apmen march 2010

Cost Saving Millingwith High ProductivitySuperior Fine Pitch Endmills

Drilling Down Production Costs with High Productivity Indexable Carbide Heads

Turning into Lower Costs with High Productivity SUMOTURN Coated Grades

Cutting Down Production Costswith the High Productivity Tangential Parting System

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2010

M.I.C

.A. (P

) No

. 233/06/2009 • PP

S 840/10/2010(028278) • IS

SN

0129 5519

M.I.C.A. (P) No. 233/06/2009

March 2010

www.equipment-news.com

ADVE

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THEAVY INDUSTRIES:

MAKING BIG WAVESLASER WELDING PROCESSES:

MEETING THE CHALLENGEHSM POINTS TO

HIGHER PRODUCTIVITY

P M K N S H3 3

P M K N S H3 3

P M K N S H3 3

P M K N S H3

P M K N S H3 3

P M K N S H3

P M K N S H3 3 3 3 3

P M K N S H3 3 3 3

P M K N S H3 33

P M K N S H3 3 3 3

P M K N S H3 3

A very hard substrate with a cobalt enriched layer, improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Features excellent thermal stability, resistance to chipping and plastic deformation. Recommended for high speed machining of steel at stable or slightly unstable conditions.

A tough substrate with a cobalt enriched layer combined with improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Recommended for general use machining of steel in a wide range of conditions, featuring high toughness and resistance to chipping and plastic deformation.

A very tough substrate with a cobalt enriched layer combined with an improved MTCVD TiCN and alpha Al2O3 CVD coating. Provides excellent toughness and chipping resistance on steel for interrupted and unstable cutting conditions.

A very hard substrate, improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Features excellent thermal stability and resistance to chipping and plastic deformation. Improved wear resistance. Recommended mainly for nodular cast iron at stable or slightly unstable conditions. Can also be used successfully on grey cast iron.

A tough substrate with a new MTCVD and alpha Al2O3 coating.Recommended for milling grey cast iron at high cutting speeds, providing excellent tool life.

A hard substrate, improved MTCVD TiCN and a thick alpha Al2O3 CVD coating. Features excellent thermal stability and improved toughness.Recommended mainly for grey cast iron at stable or slightly unstable conditions. Can be used successfully also on nodular cast iron.

A tough submicron substrate, improved TiAlN PVD coated grade for better chip flow. Suitable for turning heat resistant alloys, austenitic stainless steel and hard steel at low to medium cutting speeds.

A tough submicron substrate, improved TiAlN PVD coated grade for better chip flow. Designed for machining heat resistant alloys, austenitic stainless steel, hard alloys and carbon steel at medium to high cutting speeds, interrupted cut and unfavorable conditions.Excellent notch wear and built-up edge resistance.

A tough substrate combined with an improved AlTiN PVD coating that provides high oxidation resistance. Recommended for milling nodular cast iron at high speeds and grey cast iron at low to medium cutting speeds under unstable conditions.

An improved PVD TiAlN coated tough grade with better chip flow. Suitable for milling stainless steel, high temperature alloys and other alloy steels. Recommended for interrupted cut and heavy operations.

A hard fine grain substrate with MTCVD and alpha Al2O3 coating. Features excellent chipping and wear resistance. Recommended for high speed drilling of cast iron and steel, to be used for the peripheral insert on DR drills.

SINO TOOLING SYSTEMTel + 65 6566 7668 [email protected]

ISCAR THAILANDTel + 66 (2) [email protected]

CV MULTI TEKNIK Tel + 62 21 [email protected]

ISCAR JAPAN Tel + 81 6 835 [email protected]

MESCO Tel + 63 2631 [email protected]

ISCAR TAIWANTel +886 (0)4 247 [email protected]

ISCAR VIETNAM Tel + 84 8 8123 519/20 [email protected]

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Large range ofhigh performancesolid carbide endmillswithvarious designs for awide range of materials and applications.

Inserts have sharp helical cutting edges, polished rakes and a wide range of different corner radii.They are mounted on GOLDALU tools that are balanced for very high RPM machining.

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A new generation of high speedface mills for machining materialssuch as cast aluminum alloys,cast iron and carbon fibermaterials, which are usedmainly in the automotiveand aerospace industries.


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Walter AG Singapore Pte. Ltd. Teletech Park, Singapore+65-67736180service.sg@walter-tools.comwww.walter-tools.com

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TOUGHER. HARDER.SHARPER.

Tiger·tec®Silver is the new high-performance mira-cle tool for steel and cast-iron milling from Walter. Extremely tough, extremely hard and extremely long-wearing, it improves performance by up to 100%. Featuring wear detection, a smooth cutting face and extremely sharp cutting edges, it ensures supreme surface-fi nish quality. Let the Tiger work its magic on your production line.

The machining age is over. It’s time to Tiger.

T-tecSilver_210x278_en_WSG.indd 1 2009-12-7 16:30:23

ENQUIRY NO 035

ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd, 1100 Lower Delta Road, EPL Building #04-02 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

SUBSCRIPTION RATES: M.E.N. is available to readers on a per annum subscription basis depending on location: Singapore: S$60.00, Malaysia: S$60.00, Asia Pacific/America/Europe/Others: S$100.00. Refer to the subscription card in each issue for further details. For change of address, please notify our Circulation Manager. For more subscription information Fax: (65) 6379 2806 Singapore E-mail: [email protected]

JOINT ADVERTISING DISCOUNT WMEM, 30,000 copies circulated quarterly in China combines with M.E.N, 10,000 copies circulated bi-monthly in ASEAN in joint advertising. Ask for more details now.

IMPORTANT NOTICETHE CIRCULATION OF THIS MAGAZINE

IS AUDITED BY BPA WORLDWIDE.

THE ADVERTISERS' ASSOCIATION

RECOMMEND THAT ADVERTISERS

SHOULD PLACE THEIR ADVERTISEMENTS

ONLY IN AUDITED PUBLICATIONS

Federation of Asian Die & Mould Associations

(FADMA)

China Machine Tool & Tool Builders'

Association (CMTBA)

Indian Machine Tool Manufacturing

Association (IMTMA)

Federation of Malaysian Foundry & Engineering Industry

Associations

Machine Tool Club(MTC)

Singapore Precision Engineering and

Tooling Association (SPETA)

SPETA

INDUSTRYEndorsements

metalworking equipment news March 20102

CoNTENTS

Taiwan Association of Machinery

Industry (TAMI)

FIRST CUT24

Is There A Speed Limit In HSM?To reap the benefits of significant investments in high-speed machine tools and accessories, NC programmers need to optimise and reach the safe limits of the system. By Edwin Gasparraj, senior product manager, CAM product development, Siemens PLM.

28

Using Software To Maximise Your Hardware Given the current economic climate, working with available machineries and getting more out of them is a dream come true for many manufacturers. By Michael E Neumann

SOFTWARE & MEASUREMENT34

The Key To Higher Productivity High Speed Machining is not just a technology for shortening the production time and increasing the accuracy of machined parts, but a tangible strategy for increasing productivity. By Dr Moshe Goldberg, marketing technical advisor, Iscar

TECHNOLOGY UPDATE32Metalworking Fluids: Handle With CareAlthough regulations are in place to remove some harmful substances from metalworking fluids, it is still important for operators to exercise the same level of care normally reserved for operating drills and cutters. By Matthew English

March 2010

Robotic Laser Welding Process: The Future Is NowChanges in production strategies and adjustments to current manufacturing climate can often give rise to a major investment. By Ryu Tan, product manager, solid state laser technology, Trumpf

FAB & FORM36

ST-30 TURNING CENTERThe all-new, 2010 ST-30 turning center is the culmination of 15 years of continuous development, and it offers the most performance for the money – the best value – of any turning center on the market today.

more rigidity. more tools. more power . . . more value.r e l e a s e d f o r a c t i v e d u t y : 0 1 . 0 1 . 1 0

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Specifications subject to change without notice. Not responsible for typographical errors. Machines shown with optional equipment.

Singapore DKSH TechnologyHarbour Front Phone: +65 6471 9248 Malaysia A Division of SPC Machinery Sdn BhdKuala Lumpur: 03-5569-5901Penang: 604 3801581

Thailand A Division of Machine Tech Co., Ltd. Bangkok: 02 726-7191-5Chonburi: 66 3811-2700Philippines A Division of Gaylan Technologies Manila: 63 2 915 8725

Vietnam Diethelm and Co. Ltd. TechnologyHanoi: +84 4 9424 725HCMC: +84 8 5121 334

Haas Factory Outlet

2010Ads_AsiaPacific.indd 2 12/8/09 10:42:00 AM



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Haas Factory Outlet




THE

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Haas Factory Outlet




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ENQUIRY NO 031

RefeR to AdveRtising index foR AdveRtiseRs' enquiRy numbeRs

Regulars• 8 Business News• 75 Product Finder• 79 Exhibition Programmes• 80A Product Enquiry Card

Pg 80

Ivan Prole, Belgrade, Serbia





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.I.C.A

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N 0129 5519

M.I.C.A. (P) No. 233/06/2009

March 2010


ADVE

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HEAVY INDUSTRIES: MAKING BIG WAVES

LASER WELDING PROCESSES: MEETING THE CHALLENGE

HSM POINTS TO HIGHER PRODUCTIVITY

In The Grand Scale Of ThingsFrom power generation to major infrastructure overhaul, the heavy industries are generating big movements that can even be felt in the metalworking community. By Joson Ng

INDUSTRY SPOTLIGHT46

Sustainability: Take it, It’s Yours! SMC’s Dr Song Bin discusses his vision for the newly launched centre. By Joson Ng and Derek Rodriguez

FEATURES52

EVENTS & EXHIBITION66

Laser Welding: On The SpotReplacing traditional light sources with laser increases accuracy and also open doors to technologies that are light-years ahead. By Augustine Quek

40

Multi-Axis Laser Processing In The Aerospace IndustryLaser systems continue to meet aerospace manufacturing challenges. By Peter Thompson, technical director and Mark Barry, VP, sales and marketing, Prima North America, Laserdyne Systems

42

Thick Section Welding With Fibre LaserWith the availability of high power fibre lasers of more than 10 kW, new application fields in thick section welding could be developed, especially in the heavy industries. By Michael Grupp, Karsten Klinker, IPG Laser and Stefano Cattaneo, IPG Photonics.

