A MAG A ZINE FRO M SEC O I S SUE 2 – 2 016
3D PRINTING HOPE OR HYPE? PRESS ‘S’ FOR SPACE
Made by magic hands. Industrial robots are at the core of German gear-manufacturer Stelter Zahnradfabrik’s production.
THE ROBOTIC TOUCH
Contents EDGE ISSUE 2 – 2016
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NEWS AND TRENDS
07 KNOWLEDGE GREEN – AND PROFITABLE Sustainability is increasingly being linked to the long-term competitiveness of companies.
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CASE: GERMANY MAGIC HANDS
COVER STORY
If you want to avoid mistakes, let robots do the work. That’s the philosophy of German gear-manufacturer Stelter Zahnfabrik.
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CUTTING EDGE Q&A WITH PATRICK DE VOS Seco’s cutting-expert answers technical questions submitted by readers.
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CASE: PHILIPPINES SPARK OF INNOVATION The Philippines’ booming economy is providing a boost to Ramcar Technologies, a producer of molds for car batteries.
18 POSSIBILITIES SPACE ELEVATOR Instead of sending rockets up into space, why not simply build a huge lift?
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EDGE AND YOU ASHLEY MOFFAT/AUSTRALIA “The Mint is the sole supplier of A ustralia’s circulating coinage, so it’s quite a unique place to work.”
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CASE: FRANCE HIGH EXPECTATIONS In the French aerospace industry’s heartland at Saint-Nazaire, Seco is helping FAMAT to machine parts for tomorrow’s jet engines.
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EDGE OF THE WORLD ION TÂMPU “Vintage cars were designed from the heart,” says Ion Tâmpu from Seco Tools, Romania, a passionate car collector.
32 EDGE-UCATION HOW TO TACKLE THE 3D CHALLENGE Seco’s Head of Research and Development, Anders Ericsson, explains the do’s and don’ts of additive manufacturing.
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EDGE (2. 2016)
Inspiration and insights Our business environment is changing rapidly. New technology
such as the Internet of Things, automation and additive manufacturing, along with increasing concerns about environmental impacts and sustainability are all strongly influencing the current state of our industry. In this issue of Edge, we dive deeper into these matters in order to provide you with inspiration and valuable insights. You will meet the German gear-manufacturer Stelter, which has an exceptional level of automation in its production processes; Seco’s Head of Research and Development Anders Ericsson will provide you with insight and advice regarding additive manufacturing; and you will find an inspiring article about achieving a circular economy. As usual, Edge also contains a mix of articles on business, methods, and people from all over the world. Make sure you don’t miss the feature on Ion Tâmpu, a technical representative at Seco Tools in Romania who is also a passionate collector of vintage cars. Enjoy! HANS HELLGREN
VICE PRESIDENT, SALES AND MARKETING EDGE@SECOTOOLS.COM
EDGE is a customer magazine from Seco Tools published in 25 languages worldwide. Seco Tools AB Marketing Department, 737 82 Fagersta, Sweden. Phone +46 223-400 00 Fax +46 223-718 60 Internet www.secotools.com Publisher Hans Hellgren E-mail hans.hellgren@secotools.com Managing editor Jennifer Gauffin E-mail jennifer.gauffin@secotools.com Editorial production and layout Appelberg Publishing Group Project manager Per-Ola Knutas Editor Daniel Dasey Art directors Cecilia Farkas, Johan Nohr Print Elanders Coverimage Martin Nicolausson /Agent Molly & Co EDGE (2. 2016)
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NEWS AND TRENDS
MIKAEL LINDHOLM
has been involved in product development for nearly 20 years and over several generations of innovation. One of his current focus areas is the new range of Duratomic products.
SHORT FACTS Mikael Lindholm Position: Product manager ISO turning tools and grades. Education: Master of Science in materials design, additional postgraduate degrees, and a degree in innovation management. Career: Process and Product Development, Project Manager followed by product manager positions, including several international assignments.
PHOTO: GETTY IMAGES
NEWS FROM THE TOOL EXPERT
The right type What do Seco Tools’ logo and the science fiction films Star Trek and Alien have in c ommon? They all use the Microgramma font, a so-called sans-serif font designed in 1952 by Aldo Novarese and Alessandro Butti for the Nebiolo Type Foundry. Not long after inception, Microgramma was widely appropriated for use in science fiction films, representing advanced technology and space exploration. Microgramma and its related variations are used throughout the original Alien films, as well as the more recent reincarnations. The font, in both its original and various altered forms, was also incorporated into numerous displays and on ship exteriors in six of the Star Trek motion pictures.
Seco’s new office in Casablanca at the inauguration in February.
New office in Morocco Sharing the premises with Haas Machine Tools, Seco has opened a new office in Morocco in North Africa in order to better serve customers in a range of expanding industrial sectors. “A number of French and Canadian Aerospace subcontractors are already investing in the region or soon will be,” explains Thierry Cros, Managing Director for Seco Tools France. “This is only the first wave. An automotive wave now being formed will see investments from Renault and PSA.”
45% TK1501 AND TK0501 CAST IRON TURNING GRADES Seco’s Duratomic coating technology and the company’s Edge Intelligence concept are now making it possible to achieve the highest possible performance in all cast iron turning applications. The new TK1501 and TK0501 cast iron turning grades feature Duratomic technology, with Edge Intelligence's Chrome Used-Edge Detection ensuring customers don’t throw away inserts with unused edges. Seco’s new balanced productivity grade TK1501 takes over from TK2001 as the number one grade for reliable outcomes in cast iron turning. The new high-speed productivity grade TK0501, meanwhile, further lifts the wear resistance of the TK1001 grade, meeting the highest requirements for dimensional stability in demanding grey cast iron high-speed applications.
