machining VOLUME 1 I ISSUE 1 SEPTEMBER 2011
australia
With a tool overhang of 16 times the diameter vibration tendencies can become more apparent, and tuned bars, or Silent Tools, come into the picture as the solution.
out tuning
the chatter
ENGINEERING
Embracing technology, engaging his employees as well as technology partners like Iscar, Carlos Broens has led Broens Industries through some hard times to remarkable success.
THREAD CUTTING
CNC UPDATE
The production of female threads is among the most time-consuming and therefore expensive individual operations. A high level of process reliability is required.
An array of new functions for Sinumerik 840D sl from the Siemens Drive Technologies Division further improves the productivity of complex machine applications.
VOLUME 1 I ISSUE 1
machining australia
PURSUIT OF EXCELLENCE P.22 Everyone encounters obstacles, but the real challenge is in whether you cave in or carry on. Carlos Broens is a man who chose the latter—time and again. Embracing technology, engaging his employees as well as technology partners like Iscar, he has led Broens Industries through some hard times to remarkable success.
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CUTTING-EDGE SIGNS P.28 Signs need to deliver a clear message to avoid confusion, which is why all signs are custom-made to help brands inform, instruct and look good in all the right places. Melbourne-based Signcraft Group designs and manufactures its complete range of signage solutions in-house, and the company’s ART CNC routers offer the high-quality cutting capabilities Signcraft needs to be competitive.
COVER STORY P.14 With a tool overhang of 16 times the diameter vibration tendencies can become more apparent, and tuned bars, or Silent Tools, come into the picture as the solution.
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news
technology
BAE SYSTEMS P.5 BAE Systems has completed a successful Production Readiness Review (PRR) for manufacturing critical airframe components for the F-35 Joint Strike Fighter (JSF) Program.
SOFTWARE P.8 Okuma’s “Machining Navi” software improves cutting times and performance by searching for the optimum cutting conditions by measuring chatter vibration.
DMG/MORI SEIKI P.6 Paul McDermott, National Product/Agent Manager at DMG/Mori Seiki Australia, has been ranked as one of Mori Seiki’s top sales managers. AUSTRALIA P.7 The manufacturing industry slumped in July reflecting the tough trading conditions that continue to restrict growth in the sector.
MACHINING CENTRES P.23 Hermle’s C 42 U is a 5-axis machining centre with a 800 by 800 by 550 mm working envelope is ideal for applications in the tool and mould, medical, aerospace, motorsport and other industries requiring complex, close-tolerance components.
IN THE NEWS
CARBONTAX
The Federal Chamber of Automotive Industries estimates the impact of the carbon tax on the local automotive industry as a whole will be at least $30 million a year. The new carbon plan is set to start on July 1, 2012, with the Emissions Trading Scheme to start on July 1, 2015, at which time the price of carbon will rise to $29 per tonne. Holden has announced that it does not fit into the Government’s PHOTO: SCHULZ 4 machining September 2011
criteria as an ‘emissions-intensive, trade-exposed industry’ (EITE), despite designing, engineering and manufacturing vehicles for domestic and overseas markets. As a consequence, it and many other major manufacturers will only be potentially eligible to apply for compensation to partly offset the impact of manufacturing under the $1.2 billion Clean Technology Program. Holden says the compensation measures are a “step in the right direction”, but says the government needs to understand how much competition there will be for funding from other manufacturing sectors. BAE Systems takes next step on strike fighter manufacturing journey
ADELAIDE - BAE Systems has completed a successful Production Readiness Review (PRR) for manufacturing critical airframe components for the F-35 Joint Strike Fighter (JSF) Program. The PRR was an important step for South Australia becoming a key supplier in the JSF Program’s global supply chain, according to Land & Integrated Systems Director Kim Scott. The review was held at BAE Systems Edinburgh Parks site. Attendees from the global JSF Program included representatives from Lock-
heed Martin, BAE Systems UK and Marand. Mr Scott said the company had so far delivered more than 370 Vertical Tail parts, comprising 13 aircraft ship sets, from its Edinburgh Parks manufacturing facility in northern Adelaide. “Achieving this key milestone of PRR means we are a step closer towards Full Rate Production, which would involve further production readiness assessments. At full rate production we will be delivering 70 aircraft sets per annum, with over 30 parts in each set. Manufacturing times can range from one hour to 50 hours per component. These parts consist of highly complex shapes and fine tolerance features requiring the latest five Axis
Machining technology available today. “BAE Systems Australia has a proven track record in successfully delivering parts direct to the JSF Vertical Tail production line in time for production. To date, all ship sets delivered have met the stringent quality standards and customer schedule expectations. “Continuing to deliver to our current performance level should lead to more JSF manufacturing opportunities in avionics and airframe parts, which will also have flow on benefits to Australia’s SME community,” Mr
Scott said. The outcomes of the PRR will be reported back to the United States Department of Defense 2012 Defense Acquisition Board Review of the F-35 Joint Strike Fighter (JSF) Program. India: Australia seeks to build ties with auto industry Australia is exploring possibilities to improve ties between its automotive companies and the Indian automotive industry. This move is aimed at capitalising on the rapid growth witnessed by the industry, and to create new export opportunities. In this regard, Australian minister for Innovation, Industry, Science and Research, Kim Carr, is on a threeday visit to India. He said Australia is well placed to provide products in the areas of vehicle design, manufacturing processes and low-emission technologies, Press Trust of India said. “With the help of the Australian government’s ‘A New car plan for a Greener Future,’ our auto industry has not only survived the global economic downturn but is transforming and becoming a world leader in new technology. This expertise makes our companies attractive partners for international companies including India,” the newswire quotes Carr as saying. Among the companies the minister met, were Mahindra & Mahindra and Tata Motors. Carr added that the Indian automotive companies using technology innovations from Australia for scaling up and manufacturing parts could make use of the country’s newly introduced R&D Tax Credit Legislation, PTI said. In April this year, the Australian Federation of Automotive Products Manufacturers signed a memorandum of understanding with the Automotive Component Manufacturers Association of India (ACMA). September 2011 machining 5
IN THE NEWS
Paul McDermott, National Product/ Agent Manager at DMG/Mori Seiki Australia, has been ranked as one of Mori Seiki’s top sales managers. When asked about being named the No. 7 in the Japanese machine tool builder’s “Fiscal year 2010 MBO Achievment Ratio” program, Mr McDermott can give you a number of possible reasons:
Paul McDermott, National Product/Agent Manager at DMG/Mori Seiki Australia, has been ranked as one of Mori Seiki’s top sales managers 2010. From having a great team, to commitment to customers, to paying attention to what kind of machines and solutions people want – there are a number of reasons and tactics used by the NSW-based salesman which led him to be amongst the top 10 Mori Seiki salesmen worldwide in two consecutive years (2009/2010). “If I promise something I make sure that I deliver on the promise,” he explains how he creates solid client relationships. “That’s the core for any business in general. If you make a commitment to your customer, you have to realise that commitment.” Mr McDermott, who joined Mori Seiki in 2003, will continue to focus on building the company’s customer relationships and look to cement the joint company’s complete range of CNC machine tools in the Australian market. He brings a depth of experience from a manufacturing career spanning 17 years across
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various roles, including an apprenticeship in toolmaking, fitting and machining and supervising the CNC machining section at Esco Industries, NSW. He previously worked at Mori Seiki as State Manager NSW. DMG/Mori Seiki Australia’s decision to form a new sales structure in Australia in May 2011 facilitates further strengthened customer relations and service, Mr McDermott comments the company’s ongoing activities to form one team, one company. German machine tool builder GILDEMEISTER AG commenced joint sales and services with the Japanese machine tool manufacturer Mori Seiki Co Ltd in Australia on 1 March 2010. The joint company DMG/Mori Seiki Australia is a now market leader in Australia, and plans to increase its market share to 50%. With the combined strength of two leading global machine tool builders, DMG/Mori Seiki offers solutions for 95% of all metalcutting applications. “Selling the two brands is certainly an advantage,” Mr McDermott says. “The product overlap between the two companies is only about 3%. While DMG is traditionally strong in 5-axis technology, Mori Seiki is leading in turning and horizontal machining centres. Now we can cover all of our customers’ needs.” Mr McDermott is also very pleased about the introduction of the ECOLINE machines: Now he can offer his customers a complete range of CNC machine tools, from entry-level to high-end mulit-axis and functional machines. The ECOLINE machines are available at very reasonable cost-/performance effective selling prices and DMG/Mori Seiki plans to expand its market share in this segment. “Today, we have the strongest machine tool and automation program in the metalworking world,” Mr McDermott says. “Next to our new sales structure, we are now also setting up a stronger service system to maintain the highest service level and product support for our customers.”
