April 2014 Canadian Metalworking

April 2014 • www.canadianmetalworking.com

Serving the Canadian Metalworking Industry Since 1905

TOOL & MOLD OUTLOOK 2014 Stability, growth, innovation

MMTS MONTREAL SHOW PREVIEW MARKET REPORT: QUÉBEC WHAT Ra REALLY MEANS

PM 40069240

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Door Opening Solutions for Internal Turning

Minimum bore diameter from ø4.5 mm Ideal tool geometry for excellent chip evacuation Increased rigidity for minimizing bar deflection and chatter

Ask for More of Tungaloy's Door Opening Solutions

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Highly economical double sided insert with unique design Minimum bore diameter from ø12 mm One type insert covers the shank diameter range from ø10 mm to ø20 mm Optimum design for smooth chip evacuation and high rigidity

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80% productivity* increase

, ins in tool life *average ga rded d feeds reco an d ee sp cutting etitor systems mp co st ain ag worldwide.

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CoroCut ŽQD – Twice as cool CoroCut QD takes your parting off to new heights. Optimized for bar-feed lathes, it brings unbeatable strength and security for deep grooves and long overhangs with a helping hand from unique new technology: over- and under-coolant for the most effective, trouble-free machining.

Unbeatable security: stronger blade design, advanced grade technology and the most stable insert clamping.

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Ultimate chip control and tool life: over- and under-coolant with two high pressure jets and dedicated insert geometries.

Easy handling: quick and easy coolant connection with plug-and-play adaptors for many machine types.

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A LOOK INSIDE Vol. 109 | No. 3 | April 2014 | www.canadianmetalworking.com

COVER STORY MOLD TOOL AND DIE OUTLOOK.............. 35

FEATURES TRAINING PROFILE............................................................ 24 EMAM, Montreal, Québec

24

JOB SHOP SNAPSHOT..................................................... 32 J&J Trailer, Toronto, Ontario

QUÉBEC REPORT.............................................................. 67 Will the province’s manufacturing base feel the effects of sovereignty politics?

MMTS PREVIEW................................................................ 72

32

We take a look at Montréal’s most anticipated manufacturing event scheduled for May 12-14

FILL IT UP.......................................................................... 86 Filler metal is crucial to proper aluminum welding

TWO MEASURES OF SPEED............................................. 94 RPM or SFM. Which is appropriate?

“A LOOK INSIDE”, continues on page 8

86

72

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Amada_4-2

FEATURES cont’d 90

“W ORDERED BY LASER........................................................ 90 Enhancing traceability with laser marking

ROUND TOOL WRAP-UP................................................. 100

w

Spinning edges for straight line speed

CREEP-FEED GRINDING.................................................. 104 How to get big removal rates with accuracy and excellent surface finish

THE ROUGHNESS AVERAGE...........................................108 What does Ra really mean?

100

FINE FINISHES ON HARD PARTS.....................................110 Flexible finishing for the Sikorsky helicopters

104

67

110

DEPARTMENTS

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View From the Floor..........................................................10

Fabricating & Welding News.....................................84, 112

News.................................................................................12

Business of Tooling...........................................................98

Ken Hurwitz on Finance....................................................27

By The Numbers..............................................................114

Cover design by Andrea Smith

Rick Johnson on “Jason Kenney heading to Germany to study apprenticeship systems”

G

ermany like many other countries in Europe has a centuries old history behind their apprenticeship system. In that history lies a tradition of mentorship which is very much unlike our fast tracking methods here. When I entered my apprenticeship in Germany in 1989, I spent a full year amongst 15 and 16 year olds, though I was 25 at the time. The root of the problem here is no one wants to start at the bottom if there is a faster way to management. ie; through a University degree program.

Yes the stigma behind the trades is prevalent here but not so at all over there. The following is the reason and the only reason why: Many senior engineers, designers, and executives started their careers via the apprenticeship route. When they finished their apprenticeship, they were then given (real) credits toward furthering their education. They are able to continue studies toward their Meister Brief which is equal to an undergraduate degree, then on toward a Masters degree. It really is not hard to get fish to jump into a tank of water if they are guaranteed an opportunity

to move into a bigger tank after they have learned all they can in the smaller tank.

There are many checks and balances in place there. One being; in order for a tradesperson to become self-employed in their vocation, they need to obtain their MeisterBrief. Another is; a company has to have a Meister employed in order to conduct relevant business and hire apprentices. Many Meisters are preferred over a University graduate for middle management positions due to the benefits of being able to perform even more of the same duties while enabling the organization to maintain a staff of labour cost efficient apprentices.

We have much to learn, but I have seen vast improvements since I completed my apprenticeship here in 97.

If you’ve got a something to say about a story making news, visit our website, and let us know what you think — we may feature it in an upcoming issue!

And don’t forget to follow along and engage with us on social media – look for us on Twitter, Google+, and Facebook!

8 | APRIL 2014 | www.canadianmetalworking.com

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Reh Abdulla, General Manager (left) and Feroz Abdulla, Production/Lean Manager of Metalcraft Technology Inc.

“We’ve increased productivity by more than 30% while reducing lead times, setup, scrap and overall costs.”

— Feroz Abdulla, Production/Lean Manager Metalcraft Technology Inc.

The Power of Integrated Technology and Automated Processing.

With 220 punches and 440 dies, the PDC ensures that the right tool is always available.

www.amada.ca

Amada’s networked machines and digital technology enable Metalcraft to provide fully integrated and highly-precise bending, punching and laser cutting.

Amada Canada, Ltd. 885 Avenue Georges Cros, Granby, Quebec, Canada J2J 1E8

800-363-1220 2345 Argentia Road, Unit #101 Mississauga, ON L5N 8K4

800-561-4578

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Since 1997, Metalcraft Technology Inc. in Coquitlam, BC has been a leading provider of custom sheet metal products for a wide range of industries.

Founded by Azim Abdulla, the company operations are now managed by second generation family members Reh Abdulla, General Manager and Feroz Abdulla, Production/Lean Manager. Committed to uncompromising quality and lean manufacturing, Metalcraft partnered with Amada. After an in-depth analysis of Metalcraft’s specific manufacturing challenges, Amada provided the optimal solution.

Amada’s solution included the EML 3610 NT punch/laser combination machine equipped with an automated load/unload system and a single-part picking machine. To maximize machine utilization, the EML is also equipped with a PDC automated tool changer. Reflecting on the purchase, Feroz Abdulla states, “ The EML is a model of efficiency and productivity allowing us to run 24/7 without operator intervention.” The EML provides fully automated production of complex parts (including nested sheets with a large variety of components) while eliminating manual tool changes.

Amada’s integrated, automated solution enabled Metalcraft to: • Reduce Operating Costs (The EML’s energy-efficient, servoelectric design eliminates the need for hydraulics and delivers up to 50% cost reduction over conventional turret punch presses.

Time-consuming and costly manual tool changes have been eliminated by automated precision).

• Expand Capabilities (Capable of handling 5' x 10' fully-nested sheets without repositioning, the EML combines the punching, forming and tapping power of Amada’s innovative 33-ton Electric Motor (EM) turret punch press with the unlimited shapecutting capabilities of a laser).

• Maximize Efficiency (Equipped with TK/ASR material handling options, enables the EML to cost-effectively produce smaller lot sizes in a variety of material types and thicknesses or operate lights-out for extended production runs).

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PUBLISHER Steve Devonport 416-442-5125 | SDevonport@canadianmetalworking.com ASSOCIATE PUBLISHER Rob Swan 416-510-5225, cell 416-725-0145 | RSwan@canadianmetalworking.com EDITOR Jim Anderton 416-510-5148 | janderton@canadianmetalworking.com ASSOCIATE 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 9 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.

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View From the Floor The Chrysler fiasco

I

t’s a rare day indeed when a major corporation turns down free money, especially in amounts as vast as the recent $700 million deal proposed by the Government of Ontario to keep Chrysler’s Windsor operations in place. Chrysler’s second thoughts are a warning sign, one that the autoworkers’ union, Unifor, sees clearly — even if Ontario and federal politicians do not. Ontario Progressive Conservative Party leader Tim Hudak fired a shot across the bow by openly questioning the sense of handing such a vast amount of money to a corporation that should be able to raise the funds readily in either the equity or debt markets. Following Hudak’s statement Chrysler stepped away from the deal, announcing that the firm will raise the funds privately, citing the “politicization” of the process. What really happened, in my opinion at least, is that Chrysler determined that job guarantees would be attached to that $700 million, guarantees which would lock the firm into manufacturing in Windsor for perhaps another decade. The union understands this, which is why they’re worried, although it’s far from clear that the governing provincial Liberals understand or care about the long-term viability of the province’s auto sector.

Ontario Premier Kathleen Wynne demonstrated this by the way her government handled the process, offering vast sums of taxpayer money like a life preserver tossed to a drowning man, forgetting that Chrysler is swimming quite nicely, thank you.

Automakers have learned to leverage the jobs they provide by pitting jurisdiction against jurisdiction, originally in the construction of new plants and now during the redesign cycle that occurs every five or six years. Hudak is correct in characterizing the process as blackmail; I believe however, that there is another way to approach the problem although no one in the media seems to address it. In my world, the deal is simple: the $700 million would be used to buy Chrysler stock at 15 per cent below street value. The stock would be carried on provincial books as an asset, making it slightly cash flow negative from a provincial standpoint, but a non-factor in overall debt levels. The 15 per cent discount would provide a cushion for any potential share price drop due to the dilutive effect of a single major purchase. This deal would be restricted to class A equities with full voting rights, and given the billion-plus dollars fronted to Chrysler during the bailout, a seat on the Board of Directors would not be unreasonable.

That board member would ideally be a senior-level economist, isolated by statute from the political process. From Chrysler’s perspective, they increase the value of their Windsor manufacturing assets by $700 million with no additional debt burden.

If government interference in the markets is an issue, build in a provision that triggers an automatic share sale or buyback from the provincial government when the share price appreciates to 25 per cent over the purchase price, returning a modest profit for Ontario taxpayers. Politicians, including Premier Wynne refer to cash handouts to automakers as “investments”, yet using cash to make an actual investment is for some reason taboo. I believe Chrysler backed out of the free money offer because their long-term strategy is to move all operations to Mexico if possible, or use the threat of doing so to drive wages to Mexican levels. If this continues industry-wide, elimination of these middle-class jobs will have a short-term and long-term effect. Short-term, the provincial government of the day will pay a price at the polls but more worryingly in the long term, it makes automotive manufacturing less economically and politically relevant, driving us further down the road toward a low-wage, low-value service economy. The world is about to enter a new, high-tech manufacturing renaissance and Canada appears to be too busy tearing natural resources out of the ground to notice. Given the millimeter deep pool of political talent within all three major political parties, provincial and federal, I’m worried.

As it stands now, globalization and trade liberalization is turning Canada into the world’s raw material warehouse at the expense of meaningful manufacturing industries, with auto assembly the most visible example. We must remember that the people that run this country have no skin in the game; they’ll lead lives of comfort and security regardless of what happens to the man in the street or the country as a whole. Even if your political activism never reaches past your smart phone, a Tweet, Facebook posting, or better yet an email or phone call to your MLA’s or MPs office is well worth the effort.

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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Micro Circular Milling Taken to the Extreme Booth #349

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IN THE NEWS

DMG MORI Open House draws over 6,000

The LASERTEC 65 Additive Manufacturing was a major launch at the open house

D

MG MORI held the firm’s annual open house and exhibition at Pfronten, Germany on February 18-22, drawing over 6,600 visitors from around the world. Seven of 24 ma-

chine premiers in 2014 were present at the open house, which featured 66 machines in operation. Educational seminars were offered on life cycle services, die and mold, aerospace and automotive engineering. Prominent was DMG MORI’s CELOS common machine interface, which replaces the traditional interface between shop floor machine functions and higher level ERP packages and CAD/CAM Serving the apps. New models on exhibition were the Automotive Parts CTX Beta 88TC, two new V-series models, Manufacturing DMC 850V and DMC 1150V, two new additions to the fourth — generation duoBLOCK Industry for line, the DMC 80 FD duoBLOCK and 55 years DMC 80H duoBLOCK, the DMU 270P and DMU 70 ecoline. One machine generated particular interest, the LASERTEC 65 AddiEngineered tiveManufacturing, which features a diode Solutions for laser mounted in place of a cutting tool; the High Production material is added by spraying metallic powder into the laser beam, melting the powder Manufacturing in layers into the base material. The process is up to 20 times faster than laser sintering in a powder bed. The LASERTEC 65 AdditiveManufacturing combines 5-axis milling and laser metal deposition. All comManufacturer of Exclusive North American Dealer for mon metal powders can be processed, Custom Designed Chucks and Fixtures Gamet DELTA Series Jaw Chucks including steel, nickel and cobalt alloys, for High Volume CNC Turning Collet, Diaphragm, Offset and Bruckner Live and Dead Centers, and Face Drivers brass or titanium. Series production of the Many Other Chuck Designs LASERTEC 65 AdditiveManufacturing is planned for autumn 2014.

As a result of the open house exhibition, the DMG MORI SEIKI group recorded 690 units sold at a value of €167.6 million (compared to the previous year at € 150.5 million). In 2013, the DMG MORI SEIKI group Old Indian Trail, Middlefield, CT 06455 USA | T: 860-349-1044 | F: 860-349-1815 exceeded € 2 billion in sales.

THE WORKHOLDING ENGINEERS

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IN THE NEWS

Canadian Metalworking to host second annual tabletop expo in B.C. Exhibitor space at the BC event is already sold out, and another show has been added in Calgary to keep pace with demand in the western Canadian market.

By: Nick Healey or the second year in a row, Canadian Metalworking magazine will be hosting a one-day tabletop show at the Hard Rock Casino Vancouver Theatre in Coquitlam, British Columbia.

The Metalworking Manufacturing and Production Expo (MM&P Expo) will take place May 6, and feature displays of the latest in machine tools, cutting tools, fabricating and welding technologies, production software, and metrology.

Exhibitor space at the show has already been sold out this year, but attendance and parking will be free for visitors. The show will be open from 10:00 am to 4:00 pm.

Like last year’s event the show will be co-locating with Canadian Metalworking’s sister publication, Design Engineering. Combined, there will be 88 total exhibitors for visitors to interact with.

“After the successful launch of the inaugural Metalworking Manufacturing and Production Expo in 2013 the show is returning in 2014 to British Columbia on May 6,” says Stephanie Chiang, Event Manager for the MM&P Expo.

“Filling a niche market, MM&P Expo provides a comfortable, cost-effective and efficient environment for buyers and suppliers to re-connect and develop their relationships.”

The Coquitlam show will also feature a keynote address from Ed Beange, the owner of the local firm Hansen Industries.

Beange, who is an electrical engineer by trade, has attributed his company’s success to their commitment to customer service.

F

The MM&P Expo will also be expanding to include another stop in western Canada and a show in Windsor, Ontario later this year.

“Based on the overwhelming success of the Coquitlam MM&P Expo in 2013, we are pleased to announce the addition of a second show in western Canada, in Calgary on May 27,” says Rob Swan, Associate Publisher of Canadian Metalworking.

“This type of event was a new concept for us, and quite frankly we didn’t know what to expect. We’re pleased to say it exceeded all expectations, and has given us a great opportunity to connect our readership with leading suppliers from across Canada and the U.S. “Canadian Metalworking is a national publication, so it’s important for us to explore all areas where metal manufacturing thrives. Expanding this successful event in western Canada was really a no-brainer.”

The Calgary show will be held at the Commonwealth Centre, while the Windsor event will be at the city’s Ciociaro Club.

The Coquitlam MM&P Expo is sponsored by Sandvik Coromant, Mazak Canada, ElliotMatsuura Canada, TRUMPF, and Renishaw.

If you would like to register to attend, visit the show website: www.mmpshow.com.

Stay tuned to www.canadianmetalworking.com for more information about the Coquitlam show, and other upcoming events.

Attendees visit the MM&P Expo in Coquitlam, May 7 2013. (Photo: Canadian Metalworking)

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META MET ME TAManufacturing LMANUFACTURING LWORKING WORKING&& W PrODuctiOn PRODUCTION Expo EXPO

MARK YOUR CALENDARS! MAY 6, 2014

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A one day table-top show targeted to the manufacturing & production audience in the greater Vancouver market. n Meet face-to face with knowledgeable product and application engineers n Get hands-on experience with the latest products and solutions on display n Learn about processes in industries including automotive, aerospace, energy and resources, medical, transportation and tool-die moldmaking.

FEAturEd produCtS And tEChnoLogiES inCLudE: the latest machine tools, cutting tools, software applications, automotive, fabricating and welding technologies, And MorE! SponSorEd BY:

AdMiSSion iS FrEE Register to attend at: mmpshow.com Registration also grants you access to Design Engineering Expo.

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IN THE NEWS

Chrysler pulls financing requests to Ottawa, Ontario amid turmoil Future of plants in Windsor, Brampton, Ont., unclear after requests for reported $700-million withdrawn By: Dan Ilika, CanadianManufacturing.com

WINDSOR, Ont.—Chrysler said it has withdrawn financial assistance requests submitted to the federal and Ontario governments due to the political implications they have had in recent weeks.

“It is clear to us that our projects are now being used as a political football, a process that, in our view, apart from being unnecessary and ill-advised, will ultimately not be to the benefit of Chrysler,” Chrysler said in a statement released March 4.

The automaker had submitted requests to Ottawa and Queen’s Park for financing to help expand its plants in Windsor and Brampton, Ont. At the time, Steve Rodgers, president of the Automotive Parts Manufacturers’ Association (APMA), said he was a caught off guard by the announcement, and is working to determine what motivated Chrysler to withdraw the funding requests.

“Early on, I would have to say it would be very disappointing if somebody else has stepped into the breach and convinced Chrysler to go in a different direction with respect to facilities,” Rodgers said in an interview. “At this point it looks like it could be setting us up for a huge disappointment.”

Ontario Progressive Conservative Leader Tim Hudak urged the governing Liberals last week to deny Chryler’s “ransom” demand in response to its request for a reported $700-million from the two governments.

“Should we pay a nine figure ransom to Chrysler? Of course not,” Hudak said last week, according to The Canadian Press.

The automaker said it would instead “fund out of its own resources” the necessary capital for retrofits at the plants, but was unclear about whether the lack of government financing would impact the scope of the work.

Chrysler builds its Dodge Challenger and Charger models at the Brampton plant, and its minivan models in Windsor.

Part of the internal talks at Chrysler surrounding its Canadian plants involve the development of its next-generation minivans.

“These capital allocation decisions will be governed by and continuously monitored on the basis of a variety of considera-

tions that determine the competitiveness of Canada first and foremost in a NAFTA context but also increasingly on a global basis,” Chrysler said.

It also warned of the potential impact upcoming collective bargaining talks with the union representing workers on the facilities may have on expansion plans in the province.

Those negotiations are set to kick off in 2016.

“It is my sincere hope that all stakeholders involved commit to do what they can to preserve the competitiveness of the country, and in particular of the province of Ontario,” Chrysler CEO Sergio Marchionne, a Canadian, said in the automaker’s statement.

“We will do what we can to preserve and nurture the competitiveness of our operations, but we reserve the right, as is true for all global manufacturers, to reassess our position as conditions change.”

According to Rodgers, the importance of Chrysler’s expansion here becomes increasingly important with Canada negotiating its Comprehensive Economic and Trade Agreement (CETA) with the European Union.

“Going into the future, we had counted on the fact that with the Canada-Europe free trade agreement, the ability to do a new global platform in Windsor would have been a distinct advantage for that assembly facility and for the Canadian automotive industry,” he said.

“This would would definitely be a trend in the wrong direction.”

Rodgers, though, is remaining optimistic deals can be put in place to preserve the production at Chrysler’s facilities, and thinks the automaker’s sales in recent months will only drive its need for more capacity.

“I don’t think it’s too late,” Rodgers said. “I still think there’s time, I still think there’s definitely an opportunity to put something in place here from a capacity standpoint.

“We truly believe that Chrysler needs that capacity … and we don’t think it’s too late for that.” CM

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Creating Tool Performance

A member of the UNITED GRINDING Group

HELITRONIC POWER DIAMOND

Visit us at GrindTec BOOTH #7-7050

Two-in-one machine powers up advanced tool production for 12 years running

Well ahead of its time, the HELITRONIC POWER DIAMOND combines grinding and erosion technology for the fast, precise and repeatable production or resharpening of complex cutting tools made from PCD, CBN, HSS, carbide, ceramic and more in a single setup.

Come see this highly advanced two-in-one machine at GrindTec in Booth #7-7050 and learn how it provides quality tooling and impressive savings in manufacturing lead times.

Creating Tool Performance www.grinding.com – Phone 540-898-3700

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C

IN THE NEWS

SME announces RAPID show expanding to Canada Worldwide sales of 3D printed products could be expected to reach US $6 billion in a few short years.

By: Jim Anderton

Nick Samain, Group Manager for SME Canada announces the new RAPID show.

O

n March 20, at FABTECH Canada 2014, SME group manager Nick Samain announced a new initiative launching September 23 and 24, 2014 at The International Centre in Mississauga, Ontario — the Advanced Manufacturing Expo (AMExpo).

AMExpo 2014 will include the Medical Manufacturing Innovations show and the RAPID conference and exposition covering 3D printing for both prototype and production processes.

“We’re able to bring RAPID to the Canadian marketplace for attendees who are interested in the technology as well as the entire spectrum of advanced manufacturing technologies”, said Samain. RAPID is a Canadian debut, but the show has been an

authoritative venue for additive manufacturing technology for nearly 25 years.

Additive manufacturing is expected to be highly synergistic with medical device manufacturing, making the event a single source information platform for multiple industry segments.

Because the show is brand new to the Canadian market Samain was eager to emphasize that there would be a focus on learning opportunities at RAPID. He also noted that by 2017, worldwide sales of 3D printed products could be expected to reach US $6 billion, adding, “the introduction of RAPID Canada is a direct response to market demand.” www.AMExpo.ca

The best press alternative on the market for unitized tools and small die sets.

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IN THE NEWS

Studer takes over aircraft carrier U

nited Grinding/Studer held a unique coming-out party for the firm’s new S11 small footprint production grinder by holding the event, called Mini Motion USA, aboard the World War II aircraft carrier the USS Yorktown, in Charleston, South Carolina. Mini Motion USA was part of United Grinding’s “The Grind” distributor event, which brought management, sales and technical personnel from across North America. The seminar-filled days were followed by entertaining evenings including gourmet food, live music and a fun problem solving teambuilding event. Rodger Pinney, president and CEO of United Grinding North America Inc. discussed the market outlook for cylindrical grinding, the overall market climate and company goals. Top U.S. dealers were treated to a special awards dinner aboard the Yorktown and media also enjoyed a unique luncheon served in the chief petty officers’ wardroom below the hangar deck aboard ... continues next page

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IN THE NEWS

... continued from previous page

Salvagnini to open Canadian facility May 1

S

United Grinding North America president and CEO Rodger Pinney hosted an information rich event along with the launch of the Studer S11 machine

the historic carrier. Extensive presentations on the new S11 grinder, including applications were presented and the S11 machine was on display just forward of an Apollo space capsule on the hangar deck. CM

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alvagnini Canada ULC, a subsidiary of Salvagnini America, will move into its new facility at 4181 Sladeview Crescent, Unit 44, in Mississauga, Ontario by the beginning of May. Build-out of the office and warehouse space is scheduled to be completed by May 1.

