,3x123,825_EN.indd 1
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FEIN Fillet Weld Grinder Booth #1457 Compact solution for angles and edges. Work with extreme accuracy, even in hard-to-reach places with the FEIN Fillet Weld Grinder KS 10-38 E. FEIN rounds out its range in the stainless steel surface-processing field with the FEIN Fillet Weld Grinder. The small, low-profile and handy tool ... continues on page 34
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... continued from page 32 Fein Canadian Power Tool Co Ltd.
removes fillet welds quickly and easily after welding. Even in the tightest corners and angles, seams can be levelled, ground and polished while scratches and unevenness can be removed with precision. With the ability to match the optimal speed to each application and original FEIN accessories; consistent and flawless results can be achieved.
• Flexible operation using the tool-free, rotating arm • Low-profile design for corners, angles and hard to reach places • Electronic speed control • Long belt drive service life due to maintenance-free tensioning system • “Made in Germany” quality
MULTICAM WESTERN CANADA
Mulitcam 3000 Series 5 Axis Waterjet. Booth #1111 The newest edition to the Multicam Waterjet line is The Multicam 3000 Series 5 Axis Waterjet! It offers the ultimate in high performance CNC Machining! The Multicam 3000 Series Waterjet is an affordable, easy to use cutting solution designed for manufacturers who want the ability to cut a wide variety of materials. High pressure Waterjet machining also offers unique advantages over other cutting technologies allowing the user to cut highly accurate parts with excellent finish and no heat affected edges. A Multicam 5 Axis Waterjet will add versatility, diversity, abd accuracy. With its proprietary design, excellent range of motion, multiple software options, and 60K PSI or 90K PSI capability, The Multicam 5 Axis Waterjet can’t be beat. Options include: Abrasive Feeder – Works under full CNC control; Closed Loop Filtration; Chiller; Abrasive removal System; Multicam teams with KMT Waterjet and uses only KMT Pumps, including the 90,000 PSI Pump – which provides the FASTEST cutting on the market! Come and check out the Multicam Booth #1111 at the WMTS Show June 4 – 6 2013! Multicam Western Canada, 604-626-4096
OMAX CORP A-Jet & Rotary Axis. Booth #1812 The innovative OMAX A-Jet and Rotary Axis combination brings 6-axis 3D cutting technology to abrasive waterjets, allowing for complex 3D cutting and advanced tube and pipe bevel cutting capabilities. OMAX, the global leader in innovative abrasive waterjet technology, expands versatility with groundbreaking six-axis 3D capabilities, available on new and existing OMAX JetMachining Centers. New advancements in the OMAX Intelli-MAX Software Suite open up exciting possibilities in continuous rotational cutting with the Rotary Axis accessory, while the A-Jet articulated cutting head has expanded taper removal functionality and bevel cutting up to 60°. Combined, the A-Jet and Rotary Axis are capable of complex 3D cutting, with advanced tube and pipe cutting and bevel cutting made simple through parametric shape functionality.
MAZAK CANADA & MACHINE TOOLWORKS Mazak Canada and Machine Toolworks can help you overcome your unique part production challenges by offering the latest, most comprehensive manufacturing solutions around. From high-performance machine tools to innovative technologies to productivity-driven processes, these two companies are bringing more to WMTS 2013 – and your bottom line. Mazak and Machine Toolworks will be displaying the large turning and boring capability of the STN550M. Integrated into a robot cell, the QTS300 will demonstrate the high production capabilities of Mazak product in conjunction with Fanuc Robotics. As the leader in multitasking no show would be complete without an Integrex. Mazak will be displaying the i200 with a unique demo relevant to the oilfield industry. Completing the lineup will be one of Mazak’s newest VMC’s the QTS530C. 34 | MAY 2013 | www.canadianmetalworking.com
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Toolholding Trends 2013 Industry Experts Mull Trends and Techniques By Nate Hendley
I
t’s one of the machining tragedies of the ages: shop owners who drop six figures on a machine tool then try to save a few dollars by picking the cheapest toolholder they can find. Such behavior is “very common ... we see it almost daily. The normal reason for this is that the tooling is forgotten about until the machine arrives. At this point the company only has a small budget left and they get what they can. We have seen several machine tool dealers starting to work on the front side of machine orders to get the tooling included in the machine purchase.
When this happens the customer gets the tooling they need for the machine they ordered. I really don’t have an opinion on what percentage [of a shop’s budget] needs to be spent on tooling—it just depends on what they need to do. We have seen cases where the tooling cost as much as the machine, but it was needed for that application,” notes David McHenry, product engineer at Rego-Fix in Indianapolis, Indiana. “I do see a lot of people buy $600,000 Makino machines then try a $24 ER collet chuck on them. The connection between the spindle and cutting tool is an important part that a lot of people overlook,” echoes Mike Smith, reaming and EPB product manager at Seco in Troy, Michigan. “The toolholder must be part of the budget/investment. Cheap tooling will badly affect machining performance/productivity and therefore will [hurt] the investment,” agrees Thomas Hagan, milling product manager at the Canadian branch of Israeli firm Iscar Tool, based in Oakville, ON. Another perennial question: what are the most important factors to consider when purchasing a toolholder? “I would definitely start with concentricity. A good concentric holder will always save you money, but it needs to include ... other features like holding strength to be useful. A holder that gives you concentricity and gripping force opens up options for high speed machining and heavier roughing applications all in one,” says McHenry. “Associating the right [toolholding] system to fit the right demand is very important ... in other words, you should select [toolholding] systems to fit your application,” says Ross Carpino, general manager at Sandvik Coromant Canada, in Mississauga, ON. Pundits have picked up on a few trends in the wind. “The trend in the toolholders is [towards] more machines with Capto spindles,” says Hagan. “There seems to be a growing market for large capacity tap holders due to the increased need to support tapping operations in larger components. Larger taps are being used in applications in the oil industry, wind turbine and power generation and the production of large diesel, locomotive and ship engines,” says Mark Hatch, product director of taps and thread mills at Emuge, in Boylston, MA. Here’s a look at what’s new and/or noteworthy in toolholders:
36 | MAY 2013 | www.canadianmetalworking.com
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BIG KAISER Big Kaiser of Hoffman Estates, Illinois, recently released the Hydraulic Chuck Super Slim line of toolholders. As the name implies, these toolholders have slim bodies to eliminate interference in confined areas, making them ideal for five-axis precision machining. High precision run-out accuracy is less than .00012 inches (3µm) at 4 x D, which improves workpiece surface finish and extends the life of the tool. Repeatability is under .00006 inches (1.53µm). These chucks can be easily clamped and unclamped with one wrench and one screw and offer vibration-free machining at high speeds, up to 35,000 rpm. “Compared with the traditional two-part construction sealed with O-rings, BIG Hydraulic Chucks are long lasting and maintenance free. Also, the rigidity is greatly improved by the short projection length and dual pressure points,” states Big Kaiser literature. www.bigkaiser.com
Big Kaiser’s Hydraulic Chuck Super Slim line
Reversible Hard Jaws
• Available in - Serrated, Acme Key, Square Key, Tongue and Groove styles • Option of either single or two-step jaws • Reversible - suitable for OD & ID workholding • Accurate gripping and locating serrations • Heat treated and precision ground
SANDVIK COROMANT Asked what he considers the most notable feature of the new Sandvik Coromant CoroChuck 930, and Carpino, is quick to reply. “It’s the Fulcrum Technology that is inside the chuck ... for us, this is a new concept completely,” says Carpino. “The secret behind the high-precision and pull-out security is the optimized design of the brazed membrane which allows for maximum secure clamping with two supports on each side (fulcrums) ... this design ensures excellent torque transmission to improve the performance of solid carbide end mills, drills, and reaming tools. This performance is repeated over multiple clamping cycles to retain high quality component surfaces and extend tool life. Additionally, the CoroChuck 930 is designed with
• Diamond shaped serrations and black oxide finish • Made in the USA
ISO 9000 Certied QMS
DillonManufacturing, Inc. Peter Seessle | Expertech Dist. & Tech. Inc. 44 Goodfellow Crest | Bolton, Ontario Phone: 647-960-4478 | Email: peteseessle@rodgers.com www.canadianmetalworking.com | MAY 2013 | 37
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dampening features that minimize vibrations during the machining process,” explains a Sandvik press release. The CoroChuck 930 can be used in die and mould, automotive work, aerospace, general machining, etc, says Carpino. “The new CoroChuck 930 offers easy handling which leads to quick tool change and set-up. The precision run out gives enhanced surface finishes, increased tool life, and closer hole tolerance,” adds Randy McEachern, product and application specialist at Sandvik Coromant Canada. Sandvik Coromant is looking to expand the CoroChuck 930 family in October of this year. www.sandvik.coromant.com
Sandvik Coromant’s new CoroChuck 930
ISCAR Iscar calls their new Hydro-Sure chucks “revolutionary” and “unique”. Available for a tool diameter range of 16 – 32 mm, the HydroSure chucks can be used in a wide variety of applications, including aerospace, power generation and general machining, says Hagan. The chucks have side screw clamping for Weldon type standard shank tools, very accurate concentricity of 0.003 mm and rigid peripheral hydraulic clamping. Hydro-Sure chucks are also suitable for heavy machining applications, says Hagan. www.iscar.com Iscar’s new Hydro-Sure chuck
REGO-FIX In early 2013, Rego-Fix unveiled the new millTite Milling Chucks, designed to offer the least possible run-out and highest possible gripping force. The chucks boast a concentricity of 0.0004 inches at 4 x diameter and are ideal for roughing and finishing, according to the company. “The most notable feature [on the millTite toolholders] would probably be the thick nut used on the chucks. This large nut provides superior torque and gripping force, durability, rigidity and overall increased all performance,” says McHenry. MillTite chucks work in CAT 40, CAT 50, BT-40 and HSK 63A spindles. Helical internal slots and extra thick walls increase durability, working life and smooth clamping. The chuck’s multi-seal design keeps debris out while sealing the system for coolant through applications. Rego-Fix has also been adding new holders and lengths to the slim nose powRgrip 6 (PG6) family which was unveiled at IMTS 2012, says McHenry. “The PG6 actually offers a few notable features. The first is the small outside diameter of 10 mm, making it the smallest nosed PG system we offer. This makes it ideal for small, tight working applications. The second is the holders’ ability to change collets from 0.2 mm to 3.125 mm (1/8 inches) and still offer 3 micron run-out,” says McHenry. www.rego-fix.com
Rego-Fix’s slim nose PowRgrip 6 (PG6)
WA
Wa N22 Wa 800 ser
Rego-Fix’s new millTite Milling Chucks
ww
38 | MAY 2013 | www.canadianmetalworking.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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KENNAMETAL Kennametal of Latrobe, PA released the KM4X spindle connection in late 2011. While the “basic configuration” of the spindle connection has remained the same, says Mark Huston, vice-president engineered solutions at Kennametal the KM4X was recently put through a gruelling study that involved the precision machining of a titanium workpiece. The experiment was conducted in April 2012, in tandem with machine tool builder Mitsui Seiki, of Franklin Lakes, NH. A Mitsui-Seiki HPX63 CNC horizontal machining center with four Kennametal cutting tools, each equipped with a KM4X 100 spindle connection, was used to cut the titanium workpiece. “Achieving the ultimate system to precisely machine titanium at maximum metal removal rates requires close attention to the machine tool providing the force, the point where the cutting tool edge meets the workpiece, and the spindle connection—the ‘handshake’ between the machine tool and the cutter,” stated Scott Walker, president Mitsui-Seiki and Huston, in a paper documenting the experiment. The cutting tools used were a face mill with different inserts, a helical cutter and a flat-bottom indexable drill unit. For the experiment, the KM4X 100 generated 90 kN clamping force (more than double what an HSK100 and three times what a BT50 would manage). “The KM4X spindle connection also provides more-than-
Kennametal’s KM4X spindle connection
adequate rigidity, bending moment resistance and torque capacity to take full advantage of the higher rpm’s and torque levels offered by the machine tool and spindle. As a result, the combination makes the most of the productivity potential and cutting performance of the machine tool to deliver superior results,” reads Walker and Huston’s paper. “Between the power of the machine tool and spindle and the superior clamping force of the spindle connection, the test achieved unparalleled results across the board,” continues the report, noting that the helical cutter, “cutting in X and Y directions simultaneously, topped 309 cc/min. material removal rate at a spindle speed of 171 min-1, 101.6 mm/min. cutting feed, 40 mm depth of cut and 76.21 mm cutting width.” Too often, notes Huston, the spindle connection “is the weak joint in the system.” The KM4X, by contrast, enables users to make optimal use of their machine tools, he explains. www.kennametal.com
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40 | MAY 2013 | www.canadianmetalworking.com
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EMUGE Emuge has released KSN5 and KSN6 Softsynchro tap holders and Softsynchro HD and MQL Modular Systems. The KSN5 and KSN6 are used for tapping operations involving components used for power generation, wind turbine applications and the production of diesel, locomotive and ship engines. These toolholders “provide excellent concentricity, rigidity and safe tool clamping in machines with synchronous spindles,” says Hatch. The Softsynchro HD and MQL Modular Systems, meanwhile, are designed for machines with synchronous spindles, he continues. “The new Softsynchro HD and MQL Modular Systems make it possible for the same tool holder body to be used for minimal quantity lubricant (MQL) or HSK coolant applications. A heli coil mechanism compensates for axial movement to prevent unwanted displacement. The modular tool holder can be supplied with a spring-loaded tube for MQL applications. Also, the same adjusting screw can be added to the HD unit in high-pressure Softsynchro holders,” says Hatch. http://www.emuge.com
1-800-265-2581
(Above) Emuge’s Softsynchro HD and MQL Modular system (Left) Emuge’s KSN5 Softsynchro tap holder
www.fein.ca www.canadianmetalworking.com | MAY 2013 | 41
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SECO This spring, Seco launched the 5600 series of Reinforced Shrinkfit Holders and 5672 high precision collet chucks. The 5600 series boasts low run-out (max. 3µ at 3xD), good clamping forces and high rigidity, which allows machinists to run their machine tools at full tilt. As a result, higher-strength workpiece materials can be easily machined. Coolant through the center of the tool shank extends tool life while allowing good chip flow and faster heat dissipation. The 5672 chucks meanwhile, “gives you versatility but ... because of the design of the collet, it actually gives you a lot of gripping force, almost like traditional shrinkfit holder, says Smith. The 5672 chucks have run-out maximum 3µ at 3xD, can be used with CBN and PCD cutting tools and offer high clamping forces and a high degree of flexibility (the chucks can be used for drilling, reaming, milling, etc). Seco plans to expand the 5672 range later this year. www.secotools.com/
Seco’s new 5672 high precision collet chucks
THE CUTTING EDGE We use Premium Micro grain solid carbide for longer tool life and increased feeds and speeds. Tools are stocked uncoated and ALTiN coated. Designs for threading, grooving, PCD, and CBN-tipped inserts
Solid carbide grooving, boring and threading tools.