PHOTO: SCHULZ
DMG/Mori Seiki National Sales Manager among global top 10
PHOTO:
Australian Manufacturing contracts in July The manufacturing industry slumped in July reflecting the tough trading conditions that continue to restrict growth in the sector. The latest seasonally adjusted Australian Industry Group – PwC Australian Performance of Manufacturing Index (Australian PMI®) fell 9.5 points to 43.4 in July to be below the 50 point level separating expansion from contraction. The decline in activity was evident across manufacturing with only three of the twelve sub-sectors expanding in July. The best performing sub-sector in the month was construction materials (61.5) while wood products and furniture was the weakest performing sub-sector (18.5). New orders fell sharply in July, down 14.4 points to 40.2. Australian Industry Group Chief Executive, Heather Ridout, said: “The difficulties facing manufacturing due to the high dollar and sluggish domestic demand intensified in July. The survey respondents indicated that adding to their broader concerns was the prospect of a carbon tax and this was clearly weighing on sentiment. Perversely, the only indicators of broad business conditions showing an increase were input costs and wages, both of which are negatives for the industry. “We are currently in the midst of a boom and gloom economy and I defy anybody to say with any degree of certainty what the impact would be on the Australian economy if the dollar remains at current levels for a protracted period. The high dollar and high interest rates are impacting on the big employing sectors in Australia. This, together with the volatile and precarious state of international economic conditions and ongoing political uncertainty in Australia, are seriously undermining business confidence in large parts of the economy,” Mrs Ridout said.
PwC Global Head of Industrial Manufacturing, Graeme Billings, said: “The sharp downturn in the production, new orders, inventories and supplier sub-indices of the Australian PMI® in July has put an end to the tentative signs of recovery that appeared to be building over the previous months. The seriousness of the challenge facing domestic manufacturers is clear in the further fall in employment in the sector in July – the ninth consecutive monthly fall,” Mr Billings said. $6.2m in funding to help make lighter, greener cars The automotive industry is innovating to create lighter cars that will help us reduce greenhouse gas emissions and become a richer,
greener and fairer nation. Announcing four Green Car Innovation Fund grants in July, Innovation Minister Kim Carr said the new projects would bring new technologies, skills and job creation to Australian manufacturing. “Over $6.2 million is being awarded to component manufacturers CFusion, Toyoda Gosei Australia, Composite Materials Engineering and Hirotec,” Senator Carr said. “The components being developed to retool our automotive industry will help cars that are friendlier on the
environment and the pocket — in this case, we expect the four projects will reduce greenhouse gas emissions by around 133,000 tonnes and significantly reduce fuel consumption.” CFusion is using funding of around $1.4 million to commercialise the world’s first one-piece carbon fibre automotive wheel, at about half the weight of aluminium wheels. Toyoda Gosei is using funding of over $2.3 million to introduce and refine technologies for manufacturing lighter components, namely body sealing products and safety system products, such as air bag modules and plastic interior trim products. CME is using funding of $797,399 to develop a high strength, lightweight
sandwich panel to be used in the load floor of Australian vehicles. Senator Carr said the Government’s $5.4 billion New Car Plan, which includes the Green Car Innovation Fund, was transforming the Australian automotive industry and ensuring significant co-investment from around the world. While the Fund closed to new applications in January to help fund flood recovery, it is continuing to generate approximately $2 billion in total project investment in the manufacturing sector. Visit www.innovation.gov.au for more information. September 2011 machining 7
TECHNOLOGY
MACHINING NAVI
IMPROVES CUTTING TIMES
T
ools with long overhangs are becoming increasingly more common, especially on machining centers where many operations are often performed on one machine. A long tool overhang is always a critical factor. Long unsupported lengths frequently lead to undesired chatter whereby the tool machines the workpiece under vibration-related noise. An effective countermeasure is a change of the spindle speed. Okuma’s “Machining Navi” software improves cutting times and performance by searching for the optimum cutting conditions by measuring chatter vibration. Machining Navi M-i (Intelligence) automatically adjusts tool rotation speed and Machining Navi M-g (Guidance) advises the operator on the optimum spindle speed for cutting. This provides the right balance between fast cutting and chatter reduction, improving cutting efficiency. The automatically operating Machining Navi M-i receives its evaluation signals from the machine-integrated noise sensors. The Machining Navi M-g records the cutting sound by means of a microphone. Whilst the sensor-integrated solution is available in new machines only, Machining Navi M-g can be retrofitted to all OSP-P200 controls. Apart from its own, autarc and fail-safe real-time NC operating system (Volante), the OSP integrates unrestricted (embedded) Windows functions – and thus offers its connectivity and primarily the use of Windows programs, such as Excel and Browser or Windows applications from peripheral suppliers, such as robot UIs, tool setting devices, measuring systems, et cetera. Okuma recently awarded the 2010 Japan Society of Mechanical Engineers Medal (Technology) for “Intelligent Machining System with Automatic Chatter and Vibration Detection and Avoidance”.