48

Accelerating Die DuplicationThe process of duplicating a stamping die is generally painstaking and time-consuming. Through 3D technology and software programs, it is considerably shortened. By Sophia H Jeon, business partner manager, Rapidform

54

Time Is MoneyEconomic considerations in purchasing a jet cutting machine are just as important as the machine’s capabilities. By John H Olsen, VP Operations, Omax Corp

58

Direct Digital Manufacturing: Viable AlternativeIn an increasingly competitive market, major savings are still possible with new approaches to old methods. By Scott Crump, CEO, Stratasys

62

3D Technologies: Getting Into The X, Y & Z Of ThingsThe latest technologies in rapid prototyping reduce cost and usher in the digital age in a big way. By Augustine Quek

64

Event Preview: SIMTOS 2010Event Preview: Intermach 2010Event Preview: Medtech Manufacturing 2010Event Review: Automechanika ShanghaiEvent Review: Singapore Airshow 2010

CoNTENTS

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editor’snote

EastErn tradE MEdia PtE LtdPublished by:

(a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

Head Office & Mailing address:1100 Lower Delta Road,EPL Building #04-02, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806

thailand Office:Thai Trade and Industry Media Co., Ltd16/F Italthai Tower, 2034/73 New Petchburi Road,Bangkapi, Huaykwang, Bangkok 10310, ThailandTel: 66(0) 2716 1722 Fax: 66 (0) 2716 1723

etm EasternTrade Media Pte Ltd

an Eastern Holdings Ltd company

EastErn HOLDInGs LtDExEcutIvE BOarD

managing director Kenneth Tan

assistant editor Joson Ng [email protected]

advertising sales manager Derick Chia [email protected]

advertising sales manager Yessica [email protected]

editorial assistant Sharifah Zainon [email protected]

senior art director / studio manager Lawrence Lee [email protected]

graphic designer Jef Pimentel [email protected]

contributing graphic designer Libby Goh [email protected]

circulation executive Irene Tow [email protected]

contributors Dr Moshe Goldberg, Edwin Gasparraj Michael E Neumann, Ryu Tan Augustine Quek, Peter Thompson Mark Barry, Michael Grupp Karsten Klinker, Sophia H Jeon Vandhana Venkatesan, John H Olsen Scott Crump, Matthew English Stefano Cattaneo

board of consultants Wäinö a Kaarto AB Sandvik Coromant dr Moshe Goldberg ISCAR

All rights reserved. No portion of this publication covered by the copyright herein may be reproduced in any form or means – graphic, electronic, mechanical, photocopying, recording, taping, etc – without the written consent of the publisher. Opinions expressed by contributors and advertisers are not necessarily those of the publisher and editor.

Printed in Singapore by Fabulous Printers Pte Ltd

MICA (P) No. 233/06/2009PPS 840/10/2010 (028278)ISSN 0129/5519

chairman Stephen Tay

group executive director Kenneth Tan

financial controller Robbin Lim

6

The year 2010 may belong to the Tiger in the lunar calendar, it is also a year associated with natural elements such as metal according to experts practitioner of Fengshui, a traditional Chinese practice of predicting fortunes through dates and classical Chinese texts.

Though it may mean other things in Fengshui, there are several happenings in Singapore that have indicated that 2010 will be a good year for metal, or more specifically, for the metalworking industry.

The start of the year saw Singapore host the Singapore Airshow. Touted the ‘Asia’s biggest for aviation’s finest’ by the organiser, the show saw deals and announcements worth about US$10 billion over the first three days.

There was also a notable growth in the total number of countries/regions represented, with the count moving up from 113 in 2008 to 119 this year. In terms of exhibitors, there was representation from more than 60 countries/regions.

“As the first major airshow taking place at the beginning of the year, the

Singapore Airshow is in a position to gauge the pulse of the industry,” said Jimmy Lau, MD, Singapore Airshow and Events (SAe). Judging from the response and post show results, the ‘pulse of the industry’ is showing some healthy readings on the pulse meter.

Staying with the Aerospace industry, this issue of Asia Pacific Metalworking Equipment News will feature the Heavy Industries in our Industry Spotlight section. We study the number of power generation and large-scale construction projects in the Asia region and how the governments in various countries like Singapore and Japan are improving infrastructures such as airports and railways.

These construction projects will or already have given the heavy industry a boost. For those who are staunch believers of astrology or constellations, they will feel that maybe it is already written in the stars that 2010 will be a good year for metalworking.

Joson NgAssistant Editor


TheMetal

Year (Working)

Worldwide uniqueEven the most complex work pieces can now be ground in one clamping. A new wheelhead with two motor spindles for external grinding and an Internal grinding unit make this possible. Now three wheels can be used to grind a workpiece to your individual requirements and even faster than before – a complete machining in the extra class.

Fritz Studer AGCH-3602 ThunTel. +41-33-439 1111 · Fax +41-33-439 1112www.studer.com

S33 NEWThe reasonably priced for unrestricted grinding length & simplest programming.

Munger Machine Tool Pte Ltd.Tel. +65 6764 63 88E-mail [email protected] Thailand, Tel. +66 2 391 9953MMT Malaysia, Tel. +60 12 326 6309

Integrated Machine Tool Sales, Inc.Bacoor, Cavite, PhilippinesTel. +63 46 417 1359 / 417 0134E-mail [email protected]

STU_S33_Ad_205x275_EN_100205_korr.indd 1 05.02.10 14:37











































ENQUIRY NO 036


8 metalworking equipment news March 2010

Businessnews

Metalworking Equipment News Thailand & Asia Pacific Food Industry Thailand To Cease PublicationSingapore: Metalworking Equipment News Thailand (MEN Thailand) and Asia Pacific Food Industry Thailand (APFI Thailand) have ceased their publication.

In 2003, publication for both Metalworking Equipment News Thailand (MEN Thailand) and Asia Pacific Food Industry Thailand (APFI Thailand) began with great promise, in a bid to forge greater collaboration between publisher and industry players.

Due to strategic considerations and the adverse impact of the recent global economic and financial crisis, Eastern Trade Media (ETM) has ended the joint venture in Thai Trade & Industry Media (TTIM),

publisher of both MEN Thailand and APFI Thailand. With the conclusion of the joint venture, TTIM will have no further rights to publish both titles.

ETM would like to thank all customers and suppliers who have shown support in the Thai publications. Though the publication of MEN Thailand and APFI Thailand have ceased, efforts to serve the marketing communication objectives of customers have not.

With the industry knowledge of APMEN and APFI and the expertise in delivering marcom objectives, ETM will be striding ahead upon the strength of the relationship fostered with partners.

Berlin, Germany: As it profits from ongoing growth in the emerging nations, Siemens is seeking to expand its investment in India. Experts forecast that the Indian economy, for example, will grow seven percent in 2010 and eight percent the following year.

“India is already one of the growth drivers worldwide and will remain so in the future. We’ve been optimally positioned here for over 140 years and intend to further strengthen our position,” said Peter Löscher, president and CEO of Siemens in New Delhi, where the entire Siemens managing board met for the first time ever.

Over the next three fiscal years through 2012, the company intends to invest more than €250 million (US$341 million) in the country, thereby doubling its current annual investments. A major part of this will be invested in renewable energy and value-priced

Siemens To Invest More Than €250 Million In India By 2012products business. The company also wants to increase its market share in India to 10 percent by the year 2012. With recently signed orders totaling over €500 million, primarily for energy technology, the company is well on its way.

The country’s power supply is of particular concern to the Indian government. Currently about 30 percent of India’s population has no access to power, which is why the Indian government is planning to add 150 gigawatts over the next seven years – an amount equal to Germany’s entire installed capacity.

One project involves an investment of approximately €70 million in the construction of a wind turbine factory in India by 2012. The first turbines are scheduled to leave the plant in a little over two years. The company also intends to invest in its value-priced products business.

Six new centres of competence for value-priced products from all Siemens sectors will be established in India by the end of 2010. Plans call for the centres to manufacture a number of various products, including new products in the area of signaling technology as well as steam turbines. These centres will also be responsible for the entire value chain, from product design, development and production to sales and marketing in India and abroad.

“India will become a major centre for value-priced products. By the year 2020, we intend to generate revenue of about €1 billion with these products – both within the borders of India and beyond,” said Armin Bruck, CEO of the Siemens regional company in India.

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ENQUIRY NO 049



Businessnews

Tokyo, Japan: Mitsubishi Heavy Industries (MHI) has established Mitsubishi Heavy Industries (China) (MHIC) in Beijing to serve as a regional headquarters overseeing all company business in China. With the establishment of MHIC, MHI aims to increase new business opportunities in the rapidly growing Chinese market by establishing a structure enabling it to leverage its company-wide capabilities.

MHI Establishes Subsidiary To Oversee Business In China

At the same time, with this initiative the company also looks to further enhance local corporate management and administrative functions and solidify its base of business operations in China by strengthening managerial support and corporate governance to its group companies.

MHIC, capitalised at US$31 million, is a wholly owned subsidiary of MHI. Kenji Yuasa, formerly MHI’s general representative in China, has been appointed as GM. The subsidiary initially started with 14 employees, including office staff assigned to a Shanghai branch opening in February.

With MHIC’s head office located in the Chinese capital, where central government offices and the decision-making organisations of the major state-owned companies are concentrated, MHI will further strengthen its company-wide engagement in Chinese business, encompassing its entire business organisation.

Working closely with respective departments at the company’s head office in Tokyo, including the sustainability energy & environment strategic planning department, MHIC will effectively gather business information throughout China and increase its business opportunities in large-scale projects, such as urban development, energy and the environment, by offering business models incorporating its capabilities.

Plans further call for the subsidiary to set up liaison offices in China’s interior regions, where high economic growth is expected. This move aims to create a structure that will enable prompt acquisition of local information through establishment of the subsidiary’s own information network spanning from the coast to inland.

L&T Bags US$125 Million Orders For Electrical ProjectsMumbai, India: Electrical & Gulf Projects Operating Company, a part of L&T’s Construction Division, has bagged orders worth Rs 582 crore (US$125 million) from various customers for four electrical projects in India and UAE.

The projects awarded include an Rs 155 crore order from Tamil Nadu Electricity Board, Chennai, for the turnkey construction of 37 km of 400 kV environment-friendly multicircuit transmission line involving narrow base towers. The project is to be completed in 10 months and will transmit power from North Chennai Thermal Power Station Stage II to Almathy 400 kV Substation.

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Tungaloy Set Up Office In MalaysiaSelangor, Malaysia: Tungaloy, the maker of cutting tools, PCB drills, wear resistant tools, civil engineering tools, and advanced material tools has set up a Malaysian office. With the setting up of Tungaloy Malaysia office early this year, the company hopes to support customers in a greater manner whereby direct technical support from Japan can be arranged on a regular basis.

In globally supplying the products, the company looks to bolster the sales, manufacturing and development capabilities in order to respond more effectively to the diverse requirements of overseas customers.

P

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HSingapore Tel + 65 68412802Malaysia Tel + 60 3 90591833Thailand Tel + 66 2 7467 801Vietnam Tel + 84 8 9144393

Indonesia Tel + 62 21 8088 8122

JABRO-SOLID2

A COMPETITIVE EDGE IN ALL MATERIALS

In these challenging times, everyone is looking to economise or save mon-ey. The new “easy to use” Jabro-Solid” will give you that extra edge. Consistent good performance in all materials means you can reduce and standardise tool inventory. The outstanding SIRON-A coat-ing ensure optimum wear resistance in both wet & dry operations provid-ing you with longer tool life and less machine down time.

JS510 SERIES – EASY TO USE

• 2-3-4 flutes for optimum choice and complete flexibility

• Increased core diameters per cutting length adds to stability

• Siron-A coating for long tool life

JS550 SERIES – INCREASED PERFORMANCE

• The double core provides excellent rigidity and cutter stability

• Differential tooth pitch for chatter free machining

• Polished Siron-A allows for better chip flow and superior tool life

Ads Solid2 MEN format.indd 2 04-Feb-10 23:55:23

JETSTREAM TOOLINGTM

DIRECTED COOLANT STRAIGHT TO THE EDGE.

Answering a call from the aerospace industry to improve the machining of difficult to machine alloys, Seco developed Jetstream Tooling – a revolutionary new solution to the age old problem of delivering coolant precisely to the cutting zone.

Jetstream Tooling works by delivering a concentrated high pressure jet of coolant at high velocity straight to the optimum position close to the cutting edge. This jet of coolant lifts the chip away from the rake face, improving chip control and tool life enabling increased cutting data to be applied – not just in aerospace materials. Jetstream Tooling has been proven to work in nearly all material groups and with a wide choice of coolant pressures..