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EDGE (2. 2016)
The proportion of hard-metal powder production within Seco that is based on reuse, according to figures from the company’s buy-back scheme for used inserts.
10,606 MWh The amount of heat energy recovered from Seco’s production facility in Fagersta through recycling. The total amount of heat transferred to the district heating grid was sufficient to heat about 400 homes for a year.
26% The reduction of energy use within Seco in 2015 compared to 2005 thanks to a dedicated focus on environmental issues.
Go to the source Have you ever wondered about the specific details when it comes to tool wear in finish hard turning? Do you want to know more about hard turning with wiper inserts or when to select an S-edge, T-edge or E-edge preparation when machining heat resistant super alloys with ceramics? You can find out the answers to these questions and much more in Seco’s technical blog “Seco Tools CBN Expert”, where Seco’s technical experts exclusively share their tips, techniques and knowledge relating to CBN tools for the advanced manufacturing industry. Read more at cbnexpert.blogspot.se (content in English)
JS564 JABRO SOLID2 TOOL Seco’s new generation of JabroSolid2 solid end mills represents over 800 universal products that apply to all commonly machined materials, from steel to titanium alloys. The JS564 tool is for advanced roughing in ISO-PMS materials and has been developed in response to market demand for tools that can operate in both AXIAL and Z LEVEL operations, as well as typical advanced roughing toolpaths, according to workpiece complexity. Key features include optimized frontal teeth design allowing for fast and effective axial operations; strong core design, dealing with high radial engagement: and optimized chip control thanks to NXT coating and designed flute space.
EXPANDED DISC MILLING CUTTER RANGE PHOTO: GETTY IMAGES
Take the next education step Seco’s NEXT STEP is a high‑level education and production philosophy that takes a comprehensive approach to process optimization. The approach uses recognized strategies built on proven physical and mathematical models to examine total production economy. This includes the correlation between factors including performance, workpiece quality, variable costs,
verhead costs, downtime, output, o and throughput. NEXT STEP provides tremendous insight into your production organization. Seco will work closely with you during the course to develop a map that compares where your facility is today and where it could be with complete optimization. For more information – contact S eco’s Patrick De Vos, patrick.de.vos@secotools.com
Seco has expanded its disc milling cutter range to include a small diameter cutter solution, with diameters starting at 10 mm. The 335.14 range of cutters feature exchangeable carbide heads and are the perfect solution for applications such as groove milling, circlip grooves, full-radius profiles, and even top and bottom chamfering. Thanks to the versatile and precise cutting profile, the range can be employed on any type of materials. The heads are available with either three or six teeth, while the wide variety of shanks, either cylindrical or with integrated collet chuck, can tackle a large variety of workpieces and machine configurations. EDGE (2. 2016)
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NEWS AND TRENDS
Inserts for difficult-to-machine materials Seco 218.21 inserts are doubled-sided trigon-shaped inserts with a center-locking screw for use in high feed milling. Developed for use in segments including general engineering, aerospace, mold and die, and power generation, the inserts are suitable for use with difficult-to-machine materials, including medium to hardened alloys, and provide a high material removal rate and high levels of performance in combination with good edge economy. They are designed for high-feed applications like facing, pocketing, light ramping, and side milling.
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EDGE (2. 2016)
KNOWLEDGE GLOBAL TRENDS
Susanne Evegård Manager Sustainable Business, Seco Tools
T
MORE GREEN – AND MORE PROFITABLE
Circle of sustainability
HERE HAS BEEN a much greater
focus placed on sustainability issues in recent years. The area has taken on a more direct connection to profitability and business models, partly because sustainability is closely linked to the company’s long-term competitiveness, and partly because it’s often linked with reduced costs in production itself. Seco Tools is working with sustainability in an active and structured way. We want to recycle as much raw material as possible, steadily increase the efficiency of our processes, and continue to reduce our waste and our consumption of energy and water. We introduced the Green Fund four years ago, into which we set aside money every year. We are, therefore, able to finance new investments and projects aimed at strengthening our sustainability work. Furthermore, sustainability often comes in when we help our customers to analyze their production processes. When we propose measures that increase the efficiency of a customer’s production system, the customer gets a more sustainable profile as a result – at the same time as reducing their costs.
Interview by Per-Ola Knutas Illustration by Christoffer Pettersson
THREE TRENDS IN SUSTAINABILITY
Circular economy There’s an increasingly strong trend for a global ‘circular economy’, whereby companies look at their operations as cycles rather than as linear processes with a start and a finish. The key words are: reuse, reduce, and recycle. Seco is working increasingly according to this philosophy.
Water: a scarce resource
UN sustainability goals
In many locations, water is a scarce resource that increasingly has a price set on it. As a result, the consumption and recycling of water is something that companies need to focus more on in terms of processes, with a view to saving both money and water.
Companies and industries must now start meeting the UN’s 17 sustainability goals and the goals set at the 2015 UN Climate Change Conference in Paris. We see these goals as an opportunity to actually show how much and in what ways we are contributing to global change.
EDGE (2. 2016)
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CASE STELTER, GERMANY
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EDGE (2. 2016)
BY MICHAEL LAWTON PHOTOS BY THOMAS MÜLLER ILLUSTRATIONS BY MARTIN NICOLAUSSON /AGENT MOLLY & CO
GEARING UP WITH ROBOTS
If you want to avoid mistakes, let robots do the work: that’s the philosophy of German gear-manufacturer Stelter Zahnradfabrik. Now the company’s operations have become even more efficient, with help from Seco. EDGE (2. 2016)
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CASE STELTER, GERMANY
THE ADMINISTRATIVE BUILDING for gear manufac-
turer Stelter in the north German town of Bassum may look old-fashioned, but it’s home to a business that’s at the cutting edge of its field. The company’s Production Director, Christian Stelter, explains, “We have an exceptional level of automation, with several robots linked together in a single process.” This highly automated arrangement allows for a dull, grey blank to be put on a conveyor belt and emerge shining at the other end, following a whole series of turning, milling, CHRISTIAN and grinding procedures. The STELTER, company likes to say that its PRODUCTION products are “made by magic DIRECTOR, STELTER hands”, a reference to the work of its industrial robots.