Set includes boring bar, 5 inserts, 5 screws, and a torx plus key
Threadmills
Available in coated AlTiN or uncoated sub micrograin carbide
Port tools
Hardened steel head features proprietary mechanical attachment... no annealing from brazing heat Pocket keeps chips away from machined surface Fits into SCI standard QHC coolant tool holders Inserts lapped and ground to fine finish for maximum chip flow Available in right-hand and left-hand versions Bars stocked with or without locating flat... Low profile screw keeps chips flowing
SCIENTIFIC CUTTING TOOLS, INC. 110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com 42 | MAY 2013 | www.canadianmetalworking.com
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S
IS SHRINK-FIT THE FUTURE?
hrinking technology has developed into a permanent feature of the automotive industry, aircraft manufacturing and die and mould making. The reason is performance: the shrinking process forms tool and chuck into a very stable unit, and optimal retention forces improves precision during machining. “Concentricity of under three microns can only be achieved with this technology,” explains product manager Michael Schinke of Ostfilderm, Germany-based Bilz GmbH, a major
overheating the tool during the process, which can damage the composition of the solid carbide and affect the tool’s
performance. Look for more coverage of shrink-fit technology in upcoming issues of Canadian Metalworking.
The Bilz ISG 1000 entry-level shrink fit unit.
manufacturer of clamping systems for high-performance tools. The process is simple. The bore diameter of the chuck is a little smaller than the tool shaft. An electromagnetic field is used to heat the chuck and expand the bore diameter before the tool is fitted. During cooling the holder shrinks clamping chuck and tool solidly together. It is a thermal expansion process; it’s important to avoid
www.canadianmetalworking.com | MAY 2013 | 43
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Tool Talk
Hardinge releases two new 5-face VMC’s
H
ardinge has announced the release of two all-new Bridgeport 5-Face (4+1) vertical machining centres – the GX 250 5F and GXR 320 5F. These new machine tools are designed for use in the OEM, aerospace, medical, electronic, defense, automotive and power generation industries, among others. Two machine sizes are available and come standard with a Fanuc 0i-D control for 4+1 machining.  The term 4+1 refers to the use of four simultaneous axes plus one axis that is used for positioning only. This 4+1 machining allows the part to be machined on 5 faces in one single set-up. The part remains in one fixture instead of being moved from one fixture or vise to another, reducing set-up time while improving accuracy. The GX 250 5F (4+1) with travels of 11.8-inch x 15.6-inch x 16.9-inch (X,Y,Z) provides fast rapid traverse of 1,181 inches per minute on X, Y and Z axes and features a powerful
20hp, 15,000-rpm direct-drive spindle motor with 70.4 ft-lbs of torque and a 30-tool swing-arm automatic tool changer. The larger GXR 320 5F (4+1) with travels of 20-inch x 24-inch x 20-inch (X,Y,Z) provides very fast rapid traverse of 1,693 inches per minute on X and Y axes and 1,417 inches per minute on the Z-axis. The machine also has a powerful 25hp, 12,000-rpm direct-drive spindle with 86.3 ft-lbs of torque and a 48-tool swing-arm automatic tool changer. The machining centres are designed with an optimum work envelope to machine small to medium parts. Both machines also come with features like a BIG-PLUS spindle, oil chiller, chip conveyor, coolant flush system, preparation for through spindle coolant (with rotary union), coolant wash down gun, tri-color stack light and other standard control features. www.hardinge.com
44 | MAY 2013 | www.canadianmetalworking.com
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Tool Talk
M
Makino announces online seminar lineup
akino has announced its line-up of online seminars that will take place throughout the spring and summer of 2013. Topics include a variety of new technologies and processing techniques for improved speed, accuracy and quality in die/mold and job-shop environments. “Advanced technologies and process engineering remain the strongest differentiators for success, for North American manufacturers,” said Mark Rentschler, marketing manager at Makino. “Our latest line-up in Makino’s webinar series promises to deliver on key insights and technologies that will support U.S. manufacturers in achieving the highest level of manufacturing efficiency possible. From zero stock machining techniques to competitive tips for improved spindle utilization, attendees will be equipped with the expertise necessary to overcome global competition.” Each online seminar consists of a 20- to 30-minute presentation and a live Q&A session with the speaker. Registration is required to attend, but all seminars are presented free of charge.
geometry, and cutting parameters. A review of appropriate tools for stainless steel applications is also on tap. ... continues on page 46
Cut
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M-Four M-Six Milling Cutters and
featuring double-sided, thick edge inserts and long lasting MEGACOAT NANO Grades for superior performance
The schedule includes the following:
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MAY 23 – Proper Tool Selection for Die/Mold Applications:
An overview of the latest tools available for different die and mold materials and applications. Special emphasis is going to be placed on differences in accuracy, coatings and tool life. Graphite milling applications in accuracy are to be highlighted. Milling tools for H13 and P20 tool steels are also going to be discussed, along with a special focus on hard-milling tool selection — including a discussion on specific coatings,
unchallenged Scan for complete Milling Kit Sale details
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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
www.canadianmetalworking.com | MAY 2013 | 45
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Tool Talk ... continues from page 45
set-up times. Learn about new tool and chip management features and how simple automation can dramatically improve flexibility and throughput.
JULY 11 – Die/Mold Process Training; Class Highlights:
This webinar shows the highlights from Makino’s week-long training class that gives operators and programmers the knowledge, and materials to make appropriate processing decisions surrounding tooling and programming part geometry in die and mold applications.
JUNE 13 – Productivity Improvements for Vertical Machining Centers in Job Shops:
Versatility and productivity are keys to successful jobshop operations. Learn about several easy-to-deploy improvements for vertical machining centres that can help increase spindle utilization and reduce changeover and
An April 11th seminar titled “Cutting to Zero Stock” has already taken place. However, all Makino online seminars are archived for later viewing at www.makino.com/library. Over 125 seminars are available covering topics such as micromachining, die/mold manufacturing, EDM, aerospace machining, automation and production machining. New seminars are added the week after they are initially broadcast. To see the full schedule or register to attend an event visit: www.makino.com/events CM
46 | MAY 2013 | www.canadianmetalworking.com
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Tool Talk Seco releases new cutting tool S
The X4 is offered in shank sizes of 0.63-inch, 0.75-inch and 1.00-inch, as well as Seco-Capto C4, C5 and C6. www.secotools.com
eco has introduced their X4, a new multi-edged, tangential tool for grooving and parting off of small components. The tool is available in cutting widths from 0.031-inch to 0.093-inch. It minimizes material consumption in parting off, and enables precise grooving and copying of small and medium-sized complex parts. To increase flexibility, each X4 insert type can be fastened to any X4 insert seat, allowing for reduction of tooling inventory. Depending on the cutting edge width, the tool’s maximum cutting depth ranges from 0.102-inch to 0.256-inch and can cut off maximum bar diameters from 0.205-inch to 0.512-inch. X4 inserts are available in neutral, right-hand angled and left-hand angled cutting edge options. Ideal for a wide variety of common workpiece materials, X4 uses CP500 and CP600 insert grades. CP600 features a mix of toughness and wear resistance suitable for most general applications, while CP500 provides increased wear resistance for more challenging cutting scenarios. Inserts with the MC chip-breaking geometry can be applied. This versatile geometry achieves excellent formation of comma and clock-spring chips in a variety of materials and uses astraight front edge line to guarantee a straight bottom within a SGS is proud to introduce a line of Composite solutions specific to groove. the unique qualities of machining this complex material. We know All X4 toolholders incorporate composites can be challenging and that’s why we Seco’s unique Jetstream Tooling designed new cutting tool technologies that provide Duo technology to further enhance the optimal combination of substrate, geometry, productivity, lengthen tool life and edge preparation, and our proprietary Di-NAMITE Solid Carbide Tools improve chip control. coating for maximum performance. By delivering coolant from two Delivering performance by design. Contact your local SGS distributor for details. outlets to optimum points in the cutting and heat zones, Jetstream Tooling Duo contributes to efficient www.sgstool.com | 330-686-5700 | Manufactured in the USA cooling, ideal chip formation and high part quality.
YOU ASKED FOR IT.
WE DELIVERED.
Composite cutting tools from SGS Tool Company.
www.canadianmetalworking.com | MAY 2013 | 47
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Tool Talk Walter releases new Titex solid carbide reamers
W
alter has released a new series of Titex reamers. The reamers are solid carbide and feature shank tolerance of h6 according to DIN 6535 HA. The new Titex product comes in two versions: The straight fluted F2162 for blind and through holes, which comes in sizes ranging from 4 to 20 mm in diameter, while the spiral fluted F2171 for through holes is available in sizes ranging from 2 up to 20mm diameter. Both versions have diameter tolerance for h7 hole size, and cutting geometry that features unequal division for best roundness and surface quality.
They are engineered for use on steel (ISO P), stainless steel (M), cast iron (K), aluminum (N), heat resistant alloys (S), and hardened steels (H), as well as composites and plastics (O). Common applications include the automotive, aircraft, energy and medical device industries, as well as general metalworking. The Titex reamers boost productivity by working equally well on machining centres with shrink fit and hydraulic chucks, and deliver reliable tool life due to their high run-out accuracy, enhancing process reliability. www.walter-tools.com
Come visit us at
Booth #1028
Tungaloy expands TungCut line Tungaloy has extended the their TungCut product line with new insert grades. The new toolholders and insert geometries are enhanced with a new T9125 CVD coated grade for machining steel at high speeds, a new AH905 PVD grade for machining superalloys and a new NS530 Cermet grade for delivering fine surface finishes when cutting steel. The multi-function grooving system that offers grooving, parting, traversing, profiling and undercutting has now been extended to offer a greater variety of standard items that can reduce tool changeover. The new CVD, PVD and Cermet coatings will now be available with all the existing insert designations and geometries to extend the capabilities and performance of the existing lines. www.tungaloyamerica.com
48 | MAY 2013 | www.canadianmetalworking.com
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The Business of Metalworking
Tool life: a smaller segment of partmaking cost than you think By Ronnie O’Byrne, General Manager, Iscar Tools Inc.
T
hrough its global operations and partnership cooperation with leading companies around the world, Iscar has identified that tooling costs in 95 per cent of machine shops it supplies, represent approximately 3 per cent (on average) of the total manufacturing costs. Since Iscar introduced their Matrix Tool Management Systems to their customers around the world the data collected has clearly identified the true cost of tooling and inserts for the manufacturing business they supply. With 3000 Matrix installs in over 50 countries across all market sectors from automotive, aerospace, oil & gas, medical and others the Matrix reporting system has clearly shown that the average expenditure on tooling is 3 per cent of the total cost to produce a part.