The future is here, head straight to www.secotools.com

Singapore Tel + 65 68412802Malaysia Tel + 60 3 90591833Thailand Tel + 66 2 7467 801Vietnam Tel + 84 8 9144393Indonesia Tel + 62 21 8088 8122

WORKS BEST WITH NOW FOR TURNING, MILLING, DRILLING AND GROOVING

MILLING NEWS:

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ENQUIRY NO 033



Businessnews

JJ-Lapp Supplies Roller Coaster CablesSingapore: The opening of Universal Studios Singapore at Resort World Sentosa, a movie-theme park featuring 24 rides and attractions, 18 of which are unique only to Singapore, took place in early 2010.

As part of the many attractions, fun-seekers will be able to enjoy the world’s highest dueling roller coaster (42.5 m). But there is no ride without

cables. To make the ride work, JJ-Lapp Cable supplied 45 km of cable, including the

Olflex Classic 110 Black 0,6/1 kV, a multi-conductor, flexible control cable designed for outdoor use in all electrical equipment in dry, damp and wet conditions.

Toshiba, JSW & Toshiba JSW Celebrate Cornerstone Laying CeremonyChennai, India: Toshiba Corp (Toshiba), JSW Group (JSW) and Toshiba JSW Turbine and Generator (Toshiba JSW) have held a cornerstone laying ceremony for the production facilities of Toshiba JSW in Chennai.

Toshiba JSW is a Joint Venture (JV) between JSW and Toshiba that will manufacture and market super-critical steam turbines and generators for thermal power plants in India.

The JV was established in September 2008, and is expected to start operation in January 2011. The site has a ground area of approximately 400,000 sq m. Over the five years from fiscal year 2009, the JV expects to invest approximately US$160 million in the plant and its manufacturing equipment and essential facilities, including waste-treatment facilities.

The JV will manufacture and market mid- to large-sized steam turbines and generators ranging from 500-megawatts (MW) to 1,000 MW, for super-critical thermal power plants in India. Keihin Operations, Toshiba’s power equipment production facility in Yokohama, Japan, will support Toshiba JSW in ramping up manufacturing, and in working toward establishing an independent production scale of 3,000 MW a year by 2014.

Toshiba JSW anticipates sales in the region of US$400 million by the end of fiscal year 2015. The Government of Tamil Nadu is extending support to the company and is promoting infrastructure development that includes power and water supply, and strengthening roads and bridges between the plant and the port of Ennore.

Itaru Ishibashi, MD of Toshiba JSW Turbine and Generator, said: “Toshiba JSW will manufacture products essential for future thermal power plants, and by doing so will contribute to the development of India’s power systems industry. The support we have received from the government and local community gives me every confidence for the long term success of Toshiba JSW once it starts operation in January 2011.”

Driven by strong economic growth, the Indian power generation equipment market is expected to see demand growth of more than 16,000 MW a year for the next decade, according to the Eleventh (2007-2012) and Twelfth (2012-2017) Five-Year National Electricity Plans published by the Indian government. Coal-fired thermal power stations will account for over 60 percent of the capacity growth, far surpassing other energy sources.

tungaloy turning ad.indd 1 10/02/02 18:28





Tungaloy Singapore Pte. Ltd.50 Kallang Avenue, #06-03Singapore 339505Tel: (65) 6391 1833 • Fax: (65) 6299 4557www.tungaloy.co.jp/tspl/

Tungaloy Malaysia Sdn Bhd (876763-H)50 K-2, Kelana Mall, Jalan SS6/14Kelana Jaya 47301 Petaling Jaya, MalaysiaTel: +603-7805 3222 • Fax: + 603-7804 8563www.tungaloy.co.jpENQUIRY NO 047



Sakhalin-1 Project Continues Drilling

Texas, USA: ExxonMobil have completed the first two extended-reach wells at the Odoptu field offshore eastern Russia, employing one of the world’s most powerful land-based rigs. ExxonMobil subsidiary Exxon Neftegas Limited (ENL) is operator on behalf of the five-company international Sakhalin-1 consortium.

The Yastreb rig, which is located onshore Sakhalin, drilled horizontally under the Sea of Okhotsk to a target area in the Odoptu oil reservoir over 9 km offshore. The extended-reach wells are the first two of seven, which will tap the reservoir at Odoptu. The field is anticipated to begin producing oil in the second half of 2010.

The continued application of the company’s Fast Drill technology has resulted in record performance at Odoptu, paving the way for lower development costs. Additional ongoing activities at Odoptu include the construction of a new onshore oil and gas treatment facility and flowline to the existing Chayvo onshore processing facility.

The Sakhalin-1 Project includes the phased

development of the Chayvo, Odoptu and Arkuntun-Dagi fields, with an estimated total resource of 2.3 billion barrels (307 million tonnes) of oil and 17 trillion cubic feet (485 billion cubic metres) of natural gas. The Chayvo field, which was the initial phase of the Sakhalin-1 Project, began production in 2006.

Since startup, the project has produced over 240 million barrels (32 million tonnes) of oil for export to world markets. It also has been a key supplier of nearly 180 billion cubic feet (over 5 billion cubic metres) of associated natural gas to customers in Khabarovsk Krai, in far eastern Russia, to heat homes and meet growing energy needs.

The project will continue to help meet future natural gas demand in this region. Since the start of the project, the Russian State has received US$2.6 billion in royalties and its share of oil and gas, and the Sakhalin Oblast has received nearly US$650 million in production bonuses.

Zug, Switzerland: Foster Wheeler’s subsidiary of its Global Engineering and Construction Group has been awarded a contract to provide project management consultancy services to Singapore LNG Corp ( SLNG ), a fully owned subsidiary of the Energy Market Authority of Singapore, in support of the development of the LNG terminal to be located on the southwestern part of Jurong Island, Singapore.

SLNG owns and oversees the LNG terminal’s

Foster Wheeler Awarded Contract For LNG Terminal development. The terminal, which will have an initial capacity of 3.5 million tonnes per annum (Mtpa), with provisions for expansion to 6 Mtpa, is targeted to be ready for start-up in 2013.

The company and Foster Wheeler will jointly manage the engineering, procurement and construction contractor through an ‘Integrated Project Management Team’ approach, which will allow SLNG to be fully involved in the management of the design and construction activities.

Businessnews

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Businessnews

SHI To Make Only Eco-Friendly Ships

Seoul, South Korea: Samsung Heavy Industries (SHI) declared its green management policies at a ceremony that was joined by more than 120 guests. The company unveiled its plan to build only eco-friendly ships from 2015, by achieving a 30 percent reduction in greenhouse gas emissions.

The announcement makes SHI the first shipbuilder in the global shipbuilding industry to declare a green management policy that includes a detailed vision for the development of eco-friendly products and the reduction of greenhouse gas emissions.

In relation to its green management plan, the company announced three key strategies, which include the development of eco-friendly ships with up to 30 percent less greenhouse gas emissions, the development of green workplaces and green networks,

and the development of zero-energy houses. As the first step of its journey, the company aims

by 2015 to design the optimal shape of ships that will maximise fuel efficiency, and to develop diverse technologies to improve energy efficiency, including heat recovery devices and low-temperature combustion devices, in order to reduce the greenhouse emissions of its ships.

The greenhouse gas reduction achieved by building a single ship in this manner is the equivalent to the gases absorbed by 12 million pine trees in a year. In other words, building a single eco-friendly ship is like planting 12 million pine trees in the sea.

Experts predict that companies that enter the green technology shipbuilding market early will lead the shipbuilding and marine transportation industries in the future, as ships account for 3.3 percent of CO2 emissions worldwide, and IMO is introducing standards for the reduction of the greenhouse gas emissions of ships.

The company also announced that it has organised a green management committee, chaired by its CEO. It aims to develop eco-friendly ships and introduce green management policies to its shipyards and partner firms.

In detail, the company aims to make the Geojeo Shipyard a green workplace by developing eco-friendly shipbuilding facilities, using eco-friendly paints and saving energy, while building a green network by providing technical support to its partners to reduce greenhouse gas emissions, and by introducing a certification system.

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Mori Seiki Wins Product AwardNagoya, Japan: The NT1000 integrated mill turn centre received one of the 2009 (52nd) Best 10 New Products Awards sponsored by Nikkan Kogyo Shimbun. The company won this prize for the fourth time in a row, following the success of the Dura Series in 2006, the NZ Series in 2007 and the NT6600 DCG in 2008.

In recent years, the demand for high-precision machining of complex-shaped workpieces has been growing in the field of small precision parts manufacturing, such as medical equipment, watches and measuring instruments.

In response to such demand, the company has developed the mill turn centre. The machine features a workpiece discharge unit that is capable of transferring a workpiece, and achieves complete machining from bar or slug stock to finished parts.

Resilience Shown By Automotive Industry In IndiaIndia: The Indian automobile industry is thriving despite recession. A research report, ‘Indian Automobile Sector Analysis’ by RNCOS, a market research firm, has highlighted that the automobile production continued to move upward even in tough business conditions and registered close to 3 percent year-on-year growth in FY 2009 when the automobile industries of other countries were heavily battered by economic slowdown.

The passenger vehicle market constitutes nearly 80 percent of automobile sales, and holds tremendous growth potential considering the fact that passenger car stock stood at just 11 per 1,000 people in 2008.

Strong domestic demand and exports of auto components infused 16.6 percent CAGR production growth (in value terms) in the country and are well poised to sustain their phenomenal growth track in coming years.


17March 2010 metalworking equipment news

Businessnews

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Tata Steel & Nippon Steel In Joint Venture Mumbai, India: Tata Steel Board approved a framework for a Joint Venture (JV) between Tata Steel Limited (TSL) and Nippon Steel Corp (NSC) for the production and sales of automotive cold-rolled flat products at Jamshedpur, India. This is to address the localisation needs of Indian automotive customers for high-grade cold-rolled steel sheet and contribute to further expansion of the Indian automobile industry.

TSL will hold 51 percent and NSC will hold 49 percent of equity capital of the JV company. The JV aims to capture the growing demand for high-grade automotive cold-rolled flat products in India by setting up a continuous annealing and processing line with a capacity of 600,000 tonnes. NSC will transfer its technology for producing high-grade cold-rolled steel sheet for automotive application, including skin panels and high tensile steels.

In addition to this, both companies will continuously discuss further collaboration in other fields such as automotive CGL or up-stream processes.

Greenkote Coating Process Chosen By DaimlerOhio, USA: Greenkote, a coating technology company, will provide corrosion protection for selected Daimler automotive parts beginning the first half of 2010. Initial orders include components for passenger safety related applications. Additionally, the automotive industry giant is finalising technical approval of the company as one of its suppliers of zinc diffusion coatings, using the company’s thermo-diffusion coating process.

The decision by Daimler to use Greenkote zinc thermal diffusion coating protection comes after nearly two years of testing zinc diffusion systems and topcoat on its products, especially those most sensitive to corrosion.

The extensive testing involved mostly small screws, with more than 10 potential products identified to undergo the duplex coating process. Other small parts include fasteners, fixtures, screws, nuts and some critical wiper parts on several of Daimler’s automotive platforms including Limousine E-Class and S-Class vehicles.

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Businessnews

Endress+Hauser Expands Production In India

Reinach, Switzerland: Endress+Hauser inaugurated production facilities for flow measurement, level and pressure measurement engineering equipment in India. The company has invested a total of €19 million (US$25 million) in land, buildings and machinery at the Aurangabad site.

The €6 million premises are divided into three buildings, with a total of 5,000 sq m of floor space for the production of level and pressure measurement instruments as well as logistics and administration.