The Salvagnini Canada team will include Steve Spilak, Sales Manager, Neil Crawshaw, Service Engineer, and Helen Gornias, Office Administration.

The office will develop into a service and spare part stocking depot, with a full complement of spare parts to mirror the universe of Salvagnini machines now operating in Canada. Most spare parts will be able to be delivered to Canadian customers directly from Salvagnini’s Canadian office.

Service engineers will be based in both Toronto and Montreal giving them easy access to customers in those areas. Scheduling and customer requests will continue to be coordinated through the Salvagnini headquarters in Hamilton, Ohio.

The company designs and manufactures flexible sheet metal processing systems, machines, process software and tooling for factory integration. Major product lines include punching and shearing, automatic panel bending and fiber laser cutting systems. www.salvagnini.com

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IN THE NEWS

Canadian auto sector’s concerns over South Korea trade deal ‘misplaced’ Firms should approach agreement as strategic opening to Asian market rather than one-sided deal, paper argues

Prime Minister Stephen Harper, joined by James Moore, Minister of Industry, and Ed Fast, Minister of International Trade, meets with Park Geun-hye, President of the Republic of Korea, at the Blue House during his visit to the Republic of Korea.

C

ALGARY— A new report from the School of Public Policy at the University of Calgary is suggesting Canadian auto industry stakeholders should be more optimistic about Canada’s recent free trade deal with South Korea.

The paper suggest that industry players—such as Ford Motor Co. of Canada, which already stated it “cannot support” the deal—should view the agreement as an opportunity to do business in the lucrative Asian market rather than a one-sided deal that will see more Korean cars enter the Canadian market.

“Automakers may find that whatever increased competition comes from cheaper Korean car imports are offset by the opportunity to more easily sell Canadian-made vehicles in the much larger Asian marketplace,” author Eugene Beaulieu wrote in the paper.

Arguing against fears trotted out by the Ontario government that automakers like Hyundai Motor Co. and Kia Motors Corp.

will dump tariff-free vehicles in the Canadian market, Beaulieu’s paper said the deal includes safeguard provisions that will allow Ottawa to take action against import surges.

However those potential actions have not been announced by the federal government, and were not published in the paper.

“Canadian automakers are concerned about competing with South Korea’s Hyundai (and) Kia,” Beaulieu wrote.

“But the agreement also offers improved access to the Korean market for Canadian-made automobiles—and, more importantly, provides an opening to the vital and burgeoning wider Asian automobile market.”

Since the United States entered a similar free trade deal with South Korea in 2012, the paper notes, its auto exports to the country doubled, though were still relatively low at just 24,000 vehicles in 2013.

With files from CanadianManufacturing.com Staff

22 | APRIL 2014 | www.canadianmetalworking.com

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Training Skills

L’École des métiers de l’aérospatiale de Montréal, Quebec By: Luc Boily

A

s the third largest global centre in aeronautics (after Toulouse and Seattle), Montreal provides a great deal of training opportunities to students looking for a career in this booming industry. The aerospace industry is known for the exactness, thoroughness and sense of responsibility of the work involved in it – so proper training is of paramount importance.

TOP-NOTCH PROGRAMS L’École des métiers de l’aérospatiale de Montréal (ÉMAM) – a part of the Commission Scolaire de Montréal – offers cuttingedge educational programs in innovative school/plant facilities, with courses designed to meet the needs of aerospace businesses. Students are supported by the school with financial assistance applications and job opportunities – and each training program ends with a two or three week in-plant training placement. “This field immersion allows students to get used to the work schedule and plants production requirements. It’s also an excellent opportunity to raise their profiles as a potential worker,” says Mario Cardin, the teacher in charge of student’s practical training placements.

THREE STRATEGIC LOCATIONS The school has three educational facilities: its main campus in Montreal is located near l’Assomption metro station and has 9,975 square metres of work area, as well two accessory buildings in Mirabel and Trois-Rivières located near partner companies (to help take care of local training).

Teacher Amelie Chiasson with a Numerical Control Machine Tool Program group of students.

ÉMAM meets industry needs thanks to many famous names, including Bombardier Aerospace, Pratt & Whitney Canada, Bell Helicopter Textron, Messier-Dowty, Sonaca Montreal, etc. In some cases, work/study agreements may be made to meet specific production needs. ÉMAM also incorporates customized training on site by teachers on the go. “It is very exciting for a teacher to be able to make a difference both with students in school and with employees in plant,” says Sylvain Mayer, ÉMAM Precision Sheet Metal Work teacher.

“In addition to teaching students the know-how they need, we try to instil in them life skills to help distinguish themselves among others in their environment.”

IMPRESSIVE STOCK OF EQUIPMENT Videos posted on ÉMAM website give a good overview of the many types of equipment available for students. For example, there are more than 35 CNC machine-tools, including machining centres, cutting edge lathes and 3D coordinate measuring machines (CMM). Equipment manufacturers also share a close relationship with the school, both for training and demonstration activities.

It should be noted that some courses are given in English, and that since 2013 winter, students who wish to go further after they got their diploma of vocational studies (DVS) in Machining Techniques (1800 hours), can access to a diploma of college studies (DCS) in Mechanical Engineering Technology (Manufacturing option) at Cégep de Saint-Laurent through a service called Passage DEP-DEC established by the College.

For more information visit: www.emam.ca.

L’ÉCOLE DES MÉTIERS DE L’AÉROSPATIALE DE MONTRÉAL AT A GLANCE LOCATION: Montreal 1, Mirabel 2, TroisRivières 3

•C able and Circuit Assembly – 945 hours DVS1

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•A ircraft Structural Assembly – 975 hours DVS1-2-3

• Machining Technique – 1800 hours DVS1 •P recision Sheet Metal Work – 1275 hours DVS1 • Tooling – 900 hours AVS1

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24 | APRIL 2014 | www.canadianmetalworking.com

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FINANCING

Evaluating used machinery How appraisers assess the value of your machine tools

By Ken Hurwitz ..........................................................................................................................................

E

quipment valuation is an important consideration in any successful machine shop. If you own a piece of machinery or equipment, you need to understand how it’s valued for insurance, estate planning, partner or shareholder buy-outs; or if the older piece must be sold to make room for upgraded technology.

In terms of financing, machinery and equipment owned free and clear may also be leveraged in the event the business requires some working capital. Regardless of the motivation for the valuation, the process usually involves a set of common factors.

From a professional standpoint, the Association of Machinery and Equipment Appraisers (AMEA) is the premier international organization for certified equipment appraisers. They specialize in appraising machinery and equipment and I’m very fortunate to be a member of this association. Below are a few of the more important aspects a certified appraiser would consider during valuations: 1. Manufacturer and class: There are many different builders of machinery and equipment, all of whom have their place in the market. The idea here is to think about how that manufacturer is perceived in the marketplace.

The answer to this question can be found in the approximate number of existing installations and whether those machines are known to maintain tolerances over time (if properly maintained). Most importantly, what is the availability of spare parts and technical support? A piece of equipment may have an excellent reputation but if you can’t find anyone credible to provide parts and service, the value of the piece will be significantly reduced.

2. Model and age: As long as the machine can be inspected in person, finding the model and age is relatively easy. It’s normally stamped on a plate attached to a major component of the machine (such as the column, table, or electrical panel). Once this information is confirmed—and assuming the manufacturer has had stable representation in the market—the equipment can be researched.

3. Usage: This is very important since the same machine can be used to manufacture a variety of different parts across a wide number of industries, and there are plenty of differences between manufacturing environments. Two machines of identical age could have vastly different values depending on how they were used. An average machine tool is run 2,000 hours per year which is known as one shift (eight hours per day, five days per week). However, the

largest customer base for machine tools in Southern Ontario is the automotive industry, which is known to run machines much harder; in many cases two or three shifts. In this case, two identical machines of the same age will be valued quite differently to account for the additional usage.

4. Condition: A machine tool is designed to Ken Hurwitz manufacture parts to very tight tolerances, in many cases microns (thousandths of an inch) and in order to function properly over a long period of time it requires regular maintenance. In the world of machine tools, this means preventive maintenance—no different than any other mechanical asset. The amount of maintenance a machine requires is related not only to its usage but also to the type of material it has been cutting. A piece of equipment that has been cutting aluminum, a light material which is very easy to machine will be in significantly better condition (and in turn worth more) than an identical piece which has been cutting cast iron, a very abrasive material which produces chips that are known to cause long term damage.

5. Original purchase price: This seems like an obvious place to confirm value but it’s not always easy to appraise based on the original purchase price. The equipment may have been purchased with additional options which had value to the original owner but not to future ones (such as specialized chip conveyors, loading systems, fixturing/workholding devices, engineering fees). It’s also possible the piece is considered an SPM (special purpose machine) which basically means it was manufactured to produce a singular part for a particular customer, very valuable to the company which has that contract but of no value to anyone who does not.

6. Replacement cost: In many cases, particularly for older equipment, it’s tough to determine the original selling price. The next place to look is replacement cost. There are many instances however where this may not be so easy to find. In turn, it may have an impact on value. For example, the model might no longer be manufactured because it was redesigned or upgraded. Or perhaps the model didn’t ... continues on page 113 www.canadianmetalworking.com | APRIL 2014 | 27

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THE BUSINESS OF WELDING

Success through innovation A

fter a strong Canadian showing at the winter Olympics I started thinking about what it takes to generate gold medals, and what it takes to achieve success within our own industry. In sports, success comes as a result of training, drive and technique, with innovation being a key critical factor all share.

The act of “innovation”, making progressive changes, is one way to measure success but it’s worth noting that simply being innovative is no guarantee of success.

Simply making a change for the sake of change is always a risky move. To have a good chance at success, innovation needs to be to be tied to something larger; a goal, an objective – in our case increased revenue and market share. To help move this discussion along, I’ve categorized innovation into two types:

PROGRESSIVE INNOVATION This is where a product or service evolves in stages to adapt to changing business needs. Most companies already do progressive innovation and likely don’t give it much thought. For most it’s just part of doing business and staying competitive. In progressive innovation, change happens at a very measured, incremental pace, allowing everyone equal opportunity to react and catch up regardless of where they are on the playing field. In business this creates a “race to the bottom” scenario, as cost becomes the only real differential between competitors. Survival becomes a simple numbers game - with the companies that can operate on the smallest possible margins coming out the ‘winner’. The problem here is these types of wins do not always guarantee long-term business success.

History has shown that at some point, someone is going to change the playing field – and those without the capital to invest in R&D, workforce skills and new equipment or upgrades will be hard pressed to keep up.

DISRUPTIVE INNOVATION This is where a company takes a radically different approach to winning market share and in one big step change commonly held notions and ideas. It is no longer about moving the ball down the field, it about creating a whole new field, maybe even inventing a new game to play on it. The goal here is to open up and lock up brand new markets, or dominate the ones you are in, or both!

When done successfully, disruptive innovation puts you in the “driver’s seat”, forcing competitors to react. As you might guess, not everyone is going to be able to react, or react fast enough – which means they will rapidly exit the market, opening up yet more revenue potential.

So how does someone get ‘disruptive’? Start by looking at your nearest competitors and who their customers are. Take the time to learn what these customers really want and how their needs are being serviced – you may be surprise to find out neither are what you assumed.

The next step is to get an understanding of your own

situation with respect to what you have uncovered. You might want to look at quality systems like LEAN and assessment tools like the CWB Ian Campbell, Director of Value Optimizer program as a Marketing and New Product starting points for getting a handle Development, CWB on your current state of business.

This is your starting position.

READY, SET, GO! Once you know where you stand, start thinking about how you can improve your position though expanded staff knowledge and certification/ accreditation, partnerships with other players, initiatives like capacity and skill sharing agreements (within and outside your current market) and other key business activities. Also think about things like improved access to materials, transport, grants and tax breaks, training funds and expanded labour pools.

This kind of thinking might lead you to some interesting possibilities.

Being disruptive is also tied to your willingness to invest. If you are going to invest, then invest in technology, training, partnerships and business processes (don’t forget marketing!) that will put the maximum distance between you and the competitors. Alternately, maybe the right thing to do is invest in your competitors – partnering with them to create a more competitive team.

Regardless, the key is doing something different that makes a big impact in the market. Don’t run immediately to the obvious options based on what you think you know, and don’t just invest in a newer version of what you already have. Look at what is available in the market and measure this against what your customers need now and in the future. If by switching focus, partnering and or jumping a technology generation ahead of everyone else results in delivering superior value to the customer – then you are likely looking at the fastest way to the finish line.

Finally, it’s worth noting that doing the bare minimum may keep you in the game – but for how long? Clearly being disruptive comes at a cost, but so does doing nothing. Ask yourself is are you playing to win, or just standing on the sidelines hoping the action will head your way … sometime … maybe … ?

As always, reach out for help when you need it. The CWA and CWB Group are here to help grow the Canadian welding and joining industry and are just a call away.

Canadian Welding Bureau/Canadian Welding Association

30 | APRIL 2014 | www.canadianmetalworking.com

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Job Shop Snapshot

J & J Trailer, Toronto, Ontario

A

s the company name implies, J & J Trailer specializes in “trailer fabrication, sales, service and spare parts,” says president, Al Abdelmalek, P. Eng. This busy Toronto-area firm also does custom metal fabrication on the side and has full CNC plasma welding and CAD capabilities.

The company offers a range of custom-designed and custom-built equipment, including flat-bed trailers, water tank trailers, cable reel trailers, heavy equipment low-bed trailers, disposal bins, car and truck hitches, truck ramps, etc.

“Our versatile and durable trailers are designed to carry virtually any type of load, including heavy equipment, building materials, water tanks and even vehicles,” states the J & J website.

The handling capacity of these trailers ranges from five to 85 tonnes.

J & J also offers a wide range of trailer parts, from lights and wiring, to axles and suspension, tires and rims, jacks, hitches and accessories, brakes and bearings, hydraulics and hardware.

Additional, related services include truck and trailer sandblasting, truck and trailer painting and the application of anti-slip floor coating on trailers. The company can also design, build and install truck ramps, manufacture and install truck and trailer hitches and do complete overhauls and rebuilds.

“J & J Trailer was founded in December, 1974 by Joseph Mongilo. In September, 2005, I bought the company and moved to a new location and expanded operations by approximately 300 per cent,” says Abdelmalek.

J & J Trailer currently operates from two separate locations. There’s an east-end locale in Scarborough, ON, that

houses the main manufacturing plant, sales, service and parts. Then there’s a west-end locale, in North York, ON, that handles sales, parts and service for that region.

Abdelmalek isn’t sure what the first machine the company ever purchased was. J & J’s current equipment inventory, however, is posted on its website, for all to see. The list includes three oversized drive-in doors, five overhead cranes each weighing five tonnes, six large paint booths (with airless and electrostatic painting gear), 16 MIG welding machines, two shears, two press brakes, three ironworker machines (coming in at 10 tonnes, 35 tonnes and 75 tonnes), two Hydmech miter saws, two band saws (one horizontal and one vertical), six fork lifts and four drill presses.

Additional gear includes two plasma cutting machines, 11 torch-cutting sets, one stick-welding machine, an axlewelding fixture, a 50-tonne hydraulic press, a tire-changing machine, pipe notch machine, belt sander, twist machine, stone grinding machine, a state-of-the-art CNC plasma table, etc.

The most recent machine the company purchased is a CNC plasma cutting machine. On the company’s wish list is a large brake (metal bending) machine.

Business is increasing, which poses certain challenges in that floor space in the manufacturing plant is getting tight.

It’s a nice challenge to face, however, compared with earlier challenges cited by Abdelmalek, such as finding qualified personnel and updating equipment.

Abdelmalek foresees continued growth and improved quality at his shop as well as expansion into new products and new markets.

Asked to comment on the future of Canada’s machine shop sector in general, and Abdelmalek offers a one-word summary: “Promising.”

ESSENTIAL NUMBERS FOUNDED: 1974 OWNERS: Al (Wael) Abdelmalek, P.Eng SIZE: 22,400 square feet NUMBER OF EMPLOYEES: 22 SPECIALTIES: Custom metal fabrication, trailer design, manufacture, repairs and servicing, trailer parts, car and truck hitch design and installation, manufacture of disposal bins

forming, machining, CNC plasma and welding machines, in addition to lots of other small tools.

MOST RECENT ADDITION: CNC plasma cutting machine QUALITY STANDARDS USED: CWB certified/Division 1 certified (welding), DOT; internal quality systems

MARKETS SERVED: Industrial transportation and personal automotive

WEBSITE: www.jjtrailer.com and www. jjtrailer.ca

EQUIPMENT: Approximately 45 metal

FUTURE PLANS: Expansion

32 | APRIL 2014 | www.canadianmetalworking.com

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CUTTING TOOLS High feed milling rules

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contents

Revving up for the auto recovery

Cover photo ©Ingram Publishing/Getty Images/Thinkstock Background photo: ©SafakOguz/Getty Images/Thinkstock

W

ho would have thought, just a few short years ago, that 2014 would be a good time to be a moldmaker or automotive supplier?

Market analyst IHS Automotive projects that automakers will build 16.1 million cars and trucks in North America this year — up four per cent from 2013, and a ten-year high.

It’s good news and it will likely get better still. Analysts such as Canada’s Dennis DesRosiers are forecasting historic levels of new work that will be up for bids to North American auto parts molders and moldmakers. In service of post-recession pent-up consumer demand, automakers are expected to launch approximately 70 new vehicle models each year for the next five years — compared with about 40 all-new vehicle models launched each year before the auto slowdown and recession — each of which will need new molds for new exteriors and interiors, including new body moldings, new fascia, new lighting, new electronics, and new under-thehood parts. And it’s more than just unit growth; the auto industry is poised to pick up business from OEMs looking to cut vehicle weight to satisfy upcoming CAFE regulations.

But there’s a problem: the manufacturing sector — and the mold, tool, and die industry in particular — is nowhere near the employment level it should be to take advantage of the automotive growth. In 2006, for example, there were 27,626 workers in the tool, die, and machining field, according to Statistics Canada, a number that plummeted to 18,597 in 2010. And it hasn’t really recovered.

Given that handicap, is the Canadian automotive sector ready for the resurgence? We’d better be because — bet on it — competitors in weaker global markets are going to be swarming in faster than flies at a barbecue.

Jim Anderton, editor Canadian Metalworking

38 Market Outlook: Red light, green light A new vendor tooling study identifies some major obstacles ahead for North America’s auto industry...and a few ways to get around them.

41 Cutting Tools High feed milling rules!

48 Machine Tools Cavalier Tool & Manufacturing is doing it right with big, high value molds.

54 Tool Steel Mold steel considerations for buying the best in performance.

59 Skills Training Valiant Machine & Tool has a training program that works.

Here’s how.

62 Moldmaking, Shop Floor Components Here’s some of what’s new, now.

Mark Stephen, editor Canadian Plastics

A supplement to Canadian Metalworking and Canadian Plastics

Canadian Plastics www.canadianmetalworking.com | APRIL 2014 | 37

2014 April Mold Supp_widerMetalwork folios.indd 37

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market outlook

By Mark Stephen, Canadian Plastics

©leszekglasner/Getty Images/Thinkstock

RED LIGHT, GREEN LIGHT A new vendor tooling study identifies some major obstacles ahead for North America’s auto industry — and a few ways to get around them.

A serious vendor tooling capacity constraint will hit the North American automotive industry by 2018, a new report concludes, and it’s going to affect the entire value stream from vendor tooling suppliers to Tier 1 suppliers to original equipment manufacturers (OEMs).

According to the 2013 Vendor Tooling Study by Royal Oak, Mich.-based automotive market research firm Harbour Results Inc. (HRI) and the Original Equipment Suppliers Association, in approximately five years the required capacity of the vendor tooling industry will reach US$15.2 billion, with available current supply of only US$9.25 billion. Vendor tooling — tooling purchased by the OEM to be run in Tier 1 or Tier 2 facilities — is a crucial part of the automotive industry and the vehicle development process, accounting for an average of US$550 per vehicle in North America at 2012 vehicle volume.

“Capacity will become a serious challenge for the automotive industry in the near future,” said Laurie Harbour, HRI’s president and CEO. “If the North American tooling industry doesn’t respond to the challenge, someone else — such as European and Asian tooling suppliers — will,” The study — which gathered information from 10 OEMs, nearly 50 major Tier 1 suppliers, and more than 50 global tooling suppliers — identifies several factors that will contribute to the demand increase, including mass customization, increased complexity, European and Asian OEM tool localization to North America, increased vehicle content, a looming skills shortage, and increased price pressure.

THE VIEW THROUGH THE WINDSHIELD The study begins by sketching the current state of North America’s automotive and automotive tooling industries.

“The global economy has been gradually recovering from the 2009 recession, and near-term global vehicle demand holds in positive territory, but the picture is mixed across the landscape,” the report said. “Sales in North America (rising seven per cent to 18.4 million units) and Asia (rising five per cent to 35.7 million units, driven by China at 11 per cent or 21.3 million units) saw the largest growth in 2013. The balance of the regions remained flat or saw a drop in light vehicle sales. In total, global light vehicle sales increased four per cent to 83.4 million units.”

Forecasts of vehicle production growth indicate that Asia will remain dominant and, specifically, China will continue to be the most rapidly growing area. “From 2012 to 2017, global vehicle capacity will increase from 111.7 million units to 134.7 million units,” the study said.

“Regional production will be driven by emerging growth and mature recovery. Globalization and localization will shape future vehicle production.”

For the first time since 2002, the study continued, North American production hit 16 million units in 2013, which included a four per cent growth in production volume from 2012 (15.4 million units) to 2013 (16.1 million units). North American light vehicle sales will continue with gradual growth for the remainder of the decade. “U.S. growth will be spurred by retail sales, which should outpace expectations,” the study said. “By 2020, the projection is that the North American sales volume will be more than 20 million units — numbers that this market has not seen before — with the largest percentage of growth forecast to come from Mexico, which is expected to grow by 10 per cent.”

The key dynamic in the North American auto industry for the last several years has been the change in con-

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market outlook sumer taste, the study noted. “Vehicle owners are looking for something very different in their automobiles than in the past,” the study said. “These new consumers want customized, exciting new features and technology. This has driven tremendous complexity into vehicle offerings and the need for mass customization. In response, automotive OEMs are designing more models from common platforms and increasing the vehicle mix, while producing fewer vehicles per model. As a result, there will be fewer vehicle platforms with more models, an increased number of trim packages, and more options than ever before.”