KARL-HEINZ WILKENS, TECHNICAL DIRECTOR, STELTER
KARL FÖRSTER, SECO TOOLS, GERMANY
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EDGE (2. 2016)
STELTER ZAHNRADFABRIK’S newest production hall, built in 2014, features a number of machines that make the various gears required for a new duplex clutch gearbox for a major German automaker. At each workplace, a computer screen reminds operators to carry out various checks at predetermined intervals. Is the inner diameter still within tolerances? How deep is this or that groove? Every few minutes, the screen flashes up a new parameter for checking. “We decide what needs to be checked, and we can see in the office if the checks have been done and what values
they show,” explains Stelter. This combination of operator and machine is one that Stelter and company Technical Director Karl-Heinz Wilkens believe will characterize the industry for some time to come. “A human being is always in charge,” says Wilkens. “A person controls the control processes and programs the programs. But people should be mostly involved with quality issues. Filling the oil
Improved operating times
“ We have an exceptional level of automation.” CHRISTIAN STELTER, PRODUCTION DIRECTOR, STELTER
tank can only be a sideline.” Stelter says it’s a matter of getting rid of the human element as a source of errors. By using robotic equipment managed by workers, who in turn are helped by computer systems, he has put his staff in charge of quality. “We started using this system ten years ago, and we have improved quality enormously,” he says. Quality is the key. According to Stelter, his company is one of
the top three in the field, and he puts this down to quality, flexibility and, of course, price. And that means absolute reliability in the 24-hour-a-day production process. As Wilkens puts it, “We have an automatic line, so we need insert operating life times that are reliable. If we have to break the process, we lose production. And that’s where Seco Tools has helped.”
Seco Tools’ new Duratomic grades, TP0501, TP1501, and TP2501 have significantly improved insert operatingtimes at Stelter. The grades have been created following analysis of surface and substrate at the atomic level. Seco’s wiper geometry also ensures excellent surface quality at high throughput. A welcome side-effect is that the chrome-colored inserts turn black when used, ensuring that inserts with unused cutting surfaces are not discarded.
Gear specialists Stelter Zahnradfabrik has seen rapid growth over the last few years. Turnover has risen from EUR 40 million to EUR 65 million since 2012, and staff numbers have increased from 210 to 350. The company specializes in making and finishing all kinds of gears. Automotive makes up 60 percent of production, other industry 35 percent, and large gears for such fields as wind power and railways, 5 percent.
EDGE (2. 2016)
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CASE STELTER, GERMANY
Stelter Zahnradfabrik specializes in making and finishing all kinds of gears. Automotive makes up 60 percent of production, with major German car manufacturers among the company’s customers.
Wilkins explains that inserts featuring Seco’s new Duratomic grades have improved insert operating-times by 20 percent, leading to a five percent improvement in productivity. “We’ve won time, and the process is faster and more stable,” he says. Stelter adds, “It helps the workers, too, if they don’t have to interrupt the process so often.” STELTER SEES THE relationship with
Seco as a two-way process: “We go to them with problems, and they come to us with ideas,” he says. Seco Tools’ Regional Sales Manager for North Germany, Karl Förster, has been the link to Stelter for the last 20 years. “It’s a team,” he says. “We all
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EDGE (2. 2016)
know each other well, and we’re all passionate about productivity.” Demands on quality and reliability have increased enormously over the last few years, and the product has changed too. And, as customers’ demands increase, Stelter demands more of his suppliers. Seco and Stelter are currently working on optimizing the turning of HRC 60 hardened materials to improve reliability and productivity by using the new CH grades in the Secomax CBN family which feature a new substrate. They’re also testing the new TGH1050 grade – Seco’s MDT system for recess turning – again to further improve reli-
COMPONENT:
Fixed gear for duplex clutch Material: 20 MoCr 4 Operation: outer face and side turning Machining objective: increased insert tool life Machine tool: Emag VL 5i with Seco Tools’ CNMG120408W-TP2501 insert Machining data: 700 units were turned, compared to 450 previously
ability and tool costs. Stelter doesn’t think that technical progress can be as fast in the future as it has been, but demands will continue to rise, especially in terms of transparency. He sees a time when customers monitor the machines directly and watch the process as it happens.
“ A human being is always in charge.” KARL-HEINZ WILKENS, TECHNICAL DIRECTOR
EDGE (2. 2016)
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CUTTING EDGE Q&A
PATRICK DE VOS, CORPORATE TECHNICAL EDUCATION MANAGER AT SECO TOOLS GROUP, ANSWERS YOUR QUESTIONS ABOUT MACHINING.
How can Seco’s digital services help me?
ASK PATRICK
Do you have questions? Send them to the email address below: patrick.de.vos@secotools.com
ANSWER: In the past, machinability models were rather simple, and applying them practically was easy. But the value of such models in modern machining is questionable, as theory is not always in line with practice. Modern machinability models are based on state-of-the-art research and describe very accurately the reality of the machining process and all the interactive elements within it. But, the mathematical models describing these machinability models are no longer easy to apply ‘manually’. Adding to the problem is the broad range of different tools available for various machining applications, meaning manually selecting the most appropriate tool is a time-consuming exercise. This is where Seco’s digital services, such as MyPages and Suggest, come in handy. Both provide customers with access to Seco’s huge databases, with information on the suitability and the selection models of the different tools. Customers can also use the machinability engine to determine the best cutting conditions for the tool selected. The engine brings together all the state-of-the-art machinability models for describing machining processes. Seco Suggest is one of the best software tools available for cutting data determination. It is one of only a few of these types of tools that provides users with the potential to work actively with the desired tool life for the cutting edge. For more information – go to www.secotools.com/mypages
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EDGE (2. 2016)
In finish machining of strain-hardening materials such as austenitic stainless steels, how can the depth and hardness of the strain-hardened surface layer be minimized?