“Our new production facilities enable us to serve our customers in India and throughout the whole of East Asia even faster, better and more flexibly,” declared Matthias Altendorf, MD of Endress+Hauser in Maulburg, Germany. “In this way we can safeguard our future growth, learn faster from the markets we supply and at the same time strengthen the position of our Maulburg plant.”

Immediately next door, Endress+Hauser Flowtec has invested €13 million euros in the extension of their production facilities for flow measurement engineering.

The production facilities, built in 1999, have been expanded by 11,400 sq m and now cover a total of 14,500 sq m. “In the past few years the Indian market has grown at a rapid pace,” said Dr Gerhard Jost, MD of Endress+Hauser Flowtec in Reinach, Switzerland. “With the expanded capacity, we are now equipped to meet future developments. In addition, our plant houses the precise flowmeter calibration facility in India – calibrations are a central feature of our customer services.”

In addition to the Indian market, Aurangabad also directly supplies the markets of Australia, South Africa, Singapore, Malaysia, Thailand and Japan. Expansion into other countries in the Southeast Asian region and the Middle East is planned for the future.

Husky Energy Announces Third Discovery In South China SeaCalgary, Canada: Husky Oil China, a wholly owned subsidiary of Husky Energy, has made its third gas discovery on Block 29/26 in the South China Sea.

The Liuhua 29-1 exploration well was drilled 43 km northeast of the Liwan 3-1 gas field and 20 km northeast of the LH 34-2 gas field in a water depth of 723 m. The well encountered a gross gas column of 145 m, with a significant thickness of high quality gas charged reservoir, and an oil zone was encountered in a deeper reservoir. The well tested natural gas at an equipment restricted rate of 57 million cubic feet (mmcf) per day, with indications that the future deliverability of the well could exceed 90 mmcf per day.

The front end engineering design for the Liwan 3-1 deepwater project has been completed. Husky expects the plan of development for the project to be submitted to the regulatory authorities in early 2010. The company anticipates the Liwan 3-1 field and the Liuhua 34-2 field are to be developed in parallel with first gas production from both fields targeted to be in the 2013 timeframe. The new Liuhua 29-1 field, which will be appraised later this year, will utilise the Liwan field infrastructure.

The West Hercules deepwater drilling rig is currently preparing to spud the first delineation well on the Liuhua 34-2 discovery.

ENQUIRY NO 037



AEROSPACEBusinessnews

Bombardier Aerospace Delivers 302 Aircraft In FY 2009/10

Montréal, Canada: Bombardier Aerospace delivered 302 aircraft for the fiscal year ending January 31, 2010, compared to 349 aircraft deliveries in the previous fiscal year 2008/09 (year ending January 31, 2009). It received 11 aircraft orders, net of cancellations, compared to 367 orders, net of cancellations, for the previous fiscal year. With the aviation industry continuing to struggle in the current difficult economic environment, the company’s performance was solid.

“The global economic crisis which began in 2008 continued to impact the civil aviation industry throughout 2009 as conditions remained challenging,” said Guy C Hachey, president and chief operating officer, Bombardier Aerospace.

“While indicators of market stabilisation have started to emerge, we remain cautious as economic uncertainty still prevails. We have taken steps to strengthen our operations and continue to invest in future programs. We believe that by creating a loyal customer base for our products and services, we will emerge from this crisis a stronger and more efficient company,” he added.

Business Aircraft In fiscal year 2009/10, the company delivered 176

Singapore: Singapore Polytechnic (SP) and Pratt & Whitney have signed a three-year Memorandum of Understanding (MOU). Under the MOU, SP’s students will have the opportunity to embark on their overseas industrial training programme at Pratt & Whitney’s customer training centre in Beijing, China.

Over a six-week period, the students will gain relevant exposure and training in aviation at Pratt & Whitney. They will receive the same training, both

SP’s Students Take Flight With Pratt & Whitney

business jets, compared to 235 for the same period last fiscal year, in line with the 25 percent decrease in business aircraft delivery guidance provided in 2009.

Business aircraft deliveries for the current fiscal year 2010/11 are expected to be approximately 15 percent less than fiscal year 2009/10.

Commercial Aircraft In fiscal year 2009/10, the company delivered 121 commercial aircraft, compared to 110 for the previous fiscal year. This is in line with the 10 percent increase in commercial aircraft delivery guidance provided last year.

The company expects that most of the deliveries of its commercial aircraft will take place in the last three quarters of the current fiscal year 2010/11 as a result of the production rate reductions announced in 2009 and the delay in the certification and entry into service of the CRJ1000 aircraft to the second half of fiscal year 2011. Compared to the previous fiscal year, the corporation expects to deliver approximately 20 percent fewer commercial aircraft in fiscal year 2010/11.

Note: All fiscal year 2009/10 delivery and order numbers are unaudited.

instructional and practical, as aircraft maintenance engineers under this program.

The company’s customer training centre in Beijing is a joint venture company partnered with China Aviation Supply Holding Company. Opened in 2002 and serving more than 400 students annually, this training centre offers a wide range of aerospace courses and hands-on training opportunities for aviation professionals in the Asia-Pacific region.

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ENQUIRY NO 046



AEROSPACE

Toulouse, France: Airlines in Asia and the Pacific will acquire some 8,000 new passenger and cargo aircraft over the next 20 years, according to European aircraft manufacturer Airbus. Valued at US$1.2 trillion, the requirement represents one third of predicted global deliveries between now and 2028, with the region driving demand for larger aircraft types.

In the passenger market the manufacturer predicts that traffic in the region will grow at an average annual rate of 5.9 percent, while cargo traffic will increase by 6.3 percent per year. This compares with a global average of 4.7 percent for passenger traffic and 5.2 percent for air freight. As a result of this growth and continuous fleet replacement, the region is expected to take delivery of some 880 very large aircraft, 2,570 twin aisle widebodies and 4,560 single aisle aircraft.

The high proportion of larger aircraft types reflects the concentration of populations around main urban centres in the region, generating high density traffic on key intra-regional routes, as well as to capacity constrained international destinations in Europe and North America. Meanwhile, demand for single aisle aircraft in the region is expected to accelerate in the coming years, driven by the growth of low cost carriers and opening of new routes between secondary destinations, especially in China, India and South East Asia.

In the cargo sector, the region will continue to dominate the global air freight market, with the dedicated freighter fleet operated by Asia-Pacific airlines

Asia-Pacific Airlines To Buy 8,000 Aircraft Over Next 20 Years

growing five times to 1,500 aircrafts. While many of these will be converted from passenger models, Airbus predicts that around 340 new production freighters will be delivered to the region over the 20-year period. These will be predominantly widebody aircraft and will represent 40 percent of expected global demand for new production freighters.

Presenting the details, John Leahy, Airbus chief operating officer, Customers said that within 20 years the region would overtake the US and Europe as the world’s largest air transport market, with Asia-Pacific airlines carrying over 30 percent of global passenger traffic and around 40 percent of all air freight.

“To meet this demand larger aircraft will be needed to ease congestion and do more with less,” he said. “This will see airlines from the region account for over 40 percent of twin aisle deliveries and more than 50 percent of the demand for very large aircraft, such as the A380.”

Service Centre For Triumph Actuation SystemsSingapore: ST Aerospace’s subsidiary, ST Aerospace Systems, has been appointed by Triumph Actuation Systems as an authorised service centre for the repair and overhaul of power transfer units installed on A320 aircraft. This agreement is for three years, with an option for renewal for an additional three years.

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Businessnews


23March 2010 metalworking equipment news

World crude steel production22 January 2010

Summary Table

million metric tons 2003 2004 2005 2006 2007 2008 2009%2009/2008

Europe 320.3 339.8 333.8 355.1 364.5 344.1 265.8 -22.8of which:EU (27) 192.5 202.5 195.6 207.0 209.7 198.0 139.1 -29.7EU (15) 161.0 169.1 165.1 173.2 175.2 167.7 117.7 -29.8CIS 106.5 113.4 113.2 119.9 124.2 114.3 97.5 -14.7

North America 126.2 134.0 127.6 131.8 132.6 124.5 82.3 -33.9of which:United States 93.7 99.7 94.9 98.6 98.1 91.4 58.1 -36.4

South America 43.0 45.9 45.3 45.3 48.2 47.4 37.8 -20.1

Africa 16.3 16.7 18.0 18.8 18.8 17.1 15.2 -11.0

Middle East 13.4 14.3 15.3 15.4 16.5 16.6 17.2 3.3

Asia 442.3 512.5 595.5 672.3 756.5 768.3 795.4 3.5of which:China 222.3 282.9 353.2 419.1 489.3 500.3 567.8 13.5Japan 110.5 112.7 112.5 116.2 120.2 118.7 87.5 -26.3

Australia/New Zealand 8.4 8.3 8.6 8.7 8.8 8.4 6.0 -28.6

World 969.9 1 071.5 1 144.1 1 247.3 1 345.8 1 326.5 1 219.7 -8.0

World Crude Steel Output Decreases By -8.0 Percent In 2009Brussels, Belgium: World crude steel production reached 1,220 million metric tonnes for the year of 2009. This is a decrease of -8.0 percent compared to 2008.

Steel production declined in nearly all the major steel producing countries and regions including the EU, North America, South America and the CIS in 2009. However, Asia, in particular China and India, and the Middle East showed positive growth in 2009.

In December 2009, world crude steel output for the 66 countries reporting the World Steel Association (worldsteel) was 106.4 mmt, an increase of 30.2 percent compared to December 2008. Most major-steel producing countries showed two-digit growth in December 2009.

The world crude steel capacity utilisation ratio of the 66 countries in December 2009 was 71.5 percent, a decrease from 74.7 percent in November 2009. Compared to 2008, the utilisation ratio in December 2009 increased by 13.4 percentage points.

China’s crude steel production in 2009 reached 567.8 mmt, an increase of 13.5 percent on 2008. This is a record annual crude steel production figure for a single country. China’s share of world steel production

continued to grow in 2009 producing 47 percent of world total crude steel, an increase of nine percentage points compared to 2008.

Asia produced 795.4 mmt of crude steel in 2009, an increase of 3.5 percent compared to 2008. Its share of world steel production increased to 65 percent in 2009 from 58 percent in 2008. Japan produced 87.5 mmt in 2008, a decrease of -26.3 percent on 2008. India’s crude steel production was 56.6 mmt in 2009, 2.8 percent growth on 2008. South Korea showed a decrease of -9.4 percent, producing 48.6 mmt in 2009.

The EU-27 where all major steel producing countries including Germany, Italy and France showed substantial decline recorded a decrease of -29.7 percent compared to 2008, producing 139.1 mmt of crude steel in 2009.

In 2009, crude steel production in North America was 82.3 mmt, a decrease of -33.9 percent on 2008. The US produced 58.1 mmt of crude steel, 36.4 percent lower than 2008.

The CIS showed a decrease of -14.7 percent in 2009. Russia produced 59.9 mmt of crude steel, a -12.5 percent reduction on 2008 while Ukraine recorded a decrease of -20.2 percent with year-end figures of 29.8 mmt.

2009/2008

World Crude Steel Production

Businessstatistics

Australia/New Zealand



The essence of High Speed Machining (HSM) is to apply higher spindle speeds and feeds to

achieve machining results. Very thin walls, very smooth surfaces and high metal removal rates are only a few examples of the performance that can be achieved with applying HSM.

This strategy can be applied not only to nonferrous materials and more precisely, aluminium, but even to hardened steel and exotic materials; making it applicable for industries such as the aerospace, die/mould, miniature and medical.

Even though high-speed cutting has been known for a long time (the first attempts were made in the early 1920’s), there is still large ambiguity concerning its definition. It was Carl Salomon in 1931 who proposed the first definition of HSM, defining it as a certain cutting speed which is 5 to 10 times higher than that used in conventional machining.