The answer? Very little! Everyone recognizes that it is important to ‘test’ the performance of tooling and inserts to ensure quality. But the next time you find yourself with a new insert or milling tool that provides a tool-life advantage to your business — the first task for your manufacturing team should be to redeploy the advantage into increased speeds and feeds to reduce cycle times. Here’s why: a 50 per cent improvement in tool-life will only reduce over cost of part manufacture - by 1.5 per cent (50 per cent of 3 per cent of tooling cost) The same applies to all those negotiations regarding price of tools and inserts supplied. Let’s say tomorrow you negotiated a deal with all your
This leads to a couple of important questions: If tooling and inserts only represent 3 per cent of the cost of part manufactured, what benefits are there in cutting tool companies providing 50 per cent improvement in tool-life? The second question is: what advantage is there for a manufacturing business securing a 20 per cent price reduction on tooling and inserts, and what would that do to the bottom line?
suppliers to get a 20 per cent price reduction on every tool and insert supplied for the next 12 months. The net effect is that you will only reduce your overall cost of manufacturing by 0.6 per cent (20 per cent of 3 per cent tooling costs) Any areas where you see improve tool-life should be redeployed to an improved production target. The real cost savings are achieved when businesses redeploy these advantages back into production.
50 | MAY 2013 | www.canadianmetalworking.com
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By increasing speeds, feeds, DOC and metal removal rates to improve cycle times is where real bottom line savings can be achieved. When tool life improvements are achieved the target should always be linked to reducing cycle times — to the extent that the tool-life and tooling costs remain the same and the tool-life advantage is used up through increased speeds and feeds to reduce cycle times.
All cutting tool suppliers understand that their customers need to ensure value in the market and that we compete all compete in a competitive global market. But the next time an engineer or operator testing a tool tells you it is a “good grade” or has achieved 30 per cent improvement in tool life. Ask yourself… What can I do with that? CM
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www.canadianmetalworking.com | MAY 2013 | 51
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Nothing Run-of-the-Mill Advanced features grow in new multi-axis equipment By Nate Hendley
H
ardmilling, multi-axis machining and automation are growing trends in the milling machine sector, say industry experts. “We’ve definitely seen an increase in the popularity of multi-axis machining, particularly 4-axis and 5-sided (3+2) machining as a means to reduce setups and increase accuracy ... advances in CAD/CAM systems have simplified programming of 5-axis machines,” says Bryan O’Fallon, product technical specialist, milling at Haas in Oxnard, California. “We have noticed a trend of companies wanting to do more and more hardmilling, for sure. I think there’s also a trend to want more automation. Most likely, this is due to the shortage of machinists in the market and wanting to stay competitive in the global market,” adds Joe Poulin, Canadian sales manager for Hurco, headquartered in Indianapolis, Indiana. “There is a distinct trend for North American manufacturers to invest in new, high-speed, high-precision technologies and automation to improve their throughput and quality,” adds Mark Rentschler, marketing manager
at the Mason, Ohio branch of Japanese firm Makino. Echoing his colleagues, Gisbert Ledvon, director of business development at the Lincolnshire, Illinois-based branch of Swiss firm GF AgieCharmilles, says milling machine customers are clamouring for more automation. So, what else are customers asking for? “With the increasing difficulty of finding skilled labour, many [customers] are interested in ways to simplify machine operations and also CNC control elements that make the recovery from an alarm or fault an easier process,” says Rentschler. “People are asking for the ability to do more with their machine, which could mean 5-axis, 4-axis, hardmilling, high-speed machining and being able to do heavy duty operations,” says Poulin. “I think it’s pretty universal that customers always want more capability for less money. They want to get the job done as quickly as possible but they want machines that are affordable and reliable,” adds O’Fallon. Here’s a look at what’s new and/or noteworthy in milling machines:
HURCO Hurco’s VMX50i 50-taper mill will make its Canadian debut at the Western Manufacturing Technology Show (WMTS) in Edmonton in June. This mill “has double-nut pre-tensioned ball screws anchored at both ends to increase accuracy and rigidity. The large linear rails are strategically spaced for increased strength and wedge locked to a machined shoulder to reduce vibration. The VMX50i is equipped with UltiMotion, Hurco’s patented motion control system, which simultaneously reduces cycle time up to 30 percent and improves surface finish quality. UltiMotion uses complex software algorithms for motion planning instead of conventional hardware, which means it optimizes look-ahead, up to 10,000 blocks,” reads Hurco literature. As with all other Hurco machine tools, the VMX50i boasts integrated Hurco control with standard ISO/EIA for NC programming. Later this year, Hurco will be releasing a 5-axis version of the DCX32 machining center. “The size of the machine and our control are the most notable features of the 5-axis DCX32. Our 5-axis control has multiple features that make 5-sided programming painless, which eliminates multiple setups for parts that were traditionally machined on a 3-axis machine. The sheer size of the 5-axis DCX32 is beneficial for customers manufacturing parts for the aerospace and energy sectors,” says Poulin. www.hurco.com 52 | MAY 2013 | www.canadianmetalworking.com
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MAKINO “In October 2012, we announced the F8 and F9 vertical machining centers. These are machining centers with several optional spindle and machine specifications that could be customized for either large part or large die/mould production. Most recently, Makino has brought the new N2 and N2-5XA machining platforms to market. These new horizontal machining centers are aimed at the medical production market, where floor space and productivity are critical concerns,” says Rentschler. The new F8 and F9 centers were introduced as part of an expansion of Makino’s F-Series of VMCs. The F8 is the smaller of the pair, with x, y, z-axis travels of 51.2 inches, 31.5 inches and 25.6 inches, a table that measures 61 inches by 31.5 inches and maximum workpiece size of 61 inches long x 31.5 inches wide x 21.7 tall. The F9, for its part, has x, y and z-axis travels coming in at 63 inches, 31.5 inches and 25.6 inches respectively. Its table is 72.8 inches by 31.5 inches, with a maximum workpiece size of 72.8 inches long by 31.5 inches wide by 21.7 inches tall. Both VCMs have a payload capacity of 5,510 pounds and boast a 30-tool automatic tool changer. “As an option the F8 and F9 can be equipped with a 40.2 hp, 20,000 rpm, HSK-A63 spindle. This configuration provides the vibration-free, chatter-free high-ranging spindle speeds required for efficient high-speed hardmilling of small details
and fine surface finishes typical of the die/mould market,” notes a Makino press release. As for standout features, Rentschler says, “the unique splashguard of the F8/F9 makes loading and unloading large parts much easier and quicker.” Makino also recently introduced N2 and N2-5XA CNC horizontal machining centers for high productivity in medical and small aluminum parts manufacturing. The machines take up a very small footprint (45.3 inches wide by 83.7 inches long by 84.6 inches tall—or 1,150 mm by 2,125 mm by 2,150 mm in metric). The 4-axis N2 has a 400 mm tall, 400-mm diameter cylindrical work envelope, with x, y and z-axis travels coming in at 300 mm by 230 mm and a 300mm diameter directdrive rotary table. The 5-axis N2-5XA has the same linear axes and features a twin, trunnion-style direct-drive A and B rotary axes for making complex, contoured parts. The N2-5XA can handle 300 mm cylindrical workpieces that are 270 mm high, weighing up to 66 pounds. Both machines have an HSK-40 spindle that can achieve 20,000 rpm and accelerate to full throttle in under a second. Coolant is provided directly to the cutting zone through four spindle nozzles for efficient cooling and enhanced part quality. www.makino.com
NAKAMURA-TOME Elliott Matsuura Canada has introduced the NTJ-100 Multitasking Turn/Mill Center from Japanese firm Nakamura-Tome. The center can be used for various applications in medical and aerospace manufacturing, job shops, etc. The NTJ-100 has x-axis and z-axis speeds of 787 ipm and 1,574 ipm respectively. The machine weighs 22,046 pounds (10,000 kg) with a small footprint coming in at 149.6 inches (3,799 mm) long and 78.7 inches (2,100) wide. It has a large tool capacity (54 tool stations for turning and 24 stations for milling). The NTJ-100 has two high rigidity turrets, both of which feature a y-axis of 3.5 inches (80 mm) on the upper and 2.6 inches (65 mm) on the lower, facilitating pinch turn and pinch mill operations. The machine also boasts two milling-tool motors that can manage 9.5/3 hp—double the performance of traditional multitasking centers. Designed with ease-of-operation in mind, the NTJ-100 has a large 19 inch, high-resolution touch screen LCD panel. A PC-based control called the Nakamura-Tome Intelligent Programming System (NT-IPS) is built into the turn/mill center. The NTJ-100 also comes standard with CAMplete TruePath Turn/Mill software which boasts an integrated suite of G-code editing, optimization, analysis and verification tools, which enable a wide range of turn/mill functions.
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Late last year, Methods also introduced the new D21 RoboDrill Vertical Machining Center from Japanese firm FANUC. This VMC comes in three models: D21-S (small), D21-M (medium) and D21-L (large) and boasts a 14 or 21-tool changer. The D21 offers torque to 56 ft-lbs, rigid tapping to 5,000 rpm (8,000 rpm optional), accelerations in x, y and z axes to 1.5 G, rapid traverses to 2,125 ipm, feed rates to 1,181 ipm (with an option for 2,362 ipm), high-speed reverse tapping, thread milling, etc. Spindles range from 10,000 to 24,000 rpm (with an optional spindle capable of 90,000 rpms). www.elliottmachinery.com
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Major League Machining Bob Wolcott came to metalworking with an interesting background — pitching for the Seattle Mariners ................................................................................................................................................................................................................