ANSWER: Strain-hardening materials are materials that show a noticeable tendency to become stronger and harder when they are deformed. Machining is a process through which material is deformed to such a level that the material shears off in the form of chips. When machining strain-hardening materials, the machining process can unintentionally create a thin layer of strain-hardened material on the machined surface. For the actual cutting edge this is not a problem, but the next cutting edge (such as in milling applications) will have to cut through this strain-hardened surface layer, influencing the tool-deterioration process and leading to a shorter tool life. To minimize the thickness and the strength of the strain-hardened layer, the actual material deformation during machining has to be minimized. This can be done by using sharper cutting edges and smaller nose radiuses, and through the accurate selection of cutting speed (not too high to minimize the deformation speed) and feed. The feed in particular deserves careful consideration. Feeds that are too high will create more deformation and will lead to higher strength of the strain-hardened layer. But too small a feed will lead to the effect that the ‘next’ cutting edge is constantly cutting in strain-hardened layers created by the previous cutting edge. In general the correct balance between not too high and not too low will be more towards higher feeds, especially in operations where several cutting edges cut simultaneously, such as milling.
CASE RAMCAR, PHILIPPINES
EMPOWERING THE FUTURE Fueled by booming domestic car sales, Philippine company Ramcar Technologies is now speeding into a new era, with the help of Seco Tools. BY EVAN TAN PHOTOS BY JULIAN WAINWRIGHT AND GETTY IMAGES
CASE RAMCAR, PHILIPPINES
The year was 1919.
“
We’ve had a large improvement since we started using Jabro-Solid2.” Noel Jarical, Manager, Ramcar
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EDGE (2. 2016)
World War 1 had just ended. The Philippines was just emerging from 300 years of Spanish colonial rule, with the United States of America taking over. It was in this environment of change that an enterprising young man named Ramon Caro established Caro Electrical Services, an automotive-electrical shop in Manila. The new enterprise was to prove a success, inspiring Caro to venture into automotivebattery manufacturing. He renamed his company Ramcar and launched a flagship battery brand onto the local market – Oriental Battery. Ramon’s vision for the company to be the best in the industry led to it introducing polypropylene casings for car batteries in 1978 – a first for the Philippines. The company also eliminated its dependence on imported lead by establishing Philippine Recyclers Inc., a subsidiary that began recycling batteries. That same vision was also behind Ramcar’s decision to acquire its main competitor, Motolite Battery in 1997, securing leadership of the market. With its steady growth, the company next spun off its machine shop department into another company, Ramcar Technology. This was a logical step that allowed the new company to dedicate more resources into breakthrough engineering services and cutting-edge technology. Ramcar Technology today has a solid track record for investing in new technologies. In 1989, it brought in NC milling and EDM machines and installed its first computers to mechanize drawing activities. In the same year, it set up a complete machine shop operation and made its first plastic injection mold. Now housed in Santa Maria Industrial Park, a sprawling economic zone located north of Manila, Ramcar Technology services the other businesses under the Ramcar Group of Companies. These include a
Producing molds for car batteries, Ramcar is benefitting from the booming Phillippine economy, creating an increase in car sales.
diverse range of brands, such as Motolite and Supercharge Batteries, and local franchises of Mister Donut and KFC. With the economy of the Philippines booming, car sales rose 23 percent in 2015, creating soaring demand for the batteries that Ramcar helps build. RAMCAR’S MANAGER, Noel Jarical, has been with
the company 22 years and has witnessed the positive change, first-hand. Having joined the company as a mold designer, Jarical rose up through the ranks to become head of the company’s Tool Shop department. He says the growth of the business has been achieved by focusing on developing talent and tools and always being on the lookout for innovations. One of the things in which the company
Longer tool life with Jabro-Solid2 Ramcar uses Seco Tool’s Jabro-Solid2 solid end mills, a range comprising of over 800 universal products that apply to all commonly machined materials, from steel to titanium alloys. With its industry-standard titanium aluminum nitrite (TiAlN) coating, applied using Seco’s advanced coating process, Jabro-Solid2 offers a longer tool life – making it more cost-efficient.
“ We’re now 40 percent more efficient.” NOEL JARICAL, MANAGER, RAMCAR
has invested is in optimized roughing operations, making use of Seco Tools’ JabroSolid2 solid end mills with chip splitters. Upon Seco Tools’ recommendation, Ramcar Technology also acquired the software needed to properly utilize the end mills – which are more resistant to chipping, heat, and wear – when cutting the different materials that it handles. “While Ramcar was already familiar with optimized-roughing strategies, it wasn’t until 2014 that they fully understood how these strategies worked in detail – using the Jabro-Solid2 solid range with chip splitter,” explains Ronald Caling, Seco Tool’s country representative in the Philippines. “We challenged them to provide us with a project so that we could demonstrate the techniques using our tools, and they asked us to help
build the mold cavity for their battery. The outcome eventually convinced Ramcar that the strategies combined with our tools made their processes more efficient.” By combining Optirough with the highfeed milling strategy, Ramcar’s roughing process has been reduced to 70 percent of its previous level. “We’ve had a large improvement since we started using Jabro-Solid2,” says Jarical. “We’re now 40 percent more efficient.” Today, 90 percent of Ramcar’s tools are made by Seco Tools, and the two companies are working continuously on helping Ramcar to remain relevant to its market. Ramcar is currently undertaking research on developing better batteries for electronic vehicles – a bold step for the company and one that is helping it remain abreast of future trends.