The problem? As mentioned above, there’s a capacity constraint coming, and it’s going to put a serious crimp in the industry’s ability to satisfy these projections.

HANDLING THE CURVES So how does the industry rise to the challenge? The report recommends a three-pronged approach. First, Harbour said, the industry would see a 10 to 20 per cent reduction in absolute tool costs if there was more collaboration between OEMs, Tier 1s, and tooling suppliers as early as 36 months before vehicle launch. “Increased collaboration leads to improved manufacturing feasibility, increased input on part design, improved understanding of supplier capabilities, and more,” Harbour said. “Modifying processes throughout the vendor tooling value stream will not only improve tooling cost, but, more importantly, improve capacity needed to offset the impending constraint. OEMs, Tier 1s, and tooling suppliers will need to work together to create more efficient practices and reduce wastes throughout the entire process, from planning through to development, kick-off, production, and beyond to address the entire capacity gap.”

Second, there needs to be an industry-wide focus shift away from price and towards cost. “Too often today, the industry is focused on the increased price pressures and the price of tools, rather than the cost created through-

Proportion of tooling available for planned vehicle launches

Credit: Harbour Results Inc.

Projected size of N. American tooling industry

Credit: Harbour Results Inc.

out the entire tooling value stream — OEMs are utilizing a number of different tactics to lower the price of tools and services, including adjustment of payment terms and low-cost country sourcing,” Harbour said. “Seeking lower prices, especially with low-cost countries, is not the answer. The advantage gap for countries like China has been shrinking and will continue to shrink. China is still an option for tools, but high complexity, critical tools will stay here. If the focus does not shift to managing costs, the industry will face incredible challenges as capacity grows in this region.”

And third, the industry has to find, and eliminate, inefficiencies in the value stream. “OEMs, Tier 1s, and tooling suppliers need to analyze the entire value stream to identify key areas of improvement,” Harbour explained. “Inefficiencies, such as multiple or late-in-the-game engineering redesigns, come with a significant cost that could be avoided by adjusting current processes. A majority of the costs associated with the vendor tooling value stream are a result of process wastes and, when improved, can make a considerable difference to the overall cost of the industry.”

THE ROAD AHEAD Getting more specific, the study examines the respective steps that OEMs, Tier 1 suppliers, and tool suppliers are going to have to take to better adapt themselves to this brave new world.

“OEMs have to decide what needs to evolve within their strategies and tactics to secure their portion of capacity among tool suppliers,” the report said. “Are progressive payments critical to secure capacity? What are the most important modifications of strategic elements that will develop long-term relationships and allow tool suppliers the comfort they need to commit to upfront involvement in the design process? For newer OEM entrants to North America, it’s critical to develop the strategy to break into this tool supply base and create the right relationships.”

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market outlook Tier 1 suppliers, meanwhile, have to decide what role they want to play. “As the middleman, many have actually talked about making their own tools directly and are investigating putting in their own tool shops today,” the study said. “This may or may not be the right decision, and in some cases the OEMs will not be excited about this possibility, but the Tier 1 companies have a difficult role to play between the tool supplier and the OEM. In the end, they have the right to make profit for management of tools, and they have the responsibility to manage that effectively and appropriately.”

And last but definitely not least, the tool suppliers have to decide if they want to evolve and work on what they control, invest more in those relationships, and support this future gap in capacity. “Tool suppliers have to strategically start asking their customers, ‘What is it about you that makes me want to do business with you?’”, the study said.

The key for all three stakeholders — particularly the OEMs — is consistency of strategy, the study said: “If they change after one attempt, why would suppliers and tool suppliers continue to follow them, and how would things actually change in the long run?” Additionally, OEMs

have to focus on a strategy that’s right for them and not try to borrow one from the firm down the road. “Every company has a different culture, and the strategy has to fit the culture of that company,” the report said.

If the findings of the Harbour report strike you as Stephen King-style scary, you can semi-relax: it all ends on a positive note. “If the stakeholders are able to achieve the recommended collaborations, the vendor tool industry in North America will meet the future demand; the industry will keep a large manufacturing base in North America; the skills gap will be minimized, reducing the crisis in the country; OEMs will be able to invest in more products, in particular low-volume models that are typically cut due to high investment budgets; and new technologies, such as aluminum tools, will be able to be implemented,” it concluded.

It might just be the nearest thing to a happy ending the North American auto sector has experienced in years.

MT&D For the full HRI 2013 Vendor Tooling Study, or for more information, contact Harbour Results Inc. at info@harbourresults.com or 248-629-9331.

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cutting tools MOLDMAKING: High Feed Milling Rules

By Nate Hendley, Canadian Metalworking When asked about cutting tool trends on the moldmaking front, industry pundits repeat the words “high feed milling” like a mantra.

“The main tool used in the mold and die industry is high feed milling cutters for roughing. High feed milling works from a chip thinning theory, by using the lead angle of the cutter. This has transformed the way today’s applications are produced. The past method was to take large DOC (depth of cut) with very low feed rates with a 90 or 45 degree cutter. Today the industry has moved to high feed milling small DOC with high feed rates,” says Thomas Hagan, milling product manager, Iscar Canada in Oakville, Ontario.

Hagan does not see shops going back to their old ways: “High feed is definitely the way to go. It increases your productivity,” he says.

It’s a sentiment shared by others in the field.

“We would totally agree with that. A high feed cutter is designed to have very low depth of cut but work at a very, very high feed rate. This usually produces a lot less load on the machine tool itself...doing such a low depth of cut and going very fast tends to be a much better way to machine the part. Overall, it’s usually a much faster metal removal rate than taking a large depth of cut at a slow feed rate,” says Cullen Morrison,

business development manager of threading at Komet of America, in Schaumburg, Illinois.

In terms of other new developments in moldmaking methods, William Fiorenza, die and mold product manager at Ingersoll Cutting Tool in Rockford, Illinois, points to roughing applications.

“As far as milling goes, mold manufacturers and programmers are beginning to push the envelope with regards to roughing techniques which I believe [will save money for] moldshops,” says Fiorenza.

On the same note, Morrison says moldmaking programming technology is improving.

“I’ve seen quite a bit of evolution with CAM systems...for quite some time, the tooling manufacturers were ahead of the CAM programming and now we’re starting to become pretty equal and we can see some pretty good performance with that,” he says.

According to Hagan, the recovery of the moldmaking sector is a good sign for the economy as a whole.

Moldmaking has “definitely picked up from where it was in 2008. Now we’re seeing a huge increase in the mold and die industry. That’s good.

Once you see an increase in mold and die, you know the rest of the industry will pick up too. It’s good all around,” says Hagan.

Here’s a look at what’s new and/or noteworthy in cutting tools for molds: Horn USA Horn USA, of Franklin, Tennessee, has a new DAH25 high feed milling system that includes four end mills with Weldon toolholders offering cutting edge diameters of 12, 16, 20 and 25 mm (0.472 inches, 0.631 inches, 0.787 inches, and 0.948 inches respectively).

The end mill with the 12 mm cutting edge diameter comes with two indexable inserts, while the end mills with 16 and 20 mm cutting edge diameters have three indexable inserts and the end mill with the 25 mm cutting diameter has four. Shanks have internal cooling and the holders have TiN coating. MaxiHorn USA’s new DAH25 high-feed milling system. mum cutting depth

is 0.8 mm (0.031 inches) while the cutting edge corner radius is 0.4 mm (0.015 inches).

Like previous DAH high feed milling systems, DAH25 is designed to boost productivity in roughing operations by “removing material at high feed rates,” says Jason Farthing, marketing and sales coordinator at Horn USA. Horn plans to introduce carbide insert grade SC6A—previously introduced to the DAH62 and DAH37 systems—to the DAH25 system, “later this year,” adds Farthing. www.hornusa.com/

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for drilling depths in these product ranges.

The Titex X-treme DM micro drills which can be used in die and mold applications, have internal Walter USA’s expanded cooling, optimized point Titex X-treme DM geometry with special cutmicro drilling line. ting edge preparation, and precisely dimensioned flute geometry. The endresult is exceptional chip formation and significant process reliability. Flutes have polished surfaces, which enhances chip evacuation.

Walter USA has “another program” in the works, but it’s “too soon to talk about … it is in the microdrill area, without coolant through,” says Pat Nehls, product manager at Walter USA. As for Titex X-treme DM micro drill handling tips, he says, “Small diameter drills are sensitive to run-out. So use it in a shrink holder.” www.walter-tools.com

Ingersoll Ingersoll has introduced the Hi-QuadXXX—a 30 degree bevel high feed face mill with 13 mm and 19 mm IC insert sizes.

“The Triple X has the ability to operate at lower speed and leverage the depth of cut … depending on the application, you can actually almost triple your material removal rate,” says Fiorenza.

Like its predecessor the Hi-QuadF high feed milling family, the Hi-QuadXXX offers flexibility and a wide application range. The Hi-QuadXXX can be used for aerospace and general purpose machining in addition to die mold work. This versatile mill boasts seven different geometry options and two insert sizes with four indexes per insert.

According to Fiorenza, the most notable feature of the Hi-QuadXXX is its “aggressive ability to leverage a deeper depth of cut while maintaining the free cutting nature of a shallow depth of cut high feed mill.”

As for HiQuadXXX handling tips, he adds, The Hi-QuadXXX 30 degree bevel high-feed face mill from “If I was a moldIngersoll. maker or a lead pro-

The idea: Achieving cutting performance and tool life in highly abrasive materials.

Why it’s great: • Drills and milling cutters with proprietary diamond coating • For machining CFRP, graphite, and aluminum alloys • Engineering and testing capabilities to deliver applicationspecific tools for your unique machining operations Learn more about this and other great ideas.

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cutting tools grammer in a mold shop, I would be looking at heavyduty MPR inserts.”

MPR inserts are notably strong, with a flat rake face and a large insert radius profile for deeper depth of cut and aggressive operating parameters. www.ingersoll-imc.com

Data Flute “A common problem faced by many machinists is how to solve the issue of varying stock still remaining on a mold after roughing. As a programmer, I have specified the amount of stock I want left for semi-finishing, but as a machinist I can see there is excess material, sometimes in varying amounts, in areas of my mold. Frequently, the only solution is to stand by the machine and slow the feed rate down in these areas or if I am running multiple machines, run The SS-I-4 BN the entire program at a lower solid carbide end mill from feed rate. At Data Flute we Data Flute. have developed a tool that can

be run at 100 per cent feed rate and still handle this varying material when profiling and 3D contouring in all mold materials up to 56 RC,” says Dan Holmes, Canadian sales manager at Data Flute, which is headquartered in Pittsfield, Massachusetts.

“The tool to use is the SS-I-4 BN [ball nose] solid carbide end mill. We have taken our variably indexed, four flute, SS-I geometry and added a precision, CNC ground full ball. Data Flutes’s unique end geometry allows for heavier, and varying chip loads at higher metal removal rates for roughing, rest milling and semi-finishing. So rather than slowing down and sacrificing productivity, you can run at full feed rates with confidence,” says Holmes. www.dataflute.com

Kennametal Kennametal’s new Rodeka inserts for indexable milling work well in moldmaking applications, says Kennametal’s new Rodeka Juan Seculi, the Latrode, inserts for indexable milling.

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cutting tools Pennsylvania-based company’s senior product manager, global product management, indexable milling.

“Traditionally, round inserts are the cutting tool of choice for complex 3D shapes such as moldmaking … inserts do make a difference. Kennametal’s Rodeka inserts are double-sided with up to 12 cutting edges and are available in a comprehensive range of sizes and styles, including screw-on, end mills, and shell mill cutters with internal coolant. Three different insert sizes and three topographies per size cover any type of work material and application,” says Seculi.

Kennametal’s –LD style insert is recommended for stainless steel and titanium operations with a honed edge for light to medium machining. The –GD insert style is recommended for medium to heavy machining and is a good choice for general purpose applications.

The Rodeka –HD inserts meanwhile can be used for heavy machining applications and cast iron materials. www.kennametal.com

Iscar Iscar’s Helido H606 double-sided profiling inserts are “an excellent solution for profiling applications that require ramping down or face machining with shoulder milling,” says Hagan.

These inserts can be used in semi-finishing and roughing operations as part of the mold-making process, he adds.

The Helido H606 features a 6 mm radii with 90 degree vertical cutting edge, very positive rake angle to lower power consumption, dovetail rigid clamping, AXT chipformer for steel and cast iron, AXMP chipformer, suitable for austenitic stainless steel and high temperature alloys and a diameter range of 40 - 80 mm.

“The Helido H606 double-sided insert provides 6 x 90 degree cutting edges, both with ramping down capability. We are able to place more inserts on the cutIscar’s H606 double-sided profiling insert.

ter than a regular button insert. This enables Iscar to provide more productivity,” says Hagan.

Iscar has also introduced the H600 WXCU 070515… insert for roughing, among other mold-related operations. www.iscar.ca

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cutting tools

Niagara Cutter’s MZN410R/510R solid-carbide cutter, as distributed by Seco Tools, LLC.

Seco Niagara Cutter’s high feed cutters excel at mold making, according to Seco Tools, LLC, which distributes the tool.

“Niagara MZN410R/510R solid-carbide cutters from Seco Tools, LLC, deliver high feed machining capability for reduced cycle times in moldmaking applications.

With special designs, the tools transfer cutting forces

axially into machine tool spindles rather than radially. This allows mold shops to use lighter duty machines, yet with the same benefits as would result from using heavier duty machines,” says Larry Lefkof, manager of Niagara Sales at Seco LLC, headquartered in Troy, Michigan.

“The Niagara high feed cutters, offered in inch sizes, provide much tighter and closer access to smaller corner radii at mold cavity floors and side walls. There is less cutting tool pressure (wall contact) than is the case using a ballnose or round inserted tool. Plus, the cutters provide process reliability—in addition to increased metal removal rates—for unattended operation, thus freeing operators to tend multiple machines,” says Lefkof.

HE IND EX INC

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Komet of America Komet’s Quatron hi.feed milling cutter is not new, but it has been undeservedly overlooked, says Morrison.

“It’s an excellent tool for die and mold but hasn’t quite got the popularity and following we were hoping for,” he states.

This product ignorance might be based on the fact Komet had “always been known as an indexable drilling company in boring and reaming” not a manufacturer of milling tools, says Morrison.

In any case, the Quatron hi.feed milling cutter is specifically designed for plunge milling, a machining style for cutting deep grooves and large cavities. A high-performance roughing tool, the Quatron hi.feed can manage high feed rates, up to 2 mm per cutting edge. www.komet.com

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AGGRESSIVE in WINDSOR Cavalier Tool & Manufacturing Ltd. wins in Windsor with big, high value molds.

By Jim Anderton, Canadian Metalworking

When times are tough, there’s only one way for manufacturers to come out ahead of the rest: by being aggressive and forward thinking in their business planning and investments. Cavalier Tool & Manufacturing Ltd. of Windsor, Ontario, took this approach by investing in high speed machining capabilities and has reaped the rewards ever since.

Cavalier Tool, established Cavalier Tool boasts 85 employees, a 50,000-square-foot facility, tools for 250 to 4,000 in 1975, is a global manufac- ton presses, and produces over 200 molds per year. turer of mid-sized to large molds for the automotive, commercial, recreational, door panels. Within these applications, the company medical and aerospace industries. It specializes in appli- uses a wide range of materials but primarily works with cations with high glass content including fans, shrouds, aluminum, P20 and H13. In fact, Cavalier Tool is the radiator intakes, lighting tools, door carrier plates and single largest consumer of aluminum in Windsor.

“It’s important to know the capabilities you’re strong at and those where you could use some improvement,” says Brian Bendig, president of Cavalier Tool. “For the longest time, high speed machining in hardened material wasn’t our strong suit, and as such we relied heavily on outsourcing. However, once the economy took a turn for the worst, we decided it was time to regain control by investing in high speed machining to ensure quality mold finishing on hardened materials.”

HARD MILLING, EASY CHOICE

Investing in new capabilities pays off with short- and longterm benefits in cost-cutting and increased productivity.

The shop that Cavalier Tool was previously using to machine hardened material applications employed a Makino A100 horizontal machining center, and Bendig was impressed with the speeds, accuracy and milling surface finish it achieved. So when it came time to reevaluate Cavalier Tool’s high speed machining capabilities to recapture the hardened work it was outsourcing, Bendig turned his eye toward Makino’s selection of high speed horizontal machining centers.

“We wanted a machine with high-quality milling surface finish capabilities that could manufacture molds

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machine tools quickly, accurately and with high repeatability,” he says.

“We had a lot of work coming through and had been researching machines for a couple of months. We had a relationship with Makino, as we have a Makino SNC 86 graphite mill and have been happy with the results it produced. Another reason we wanted a Makino was longevity and reliability. We knew a Makino HMC would be able to support our business well into the future. Our oldest Makino has been on the floor for 17 years, and still provides reliable high-quality mold finishing.”

In June 2010, Bendig invested in a Makino a92 horizontal machining center based on its similar characteristics to the A100.

The a92’s 10,000-rpm spindle, 1,969 IPM rapid feed rate and 0.4G acceleration/deceleration rates offer Cavalier Tool a whole new level of productivity in its large-part production. Its extra-rigid machine construction reliably provides extremely tight positioning tolerances of ±0.00010 inches, with a repeatability of ±0.00006 inches.

The machine has a 31-inch-by-39-inch pallet and X-, Y- and Z-axis travels of 59 by 49 by 53 inches to handle workpieces up to 59 inches in diameter and height, and weighing up to 4,400 pounds. Its automatic pallet changer allows for a full pallet change in 23 seconds, significantly reducing spindle downtimes that occur during setups on vertical machining centers.

A WELCOMED ADDITION WITH IMMEDIATE IMPACT The a92 was a welcome addition, and Cavalier Tool saw an immediate impact as soon as the machine arrived on the shop floor. One of the greatest advantages of the a92 is its speed.

“A lot of times, the orientation of the glass in the mold finishing process is an unknown during tool

Cavalier specializes in applications with high glass content including fans, shrouds, radiator intakes, door carrier plates, door panels and lighting tools like the automotive turn signal element shown here.

Cavalier’s Makino a92, a high speed, high torque production machining centre with an X-Y-Z of 1500 mm x 1250 mm x 1350 mm.

production,” says Bendig. “As a result, we have to be prepared to handle any engineering changes from the OEM that occur during our production process. This makes it critical for us to be able to set up and tear down parts as quickly as possible without disrupting our overall workflow.”

The a92’s automatic pallet changer, combined with a rear-clamping FCS fixture system, enables Cavalier Tool to quickly and accurately set up several parts on a single tombstone without interrupting the current high speed machining processes or losing positioning accuracy. The rotary B-axis table provides increased flexibility much like that of a 5-axis machining center but without the inherent reduction in accuracy.

“The combination of Makino’s programmable through-spindle coolant technology, 92-capacity automatic tool changer and B-axis rotary table enable us to perform several types of operations with fewer setups,” says Mike McNaughton, Cavalier Tool’s machining supervisor. “This configuration allows us to do drilling, boring, thread milling, tapping, 2-D and 3-D machining without the operator ever touching the part. With jobs we’ve transferred to the a92, we’re typically seeing a 50 per cent reduction in the number of setups and up to three times the productivity of previous processing techniques.”

Cavalier Tool reports that, in hardened materials, the Makino a92 completes jobs up to twice as fast as

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machine tools A Pulse monitoring system enables Cavalier to gather idle times, feed rates, component name, operation type, operation length and more in an organized daily, weekly or monthly report.

with competitive machines. The shop also tracks spindle utilization through Lemoine’s “Pulse” machine monitoring software.

“All of our machines are monitored day in and day out through our Pulse monitor for performance tracking,” says Bendig. “With this system, we’re able to gather idle times, feed rates, component name, operation type, operation length and more in an organized daily, weekly or monthly report. In each of these reports, the Makino demonstrates exceptional performance with spindle uptimes frequently in the 90 per cent range.”

ACCURACY IS KEY Speed and uptime are nice, but they are insignificant if the machine isn’t accurate. Of course, the goal of any machine shop is to process at a level of mold finishing quality that no longer warrants secondary machining operations or benching procedures. The Makino a92 provides that capability to Cavalier Tool.

“The rigidity of the a92’s Z-axis has allowed us to significantly reduce the time we spend performing secondary gun-drilling operations,” says Bendig. “With the ability to accurately and reliably drill up to 10 inches deep, we’re able to complete primary gun-drilling operations on the a92, saving us from wasting costly time performing two setups on our gun-drilling machine.”

The a92’s horizontal configuration and coolant management technologies have enabled Cavalier Tool to avoid recutting of chips for the highest level of accuracy and milling surface finish achievable.

“Even the slightest inaccuracy in some of our applications can

cause huge problems down the road,” says McNaughton. “If a single blade in one of our fan tools is off by even 0.001 inch, this could cause a slight imbalance in its use that would ultimately reduce the fan’s life span. With the a92, we’re able to dramatically exceed required specifications

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machine tools with tolerances under plus or minus 0.0001 inch for perfect seal-offs and little spotting.”

“The overall milling surface finish produced on the a92 has substantially reduced spotting and benching times as well,” says Bendig. “Every tool coming out of the a92 is pre-tapped, chamfered, engraved and with mold finishing and milling surface finish that require little to no manual labor. Instead of starting at 80-grit benching procedures, we can move straight into 200 grit. And in many cases, it actually takes longer to put the tools in the press than it does to spot them.”

Cavalier Tool’s a92 offers nearly three times the productivity compared to their previous technology.

GROWING IN A DOWN ECONOMY Cavalier Tool has proven a shop doesn’t have to be at the mercy of the economy. The company took steps to add capacity in order to acquire more business and regain business it was outsourcing, and the PowerUpAd-CanMetal1113_layout 10/9/13 11:19 AM Page 1

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machine tools efforts are paying off.

“We’ve acquired a lot of new customers and continue to grow,” says Bendig. “We’ve become successful because of how we machine. We leave the simple stuff to other shops. Everything we do is complex.

From high speed machining to milling surface finish capabilities and mold finishing, Makino has helped us deliver.””

How well is the company doing? So far, its best year was 2009. While other companies were laying off staff and closing their doors, Cavalier Tool had its best year ever. The company isn’t satisfied, however. It recently opened a 20,000-square-foot facility in El Paso, Texas, to serve the Mexican market.

“The a92 has added more versatility to our operation,” says McNaughton.

“The Makino has reduced our setup time, costs and handwork. It’s helped us increase production even though we removed seven machines from the shop floor.”

Of course, Makino isn’t the only factor in Cavalier Tool’s success. Bendig believes in order to be successful, a shop needs to focus on three things: people, processes and equipment.

Cavalier Tool has done just that for 36 years, and it won’t be changing its approach anytime soon.

Cavalier Tool & Manufacturing Windsor, Ontario www.cavaliertool.com

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tool steel

By Jim Anderton, Canadian Metalworking

SMART

STEEL Mold steel considerations for buying the best in performance Modern rouging tools using advanced inserts like these Iscar products can hog out a rough cavity very quickly, even with pre-hardened materials.