www.okumaaustralia.com.au 8 magazine September 2008
Hermle C 42 U 5-axis machining centre with turning facility H
ermle’s C 42 U is a 5-axis machining centre with a 800 by 800 by 550 mm working envelope, it is ideal for applications in the tool and mould, medical, aerospace, motorsport and other industries requiring complex, close-tolerance components. Hermle C 42 U 5 axis machining centre with turning facility.The machine is also offered in MT (mill-turn) version, whereby turning operations at 800 rpm or less can be carried out in the same clamping using the C-axis table mounted on a ± 130 degree swivelling A-axis trunnion. Parts can weigh up to 700 kg, half the maximum possible (without turning) on machines configured for 5-axis machining. Alternatively, a 3-axis machine can be supplied with a fixed table capable of supporting parts over one metre long and weighing two tonnes. The spindle features Hermle’s slimline design to facilitate machining of deep cavities and is available with maximum speeds of 10,000, 18,000 or 25,000 rpm offering up to 29 kW of power and 200 Nm of torque. The two-part design incorporates six displacement sleeves that collapse to prevent damage to the spindle in the event of a collision. Control system is either Heidenhain iTNC 530 or Siemens 840 D SL with 19’’ screen and 30 degree tilt.
www.bettamachinetools.com.au
840D sl offers multitasking capability A
n array of new functions for Sinumerik 840D sl from the Siemens Drive Technologies Division further improves the productivity of complex machine applications. The newly integrated complete machining functionality makes for simpler, more economical machining operations in a single work step on multitasking machines such as turn-mill centers or mill-turn centers. Operator panel OP 019 allows modern touchscreen operation functions to be initiated even when wearing work gloves. The Sinumerik 840D sl system platform offers a comprehensive range of functions for machine tools. This universal control covers wide-ranging machining technologies used in metal working operations such as turning, drilling, milling, grinding, laser machining, nibbling and punching, and can also be used in multitasking machines such as turn-mill centers or mill-turn centers.
www.cncdesign.com
September 2011 machining 9
MADE IN AUSTRALIA
AUSTRALIAN-MADE
WHAT DOES IT TAKE ART’s Director David White, who co-founded the 100%-owned and operated company in 1997, talks about the challenges and advantages of local manufacturing, and what it takes to compete against low-cost countries and imported products to move forward and keep making things in this country. As one of the few local CNC machine (flatbed routers and plasma cutter) manu facturers, what are the biggest challenges you are currently facing? Finding skilled personnel to fill key positions is a very challenging task in our part of the world. Many skilled workers are being syphoned off by the mining sector. This creates both a skills vacuum, and also tends to drive up the cost of labour.
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Competing against cheap imported products is a challenge to our sales team. We invest a lot of resources into developing new features and functionality into our products. Australian manufactures need to keep ahead of the competition in order to prosper.
10 magazine September 2008
How do you think the carbon tax will influence your business? Australian taxation is one of the highest in the world and is a definite disadvantage to doing business in our country. We currently face company income tax, payroll tax, goods and services tax, road taxes, import duties and fringe benefits tax, along with other compulsory expenses such as compulsory employer superannuation contributions, public liability insurance, workers compensation payments, and now a carbon tax. The high percentage of income that goes to these expenses makes it a challenge to do business within Australia. Do you feel a lot of competition from imported machinery? Competing against cheap imported products is a challenge to our sales team. Many customers that are new to our type of product are unaware of the many pitfalls of buying inferior products from overseas, with little or no support. The challenge is to help our potential clients to identify the vast differences that can be found between quality engineered machinery from a reputable manufacturer, and the copy-cat imports that often fail to deliver on their promises. What strategies are needed to compete with low-cost countries in today’s global marketplace? We invest a lot of resources into developing new features and functionality into our products. Our machines have a lot of high end features that are focussed on productivity and versatility. Many of the functions that we have on our machines are simply unavailable on other machines. For example, we develop our software from front to back. Because our software developers work closely with our mechanical and electronics engineers, as well as our own in-house CNC operators, we have an extremely short development cycle time.
This also allows ART to respond to the needs of customers by developing processes to suit their needs. Australian manufactures need to keep ahead of the competition in order to prosper. Why are Australian-made products good value-for-money for local buyers? One of the big advantages is the local support and immediate availability of all spare parts and consumables. We have local stocks of common components in various locations around Australia, and our Brisbane-based factory stocks almost every component ever used on an ART machine. Is there anything you’d like to see from Federal/State Government in terms of support for local manufacturing? While there are various grants and concessions available for development or export-related enterprises, these are prohibitively time consuming to prepare submissions for. We have previously used consultants to assist with the submission process; however the combined cost of these, along with the internal resources that were required to produce the relevant information negated any benefits that were received from the grants. The R&D tax concession application process has also recently been reviewed and now requires much more in-depth documentation to be prepared for each submission. While this is obviously designed to weed out abuse of the system, it also creates more of a burden on legitimate companies that rely on this financial relief. Any assistance from the government to make these processes easier and less costly would be appreciated. How much does your company export and would you like to expand this? In the past, ART has primarily focused on the domestic market; however it is becoming more and more common for us to export machines to other markets. We currently have customers in the UK, the USA, Russia, Spain, Indonesia, Malaysia and New Zealand among others. Our expansion is organic, in the sense that we grow into a market slowly, making sure that we can provide adequate support to our clients. Supporting our machines well has always been our first priority. What role does R&D/innovation play at ART? How much is developed in-house? As I mentioned earlier, ART devotes a large amount of effort and resources towards the development of new and exciting products. Our developers work across many disciplines including software, hardware, mechanical and electrical design. The investment me make in development is a big commitment, however it is our main focus and always has been. In this way, we can quickly adapt to the demands of the market and provide the solutions that our clients need. We are much more than a machine assembler – we design from the ground up, and that gives us unprecedented control over the whole system. Where do you see future potential growth markets for your products in Australia? We are always investigating new applications for our technology. For example, our new XR series routers are breaking ground with a range of new attachments. Applications such as box prototyping, packaging, air conditioning duct making, sign making, fibreglass mat cutting, fabric and film cutting and many others are now possible using this one machine. We are currently in development of a high precision fibre laser profile cutting machine for processing up to 12mm steel plate. We are anticipating a strong demand for this machine in light to medium sheet metal and steel fabrication industries. How do you see the future for local manufacturing? Although the previous couple of years have been marked with financial upheaval around the world, we have recently seen a marked upswing in the marketplace with a return to the realisation that it takes money to make money. Industry seems to have come to a realisation that you can’t just hold the pause button down indefinitely. We need to move forward, and the only way to do that is to get on with business. September 2011 machining 11
PROFILE The engine reconditioning industry within Australia, New Zealand and Pacific Islands is serviced by a sometimes unknown but highly competent component manufacturing company Premier Engine Components based in Melbourne’s manufacturing heartland.