Role in solar-powered car Ramcar Technologies began as the machine shop department at the Ramcar Inc. battery plant. Originally, the department handled repair and maintenance work for the production departments, until it was spun off into another company. Ramcar Technologies was actively involved in the development of SINAG, the Philippines’ first solar-powered car, which was the country’s entry in the 2007 Panasonic World Solar Challenge.
EDGE (2. 2016)
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All the way to the top Press the ‘S’ button for space. That’s the option travelers of the future could have, thanks to the latest innovation from the aerospace industry – a space elevator. Thoth Technology, a firm based in Canada, has proposed a 20-kilometer-tall tower from which spacecraft could be easily and economically launched on space missions. Astronauts would ascend to the top of the tower, positioned in the stratosphere, in an electric elevator, greatly reducing the cost and difficulty of breaking the hold of the Earth’s gravity. Space elevators have previously been deemed unfeasible as no current material can support its own weight all the way up to geostationary space, some 35,000 kilometers above the planet. The patented ThothX Tower circumvents the problem by being far shorter, while still bringing major advantages. The tower would be made of inflatable segments which could be reused after the completion of each launch.
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EDGE (1. 2016)
BUILDING YOU OWN SPACE ELEVATOR?
In EDGE’s Possibilities section, we look at some of the world’s more interesting curiosities and the Seco tools that can be implemented to help construct them.
Space program Tools made by Seco have been used in the development of the rocket thruster nozzles. Seco produces a range of products aimed at the space and aerospace industries.
ThothX Tower:
20,000 meters
MS2050 The introduction of Seco Tools’ new MS2050 insert grade allows for a whole new level of productivity. When machining aerospace parts in titanium, MS2050 will extend tool life by 40 to 60 percent compared with conventional inserts across the same cutting parameters. Perfect for square shoulder milling, face milling, copy milling and high feed milling in titanium applications, the grade MS2050 features a new coating technique and substrate, optimised for difficult situations.
Mount everest:
8,848 meters
Read more at secotools.com/aerospace
Burj Khalifa (world’s tallest building)
828 meters
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EDGE AND YOU
Mint condition As Tool room Manager at the Royal Australian Mint, Ashley Moffat plays an important role in ensuring that Australians have the coins they need for millions of daily transactions. He is working closely with Seco to boost productivity and raise the quality and attractiveness of the coins the Mint produces. Interview by Daniel Dasey Photo by Rohan Thomson
Ashley Moffat AGE: 33 JOB: Toolroom Manager, Tooling, Coining & Engineering Branch, Royal Australian Mint LOCATION: Canberra, Australia FAMILY: Married with two children, 3 and 8 HOBBIES: Motorcycling, mountain biking, and watching F1 and MotoGP EDUCATION: Completed apprenticeships in toolmaking and mechanical engineering.
“THE MINT is the sole supplier of Australia’s circulating coinage, so it’s quite a unique place to work. We also produce coinage for a number of smaller nations, as well as commemorative coins and medals. I head a 23-member team, most of whom are qualified toolmakers. The Mint produces coins by pressing metal blanks between two dies in a coin press, and one of our jobs is to produce the dies and the master tools from which all the dies are created. The master tools are created on CNC high-speed engraving machines and then require hours of hand polishing under a microscope to get just the right finish. We are constantly striving to use the most modern technologies and methods, to increase output and consistency, and to produce finer design details while lowering costs and lead times. We stepped up our cooperation with Seco about six years ago and four years ago they assumed responsibility for the production of our engraving tools, which was previously done in house. Over the past two years, we have been trialing a new generation of engraving tools that can run faster, last longer, and have an end radius of just 0.04 of a millimeter – something previously unattainable for us. The trials are going well and it is hoped they will replace the current generation, improving coin detail, tool durability and workshop safety.”
EDGE (2. 2016)
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CASE FAMAT
SOLUTIONS
TAKE
OFF In the French aerospace industry’s heartland at Saint-Nazaire, Seco is helping FAMAT to machine parts for tomorrow’s jet engines. BY CHARLES MASTERS PHOTOS BY TIM FOX
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EDGE (2. 2016)
PHOTO: BUENA VISTA IMAGES/GETTY IMAGES EDGE (2. 2016)
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CASE FAMAT
The jet engine frames FAMAT produce are used in the Airbus family, as well as in Boeing 737s and 777s.
Frames for jet engines Fabrications Mécaniques de l’Atlantique (FAMAT) was founded in 1981 as a 50/50 joint-venture between US jet engine manufacturer General Electric and its French counterpart Snecma. Today the company has a staff of 430 employees. FAMAT’s headquarters are in Saint-Nazaire, France. The annual turnover is EUR 171 million (2014). Its main activity is the production of frames for jet engines for its two parent companies, including the GE CF6, GE90, CF34, CFM CFM56, and Engine Alliance GP7200 families of engines, plus the next-generation engines, the GE9X and the Leap. Its principle expertise areas are: CAD/CAM systems; numerical control machining; TIG, plasma, and electronbeam welding; heat treatments, X-ray, and CMM inspection.
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EDGE (2. 2016)
The factory has some 40 machine tools for working with titanium, aluminum, and inconel.