High Speed ZoneProcess that requires fast metal removal, (in many cases automotive components, small computer parts or medical devices made from aluminium) calls for HSM. For the wings or aircraft fuselage, the aerospace industry also requires machining long aluminium parts which often have thin walls, relying heavily on HSM, applying cutting speeds as high as 15,000 - 50,000 rpm coupled with high feeds.

The die and mould industry is another area for HSM milling, demanding tight tolerances, high accuracy and strict surface finish conditions on hard and soft materials, as well as electrodes made from graphite and copper for the Electrical Discharge Machine (EDM) industry.

High speed cutting also makes it practical to use small tools and light depths of cuts in the machining of dies and moulds, so slots and intricate details can be

Productivity Higher

High Speed Machining is not just a technology for shortening the production time and increasing the accuracy of machined parts, but a tangible strategy for increasing productivity. By Dr Moshe Goldberg, marketing technical advisor, Iscar

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March 2010 metalworking equipment news


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produced with milling instead of EDM. Moreover, the inherently smooth finish achieved from this technique makes it possible to eliminate manual polishing.

Such applications require not only speed but also a stable process that can accommodate it. That process involves tooling, control and programming considerations that are completely different from the demands of conventional cutting. In some cases the process requires the understanding of the machine’s behaviour at different speeds.

Think Before You SpeedC o n c e r n i n g t h e m a c h i n e specifications, achieving high speed machining performance in a variety of applications requires a machine design that harmonises all of the machine’s components i n to a we l l - p rop o r t io n e d system. This requires taking

Process that requires fast metal removal calls for HSM

into consideration important mechanical design elements, such as:

Cutting Tool MaterialsThe grades and parameters of cutting tools play a significant role in the process. Iscar developed the IC903 grade, a carbide grain with 12 percent cobalt, TiAlN PVD coated with wear resistance and toughness for HSM of hardened steel (up to 62 HRc), titanium, nickel-based alloys and stainless steel. These tools exhibit toughness properties for sustaining impact at high frequency, as well as defeating heat and thermal expansion.

Toolholder – The Unbalancing ProblemTo ol sub - s y s te m s t h a t determine efficiency of HSM are:

spindles, axes, motor drivers, toolholders and cutting tools. The spindle is probably the most critical element, so in order to maintain maximum productivity and accuracy it is important to ensure runout as small as possible. The smaller the runout, the shorter the time between the necessity to replacement of endmill cutters or index inserts.

Especially in HSM applications the size of runout is crucial for accuracy. The Total Indicator Readout (TIR) should be maximum 10 microns at the cutting edge. Every 10 microns in added runout gives a 50 percent reduction of tool life. Even if the tool, toolholder and spindle are precisely balanced, there still can be several sources of instability.

One of the sources of instability is the fit between toolholder and spindle interface, where there is often a measurable amount of clearance. Moreover, this gap can also be attributed to clogged chip or residue of dirt inside the taper. In practice, an endmill running at 20,000 rpm may not need to be balanced to any better than 20 g x mm.

Other parameters, which need to be considered for ensuring precision of HSM are spindle construction, thermal stability, movement guides, hardware, centrifugal expansion, thermal expansion and vibration.

Regarding vibration, it can result from interaction between the tool and workpiece, resulting in ‘chatter’; or from the centrifugal force that acts on an unbalanced mass in the tool and toolholder assembly.

Control l ing v ibrat ion is essential not only for the accuracy and productivity of the process, but also for the length of service of the spindle and the tool. Vibration also gives rise to poor surface finish, cutting edge damage, and irritating noise.



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Improving Productivity The shape and accuracy of a produced part is essentially determined by the kinematic machine tool behavior and the static, dynamic and thermal stiffness of the machine tool system. Moreover, the surface quality that needs to be achieved depends on the geometry of the cutting edge, machining parameters and the dynamic behavior of the system. This implies that a mechanically sound unit will provide the best return over time in HSM.

Productivity can be improved by using linear motors for axis motion in place of rotary motors and ball screws. A linear motor does away with much of the axis reversal error, or backlash, inherent in systems that make use of rotary motors or ball screws.

Making the most of the evolving technology of HSM is a manageable affair. It also involves harmonising other key aspects of shop floor operations in order to fully capitalise on the increase in machining productivity.

Conclusion & BenefitsStiff competition in the market calls for rapid development of machining technology and the design of new solutions. HSM is a prime example how high metal removal rates can boost productivity and at the same time cut down on production costs.

In spite of high requirements of machining tools, this technique gives numerous benefits. It allows the shortening of production time and eliminates some treatment (such as manual finishing), while simultaneously retaining accuracy. Even though this technique has been known for a long time, the research is still being developed for further improvement of quality and minimisation of costs.

Enquiry No. 2001

HSM is a prime example how high metal removal rates can boost productivity and at the same time cut down on production costs

Theoretical and experimental ana lyses have shown that increased local stability occurs when the tooth passing frequency of the cutter is equal to the natural frequency of the most flexible system. Selection of the maximum available spindle speed that corresponds to these stable tooth passing frequencies is also referred to as HSM.

T h i s c once pt re l i e s on regeneration of waviness as a primary cause of instability (self-excited vibrations) in machining. This waviness regeneration occurs

when a cutter tooth encounters an undulating surface left by the previous tooth.

The prediction of system stability depends on the phase r e l a t i o n s h i p b e t we e n t h e displacement of the current cutter tooth and the waviness it encounters. For certain phase relationships, the succeeding tool vibrations diminish, while for others they increase until either failure or a system non-linearity limits the motion. MEN

Enquiry No. 2002

HSM: Concepts & Definitions

M YC K

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ENQUIRY NO 089



Two cuts showing stable and chatter machining conditions

Speed LimitHSM?In

Is There A

To reap the benefits of significant investments in high-speed machine tools and accessories, NC programmers need to optimise and reach the safe limits of the system. By Edwin Gasparraj, senior product manager, CAM product development, Siemens PLM

One of the major challenges an NC programmer faces everyday is identifying cr i t ica l mach in ing

parameters, such as depth of cut, step over, spindle speed and feed rate. Traditionally, the starting point for this data has been either a machining data handbook or the experience of senior machinists on the floor.

In a majority of cases, this data is very conservative and/or outdated. When problems arise, the usual recourse is to reduce one or more critical machining parameters. These remedies invariably reduce the Metal Removal Rate (MRR). While this may have been acceptable in the past, today’s highly competitive die/mould machining market is forcing users to push the limits of productivity.

The widespread application of high-speed machines in the past several years necessitates a fresh look at how things are done on the shop floor. Simply increasing the spindle speed and feed and decreasing the chip-load significantly do not constitute high speed machining.

Making The CutUnstable machining results in poor and wavy surface finishes that many people associate with the pinging noise of chatter. A new methodology leverages these simple characteristics to identify optimum spindle speeds and cutter loads for any given tool, holder, machine and workpiece material combination. In

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Figure 1: Z level cuts on a test piece – each pass is performed at increasing spindle speed and feed, maintaining the same chip load for all passes

essence, this method cuts a number of Z level passes at varying spindle speeds to identify stable machining conditions.

A series of identical passes are made on an inclined face of a test block, as in Figure 1. Each pass is performed at increasing spindle speed and feed, maintaining the same chip load for all passes. Listening to cuts and inspecting the surface finish of each pass can identify stable-cutting conditions.

Trials & TribulationsA newly proposed alternative was put into practice on a Makino V33. In this instance, a 10 mm diameter Jabro Tornado ball end mill was analysed. The length of the tool was set at 30 mm on an HSK holder. A P20 workpiece measuring 82 mm in length, 65 mm in width and 48 mm in height was used as a test piece. A 30-deg taper was cut on one side of the block to accommodate the holder and to view each cut distinctly.

For this example, assume a depth of cut equal to approximately 30 percent of the tool diameter. If there are other considerations limiting the load on the tool, follow the lesser one. Make sure the tool creates clear cusps to distinguish one depth from another.

The height of the block should accommodate at least 12 depths of cut. Slope on the cutting side should clear the tool holder. Length of the block should be sufficient to hang off the vise to allow at least 10 side passes. The width should be sufficient to be able to see the cuts.

The tool manufacturer provides two very important pieces of information – the maximum cutting speed and the chip load. The maximum cutting speed depends on the type of coating on the tool and the maximum temperature it can safely withstand. Chip load (feed/tooth) is based on the material and the geometry of the tool tip.

Take for example, a maximum cutting speed of 280 mm/min and the chip load of 0.072 mm/teeth. This example assumed side rough milling conditions for the trial. In order not to violate the maximum cutting speed, you need to stay below 9,000 rpm.

Maximum RPM = (Max Cutting Speed in mm/min) ( ∏ x Tool Diameter)

Maximum RPM = (280 x 103) ( ∏ x 10)

= 8,912 ≈ 9,000

For these trials, the spindle speed was varied from 6,000 to 11,500 at intervals of 500 rpm. The maximum rpm was increased to keep the results applicable to finishing conditions as well. The depth of cut for each Z level cut was 4 mm. The program was manually edited to reflect the changing spindle speed at each cut level.

The feed was correspondingly

Figure 2:Stable and unstable machining conditions – notice that the third and eighth steps indicate clean cuts at 7,000 rpm and 9,500 rpm

adjusted to maintain constant feed/teeth throughout the trial.

Feed mm/min = Feed per Teeth x Number of Teeth x RPM

Crunching Number Cutting MetalAn initial cut with a 0.5 mm side stepover was cut on the slope. The side stepover was adjusted on the X offset register of the machine. This eliminates the need for a new program for each cycle.

The initial cut with 0.5mm stepover was repeated once again to allow similar starting conditions for each cycle. This cut produced stable cutting conditions throughout the slope. (Some of the cuts were dull at the bottom of the cusp due to decreased cutting speed.)

The stepover was increased to 1 mm and the cycle was repeated. Even though the stability lobe diagram predicts stable-machining conditions at all spindle speeds, very low chatter signals were noticed at both extremes of the spindle speed.

This process was repeated with increasing stepover values until severe chatter signals were noticed at 2 mm. This cycle clearly showed stable cutting at 7,000 rpm and 9,500 rpm.

The stepover was progressively increased all the way to 3 mm. The cuts at 7,000 and 9,500 rpm remained stable.



firstcut

In many cases, when chatter is encountered, machinists tend to reduce spindle speed to eliminate chatter. While this technique will result in a stable cutting condition, it may not be the most efficient.

Instead, it is often possible to increase the spindle speed, which will eliminate chatter, while also improving cutting efficiency.

In diagram A, slight chatter is encountered at Point A (8,000 rpm

with 2.0 mm side step over). Outside of re-programming the

part with a smaller step over, there are two easy options to remedy the chatter, either decrease or increase the spindle speed. Because the lobe diagram clearly illustrates that a stable cutting condition can be achieved by increasing the spindle speed, this is best option because it is more efficient.

Often times, when using high-speed machines, the inclination is to run the machine at its top permissible speed. While chatter free conditions can be achieved at extreme speeds, the machining efficiency as measured by the MRR can be quite low.

Material Removal Rate = Feed rate mm/min x Depth of Cut mm x Side Step Over mm

In diagram B, stable cutting is achieved at 11,500 rpm with

0.5mm side step over (Point A). Because the spindle is running at a high rpm, it is quite common to assume that the system is performing efficiently. However, as illustrated in the lobe diagram, this is not the case.

Point B, a much slower rpm but with a greater depth of cut results in nearly six times greater machining efficiency.