There are a thousand ways to spell “trouble” in plastic mold manufacturing and when it strikes, the finger pointing begins in earnest. The material is always a suspect, which is natural when dealing with defects, but there’s a lot going on in a cavity or block between skinning the steel and final benching. Here are some problems and causes of common issues:

SOFT AREAS ON THE MOLD SURFACE Soft regions in the mold surface post heat treating can affect all performance aspects of the mold, but in particular lower wear resistance and reduced life are the biggest. Some basic causes are: •P oor or no surface preparation prior to heat treating • I ncorrect or inadequate heat quench cycles •W rong or contaminated quenching medium •M ismatch between desired hardness spec and steel or process.

How can we prevent these problems? Oxygen is the enemy of most processes that alter material properties, and mold steels are no exception. Oxide layers are a bad thing and should be removed, and optimal heat treatment should occur either in a vacuum, or controlled atmosphere oven. Wrong or inadequate heat/quench profiles occur due to two primary factors. The first is

specification related. Most mold builders have a desired surface hardness they need for achieving polishability, but rarely specify a particular heat treat methodology.

Lead times are short these days, and the need to turn around mold parts quickly results in pressure to cut corners in cycle times or substitute marginal processes to meet delivery deadlines. Done properly, there’s no way to cut corners in heat treating; switching suppliers to a treater or that promises very ambitious turnaround time may suggest that they’re shaving minutes or omitting entire steps in a process that often takes tens of hours.

The other issue is based on material selection. The mold maker may have a desired hardness, and even specify a particular heat/quench profile, but if the chosen alloy is non-uniform, dirty, or is marginal in its hardenability to the desired level, problems are highly likely.

Even a contaminated or incorrectly chosen quenching medium can have a major effect. It’s important to establish a good working relationship with the treater to understand the variables.

CRACKING Large or small, cracks on extensively machined mold part are frustrating and expensive. The nature of the heat treating process is that the soak at a specified ele-

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tool steel vated temperature develops and homogenizes a desired microstructure, which is then frozen in by quenching.

The key factor in quenching is that the rate of cooling is critical, rather than the final temperature. This is why different steel grades and different hardness levels require a variety of quenching media. Steels are crystalline solids, and the rapid rates of cooling associated with hardening seriously stress the material. Even worse, mold parts are not perfectly uniform, so varying section thicknesses cool at slightly different rates, introducing stresses that can both crack and distort the part. Some causes are: •C old plastic deformation and residual stresses in the part •C omplex part shape than consistent cross-sectional thicknesses • f ailure to remove the white layer on EDM parts • i ncorrect heat/quench profile for the steel chosen • i nadequate or no stress temper before heat treatment All machining processes deform the steel to some extent, and residual stresses have to be relieved to prevent later cracking or deformation, especially if machining processes are aggressive and/or the material selection is susceptible to stress cracking. Modern

Figure 1

alloys are harder, more complex and high productivity mold making uses very aggressive cutting profiles with high feeds and speeds all of which combine to put considerable stress into the part. Cavities are more complex than ever with little consistency in wall thickness, making it impossible to achieve exactly the same quenching conditions uniformly throughout the part. Experienced heat treaters will spot this problem before they treat, and can compensate to some extent (by damming or plugging holes for example), to slow heat soak and cooling in some critical areas. Similarly, a good heat treater will spot a mismatch between the requested specification and material selection and part shape. Sometimes it’s simply not possible to safely achieve the hardness requested without a serious cracking risk. A stress relieving heat is a good practice, as is mold design that takes steel grade selection and heat treating into account. And like the soft spot problem, clean, uniform material is essential.

PROCESSES FOR CLEAN, CONSISTENT METALS

Multi-cavity and family molds can be very large, representing a major upfront investment. In-machine welding is tempting, but done properly, the mold should be removed and properly prepared for a weld repair.

Great molds always start with highly uniform and homogenous metal alloys. One process that helps achieve super clean steel is electro slag remelting or ESR. Electro slag remelting is deceptively simple. In a water cooled ingot, a consumable electrode is re-melted in contact with a molten slag bath inside the crucible.

Electric current passing through the electrode provides the heat source, and as the electrode melts and the molten metal passes through the slag layer, pro-

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tool steel duction of sulfur and oxygen occur chemically. Another process, vacuum arc remelting is similar. In VAR, a source electrode is also melted by electric current in a crucible, except under a high vacuum. The crucible is water cooled and the ingot grows from the bottom up as the arc zone melts away the source electrode. The vacuum allows strong degasification before the metal solidifies resulting in very homogenous clean metal with minimal oxide content. Both processes give better hot and cold workability superior mechanical properties. Disadvantages to the processes are a limit to the size of bar due to size constraints on the crucible, and some waste as the ends of the ingot are often sawed away to ensure complete uniformity throughout the block (Fig. 1).

Another high-tech process getting lots of attention today is powder metallurgy. Powder technology works by compacting superfine metal powders and then firing the green compact in an oven to center the particles

into a solid mass. With a very fine very uniform particle size, grain boundary growth is also consistent, producing a block with essentially identical mechanical properties throughout. Sintered powder processes are popular for carbide materials, but advancements in vacuum and electroslag processes make remelted product a cost-effective alternative for even demanding applications like lens and die casting molds.

HARDENING IS STILL KEY The hardening process is still key to the production of long life molds, regardless of the starting metallurgy or machining processes. Despite its importance, the hardening process is still not well understood by many mold makers. Michael Schmidt, Division Manager, Bohler-Uddeholm Thermo Tech relates: “heat treaters have to be conscious of the geometry of the part and how it was machined. Heat treatment almost always results in some form of dimensional change. Our rule

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tool steel be in the tens of hours, days really, meaning time in a vacuum oven is apportioned by a strict schedule. It’s important to work with the treater to allow adequate lead time to get critical parts through the process and into the finished mold in time to meet delivery schedules.

It’s also important for the mold maker to thoroughly understand effective heat treating on their material. According to Schmidt, “There are grades that may be more susceptible to movement, some more susceptible Small, shaped inserts like these Seco tools, allow fine machining on small scales with hard materials, or at very high speeds with conventional grades. to shrinkage and some to growth….these are of thumb is typically one and a half-thousandths per variables that must be factored in. For customers that do inch, per side… that should be the minimum amount repetitive work, they may experiment with the first few left on the steel when it comes for heat treat. This tools or components and see what the trend is after heat should provide adequate stock to allow for proper treating, then adjust all subsequent orders accordingly.

Some companies for example know how much a hole clean up afterwards.”

In the 1990’s surface hardness was commonly 28- will change in size for a given heat treat process based on 32HRC, but today its common to harden to 34 HRC the historical data, so they leave a very specific amount of or higher. The higher surface hardness improves polish overstock for finish machining based on that knowledge.”

Prehardened material can eliminate many of these ability, but over polished surfaces are still at risk of pitting due to carbide pull out during the final stages of problems, and with modern insert technology, it’s posbenching. Higher core hardness is another reason for sible to machine very hard materials cost effectively, higher Rockwell numbers; today’s tools are larger, more but prehardened metal doesn’t always eliminate the complex and necessarily more expensive, so mold life is need for post treatment. Schmidt adds, “I think it’s a more important than ever. As molding toolmakers de- balancing act depending on the job itself and to some mand higher and higher through hardness, heat treat- degree how much money you have in that job. Iners now commonly use vacuum and a multiple stage serts and modern cutting tools can definitely machine heat treating process involving step heating with hours through hardened steels better, but there’s a definite long hold times at preset temperatures, as well as inter- difference between a hardened H 13 which may be 46 rupted quenching cycles, freezing intermediate micro- HRC, versus D2 or high-speed steel at a 60-62 HRC, structures than reheating and quenching again to a final, the latter being much more difficult. A P 20 with a fine microstructure. These processes are more involved, mid-30s hardness naturally is easier to machine, somemore expensive and just as importantly in a fast turn- thing that should be taken advantage of. Where it gets around shop environment, take time. For step heating tricky is when you work with hardness’ entering into and interrupted quenching processes, cycle times can the high 50’s (HRC) and above.”

MT&D

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skills training Turn the “Skills Gap” into your COMPETITIVE EDGE Mike Ouellette (right) on the shop floor with a student.

T

he job skills gap has been an ongoing subject of controversy. The problem is that while unemployment is high, many jobs remain unfilled because workers don’t have the skills to fill them. I am convinced that if we keep blaming things on external circumstances, we’ll prevent ourselves from creating the change we want and need.

The conversations around the skills gap are astounding to me, in that very rarely do I hear anybody putting a positive spin on this much-publicized challenge.

Most companies clearly know what they don’t want, don’t have, and don’t like, and unfortunately this is also

By Karin Lindner, Karico Performance Solutions where their main focus and attention goes. But what would you think if I told you that this gap actually presents you with an excellent opportunity to stay ahead of your competition?

Some companies are already refusing to accept the status quo. The companies that really get it have stopped blaming, moaning, and whining. And by doing something about it, they’re leaving their competitors in the dust.

AN EXAMPLE THAT WORKS If you’re looking for a shining example of what’s possible when you put your mind to it — set right here

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skills training in Canada, no less — here it is. The “Earn While You Learn” training program of Windsor, Ont.-based Valiant Machine & Tool Inc. is certainly unique in its own right.

It all started about five years ago with Valiant having a vast need for skilled workers. However, instead of complaining about it, they took action. With an aging workforce looking to retire and not enough young people to fill the gaps, they knew that they had to do something to overcome this tremendous challenge. This 46-week paid program provides students with a first class learning environment that combines theoretical knowledge and practical applications. The Valiant Training and Development Centre’s success is based on relevant industry experience, very much like the well-established apprenticeship programs in Europe. The really admirable thing about this is that Valiant is challenging the status quo by educating young people in the shortest possible time to bring skill, talent, and value to their organization. Times have changed, our young people are different, and we have to meet current needs. We have to make learning the skilled trades — dare I say it — “sexy” for our next generation. A shorter program with greater quality is a win-win situation for everyone involved.

The man behind the scenes at Valiant who makes it all happen and who has contributed tremendously to this success story is training coordinator Mike Ouellette. With over 35 years of experience in the industry, Mike knows what it takes to make a quality product to the highest possible standards. As soon as I met Mike two years ago, I recognized something special in him — he’s not only a “people person”, but one who actually appreciates young people (compared to others who have nothing but negative things to say). Can you see how much perception matters? Mike makes sure that his students don’t only learn technical skills, but also basic life skills along the way, and he certainly leads by example. Young people have to understand the value of showing commitment, being responsible, and taking initiative. Great communication skills and a good attitude will help them to go wherever they want. Mike isn’t shy about expressing his belief that our youth are the future in North America, and that, if we believe in these young people, they won’t disappoint us. The energy, time, kindness, and patience that Mike invests in his students on a daily basis guarantee a payback as

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soon as they enter the work environment.

Since the initial launch, 140 students have gone through this training program and 120 of these students were placed within Valiant. Valiant invests approximately $50,000 per student for the first year without any kind of contract. How amazing is that? In other words, they are free to go and work somewhere else if they want to. Valiant is demonstrating that they do their part to develop new talent for the benefit of making our industry strong again. Now that Valiant has fulfilled their own immediate needs, they are exploring next steps on how to help other companies — yes, even their competitors — to train students for them in the Valiant Training and Development Centre. They have just opened their doors to a second such centre in Windsor. And with more than 2,000 inquiries, it definitely won’t lack new applicants. The next challenge is to introduce a provincial standard curriculum to the government, so that the students can receive the proper accreditation for their accomplishments.

So what’s the difference between your shop and Valiant? Nothing, really — you are only one decision away from taking the bull by the horns, as Valiant has done.

OLD “SOLUTIONS” WON’T CUT IT Recently, I’ve heard conversations again about importing skills from overseas to address what one individual called “a more immediate solution”. Brilliant — and while we’re at it, we might as well just travel back in time to the 1950’s and 60’s. We’ve done this before, in other words, and it hasn’t solved the problem in the long run. Importing talent and skill is obviously an easy way out that doesn’t require any creative and innovative thought.

Ask yourself these questions: Can we really afford to ignore our high unemployment rate? Would importing talent and skill help the population in North America to increase their standard of living? Does this encourage our organizations to take a bigger step towards social responsibility? How can we just stand by and do nothing while a global message is being conveyed that North America doesn’t have the talent, skill, and creativity within its own borders to succeed?

I grew up in Austria and — like many immigrants — have always looked at Canada and the U.S. as places of endless possibilities. There was something magical about these countries: people were able to make things happen

......stay connected with

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Photo Credits: All photos courtesy of Valiant Machine & Tool Inc.

skills training that they want to replace the lack of skill and education with process improvements.

In Germany, companies incur the costs of their apprentices before they reap the benefits, and that’s exactly what Valiant has done. We need more companies in North America that are Apprenticeship students and staff outside the Valiant Training and Development Centre. willing to invest in their current and future emas long as they put their hearts and minds to it. Have we ployees. Many times I have noticed that employers don’t want to pay appropriate wages to recruit people with really lost the magic?

Just recently a business owner said to me, “I’m not needed skills. If this is the case, we shouldn’t define it as in the business of training people, I’m in the business a skills gap — it’s actually a mindset gap.

In the end, a business must know what it stands for, of making money.” In his own way, he’s right. Making money is his reality — the lens through which he sees and so must the employees who work there.

Every day we each have countless opportunities, all the world. But it’s unfortunate that he cannot see that there is a tremendous need for companies to provide dictated by the choices we make. Many times, the smallon-the-job training and education if they want to stay est shift in thinking or doing can create the biggest oprelevant. In the wider sense, it is indeed in his interest portunity. What could this mean for you?

These days, it’s essential to challenge your beliefs to see that young people are being trained in the skilled trades. How else can he — and we — keep up with a about what you can and can’t do; to shift your focus and energy from complaining to taking action; to spot and constantly changing world?

There is no shortage of data suggesting that although attract talent and skill, no matter what it takes; and to many companies continue to complain about the so- get into the heads of our Millennials As someone once put it, “Some will hear, but not liscalled skills gap, few are taking steps to fix it. The CareerBuilder survey of 1,648 U.S. hiring managers and hu- ten. Some will listen, but not understand. And some will man resources professionals, released in November 2013, understand, but not act. But the ones who hear, listen, found that nearly 80 per cent of managers are at least and act will go places.” somewhat concerned about the skills gap, but only about It’s something to think about.

MT&D 40 per cent are doing anything to alleviate the problem.

According to a recent Adecco telephone survey of Karin Lindner is a business college graduate from Aus500 top executives, 92 per cent said there’s a job skills tria, and the author of the book “How Can We Make gap. And of that overwhelming majority, nearly half Manufacturing Sexy? A Mindset of Passion and Purpose believed the gap was in “soft skills” — communication, from the Production Floor to the Executive Suite”. After critical thinking, creativity, and collaboration. moving to Canada in 2003, she worked for auto parts Some companies may be hurting because they can’t maker Magna International Inc. Since founding Karico find the right technical help, but I’m certain that a lot Performance Solutions, a Richmond Hill, Ont.-based emmore will suffer if they can’t find people with basic ployee engagement and motivation consulting company, communication skills. she works as a trainer, facilitator, coach, and inspiraCan it be that our organizations don’t spend tional speaker. She is also an instructor at the Faculty enough on productivity and infrastructure? I believe of Applied Science and Technology at Sheridan College.

cted with aCEtronic ......

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moldmaking / shop floor Increased stock of DIN metric components DME has increased its stock of DIN metric components by 40 per cent, giving moldmakers more access to North American-style products supported with same-day shipping.

The expansion is designed to accommodate an increased demand from North American moldmakers who want DIN metric dimensions.

The component line features metric measurements with a familiar North American design.

All metric-sized components are in stock and ready to ship. Orders placed by 5 p.m. Eastern Monday through Friday will ship the same day.

The component line includes: • Bronze-plated wear plates — Manufactured with a long-lasting wear surface for bronze-plated molds requiring slides, cams or flat surfaces where frictional wear is a factor.

• Self-lubricating L-Gibs — Featuring a long-lasting wear surface for high-production molds. L-Gibs are easy to machine and can be shaped to any configuration, requiring no special tools.

• Leader pins — Metric guide pins are precision made of high-quality steel, and are hardened and finished ground to close tolerances.

• Bronze-plated shoulder bushings, ejection bushings, and self-lubricating guided ejection bushings — Made of precision-ground steel with oil grooves and a true bushing surface that extends the full length of the bushing. Bronze bushings perform smoother and longer than plain steel, as lubricant is distributed throughout the bearing surface by the figure-eight oil groove system.

DME of Canada Ltd. (Mississauga, Ont.); www.dme.net; 800-387-6600

High-performance general purpose forming tap Emuge Corporation has introduced MultiTAPForm, a forming tap designed to deliver performance increases in a wide range of materials including carbon steel, steel alloys, stainless steel, aluminum, copper, brass, and bronze.

In lab tests, MultiTAP-Form demonstrated four times the life compared to a leading brand form tap. MultiTAP-Form is also uniquely designed to produce threads within both 2B and 3B classes of fit, eliminating the guess-

work of calculating H-limits.

MultiTAP-Form features a new innovative geometric design, a proprietary grade of high speed steel (HSS-E) and is TiN-coated for long life and versatility. A short chamfer lead of 1.5 — 2 Pitch is ideal for bottom tapping, and lubrication grooves allow coolant flow-to-form action for holes requiring long thread length.

The forming of threads offers many advantages over conventional thread cutting. A formed thread is one where the material has been displaced instead of cut, which provides excellent thread surface quality and increased static and dynamic strength of the thread. Additional benefits include eliminating the risk of poor threads due to axial “miscutting”, and the ability to increase tapping speeds.

All MultiTAP-Form Taps are made with Emuge’s trademark long shanks, which are DIN length and designed for extra reach. Tap sizes include a range for UNC or UNF threads, from #4-40 to 3/8-24 inch sizes, to metric sizes from M4 x 0.7 to M10 x 1.5.

Emuge Corporation (West Boylston, Mass.); www.emuge.com; 508-393-1300

Fast hole EDM drilling Makino has released the EDBV8 fast hole EDM drilling machine for the production of film cooling holes and shaped diffuser holes in blade and vane segments.

The EDBV8 is well-suited for large turbine engine component machining for the aerospace and power-generation markets, and it is equipped with a two-axis rotary table for enhanced workpiece positioning.

The EDBV8 offers X-, Y-, Z- and W-axis travels of 800 mm, 600 mm, 750 mm, and 500 mm (31.5 inches, 23.6 inches, 29.5 inches, and 19.7 inches) respectively. The machine is also equipped with a twoaxis rotary table that can accommodate a maximum workpiece size of 500 mm (19.7 inches) diameter by 635 mm (24.96 inches) long, and a maximum payload of 150 kg (330 lbs). Its rotating C-axis head features an EROWA compact chuck that enables automatic changing of electrode diameters from 0.2 mm (0.008 inches) up to 6.0 mm (0.236 inches), with rotation speeds up to 1,000 rpm.

The EDBV8 uses a rigid guide-arm assembly to hold, locate, and support the die guide, which can be alternately used as a programmable axis (W-axis) that runs

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moldmaking / shop floor parallel to the Z-axis. An integrated “middle guide” system is also contained within the W-axis, and is used with long small-diameter electrodes to prevent whipping, bending, and vibration of the electrode.

The EDBV8 has been designed for easy operation, and it offers the operator easy access to the work tank with its three-sided, rise-and-fall work tank. The EDBV8 is also capable of on-machine probing to determine workpiece locations and offsets. Electrical touch-sensing probing or a conventional mechanical touch probe can be used to capture location data points. The standard configuration of the EDBV8 includes a 24-station tool carousel and 24 tool assemblies to fully stock the machine for maximum productivity.

And as with any scissor lift table, EnKon’s engineering team can customize the lift for a specific application to answer a customer’s need.

EnKon Systems (Walled Lake, Mich.); www.enkon.pro; 800-444-4351

Makino (Auburn Hills, Mich.); www.makino.com; 800-552-3288 Single Source Technologies (Mississauga, Ont.); w ww.singlesourcetech.com; 905-565-6886 (St. Laurent, Que.); 514-333-5793

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moldmaking / shop floor Flat air nozzle saves space and money The new Flat Super Air Nozzle from Exair Corporation produces a flat one-inch (25 mm) wide airstream with a strong blowing force of 9.8 ounces (278g) when mounted 12 inches (305 mm) from the target, and the unique design of the nozzle makes it a good fit for both tight spaces and tight budgets.

The air nozzle maximizes entrained airflow while reducing noise levels. The airstream pulls in surrounding room air to produce a wide, forceful stream of high velocity, laminar airflow. Air consumption is 10.5 SCFM at 80 PSIG. The 75 dBA sound level is below the limits of the OSHA maximum allowable noise exposure standard 29 CFR 1910.95(a). Force and flow may be easily adjusted by installing different shim thicknesses.

Exair Corporation (Cincinnati, Ohio); www.exair.com; 513-671-3322

Ejector sleeve with DLC coating Ejectors are some of the parts that are subject to the most stress in the mold — and with its extensive range of ejector elements, Hasco offers individually-tailored solutions for functional component removal from injection, compression molding, and die-casting molds.

Hasco is supplying the first standard sleeve range

Advertiser’s Index ADVERTISER

PAGE

WEBSITE

AceTRONIC......................... 60-61............ www.acetronic.com AMT Machine Tools Ltd....... 51.................. www.amtmachine.com Blaser Swisslube Inc.......... 53 ................ www.blaser.com Bohler-Uddeholm Ltd.......... 55................. www.bucanada.ca DME................................... 36 ................ www.dme.net Eriez Magnetics................. 52 ................. www.eriez.com Hotset America.................. 63 ................ www.hotset-worldwide.com/us ITI Tooling Company Inc..... 46 ................. www.indexingtechnologies.com Komet Canada................... 43 .. ............... www.komet.com/greatideas Kyocera Industrial ............. 45 ................. www.americas.kyocera.com/ Ceramics Corp. raptor Makino Inc......................... 49 ................. www.makino.com/diemold Metalworking Magazine..... 47 ................. http://www.canadianmetal working.com Schmolz + Bickenbach....... 66 ................ www.schmolz-bickenbach.ca Scientific Cutting Tools....... 57 ................. www.sct-usa.com Seco Tools Inc.................... 42 ................. www.secotools.com SME – MMTS...................... 65 ................. www.mmts.ca Sorel Forge Co................... 40 ................. www.sorelforge.com SST Canada....................... 44 .. ............... www.singlesourcetech.com/FCS Synventive Molding ........... 59 ................. www.synventive.com Solutions

Z457 with DLC coating. In combination with ejectors Z400, the advantages of the DLC coating can now also be optimally used for ejector pins and sleeves. The DLC coating combines a high hardness with the very best tribological properties, thus keeping friction and wear down to a minimum.

The new sleeves are especially suited to use in the food and medical sectors, since production can be run without lubricants, making it compatible with a cleanroom environment.