PREMIER MACHINERY &
COMPONENTS BY GRAEME McLEAN
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Premier prides itself on its ability to supply the reconditioning industry with a broad range of competitivelypriced locallymade products manufactured where possible from locally sourced raw materials,
12 magazine September 2008
remier Machinery & Components was originally founded in Sydney in 1983 in a partnership between General Manager Keith Seward and Gem Engines. Mr Seward had a solid engineering background and the close link with Australia’s largest engine re-manufacturing plant combined with his skills allowed the company to not only expand its range but also keep up-to-date with the day-to-day requirements of the broader industry. Originally located on the Chipping Norton site of Gem Engines, the company moved to larger premises at Ingleburn in 1995 as a result of ongoing expansion. Following the retirement of Mr Seward in 2003, the company relocated all plant and machinery to its current manufacturing site in Dandenong, Victoria. This enabled Premier to maintain its close relationship with HM-Gem whilst also being situated alongside its largest distributor, Nason Engine Parts. In early 2007 the company was purchased outright by its current owner Daniel Parker. A hands-on operator with four highly skilled and experienced production staff to support him, Daniel is a qualified fitter/machinist and toolmaker who has worked in all areas of engine re-manufacturing.
Premier Machinery was formerly the Machinery sales division of NASON Engine Parts & Machinery which was separated from NASON back in April 2007. More recently Premier Machinery has merged with the already existing Premier Engine Components to become “Premier Machinery & Components”. Both Premier Machinery and Premier Engine Components have existed for over 25 years serving the engine reconditioning industry throughout Australia, New Zealand and South East Asia. The machinery segment of the business has been supplying and servicing a number of the world’s leading Engine reconditioning machinery brands for all that time. Brands such as Rottler, AMC-Schou, Serdi, KwikWay, Hines and Van Norman. Premier Machinery & Components is equipped with the latest CNC controlled machines, lathes, milling machinery, grinding, drilling and stamping presses and maintains a Quality System audited to the internationally recognised standard ISO 9001:2000. The on-going close working relationship with the largest engine re-manufacturing operation within Asia Pacific means that the company benefits from direct exposure to all new developments. Today the company services
Below left: The Premier Engine Components Team (left to right): Richard Wright, Daniel Witcombe, Managing Director Daniel Parker and Matthew Middling.
the Australasian market with a comprehensive range of aftermarket engine parts from early models such as the Holden grey motor through to late model engines. “Premier prides itself on its ability to supply the reconditioning industry with a broad range of competitivelypriced locally-made products manufactured where possible from locally sourced raw materials,” says Managing Director Daniel Parker. “Our policy in this area encourages Australian manufacturing jobs and helps the local economy.”
sleeves, sump plugs, tubes and bushes, solid and hollow dowels, gallery and blanking plugs, hydraulic lash adjuster kits plus cylinder head jobbing centres and engine reconditioning machinery parts and components. Today trusted Premier Machinery & Components are sold by leading suppliers to the automotive repair and engine reconditioning trade throughout Australia, New Zealand and the Pacific region.
www.premiermachinery.com.au
The many and varied product lines the company produces, today totalling more than 1300, include such items as valve seat inserts, cast iron and bronze valve guides, brass, steel and stainless steel Welch plugs, oil pump bypass and relief valves, bronze guide
September 2008 magazine 13
COVER STORY I CUTTING TOOLS
With a tool overhang of 16 times the diameter vibration tendencies can become more apparent, and tuned bars, or Silent Tools, come into the picture as the solution.
SILENT
REVOLUTION BY BARBARA SCHULZ IMAGES BY BARBARA SCHULZ
W
hen it comes to forging, heat treatment, metallurgic expertise and semi-finish machining, Albury-based Overall Forge is the number one address in Australia. As the largest and one of the few remaining forging companies in the country, the business has continuously retained a high profile in the global oil & gas exploration and mining industries, providing customers across the world with superior forgings. Established in 1883 by John Overall in Sydney, the company relocated to Albury in 1996 and has since tripled in size, now covering a whopping 10,000m² floorspace, and further extensions are planned. In January 2010, the company sought to diversify into new markets by expanding not only the forging but also the machining capacities of the business. As part of the growth plan, Overall Forge decided to further upgrade the existing 1915-built forge press by increasing speed and force of the press and manipulator and invest in state-of-theart machine tools to bring the currently outsourced high-precision machining work in-house. But when it comes to mechanical engineering, complex cutting and high-precision machining, Overall Forge is lacking behind. “We have the 14 machining September 2011
capacities to rough machine forgings such as bars, blocks, hubs, step-down shafts, wellheads or forged rings to near net shapes,” Operations Manager Reinhard Radisch explains. “The finish machining process is either done in-house by our customers, or they outsource the machining, which is often done overseas.” Value added: Precision machining “If we can jump into that market and perform the finish machining here in-house which is currently done overseas, we will be able to save our customers considerable time and costs,” he continues. “Hence, we decided to invest in a CNC lathe and a CNC vertical borer, which will allow us to machine shafts, discs and rings of complex shapes to much tighter specs than what we are currently capable of.” Mr Radisch admits that the company is by far not advanced enough yet to use the new machine to its full capacity – but having a reliable supplier and partner like Sandvik Coromant makes it easier. While the two companies look back on a longstanding working relationship, the co-operation became even closer when Overall Forge decided to invest in a 4m long x 250mm diameter boring
The CoroTurn SL damped Silent Tool Sandvik Coromant delivered to Overall Forge is Coromant’s largest standard tool and is a very flexible solution for vibration-free internal machining, threading, parting or grooving applications.
September 2011 machining 15
COVER STORY I CUTTING TOOLS
bar with a total weight of 1000kg supplied by Sandvik Coromant. “While there were cheaper offers on the table, we decided to partner with Sandvik because of their professional approach and proven expertise,” Mr Radisch says. “With Sandvik you don’t just buy the tools, you buy a package which includes their expertise and backup support. The support-side of this partnership is very important to ‘beginners’ like us, the support you need every day. Sandvik’s Sales Engineer Mark Lampe is part of the furniture. Being located in Albury, it only takes a phone call and he can be here within 20 minutes, which was definitely part of our decision making process.” Reliable partner More importantly though, Overall Forge needed a reliable partner in their endeavour to get to the higher level of precision machining and solve the problems they were facing machining large wellhead installation forgings for the petroleum industry. “Overall Forge was machining the wellheads with varying success, but with their home-made solution they couldn’t quite get the surface finish and tolerance they needed to achieve, which drove them to invest in a new CNC lathe and thought that they might as well have the right tooling to do the job,” says Sandvik Coromant’s Sales Engineer
Mark Lampe. “They needed to achieve a surface finish of 3.2RA and a tolerance of +/- 0.5mm. At a first glance, this doesn’t sound too hard to achieve, however, the job required internal turning, which is very sensitive to vibration, especially if the tool overhang exceeds the normal limit of the 4 x D ratio.” A basic tenet of metalcutting is shorter tools are more rigid than longer tools and generally deliver better cutting results. Closer proximity of a cutting edge to a machining centre spindle or turning centre turret translates into higher feeds and speeds with better surface finish and less chatter. “For many of the metalcutting applications such as external turning, the tool overhang is not affected by the length of the workpiece and the size of the tool holder can be chosen so that it withstands the forces and stresses which arise during the operation,” Mr Lampe explains. “And in cases where some chatter is induced, a change in speeds and feeds will generally eliminate it. But there are applications where it’s necessary to ‘hang a cutting tool out there’.” Tuning out the chatter With an overhang of 16 times the diameter in Overall Forge’s case, vibration tendencies can become more apparent, and tuned bars, or Silent Tools, come into the picture as the solution. “Overall Forge has experienced how vibration can cause unwanted side effects such as poor surface finish, insufficient accuracy and reduced productivity,” Mr Lampe says. “The limitations with regard to stability in boring means that some extra care must be taken with production planning and preparation. Selecting the right boring bar for the operation, applying it correctly and clamping it properly has considerable effect on keeping tool deflection and vibration to a minimum, and consequently the quality of the hole being machined.” Overall Forge was convinced that by digging deep into their pockets to invest in a Silent Tool from Sandvik Coromant would pay off. Being productive from the very beginning means Overall Forge’s Operations Manager Reinhard Radisch (left) and Sandvik Coromant’s Sales Engineer Mark Lampe look back on a long-standing working relationship.