Enquiry No. 2003

Dispelling The MythsFact or fallacy, true or false, let the numbers to the talking.

• Fol low practical, repeatable conditions (for example, tighten the collet-holder with the same torque every time). This needs to be repeated for every tool/holder/machine combination. While this sounds like a lot, it can easily pay off.

• The sweet spots are transferable to other workpiece materials directly. The corresponding maximum depth of cut and stepover values will vary.

• You could replace the tool with a similar replacement tool from the same manufacturer. The results are still valid. It is true for holders as well.

• Reset the tool length as close as possible to the testing conditions.

• You could increase the depth of cut while decreasing the stepover correspondingly and vice-versa.

• Do not use this data on thin walled parts since the natural frequency of the part being machined changes during the machining process.

Useful Tips In Machining

Results & AnalysisThe part in Figure 2 shows stable and unstable machining conditions. This indicates a 4 mm depth of cut and 3 mm side step. Notice that the third and eighth steps indicate clean cuts at 7,000 rpm and 9,500 rpm.

The stability lobe diagram is a useful tool for identifying stable cutting conditions at varying spindle speeds and MRRs. The diagram can be used to find the maximum allowable MRR, a key performance indicator for machining efficiency, for a given spindle speed.

It is important to note that stable machining can be achieved at any RPM, but at the cost of MRR. A global view of the stability lobe diagram, either computed with chatter prediction hardware tools or by the method prescribed in this article, helps users achieve high MRRs at certain stable RPMs. MEN

Enquiry No. 2004

Reducing speed is the most efficient remedy for chatter WRONG

Machining at higher speeds is the most efficient WRONG

Spindle Speed

FeedRate

ChipLoad

DepthOf Cut

Side Step Over (mm)

(rpm) (mm/min) (mm/teeth) (mm) 0.5 1.0 1.5 2.0 2.5 3.0 3.5

6000 840 0.072 46500 910 0.072 47000 980 0.072 47500 1050 0.072 48000 1120 0.072 48500 1190 0.072 49000 1260 0.072 49500 1330 0.072 410000 1400 0.072 410500 1470 0.072 411000 1540 0.072 411500 1610 0.072 4

An increase in spindle speed results in stable cutting condition and improved machining efficiency

Option 1: Reduce spindle speed to 7,500 rpm. Chatter is eliminated, but machining efficiency is decreased

AOption 2: Increase spindle speed to 9,000 rpm. Chatter is eliminated, but machining efficiency is improvedDiagram A

Stable machin-ing at a slower rpm with a greater depth of cut is much more efficient than machining at a much higher rpm with a lighter depth of cut

Spindle Speed

FeedRate

ChipLoad

DepthOf Cut

Side Step Over (mm)

(rpm) (mm/min) (mm/teeth) (mm) 0.5 1.0 1.5 2.0 2.5 3.0 3.5

6000 840 0.072 46500 910 0.072 47000 980 0.072 47500 1050 0.072 48000 1120 0.072 48500 1190 0.072 49000 1260 0.072 49500 1330 0.072 410000 1400 0.072 410500 1470 0.072 411000 1540 0.072 411500 1610 0.072 4 A

B

Diagram B

Chatter-free machining at 9,500 rpm with 3.5mm side step over

MRR = 18,620mm^3/min

Chatter-free machining at 11,500 rpm with 0.5mm side step over

MRR = 3,220mm^3/min

Stable

Slight Chatter

Severe Chatter

Legend:

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ENQUIRY NO 042



technologyupdate

Safety is number one priority in any machine shops. While many are doing a very good job

in protecting the operators by deploying warning signs and demarcating plant walk-through paths, some subtle danger still remains, largely hidden to the naked eye.

Metalworking fluids (MWFs), the usage and disposal are important both from the operators’ health and environmental point of view. From the minute the MWF leaves the drum, while it is in use and finally to the time it is disposed of, proper handling procedures must be in place to protect operators from the fluid.

While the transportation and eventual disposal of the fluid arguably poses less risk or is deemed more controllable, it is the mist created during usage (machining process) that requires more attention, care and ultimately more protection.

Protection From The Mist MWF is widely used in metalworking processes such as turning, grinding and drilling. The purpose for using these fluids are mainly for cooling and lubricating although using different MWF may result in different

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Although regulations are in place to remove some harmful substances from metalworking fluids, it is still important for operators to exercise the same level of care normally reserved for operating drills and cutters. By Matthew English

HandleWith

Care

Metalworking Fluids:

performance and part quality. MWF is a mixture of petroleum products, animal and vegetable fats and some additives. Their usage is usually for properties enhancement.

During machining in particular, fine droplets or ‘mist’ of MWFs are developed. They are potential occupational health problems. Operators are usually the ones at risk as they are exposed to MWF either by inhalation or through skin contact, which can cause a variety of health problems like dermatitis and respiratory problems. Long-term exposure can even lead to cancer.

With health and safety in mind,

it is imperative to take steps to protect operators from harmful exposure. A way to mitigate risk posed by MWF mist or vapour is by installing appropriate filter and ventilation system.

Oil mist collectors are available in the market to aid the efficient removal of oil mist. Some collectors use centrifugal impaction method to collect the mist, removing them from the source. As a result, clean air is returned to the work place as clean oil is returned to the machine. These collectors are compact and can be mounted to the machine.



33

H Berends, Netherlands

The usage and disposal of metalworking fluids are important both from the operator health and environmental point of view

technologyupdate

Alternative ProtectionAnother way to get around the potential hazards of certain MWF is the usage of fluids that is claimed by the makers to be non-toxic, non-carcinogenic, readily biodegradable, safe to use, store and dispose. Those fluids do not contain petroleum fractions, sulphur, chlorine and heavy metals according to the manufacturers.

L a s t l y prote c t i n g t he hardware, ie: the machines, should also rank high on the list of priority. Though the importance of protecting operators cannot be ignored, protecting machines from MWF can also bring about practical savings in cost. One good example is rust. Prevention of rust should be one of the main concern as metal corrosion can cause products to be sold at a lower grade or rejected.

Using suitable MWF and coupling that by protecting operators and machines from potential harm from MWF can go a long way in ensuring not just a safe work place, but also savings in terms of cost.

Enquiry No. 2101

Play It SafeTo protect yourself from potential

hazards associated with metalworking

fluids, knowing more about it and taking

relevant precautions will keep you safer.

• Adopt the safety training given

by employer

• Follow all safety instructions

• Use splash guards

• Allow time delay before opening

the door to machine

• Report all damages to protective

equipment

• Reduce contact with wet surfaces

• Wear suitable PPE

• Avoid eating, drinking or smoking

in areas where metalworking

fluids are used.

World Demand For Lubricants To Exceed 40.5 Million Metric Tonnes In 2012World lubricant demand will increase 1.6 percent per year to 40.5 million metric

tonnes in 2012. Although growth will be modest in volume terms, value gains will be

more substantial as more expensive high performance lubricants are substituted

for lower value ones. Advances will be the strongest in the developing Asian

countries due to ongoing rapid industrialisation as well as rising car ownership

rates, particularly in China.

These trends will also favour growth in the Africa/Mideast region and Latin

America. In contrast, greater availability of high performance lubricants, increased

global competition and increasingly stringent environmental regulations will restrain

advances or contribute to negative growth in lubricant demand in the more developed

countries of Western Europe, the United States and Canada, as well as in the European

Union member countries of Eastern Europe and in Japan. These and other trends are

presented in World Lubricants, a study from the Freedonia Group, a Cleveland-based

industry research firm.

The more developed countries of North America and Western Europe, as well as

the European Union member countries in Eastern Europe and Japan, will experience

reduced or negative growth in lubricant demand due to greater availability of high

performance lubricants, increased global competition and increasingly stringent

environmental regulations.

Despite the downturn in the global motor vehicle market in late 2008 and early

2009, motor vehicle lubricant demand will continue to expand throughout the forecast

period once an economic recovery begins to take hold. Increases in lubricant demand

will be led by strong gains in the Asia/Pacific region due to rapid expansion of the

motor vehicle park in developing countries such as China and India.

While the fastest growth will be in manufacturing and other markets, it will still

represent a slowdown from the 2002 to 2007 time period as the global economic

slowdown of 2008 and 2009 restrains upward advances in lubricant demand through

2012. The Asia/Pacific region, led by China, will continue to be the primary driver

of growth in these markets due to companies worldwide pursuing the region’s key

advantages of relatively low labour costs and political stability. MEN

Enquiry No. 2102



Machine automation i s p a r t a n d parcel of modern m a n u f a c t u r i n g .

Under this big umbrella, there are various subsets like CNC programming, software, CNC controllers, servomotor and motion controllers.

CNC machines utilise digital electronic computers and circuitry to direct machine movements. They provides adaptable control over machine tools. This is highly desired as most machining operations demand that a cutting tool to be fed to a workpiece at considerable speed.

Another salient point is the mechanism used in these machines allows the automatic correction of a mechanism, by means of error-sensing feedback. This work is carried out by the servomotor systems in which the feedback and error-correction signals control mechanical position or velocity.

The face of the manufacturing industry was dramatically changed with the introduction of CNC machines. Human intervention has been reduced and complex machining operations were made easier. Though this technology has made manufacturing easier, the issue of consistency, especially with

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increasing demands brought by technological advancement, have placed the onus firmly on quality, or rather, how to achieve them repeatedly. In addition, it should be achieved with no strain on the operator.

Enter The SoftwareUpgrading existing machinery can just simply be buying the latest machines that are available in the market. While many may balked at the idea of splashing the cash at uncertain economic times, making use of CNC software programs and controls may be the answer. Incorporating software into machine tools is by no means

a breakthrough technology but the real question here is the type of CNC software programs available today. Pick the correct one which fits your operation and the benefits of CNC software can be seen.

The S iemens S inumer ik 802D solution line, an operating panel control, is said to make available all CNC components (NC, PLC, HMI) in one single unit. The maker claims that this control is suitable for turning and milling machines in the lower and medium performance range.

Solutions provided include ‘standard’ solution milling and ‘standard’ solution turning. In ‘standard’ milling, time-saving

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Though software programs bring about improved performance in machine tools, there are times when they themselves are in need of an upgrade

SoftwareMaximise YourTo

Hardware

Using

software&measurement

Given the current economic climate, working with available machineries and getting more out of them is a dream come true for many manufacturers. By Michael E Neumann



35

software&measurement

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The Ipsen for do-it-yourselfmetal heat treat- ments. If only every decision were this easy.

For more information,

call +49 2821 804-293, e-mail us at

[email protected] or www.ipsen.de

Hard work wins

Couldn’t I harden my high-cost components myself right here?

Would modern equipment fit in here?

Can we handle that without specialists?

Would that be expensive?

What would be the fastest solution?

Anzeige-Equipment-News.indd 1 05.02.10 15:16

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is possible through the DIN/ISO programming with graphic assistance through technological machining cycles according to Siemens. In addition, 2-D simulation with zoom and calculation of machining time makes the operation easier for users.

Keeping With The TimesThough software programs bring about improved performance in machine tools, there are times when they themselves are in need of an upgrade. Manufacturing solutions provider Cimatron has developed the CimatronE 9.0, which provides a machine simulator that verif ies the machining process. The simulator displays material removal within the machine environment for both 3-axis and 5-axis machines.

The program provides NC programmers with increased

machining efficiency, better surface quality and improved performance. Version 9.0 also includes a Product Manufacturing Information (PMI) display.

Programming functions allow a higher surface quality to be achieved. Finishing functions include features that improve accuracy and smoothness. Area left by the previous cutter can be machined using a ‘cleanup-all along’ function as it enables long uninterrupted tool passes. The version a lso includes enhancements to mainta in the sharpness of external and embedded edges.