Hasco Canada (Toronto); www.hasco.com; 416-293-5044

Accurate rotary axis calibrator The new XR20-W calibration system from Renishaw measures the angular position of rotary axes to within ±1 arc second, wirelessly, for testing the accuracy of lathes, multi-axis machine tools, millturn machines, trunnion tables, and spindles.

The XR20-W works in conjunction with XL-80 or ML10 laser interferometers, as the system combines the readings of the rotary calibrator and laser to determine positioning errors in axes under test.

The rotary axis calibrator is generating positive feedback from the field with its advanced, compact design, allowing for easy setup and use. Application flexibility is extended by the addition of new off-axis rotary software that allows the XR20-W to be used even when it cannot be positioned directly on the rotary axis under test.

The software calculates true position and records axis performance and errors when compared to the intended target. The test takes about 10 minutes, and results are sent to a PC via Bluetooth connection.

The XR20-W is lightweight — at just over two pounds — and wireless the operation allow fast setup and also eliminates safety hazards created by cables. It attaches to a rotary axis via a flexible mounting ring assembly, and is centred within ±1 mm (0.04 inches) using a visual aid. Flexible mounting options include an adapter plate for rotary tables with unsuitable centre recesses, and a chuck adapter for lathes.

M

Renishaw (Canada) Ltd. (Mississauga, Ont.); www.renishaw.com; 905-828-0104

64 | APRIL 2014 | www.canadianmetalworking.com

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14-04-07 6:30 AM

Want to grow your market share?

Gain exposure and get face-to-face with decision makers from Quebec’s manufacturing industry by exhibiting at MMTS 2014.

Quebec Manufacturers will be in Montreal to

GET EQUIPPED

Your competitors will be here. Will you?

More than 90% Booked. Reserve today!

Montreal Manufacturing Technology Show | May 12–14 2014 | Place Bonaventure | Montreal QC

To book your exhibit space, visit mmts.ca or call Julie Pike 1-888-322-7333 ext. 4471.

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Political Uncertainty, Economic Stability?

Sovereignty politics grip Québec during a critical provincial election.... will industry be affected?

By Jim Anderton, editor ............................................................................................................................................................................

I

t said that nature abhors a vacuum, but in business there is no question about it: business abhors uncertainty. Unfortunately, new developments in this year’s Québec provincial election have again stirred the sovereignty issue, with unknown consequences for the business environment in La Belle Province.

2013 economic performance in the province underperformed according to the Québec Ministry of Finance 2013 economic and financial update released at the end of November. The report points to increase household saving and proportionately decreased spending, depressing retail sales and new home starts which were down by nearly 22 per cent year-to-date in October. Exports however, rose by 4.5 per cent year-over-year, driven by strong commodity, auto and aerospace sector perform-

ance, which suggests that anemic growth is entirely due to weak domestic consumption. According to the RBC Economics Provincial Outlook, December 2013, senior economist Robert Hogue expects a better 2014, mainly because of currency and export demand issues: “We expect further advances in exports in 2014, supported by growing US demand and a modestly weaker value of the loonie. It will be developments on the domestic side that, we believe, will add more to growth, however.

First we expect less housing construction drag because housing starts have much more limited downside left in them after slow-to-12-year lows in 2013. Second, signs that job creation resumed in the fall of 2013, following substantial losses during the first half of the year, will set the stage for stronger household spending in 2014.

Capital Expenditures for Machinery and Equipment, Quebec 2010 2011 2012

Actual Machinery and equipment $ millions Que.

18,886.70 18,116.30 19,360.90 18,900.30 19,677.10

Agriculture, forestry, fishing and hunting

434.6

356.8

376.5

756.7

898.1

1,118.10

Mining and oil and gas extraction

Utilities

Construction

Manufacturing

2013 2014 Preliminary actual Intentions

411

410.5

981.1

745

590.4 588 647.6 651.1 672.3 1,040.10 1,072.90 976.9

1,091.00 1,130.20

2,838.60 3,262.90 3,267.90 3,120.00 3,504.30 Source: Statscan

Government support and investment intentions send economic signals, but there’s no substitute for hard data, particularly capital expenditure on production machinery and equipment. This StatsCan chart shows modest overall growth in capital expenditure, with a noteworthy decline in mining and oil and gas extraction spending as well as static growth in the ag/forestry/fishing and hunting sector. Construction is up slightly, but the star is clearly manufacturing with 2014 predictions showing growth approaching 15% over 2013 numbers, reversing the downtrend over the relatively flat 2011/2012 figures. With aviation and auto booming, and strong demand for resources such as aluminum, the province should enjoy stable growth in the manufacturing sector for 2014. www.canadianmetalworking.com | APRIL 2014 | 67

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And third, the economic stimulus plan announced by by powerful unions on the Left and nationalist politics the provincial government in October (with an array of on the Right. While English-speaking Canada tends to remeasures totaling $2 billion over four years) will begin gard the province as a single economic entity, internally, to contribute slightly to growth in 2014”. provincial government support for economic growth is A stimulative provincial fiscal policy is always a sigtargeted, both in urban and rural districts, says Québec nificant factor, and in an election year program spendMinister of Finance and the Economy, Nicolas Marceau. ing promises are a given. Spending however, has deficit “Québec’s economic performance depends directly on implications in the medium to long term; the provincial the growth of each of its regions. By focusing in particugovernment expects deficits of $2.5 billion in 2013-2014 lar on measures supporting investment, all of Québec’s and $1.8 billion in 2014-2015, and the accumulated debt regions become wealthier. will make it very difficult for the province to ameliorate the effects of the recession into 2016, especially with the major parties’ commitment to control government spending.

But will the recession continue? With Québec exports leading the way and now solid signs of recovery in the U.S., the combination of high-tech manufacturing, particularly in the aerospace sector, and recovering global demand for raw materials brightens the longterm outlook considerably. An example is the recent agreement between U.S. aluminum producer Alcoa and the Government of Québec to update Alcoa’s three smelters in Québec, securing approximately 3,000 jobs. Under the agreement, Hydro-Québec will renew Alcoa’s power supply contracts for the Becancour and Deschambault facilities until 2030 and for the Baie-Comeau plant through 2036.

The agreement includes $250 million of planned investments at the smelters over the next five years and as part of that investment, Alcoa will increase production of aluminum used for auto manufacturing and reWhether you’re cutting, grinding or finishing, Weiler is your source to duce production of commodity-grade get the job done quickly and safely! Choose from our complete line of: aluminum at the Baie-Comeau cast n Tiger® Disc Abrasive Flap Discs - choose from 3 performance levels to house to capture increased demand find the ideal flap disc for your specific application. from automakers for the light metal. n Vortec Pro® Cutting and Grinding Wheels - resin bond formulated According to automakers, aluminum to Weiler’s specifications and reinforced with fiberglass for body sheet content in North American fast cutting action and aggressive stock removal vehicles is expected to quadruple by 2015 and increase tenfold by 2025, When Performance Counts... Count on Weiler! from 2012 levels.

2014-2015: ALL ABOUT JOBS Integration of government into the manufacturing and other sectors is historically high in Québec, driven both

©2014 Weiler Corporation. All Right Reserved.

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Quebec’s economic performance depends directly on the growth of each of its regions....by focusing on measures that support investment all of Quebec’s regions become wealthier The scope of the actions brought forward in recent months is a good indication of the government’s commitment to develop their full potential,” the Minister said, during tabling of the 2014–2015 budget. Québec government support of private investment in the regions includes targeted initiatives for the forest and oil sectors, a tax credit for investments with higher rates in the resource regions, measures for the development of Northern Québec and steps to promote tourism.

“Since last October, the Québec government has contributed to $1.8 billion of private investment projects in the resource regions. These initiatives will help create or maintain roughly 2500 direct jobs,” the Minister noted. The plan includes allowing the Capital régional et coopératif Desjardins (CRCD) to issue $150 million in shares throughout 2014 targeting the financing of Québec cooperatives and SMEs, especially those located in the resource regions. Regional disparities in economic growth are addressed by small business support and financing programs that are regionally driven and designed for local conditions.

Local development centres, providing financing through local investment funds, are regarded as essential for supporting regional entrepreneurship, and under prebudget terms, local investment funds (LIFs) were set to expire on December 31, 2014, leaving local development centres (CLDs) without a financing function as of January 1, 2015. The budget includes plans to defer repayment of local investment funds for additional five years maintaining CLD activities in the regions, allowing them to make additional investments of $25 million through 2020 without recapitalizing the programs.

In Québec’s major cities, stimulus is driven by public works programs; the government plans to spend $125 million for four major capital projects in Montréal and significant spending on tourism driven cultural projects in Québec City, including a new indoor ice facility, although the government has not stated a direct intent to use the program to support an NHL franchise in the city.

PQ MAJORITY? IT’S DIFFERENT THIS TIME At press time, Parti Québécois leader Pauline Marois clung to a small lead in popular support, but was threatened by a resurgent Liberal Party. Although the election call by the PQ was based on a proposal to limit overt

expressions of religious affiliation in government, the message has deflected the Liberal Party strategic use of the sovereignty issue in their campaign, and the emergence of PQ superstar candidate Pierre Karl Péladeau.

While Marois has repeatedly stated that referendum was not in the cards in the short or medium term after a PQ majority victory, when pressed she did state that a sovereign Québec would retain the Canadian dollar and hoped for a seat on the board of the Bank of Canada. Further, she expected that an independent Québec would have no formal border control with the rest of Canada. The currency issue is a serious problem for the PQ. Retention of the Canadian dollar would calm investor sentiment and prevent a capital flight to Toronto as happened with the victory of the Rene Lévesque-led PQ government, but retention of any influence at the Bank of Canada, let alone a seat on the board, would be unlikely, leaving Québec with no way to influence monetary policy — something critical for an export — driven economy. And from a national debt standpoint, if that was apportioned per capita, Québec would have a debt to GDP ratio approaching 90%, debt which would be serviced with a currency outside their control.

Several commentators have warned that the situation could be similar to that of Greece within the E.U. Conversely, a new Québec-only currency would almost certainly be traded at a significant discount to both the Canadian and US dollars, potentially boosting exports especially of raw materials, but collapsing consumer purchasing power, an outcome politically impossible to a government.

With Aboriginal land claim issues in Québec’s North an unresolved and highly contentious issue, few believe that a PQ victory will lead to radical political changes in the short or medium term, you would be mistaken.

The emergence of Québecor media magnate Pierre Karl Peladeau was clearly intended to add star power and business credibility to a PQ platform that has historically been left-leaning. The effect however, has been to overshadow Pauline Marois and create considerable internal dissent from the party’s left wing and affiliated union supporters. The result has been an election campaign that, while politically volatile, isn’t expected to have a major impact on the manufacturing sector in Québec, regardless of the outcome. CM

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F

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Untitled-7 1

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PREVIEW

2014

Montreal Manufacturing Technology Show The province’s most anticipated manufacturing event, to unveil industry’s latest technological breakthroughs

By Jim Anderton, Editor ............................................................................................................................................................................

QUEBEC MANUFACTURERS COMPETE GLOBALLY WITH STATE-OF-THE-ART EQUIPMENT his spring, Quebec manufacturers will discover the best places to put their investments to profitable use when the Montreal Manufacturing Technology Show (MMTS) 2014 opens its doors May 12-14 at Place Bonaventure, unveiling some of the industry’s most stateof-the-art equipment designed to help manufacturers compete on a global scale.

The technologies, many being introduced to the Quebec market for the first time, cover machine tools, tooling, metalworking, automation, additive manufacturing, design

T

and physical asset management. Key exhibitors include Elliott Matsuura, Machineries B.V Ltee., Huron Canada, Megatel, DMG/Mori Seiki/Ellison Technologies, Haas Automation, AW Miller and Single Source Technologies.

“Quebec manufacturers increasingly have to do more with less,” said Julie Pike, Event Manager. “This event gives them a sneak peek into the future of manufacturing that’s available now, and the knowledge and tools on how best to incorporate new advancements into their own operations.” She explained that an added bonus is the unprecedented networking and business development opportunities the show delivers.

Place Bonaventure, Montréal

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Watch trailer:

POWERFUL, PRECISE, RELIABLE. The new generation of mills from Walter BlaxxTM stands for a reliable system which captivates the user with its absolute precision and stands out through its extremely high productivity. The Blaxx™ F5041 and F5141 shoulder mills are therefore based on a newly developed, incredibly robust tool body, which is fitted with the most efficient of Walter Valenite indexable inserts, powered by Tiger·tec® Silver.

Find out more about the unbeatable combination of Blaxx™ and Tiger·tec® Silver now: www.walter-tools.com/us

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WALTER NORTH AMERICA Walter USA, LLC N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.us@walter-tools.com

Walter Canada N22W23855 RidgeView Pkwy W Waukesha, WI 53188, USA 800-945-5554 service.ca@walter-tools.com

Walter Tools S.A. de C.V. Carr. Estatal KM 2.22 #431, Módulo 3, Interior 19 y 20 El Colorado Galindo, Municipio El Marqués, Querétaro, C.P. 76246, México +52 442-478-3500 service.mx@walter-tools.com

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www.youtube.com/waltertools

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PREVIEW

More than 5,000 people are expected to attend MMTS 2014, the province’s most anticipated industry event, which will feature working demonstrations of the cuttingedge technologies right on the show floor. Examples of some of the leading solutions being unveiled are: Elliott Matsuura’s MX-850, a very flexible multi-axis machine capable of producing a variety of parts used in industries such as aerospace, mold and die, automotive and energy; as well as new friction stir welding technology from FPT Industrie represented by Machinerie B.V Ltee., including machines that have five or more interpolated axes, with rotary tables and workholding systems designed specifically for each application.

A new product program, publicized in advance at www.mmts.ca, enables attendees to learn about the products being launched at the event before arriving, so they can plan their exhibit visits accordingly.

Educational and technical sessions, cover topics such as: Quebec’s economy and its impact on manufacturing; business growth opportunities; the latest developments in manufacturing; metalworking applications; auto-

2014

mation, design and additive manufacturing; continuous improvement and much more.

A range of networking events, including the MMTS Opening Reception (May 12, 6:00 p.m.) and Quebec Job Shop Night (May 13, 4:00 p.m.–8:00 p.m.), offers small and medium-sized business owners and employees after-show access to the exhibit floor.

“This is the main event dedicated to the growth and advancement of industry in Quebec,” Pike said.

“It’s the number one place Quebec manufacturers can go to find creative solutions for their manufacturing operations.”

MMTS 2014 is produced in partnership with The Canadian Machine Tool Distributors Association (CMTDA), The Canadian Tooling and Machining Association (CTMA), and Manufacturiers et exporateurs du Québec (MEQ) and supported in partnership with Business Information Group, STIQ and MCI. For more information or to register for the event, visit www.mmts.ca or call 1-888-322-7333. CM

Networking & Special Events

E

xpand business contacts, meet industry peers to discuss industry challenges and opportunities and form new allies to help grow your business.

MMTS has several networking events to help bring industry together including:

MMTS OPENING RECEPTION MMTS Opening Reception accompanied with light hors d’oeurves and beverages where you can connect and enjoy an hour of mixing and mingling with like-minded colleagues. Monday May 12 in the SME Theatre at the close of show.

INDEPENDENT JOB SHOP NIGHT A late night designed to give small and medium sized owners and employees a chance to attend MMTS outside of business hours to source solutions for their manufacturing operations. Stay tuned for a special announcement on the Job Shop Night Celebrity guest!

OPENING KEYNOTE & PANEL DISCUSSION IN THE SME THEATRE Hear from industry experts as they share exchange best practices and insight on industry. Attend to discuss challenges and gain opportunities.

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Emec_8.

Visit us at MMTS Booth #557 & #565

Come see these machines and more!

MU-6300VL Universal Machining Center High efficiency, high productivity 5-axis machining Easy-to-use 5-axis High accuracy 5-axis machining through advanced technology  Thermo Friendly Concept   

MU-6300VL

Okuma MB-4000H Horizontal Machining Center Okuma Turn-Cut Eliminates The Need For Secondary Turning  400mm Table  Thermo-Friendly Design and Thermo Active Features 

OKUMA MB-4000H

Grob G350 – 5-Axis Universal Machining Center   

Compact – Rigid – Accurate Travels - X: 23.6” Y: 30.3” Z: 26. 6” Horizontal Spindle – Unique Axis Configuration Allows Optimized Chip Flow

GROB G350 Tsugami B0326 Swiss Turning Center    

TSUGAMI B0326 Mississauga Head Office 205 Admiral Blvd.

Mississauga, ON L5T 2T3 Tel. 905-565-3570 Fax. 905-565-3580

   

Montreal Office 159 Rue Merizzi Ville St. Laurent, QC H4T 1Y3 Tel. 514-735-6888 Fax. 514-735-6845

32mm capacity Swissturn Electronic servo driven guide bushing Easy access tool zone Modular quick change driven tool positions for maximum flexibility Deep hole drilling positions standard X, Y, C, Z sub side spindle control Sub side cross drilling Easy to use with Abile software Windsor Office Tel. 519-222-8716 Fax. 905-565-3580 Manitoba Office Winnipeg, Manitoba Tel. 416-896-0489

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 Emec_8.125x10.75.indd 1 072-083 cmw apr 2014 MMTS Preview p 072-083.indd 75

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PREVIEW

2014

Getting to and around MMTS

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etting to MMTS is easier than in most convention cities in North America. With over 200 U.S. and international flights touching down at the newly refurbished Montréal-Trudeau International Airport — serving over 70 international and 25 domestic cities — daily, Montréal is easy to get to from most major destinations.

Downtown is a 20 minute cab ride, where 15,000 hotel rooms are located. Four thousand of those rooms are

in hotels directly linked to the 32 km long Underground Pedestrian Network, although Montréal in the spring is best experienced at street level. The show venue, Place Bonaventure offers over 5,000 parking spaces and is near Montréal’s train station and subway stops. An express bus shuttles attendees directly to the airport, and charming Old Montréal and the Quartier International are both within easy walking distance from the show, as are hundreds of restaurants. CM

76 | APRIL 2014 | www.canadianmetalworking.com

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DoosanP Ferro-Do

Doosan Infracore America

Optimal Solutions for the Future

Visit us at booth 544

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The optimal manufacturing solution for you is more than just an advanced machine tool.

It’s also a skilled team of individuals dedicated to ensuring the technology is properly applied to your application and then standing behind you for the life of the machine as your needs evolve. That’s the best strategy to win when your customer demands you to perform under pressure. We at Doosan would like to be that team for you.

We understand the demands you are under and have built our reputation on providing optimal manufacturing solutions and outstanding support.

Contact us today, let our team perform for you, and win!

Horizontal Machining Centers

Vertical Machining Centers

Turning Centers

Doosan Infracore America Machine Tools Corporate Office & Engineering Center

19A Chapin Road, Pine Brook, NJ 07058 - Tel. +1 973 618 2500

Windsor, ON | Tel: 519-257-3557 Mississauga, ON | Tel: 905-890-3231 sales@ferrotechnique.com St-Laurent, QC | Tel: 514-341-3450 info@ferrotechnique.com www.ferrotechnique.com

DoosanPUPme.indd1 1 Ferro-Doosan.indd 072-083 cmw apr 2014 MMTS Preview p 072-083.indd 77

dia.sales@doosan.com www.doosanmachinetools.com/usa

Midwestern Technical Center

1701 F Howard Street, Elk Grove, IL 60007

Western Technical Center

488 W. Meats Avenue, Orange, CA 93865

1/10/14 1:57 14-03-27 4:51 PM PM 14-04-04 2:51 PM

PREVIEW

2014

What’s new at MMTS MACH KO-GA-ME 3D CNC MEASUREMENT SYSTEM

HAAS VF-2SS SUPER SPEED VMC The VF-2SS is a high-performance vertical machining centre that comes standard with a 12,000-rpm inline direct-drive spindle, an ultra-fast tool changer and 1400-ipm rapids.

Haas Automation Inc.

Mitutoyo is pleased to announce Ko-ga-me, a totally new concept 3D CNC measurement system offering a unique and flexible configuration for optimum versatility.

Mitutoyo Canada Inc.

AGIE CUT200P

TRUMPF POWER TOOLS

GF AgieCharmilles is the world’s leading provider of machines, automation solutions and services to the tool and mold making industry and to the manufacturers of precision components.

Elliott Matsuura Canada Inc.

As a special feature, TRUMPF Power Tools will be with us to answer your questions and demonstrate their tools. A perfect opportunity for a hands-on trial!

Be sure to pass by booth #935.

Garrett Industriel Inc.

FAGOR 8065 CNC SYSTEM Powerful CNC System designed for high performance applications common in the aerospace and mold and die market. High-speed with advanced algorithms ensuring maximum servo performance.

Fagor Automation

NOVA GRUP NGT TOOL­HOLDERS – STATIC TOOLS Static ToolHolders produced by NOVA GRUP will fulfill your requirements for endurance, dimensional and functional precision. ToolHolders concept, materials and parts sustain a long range of tests on our functionality testing stands.

Machine Impex Canada Inc.

ROTARY SCREW AIR COMPRESSORS Ranging from 5 to 100 HP, these heavy-duty, high-performance & High-Efficiency Rotary Screw air compressors operate at a 100% duty cycle and are ideal for continuous-use applications where reliable, dry, clean air is required.

DV Systems Inc.

INTELLI-CAM New 3D CAM software for Waterjet programing. Intelli-CAM is part of the intuitive and powerful Intelli-MAX Software Suite, expanding capabilities for the operator. Intelli-CAM is a highly advanced computer-aided manufacturing (CAM) software tool that can generate 2D and 3D tool paths from 3D models.

Spark & Co Machine Tools Inc.

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LASER PROCESSING of METALS Laser Solutions for Marking, Welding, Cutting, and Surface Treatment

ROFIN FULL PAGE AD

ROFIN offers a full range of innovative laser system solutions for your specific marking, welding or cutting application based on our comprehensive range of products and technologies. From laser sources to customised systems to lasers for integration. Standard or custom, high-precision production systems or desktop units; when it comes to High-Quality Laser Systems,

Think ROFIN Call us at 1-905-607-0400 for a demonstration, or send us your sample parts ROFIN-BAASEL, Canada LTD., 3600(A) Laird Rd., Mississauga, ON. L5L-6A6 info-canada@rofin-baasel.com

WE THINK LASER

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VISIT ROFIN’S BOOTH #435 www.rofin.com

14-04-04 2:51 PM

PREVIEW HAAS DT-1 DRILL/TAP CENTER The DT-1 is a compact, high-speed drill and tap machine with full milling capabilities. The machine features a generous 20” x 16” x 15.5” work cube and 26” x 15” T-slot table, while maintaining a very small footprint.

Haas Automation Inc.

2014 PCBN TIPPED TOOLS CBN is used for cutting ferrous, hardened steel, cast iron, powder metal. It has high wear resistance, shock resistance, frictioin coefficient, good cutting stability at high temperature (>1500ºC), Stable size, Good thermal conductivity.