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With the CoroTurn damped Silent Tool, Overall Forge achieves the required surface finish of 3.2RA and a tolerance of +/- 0.5mm.
being more competitive – and Sandvik Coromant is the No.1 provider worldwide for internal turning solutions of landing gear and jet engine components, areas where Silent Tool technology is mainly used. The tuned boring bar controls chatter by means of a passive damper within the bar. This damper consists of a heavy tuning body suspended in the bar by two rubber bushes. A viscous liquid fills the gap between the tuning body and the inside surface of the bar. If vibration occurs during the machining process, then the tuning system will come into play and the kinetic energy of the bar will be absorbed into the tuning body. As a result, vibration is minimised, and precise dimensional tolerances and surface finish can be attained. “The CoroTurn SL damped Silent Tool bar we delivered to Overall Forge is our largest standard tool and is a very flexible solution for vibration-free internal machining, threading, parting or grooving applications,” Mr Lampe says.
“The bar features a CoroTurn SL quick change function, which means heads can be easily adjusted sideways for different size bores and quickly changed to adapt to a range of applications.” The CoroTurn SL standard range with exchangeable cutting heads is a wide ranging program available from 16mm to 250mm diameter for vibration-free internal machining with long overhangs of up to 16 x D. The Silent Tool boring bar is the first step for Overall Forge into making large precision turning work its specialty. “You obviously have a competitive advantage when you can machine parts that others can’t,” Mr Radisch concludes. “We have some complex forgings we want to machine in-house in future and hope this will be a gravitational pull on more machining work from new and existing customers.”
www.coromant.sandvik.com/au www.overallforge.com.au September 2011 machining 17
COVER STORY I CUTTING TOOLS
PRODUCING
HIGH-QUALITY THREADS The production of female threads is among the most time-consuming and therefore expensive individual operations. A high level of process reliability is required, as thread production is the final stage of a job, which gives it a certain volatility – if anything goes wrong, the whole workpiece can be at stake. This scenario can be avoided using the right tool combinations and cutting data. BY WALTER AUSTRALIA IMAGES BY WALTER AG
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n themselves, female threads are hardly rocket science - or so it appears. But given ever tighter production deadlines, time-honoured processes lose their apparent triviality. With modern thread cutting production processes a problem often arises that in the days of slower cutting speeds and feed rates had nowhere near the same significance: the high cutting parameters place extreme strain on the core-hole drill, in particular with stainless, acid-resistant steels and materials that are difficult to machine (ISO-M, ISO-S materials). Very high temperatures can develop on the cutting edges, which causes the material to harden. Lower-quality drills tend to wear more quickly, exacerbating this effect. The subsequent tap meets greater resistance, and its useful life is reduced. This also affects the surface finish quality and gauge accuracy of the finished thread, let alone the possibility of breaking the tap and the attendant consequential costs. Ultimately, it is a matter of the quality of the threading tool. The great importance of boring the core hole is often disregarded when assessing a situation. Perfect threads need perfect holes “Perfect threads require perfect holes,” say the thread specialists of tool manufacturer Walter AG of Tübingen. The merger of the brands Walter, Walter Prototyp and 18 machining September 2011
Walter Titex, has brought together all the expertise needed for metalworking under one roof, including all technologies related to the production of female threads. “It’s not our intention to reinvent thread cutting,” says Timo Mager, Threading Product Manager at Walter, “but our job today is to offer our customers high-performance solutions for all kinds of machining. As thread cutting comprises two separate processes, we want to offer the best tools for both in the form of a complete solution.” And this is it: a Walter Titex Xtreme Plus core-hole drill – with a Walter Prototyp Paradur/Prototex Eco-HT tap. The Xtreme Plus is a solid carbide spiral drill with internal coolant supply. Its salient feature is a patent-applied-for DPL coating (DPL = Double Performance Line), made up of a base coating and a tip coating. The combination of these two layers enables high cutting speeds to be used with above-average tool life. A special point grind ensures low power consumption and a good surface. The high wear resistance and internal coolant supply help guard against the hardening of the hole wall, an essential condition for high-quality threads, particularly when producing large numbers. The Walter Prototyp Prototex Eco-HT (through hole threads) and Walter Prototyp Paradur Eco-HT (blind hole and through hole threads) make the ideal partners. With internal coolant supply, a special coating and chamfer
geometry, both types offer reliable chip control even when producing deeper threads up to 3xD. The Eco-HT taps are made of HSS-E tool steel and are suitable for long- and short-chipping materials with a tensile strength up to 1300 N/mm2. There is an Eco-HT tap for every processing situation - wet, dry or under MQL conditions. Cut processing time to half “The Xtreme Plus solid carbide drill and the Eco-HT tap represent a benchmark pair for the production of female threads,” says Mr Mager.” In comparison with standard tools they reduce processing times by up to 50%; this applies to both operations, drilling and thread cutting. They also have an above-average tool life and process reliability. The higher the quality of the workpieces, the more important these properties become.” Solid carbide is increasingly being used for taps. “One aspect of the development work at Walter Prototyp over the last two years has been aimed at introducing to the market solid carbide taps for steel machining with tensile strengths of up to approximately 1200N/mm2,” says Josef Giessler, Development Manager for Rotating Tools at Walter Prototyp. “To date tools of this kind have been difficult to find. Wal-
ter Prototyp is among the few suppliers whose range already includes a solid carbide through hole tap, the Prototex HSC. The Paradur HSC, the solid carbide blind hole version, will be introduced in Autumn 2009.” The maximum cutting speeds of these high-end threading tools are 60m/min. By way of comparison, speeds of 20m/ min are usual for HSS-E taps; the tool life is as much as 8 times higher. They are used above all in the automotive industry. A trend towards milling and forming Most female threads are still produced by thread cutting, but the alternative methods of thread milling and thread forming are gaining ground. “We are seeing a trend towards these technologies and are ourselves making developments in these directions,” confirms Mr Giessler. This is confirmed, for example, by the Prototyp solid carbide orbital thread mill for threads from M1.6 to M8. In addition to the rotary motion, these tools also work in an axial motion (hence “orbital”). They produce precision threads right down to the root. The orbital motion prevents lateral yielding, often a problem with usual thread mills. The high process reliability makes these tools especially attractive to users who machine high-alloy materials that are difficult to machine.