Bob Wolcott stands with his recently acquired Makino PS95 vertical machining centre
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sk Bob Wolcott what matters, and he’ll excitedly talk about his passion for doing jobs he finds interesting, challenging and rewarding; he has always followed that credo in his work. As the president and owner of Wolcott Design Services, he oversees the design, analysis and fabrication that his Newberg, Oregon, shop provides for racing, technology, outdoor equipment and other industries. From concept to creation, this small shop prides itself on having all of these capabilities under one roof — creating a fluid transition between design and production while offering increased part quality at a reduced cost and lead-time. This is Wolcott’s second start in what has been a
doubleheader career, where he started out as a Major League pitcher for the Seattle Mariners. After retiring from baseball, he studied mechanical engineering from Oregon State while working an internship at Intel. Running a milling machine initially began as a hobby for Wolcott, but he soon learned that the work he enjoyed doing on his manual machine could be the start of a lucrative business opportunity. He opened Wolcott Design Services while handling contract work for Intel. As the business began to grow, he found himself manufacturing the very parts he was designing — for customers like Gerber, PCC Structurals, Bridge City Tool Works and Rothsport Racing. Today the company has hit its stride making proto-
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type and production parts. Wolcott Design Services is small but competes easily with the larger shops. “For a small-size company like us to offer the kind of robust manufacturing capabilities and high-performance horizontal and vertical machining centres that you may not even see in some mid-size manufacturing facilities, it shows our dedication in emphasizing quality,” said Wolcott. ADDED CAPACITY PUTS WOLCOTT IN A LEAGUE OF ITS OWN Wolcott operates his shop on his own land, which means he has low overhead and routinely passes that cost saving along to his customers. The company had been using three vertical machining centres to produce its parts, but, as business grew, Wolcott found himself in a situation where he needed to add more capacity and flexibility without adding more floor space. “We needed more speed than our vertical machining centres could provide — faster processing, quicker changeovers and improved workflow management,” said Wolcott. “It was too time-consuming to take down a big production job in order to squeeze in a smaller prototype job. We knew that a horizontal machining centre could offer more parts per fixture, offline set-ups, higher-volume tool magazines and consolidated operations with multi-face machining. By employing these capabilities, we would be able to run production parts and prototypes in the same setup while preventing spindle downtime. Having that level of versatility was important to us, so we set out to find the right horizontal machining centre platform.” When evaluating machines, Wolcott looked at several brands before choosing the Makino a51nx horizontal machining centre for his operation. He valued the speed and precision of the a51nx and the added benefit of its 5-axis programming capability for more complex parts, if needed. As he had hoped, the company found that the a51nx provided all the features required to accomplish their production needs. “The 40-taper spindle is extremely rigid and robust, which has allowed us to expand our versatility and the
Unlike its previous VMCs, Wolcott’s a51nx allows operators to perform setup operations outside of the machine without interrupting the machining process
variety of parts that we produce. The 14,000-rpm spindle gives us the range of speed necessary to machine a variety of materials and features. Whether we are hogging out material or producing a pristine finish, the a51nx provides the power and torque we need to produce parts from start to finish in a single set-up,” Wolcott explained. Wolcott praises the casting design of the a51nx and its roller-type linear guides which allow it to conduct precision machining even on the far extremities of the X- and Y-axes. Its expanded axis travels over the original a51 can also accommodate larger parts. Because the machine can handle more parts per fixture and does not need frequent changeovers, it is always cutting. Its automatic pallet changer and highcapacity tool magazine helps Wolcott boost spindle utilization by loading parts and tools outside of the work zone without interrupting the machining process. The company has also improved its manual labor efficiency by allowing one person to operate both the a51nx and a neighboring vertical machining centre — a task that was not previously possible with two verticals. “We appreciate that we don’t have to interrupt the machining process on the a51nx,” said Wolcott. “We get up to 85 percent spindle utilization, allowing us to move lots of work through the machine. Producing batches of 10,000 parts is easy for us now — and, because of that, we are pursuing more high-volume jobs.” Since installing the horizontal machining, Wolcott has dramatically improved its throughput, enabling the company to shift its workload from mostly prototype machining to production jobs that it previously didn’t have capacity for with standard vertical machining centres. “When we first began to offer production capabilities, 80 percent of our business was in prototype parts,” said Wolcott. “Today none of that work has left the shop floor; however, prototype parts now only make up 30 percent of our business.” These new capabilities have enabled Wolcott to be more competitive when quoting new jobs. They now beat their overseas competition by up to 15 percent
Race car steering wheel quick release system
With its newfound machining flexibility, Wolcott is able perform more operations in a single setups, diversifying its tooling catalogue www.canadianmetalworking.com | MAY 2013 | 57
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PS95 vertical machining center producing steering wheel quick release component
Porsche Racing intake component
on price. In addition, being local means clients can physically come into the shop to have Wolcott create test parts on the fly. This has proven to be a valuable resource that has led to increased business. PRODUCTION MACHINING STRIKES OUT THE COMPETITION The success of the horizontal machine led to so much throughput that new jobs were rapidly entering the queue. As business grew, Wolcott needed additional investment to keep up with his success on larger part production runs. The company needed a cost-effective solution that would provide a much closer level of quality to that of the a51nx. What was necessary was another machine with the speed, rigidity and accuracy of the a51nx that would efficiently run in parallel to keep up. Besides having the ability to handle the increased production the company was experiencing, the machine had to be flexible enough to handle prototype work. Wolcott chose to replace one of his previous vertical machining centers with the Makino PS95. “Business is booming, and to meet these demands, we needed something economical that could take some of the load off of the a51nx, and that would produce the same parts quickly without any loss of quality,” said Wolcott. “The spindle is very similar in design to that of the a51nx, and it just blasts through the material with the rigidity we need.” The rigid construction, thermal stability and versatile 33.5-horsepower high-speed 14,000-rpm CAT spindle is ideal for achieving high-volumes of metal removal in wide variety of Wolcott’s applications. Its robust coolant system and scraper-style lift-up chip conveyor, efficiently remove chips from the workzone for improved production efficiency, accuracy and tool life. Wolcott ran a comparison between his current equipment and the PS95. On the first run, with no changes to the program, the new machine beat the existing machine by eight minutes. The next time the part was run, feeds and speeds were increased to an optimal level for the PS95, and the part was completed 30 minutes faster. On a separate part, Wolcott achieved
Prototype laptop case with finishes straight out of the PS95
metal removal rates that were four times faster than those accomplished on his previous machine. Besides enjoying the increased speeds, Wolcott has experienced improved quality — with repeatability as tight as 0.0001 inch on the PS95. Business is growing, and Wolcott’s customers appreciate the quality finishes that come off the PS95 without needing additional attention. When doing work on the previous vertical machining centres, the company had to manually polish the parts to achieve desired finishes — doubling cycle time. On the Makino machines, parts come out in half the time as on the previous machines and require minimal hand work. “Customers don’t believe me when I tell them that I haven’t touched the part, and it comes directly off the machine,” said Wolcott. “Truth is, some of the finest finishes are achieved without any polishing. One example is a laptop casing we are producing for Intel, which has a thin design and complex geometries. These typically require hours of post machining prep work before they are ready to paint or anodize, but when they are produced on the PS95 they are ready to go right off the machine — with no additional finishing. FUTURE PLANS In the next five years, Wolcott hopes to expand into another building on his property in order to allow for additional square footage for his business growth. Building on capacity, Wolcott intends to invest in automation by integrating a new machining cell with additional machining centers that can enable him to run a lights-out operation, carrying productivity into nights and weekends. In the meantime, Wolcott plans to continue to improve current processes, including fixturing and programming, and go after more production jobs. “Right now we have consistent workflow with occasional spikes in production when things get extremely busy,” said Wolcott. “As a company, we need to maintain the capacity to meet those demands. With the a51nx and the PS95 machines, we have the ability to take full advantage of those peaks, handling any work that comes our way.” CM www.wolcottdesignservices.com
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Old World Values, New World Technology Vending machine builder Fabcrest Metal Products makes customized production runs using modern equipment
Modern CAM-driven equipment allows Fabcrest to handle short runs as well as use short runs to deliver just in time inventory to major customers
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hen Fabian De Domenico arrived in Canada from Italy on Oct. 26, 1967, he had $20 in his pocket, a suitcase full of old clothes, and a dream. With him were his wife of two years, Maria, and his 1-year-old daughter Toni . A second daughter, Sandy, would be born shortly after the family arrived. The De Domenicos settled in a three-bedroom apartment. For a while, they had little but a roof over their heads. Furniture, for the struggling new immigrants, was a luxury for which they would have to wait. Young Fabian De Domenico was no stranger to hardship: In his short life, he had known nothing else. His father had already died when he was born in 1945,
in Villa Decani, a small town in what is now Slovenia, within walking distance of the Italian border. Too poor to afford shoes, Fabian went barefoot, dropped out of school to work at age 13, and lived for three years in a refugee camp with his mother, half-siblings, and stepfather. When he arrived in Canada in his early 20s, De Domenico was determined to provide a different life for his children. He had worked as a metalworker in a shipyard in Italy, and quickly found similar work in Canada. As his family grew to four children, De Domenico learned English, saved money and looked for an opportunity to start his own business. That opportun-
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ity came in the mid-1980s, when DeDomenico bought into a small manufacturer for $28,000, sold out 14 months later for $40,000, and used that capital to start his own company, Fabcrest Metal Products Inc. “When I started, I never believed I would be so successful,” De Domenico recalls. “In the beginning it was very hard. We didn’t have any money and we didn’t have any equipment.” One of De Domenico’s first investments was a welding machine purchased at an auction in Cambridge, Ontario, and transported back to the outskirts of Toronto, about 60 miles away. Shipping was prohibitively expensive, so De Domenico bought an 8-yearold GMC pickup truck for $500 to transport the welder. The beat-up brown pickup became Fabcrest’s first company vehicle. Often, in the early years, De Domenico worked until 3 a.m., went home to sleep, and was back in the metal shop by 6 a.m. Until his dream began turning a profit, most of the family’s income came from De Domenico’s second job – as a wedding photographer. As his customer base and work volume grew, De Domenico knew he needed faster, more automated equipment to keep up with the demand. Ever frugal and ingenious, Fabian first redesigned the machines he had to dramatically increase their productivity. He added a multiple punching tool to his punch press that could create many holes at once, and retrofitted his bending machines to perform multiple bends in one set-up. But soon, even the retrofitted machines couldn’t do enough to keep up with his workload. In 2001, the company moved from its original 6,000-square-foot workshop to a more modern, 50,000-squarefoot building a few miles away
STEVE DEDOMENICO ATOP ONE OF FABCREST’S MANY TRUMPF MACHINES, A TRUMATIC 5000R
Fabcrest is primarily a TRUMPF shop with 11 machines and Fabian’s son Steve De Domenico, who had been his father’s right-hand-man since age 17, was responsible for the choice of TRUMPF equipment. “Even though it’s more money, we’re getting a way better machine,” said Steve De Domenico, who says he was impressed with TRUMPF’s reputation for reliability and accuracy, as well as the “red carpet service” he received when he contacted the company. TRUMPF machines that Fabcrest uses include a TC2020 Punch (TruPunch 2020), TC5000 Automated Punch with Sheetmaster (TruPunch 5000), TrumaBend V130 (TruBend 5130) (x2), TrumaBend V85S (TruBend 5085), TruBend 7036, TruBend 5170, TruBend 5230 and a TruLaser 2030 with automation. “TRUMPF made me grow, to be honest,” Fabian De Domenico said. “(We have) no headaches, no rejects, no problems.”
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Above: Fabian De Domenico, founder, Fabcrest Metal Products Inc. Inset: By using both modern punching, laser cutting and forming technology, complex parts can run profitably at almost any volume. Fabcrest now owns nine TRUMPF machines – and say the speed, accuracy, reliability and high-tech efficiency have allowed the company to keep prices low while creating top-quality products.
Fabcrest innovation “made a difference” to Willie Moskowitz, the president of Toronto-based WD Vending Systems Inc., who had been “tortured” by a previous vending machine manufacturer before turning to Fabcrest for help in 2008. The previous vending machine supplier, Moskowitz said, had been unable to correct problems with inconsistent and poor-quality parts, slow turnaround time, and machines that were damaged in transit. When he reached out to Fabcrest, the company redesigned the machines to ship better and operate more smoothly, and took care of every step of the manufacturing process, from drawing up plans
to transporting the vending machines to their final destination. The changes helped turn his small home business into a $7.5 million revenue-maker in a year, Moskowitz says. Fabcrest was able to increase output from 200 to 2,000 machines a month and of the 15,000 vending machines Fabcrest has built, not one has had a defect, according to Fabcrest and Moskowitz. “They take on a project and they deliver what they say they are going to,” Moskowitz said of Fabcrest. “They take you in almost like a family member in terms of delivering a product to you.” Today, 26 years after it was founded, Fabcrest is a thriving company with 34 employees and hundreds of loyal clients. But it remains a family affair – top management is composed of Fabian, the president
and founder; his daughters, controller Toni (De Domenico) Domini, and Director of Sales and Marketing Sandy De Domenico-Carless; and Steve, who is the company’s director of operations. (De Domenico’s fourth child, daughter Susy, worked as an office administrator until recently when she left the company to pursue a career as a chef). The secret to Fabcrest’s success, the family and customers say, lies in a harmonious balance of human intelligence and machine intelligence; the new and the time-tested; automation and individualized; reallive-person service. “The puzzle came together by working with the customers and working with the good technology,” Fabian De Domenico said. “Without the technology, I wouldn’t be able to be like this.” CM Courtesy Trumpf Inc. www.us.trumpf.com
62 | MAY 2013 | www.canadianmetalworking.com
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Robert Muru, President, A-Line Precision Tool
A-Plus Learning at A-Line Machine A Toronto-based machine shop with a unique approach to CAM
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ntil 2006, the manufacturing workflow at A-Line Precision Tool, a Toronto defense and aerospace machine shop, was organized along traditional lines. One skilled “master programmer” per cell wrote all of the CNC manufacturing programs in Mastercam and exported to the CNC equipment where operators with little CAM experience would run them as per instructions set out for them. With only one person doing the programming, there is a clear chain of command and a pretty good control of the process, particularly the sophisticated 5-axis work. It also seemed like the most cost effective solution to programming requirements — one seat of software, one computer, and one programmer. It seemed reasonable, the logical way to set up a shop, and looking around, the way most shops appeared to be operating. But there is a down side to that philosophy. When there is one programmer, he usually doesn’t want to show anyone
else. It becomes a turf issue more than a programming function. As a case in point, about six years ago, one of ALine’s cell programmers had a request for Rob. He wanted Rob to tell its largest military customer to space out work more evenly so he could keep up. The programming and set-up work arrived in up and down cycles. Unfortunately the idea of teaching someone, even simple programming on “his” computer and set-up to do the simpler jobs, was categorically rejected as a way of helping solve the issue. Of course, the employee’s request was ridiculous. “We had the wrong environment and the wrong organizational structure,” said Muru. “The system we had ran its course and the time had come to go in a different direction. Guys wanted to learn. I wanted to teach them. I wanted to speed thngs up. The current system we had for programming/setup/organization was showing itself daily to be obsolete. It was almost on the verge of costing us business.”
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HISTORY Rob Muru inherited the business from his father, Ilmar Muru, an Estonian immigrant who opened a small tool and die shop in 1964. The staff included his mom, Marie, a couple of machinists, and Rob. Rob started working part time in the shop young, about 14 years-old. After high school, he went to the University of Western Ontario and earned a degree in finance in 1981. After that, he pursued formal training in tool and die making, metallurgy, and welding (as well as doing a stint on Canada’s National and America’s Cup sailing team). When his father retired in the mid 1980s, the shop was outdated and still had all manual milling and lathe machines. Muru convinced his dad to buy a digital readout for an ELO mill but that was it. The shop was prime for updating. “By some miracle, I landed some F18 military jet engine work. We started upgrading with CNC equipment, and gave it the current name.” A-Line was officially established. That strategy worked well, and the business grew into a 30-person boutique manufacturing operation, making small to medium production runs with quanities usually no more than 25 to 30 parts. The company attracted demanding customers in aerospace, defense, and satellite work. As a result, A-Line had to be very adept at turning small volumes around very quickly, with almost no deviations. THE TURNAROUND Muru made a 180° turn and decided that anyone who wanted training in Haas machines or Mastercam programming should get it. He bought more Mastercam seats and more computers. He even bought a smaller Haas mill with no toolchanger that he could use for training. He also bought the smallest Haas lathe, a GT 10 for CNC lathe training. Muru found out who was offering training and made incentive plans for employees to get the training.