TopTech Tool Manufacturing Inc.

Intermediate Height Jaws SERVO MOTORS & DRIVES • Available in: - Serrated, Acme & Square Key, American Standard & Metric Tongue & Groove Styles • Steel or aluminum heights of 3”, 4”, 5”, 6”, 8”, or 10” • Lower cost versus buying a short and a tall jaw

NEMA servo motors, metric servo motors, frameless motors, linear motors, coreless motors, mini motors, micro motors, servo drives, programmable servo drives, distributed control servo drives.

Electromate Industrial Sales Ltd.

• Competitively Priced • Increase tool versatility • Always in stock • Suitable for 90% of all short tall jaw applications • Made in the USA ISO 9000 Certied QMS

GEN3SYS XT HIGH PENETRATION RATE DRILLING SYSTEM

DillonManufacturing, Inc. Peter Seessle | Expertech Dist. & Tech. Inc. 44 Goodfellow Crest | Bolton, Ontario Phone: 647-960-4478 | Email: peteseessle@rodgers.com

Gen3sys XT offers increased tool life, reliability and productivity in high penetration drilling applications. Available with AM300 coating and in multiple geometries, Gen3sys XT provides excellent chip control, improved durability and stability.

Allied Machine & Engineering Corp.

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PREVIEW K100 IROQUOIS – 100 HP ROTARY SCREW AIR COMPRESSOR

2014

MOTION & AUTOMATION CONTROLLERS

These heavy-duty, high-performance & high-efficiency rotary screw air compressors operate at a 100% duty cycle and are ideal for continuous-use applications.

DV Systems Inc.

STEPPER MOTORS & DRIVES NEMA stepper motors, metric stepper motors, explosion proof stepper motors, step drivers, programmable stepper drives, distributed control stepper drives.

Electromate Industrial Sales Ltd.

Single and multi-axis motion controllers, programmable automation controllers, distributed control systems Electromate Industrial Sales Ltd.

ID-S SOLAR ABS DIGIMATIC INDICATOR The new, ID-S Solar ABS Digimatic Indicator now available from Mitutoyo Canada combines, for the first time in an indicator, the convenience of ABS origin memory with “always ready” solar power to provide highest levels of convenience.

Mitutoyo Canada Inc.

Visit us at Booth #35

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PREVIEW

2014

5 – 30 HP RECIPROCATING AIR COMPRESSORS

NOVA GRUP NGV CNC VISES Vises produced by NOVA GRUP will fulfill your requirements for endurance, dimensional and functional precision. NGT vises produced by NOVA GRUP can easily be used for both serial and one piece production.

Machine Impex Canada Inc.

The HDI Series is engineered to provide a heavy-duty, durable and dependable air compressor built to withstand the most demanding industrial environments.

DV Systems Inc.

PCD TIPPED TOOLS PCD is used for non-ferrous alloy & FRP finishing machining. It has super high hardness, high wear resistance, shock resistance, friction coefficient, Good cutting stability at high temperature (>800ºC) Good thermal conductivity, stablesize.

TopTech Tool Manufacturing Inc.

WHEN YOU ARE IN NEED OF RELIABLE & SAFE

NOVA GRUP NGT TOOLHOLDERS – LIVE TOOLS Live ToolHolders produced by NOVA GRUP will fulfill your requirements for endurance, dimensional and functional precision. ToolHolders concept, materials and parts sustain a long range of tests on our functionality testing stands.

Machine Impex Canada Inc.

CRITERION ALLIED MODULAR BORING SYSTEMS

MANUALLY OPERATED MACHINE-TOOLS

Criterion Allied’s modular boring system is a complete solution for your precision hole making requirements. You can create a specialized assembly to meet your application requirements using the large selection of standard components.

Allied Machine & Engineering Corp.

FULLY ENCLOSED HIGH QUALITY ERGONOMIC EASY OPERATION

Made in Canada with domestic and imported parts

WWW.ISOTOP.COM info@isotop.com 1.800.465.4650

WE ARE ALSO ALREADY WELL KNOWN FOR OUR LINES OF HIGH QUALITY CNC MACHINES

AUDROS Audros Technology est l’éditeur de la suite GEDT et PLM Audros dédiée à la gestion de l’ensemble des données, des documents et des opérations tout au long du cycle de vie de développement des Produits.

Tangerine Software

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PREVIEW

2014 FAGOR LINEAR & ROTARY ENCODERS

HSS M2 M35 M42 DRILLS TopTech Tool supplies straight shank, taper shank, shrink shank, aircraft, jobber length, screw machine drills, etc. Different surface finish treatment are available. Drill diameter is from 1/64� to 3�.

TopTech Tool Manufacturing Inc.

Broad range of linear & rotary encoder products for conventional applications ranging to high performance high accuracy applications.

Encoders available in both absolute & incremental protocols. Turning model capable of threading.

Fagor Automation

NCSIMUL MACHINE The realistic, smart, high-performance CNC simulation experience. NCSIMUL Machine is an innovative new generation solution of NC simulation that truly ushers in the smart factory.

Spring Technologies Inc.

WYSIWYC: SEE WHAT YOU CUT Sync. your machining simulation & instruction reports in a real time, to drive your CNC Machines. The best experience ever for users: ease of use, touch screen, multitasking gesture. 3D Simulation (machines and machined parts), synchronized with the real machine cutting chips.

Spring Technologies Inc.

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FABRICATING & WELDING NEWS

CWB shows youth group the (virtual) tricks of the trade O

n Monday March 10, the Canadian Welding Bureau (CWB) hosted 10 teenagers from the Liberty For Youth program at their Milton-area headquarters to promote welding as a career option.

Liberty for Youth, which was founded 10 years ago by Frederick Dryden, is a program that seeks to help at-risk youth in the Hamilton, Ontario area.

The event began with CWB Director Dan Tadic going through a short slideshow, and explaining some of the different types of welding, and the potential career opportunities in the field.

“Welding is one of those amazing careers,” Tadic told the audience of teenagers. “You can do so many incredible things with this technology... Welding is portable. You can work here, you can work in British Columbia, you can work in another part of the world,” Tadic continued.

And according to CWB figures, welding is also a wellpaying gig. Citing statistics, Tadic said starting salaries are typically $85,000 per year. He also highlighted some of the more unique types of welding that can lead to even more lucrative payouts such underwater welding and welding for the mining industry.

After the presentation, students were given the opportunity to try their hand at welding on one of Lincoln Electric’s VRTEX virtual welding simulators, which was donated to the CWB to

CWB Director Dan Tadic shows a student the correct angle to hold a welding gun.

use as a teaching tool. They were also shown other metal fabrication techniques, such as waterjet cutting.

The opportunity to try out a simulator left a number of students intrigued.

One of the grade 10 students, Noah, who knew nothing about welding before the event came away with a very different perception of it.

“It was pretty good… I didn’t have any idea how much money I could make, and if I did make that much, I wouldn’t know what to do with it!” he said, noting that he is considering a career in the trades.

“I’m at Delta’s Woodview program, and they’ve got an auto shop, so I want to try going into (that).”

The CWB has also agreed to help fund scholarships through the Liberty for Youth program for kids interested in pursuing the trade — something Dryden thinks will have a big impact on the success of the program.

“It was a win-win for us as a foundation. We came and did a tour, and this is (going to be) the first field trip of many,” he said.

“I think these kids have an inclination for trades. But what we really want them to do is explore. (Welding) is one trade out of many. So we’re not going to be bias… it could lead towards something else.

“Anything connected to exploration and education is very important to us.”

CWB Director Dan Tadic explains different types of fabrication equipment to students from the Liberty For Youth program.

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THE FILLER WE NEED The right filler metal is crucial to success in aluminum welding

By Nestor Gula

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F

or those that regularly weld steel, welding aluminium is tricky. It does not behave like steel and those that think they are just proficient welders, in steel, soon get humbled. Aluminium’s heat absorption properties, the reason heat sinks are made from this material, force the adoption of new techniques for welders.

Aluminium’s metallic properties also affect the way two pieces can be welded together as well. “Every steel welding engineer understands that success is, if I make a weld that is as strong as the steel I’m welding,” said Frank Armao, Director Aluminium Technology at Lincoln Electric. “That is success. When welding aluminium, the weld in most cases is not going to be as strong as the surrounding parent material you weld. One of the purposes of filler metal is to get that strength as high as you can.”

When welding aluminium, the filler metal is crucial to the process. It is not just there to fill in the gaps.

“Different filler metal will have different strengths and different properties,” said Guy Chouinard, R&D Engineering Manager at Stoody Company — a division of Victor Technologies Inc. “The most basic filler material is basically a chemical match to the base metal. As the applications evolve, sometimes you need more mechanical strength in the joint or you want to enhance corrosion properties to make sure that your joint won’t corrode first or break first. You might want to have enhanced mechanical properties of corrosion resistance.”

When welding aluminium one has to look at filler ma-

terial like the glue that holds the two pieces together.

“You can weld without filler metal, in which case you are just melting the two base materials,” said Susan Fiore, Advanced Application Manager with Hobart Brothers Co. “With a filler metal will give you added support and strength and better properties in the weld. It can increase the strength. For the most parts you cannot make a proper weld without filler material. “The filler alloy is very important because sometimes the weld will be under code restrictions or standards,” said Chouinard.

“Some standards like constructions and pressure vessels will call for specific alloys in filler materials. This is for strength or safety purposes.”

When it comes to autogenous welding, welding without filler material, many restrictions exists when welding aluminium “Autogenous is possible depending on the base material,” said Armao. “Some base materials, mostly the 5000 and the 3000 series can be autogenously welded. 2000, 6000 and 7000 welded cannot be autogenoustly welded. They have to have filler material or else they crack.” If you have a fillet weld you have to get the material to form the weld from some place.

“In many joint configurations there is just not enough metal there, if you did not have filler material, to form the joint,” he said. “The filler metal can be used, and is used in many cases, to modify the chemistry of the weld as it solidifies.”

With aluminium welding, It is generally accepted that you will choose a filler material keeping in mind what the part’s

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eventual use will be. “You might want to have the strength, but sometimes you will want a better colour match for when you anodize. It is dependent on the individual situation.

When you are doing heat treating, not all the filler metals respond the same way to being heat treated.”

Choosing the right filler material is not really a question of experimentation and trial and error. The work has been done for you. “Most of the filler metals are AWS standards so they have been identified and they are related to specific applications to the alloys or parent material,” said Chouinard. Since the specifications are tightly written to meet code and performance standards, there might be an impression that not much research or play is allowed in choosing the right filler metal. “You can definitely improve or optimise productivity by choosing the right filler

He notes that the form the filler material is presented to the weld also can effect weld performance. “You have the form of itself. The shape. It can be a wire, an electrode, a powder for example. With wires you can have solid wires or cored wires. Cored wires have the advantages that you get the right chemistry and the right properties and you don’t have to compromise on chemistry Cored wires might also make some profile welds easier.”

For proper welding procedures the real key and the reason you need the proper filler metal is that the chemical properties match. “Stainless steel welded with the incorrect filler material, you can have serious issues with corrosion,” said Fiore. “You will be placed in a situation where the weld metal is not as corrosion resistant as the stainless steel that you are welding then you may have a

material. Any research is in optimizing the filler materials to use cheaper shielding gas like using CO2 over argon mixed gases. We might also use different raw materials for economical reasons. We might use ferro-aluminium powder rather than pure aluminium when we compound the wire to create a more fluid weld,” said Chouinard.

“We also might want to improve the filler material by optimizing vertical up welding or in position welding.

We might want to play with the retaining slag on top of the weld bead. This is the crust on top of the bead. It does not effect the chemistry of the weld metal but it will effect its behaviour upon its welding. A thick slag will retain the weld bead better for vertical welding. If you are flat welding, you will want a thinner slag. So there is a lot of optimization being researched and conducted.”

situation that you get preferential corrosion along that weld and ten tat actually accelerates the corrosion in that weld.”

You don’t really use a filler metal for aluminium because it helps speed up production. “There are things you can do with the filler metal that will make the process more productive,” said Armao. “One is using the thickest filler material you can. The other general rule for aluminium is to weld as with as high a current as you can and as fast as you can. For productivity and quality this is the best you can do when welding aluminium.” He notes that in aluminium, “the weak point of the joint is not the weld metal itself. The weak point is just outside the heat affected zone. So when you have that situation, it almost doesn’t matter how strong your weld filler metal is because any filler metal will be stronger than that point.” CM

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High Dimensional Accuracy Induction Hardening

At eldec, the shape of the tool is designed with great precision using 3D CAD software by specialist in inductor design.

Manually loaded, semi-automatic or production line-integrated – the modular design of the MIND-system suits every production environment.

S

horter model life-cycles, increasing demands on quality, and technological innovations continue to drive developments in high-tech industries such as car or aircraft manufacture. Hardened parts must follow the drive for shorter cycle times with improved accuracy and repeatability in a high production environment.

Over the last three decades German-based eldec has further developed their hardening technology and in February of 2013 the company became a part of the EMAG Group. eldec has introduced a modular machine architecture, called Modular Induction (MIND) hardening, offered in two size variants, MIND-M and MIND-S. Using modular technology, the machines are configured to suit in­di­vid­ual work-piece dimensions, hardness profiles and production requirements. “The engineering of the ma­chine is, of course, greatly influenced by the work-pieces to be hardened“, explains Dr Christian Krause, eldec Head of Application Technology. “Requirements are discussed in detail with the customer. This is followed by the gradual assembly of the eldec MINDsystem, selecting the required key components: basic machine, energy source, inductor, coolant system and automation components, where required.”

HIGH EFFICIENCY, PRECISION DOSING The machine base is constructed of massive, high-precision welded components and includes the main column for the Z-axis. The vibration resistant construction ensures machining accuracy. Depending on the clamping system used, eldec machines can accommodate workpieces up to 1,200 mm diameter.

Available generators are micro-processor con­trolled single- or dual-frequency with a capacity of 5 to 3,000 kW. They are highly adjustable and automatic; the inductor and tools are manufactured according to customer specification, using 3D-CAD software, operated by experienced staff.

Performance data of the MIND-technology from The machining area with indexing table, eldec is impressive, prospindle drive, and tailstock engineered for a drive shaft application. MIND machines are cessing a differential pinion designed for workpieces between 250 and in as little as 14 seconds.

1,500 mm diameter.

The component is inserted into the indexing table of the machine through automation or manually and the hardening process takes between 100 milliseconds and a few complete seconds.

After quenching, the hardened steel is gradually tempered and the machining cycle is completed with the subsequent cooling process.

“Of decisive importance to us is not just the high speed of the process, but also the precision of the hardening operation”, states Krause. “For instance, on eldec machines the variation in effective hardening depth is no more than ±0.1 mm, an extremely low value within hardening technology.” www.emag.com

Courtesy EMAG L.L.C.

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Ordered by laser Part traceability enhanced with laser marking

By Nestor Gula .........................................................................

C

ontrolling production has always been a key to maximizing production and minimizing costs.

Knowing what parts are where is always good practice.

Laser marking has an advantage that it creates a near permanent mark on the part and it can be done efficiently and inexpensively. “The prime use for the laser marking is permanent identification of objects via no contact means, said Jake Wieloch, Regional Sales Manager for Rofin-Baasel, Inc. “This identification can be of the human readable, logo or code type markings.

Lasers are used in some decorative applications as well.

Machines capable of performing laser marking functions are specialized electro-optical systems that contain materials necessary for generating laser light. These machines will contain the laser components: active medium, output coupler, high reflector and excitation mechanism necessary to produce a laser beam.”

Tracing products and parts is not only good for inventory control but for warranty issues as well. “You can trace and follow the products, you can track it in the plant and you can track it in the field,” said Steve Sellon, Territory Manager for Gravotech Inc. “There is a lot of information that can be put into this to enhanced traceability. Each part will have a unique identifier. You can do sequential numbering date stamping.”

The marks the laser leaves can come in many forms.

They can be be machine readable, readable by human

Laser marked name plate for affixing to finished product.

eyes or a combination of both. “The prime use for laser marking is for part identification for tracking and tracing purposes. Thus, the majority of marks are bar codes (1D and 2D) or alpha-numeric strings of serial numbers,” said Dr. Mark L. Boyle, Miyachi America’s Laser Product Engineer. The marks can be standard bar codes or the more modern Aztec codes. For machine readable markings, any industrial standard, that can be read by a reader, can be used.

Machines can read laser markings on parts using Optical Character Recognition (ORC) vision systems, “which ‘read’ the human readable characters,” said Wieloch. “Another option is a vision system used to read the codes applied to parts, such as standard bar codes or 2D matrix codes.” “Vision based readers and cameras are used to “read” laser marking that requires confirmation that a marking has occurred on the material surface,” said Andrew Wellons, Laser Market Manager with Gravograph and Technifor. “In many cases bar codes (linear, 2d datamatrix, QR code, etc.) are Laser marked on materials. Standard bar code readers are used in those instances.”

Although there are many dedicated laser markers on

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the market, most laser cutters will also be able to be programmed to make necessary laser marks. “There are several laser types that can mark on different types of material — CO2 laser, Nd:YAG, Nd:YVO4, and fiber lasers. Typically, the laser is selected based on the type of material to mark,” said Dr. Boyle. The wavelength of the laser influences the result. “Infrared marking lasers are primarily used for metal and polymer marking (heat induced reaction) while green lasers are ideal for processing semiconductors, wafers, gold-plated parts and can also be used for glass drilling, which is a heat-induced and photochemical reaction,” said Thomas Burdel, TruMark Sales Manager with TRUMPF Inc. “UV marking lasers create a photochemical reaction and are use mostly for polymer and glass markings.”

Many machines are capable of laser marking, “the general requirements are having a laser powerful enough to change the surface condition of the material that needs to be marked,” said Ken Woods, Principal Engineer for Hypertherm Laser Systems. “The laser has to have a wavelength that is absorbed by the material, and there needs to be coordinated motion for the beam or part while the laser power is varied. Laser marking applications are incredibly broad. It is a tool that is very fast, completely flexible, doesn’t wear, and environmentally friendly.”

QR or Aztec codes can be laser marked in different sizes according to the need.

The depth of a laser mark can be varied to suit the particular application. “Each market will have a different requirement for the mark (and depth),” said Dr. Boyle.

“For example, medical does not want any depth since bacteria can grow in any inclusion. For those cases, we use an annealing process to create a mark. For the automotive industry, they may want to mark parts that will see high wear or that they will paint. For these applications, we typically do a deep engraving. This might be 0.020-inches deep, but could be deeper.”

The depth of the mark can be controlled through the use of different optic combinations and laser settings, such as speed, pulse frequency, power, pulse width and others. “Laser marks can vary in depth from zero depth

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An operator can cut and mark in one smooth process.

(surface mark) to 0.015”+ deep,” said said Wieloch.

“Texturing of the landing zone on a disk drive requires features on a nanometer scale (less than 100 atomic layers) whereas a bend line on a large ship hull plate could be 1-mm deep to retain visibility while moving and handling” said Woods. “Since laser marking involves a change in the actual base material, it will not wash off or fade like ink.

Instead it can only be removed with a mechanical process such as polishing, sanding, or grinding.”

For some applications removing the mark is a simple process of polishing or sanding. However, Wieloch warns,

ROFIN’S POWERLINE F 100 FIBER LASER MARKER Available with 20W, 30W, 50W and 100W of output power the Rofin fiber lasers mark almost all metals and plastics economically and efficiently.

The PowerLine F 50 and F 100 are ideally suited for high-speed marking, scribing, deep engraving, structuring and cutting applications. The PowerLine F series can be integrated into any of Rofin’s Class 1 workstations to become a complete laser marking solution. The PowerLine F housed in the CombiLine Basic class 1 workstation,as shown here, is an efficient, high-quality laser marking system www.rofin.com

TRUMPF’S TRUMARK 5020 FIBER LASER MARKER Converting high pulse frequencies into short marking processes the fast and flexible TruMark 5020 fiber laser marker from the

“most laser marks are nearly impossible to remove completely because, even though the mark shows on the surface of the part, the heat from the mark will penetrate into the material and leave indications of the mark below the surface.”

Laser marking is quickly becoming the industry norm.

“Anybody who has a warranty or wants to track their field life are the people that are using it,” said Sellon.

“The most that see a ROI are the automotive industry and other tier one accounts.” There is now a move to demand laser marked parts from subcontractors to keep track of warranty issues. “In automated facilities, laser marking can be used for parts that require part numbers, serial numbers, and QR codes which originated in the automotive industry,” said Woods. Laser marking can be integrated on an assembly line, at stand-alone stations, or as part of a processing machine such as a laser cutting system to provide bend or weld lines for downstream operations.” Laser marking is applicable across many industries. “Some consider laser marking as a crucial piece of the manufacturing process,” said Burdel. “These industries, such as the medical, automotive and aerospace industries, require a high degree of traceability for their parts. This might be as a data matrix, serial number, etc. In addition, there is need for general markings, such as logos and other indicators.

For the automotive industry, laser marking also enables back light automotive switches-also known as day/night applications.”

TruMark Series 5000 is suitable for applications on metals and plastics with high speed and excellent edge quality requirements. Due to the high pulse frequencies and its pulse-to-pulse stability it’s dynamic scanner module is able to convert pulse frequencies of up to 1 megahertz into a correspondingly high processing speed. It shows special strength in marking metal by delivering high quality customized marking or engraving in short processing times. It features an especially tough fiber protection hose with a mechanical lock that prevents the laser beam from discharging between two marking procedures. Telediagnostics makes it possible to maintain the fiber marking laser remotely with comfort and security. The TruMark 5020 comes with integrated laser power measurement and laser power calibration. www.trumpf.com

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HYINTENSITY FIBER LASER HFL020 This tightly integrated system is designed for ease of operation, simple table integration, and reliable and consistent automatic cutting and marking process. It is able to cut and mark with the same consumables for easy process changeover and efficient operation. The 2.0 kW fiber laser supply with rated cutting capacity up to 16 mm mild steel (10 mm stainless steel) has a new laser cutting head (150 mm focal length, with patent-pending integrated capacitive height control). The new laser head control console provides point-of-use application information (based on the HTA ArcGlide THC console). www.hypertherm.com

effect or part surface damage. Suitable for all metals, sensitive components and plastics, this can laser mark 2D markings on reflective metals (copper, silver, gold, etc.) and ceramics, thin coated layer removal on anodized, painted material, and micro marking on small components and wafers. www.technifor.com

LS100XP FROM GRAVOTECH This compact 20W FIBER laser gantry system marks a wide range of metals. It can engrave fine text, bar codes, technical symbols, logos and photos with a high contrast quality. With a generous engraving area 610 x 305 mm (24 x 12 in.) is is suitable for engraving series of small objects, large objects and matrices of plates. Combining a proven chassis with the marking prowess of a pulsed fiber laser technology this unit is an efficient gantry system for high quality marking on a full range of metals and even offers excellent results on ABS plastics and phenolics. It features a red-pointer beam for error-free set-up and auto-focus for precise engraving. www.gravograph.com

TECHNIFOR’S G400 With a beam two times thinner than a YAG laser and a specific wavelength of 532 nm, the Technifor G400 green laser is an effective solution for high marking quality demanding applications. It uses a process called ‘cold marking’ that marks without heating the material and eliminates burning www.canadianmetalworking.com | APRIL 2014 | 93

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Bleed

Trim

Live

Two Measures of Speed RPM and SFM are both quoted in abrasives specifications. Which is appropriate?