“ We have to deliver a level of quality that is irreproachable.” TÉPHANE MAURER, CNC PROGRAMING AND S CUTTING TOOL MANAGER, FAMAT
PHOTO: BENEDICT REDGROVE
T As a complement to disc milling cutters. FAMAT has tried switching to carbide end mills with good results.
he port of SaintNazaire on France’s Atlantic coast has traditionally been famed for its shipbuilding. But today, the city’s reputation has extended to the production of another kind of vehicle, with European airliner consortium Airbus turning out fuselage parts from a local facility. It’s no accident that this hub of engineering expertise is also the base for FAMAT, a jointventure between aviation firms Snecma and General Electric that produces frames for the two companies’ ranges of jet engines. As such, FAMAT parts play an integral role in creating many of today’s most widely used planes, including those in the Airbus family, as well as in Boeing 737s and 777s. “We make structural elements of the engines that are non-rotating parts,” says Stéphane Maurer, CNC Programing and Cutting Tool Manager at FAMAT. The Saint-Nazaire factory has some 40 machine tools for working primarily with titanium, aluminum, and inconel – a super alloy used in parts of the engine that can reach up to 800°C.
Maurer says FAMAT faces the same challenges as any other company: it needs to produce products quickly and economically. “However, first and foremost, we have to deliver a level of quality that is irreproachable; that goes without saying. In terms of machining, we have tolerances of plus-or-minus 0.025 mm on a part with a diameter of 2000 mm. Everything we machine is systematically checked using a 3D coordinate measuring machine to detect any possible flaws.” FAMAT IS CURRENTLY working on the development of next-generation engines offering new standards of fuel economy and noise reduction, including the GE9X destined for the Boeing 777. “It’s a new engine and we developed all the titanium machining for the frame with Seco,” says Maurer. “We wanted to have the direct involvement of the tool manufacturer to arrive at a new generation of machine cutting tools, and a cutting strategy with considerably improved machining time.” He estimates the time saving is in the 10- to 20-percent range. EDGE (2. 2016)
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CASE FAMAT
“ The GE9X for Boeing 777 is a new engine and we developed all the titanium machining for the frame with Seco.” STÉPHANE MAURER, CNC PROGRAMING AND CUTTING TOOL MANAGER, FAMAT
MAURER SAYS THE FOUNDRY work involved
in creating each frame means they are expensive items. “When Seco says we’re going to carry out some trials, we can’t do it on a test piece; we have to do it directly on the part,” he explains. “We prefer prudence to audacity, and that’s the trademark of the Seco team. They dare to take risks, but these are all very well judged, and they make it very clear what those risks might be. Florent Popilus, Sales Engineer for Seco, says what differentiates Seco from competitors is that it works closely with customers like FAMAT. “We provide our expertise in cutting tools, and they provide their expertise in machining,” he says. “We get round the table and decide what kinds of tools are required and which machining strategy to adopt.”
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WHEN FAMAT HAD to come up with
a rapid solution for the frame for the next-generation Leap 1B engine for the Boeing 737, it had a very short deadline to deliver a prototype. “Instead of circulating the specifications with several suppliers and comparing proposals, FAMAT worked directly with Seco on how to produce the part,” says Popilus. “That allowed them to respect the deadline.” Popilus says parts evolve and
there are new shapes, so Seco has needed to adapt. “It’s not just about tools, but also programing,” he says. “Seco offers a full machining strategy, plus technical advice. We work with FAMAT from the study phase right through to production. The Seco sales engineer concludes: “The important thing is mutual confidence – they trust us, and we trust them. It’s not just about supplying them with the cutting tools and leaving them to get on with it.”
FAMAT is based in Saint-Nazaire, a port on France’s Atlantic coast famed for its shipbuilding and aviation industry.
PHOTO: JACQUES LOICE/GETTY IMAGES
FAMAT has a long-standing partnership with Seco and the company supplies many of the plant’s machine tools. “The advantage of Seco is that they don’t make unrealistic proposals that might seem extremely attractive, but that aren’t guaranteed,” Maurer says. “They suggest things that they have tested before, so we don’t have too much of a surprise.”
From turning inserts to boring bars, Seco’s tools are present all over the factory. FAMAT has a longstanding partnership with Seco which supplies many of the plant’s machine tools.
Shorter cycle times FAMAT wanted improved machine tool solutions to produce the hub frame for the new GE9X engine for Boeing 777s. One of the aims was improved working conditions for operators, to prevent repetitive strain injury. The company was also seeking improved productivity. The previous disc milling cutters, with a diameter of 315 millimeters, weighed around 14 kilograms. Seco suggested switching this for a 25-milimeter carbide end mill, with a total weight of around four kilograms. The change of tool meant the machining cycle was 48 percent shorter than the time required using the larger disc milling cutter. The cost of the cutting tool was also 30 percent lower. In future, FAMAT is studying the possibility of replacing a 450-milimeter disc milling cutter with a special 32-millimeter carbide end mill from Seco’s JSR22 range. This would eliminate the need for manual installation of the 29 kilogram disc cutter, since the smaller carbide end mill, at 6.7 kilograms, can be fitted automatically from the tool magazine.
When FAMAT needed a quick solution to be able to produce a new jet engine frame, Seco was able to deliver the appropriate tools in just six weeks.
EDGE (2. 2016)
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A passion BY CARI SIMMONS PHOTOS BY LINNEA RHEBORG
FOR THE CLASSICS
Ion Tâmpu, a technical representative at Seco Tools in Romania, diligently stays on top of new technology, but is also happy to fall back on old traditions.
Old Cars Club Transilvania Ion Tâmpu started the Old Cars Club Transilvania vintage car club in 2005. “Our main goal is not to have many members, but enthusiastic ones with classic cars,” he says. Every year, the club holds a rally event and helps other clubs with similar events. Vintage car races are not strictly about speed as with other car races, but focus on precision. It’s about pacing the driving, or as Tâmpu says, “Keeping the precise speed to reach targets at the exact time.”