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Chad, Senior Programmer: A graduate of George Brown College Tool and Die making as well as having in plant training on solid modeling and 5 axis programming by our local Mastercam reseller In-House solutions.
905-954-0466 www.canadianmetalworking.com | MAY 2013 | 65
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Andrew, Senior Lathe Programmer: He has completed the Mastercam course at the local Sheridan College, plus On-Line Mastercam University training in CNC programming, design and toolpath generation.
“Then there is the cost,” Muru said. “The traditional thinking was, if I have one seat of Mastercam 5-axis, why would I need another that will add up to thousands of dollars worth of additional software and computer hardware costs? Who has that kind of money to blow?” So A-Line, like most medium sized machine shops, ended up with one programmer. But there are costs associated with the “one programmer” system as well. A-Line found three main costs associated with “single programmer” systems. FIRST COST: excessive overtime. “For example,” said Muru, “let’s say you have one big weekend of overtime for your (single) programmer for a rush job. That may cost close to a thousand dollars. These days, that’s close to paying for most of the hardware. Multiple programming seats, applied correctly, save on overtime.” SECOND COST: time for first chip. A lot of companies, and A-Line was one, focused heavily on delivery dates. They circled the dates, highlighted the dates, yet it did not seem to help for half the jobs. By the time the delivery date appeared
on the radar screen, with two weeks to deliver, said Muru, it was late. ALine had to look at jobs differently, and Muru came up with “time to make the first chip” to avoid working backwards from a hypothetical date, which is reactive. He and his team now think and work proactively. “For instance,” said Muru, “you have three rush jobs, and your programmer is working on one at a time, you delay time for first chip. And that’s a killer. All of a sudden, its no rush to
get the material in house. Then its no rush for tooling. Everything slows down and you are back to swimming in your cesspool of molasses because your programmer can’t start until next week. Someone wants something, and you have to start working on it right away. If you have multiple programmers, you give it to somebody and get started!” THIRD COST: (and the biggest) the human cost. Muru learned that with one seat of software per cell, and one programmer, meant anyone working in that cell did not learn or grow. “After a year or so, you have a disgruntled employee on your hands. That’s no fun. And it’s not even so much that they learn and grow, because everyone is different and has unique abilities and situations, it’s that you provide the opportunity to grow that’s important. People recognize that and appreciate it. Likewise, if you have an employee who does not appreciate that concept, they may very well be happier somewhere else.” As an owner, with single seat hierarchies, Muru actually found himself begging to get jobs programmed. “When you are asking for jobs to be programmed and saying ‘please’, and the response is ‘I will
Tony-- Haas Setup and Lathe Programmer: A graduate of Seneca College Tool and Die as well as CNC programming at Seneca, and On-line training at Mastercam University.
66 | MAY 2013 | www.canadianmetalworking.com
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try’, it’s time to think and work differently. This is not a birthday party over here and you are not asking for a piece of cake.” When looking at the big dollar picture, it struck Muru that he had over 4 million dollars worth of CNC equipment on the floor, was shopping for more, and he thought, “Why are we bickering over the price of a
PC and programming software?” He bought the hardware and Mastercam seats he needed. MANY WAYS TO TRAIN A USER With a multiple programmer and computer mandate in force, Muru began exploring every possible avenue that could lead his workers to get training, including:
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Tim-- Haas Setup and Programmer: He has completed George Brown College, Tool and Die program, Mastercam University, for programming as well as Mastertask on-line training for Haas lathe setup.
MASTERCAM UNIVERSITY: This is among Muru’s favorites. Students watch the videos on-line, do handson practical programming assignments, and take an exam at the end to certify their proficiency. If the student pays for the course himself, A-Line returns the investment to the student along with a $100 bonus check as long as he scores 80% or better. Muru noted that some people don’t have enough money to pay for the course. If the operator is serious, A-line will pay for it in advance, however the student won’t get the bonus when he passes. NEW RELEASE OVERVIEWS: Mas tercam University also creates overview courses that become available with new product releases. Users can attend these free-of-charge, to learn about what new product features are available and how to use them. COMMUNITY COLLEGE COURSES: A-Line encourages students to take these courses. In fact, when new courses are announced, the company puts notices in the employee’s pay envelope to make sure they know that an educational opportunity is available. CD COURSES: About five employees paid $25 to purchase a “How
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to Mill Course” on CD. That was ter what level an employee enters half the purchase price of the CD. the company. Many people who A-Line paid the other half. Muru do not work routinely in the shop believes that when students invest have taken advantage of training a little money of their own in a low opportunities. There was even a cost training opportunity, they case where one of A-Line’s securare more likely to spend the time ity staffers expressed interest in required to learn as much as they Mastercam programming. Muru can from it. signed him up. He is now doing Pre-Employment Course Work: machining in addition to the reguRecently, A-Line decided to hire a lar security duties! new employee out of high school and it required taking and passing SIX YEARS LATER an online Haas CNC milling course In 2006, A-Line had one CNC pro(Master Task) as a precondition of grammer per shop cell, Muru was employment. A-Line paid for the begging to get jobs on the machine course and the student demonand started, and at least half the strated her earnest desire to bejobs would work their way into the Robert Muru, President, A-Line Precision Tool come a CNC machinist by passing “late” or “rush” category. Today, it. This hire has worked out well. However, Muru believes the company has multiple 5-axis systems and four fulltime programmers capable of generating Mastercam that even if the student had failed the course, the investprograms for milling alone. There are also two full-time ment would have been worthwhile by eliminating the lathe programmers and many other operators who have risk of hiring someone who was not going to contribute. taken advantage of training opportunities and are workRESELLER TRAINING: A-Line has sent employees to ing to improve their skills and career paths. A negative training courses at In-House Solutions for Mastercam hierarchal system based on limiting people’s knowledge training and also at Sirco, their local Haas dealer, for has been replaced by an overall positive approach to CNC machining . When a new release of Mastercam is issued, A-Line will see who is available to go to the new programming solutions. product training, depending on their workload. These The approach is paying off. Recently A-Line was are valuable opportunities to learn about new product awarded a defense manufacturing contract for a large features that will improve productivity. family of parts that had to be delivered in a very short ON-SITE TRAINING: A-Line’s Maintenance license entime. There would be no way that this could be done titles the company to a number of days of on-site training using just a couple of programmers. A-Line divided the by technical experts from In-House Solutions. The comwork among its four 5-axis manufacturing cells and two pany tries to couple these sessions with new business CNC lathe cells, and put all six high-level programmers opportunities. Recently In-House Solutions conducted to work programming the process while others in the week long 5-axis Mastercam training centered on a new shop handled more routine programming tasks. This project A-Line was about to launch for a customer. The project, which would not have been possible a couple programmers who could attend make substantial gains years ago, was accomplished smoothly. This is just one in 5-axis programming proficiency, and by the time the example of the flexibility A-Line enjoys for assigning difweek was over, complex 5-axis programs had been writferent cells and programmers matching cell workloads ten for producing first pieces for the new project. and programmer availability. TEACHING EACH OTHER AND SELF-INSTRUCTION: Muru estimates that 70-80% of his workforce has The new culture at A-Line fosters employees helping taken advantage of his company’s open learning environment. He thinks that employees are better motivemployees learn all the tips and tricks to improve their ated when they know that the door is open to continued skill levels. Programmers help each other out or work learning and advancement. It is also motivational to as teams to handle new programming challenges. know that 20% of the company’s pre-tax profit will be CROSS TRAINING: A-Line places a high value on perawarded as bonuses and that the company’s pay scale sonnel flexibility, so the lathe operators are encouraged is above average for similar shops in the Toronto marto take courses in mill, and mill operators to take lathe ket. This year, A-Line Precision Tool will be expanding courses. into a new facility. CM Muru said he wants to create an atmosphere in which there are no barriers to advancement, no matCourtesy Mastercam/CNC Software www.mastercam.com www.canadianmetalworking.com | MAY 2013 | 69
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Safe and Secure Access Security builds vaults and safes for banks, governments or individuals ... and they’re more complex than you might think By Jim Anderton, Editor
I
n an unassuming, almost anonymous 60,000 square foot manufacturing facility in Oakville, Ontario, Peter Gauthier is part of a 40-strong team that builds strong boxes. Not just any boxes, but the safes seen in banks everywhere and the massive vaults as well. Access Security Products was founded by Gauthier in 1992 and now builds secure storage for a list of essentially anyone who needs to protect valuables, from pawnshops to the Canadian Government. “I was a safecracker”, declares Gauthier, noting that he plied his trade on the right side of the law. “I started as a locksmith and always had an interest in safes; I did an apprenticeship and focused on safes and vaults. I decided on manufacturing to take the skills that I learned opening and servicing safes and vaults and use it to stop guys like me.” The immediate impression of the facility is that of space. Although Access builds several standard models, the firm also builds to order, including some truly massive vaults. “The biggest weighed 1,500,000 pounds” says Gauthier, noting that it was for a major pharmaceutical firm that required secure storage for regulatory reasons. “It took 17 trailer loads to deliver.” BIG PARTS, THIN GAUGE Projects that big need space and the wide aisles and ample handling room make it easy to swing large sheets by overhead crane or forklift. Overhead gantry cranes are rated at 3 tons, surprisingly small for assemblies that ship with weights that can easily exceed a dozen tons. The reason is simple: the metal used in the construction of vaults is surprisingly thin “The thickest we handle is 12 gauge” says Gautier. The design in fact is double wall, with a thin inner and outer steel skin filled with a proprietary concrete-like matrix-binder-filler material that provides a real disincentive to thieves. Contrary to Hollywood, drilling or burning through the thin outer case won’t get the criminal very far, and the special core mix blunts even carbide drills almost instantly. The multiple components in the “concrete” are a trade secret, for obvious reasons, and make penetration of one of the Access
Peter Gauthier, president, Access Security Ltd.
units a lengthy process. Keeping the exact technology secret is essential to security, and conventional ISOstyle certification would involve divulging important information, says Gauthier “If we were to go ISO and document our processes, I think we would open up issues; our customer base respects the secrecy around our product.” The answer for Access was to go with UL certification of the finished design, he states: “All out product is UL-rated; the only people who know how our product is built is the test team.” UL testing involves professionals like Gauthier himself attacking the safe or vault and measuring the time to break in. The rating
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When you need dependable tooling solutions designed to solve your toughest fabrication challenges, turn to Wilson Tool Canada. For 45 years you’ve known us as Exacta Precision and Exacta Fabtool. As Wilson Tool Canada we’ll continue to offer all the standard and custom tooling solutions you’ve come to rely on, plus the Wilson Tool line of tooling with shorter lead times and reduced shipping costs. Whatever your tooling needs, choose Wilson Tool Canada. Call 800.268.5573 for stamping or punch press tooling. Call 800.268.4180 for press brake tooling. Or visit www.wilsontool.com today.
C A N A D A
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outside parties trying to access our information. We do R&D, fabricate and finish in house, so no one knows what’s inside the product.” The relatively thin metal shell of Access products means that they can be fabricated using conventional techniques and tools. In large equipment, Access uses Haco turret punches and has purchased a new LVD Strippit PPEB brake that has significantly improved productivity.