By Jim Anderton, Editor ............................................................................................................................................................................

G

rinding metal with abrasives looks like a wear process, but it’s really a cutting function, just like inserts and burrs. And just like machine cutting, feeds and speeds are crucial to maximum cutting efficiency and productivity. “Feed” in hand grinding is determined by the amount of pressure the user puts on the workpiece, and as an uncontrolled variable, abrasives for handheld equipment are designed to be forgiving.

Speed, however, is user controllable, either through

SFM =

abrasives with similar backing material, abrasives types and grain sizes, and the same coating.

Belts are naturally rated to cut at specified surface feet per minute, while discs are very often rated by spindle RPM. Service feet per minute is the best way to specify cutting speed, and it is possible to use the same spec for disk tools, as long as the relationship between the wheel diameter and local surface speed is understood. Mathematically it looks like this:

6.3 x disk diameter x RPM 12

variable speed control, or by choosing the appropriate fixed speed tool for the job. In metal removal, pedestal mounted equipment comes in two flavours: disk and belt. One machine may have both types, and often run

This simple equation describes local feet per minute, and effective disk diameter, because these change depending on the radius of each individual cutting grain relative to the spindle center. It’s really the old circle

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ed

m

e

Saving energy makes sense – business sense.

Purchase high efficiency equipment and receive incentives worth up to 50% of the cost of your energy efficiency upgrades.

Learn more about available incentives at saveonenergy.ca/business

Subject to additional terms and conditions found at saveonenergy.ca. Subject to change without notice.

OM Official Mark of the Ontario Power Authority.

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Disks are designed to conform to the working surface, like this Flexovit product...the actual SFM of the abrasive grains is dependent on both the tool RPM and the disk diameter

circumference equation, 2π r, divided by the rotational speed. We divided by 12 to convert the usual disk specification in inches, to feet for the SFM number.

While it’s easy to use this math to approximate the

Abrasives from reputable sources can carry great deal of information on the product label. This Pferd disk for example contains application information, a part number, critical dimensions, the manufacturers website, a cross-sectional diagram showing proper hub mounting and maximums both in RPM and in surface speed, in this case 80 m/s.

surface feet per minute of a disk grinding operation, the important take away is that the actual radius from the active abrasive grains to the spindle center scales directly to the surface feet per minute value. Larger diameter discs carry their abrasive grains at higher SFM numbers at their edge, compared to smaller diameter discs. Similarly, RPM also scales linearly to SFM. There’s no magic here; double the rotational speed, and you double the SFM figure.

What’s this mean in practice? It means that if maximum material removal rate is desired, it’s important factor in both the both diameter and the grinder RPM together. At first glance, this would suggest that a 4½ inch angle grinder spinning at high rpm will match the material removal efficiency of a 7 inch low speed unit, but unfortunately it’s not that simple. The very high-speed small diameter grinder moves the abrasive grains across the work piece quickly, but there are disadvantages.

An obvious one is frictional heat, as is smaller contact surface area with the work piece. There’s also smaller overall quantity of abrasive in a given disk, suggesting more frequent changes and potentially higher costs.

Depending on the application, it’s also possible that there is less usable disk when the hub is relatively large compared to the overall OD of the disk, compared to bigger equipment.

Does this mean that small diameter, high-speed handheld equipment is a bad idea? Clearly not, especially in the vertical or overhead grinding in tight quarters, but for

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heavy material removal and horizontal position, a larger disk, spinning at a lower RPM combines conventional removal rate with reasonable abrasive life and consumable costs.

Many smaller shops use bench or stand mounted combination sanders with both a belt and disk running from the same motor. Many units are actually woodworking machines running metalworking abrasives, and are not ideal for our trade. There are several reasons. The first and most important one is speed. To achieve a reasonable SFM figure for a belt sander, a disk driven from a common spindle would run far beyond its maximum allowable safe RPM. As a result efficient belt grinding is difficult to achieve in a combination unit.

The second reason is power. Even light industrial metalworking jobs need more than converted woodworking machines can provide. Horsepower is a measure of work, but in metalworking, torque matters and many woodworking derived machines carry adequate horsepower ratings but inadequate torque when the operator bears down. Yet another reason is the backing for the abrasive belt and disk. Woodworking equipment uses a hard platen with essentially no conformability to the metal workpiece and a high risk of tearing the belt or disk. For all but the lightest jobs, a better solution is to clamp the workpiece and use an industrial handheld grinder. In every case, it’s always worthwhile to check the abrasive manufacturers specification sheet or website

This combination sander is an excellent tool...for woodworking. Although many shops use similar equipment for metal work, the combination of compromised SFM ratings and low torque, plus hard platens backing the abrasives, makes it marginal for high productivity shop tasks

product page to match the abrasive and recommended SFM or RPM rating to both the tool and the job. CM

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THE BUSINESS OF TOOLING

Effectively managing inventory leads to major cost savings

John Mitchell, General Manager of Tungaloy Canada

By John Mitchell, General Manager of Tungaloy Canada ..................................................................................................

I

nventory management in many machines shops can be a time consuming and daunting task. The costs associated with a poorly managed inventory system may be extreme. Often a tool crib could have 500, 1,000, 1,500 or more units that need to be managed. This would require someone on staff to be consistently checking inventory levels to avoid stock outs. Some tool cribs use cumbersome spreadsheets.

Both of these methods tie up personnel and are rife with errors. Stock outs however can be extremely costly.

Running out of an insert and shutting a machine down can be very expensive.

Many machinists are aware of the cost of running out and may hoard tools at their machine, adding unnecessarily to inventory costs. Reordering tools can be expensive and time consuming. In a manual tool crib operation it is not uncommon for the person ordering tools to place numerous orders per day, taking away from more value-added activities. Often the person ordering the tools doesn’t hear about a need until it is too late. This can lead to expensive rush deliveries and potential machine shut downs. Tools placed in cabinets or bins have a potential to select the wrong tool. Cabinets and bins can also take excessive floor space.

The objective of a well-managed inventory system would of course ensure tools are readily available to the machine operator as required. The system should be fully automated, reducing the need for personnel to spend excessive amounts of time counting inventory and ordering product. A well-managed inventory system would reduce the amount of inventory required and product would be ordered exactly when it was necessary.

The system should be capable of producing reports as to which operators are using which product and in what quantities. The system should be able to track tooling costs directly to the specific job providing more accurate feedback on the true costs associated. A well-managed

system would require very little floor space, thereby providing more room for value-added assets such as more equipment.

A tool vending machine would address all of the concerns. Vending machines are capable of handling hundreds — if not thousands — of bins or allocated inventory locations and do so with a very small foot print. The machine is fully automated, automatically reordering product once an item meets a predetermined minimum quantity level, thus dramatically reducing the probability of ever reaching a “stock-out” situation.

The automatic reorder feature reduces the need for personnel to check stock and place several orders per day.

However someone would be required to re-stock the machine but in many cases this can be done in less than 15 minutes per day. Access to tools would be available through swiping a card or use of a PIN number. This would identify the user and prevent hoarding of inserts at any one machine. This would reduce inventory levels to the lowest level necessary. Operators would be restricted to select only the tools they are authorized to use. Pictures of the product would be displayed to prevent any errors. The machine would also be capable of scanning a bar code that would allocate the cost of the tool directly to a specific job thus providing more accurate costing of jobs.

Bench-top vending machines are a popular option today.

A bench-top vending machine is a much smaller machine that can be located in the center of cell or in a remote area of the plant, reducing the amount of time to walk to and from the tool crib.

Vending machines seem like an obvious choice to bringing your inventory system under control. However, there are many options to consider before making a decision.

Some of the alternatives we will look at are:

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THE BUSINESS OF TOOLING

• Purchasing the machine outright and managing the system internally. • Leasing the vending machine and managing the system internally. • Vendor-managed inventory. Meaning a supplier would take over and manage your inventory.

Of course a vending machine may be purchased outright and managed by your own staff. After minimal training your staff should be fully operational and restocking the machine should take only minutes per day.

The drawback to this method is the one-time cash outlay.

However the savings will more than pay this expenditure back quickly.

There are many independent leasing companies that would buy the vending machine and lease back to you much the same as one would lease a car. The vending machine would immediately start showing cost savings with very little cash outlay. Care should be taken when negotiating the terms of a lease agreement to ensure the buy-out is reasonable after a pre-determined amount of time.

Vendor managed inventory is where a supplier takes over your inventory and provides a vending machine at no charge. Typically the vendor management company will

provide only one invoice per month saving money on paper work such as paying invoices. On the surface this appears to be an easy solution, however care should be taken when studying the contract. Many suppliers have a heavily vested interest in providing one brand or another.

This may limit you from accessing the latest cost saving / productivity gaining technologies available through other suppliers. One method gaining popularity with end users is to have an agreement upfront that the supplier is paid a predetermined transaction fee for the lease of the machine and for loading the machine. Typically this amount is 15 to 20 per cent. The end user continues to work with any tooling supplier he/she chooses and negotiates the best price possible. The company managing the inventory and the end user are both quoted the same price. Of course the company managing the inventory would charge the end user the price from the supplier plus the predetermined transaction fee. By keeping an open door to all suppliers the end user has access to all of the latest technologies and at the best possible price. Limiting your options and not using new technologies that could reduce cycle times by, for example 50 per cent could be a very costly venture.

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Goin’ Round and Round

By Nate Hendley

Spinning edges for straight line speed

‘R

ound tools’ are simply cutting tools that are … round. As in, drills, end mills and reamers, among others.

WIDIA The VariMill II ER end mill from Widia, of Latrobe, Pennsylvania, builds on the strength of its predecessors, the VariMill I and VariMill II end mills.

Like the VariMill II, VariMill II ER end mills feature five unequally spaced flutes. Unlike other VariMills in the same line, the eccentric relief (ER) available with the cutting edges of this new end mill offer enhanced edge strength and enables high feeds and metal removal rates.

In addition, the VariMill II ER boasts a different taper core than VariMill I and II that’s designed to enhance stability and offer robust performance. Unlike its predecessors, the VariMill II ER is intended to be used for center cutting.

The VariMill II ER end mill from Widia

The VariMill II ER’s ‘Safe-Lock’ feature provides premium stability, eliminates pull-out risk and makes the tool more stable and concentric overall.

Widia plans to distribute over 100 VariMill II ER standard line items available worldwide in diameters from 3/8 – 1 inch (10 – 25 mm). These tools are primarily intended to be used for roughing and finishing applications in the aerospace sector but can also be used for machining titanium and stainless steel as well as slotting, ramping and plunging www.widia.com

KOMET Komet is expanding its Dihart brand solid carbide reaming range with an overhauled version of the Fullmax reamer.

The Fullmax solid carbide reamer offers top cutting performance in materials hardened up to HRC62. According to Komet, the integration of the Fullmax’s coolant supply makes the tool ideal for high-performance reaming of through holes in steel and nodular cast iron.

The revamped Dihart Fullmax reamer from Komet

A modified cutting edge geometry reduces chatter marks

With this in mind, here’s a look at what’s new and/or noteworthy in round tools:

and enhances chip formation. A combination of optimal cutting edge cooling and targeted coolant aids smooth evacuation of formed chips. The Fullmax reamer also features a highperformance coating for enhanced wear resistance.

The new Fullmax reamers with coolant supply are available in diameters ranging from 3.9 – 12.7 mm.

Adrian von Rohr, a business development manager for the Dihart line at Komet of America, in Schaumburg, Illinois describes the Fullmax reamer as a “hard working tool.”

Komet also recently introduced new ASG3000/ASG4000 geometries for reaming tools. www.komet.com

WALTER USA Walter USA of Waukesha, Wisconsin, has expanded its “Tough Guys” line of high-performance solid carbide endmills with the introduction of the Proto-max TG which can be used on steel, stainless steel, cast iron and some super alloys.

“The existing ‘Tough Guys’ family is our top seller. This new family will replace them but will have an improved substrate and coating that provides increased performance … Proto-max TG is very universal and can be used in all industrial sectors. It’s not designed for any specific sectors,” says Thomas Benjamin, e-Channel manager at Walter USA. The Proto-max TG can be used in ISO P, K, M and S materials, adds Benjamin. This solid carbide end mill has an advanced carbide substrate which offers an extremely high level of toughness (helpful for counteracting vibration induced fractures to the cutting edge). A pre-treatment process provides an excellent surface for the Proto-max TG’s new titanium aluminum nitride coating. This new coating enhances wear resistance, increasing tool life. The three features—substrate, cutting edge treatment and coating—combine to Walter’s Proto-max TG dramatically increase Proto-max TG cutting (“Tough Guys”) solid carbide endmills parameters.

The Proto-max TG also offers top-notch chip removal and guarantees sufficient room for chip removal

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in slot milling up to 0.9 x Dc. The rear-cutting edge has a reinforced core, giving the Proto-max TG a high degree of stability. The cutter has a reduced neck option and is suitable to be used in plunging or inclined plunging operations for deep cavities. The Proto-max TG can manage pocket, contour and shoulder milling and is available in two to 25 mm diameters with three, four or five cutting edges. www.walter-tools.com

TUNGALOY

mm). The Sumogun features indexable inserts with two cutting edges, making it more productive than traditional brazed tip gundrills.

“Gundrills, as their name implies, were originally developed for manufacturing weapons. Today they are used extensively in the metal cutting industries, including aerospace, automotive, die and moulds, etc,” explains Iscar literature.

The Sumogun can be used on standard horizontal milling centres, lathes, multi-task machines and gundrill machines— “anywhere a gundrill can apply,” according to David Vetrecin,

Tungaloy of Japan has expanded its drilling line with the introduction of new DrillMeister series of head changeable drills. The DrillMeister combines the productivity of solid carbide drills with the economic and cycle time reductions associated with indexable drills.

A simple and secure head clamping system on the new range reduces set-up time while maximizing machine time. The DrillMeiser comes in diameters from 10.0 mm – 19 mm, with hole depths up to L/D = 3 and 5. The tool is designed for drilling and possibly chamfering alloy steels, low carbon and carbon steels, stainless steel, gray and ductile cast irons, aluminum alloys and titanium.

The heads on the Tungaloy’s DrillMeister line DrillMeister boast an of replaceable innovative cutting edge head drills that breaks chips into smaller, more compact swarf. The head geometry has margins similar to those found on solid carbide drills, a feature which enhances hole accuracy beyond what conventional indexable drills are capable of.

Reduced machining time and boosted productivity can be had thanks to a chamfering adaptor that slides on the drill body and allows drilling and chamfering in a single process. Chamfering adaptors are available with 30, 45 and 60 degree inserts for drill flexibility. www.tungaloy.co.jp/us

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holemaking product manager at Iscar Canada, in Oakville, Ontario. The drilling head can be replaced inside the machine which means there is no need to remove the drill for head indexing. The Sumogun has two straight flutes that carry standard Sumocham drilling heads which enable drilling at a table feed rate two to five times higher than standard brazed gundrills.

The gundrill lets the end-user clamp different head geometries according to material and application needs.

The drilling head can be replaced at least 25 times. All drill bodies have straight coolant holes. The Sumogun maintains high hole precision and center alignment.

Iscar plans to eventually expand the size range of the Sumogun, says Vetrecin. www.iscar.ca

SGS SGS Tool Company of Munroe Falls, Ohio has introduced the TCarb line—a new series of six-flute high performance end mills.

The T-Carb line is intended to be used in aggressive high speed machining applications that utilize Trochoidal and Peel Milling techniques. These end mills excel at machining at high feed rates while reducing tool loads, which helps prevent breakage and failure. Variable pitch geometry allows the T-Carb to offer superior performance in multiple operations requiring roughing and finishing, resulting in faster cycle times and decreased costs. The new series works well in applications requiring SGS Tool Company’s aggressive ramping at high speeds. The T-Carb line of six-flute T-Carb six-flute high performance end mills high performance end mills are offered with various length, neck and corner radius options. These end mills boast SGS’s proprietary Ti-NAMITE-X coating for enhanced thermal barrier protection, better adhesion and increased tool life. www.sgstool.com

SUMITOMO ELECTRIC CARBIDE Sumitomo Electric Carbide of Mount Prospect, Illinois has introduced the new WGX Wave Mill series for face milling applications. This series features excellent surface finish and an innovative insert chipbreaker design that eliminates burrs. The WGX’s body and insert design improve run-out accuracy.

Other WGX benefits include lower Sumitomo Electric Carbide’s new cutting force thanks to a high rake angle and optimized edge treatment WGX Wave Mill Series face mill for enhanced tool life with new Super ZX and Super FF coatings.

Sumitomo Electric Carbide also recently announced the release of ACM200 and ACM300 insert grades for milling exotic and stainless steel material. www.sumicarbide.com

NIAGARA CUTTER Niagara Cutter’s new round tools include the Stabilizer HT STR440 solid carbide end mill and the expanded line of VFP (Variable Face Profile) high speed cobalt end mills.

The four-flute STR440 end mill is the latest addition to the company’s Stabilizer HT range. It boasts patented variable flute geometry and aerospace corner radii for high-performance machining of aircraft parts made of stainless steel, high-temperature alloys, nickel-based alloys and titanium.

Niagara Cutter also recently introduced the four-flute VFP435SB and six-flute VFP635SB for performing rough machining operations involving stainless steel or titanium, or operations that require significant metal removal rates. These cobalt end mills boast a cutter geometry Niagara Cutter’s Stabilizer HT that offers optimal chip formation STR440 solid carbide end mill and chip evacuation in difficult operations. While previous cutters in the VFP line could manage a corner radius up to 0.156 inches, the new tools can be modified for a corner radius of 0.250 inches. The VFP line is available in diameters ranging from ¾ - two inches with multiple lengths of cut based on diameter. Both the four and six-flute end mills are stocked standard with a 45 degree corner chamfer.

Niagara Cutter is a wholly owned subsidiary of Seco Tools, LLC, of Troy, Michigan. www.niagaracutter.com

SANDVIK COROMANT According to Sandvik Coromant literature, the Swedish tool giant’s new CoroMill Plura range of brazed PCD (Polycrystalline diamond) end mills are likely to be “of great interest to any manufacturers performing edging, surface milling, slotting or cutting operations on CFRP components.” Carbon-fiber reinforced polymer (CFRP) is a composite material.

The Plura brazed PCD end mills offer long-lasting, predictable wear patterns—important considerations when machining CFRP parts in order to reduce downtime and avoid rework or scrap. The end Sandvik Coromant’s CoroMill Plura mills use a proprietary high-perrange of brazed PCD end mills formance PCD grade optimized for CFRP that was developed by Sandvik for boosted tool life.

“For optimum machining results, Sandvik Coromant advises that the end of the cutter remains one mm beneath the composite material,” states Sandvik literature.

The cutters come in a diameter range of 6 – 16 mm and provide internal coolant and five degree ramping capability. www.sandvik.coromant.com

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Tough Materials Continue to Drive Creep-Feed Grinding Big removal rates with excellent accuracy and surface finish

T

oday’s difficult-to-process workpiece materials and complex, high-value parts have sparked resurgence in the use of continuous-dress creep-feed grinding.

At the same time, the capabilities of advanced grinding machines, CNC technology, and grinding wheel materials have boosted the cost-effectiveness of the process.

As compared with traditional reciprocating grinding, creep-feed grinding provides the means to remove significant volumes of metal in a short time and still generate top accuracy and finish. While reciprocating grinding removes

smaller amounts of material in multiple faster lighter passes, creep-feed grinding applies the wheel in single passes that are 0.300� or more deep and at slower feed rates.

When first put to use in the 1950s, creep-feed grinding utilized relatively soft, porous grinding wheels and flood coolant to minimize generation of heat. Although creep-feed grinding could cut cycle time by half in some cases, the process was limited in application because wheels wore quickly, restricting the length of cut possible before wheels required dressing.

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CREEP-FEED: BACK TO THE FUTURE The advent of continuous-dress creep-feed grinding in the 1970s addressed the issue of rapid wheel wear. As the name indicates, in continuous-dress creep-feed grinding machines dress wheels without interruption throughout the grinding process. A diamond dressing roll with a mirror-image form of the desired part profile maintains constant contact with the grinding wheel to keep it sharp.

Because the wheel is always sharp, long lengths of cut are possible. Plus, this consistent wheel performance results in lower average grinding forces and leads to more efficient abrasive use, shorter cycle times and increased production rates.

Creep-feed grinding can be considered abrasive or small-chip machining, capable of replacing milling or broaching in the machining of slots and complex forms in difficult-to-grind materials including prehardened tool steels and advanced alloys. Because the process completes a part in a single fixturing and in one pass, it reduces overall cycle time.

The process’ single pass generates much lower levels of heat, so thermal effects on the workpieces are minimized. The full wheel contact and slower feedrates of creep-feed grinding also dampen vibration, and surface finishes of 16 rms and better are possible.

As manufacturers seek ever-higher levels of performance, durability, and quality, they employ new manufacturing materials such as nickel-base alloys and tough cermet materials like titanium aluminide for parts such as automotive valves and turbocharger wheels. These parts are often complex in shape with thin walls, deep contours and other features that will easily distort or work harden under heat generated by traditional grinding or machining processes.

Additionally, some whisker-rein­for­ced materials contain fibers, and the large cutting edges of milling cutters can pull them out, but the thousands of tiny cutting teeth of a grinding wheel cut them cleanly. Creep-feed grinding fills a need for an unwaveringly sharp, cool and free-cutting material-removal process.

USE THE RIGHT EQUIPMENT According to grinding machine builders, gaining the maximum benefits of creep-feed grinding requires the use of machines and grinding wheels engineered specifically for the process. Admittedly, some shops perform a variant of creep-feed grinding involving deep passes on workpieces with narrow cross sections. Such operations are possible on standard grinding machines at somewhat reduced table speeds using conventional grinding wheels.

But doing so depends on factors that include workpiece material, depth and width of the grinding pass, rigidity of the machine and nature of the grinding wheel.

True creep-feed grinding, on the other hand, maximizes the arc of contact between the wheel and part and requires use of a rigid, high-horsepower multi-axis CNC machine designed to handle the high stresses and kinetic complication of the creep-feed process.

A major source of complication is the continuous-dress process. For continuous-dress applications, a grinding machine’s basic three CNC axes are supplemented by a fourth axis controlling the infeed of the diamond dressing roll. The roll turns in the same direction of the grinding wheel and feeds into the wheel in increments of millionths of an inch per revolution, ranging from typical rates of 0.00001” to 0.00002” per revolution to steps as large as 0.00005” or 0.00006”.