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COVER STORY I CUTTING TOOLS
The Xtreme Plus is a solid carbide spiral drill with internal coolant supply. Its salient feature is a patent-appliedfor DPL coating (DPL = Double Performance Line), made up of a base coating and a tip coating.
Thread milling requires modern machines and more complex programming. The programming itself represents a bit of an obstacle to many machinists. The machine control modules are generally not sufficient. Walter has a special way of dealing with this: the customer not only gets a tool, but also the optimum machining strategy in the form of the NC program, together with the TEC/ CCS cutting data software. This saves programming time and increases reliability. Users know that their processes work. Thread forming requires a particularly precise coordination of the core-hole drill with the threading tool. The precision of the drilled hole is in the region of 0.05mm (e.g. for M6: core-hole drill (5.55±0.05mm). As the technology is only considered for appropriate materials that can be cold formed, the range of application is more limited. The problem of hardening is also a factor here. When forming, temperatures often build up sharply, which can change the forming properties of the material. Software supports machinists Expert advice is another crucial factor for manufacturers. Walter’s TEC/CCS software mentioned above represents a comprehensive information pool for both technological and commercial questions. Machinists save time and can work more independently, as the answers to many questions can be obtained immediately. In the current version the subjects of drilling (TEC module) and thread 20 machining September 2011
ing (CCS module) are intelligently interlinked. Based on this interconnection, users can not only find the perfect combination of drilling and threading tools, but are also given the costs per thread. And there’s more: the individual threading technologies can be compared directly in terms of their economic efficiency. After inputting the machining assignment, the material and the cooling lubrication method, the cutting data are also listed. “The cutting data for drills and threading tools provided by the software are worked out in detail by us under normal conditions encountered in practice,” explains Mr Giessler. “The same applies to the coolant recommendations. We test all the coolants readily available on the market and on the basis of our experience suggest two particularly suitable and environmentally-friendly oils for thread cutting and thread forming.” In general only emulsions are used these days, although there are exceptions, for example for thread forming with high-tensile materials. In these cases the high temperatures require special cutting oils. “By using the recommended tool combinations and cutting data, machinists will always be on the right track,” Mr Giessler concludes. “In other words, the known problems relating to bore hardening are minimised.”
www.walter-tools.com
Proxima Plasma The HACO PROXIMA gives you all you need in a quality plasma system, and much more... The HACO PROXIMA base consists of IPE profiles (I-beams) over the entire length. The gantry of the machine rests on oversized linear guides, mounted on these IPE profiles, and is driven by brushless AC Servo motors with rack-and-pinion system on both sides (double X-axis drive). The plasma cutting head is mounted on a rest (carrier), which is attached to the gantry for movement in the Y-direction, with the height of the cutting torch is controlled by a DC motor. During cutting with the plasma torch, the voltage of the plasma arc is measured and used to keep the torch at an equal distance from the sheet for optimum cutting results. The cutting table of the PROXIMA is separated from the gantry and IPE Profiles. It consists of approx. 500 mm wide scrap bins with integrated fume extraction doors.
These doors are opened automatically by pneumatic valves which are controlled by the position of the gantry. The selective opening of the doors thus guarantees very efficient fume extraction, an absolute requirement for plasma cutting applications. The APC59-T Control is a graphical CNC Control System, with a 15� TFT touch screen mounted on a separate stand in front of the machine for optimum operator convenience. The highly advanced software "RoboTorch" raises the bar for other plasma software on the market due to the simple layout of the user-interface. This allows direct access to the desired functions and as a result creating optimum operator convenience. The automatic Arc Voltage System, continuously adjusts the arc voltage to correct for consumable wear and this results in correct torch height over the life of the consumables, without operator adjustment.
And what is a quality machine without professional sales and support backup? Haco Australia has highly skilled, factory trained, service technicians to ensure your machinery operates to manufacturers specifications. We go to any length to ensure that your needs and expectations are met on time, every time. Our worldwide presence is your assurance of long term service. To find out more about the PROXIMA plasma, or any of our other quality machines give us a call today, or visit www.hacoaustralia.com.au.
For all enquiries Australia wide call:
Kurt Bossuyt on (03) 9791 8255 Geoff Archer on (08) 9414 8009 email: sales@hacoaustralia.com.au
September 2011 machining 21
web: www.hacoaustralia.com.au
CASE STUDY I CUTTING TOOLS
PURSUIT OF
EXCELLENCE Everyone encounters obstacles, but the real challenge is in whether you cave in or carry on. Carlos Broens is a man who chose the latter—time and again. Embracing technology, engaging his employees as well as technology partners like Iscar, he has led Broens Industries through some hard times to remarkable success.
BY BARBARA SCHULZ IMAGES BY BARBARA SCHULZ
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arlos Broens is not a man who allows a setback or recession to get him down for long. When one road ended, he simply forged a new course of his own. When Australia fell into one of its worst recessions in 1987 when a stock market crash affected companies and economies around the world, Mr Broens turned a deaf ear on everyone’s advice and purchased land at Ingleburn, NSW, to build a bigger factory after outgrowing his premises in Liverpool.
Awards in manufacturing in 1995 and was featured on national TV.
“When I decided to buy this block of land in the middle of a recession, everybody thought I was crazy,” remembers Mr Broens. “Nobody wanted to finance my project, so I took it into my own hands and worked hard to build up the factory while my General Manager was looking after the manufacturing operations.”
“The award immediately elevated our image, we stared to talk to China and venture into export, which took us to the next stage. Broens Industries as a group evolved, as part of growing up in life, gaining knowledge and going through the university of life.”
A spot in Australian history This extraordinary effort resulted in Mr Broens’ entry in “The Australian People: An Encyclopedia of the Nation, its People and their Origins”, published by the Cambridge University Press, 2002. As an “Argentinian whose achievements have resulted in public recognition” Mr Broens reserved his spot in Australian history after winning the Ethnic Business 22 machining September 2011
“NAB, who were backing us at the time, thought we had done something extraordinary and introduced us to the awards which celebrate diversity and multiculturalism and the achievements of migrants who come to Australia with a ‘suitcase full of dreams’,” Mr Broens says. “To build up a company like that in the middle of a recession was incomprehensible to them.”