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EDGE OF THE WORLD
“OLD SCHOOL WORKS!”
says Ion Tâmpu, a technical expert who has been providing customers and Seco Tool’s sales team with technical support for the past six years. “You can improve and modernize things with state-ofthe-art technology, but it is always helpful to start at the beginning and go back to the basics if something is not working.” Tâmpu is often on the road, visiting customers and providing support and technical assistance, whether it involves improving cutting processes, juggling with milling parameters, or finding a way to improve productivity. “I’m like a problem solver. I’m there to help and improve the situation for the customer,” he says explaining that he adapts Seco products to the conditions and machines that vary from sector to sector and place to place. Prior to working at Seco, Tâmpu was a construction engineer for a
ION TÂMPU Technical Representative, Seco Tools HOME: Brasov, Romania FAMILY: Married, two kids OTHER INTERESTS: Hiking in the mountains HIS FAVORITE VINTAGE CARS: Fiat 501 Torpedo Fiat 1500S Spider Renault Alpine A110 EDGE (2. 2016)
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Ion Tâmpu’s first vintage cars were a soft top Beetle 1200 from 1960 and an East German Trabant from 1972. Today he is owns a Fiat 1800B and a Renault 16, both from 1967.
“ Vintage cars were designed with the heart and the mind – not by computers.”
Canadian steel company. He has also worked in the automotive sector as a mechanical engineer and says the same engineering principles apply regardless of the sector. “The theory is the same. It’s just the various means of applying it that are different.” Tâmpu thoroughly enjoys being able to apply all of his technical and engineering knowledge to both his ION TÂMPU, TECHNICAL REPRESENTATIVE AT SECO TOOLS, ROMANIA, AND A PASSIONATE CAR COLLECTOR current job at Seco and to his hobby, vintage cars. “I was just five-years old when I saw a VW Karmann Ghia sports car and I remember thinking ‘Wow, I like cars!’” he says. the Volkswagen Beetle: “This collectors import many of the That childhood passion has was a reliable, good design that is parts – if they can find them. They remained with him ever since, almost impossible to reproduce also recondition old parts, often resulting in his founding the “Old now,” Tâmpu explains. “Now all finding what they need in car Cars Club Transilvania” a vintage cars look and feel exactly the same. graveyards. car club in his hometown that Only the emblem is different.” TÂMPU CURRENTLY OWNS a Fiat 1800B engages in rallies and other events. Tâmpu’s first vintage car was with a six-cylinder engine and a Tâmpu’s description of restoring a soft top Beetle. After that, Renault 16, both from 1967. He vintage cars makes it clear that he he purchased an East German frequently takes them out for regards the pastime as a noble misTrabant. “This was a nice car but drives, but otherwise, like most sion. “Vintage cars bear the soul it was difficult to maintain in the vintage car collectors, he tends to of the car designer,” he says. “They 1990s because it was hard to find keep a fairly low profile about his were designed with the heart and spare parts after the [Romanian] hobby. “In the communist regime the mind – not by computers.” revolution.” of the past, vintage car collecting Take the iconic vintage classic, Today, he and his fellow
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Before buying vintage
Old Cars Club Transilvania vintage car club in session. Based in the medieval town of Brasov, the goal of the club is to have “enthusiastic members with classic cars,” says founder Ion Tâmpu. His friends’ vehicles include a Chevrolet Pickup from 1949, a British MGB from 1970 and the Jeep-like Romanian ARO M461 from 1964.
was considered elitist, a hobby for the rich only.” These days, the attitude is changing says Tâmpu, adding that young people in particular are often fascinated when they see him out and about in his 1967 cars. “They can’t believe that these cars are still working. But really, the basics haven’t changed so much. Cars still have four wheels, an engine, and a steering wheel. You can modernize old cars, but the old-school mentality and methods still work.”
“Do your homework before buying a vintage car,” says Ion Tâmpu. “Collect and study all information related to your dream car. You must be able to verify its technical condition, original parts, and more, so hire an expert if you need help.” This is what else he recommends before making any purchases: Avoid buying vintage cars online. It is better to see everything with your own eyes. Be prepared to invest time and money in restoration. Even if the car is in mint condition you should have money reserved for unexpected situations. Look out for rust. Small bubbles under paint or some scratches are easily corrected and rust can be stopped. However, if you can see the grass through the floor forget about the car. Don’t forget to make room in your garage.
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AUTOMOTIVE INDUSTRY Audi Toolmaking used a 3D printer to produce a model of the company’s historic Grand Prix sports car, the 1936 Auto Union Type C. The company is now examining further possible applications for metal printers within the produc-
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tion of complex components. The technology involves a selectivesintering laser melting layers of metallic powder with a grain size of 15 to 40 thousandths of a millimeter – roughly half of the diameter of a human hair.
Hope or hype? 3D TECH REVEALED
Everyone’s talking about 3D printing, or ‘additive manufacturing’ as some prefer to call it. But when will the technology actually break through into the mainstream, and what are the implications? Seco’s Head of Research and Development, Anders Ericsson, takes a closer look.