ABOUT PPEB SERIES PRESS BRAKES Access Security’s new bender is one LVD Strippit’s PPEB series models, and is capable of highly automated production. Bending sequences can be automatically determined from the user-drawn 2D part created with a simple-to-use graphics editor. All axes of the press brake, including the CNC crowning system, are calculated by the control and are automatically positioned for optimum bending results. 2D & 3D color graphics simulate part creation and display material handling sequencing for optimum part production. Access Security’s model 135/40 has a rigid frame design utilizing a welded one-piece frame, machined without repositioning, guaranteeing machine precision. Hydraulic cylinders are machined from a solid steel billet, and pistons are steel forgings, precision ground and micro-polished for long service. Access Security uses an LVD Strippit PPEB 135-ton 40 foot 8-axis press brake equipped with CNC sheet supports. The CNC support feature allows Access to handle notoriously difficult to bend large form thin sheet with far less manual labour than fixed stop technology.
system is really a time index and explains why the walls are not simply thick steel; no one tool is sufficient to break through. IN-HOUSE METAL SHAPING The wide variety of product Access makes combined with short production runs mean that Access cuts
metal to shape in-house: sheared blanks aren’t cost effective. Trade secrecy also means that the entire process is done in-house including finishing. “We like to keep the nature of our business controlled”, says Gauthier, adding “by keeping it in house we can control quality and also keep the processes away from
AUTOMATION ADDS JOBS Welding is by resistance and MIG processes and includes a PerformArc automated welding cell. With bending debottlenecked, Gauthier is preparing for another automation move: “The next important upgrade that we’ll deal with is our punching operation”, he says. “We’ve been considering punching and laser systems. Our product lends itself to punching. The machines are about the same price range. The punching process will allow us to go lights out, loading sheets and forget about it. Laser may be in our future as a next step.” Like most successful Canadian manufacturers, Gauthier notes that the automation didn’t result in layoffs, but instead improved productivity, which is at a level where Access can compete with offshore products from low-wage countries. “We automate wherever possible and reduce costs wherever we can. Manufacturing is alive in Canada. It’s about quick delivery of custom products in configurations difficult for offshore producers to build. In our industry, when there’s a problem they need the product now. For instance, if a jewelry store
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T Mixed in what is essentially an in-house concrete plant, a proprietary barrier filler is cast into the walls of Access safes and vaults
Access caries inventory of popular models of safes; when a customer is attacked, they demand fast delivery.
The best press alternative on the market for unitized tools and small die sets. MULTICYL INC
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Ready to ship. Wall segments in the background are as heavy as concrete slabs
with a million dollars’ worth of inventory is attacked, even an unsuccessful attack, they need product right now. We can operate with short or even no lead times. We inventory product for that customer base. It gives us an edge over offshore competition.” Growth, however has caused Access security to face a familiar problem: finding skilled help. “We cross train, and spend a lot of money on training internally. We like to grow our own workforce. Our employees are long–term. Either you like this business, including myself and our office and engineering staff, or you don’t stay. It’s different all the time.” The solution? Gauthtier believes that access to training will help. “Let young people know that manufacturing is not a blue collar job in the traditional sense. There’s money to be made; our workers are well paid with great benefits.” With a smooth-running operation that ships globally in the face of offshore competition, Peter Gauthier is not surprisingly bullish on the future of Canadian manufacturing. “I think that there will be some people that disappear and there will be companies that grow. There are opportunities out there. It’s not a downward spiral; we just need to adapt to the changing conditions and find the opportunities.” CM
L
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TAKE THE LEAD in bending productivity with ToolCell
LVD leads the way in revolutionary bending automation technology with the introduction of ToolCell. This unique press brake system will give you a leading edge in bending productivity with its integrated automated tool changing system that maximizes bending throughput. Learn more about the fast, easy-to-use, extremely reliable ToolCell by visiting us online at www.lvdgroup.com/toolcell/us or calling 800-828-1527.
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Cutting Edge Victor’s new oxy-fuel torch uses improved ergonomics
V
ictor has launched its new 400 Series of oxy-fuel torches. The 400 series is a two-piece torch with a new handle and cutting attachment design that offer better ergonomics, a clearer view of the cutting path, and visual cues for easier use and enhanced safety. The new torch is available in medium- and heavy-duty models and also sold as part of the Medalist 250 and Medalist 350 outfits. The contoured handle has a size and shape that fits naturally in most operators’ hands. The handle uses an engineered zinc-aluminum alloy called Zamak that has three times its tensile strength of brass, so it better resists deformation. The handle is lighter than brass, yet it balances naturally when hoses and attachments are connected. To simplify use, Victor colour-coded and labeled the oxygen and fuel valves for instant identification and easier operation by indicating directions for open and closed valve positions. John Henderson, Group Brand Manager, Victor Technologies, says “The 400 Series torch provides operators with the visual acuity necessary for safe and effective oxy-fuel cutting, even if English isn’t their first language.” Henderson notes that design changes to simplify
use help companies cope with the retirement of skilled operators and need to hire younger, less-skilled workers or workers who speak English as a second language. The durability of the torch handle also improves longevity in situations where tools receive rough treatment, a feature specifically requested by the supervisors interviewed during product development. The 400 Series cutting attachment provides excellent line-of-sight visibility. Victor accomplished this by departing from its traditional tube-in-tube design to a sleeker three-tube design (oxy-fuel cutting requires three tubes, one each for fuel gas, pre-heat oxygen and cutting oxygen). “Our new tube design optimizes cutting area visibility while providing strength and supporting gas flow rate requirements for tip sizes 000 through 6,” says Henderson. The 400 Series uses a universal mixer design and mixes the gases in the head of the torch. Like all Victor torches, it enables operators to use one torch for all fuels (acetylene, propylene, propane, etc.) simply by selecting the correct tips or attachments. The 400 Series is compatible with current 300 series consumables and accessories. CM
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Cutting Edge Universal Robots offer models with unique force control D
anish robot manufacturer Universal Robots has introduced force control as an integrated part of its software. The company’s force control feature lets robots operate with an additional force component allowing for more complex automation processes. The feature could be particularly useful for buffing or polishing applications. “Advanced force control is a unique feature for this type of collaborative robot. We can now automate manual tasks previously not possible due to the exact amount of force exertion needed in the application,” said Ed Mullen, National Sales Manager in North America. Two of the company’s models, the UR5 and UR10 are designed for companies that believed robots to be too difficult to integrate in their existing production. The lightweight robots can work alongside personnel
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and don’t require safety shielding in 80 per cent of installations. They can be easily moved around production areas and have a plug-and-play feature; a simple user interface lets employees with no previous programing experience quickly set-up and operate them. “A key selling point of our robots is that they are continuously upgraded”, said Kristian Hulgard, UK and Nordics Sales Manager. “Once purchased, our users can expect a steady stream of software upgrades giving them access to all the new features on the latest robots to leave the factory.” The robots are not like others because they don’t use sensor technology, instead they use patented technology to measure electrical current in the joints to determine force and movement. This feature actually reduces the price point of the robot. “Small and medium-sized companies demand a fast return on investment. Besides the robot’s low initial cost, it operates very cost efficiently and is profitable in only six to eight months,” says Hulgard. The six-axis robot arms can easily be implemented in many industries; from a small CNC lathe production to large automobile assembly lines. If the robots come into contact with an employee, the robot will automatically stop operating. The force delivered
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Cutting Edge
The robots will automatically stop if they come into contact with workers.
The robots can work well across many industries , including automotive assembly lines.
in the collision does not cause bodily harm, adhering to the current safety requirements on force and torque limitations. Tools used by the robot and other unique factors of each application should be incorporated in a full risk assessment for every installation before deciding if safety guarding is necessary or not.
The UR5 and UR10 are named after their respective payload in kilos (11 lbs for UR5 and 22 lbs for UR10). The UR5 robotic arm was labelled “The world’s most innovative robot” by The International Federation of Robotics and IEEE Robotics and Automation Society in 2012. CM
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Cutting Edge Messer introduces new cutting machine
Right: The 65HP drill with a 24-tool changer is capable of drilling four-inch diameter holes.
M
esser Cutting Systems has introduced the largest machine in their line, the TMC4500 DB. The TMC is heavy-duty dual box-beam constructed gantry cutting machine. The dual beam design is supported by large, 10-foot end trucks for greater stability. The design allows for the placement of process tools on both beams. In applications requiring a large variety of tools, the cross axis beams grows in width to accommodate the coverage of each process. It allows for a narrower footprint by utilizing both front and rear beams necessary to fit within limited workspaces. Additionally, the dual beam design is a strong enough to support Messer’s 65HP drill with a 24-tool changer, capable of drilling four-inch diameters holes. The
TMC4500 DB can support all of Messer’s process tools including precision bevel and straight plasma, laser, oxy-fuel cutting, marking, grinding. “The marketplace now is demanding this larger more productive machinery and we anticipate an excellent welcome with the new TMC4500 DB”, says Joerg Toberna, marketing manager with the company. Messer Cutting Systems is headquartered in Menomonee Falls, Wisconsin. Their machines use advanced plasma, oxy-fuel, drills, and laser cutting tools to cut shapes from mild steel, aluminum, and stainless steel plate. They have sales and service offices in the United States, Canada and Mexico. For more information, go to: www.messer-cs.com CM
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Cutting Edge Brantford’s Patriot Forge gets large-scale retrofit E
rie Press Systems has engineered and installed a complete retrofit open die frame structure at Patriot Forge in Brantford, Ontario. The project required replacing the existing 1,250-tonne Bliss press frame and designing a new structure that would be the same height, space, and sit on the same foundation while increasing its capacity to 1,650 tonnes. The new frame consisted of a base, crown, two columns and pretensioned tie rods. Also supplied were lower die lock components, redesigned gibs and wedges, gland flange, adapter plate, and guide fences. Patriot will forge standard carbon, stainless and alloy grade ingots, billets and bars weighing up to 40,000 lbs. in the new press. Henry Hendriks, Manager, Engineering and Maintenance, Patriot Forge Company said, “The finished press is rock solid and integrates with all of our existing components including the mounting of the existing die slide and magazine.” This press will produce forged step shafts, hubs and disks, seamless rolled rings, pot die products, gear blanks and steam turbine rotors. The new press capacity will also expand Partiot’s capabilities in industries such as power generation, oil and gas, nuclear, petrochemical, industrial equipment, aerospace, military, and commercial markets. Erie Press Systems are an engineering and manufacturing supplier of custom hydraulic and mechanical presses and integrated systems for open and closed die forging applications with capacities from 500 to 15,000 tonnes www.eriepress.com
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Welding News OVERCOMING OVERHEATING, FLASHBACK AND BURN BACK
With precision-machined parts to insure maximum performance and long lasting heat and flashback resistance, American Torch Tip’s Duramix design reduces the risk of overheating, flashback, and mixer burnout. It offers maximum resistance to all types of adverse conditions, improper settings and heavy reflective heat applications. The torches offer high performance with all fuel gas types by simply selecting the proper tip for the selected fuel gas. They feature forged brass torch body and head, stainless steel tubes and cutting oxygen lever, brass coupling nut & double O ring seal for quick gas tight seal and are all leak and/or flashback tested. Critical mixer components are designed to insure maximum performance, durability, and the proper mix of gases needed to generate maximum pre-heat flame and cutting. www.americantorchtip.com
ENGINE-DRIVEN WELDER/GENERATORS REDUCE FUEL USE AND SOUND
The Miller Trailblazer 275 and Trailblazer 325 are built for general construction, structural steel, maintenance and repair, mobile fabrication, and farm and ranch applications. They offer a number of technologies designed to reduce fuel use by as much as 35 per cent, extend runtimes by 50 per cent, reduce noise by 68 per cent. This new series provides a smaller and lighter footprint for ease of mobility and more space on work trucks. The Smart-Cor technology provides independent weld and generator power, ensuring no interaction between the welding arc and jobsite tools such as grinders and chop saws. Welder/generators without this capability can cause fluctuations in the welding arc when a load is simultaneously applied to the generator, creating an erratic arc. Auto-Speed technology automatically adjusts the engine speed to run at lower speeds determined by the load applied to the machine. This significantly lowers fuel use and cost, and helps reduce noise in the work area rather than having a machine constantly running at full speed. www.millerwelds.com
OFFSHORE SUBMERGED ARC FLUX
Designed for offshore welding and NACE applications, Lincolnweld 812SRC submerged arc flux is a carbon-neutral flux created for applications requiring high strength after extensive post-weld heat treatment of up to 30 hours. The carbon-neutral design provides excellent mechanical properties after extended stress-relief. It has low H4 diffusible hydrogen levels and features smooth bead appearance and excellent slag release. A low alloy solid electrode, like the Lincolnweld LA-84 wire, is recommended, as it will produce weldments with hardness values below 250 Hv10 and less than one per cent nickel. This SAW flux is available in a 50 lb. (22.7 kg) plastic bag. www.lincolnelectric.com
TRAIN TO WELD 18-INCH JOINTS
RealWeld Systems Inc. has developed a weld trainer is designed to record and score welding technique while performing real arc-on welds. The system uses motion capture to track five critical torch motions while performing actual welds with your own welding equipment. It has been enhanced to allow for testing eighteen-inch weld joints. This new capability aligns the system to AWS B2 specifications. www.realweldsystems.com
AR1
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Using Pulsed MIG can result in general improvements in weld quality compared to conventional MIG and welding speed compared to TIG.