Mr Broens and his wife Grace (Mimi) started the high-tech engineering and manufacturing company as a two-man operation in 1979 from the back of a ute, providing subcontract toolmaking and general engineering services to a variety of clients. “In 1981 I bought a lathe, a mill, a grinder and rented a little unit in Lyn Parade, Prestons, and commenced as a manufacturer of precision tooling, dies and general engineered products,” he
Today, the Broens Group employs 340 people and includes Broens Industries, Static Engineering, Calbic Precision Engineers and Broens AutoCast and Forge. September 2011 machining 23
CASE STUDY I CUTTING TOOLS
Carlos Broens (left) and Iscar Director Jason Allen in front of Iscar’s Matrix tool management system. For Broens, Iscar is more than just a cutting tool supplier – the Israel-based cutting tool specialist is a technology partner, supporting the leading precision manufacturer with technical support, advice and training.
says. “While my wife used to do the deliveries and pickups, I worked long hours in the workshop and eventually employed some people, then rented the unit next door, put a hole in the wall and filled that up with even more machines. Then I rented the unit across the road – the company grew in a natural way I suppose, being competitive and hands-on.” Today, the Broens Group employs 340 people and includes Broens Industries, Static Engineering, Calbic Precision Engineers and Broens AutoCast and Forge. Broens is a leading global provider of design, manufacturing and engineering solutions for precision engineering, tooling, special purpose machinery, automation, machine tools and component production in the precision, automotive, aerospace, marine and defence industries. Broens exports 50% of its products to more than 16 countries and has offices in China, the US and Europe. Much of the company’s growth has resulted from acquisition, as well as an aggressive business and marketing plan. “We are continually watching the market for growth opportunities,” Mr Broens says. “We are currently looking to expand our business into the mining sector to eventually create a new line of business. Despite changes in 24 machining September 2011
the economic climate over the last couple of years, we remain committed to continuing to grow our business through strategic acquisitions.” In 2009, Broens purchased SA-based Calbic Pty Ltd, after acquiring adjacent Static Engineering in 2007. Static and Calbic provide precision turnkey manufacturing solutions for land air and sea defence applications and are now operating as Broens SA. But Mr Broens doesn’t see himself as a mere business acquirer; he is flying the flag for Australia’s advanced precision engineering industry, helping struggling businesses to keep their doors open and generate profit. Strategic acquisitions “We are helping companies not to collapse and to survive,” he explains his acquisitions, which, however, are of course not completely selfless. “Without having the industry around you, you will cease to exist yourself. I have become a business curator. Static Engineering, for instance, was a $1.7m business three years ago when we took over. We turned the business around, made it profitable and next year we expect it to be worth $14m.” As most businesses, Broens was hit hard by the GFC,
Iscar works closely with its customers to evaluate processes and seek new solutions to improve productivity. Pictured: Greg Reid explains intelligent milling strategies.
especially as the automotive industry virtually came to a standstill in 2009. While Broens diversified into other markets such as aerospace, defence, mining or heavy industry, 65% of its business is still generated in automotive. But Mr Broens turned the ship around to eventually even generate further growth. “The secret is being able to react quickly to situations like this,” he says. “We didn’t retrench anybody, made agreements with our workers to work only four days a week for a little while, but now everyone is working full-time again. We also have a very high retention rate.” “We have always looked at reinventing ourselves, and Broens is a company that always managed to survive,” he continues. “We constantly strive for excellence, combining our experience with new technology and the latest processes and materials. Our strategy was always to look for niche markets where it was very difficult for other companies to tap in, to look for “China-proof” type products.” Broens produces and exports assembly and test machinery for the manufacture of power steering valves and assemblies to major vehicle manufactures around the globe. “It is a highly complex specialist area, but our Research and Development teams never stand still, always providing the most innovative solutions,” Mr Broens says. “We have come up with new ideas, how to make the assembly of power steering equipment more efficient. Worldwide, the automotive industry is picking up, and we have the infrastructure.” Mr Broens says part of his success is due to regular upgrades to manufacturing facilities, allowing for expansion
into high-technology CNC machines, CAD/CAM and R&D. Forming technology partnerships is another very important aspect of innovation for Broens, because it can lead to new ideas, access to new technology and productivity improvements. “We are constantly working to improve, and Iscar’s knowledge has been an asset in our efforts,” Mr Broens says. Technology partner When producing a large number of complex, high-valueadded parts, processes are continually examined and optimised, and this influences the style and numbers of cutting tools that are used each day. Broens knows this first-hand and has been relying on Iscar tools and services for more than 20 years now. For Broens, Iscar is more than just a cutting tool supplier – the Israel-based cutting tool specialist is a technology partner, supporting the leading precision manufacturer with technical support, advice and training. “By providing high-quality training and support, Iscar has indirectly been involved in our continued growth, teaching us how to use cutting tools more effectively and how to become more efficient.” “Process optimisation is a never-ending job, especially
September 2011 machining 25
CASE STUDY I CUTTING TOOLS
Broens Industries’ CNC multi-axis machining capabilities are able to achieve tight tolerances and intricate designs.
in the cutting tool arena,” he continues. “By the time one solution has been successfully implemented, some new innovation might very well offer even higher levels of performance. Even a manufacturer like us who recognises the importance of evaluating how the latest technology can improve operations might struggle with committing the resources required to do so. Iscar is a great help working closely with our engineering team to evaluate processes and seek new solutions to improve productivity.” Inventory management One area where the Iscar team has been able to support Broens to increase productivity is tool and inventory management. Searching for missing tools can waste valuable production time, and those that are never found add to inventory costs. Iscar’s Matrix tool management system greatly reduced downtime and stock-outs resulting from lost tools. Matrix is a total management system to control inventory, streamline purchasing and drive down costs. It combines an automated tool dispenser with Matrix-TM, a management software, which can be customised for each workshop. Access to an item stored in Matrix’s locked bins is electronically controlled by the management software according to pre-defined authorisations. Broens runs five Matrix systems managing more than 26 machining September 2011
tips and tools. Since the software can be customised for each workshop, Matrix also manages other inventory the manufacturer needs, whether it is gloves, safety-glasses or HSK tooling. “Matrix creates accountability, eliminates waste and is especially useful for the operators because they can help themselves and do not have to wait for a store person,” Mr Broens explains. “Thanks to the automated order system we never run out of stock and the material is automatically ordered via the internet.” “I highly recommend Iscar’s Matrix tool management system, every shop in this country should have some kind of tool management system in place.” While Mr Broens admits there is many ways to skin a cat and is buying equipment and tools from other suppliers as well, he is very pleased with the growing range of Iscar tools. “Iscar has to prove themselves all of the time, not only in costs, but also in cutting efficiency,” he says. “We constantly test tools and the efficiency for us and our production processes to evaluate which tool is the best for us. But Iscar has succeeded most of the time.” Carlos Broens’ success is based on his constant strive to do better, and in Iscar he has found a reliable partner to build an outstanding reputation within industry for reliability of products and on-time delivery.
www.iscar.com.au www.broens.com.au
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September 2011 machining www.iscar.com.au
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CASE STUDY I FABRICATION
CUTTING-EDGE
SIGNS
BY BARBARA SCHULZ IMAGES BY BARBARA SCHULZ
Signs need to deliver a clear message to avoid confusion, which is why all signs are custom-made to help brands inform, instruct and look good in all the right places. Melbourne-based Signcraft Group designs and manufactures its complete range of signage solutions in-house, and the company’s ART CNC routers offer the high-quality cutting capabilities Signcraft needs to be competitive.