W
hen a little over a year BY PER-OLA KNUTAS PHOTOS BY JONAS GAUFFIN, AUDI ago, Audi showed off ILLUSTRATIONS BY ANIL YANIK a half-scale model of its classic Grand Prix car, the 1936 Auto Union Type C, it wasn’t the car itself that attracted the greatest interest. Rather, it was the ‘printer’. The car was one of the first to be created through additive manufacturing or what’s sometimes called 3D-printing technology. At the same time, Audi signaled that it was now investigating new opportunities for printing out complex components directly from “powder to metal”. The Audi example is just one of many of the increasing number of uses for additive manufacturing (AM). Advocates highlight the fact that the technology allows for the metal industry to go from production-driven EDGE (2. 2016)
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design to design-driven production, that lead-times will be cut for the development of new products, and that there is now new potential for producing components featuring complex geometries. Some even call the technology a “paradigm shift within manufacturing”. But Anders Ericsson, Head of Research and Development at Seco, is keen to slightly downplay the technology’s immediate significance for the metal working industry. “AM is clearly an extremely interesting technology for many of our customers,” he says. “In some cases, it can replace roughing, but we don’t think that the technology will replace the bulk of finishing operations any time within the next 15 years.” If you go back 20 years, many thought net shape forming was going to be the new production technology that to some degree would replace traditional metal cutting. The method involves creating components that are very close to their final form. But while net shape forming is today widely used across the industry, it hasn’t become the revolution that many expected. “You can draw a parallel with this and with additive manufacturing, today,” says Ericsson. “Everyone is talking about the technology, but we don’t really know where
How additive manufacturing works There are two methods for 3D printing in metal: a cold method called Selective Laser Melting (SLM) where a laser is used to melt together metal powder, and a warm method called Electron Beam Melting (EBM), where a beam of electrons is used for melting. The choice of method depends on the characteristics desired in the component being produced. The metal powder is spread out in a
“
At Seco, we’re choosing to see AM as an opportunity and as an extremely interesting technology for our customers. Anders Ericsson, Head of R&D at Seco
30- to 50-micrometer thick layer, and a pre-programed beam then melts the metal so that every layer melts together with the previous. With each layer, the component is moved down slightly, allowing for the component to be built up. The most common materials used are titanium, stainless steel, aluminum, nickel base metals, and various tool steels.
it will lead. But, having said that, I still believe that additive manufacturing has greater potential for metals than net shape forming, primarily because AM is currently being successfully used with complex plastic components and because digitalization will work as a key enabler.” Up until now, it has been the medical sector and, to some extent, the aviation sector that have made progress with additive manufacturing within areas traditionally dependent on the metalworking industry. The method has also been effective in the medical sector in producing small runs of complex, tailor-made components such as prostheses and implants.
AVIATION INDUSTRY The constant hunt for lightweight structures is driving AM development in the aerospace industry. There are already several examples of components here, including wing details and fuel nozzles. Intelligent, lightweight structures manufactured using laser sintering processes combine high strength with a weight reduction of 40 to 60 percent. AUTOMOTIVE INDUSTRY Swedish heavy vehicle manufacturer Scania is testing 3D printing parts such as stators, at Alfred Nobel Science Park in Karlskoga, Sweden.
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DEFENSE Swedish defense group Saab has trialled the use of an AM tailpiece made from titanium in its Carl Gustaf M4 recoilless antitank rifle. Tests showed that the AM components were denser than the cast iron equivalent.
“On the other hand, it is currently rarely effective to use AM for mass production of metal components,” says Ericsson. “The cost per-component is much too high. The technology needs to become 10 to 20 times faster for it to have a major impact.” IN TERMS OF the characteristics of the compo-
MEDICAL INDUSTRY The orthopedics industry has a strong focus on new materials and designs that allow for bone growth. The combination of those two factors has increased the level of interest in additive manufacturing, making it possible to design components such as knee replacements and hip joints in a new way. In addition, dental implants can be tailor-made for each patient.
nents produced, additive-manufactured products can often approach those of solid metal items, according to Ericsson. “You can, for example, get equivalent characteristics in terms of bending rigidity,” he says. “But at the microscopic level, when the material is fine machined, it becomes clear that you need to change the machining methodology in order to carry out effective machining. We’re currently seeing this phenomenon in something like 30 percent of machining cases.” This is where Seco often comes into the discussion with its customers around the world, solving the challenges that come along with machining in terms of the characteristics of the material and the choice of work tool. Ericsson advises taking a ‘dare to dream’ approach and beginning to conduct tests using AM methods for carefully selected products. Seco has itself begun using AM to produce some metal components in its own products, he notes. “At Seco, we’re choosing to see AM as an opportunity and as an extremely interesting technology for our customers. We realise that, with the broad and deep competence that Seco has within machining, we can work closely with our customers and propose wholistic solutions that include AM and that help create an efficient production system for them.”
Anders Ericssons’ advice regarding AM: BEGIN TESTING There are component suppliers where you can get additive-manufactured components. LOOK AT THE FLOW Look at the entire process flow in your production process and analyze where it is efficient and where there’s a good case to be made for using AM. TALK TO YOUR TOOL SUPPLIER Conduct a dialog with your work tools supplier and use their expert knowledge to establish the best solution for fine machining and the entire production process.
INDUSTRIAL COMPONENTS Using AM to manufacture grapples for the manufacturing industry makes it simple to progressively update and change designs. EDGE (2. 2016)
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WANT MORE? CHECK OUT Edgeupdate.com Seco’s new JHF181 Jabro Solid end mill range is available with a torical or bull-nose design and variety of flute numbers.
where you can access all articles from the magazine, as well as Secos’ Facebook, Twitter, and Instagram pages.
EDGE UPDATED Just like the magazine, Edgeupdate.com has a new look and a lot of new features. Be sure to check it out!
YOUTUBE CHANNEL Also check Seco’s channel on Youtube to watch videos on how our products shape the metal parts that build your world – from replacement body joints to jet engines.
TOOLS OF THE TRADE
HARD HITTER LIKE US! And don’t forget to visit our Facebook and Instagram pages, and send us a tweet on Twitter about anything Seco related.
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SECO’S NEW JHF181 Jabro Solid end mill range is designed for use in high feed milling using ISO-H and ISO-S materials. Created for use in industries including aerospace, medical, and mould and die, the tools allow for easy-to-apply cutting methods with light cutting impact and high productivity. They can be used
with a wider range of materials than similar existing tools. The product’s unique coating, pre-treatment and edge preparation means that it can provide a 30 percent longer tool life in hard milling than its predecessor. It is available in Ø2–16 sizes and with a torical or bull-nose design and variety of flute numbers.
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