Other enhancements include further adaption of the interface to work with STL free form files and improvements in high speed machining and micro milling capabilities. Enhancements for 5-axis tilting include new machining

strategies to speed up the calculation process.

Calculation times have been reduced in this version in most areas and performance of the software in general has improved, with full support of dual core and quad core processors.

T h e s o f t w a r e a l l o w s manufacturers to store PMI; annotations and notes are passed on through the different stages of the project from design to the shop floor. PMI is also transferable to and from other standard CAD systems.

CNC software programs have provided platforms for better operation and at the end of the day, improved quality. Incorporating software with existing machines may yet be the way to squeeze the extra performance out of machines in the shop floor. MEN

Enquiry No. 2201



www.equipment-news.comFab&Form

FutureRobotic Laser Welding Process:

Seeing itself as a ‘digital she e t fac tor y ’, t he Thailand based sheet metal fabrication company

Jinbao has six factories in its premises. They deal with sheet metal, stamping, hard tooling, CNC machining, painting and welding factory.

The economic crisis hit most companies over the world hard. As a result, most businesses are considering cutting budgets on capital investment during this time or putting everything on hold. The company is an exception although they were not spared from the downturn.

NowChanges in production strategies and adjustments to current manufacturing climate can often give rise to a major investment. By Ryu Tan, product manager, solid state laser technology, Trumpf

The Is



37

Fab&Form

Thailand based sheet metal fabrication company Jinbao has six factories in its premises

The Highs & Lows Of ManufacturingGenerally, in the manufacturing sector, there are two main production strategies – the high-mix, low-volume and the high-volume, low mix production.

H i g h vo lu m e , l ow m i x manufacturers win businesses based on primarily the cost and quality of these products. In contrast, high-mix, low volume manufacturers earn businesses based mainly on how quickly they can deliver exactly what their clients expect.

Says Victor Chung, MD, Jinbao: “After eight years of business involvement with our clients in these industries, we have found that production volumes have decreased, while the production variety has increased. Our clients increasingly want products tailored to their particular mass-customised markets. Therefore quite some time ago, we have shifted our production strategy to the high-mix, low-volume approach, which fits well to the current changing demands in the marketplace.”

Robotic Laser WeldingLaser welding technology and robot technology have both become established fixtures in industrial production technology. The combination unites the precision of high-performance laser technology on the one hand and the flexibility of the robot on the other. Modern

lasers are reliable, and are being utilised in material processing for all kinds of different applications.

With these advantages too attractive to ignore, the company invested in a Trumpf TruLaser Robot 5020. As Mr Chung explains, the company is very much looking into the future.

“The installation of the robot in our welding factory was an important step in this strategy (high-mix, low-volume). Our approach gives us the opportunity to react better to changes and it is one of the reasons why we haven’t been too badly hit in this economic turmoil. This decision is an investment in our future. When I’m talking about the future I’m thinking of the next five years, not only the next few months,” he says.

Another aspect that led the company to using a more high-end machine is the issue of workforce. In fast developing countries like Thailand, costs are rising and that demand new strategic decisions.

R o b o t s s o l v e co m p l e x movement and positioning tasks in all degrees of freedom, and are flexible in their motion sequences. Both the laser and robot enable simultaneous exploitation of the flexibility of the robot and easy integration of high power solid-state laser, while at the same time

offering low cost, easy access to laser material processing.

Light-Years AheadThe laser units used in the system can be pulsed, disk or continuously emitting either solid-state or disk lasers, with outputs from 40 W to over 16,000 W. A constant focal diameter across the entire performance range guarantees constant quality processing. One major benefit here is the fact that the laser beam is guided along a flexible laser light cable, enabling it to be applied with precision.

In laser welding, narrow yet deep weld geometries assure that distortion and the need for subsequent straightening is reduced to a minimum or even entirely eliminated. With the welding depth easy to verify, visible backwelds on the underside are prevented.

The use of high-power lasers in industrial production has been steadily increasing for a number of years, especially in subcontractor, sheet metal, aerospace and automotive industries, where more than 10,000 cars are welded per day.

YAG laser welding technology allows designers to expand the types of joints, materials and plating options for their products. Applying laser welding

Victor Chung: “We have shifted our production strategy to the high-mix, low-volume approach, which fits well to the current changing demands in the marketplace.”



Fab&Form

A u t o m o t i v e m a n u f a c t u r e r s a r e c u r r e n t l y f a c i n g a multitude of challenges. On the one hand, they have to comply with the legal requirements for the CO2 emissions of the cars they produce. On the other hand, customers are demanding more and more from their cars.

In order to face these challenges, automotive manufacturers have to adapt their production accordingly and become more flexible. “Traditional production methods that

u s e p ress

b r a k e s to p r o d u c e

d e e p - d r a w n par ts are becoming

less and less suitable for this purpose,” says Klaus Löffler, specialist in automotive production technology, Trumpf.

One way to make production workf lows more flexible and meet c u s to m e r a n d l e g a l requirements is to use un iversa l product ion e q u i p m e n t s u c h a s sheet metal processing machines. Components are produced by f irst cutting the blanks in the laser cutting machine, then forming them in the bending machine and,

finally, welding them using the laser systems.

“ O v e r a l l , t h e automotive manufacturer can reduce component c o s t s u s i n g t h i s concept compared to conventional methods,” says Mr Löffler.

Saving Time & Cost With LaserJust-in-time production u s e d w h e r e t h e components are needed eliminates logistics costs because transport and storage are no longer n e e d e d . S i n c e t h e automotive manufacturer works wi th universa l sheet metal processing tools, it can upgrade the entire production system to the new series faster when replacing models; sometimes only changes in the machine software are needed.

The use of lasers, which are key to this p ro du c t i o n m e th o d , considerably lowers the costs per component. “Even using the laser to cut blanks allows the mater ia l to be bet ter utilised. The scrap from

a window cutout, for example, can be used for other components,” adds Mr Löffler. “This means that the usual material utilisation quota of 50 percent can be increased to more than 80 percent,” he says.

By using combined punch-laser systems, automotive manufacturers can integrate additional features such as thread-tapping, angles, louvers or brackets directly onto the component – without additional joining steps. This reduces the number of components, saving material and lowering weight and costs.

T h e p r o d u c t i o n sys te m h a s a l r e ad y passed the test phase among several automotive manufacturers and will be used to produce structural components such as pa ne l s , l ong i tud ina l supports, seat frames and other similar components. Even in motor sports, sheet metal processing systems have already proven their value. MEN

Enquiry No. 2302

Using universal sheet metal processing systems in automotive assembly process can result in cost reduction.

Other Laser Applications In Sheet Metal Processing

ma kes impossible welding possible. Reliability, minimal heat distortion, high processing speeds, a noncontact process and the flexibility of CNC programming are just a few advantages that have resulted from the increased

use of laser welding. T h e r e a r e s e v e r a l

considerations to change designs with laser welding to avoid the disadvantages of conventional welding. This will open the door to new clients in different industries. With the well-trained employees and the new machines from

Trumpf in the welding factory, Jinbao has set a benchmark on sheet metal forming in the Thai market by fully adopting European standards in their factories, particularly, in the welding operation.

Enquiry No. 2301

39Jan-Feb 2010 metalworking equipment news

www.equipment-news.com AdvertoriAl

Dörries Scharmann Technologie GmbH (DST) is one of the few European owned companies playing a leading roll in the worlds premier league of heavy-duty machine tool constructors. Precision, cost-effectiveness and reliability are the qualities in which the company, headquartered in Mönchengladbach, is claiming to lead this challenging business. Having gained decades of experience in the construction of heavy-duty machine tools in the Dörries, Droop + Rein, Scharmann, and Berthiez divisions, and with the Italian brand name of Mecof DST offers different unique technologies for a wide variety of applications

At Liebherr Aerospace Lindenberg GmbH a Droop+Rein FOGS D40 Over-Head Gantry High Speed Machining Center is used to machine forged steel Landing Gears for the Embraer series EJR-190/195 passenger aircraft. Currently the clamping area of the machining center (2,500 x 6,000 mm) is divided in to a section for machining and a section for set-up. This was done to accommodate future orders requiring a greater work piece size, where the total area of the clamping area would be available for the work piece. The FOGS D40 has full 5-axis machining capabilities and roughs and finishes the parts in three set-ups. The final “high speed” finishing operations completes a uniquely wide range of operation for this type of machine tool. This performance is facilitated by the machines innovative design concept. The “Over Head” gantry principle provides the high stiffness required for rough machining combined with the high dynamic performance needed for the finishing. The extremely

well proportioned cross rail on which the cross rail head (Y-axis) is mounted also contributes to the outstanding all round performance of the FOGS D40. Mounted in the cross rail head is the ram (Z-axis) to which is attached the Fork Type Head, which provides the 5-Axis capability through the rotary “B” and “C” axes.

The choice of the relevant appropriate machining head forms the basis of optimum results on the various work steps and requirements such as roughing, semi-finishing and finishing. Changeable milling heads and spindles are available to do this.

For application within the general engineering sector, the product range Scharmann offers two different machine lines.

The ECOFORCE line are horizontal machining centers in central design. The modular designed products are capable of providing efficient, flexible machining solutions. Configured with traversable spindle, facing head or tilting spindle the ECOFORCE with up to 63 kW power is the right solution for optimized horizontal heavy duty machining with high performance.

The HEAVYSPEED line of ram type boring mills was designed for machining large and heavy workpieces. With a combination of machining tables in various sizes and versions, floor plates and special solutions such as facing heads, or universal milling heads the HEAVYSPEED line can be adapted to meet the exact requirements of the application. Permanently high machining capacity and high damping are obtained by means of hydrostatic guides for the linear axes and the powerful main drive with up to 100 kW and 20,000 Nm.

Quality + Productivity +Availability




All types of lasing sources such as carbon dioxide, hel ium and Nd:YAG (neodymium-yttrium

aluminum garnet) are based on the excitation of atoms. The focussing lenses concentrate the beam energy into a focal spot as small as 0.005 inch (0.127 mm) in diameter or less.

Welding starts when this directed laser beam is targeted on the work piece surface to be welded. At the surface the large concentration of light energy is converted into thermal energy, which is transmitted through the material by surface conductance.

This thermal energy produces melting and coalescence before a Heat Affected Zone (HAZ) is developed, as the surface of the work piece starts melting. For welding, the energy is maintained below the vaporisation temperature of the material to reduce material loss. Because the penetration of the work piece depends on conducted heat, the thickness of the materials to be welded must be considered.

Applications Of Laser WeldingAmong the conventional welding techniques, applications for laser welding have increased steadily in recent years because it offers a number of advantages. These include improved optical appearance, small HAZ, miniaturisation, less thermal, mechanical or electrical load upon the product, less flash or no flash at all, feasibility of 3D weld geometries and even the possibility of welding thermoplastics and elastomers.

Laser welding is versatile and is applicable for joining miniature electronic components or welding steel structures in excess of 1 inch (25 mm) thick, at greater productivity and lower cost.

Using Light DifferentlySince the laser light relies upon the material’s heat conductivity to produce the weld, a relatively large HAZ can develop in certain

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Replacing traditional light sources with laser increases accuracy and also open doors to technologies that are light-years ahead. By Augustine Quek

Laser Welding: On TheSpot

types of metals with high thermal conductivity such as aluminium, resulting in limited downward penetration of less than 2 mm.