Welding Light Alloy Aluminium doesn’t have to be difficult, but it takes knowledge and skill By Nestor Gula
A
lthough metals are divided into ferrous and nonferrous metals, the non-ferrous metals are unique and have very different properties that necessitate individual welding techniques. When talking about welding non-ferrous metals most people think aluminum. The most important thing about welding aluminum is knowing what you’re welding. “Identifying the base alloy is important,” said Tony Anderson, the Director of Aluminum Welding Technology for ITW North America, the parent company of Miller Electric Mfg. Co. “There are hundreds of different types of aluminum some are weldable and others are not.” There are eight different alloys families and each of these families has a family designator. “Alloy selection is also critical as some aluminum alloys do not mix well with others such as combining 4XXX and 5XXX series alloys,” said Thom Burns, Technical Services Director for AlcoTec Wire Corporation. “Often there are several choices for welding aluminum where the application dictates the proper filler needed. Some of these characteristics of fillers for applications include; Weld Strength, Ductility, Freedom from Hot Cracking, High Service Temperature (above 150 F), and whether the material is to be anodized. Choosing the right filler material for welding is critical according to Frank Armao, the Director of Aluminum Welding Technology at Lincoln Electric. “ You need different
filler material. It is a chemistry thing.” The compounds in the filler material alloys must complement the compounds in the base material. Using the wrong filler material with the wrong base material will lead to problems of hot cracking, because of the mismatch of the chemistries. CLEAN IT WELL Cleaning the aluminum is critical to obtaining a highquality weld. Unlike the simple wire brushing that suffices as prep for mild steel, aluminum must be degreased first. “The cleaning is always done in two steps,” said Anderson. “Degreasing is done with a solvent. You can use any degreasing agent to remove any trace of hydrocarbon from the surface, like oil, grease or paint.” . The second step is wire brushing with a stainless steel brush. “The reason you don’t brush first is that if there was grease on the surface you would just work it into the base material,” said Anderson. One of the primary reasons to clean is to remove the thin layer of aluminum oxide that coats all aluminum pieces. “All aluminum has a thin oxide coating on it that appears immediately on it once it is exposed to air. You can’t prevent it,” said Armao. “If you take it off it will reform again. Aluminum oxide is a thermal insulator, an electrical insulator and an abrasive.” Aluminum oxide can absorb moisture and become hydrated and this produces porosity in the weld. If you have aluminum
The high plas of cu
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specifications that if you clean the material and do not weld within 8 hours you must reclean the material. For most applications this is not necessary.”
Victor Technologies district manager Tim Taylor (at left) explains how to set the frequency and balance control on this AC/TIG TIG inverter.
oxide and try to weld it you will have many problems. Aluminum oxide melts at three times the temperature of the base material. Pure aluminum melts at about 660 degrees Celsius and the oxide will melt at 1,980 C. Alloys will have different melting points but the oxide will always melt at a temperature three times higher than the oxide. “Aluminum oxide acts as a barrier but at room temperature it grows exceedingly slowly,” said Armao. “Lets say you take a sanding disk to an oxidized plate. You have days until you have to weld on it unless it gets wet. In some aerospace applications you will have
EQUIPMENT The two main processes used for welding aluminum are GMAW or MIG, and GTAW or TIG. “In terms of the MIG equipment. It is all to do with feeding the aluminum wire,” said Anderson. “The feeding system of the equipment has to be very different that it is for steel because aluminum solid wire is far more difficult to effectively feed through a MIG system without encountering problems associated with burn backs. Because of the aluminum’s physical characteristics it is much softer and it can be deformed very easily in the feeding system. Great care needs to be taken in using only parts that are designed for feeding aluminum and not steel.” AC is used because of the properties of the alternating current. “Inverters have the ability to use a greater percentage of electrode negative (EN) in the AC cycle, which is where the current flows from the electrode to the work piece. Increasing the amount of EN also helps achieve good penetration,” said Tom Wermert, Senior Brand Manager for Victor Technologies. “Most fabricators working with aluminum favour greater amounts of EN because it directs more heat into the work piece,
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improving penetration. However, if they notice black, pepper-like flakes in the weld puddle, it means that they need to increase the amount of EP, or “cleaning action,” to remove more of the aluminum oxide. Conversely, if an operator notices that the tungsten starts to ball excessively, it means that there is too much heat on the tungsten (too much EP). Excessively wide etching along the sides of the weld bead may also indicate too much EP. That said, the arc must be allowed to remove the oxide layer.” Since aluminum has a high thermal conductivity, when you weld this material it tends to dissipate the heat very quickly. “So that means you have to pour a lot of the heat in and do that fast,” said Armao. “The old folklore in aluminum when you weld is hot and fast.” TO PREHEAT OR NOT Although some weld operators insist on preheating the material before welding most experts in the field say that this practice is unnecessary. “There is not good reason to preheat aluminum if the proper equipment is sufficient to perform that level of welding,” said Burns. “Often, aluminum is preheated due to power supplies that can not supply the amount of amperage needed. There are guides within aluminum codes such as in the AWS D1.2 that specifies the amount of preheating that
Technology advances have made Pulsed MIG welding even more viable in aluminum applications where increased production speed is desired without sacrificing quality or appearance.
is allowed. Also the use of Oxy-Fuel systems can deposit water vapor and unspent fuel on the surface that can contaminate the weld. Lastly, excessive preheating makes the conductivity of aluminum drop requiring more power to perform the weld.” Preheating can destroy the properties of heat treatable alloys. “If you have the right equipment then you never need to preheat. Usually the welders that like to preheat are usually the ones that have equipment that is to light duty to do the job,” said Armao. “I’ve TIG welded aluminum that was seven inches thick without preheating. Now I had a really big powerful weld machine. A little bit of preheat is OK. If you use 100 C preheat to drive off moisture. Too much is bad.” GASES Unlike with filler material, there is not much choice for shielding gases when welding aluminum. This is true for both MIG and TIG welding. “The most common one is pure argon,” said Armao. “Now if you are welding heavier materials, about 12 mm or so then people start adding helium to the argon, 25 percent to 50 percent helium. That’s about it ; there are no other choices. Helium makes the arc hotter and gives you more penetration.” Helium is becoming rarer and therefore more expensive. Although researchers are working on a substitute none have been found yet. For a proper weld bead gas flow control is important. “When TIG welding aluminum, good shielding gas post-flow helps prevent porosity in the weld bead and extends tungsten life,” said Wermert. “First, set post-flow following weld procedure specifications or using your machine’s set-up guide. Note, that for materials 1/8” and thicker, post-flow duration will likely be 11 to 13 seconds or longer. After breaking arc, operators must remind themselves to hold the torch in position over the weld bead so that the shielding gas can do its job.” CM www.canadianmetalworking.com | MAY 2013 | 87
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Miniature Measuring Choose the right measuring equipment for the scale of your parts for best accuracy, repeatability and speed By Jeremy Wiebe
High Accuracy Sub-Micron Micrometer: A High Accuracy Sub-Micron Micrometer can provide measurements up to 0.01um.
E
very metalworking operation works to a set of specifications. No matter who your customer is or what you’re making, you need a way to measure your product. Do you complete quick jobs that the customer wants on their doorstep yesterday or is your work more precise with virtually nonexistent tolerances? CNC equipment makes machining to spec much more reliable, but how can you ensure that your end product meets those specifications? Whether you’re checking a sample for a control chart, trying to fine tune that program so the parts are just right or running parts through a quality control system, you need the right tool for the job and there is no shortage of measuring options available. Here’s a brief look at measuring tools and the ways you can use them. Among the most commonly used measuring tools are calipers and micrometers. Not only are they easily portable tools, but both provide accurate readings very quickly through the use of Vernier scales or digital readouts. They are easily stored and cared for. With a little practice, most can be used with a single hand for quick checks. Calipers are among the most versatile of the measurement tools, but arguably the least accurate. A caliper
works on a sliding rule with a Vernier scale that provides measurements within 0.05 mm. Over time, it’s possible for the caliper jaws to malfunction, so proper care needs to be taken to ensure reliability. Calipers are perfect for quickly checking to make sure nothing is drastically wrong and for turning out parts with more relaxed tolerance. Caliper jaws can be used to measure inside and outside diameters and a probe on the end of the tool gauges depth. Jaws come in a variety of shapes for different applications like stepped measuring or checking recessed surfaces. Caliper measurements can be read on the Vernier scale or with an optional digital readout that is easy to recalibrate if needed. If you’re looking for more accuracy, try a measuring tool with finer increments. Micrometers operate on a screw guide, making them much more accurate. A micrometer with a Vernier scale can provide readings to within 0.001 mm. Digital displays are also available to make measuring even faster and sub-micron micrometers can provide readings up to 0.01μm. Micrometers can be equipped with a ratchet on the thimble to prevent from overtightening that leads to inaccurate measuring. While micrometers can be smaller than calipers, operating the thimble accurately can be an unnecessary encumberance in some applications. Improper care like overtightening
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or insufficient cleaning can lead to device malfunctions. TM Microscope: Measuring microscopes are Available in a wide array of shapes for different useful for the most detailed measurement applications. applications, a micrometer can be used to measure inside and outside diameters, steps and depth with impressive accuracy. Though most micrometers are and a dial to indicate how far the plunger is clamp-shaped, internal micrometers work by pushing depressed. Plunger tips come in a variety contact points laterally outward and can be used to of shapes for specific applications and measure inside pipe diameters among other things. are made from an assortment Most micrometers have replaceable heads to fit of materials depending almost any surface. This makes the micrometer on the intended use. an incredibly accurate, flexible measuring tool Sometimes, a work for its size. piece requires much When measuring tools need to be checked more careful measuring than what for accuracy or recalibrated due to wear, can be achieved with normal tools. Laser dirt or other interference, it’s important to scan micrometers, profile projectors, vision have an accurate guide to reference. Gauge measuring systems and even microscopes blocks adhere to federal standards and are available in can be used to get a more accurate reading. These different grades with accuracy up to ±0.05 μm. tools work well in a quality control environment where Gauge blocks need to be treated carefully to prevent lots of samples need to be measured with precision. surface wear and corrosion. They must be oiled and For operations that need accurate, automated meascleaned before and after use. Industry standards are set urement, optical imaging provides much more specific to account for a thin oil film on the surface of the block feedback with less margin for error. By irradiating parts which aids in the process of “wringing” the blocks together. with laser beams, an optical system can watch how the Wringing is a process that slides flat surfaces against one light reflects off the object and calculate its position another so that they form a bond. Wringing is used when accordingly. stacking gauge blocks to measure without error. Laser scan micrometers work much like other miSome parts need to be measured before they can be crometers, except instead of using a screw guide, they moved. Height gauges and dial gauges provide accurproject lasers against the part to be measured. Using ate measurements without the need to move the part or get underneath it. Though these measuring processes can be more time consuming, checking to make sure a part is right before continuing often makes the difference between scrapping a part and catching an issue on time. A height gauge can measure surface height to within 0.02 mm on a sliding scale. This tool can be incredibly useful when checking steps in a part surface or gauging the height from a flat surface. It does have its own setbacks, though. Measuring uneven surfaces is often impossible to do reliably and care must be taken to keep the base of the gauge level on a flat surface. Some parts need to be absolutely straight. Dial gauges and indicators help determine how even a surface is and can ensure that a part is perfectly straight. Most dial gauge indicators Projector Application: A profile projector in use. The part is magnified clearly on the screen for accurate consist of a spring-loaded plunger measurement.
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Mechanical Micrometer: A normal micrometer with Vernier scale. Accurate up to 0.001 mm.
a laser instead of a solid object makes measuring malleable objects much more accurate, but it can also be used to check diameters of rounded parts and even measure the distance between pieces. Linear scales have existed for quite some time now. CNC equipment and even digital calipers make extensive use of the technology, but recent developments have added optical scanning technology to what is already a well-developed system of measurement. While these systems previously operated with magnetic slides, it’s now possible to check a part’s position with laser and track its movement. This makes measuring much more reliable. Where less advanced systems only watch how a part should be moving, an optical system gives feedback of a part’s actual position by “watching” the workpiece. Optical scanning systems like this are more high maintenance than other, simpler measuring tools, though. Maintaining the tools takes more care and there
is little margin for error when aligning laser beams. But for operations where a high degree of accuracy is absolutely necessary, these solutions can provide definite results with less effort than it would take to get the same level of detail with other options. Some parts need to be measured more accurately than is possible with a hand tool, even with the help of optical imaging. For strict quality control systems or parts that need micro-scale measurement, we can use magnification or detailed object scanning and rendering. There are a few different options to deal with this, but one of the simplest is profile projection. Profile projectors magnify the view of the part onto a screen, overlaying it with a grid that can be manipulated to measure the piece. The projector can be outfitted with different types of lighting to illuminate specific areas for measurement. The projected size is estimated by calculating lens magnification and comparing it to what should appear on the screen. This process requires some calibration and is prone to error without proper care. If simple projection isn’t cutting it, vision measuring machines can do this even more accurately. By scanning an object with a probe, the system can render a two-dimensional gray-scale or three-dimensional image
LEADING THE WAY SINCE 1905 | www.canadianmetalworking.com
WWW.CANADIANMETALWORKING.COM INTRODUCING Canada’s LEADING metalworking
website, from Canada’s LEADING metalworking magazine.