As the grinding wheel’s diameter shrinks during continuous dressing, the grinding machine’s programmed wheel spindle increases rpm to maintain the surface speed required to grind the part. Likewise, a variablespeed servomotor constantly changes the dresser roll’s rpm to maintain the correct pace of dressing.

Depending on the specific application, the contact pressure on a creep-feed grinding wheel may exceed 2,000 lbs total force. The structure of a machine engineered for creep-feed operations must handle such forces and stresses, and part fixturing as well must be designed to resist these high forces too.

Horsepower well beyond that of a standard grinding machine is required for creep-feed grinding to generate and maintain the high-productivity forces needed to remove large amounts of material quickly. While a typical reciprocating grinder generates 20 hp to 50 hp, a common creep-feed grinding machine ranges from 60 hp to 150 hp and more. One benchmark dictates 20 hp

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When the wheel is buried deep in the cut, the pores provide a path for coolant, and swarf to escape the grinding zone.

for every cubic inch of material removed per minute, per inch of wheel width.

Ideal creep-feed grinding machines also sport direct drive spindles that eliminate variables such as slipping belts. The drive system for their diamond roll dressers must also possess the capability to generate and withstand high levels of torque. A servomotor drives the dressing roll into the grinding wheel to reform it, but the dressing wheel needs to hold its speed and not impart accelerative forces to the grinding wheel itself.

Creep-feed grinding requires that the workpiece be fed slowly and precisely under the wheel — in general,

the greater the depth of cut, the slower the table speed.

Feed control is crucial to maintain part precision and also because any sudden change in table feed can break a grinding wheel that is under heavy grinding forces, which is often the case in the creep-feed process.

Variable-speed ballscrews, racks and pinions or electromechanical table drives will maintain tight control over table speed and position. They provide this control minus any surging that might occur with table speeds as slow as 0.5 ipm, although more common speeds are in the range of 8 ipm–30 ipm. Hydrostatic or linear-bearing ways then provide preload to eliminate slack and absorb vibration for maximized grinding precision.

A variation on the continuous-dress creep-feed process, called in-process continuous-dress, can help control manufacturing costs where possible. With the in-process strategy, the continuous-dressing operation is, in fact, not continuous, but switched on and off according to need.

Based on the workpiece material, amount of stock being removed, wheel configuration, and other factors, continuous-dressing on a long cut may result in grinding wheel overdressing. And while part dimensions remain unaffected, valuable wheel material is wasted.

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creases or surges, which would indicate a dull grinding wheel. When a rise in power usage occurs with in-process continuous-dressing, the machine initiates wheel dressing, and when consumption returns to normal, the dressing cycle stops. In the long run, such a strategy can optimize use of abrasives and save time by reducing the frequency of shutdowns for wheel changes.

high-performance workpiece materials. Accuracy and repeatability are a given. The speed of creep-feed grinding boosts productivity, and the elimination of many pre-grinding and post-process operations as well as part handling can significantly reduce overall part production times. Successful application of creep-feed grinding requires investment in appropriate equipment including specialized grinding machines and grinding wheels, but for the right situations and materials, return on the investment will far exceed a creeping pace.

NEW WHEELS, BETTER PERFORMANCE In light of renewed interest in creep-feed grinding, wheel vendors have developed wheels that minimize wheel www.grinding.com Courtesy of United Grinding consumption in the continuous-dress creep-feed process. Grinding wheels engineered for creep-feed grinding applications feature open bond, “induced iMachining Technologypore” structures.

Wizard When the wheel is buried deep in the cut, the pores provide a path for coolant, swarf and excess wheel material to escape the grinding zone. Aluminum oxide, for instance, is the most common abrasive material used in grinding wheels.

New wheels designated as ceramics (actually premium-level aluminum oxide) can grind up to three times faster than conventional abrasives, according to wheel makers, while the ceramic wheels’ durability enables them to process as many as three times as many parts per Finally, a CAM system that REVOLUTIONIZES machining to make any CUTTER, on any CNC wheel. The new wheels’ durability and MACHINE, DEVOUR any MATERIAL! productivity offset their required higher initial investment, wheelmakers say.

SolidCAM’s iMachining Provides you with: Wheel durability as well as grinding Cuts Cycle Times by at Least Half — results themselves are dependent on the or Your Money Back GUARANTEED! proper application of coolant in creepUNMATCHED Tool Life feed grinding. Coolant prevents buildup PATENTED Speeds & Feeds Wizard of heat in the part and grinding wheel, and also removes swarf from the wheel contact zone to prevent marring of the Join our Webinar to watch us cut through 1018 steel like workpiece. Sufficient coolant flow also butter with iMachining – LIVE! prevents the pores of the grinding wheel Take the iMachining Challenge – Guess the closest cycle time to from becoming filled with swarf, a conmachine the challenge part and WIN $500 cash! dition that reduces the wheel’s cutting effectiveness and further reduces the $500 cash given away at each webinar! coolant’s temperature-control benefit. th E4992) When temperatures rise too high, the S 2014 (boo T IM t a e g allen wheel may burn the workpiece and swarf 2 hours! chining Ch $500 every in ke the iMa w a T to ce an may weld to the wheel, negatively affectfor your ch ing workpiece dimensions and finishes.

Creep-feed grinding, and in many Register for the LIVE Webinar at cases its continuous-dress version, provide a variety of benefits when www.solidcam.com/cmw processing the growing selection of for Automatic Feeds and Speeds

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Law of Averages Ra or “roughness average” is a common specification for surface smoothness ...

But what does it really mean?

By Jim Anderton, editor ............................................................................................................................................................................

A

smooth surface finish is very important in massproduced manufactured goods, from stamped car bodies to blow-molded bleach bottles, and to achieve that smooth surface the tools and molds that make them must be at least as uniform... and often more so. Before electronic measuring instruments for surface characterization were developed, finishes were compared with prepared standards, usually specified on the printed agreement between buyer and toolmaker. Often, finish was simply described on the print as ‘sandblast’ or “mirror finish”. Mechanical, and later optical surface profilometers put some rigor into the process and created a numerical specification that removed the variation inevitable in an ‘eyeball’ process.

In the mold, tool and die industry, this measurement of surface variation involves features and asperities impossible to measure with the naked eye and more importantly, defects that can be usefully measured with conventional linear units. The result was the adoption of “roughness average”, a statistical interpretation of variation in a surface — specifically, a line segment of the surface under test. In a highly magnified crosssection typical surface might look like this:

component... we’re interested in how asperities deviate from the hypothetical smooth surface. An important point is that an individual peak or valley could be very large, but if the sample length is also large, the averaging process will obscure that random peak. Depending on the scale you’re using that outlier could be a defect, but the surface could still be within its roughness average specification.

WAVINESS VS. ROUGHNESS Another basic but important point is the need to distinguish between waviness and roughness. At its simplest, waviness is a macro scale surface characteristic, and roughness is micro­scale. Somewhere in between however, it’s important to distinguish between the two. Waviness is typically a function of the machining process, while roughness is associated with micro finishing or polishing.

Mathematically, surface profile can be thought of as a roughness sine wave which itself forms the waviness sine wave. The measuring instrument naturally measures both, and if the waviness is sufficiently small, and the roughness sufficiently great, the data may be noisy enough to make it impossible to separate waviness from roughness. The measuring instrument solves Roughness Average, Ra this problem by allowing the user to establish a “filter Ra Roughness Average v cutoff wavelength”, which the instruments processor uses to smooth the data sufficiently to expose the long v Height of wavelength waviness from v Asperities the higher frequency roughness profile.

The choice of cutoff value Mean Line v is described in industry standards such as ASME B46.1“Roughness average”, a statistical interpretation of variation in a surface, specifically a line segment of the surface of the test.

2002 and ISO 4288-1996.

In a highly magnified cross-section typical surface might look like the diagram above.: Why does this matter? One reason is that the use of very fine abrasives like diamond The roughness average value is determined by taking paste to deal with very small asperities in the roughness the absolute value of individual amplitude measurements along the x-axis and calculating their average. We use the profile won’t remove waviness, and conversely finishing absolute value because the y-axis negative component processes that deal with the long wavelength waviness component will invariably leave a rough surface profile. of the roughness arithmetically cancels out the positive 108 | APRIL 2014 | www.canadianmetalworking.com

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v

Waviness

v

Waviness vs Roughness

Roughness Waviness is typically a function of the machining process, while roughness is associated with micro finishing or polishing.

A slow, stepwise finishing procedure working through abrasives of progressively finer grade can deal with both waviness and roughness, but costeffective production requires as few steps as possible, and a surface profile no smoother than the specification.

The cost of producing very smooth services goes up exponentially with the specification and is a major time and cost factor in the production of injection molds, for example.

On the other hand, it is possible to have excess smoothness, typically where machine parts must hold lubricant to minimize friction, particularly in sliding assemblies. In piston engine cylinder bores for example, very smooth and glazed surfaces must be roughened to promote proper sealing of piston rings with the cylinder wall.

This barely scratches the surface of what is a highly complex subject, and is one of the few in modern metalworking where multiple standards, methodologies and measurement units exist around the world. Ra, roughness average, is a common measure, but there are others. A common one takes the RMS value of the roughness average, which will typically produce instrument readings about 10 per cent lower than Ra. It’s important to both read the print and understand the specification as well as the testing methodology to avoid expensive disputes in high-value mold and die making. Canadian Metalworking will explore service measurement this rotation and techniques in greater depth in a future issue. CM

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Hard Parts, Fine Finishes at Sikorsky C

arburized surfaces present a unique problem to manufacturers in close tolerance industries … they’re hard and often coated in a scale that must be removed to achieve a smooth finish for bearing components, shafts, sleeves and bores.

At Sikorsky Helicopter, a carburized bearing surface delivered by a supplier was coated with scale and required a very smooth finish. “We attempted to remove this scale with a carbide reamer and a diamond lap - to no avail,” says Tony Lawrence, Tooling Services Manager for Sikorsky Product Center Core Services.

“The material in question was 9310 [alloy steel], and very hard, around 66RC,” Lawrence explains, which required a tool of equal toughness to do the job properly. He notes that his group had used diamond Flex-Hones, available from Brush Research Manufacturing in a very limited set of applications previously, but not for this high volume situation.

The Flex-Hone is a ball-style tool characterized by a shaft with small, abrasive globules that are permanently mounted to flexible filaments. The tool, which can be mounted in a hand drill motor or a machine tool chuck, is used for finishing or resurfacing of the hard metals, ceramics and other tough materials used in items such as ports, sleeves, and cylindrical bores. Quite often the flexible hone is used instead of cumbersome conventional equipment such as CNC-based hones and anvil tools.

The flexible hone is available in many sizes with a wide selection of grit material, allowing the tool to be matched with a variety of materials from very hard, heat treated alloys to softer, non-ferrous. Custom sizes and grits are also available directly from the manufacturer.

In the case of Si­korsky, the flexible hone needed to be con­ structed with dia­ mond crystal grit. Brush Research offers a diamond flex-hone in a variety of mesh sizes that can easily produce finishes on hard materials to a range of Ra of 0.1 to 0.15µm.

“So now that we had the first success, we were going to need to produce thousands of these [flexible hones], since we were at a production stop,” he continues. “We contacted Brush Research and explained our dilemma. Two days later we had the first production run of brushes and we were able to ship our product again to customers all over the world.”

Grant Fowlie, Brush Research Customer Service Manager, says that “quite often the customer has a pretty good idea of what he is looking for in a flexible hone,” Fowlie explains. “For example, they know the size and hardness of the material they are dealing with and may even the kind of honing grit required. In cases like those we may simply send one or two standard hones so they can see how the tools work for their application.”

Fowlie adds that in other cases his team requests samples of the material to be honed and then performs tests on site using sophisticated surface analysis equipment to ensure that the company’s recommendations are well founded.

“Surface finish analysis will give you roughness [Ra] and a variety of other measurements as far as surface finishing analysis goes, including peak height, valley depth, bearing areas and other specifications that have their own importance in different applications,” says Fowlie.

Fowlie points out that the Flex-Hone is well suited to numerous aerospace applications, ranging from very small to quite large.

“We produce very slender hones for tiny IDs, but also produce tools for use on large jet engines that required hones 10-15-inches in diameter.”

The Flex-Hone is also in wide use throughout many other industries, including automotive, firearms, machine shops and other types of manufacturing. CM www.brushresearch.com

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FABRICATING & WELDING NEWS

Walter’s new high removal grinding wheel

W

alter Surface Technologies has introduced the XCAVATOR, their newest grinding wheel, designed for a range of industry such as metal fabrication shops, steel mills, mining, oil & gas, and shipbuilding.

The wheel has been tested on some of the world’s hardest resources, including tungsten carbide, tempered steel, Inconel, Hardox, and Boron steel.

Its aggressive, coarse front layer of Zirconium

grain delivers very high removal rates. It also features an extra strong disc base/backing for more powerful and aggressive grinding action.

The wheel uses Walter’s patented UHR multi-layer manufacturing technology to prevent edge flakiness – keeping the wheel edge symmetrically round for more safety and longer life. www.walter.com

TV personality Jessi Combs delivers FABTECH Canada keynote The South Dakota native has appeared on shows such as Overhaul, Xtreme 4×4, and Mythbusters.

By Nick Healey

O

n March 18, FABTECH Canada 2014 officially kicked off Whether it’s a racing competition or who can do the dishes with an inspirational keynote from television personality faster, I’ll take on the challenge.”

Jessi Combs. With a shock of blue dye Combs also scoffs at the idea women aren’t in her hair, the effervescent Combs took well suited for manufacturing. “So many people the stage to address an audience of more tell me, ‘you’re too pretty to weld, you’re than 150 manufacturing professionals, and too pretty to drive that fast’… I mean, my emphasize the importance of considering goodness, am I too pretty to be alive?” women for roles in the trades.

Her success hasn’t come without some As some employers are acutely aware, it adversity though. Combs suffered a serious can be difficult to find skilled tradespeople for back injury after a bandsaw fell on her and certain jobs, and Combs is a testament to the fractured vertebrae in her back. capabilities of women manufacturers.

“Because of that I had to learn how to walk The South Dakota native has hosted or again. The doctors called me a miracle case… been featured on a variety of automotive there’s no reason I should be standing here – I and tech-related shows – including Overhaul, should be sitting in a wheelchair.”

Xtreme 4×4 and Mythbusters – and her But even at the lowest of lows Combs didn’t repeated desire of wanting “to go fast” drove dwell on the negatives. “I was able to sit back, her to follow her passion into a field that has take a look at the bigger picture, and realize what traditionally been dominated by men. was really going on…. I was able to reach out to Jessi Combs She got started in the industry after my audience and hear all these stories about how photo courtesy Damian Rae Photography attending WyoTech College in Laramie, many lives I was changing,” said Combs.

Wyoming, and made a name for herself by working on a 1964 She credits this time interacting with fans of hers as Mercury Cyclone that was later showcased at the Specialty a reason she is so passionate about her industry, and Equipment Market Association (SEMA) show in Las Vegas. promoting it to younger generations.

From there, the sky has seemingly been the limit as “What I fully believe is that when bring women into Combs is now doing everything from designing her own line (manufacturing), we inspire it. I’ve inspired many girls, boys, of welding gear, to breaking the women’s land speed record – people of all ages, because of the fact that I do what I want to all in addition to her various TV duties. do.” After the keynote Combs sat in on a panel that discussed But one of the things Combs loves the most? the need to get women more involved in manufacturing, and “Most of all, I love breaking stereotypes,” she said. some of the potential ways to go about engaging young “Anybody who knows me, knows I love a good challenge… women in trades as a career. CM

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FINANCING ... continued from page 27

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

sell well because of its price point and therefore was dropped from production, or there were design issues.

There are a myriad or reasons why finding a replacement cost could prove difficult so the reasons must be researched.

In today’s world, researching a piece of equipment is relatively easy.

If it’s a standard machine tool built by a well-established manufacturer and has sold well, finding a similar model and age for sale can be done with a simple Internet search.

But just finding a quote for a similar machine and using that exclusively as the basis for value may be problematic. Back in my days as a machinery dealer there were many times we sold a machine and had to take it back for whatever reason.

When we remarketed it, the selling price was more a reflection of us trying to get costs out of the deal and less about current market pricing.

There are also cases where a dealer may be offering a machine they do not own — marketing it on behalf of a good client, and the asking price is determined by the owner based on what is owed on the machine if it’s being financed.

There are many factors influencing how any piece of machinery and equipment is valued, but if there’s one take away, it’s this: invest in wellestablished brand-named equipment regardless of whether funds are from your own account, your bank, or a private lending institution. That way, you’ll always add value to or provide options for your business. CM Ken Hurwitz is senior account manager with Enable Capital Corp., an assetbased lending company in Toronto.

Contact Ken at (416) 614-5878 or via email at khurwitz@enablecapitalcorp.com Learn more at http://www. enablecapitalcorp.com.

AceTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . 60,61

Natex Tools & Natex Machinery Group . . . . . . . . 16

Amada Canada, Ltd. . . . . . . . . . . . . . . . . . . . . . . 9

Ontario Power Authority . . . . . . . . . . . . . . . . . . 95

AMT Machine Tools Ltd. . . . . . . . . . . . . . . . . . 51 Blaser Swisslube Inc. . . . . . . . . . . . . . . . . . . . 53 Bohler-Uddeholm Ltd. . . . . . . . . . . . . . . . . . . . 57 Canadian Measurement- Metrology . . . . . . . . 109 Carl Zeiss IMT Corporation . . . . . . . . . . . . . . . . . 6

PFERD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Powerhold Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 12 Renishaw (Canada) Ltd. . . . . . . . . . . . . . . . . 111 Retention Knob Supply & Mfg. Co. Inc. . . . . . . 113 Rofin-Bassel . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Sandvik . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5

Cincinnati Incorporated . . . . . . . . . . . . . . . . . . . . 6

Schmoltz + Bickenbach . . . . . . . . . . . . . . . . . 66

CWB Group . . . . . . . . . . . . . . . . . . . . . . . . . 20,21

Schunk Intec Corp . . . . . . . . . . . . . . . . . . . . . . 33

Data Flute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Scientific Cutting Tools . . . . . . . . . . . . . . . . . . 59

Dillon Manufacturing, Inc. . . . . . . . . . . . . . . . . . 80

Seco Tools Inc. . . . . . . . . . . . . . . . . . . . . . . . . 42

DiPaolo Machine Tools . . . . . . . . . . . . . . . . . . . 13

SGS Tool Company . . . . . . . . . . . . . . . . . . . . . 101

DME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Sirco Machinery Co. . . . . . . . . . . . . . . . . . . 28,29

Elliott Matsuura Canada Ltd. . . . . . . . . . . . . . . . . 6

SME - MMTS . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Emec Machine Tools Inc. . . . . . . . . . . . . . . . . . . 75

SolidCAM Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 107

ERI America Inc. . . . . . . . . . . . . . . . . . . . . . . . 106 Eriez Magnetics . . . . . . . . . . . . . . . . . . . . . . . 52 Exsys Tool, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 83 Fein Power Tool Company . . . . . . . . . . . . . . . . . 97 Ferro Technique . . . . . . . . . . . . . . . . . . . . . . . . 77 Flexovit Canada Abrasives Ltd. . . . . . . . . . . . . . 99

Sorel Forge Co. . . . . . . . . . . . . . . . . . . . . . . . . 40 SST Canada . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Thomas Skinner . . . . . . . . . . . . . . . . . . . . . 28,29 TORNOS Technologies . . . . . . . . . . . . . . . . . . . . . 6 TRUMPF Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . IBC Tungaloy America Inc. . . . . . . . . . . . . . . . . . . . . . 3 United Grinding . . . . . . . . . . . . . . . . . . . . . . . . . 17

GF Machining Solutions . . . . . . . . . . . . . . . . . . . 6

Victor Technologies . . . . . . . . . . . . . . . . . . . . . . 31

GMN USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Walter Surface Technologies . . . . . . . . . . . . . . . 71

Gravotech, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . 23

Walter USA, LLC . . . . . . . . . . . . . . . . . . . . . . . . 73

Haas Automation Inc. . . . . . . . . . . . . . . . . . 28,29

Weiler Corporation . . . . . . . . . . . . . . . . . . . . . . 69

Horn USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 11

YCM CNC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Hotset America . . . . . . . . . . . . . . . . . . . . . . . . 63 Hougen Manufacturing Inc. . . . . . . . . . . . . . . . . 18

8CMM20186

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Hurco USA . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC Hypertherm Inc. . . . . . . . . . . . . . . . . . . . . . . . . 93 Ingersoll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Iscar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OBC ITI Tooling Company Inc. . . . . . . . . . . . . . . . . . 46 Jet Edge, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Kinetic Cutting Systems Inc. . . . . . . . . . . . . . . . 91 Komet Canada . . . . . . . . . . . . . . . . . . . . . . . . 43 Kyocera Industrial Ceramics Corp. . . . . . . . . . . 45 Lincoln Electric Co. of Canada . . . . . . . . . . . . . . 85 Machineries Isotop . . . . . . . . . . . . . . . . . . . . . . 82 Makino Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Megatel Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Metalworking Magazine . . . . . . . . . . . . . . . . . 47 Micro 100 Tool Corporation . . . . . . . . . . . . . . . 106

IN STOCK American Standards and specials.

Japanese Standards inch or metric.

FOR FAST DELIVERY: Contact your local tooling dealer or order direct.

TEL 937-686-6405 FAX 937-686-4125 www.retentionknobsupply.com Retention Knob Supply Company P.O. Box 61 Bellefontaine, OH 43311

Multicyl Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 www.canadianmetalworking.com | APRIL 2014 | 113

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By The NUMBERS Canadian Productivity Still Lags Annual productivity growth, 2000-2012 United States Japan Germany United Kingdom OECD average

France CANADA Italy 0.0

0.5

1.0 per cent

1.5

2.0

Sources: OECD Productivity database; Department of Finance calculations.

P

roductivity, the measure of outputting dollars per employee, is a common measure of the state of automation and information technologies in advanced manufacturing countries. In terms of living standards, since 2000, we have performed well compared to other G-7 nations, rising from the bottom of the list in the 1990’s to leadership since the year 2000. That income growth over the past decade has been driven by higher employment and exports along with a sharp rise in commodity prices. In productivity terms however, we lag the G-7 and more importantly, the US. According to the recently released Department of Finance jobs report “The State of the Canadian Labour Market”, between 2000 and 2012 Canada’s

productivity growth of 0.8% was less than half the 1.9% rate of the US, and significantly lower than OECD average of 1.7%. These disappointing numbers continue a trend that dates to the 1990s. The skilled labour shortage makes the problem worse, as work lost due to understaffed operations are not counted in the productivity figures. Add an aging workforce to these lost opportunities, and Canada will rely more heavily than ever on commodity exports. Will rising commodity demand from developing nations keep prices and therefore incomes high? There is no way to tell, making it more important than ever to close the productivity gap with updated equipment and higher levels of automation.

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