The RT series machining centre from ART supports rotary tool changers and high torque liquid and air cooled spindles, featuring premium quality 4 jet misting lubrication injectors which are ideal for 3D machining processes.
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altex Woolworths, Channel 10, Brisbane Airport, St Georges Bank, Nissan; the list goes on. At first sight, these companies have nothing in common. All of them, however, need to make people and customers aware of their location and products, make their messaging prominent, identify ownership or help people get from A to B. And because we live in a very visual world, all those and many more companies, organisations or road networks have one common need: Signs. Signs need to deliver a clear message to avoid confusion, which is why all signs are custom-made to help brands inform, instruct and look good in all the right places. Melbourne-based Signcraft Group understands people and the way they respond to information and instructions in diverse environments and evolved from a tradition sign shop to become a signage specialist encompassing different trades and services to become Australia’s leading signage organisation. The Signcraft Group story began in the 1960’s with Sam King taking a hard look at the signage industry and re-
solving that it wasn’t delivering the service its customers deserved. At that time, Sam was a trained sign writer with a solid grounding in the industry. He decided to form his business based on the philosophy of “performing a common task uncommonly well.” Today, The Signcraft Group continues to strive to deliver the greatest value for its clients’ investment through a team of dedicated resources and four totally self-sufficient plants and a complete service offering from design through to preventative maintenance. In-house machining “Except for some special work like waterjet cutting, we do all machining in-house,” says National Operations Manager Guy Blackman. “Essentially we are a jobbing shop, the majority of signage is tailored to the building you are going to hang it on. Even something like a Woolworths sign which looks and feels the same to the average person looking at it, it’s all tailored for the buildings, every sign is individually made, hand constructed.” The company runs a vast range of fabrication machines,
September 2011 machining 29
CASE STUDY I FABRICATION guillotines, presses, welders, vacuum forming machines for 3D moulds, as well as two ART routers. New technologies and new materials are transforming the way signs are designed and manufactured. CNC routers are designed to keep up with these developments and excel at cutting composite prototyping boards, plastics, carbon fibre and even non-ferrous metals with the proper accessories. In the past, CNC routers have primarily been used to cut contours and 3D shapes in wood, plastic and foam for signs, plaques and more. Over the years, however, routers have become more accurate and capable and are used more and more to machine parts that were once machined on CNC milling machines. The larger machine table sizes of today’s routers, coupled with the highspeed spindles, makes them an ideal choice for machining thin and small parts from sheet or plate material. Size mattered for The Signcraft Group when they were looking to invest in a second ART CNC router for their Melbourne factory, and the RT5000 Heavy Duty Profile Centre was ideal to cut the company’s most commonsized sheets of 4m x 2m. “We installed our first ART 5000SX router back in 2007 and the machine has been reliable ever since and ART as an Australian company offers the service support we need,” Mr Blackman says. The company processes many different types of material, from acrylics, aluminium, aluminium composites,
steel, stainless steel to wood. ART’s RT series machining centre is specifically tailored to these needs and even supports rigid tapping. “Recently there have been great increases in the performance of CNC routers, which has meant that the gap between machining centres and routers has closed considerably,” David White, Director Advanced Robotic Technology (ART) says. “All of our CNC routers are capable of prismatic machining as well as full 3- and 4 axis free-form machining depending on the machine options.” He goes on to say, “Our large format CNC router machines are now capable of heavy duty machining in solid aluminium as well as plastics, composites and timbers, which is why our newest machine, the RT model as installed at The Signcraft Group in Melbourne, is no longer marketed as a router. Instead we class it as a machining centre.” Router handles 3D machining tasks The RT series machining centre from ART supports rotary tool changers and high torque liquid and air cooled spindles, featuring premium quality 4 jet misting lubrication injectors which are ideal for 3D machining processes, because the coolant needs to get right to the cutter especially in deep pockets. The z-axis has often been a limiting factor on CNC routers but ART’s RT series machines have a huge standard clearance of 350mm under the gantry. The z-axis has a stroke of over 700mm, capable of handling many moulds and other 3D machining tasks. It is those features and the built-quality which attracts The Signcraft Group to ART’s routers, but as an Australianowned and operated company it is also very conscious of supporting Australian manufacturing and local companies. “The beauty about an Australian manufacturer is that if something goes wrong, the support is there and even if the supplier doesn’t have a spare they can make it or source it locally,” he explains. “Many companies source from China or the US. That’s not the same.” The Signcraft Group’s Machine Operator and Operations Manager Guy Blackman in front of their new ART RT series machining centre.
30 machining September 2011
Since its insatallation in 2007, the 5000SX router has reliably cut a vast range of materials at The Signcraft Group’s Altona plant.
Mr White agrees but admits it is a challenge to compete against cheap imported products. “Many customers that are new to our type of product are unaware of the many pitfalls of buying inferior products from overseas, with little or no support,” he says. “The challenge is to help our potential clients to identify the vast differences that can be found between quality engineered machinery from a reputable manufacturer, and the copy-cat imports that often fail to deliver on their promises.” Research and development The Brisbane-based manufacturer invests a lot of resources into developing new features and functionality into its products. “Many of the functions that we have on our machines are simply unavailable on other machines,” Mr White says. “For example, we develop our software from front to back. Because our software developers work closely with
our mechanical and electronics engineers, as well as our own in-house CNC operators, we have an extremely short development cycle time. This also allows ART to respond to the needs of customers by developing processes to suit their needs.” The Signcraft Group’s Machine Shop Operator, who has been with the company for six year, agrees. “Compare to the machinery we’ve once had the ART machines are fantastic,” he says. “Programming is easy and the touch screen is full-on. Especially the size of the machine is good and just what we need. I had good experience with ART and am very happy with their technology and service. “ Asked whether he’d buy an ART machine again the answer is clear; For sure.
www.advancedrobotic.com
machining australia PUBLISHER & EDITORIAL & ART BARBARA SCHULZ barbara@machiningaustralia. com.au
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September 2011 machining 31
Milling Down Production Costs with Winning Combinations for Optimal Productivity For more information, view this interactive ad at www.iscar.com.au
ITA recommends the optimal tool based on application parameters and your machine power. 3 tool options, 25 alternatives, cutting data, power consumption, cutting time, metal removal rates, engineering support and more