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are cheap, handheld options with reasonable accuracy. But a quality control system might require something more stationary that’s ready to measure every angle of an end product so you know it meets the criteria before it gets sent off. The metalworking industry has advanced in leaps and bounds with the advancement of computerized
systems. What was once careful guesswork can now be done by laser scanners and advanced imaging systems. And while the cutting edge provides the most detailed results, improvements in manufacturing have led to more reliable options across the board, removing every hurdle except your own part tolerance. CM
If you can make it…
WE CAN MEASURE IT. MIGHTY
MICRO
Vision System: Vision measuring systems get up close and personal with parts to get accurate measurements of all sides.
of the part to be checked against existing part drawings or CAD images in the computer. This system is highly computerized and uses image processing algorithms to detect part edges. Vision measuring machines vary in size from compact desktop scanners to full-sized CNC floor models. For even closer scrutiny, measuring microscopes give an amplified view of the part without potentially distorting the image by rendering or projecting it. Measuring microscopes have a measurement grid printed directly on the reticle so the piece to be measured can be moved into place. If the margin of error between the grid on the reticle and part to be measured is too great, the part can be placed on a grid to be viewed through a plain lens. This is the most accurate way to get detailed, eyes-on measurements. You won’t have a hard time finding options when looking for different ways to measure the parts you’re working on, but settling on the right one can be tricky. For quick checks while you’re working, there
A multifAceted meAsurement compAny
www.cmmxyz.com 2433 Meadowvale Blvd., Mississauga, Ontario L5N 5S2 Ph:905-819-7878 • Fax: 905-819-6886 • Toll Free: 1-800-606-9266 www.canadianmetalworking.com | MAY 2013 | 91
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Precision Plating Compound Metal Coatings Inc. has advanced electroless plating processes to fight corrosion and wear By Jim Anderton, Editor
ing, the electroless processes offers many options, and a major advantage: they work without the traditionally toxic chemicals used by traditional plating. While heavy metal plating like cadmium and chromium are still around, Stephen has developed electroless nickel based coatings with excellent performance, replacing the older plating in many applications. “A popular coating is electoless nickel and composite coatings with PTFE, usually called nickel-Teflon. It adds lubricity. We also do nickel with boron nitride and a unique ceramic nickel. We do a lot of oil & gas and mining applications. For the electronics industry we do silver and immersion gold as well as other new applications”, says Stephen. Most of our coatings are electroless nickel. We have various processes within electroless nickel, with different phosphorus levels and brightness. We co-deposit phosphorus and depending on the content, the coating properties changes both wear and corrosion resistance. For high-wear parts we recommend thicker coatings; for simple corrosion protection sometimes two to five ‘tenths’ gives good performance. With high phosphorus nickel it’s more homogenous and is excellent for corrosion protection. Nickel is a barrier coating, so more homogeneity gives better protection. Medium phosphorus is harder; it’s used more for wear resistance.
Compound Metal Coatings President Natalia Stephen
N
atalia Stephen loves coatings. As president of Mississauga-based Compound Metal Coatings Inc., she has taken her engineering metallurgy expertise and developed multiple processes and coatings designed to fight wear and corrosion on metal parts in industries as diverse as pharmaceuticals to aerospace. Stephen founded CMC in 2001 and has grown to 14,000 square feet and 10 employees offering engineering coating services. “We don’t do anything decorative,” states Stephen, adding with a smile, “unless I buy it for myself.” Compared to traditional electric current driven plat-
Large parts are also handled by the CMC process. The crated pump is destined for the oil patch, while the pen gives scale to the die part.
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It looks like a plating bath, but the CMC process is electroless and environmentally friendly Small parts have special challenges. A custom rack solution for small screws
The biggest volume is nickel-based coating.” Like all solution coating processes, ultimately tank sizes determine maximum part size. CMC has done
110-inch parts for a marine application, but most parts fall within a 44-inch cube envelope. The smallest parts are electronic components of only a few millimeters in length. One application for a high-performance camera
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Racking is very important in the coatings industry. Parts must not touch each other but need to be fully exposed to each solution in the process
involves small screws in volumes of 40-50,000 at a time, using a nickel-PTFE coating. Barrel plating is impossible for this application so CMC built special racks that sandwich the parts to maximize productivity compared to individual racking of the tiny screws. Quality is always an issue with the customer base Stephen serves. “We have to keep very tight tolerances. Some components need a 1-micron per side tolerance. If you maintain the parameters correctly, it can be controlled. For small, tight tolerance parts we’ll plate three ‘coupons’ with the part and check them during the process. Another way to minimize the danger of going out of ‘spec is to use a slower plating rate. Electroless processes don’t use electric current, so it’s controlled by solution pH. At a concentration that gives eight tenths an hour, for example, precision is lower, but it’s a fast process for simple protection….but that’s not our kind of business. We do precision coatings. Even large oil & gas parts have two tenths tolerances on the coatings. They use a non-destructive test method and check everything carefully. You have to control your process.” CMC’s volume customer base includes 60 per cent plastics tooling with the rest distributed among mil-
itary, medical, medical instruments, printing and the automotive aftermarket. CMC will however, do specialty jobs in small volumes or even one-offs for research purposes. “We do many small volume jobs which are very interesting” states Stephen. “We work with General Electric, Atomic Energy of Canada, a lot of companies large or small. We work with everybody and we treat everybody the same way. A small customer can become a big one, and sometimes it becomes the other way around.” Natalia Stephen is a busy woman; besides compound Metal coatings, she has a second company involved in physical vapour deposition coatings for tools and specialty applications, and has created an engineering seminar series about high-performance coating technology. In the end, it’s really about Stephen’s enthusiasm for electroless plating and the people who need it. “I love it,” she declares, adding “the tooling business is great because I love the industry and the various applications. This industry has so many great people and I work with large and small research firms. You get to solve problems and learn so much. It’s never the same thing each day.” CM
Ex bu fo ac
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Cross-Border Shopping Canadian and American aluminum designations are not all the same By Jim Anderton, Editor
C
anada is one of the world’s largest producers of alumina and aluminum alloys, so it’s no surprise that we’ve developed a classification system for identifying grades and tempers. Unfortunately, there is no global standardization of nomenclature, so in the frequent situation where Canadian firms are building from US-derived prints and specifications, it’s useful to know what’s equivalent and what isn’t. Here are some guidelines.
Canadian-US Aluminum alloy designations CANADIAN DESIGNATION
US DESIGNATION
990C CB60 CG30 CG42 CG42 Alclad CM41 CN42 CS41N CS41N Alclad CS41P GM31N GM41 GM50P GM50R GR20 GS10 GS11N GS11P MC10 S5 SG11P SG121 ZG62 ZG62
1100 2011 2117 2024 Alclad 2024 2017 2018 2014 Alclad 2014 2025 5454 5083 5356 5056 5052 6063 6061 6053 3003 4043 6151 4032 7075 Alclad 7075
Bombardier jet.
Image courtesy Bombardier Aerospace
Remember the key from a quality and customer relations standpoint isn’t just to use the correct alloy from an engineering perspective, but to be sure that the Canadian designated alloy is understood by the customer to be a valid equivalent. A great resource for this is the Aluminum Association, at www.aluminum. org. The Association’s website features extensive technical information on alloys and their tempers as well as grade equivalent designations for multiple European and ISO grades. CM
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ADVERTISERS INDEX ADVERTISER . . . . . . . . . . . . . . . . . . . PAGE
ADVERTISER . . . . . . . . . . . . . . . . . . . PAGE
ADVERTISER . . . . . . . . . . . . . . . . . . . PAGE
Abtex . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Henkel Canada . . . . . . . . . . . . . . . . . . . . 33
Renishaw (Canada) Ltd. . . . . . . . . . . . . . 67
AMT Machine Tools Ltd. . . . . . . . . . . 51, 55
HORN USA, Inc. . . . . . . . . . . . . . . . . . . . . . 7
Re tention Knob Supply & Mfg. Co. Inc. . . 97
Benz Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hurco USA . . . . . . . . . . . . . . . . . . . . . . . IFC
Bohler-Uddenholm Ltd. . . . . . . . . . . . . . . 73
Ingersoll Cutting Tools . . . . . . . . . . . . . . . 59
Canadian Measurement-Metrology . . . . . 91
Iscar Tools Inc. . . . . . . . . . . . . . . . . . . . OBC
Cecor Inc. . . . . . . . . . . . . . . . . . . . . . . . . 97
ITI Tooling Company Inc. . . . . . . . . . . . . . 15
Cincinnati Inc. . . . . . . . . . . . . . . . . . . . . . . 4
Jesse Engineering . . . . . . . . . . . . . . . . . 12
CWB Group . . . . . . . . . . . . . . . . . . . . . 86,87
Koma Precision , Inc. . . . . . . . . . . . . . . . . 43
Dillon Manufacturing, Inc. . . . . . . . . . . . . 37
KOMET of Canada Tooling Solutions, ULC 65
SME – CMTS Show . . . . . . . . . . . . . . . . . 95
Dipaolo CNC Retrofit Ltd. . . . . . . . . . . . . . 11
Kyocera Cutting Tool Division . . . . . . . . . 45
SME – WMTS Show . . . . . . . . . . . . . . . . 77
DMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Lincoln Electric Co. of Canada . . . . . . . . . 83
Star CNC Machine Tool Co. Ltd. . . . . . . . . 55
Elliott Matsuura Canada Ltd. . . . . . . . . . . 4
Lyndex Nikken . . . . . . . . . . . . . . . . . . . . 40
Strippit, Inc. . . . . . . . . . . . . . . . . . . . . . . 75
Emec Machine Tools Inc. . . . . . . . . . . . . . 31
Machitech Automation . . . . . . . . . . . . . . 79
EMO 2013 . . . . . . . . . . . . . . . . . . . . . . . 93
Mascoutech Inc. . . . . . . . . . . . . . . . . . . . 46
Exsys Tool, Inc. . . . . . . . . . . . . . . . . . . . . 48
Megatel Inc. . . . . . . . . . . . . . . . . . . . . . . 32
Fabricating Machinery Solutions Inc . . . . . . . . 27
Methods Machine Tools, Inc. . . . . . . . . . . 53
Fastems, LLC . . . . . . . . . . . . . . . . . . . . . 14
Mori Seiki . . . . . . . . . . . . . . . . . . . . . . . . 63
Fein Power Tool Company . . . . . . . . . . . . 41
Multicyl Inc. . . . . . . . . . . . . . . . . . . . . . . 72
Gibbs & Associates . . . . . . . . . . . . . . . . . 81
Nederman Canada Lrd. . . . . . . . . . . . . . . 78
Walter Surface Technologies . . . . . . . . . . 25
H&R MFg. & Supply Ltd. . . . . . . . . . . . . . 30
Okuma . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Walter USA, LLC . . . . . . . . . . . . . . . . . . . 39
Haas Automation Inc. . . . . . . . . . . . . . . . 35
PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Wilson Tool International . . . . . . . . . . . . . 71
Sandvik . . . . . . . . . . . . . . . . . . . . . . . . . 13 Schunk Intec Corp. . . . . . . . . . . . . . . . . . 41 Scientific Cutting Tools . . . . . . . . . . . . . . 42 Seco Tools Inc. . . . . . . . . . . . . . . . . . . . . 18 SGS Tool Company . . . . . . . . . . . . . . . . . 47
Sumitomo . . . . . . . . . . . . . . . . . . . . . . . . . 9 Synergy Machine Solutions Inc. . . . . . . . 29 TRUMPF, Inc. . . . . . . . . . . . . . . . . . . . . . . IBC Tungaloy America Inc. . . . . . . . . . . . . . . . . 3 Victor Technologies . . . . . . . . . . . . . . . . . 85
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By The NUMBERS Canadian oil grows for the foreseeable future
Adapted from CAPP “Crude Oil Forecast, Markets and Pipelines 2012. www.capp.ca
T
he Canadian Association of Petroleum Producers annually publishes a long-term outlook for Canadian crude oil production. The current forecast has been extended by five years to 2030. Growth in conventional oil production is even stronger than was expected last year, however, oil sands remain the dominant component of future production. This longer term outlook predicts total Canadian production will exceed 6 million barrels/day at the end of this period. Western Canadian crude oil producers need to find new markets for their expanding production. Eastern Canada, which currently imports over half of its oil from offshore foreign suppliers, is a prime candidate. Other market opportunities in-
clude increasing the share of the U.S. markets that have been traditionally served, as well as accessing new U.S. markets, particularly those located on the U.S. Gulf Coast. Beyond North America, growing economies in Asia represent a market that producers are actively pursuing. As a result of strong growth in both U.S. and Canadian oil production, pipeline capacity is expected to be tight in the next few years, requiring the need for timely expansions to provide market access. A number of pipeline projects are being proposed to connect the growing supply with the anticipated market demand. For more information, visit www.capp.ca
98 | MAY 2013 | www.canadianmetalworking.com
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