To get around this problem, a technique known as ‘keyholing’ is used. It involves higher power lasers (>106 W/cm²) that can make deeper penetrations. A vaporised hole is formed in the metal by heating the spot of laser focus above the boiling point. The hole traps about 95 percent of the laser energy into a cylindrical volume, known as a keyhole.

Temperatures within this keyhole can reach as high as 25,000 deg C, making the keyholing technique very efficient. As the laser beam moves along the work piece,

the molten metal fills in behind the keyhole and solidifies to form the weld. This technique permits welding speeds of hundreds of centimeters per minute or greater, depending on laser size.

Another technology combines laser welding with conventional Gas Metal Arc Welding (GMAW). It brings together the advantages of the two techniques, ie: deep weld penetration with low heat input and small HAZ and improved tolerance of joint root openings, surface conditions, impurities, root opening filling and contouring.

Originally used as a cost-effective method for producing beams from high-strength plate for use on US Navy ships, it can now

fab&form



41

fab&form

be used to join sandwich panels, structural beams and pipelines.

According to US-based ESAB Welding & Cutting Products, it can even be used in shipyards for ship fabrication and assembly, as well as superstructures in bridge building.

The company also provides hybrid laser arc welding in a 2D gantry, 3D robotic, or custom mechanised solution, together with its real-time closed-loop process control and automated quality assurance system. These systems are claimed to have welded beams from ordinary and high-strength plate at rates that are five to ten times that of conventional welding processes.

Laser Automation Laser automation involves combining laser welding devices with robotics. One example is the Servo Robot Digi-Las laser welding head from Canadian company Servo-Robot. The laser welding head combines seven different functions into one tool.

These functions include integrated joint finding, integrated joint tracking, adaptive weld parameter control, robot error compensation, process and system monitoring and integrated weld bead inspection.

The system is compatible with any Nd:YAG or fibre laser interfaced with either a CNC welding machine

or welding robot. According to the company, 3D complex joint welding can be achieved when the laser head is interfaced to a robot.

Putting Medical Devices TogetherAnother major improvement in laser welding has been its use in medical devices. Requiring exceptional precision in their welding processes, medical device manufacturers are looking to laser technology to provide solutions that enable a high degree of accuracy.

Advances in laser resonance design and fibre optic based beam delivery have made possible laser spot welds up to 30 micrometers. Take the example of a guidewire, a 250 - 500 micrometer diameter wire that can be up to 3 m long.

These dev ices are used along with other technologies, such as catheters, to establish a pathway through a portion of the human circulatory system for drug delivery or deployment of angioplasty devices.

A typica l laser welding application in the production of guidewires is welding the spring to the core wire. A consistently successful guidewire laser welding process requires innovative design of parts fixtures to ensure intimate contact between the core and the spring, and a modern laser with real-time instantaneous power feedback

to guarantee that every laser weld pulse in within specifications.

Other devices such as heart rhythm management devices require seam-welding two halves of the device together to achieve a reliable hermatic seal. This requires motion control systems, which usually includes a rotary stage holding the implantable device while applying pressure to clamp the two halves together. An XYZ-axis robot aims the laser beam at the edge seam, maintaining orthogonality to the seam.

A conventional approach has been to slow down the whole operation so the force impulse of the changes in direction of the work piece is low enough to not affect the performance of the weld, but at a much reduced production rate and higher cost.

An improved solution is to set up the motion system to minimise the magnitude of the sharp changes in acceleration by slowing down as needed at these inflection points and then speeding up along other segments of the contour. Using special software, it is possible to fire the laser in response to the work piece’s actual position rather than at a constant repitition rate.

L a se r we ld i n g pro ce s s continues to expand into modern industries and new applications because of its many advantages like deep weld penetration and minimised heat inputs. Since the invention of the laser in the 1960s, laser welding use has grown from one for exotic applications to today’s high-speed, automated welding processes.

Laser welding is now a full-fledged part of the metalworking industry, routinely used for many products, from common items such as cigarette lighters and watch springs to specialised uses such as pacemaker cans and hybrid circuit packages. MEN

Enquiry No. 2303

Another major improvement in laser welding has been its use in medical devicesK

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Multi-Axis Laser Processing In The

AerospaceIndustry

Laser systems continue to meet aerospace manufacturing challenges. By Peter Thompson, technical director and Mark Barry, VP, sales and marketing, Prima North America, Laserdyne Systems

Mu l t i - a x i s l a s e r processing system t e c h n o l o g y continues to provide

advantages to manufacturers involved in the aerospace industry particularly for suppliers of turbine engine components.

Driving this movement is the global aerospace competition in military, commercial, and private aviation sectors. Another factor is rising aviation fuel costs and the need for greater fuel efficiency that is being addressed by innovative engine design and manufacturing techniques. Also there is the desire for consistent manufacturing processes that can be better controlled.

A further factor is the use of improved or new aerospace materials in combination that pose manufacturing challenges. Last, but certainly not least, is the growing concern for environmental issues including the need for lowering engine emissions and noise. All of these factors are opening the door

fab&form

wider for the use of multi-axis laser system technology.

Multi-Axis Laser Technology The advantage that these systems bring to the user is obvious. As an example: In India, a company has begun to produce a legacy aero-engine component using multi-axis laser technology. When compared to the original parts manufacturing process using older laser technology, the quality of the processing using the new system

is more consistent (less rework and scrap), the manufacturing cycle time is lower, and the skill set required of the system operator is reduced. The net result is a superior part with total manufacturing costs that are lower.

Another example involves a North American company that produces land based turbine components. This company was able to reduce part cycle time by 75 percent using the technology versus their previous process.



43

fab&form

Complex aerospace transition components processed with laser gives aerospace engine manufacturers improved processing and quality

An array of aerospace turbine engine transition components shows complex holes produced in many shapes at difficult angles

Growing Market For Hole MakingToday’s turbine engines operate at above the melting point of the materials from which they are made. For proper cooling and to prevent damage to engine components, complex cooling schemes relying on elaborate hole patterns are required.

Consider the engine cooling requirements of the Joint Strike Fighter aircraft. It has over 2,000,000 holes in each of its two engines. These holes are ‘drilled’ or created using a pulsed Nd:YAG laser as part of a multi axis processing system.

With thousa nds of new commercial aircraft being built annually requiring similar complex engine cooling systems, it is easy to see that the market for hole making is growing.

This growth is compounded by in-service engines that require periodic maintenance also using the same laser systems to refurbish cooling holes. Size, shape and positioning as well as metallurgy are key considerations in the creation of cooling holes for this market.

In earliest turbine engine designs, holes were round and positioned in an easy to describe fixed pattern. Today’s engine designers call for many different hole sizes, in increasingly complex

shapes and irregular patterns. Performance analysis has

proven that non-round holes and less formal hole patterns provide more efficient cooling and therefore less polluting engine emissions.

Today’s designers are not seeking to simply make a hole to a particular shape or diameter but rather the goal is to produce a rate of flow through a given component. The most efficient flow rate is determined by complex modelling and trials to determine the best hole size, shape and location.

T h i s m e a n s t h a t t h e manufacturing process must be capable of adapting to changes in design. The latest multi-axis hole drilling technology now allows for drilling to a flow rate that can often be held to ± 2 to 3 percent of specification at high throughput. This recent achievement further clarifies laser-processing position as the standard process system for creating turbine engine components.

The Challenges Of New Materials As cooling requirements for turbine engines have required increasingly more sophisticated designs, so has the use of exotic materials for these designs. Many of these materials are new or combinations of materials that have high strength features and high heat resistance but by their nature have limited options for processing.

The materials of choice by turbine engine designers now include Inconel 617, Titanium, Hastelloy X and single crystal materials.

To achieve increased heat resistance, designers are specifying a growing array of Thermal Barrier Coatings (TBC) to be applied to the surface of the metal material prior to processing. These TBCs add to the processing difficulty. For all practical purposes, most of these new coated and uncoated materials can only be efficiently processed with quality results using a multi-axis laser system.



fab&form

Overcoming the problems encountered with conventional processing options such as EDM, multi-axis laser drills holes in thermal barrier coated parts with precision

The type of material and the constraints employing that material in a design most often is overcome with the Convergent Lasers CL50k Laser, which has features that are the result of the focus on high speed hole drilling.

This laser produces both the high-energy pulses required for drilling meter sections (cylindrical portion of the hole) and the shorter, higher frequency, lower-average-power pulses required for machining diffusers (shaped portion of the hole).

Refurbishing Turbine Engine Components High value engine components, such as combustors, nozzle guide vanes, blades and other transition parts, for both land and aerospace engines, are regularly refurbished and put back into service. This is a growing and technically demanding business.

One leading turbine engine manufacturer for aircraft alone repor ts 25,0 0 0 eng ines in active service, all of which are continuously monitored for periodic maintenance. To keep maintenance costs as low as possible and to extend time between overhaul, engine manufacturers are requiring suppliers to improve their processes. Once again, multi-axis laser system technology stands up to the challenge.

Refurbishing airflow holes requires ‘recreating’ in the same position and with identical precision size characteristics as the original part when new. Recreating precision holes can be more difficult than generating precision holes in a new part because there is little margin for error.

Holes are positioned closely together and have diameters as small as 0.020 inches (0.508 mm) and require tolerance accuracies as tight as ±0.002 inches. To position and laser process each of these holes accurately – without damaging the part – requires the

best multi-axis laser machining technology and often a high level of operator skill.

Percussion dr i l l ing a nd trepanning processes recreate the cooling holes. Percussion drilling is frequently used and generates a hole with the laser’s focused beam diameter. With the part held stationary, the laser beam is moved with simultaneous multiple action motion. The beam is focussed at the point where the hole is.

A single pulse or a series of pulses removes the material in the beam path, with an assist of co-axial flowing gas until the hole is recreated. Repair material, whether weld or braze, and foreign material that has built up in the holes during engine operation including slag and exhaust refuse is removed cleanly and accurately by operating the laser system in this way.

Laser System Projects Airflow RateA real time hole measurement technique that is currently in development using multi-axis laser processing is called Dynamic Automated Visual Inspection System (DAVIS). DAVIS is designed to capture images of laser-drilled holes and shapes in real time and analyse the data on-the-fly

for conformance to specification including proper hole size and projected airflow.

The DAVIS system is being developed to interact with Laserdyne’s 795 laser drilling system and its S94P laser process control. The system is designed to provide information for dynamic holes size control and compensation for deviations in real time. While still in the developmental stages, the near-term outlook for its use in engine hole making appears promising.

Standardisation Of Laser Processing TechniquesAn international movement is underway for the standardisation of laser processing techniques within the aerospace industry. Real time data logs such as the information projected to be captured using the DAVIS process. It can be used for creating National Aerospace and Defense Contractors Accreditation Program (NADCAP) reports.

Increased mandatory reporting to a NADCAP standard to satisfy OEM’s is now influencing Asian and other global turbine engine component manufacturing centres to increase the scope and number of reports. MEN

Enquiry No. 2304

“Made by BRUDERER” is a guarantee that has,

over the past six decades, become a worldwide

synonym for outstanding precision, perfor-

mance, reliability and highly efficient stamping

technology. BRUDERER customers also profit

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HeadquartersBRUDERER AGCH-9320 Frasnacht · SwitzerlandTel. +41 71 447 75 00 · Fax +41 71 447 77 [email protected]

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28. – 31. March 2007 · Hall 6/Booth 6H1-01

Welcome to the world of high performance stamping.

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The biggest obstacle in the production ofLead Frames and other sensitive elec-tronic parts lies in maintaining the exactpunch position during the cutting and coining process. Only BRUDERER can assure a prolonged tool life due to the unique ram guiding technology and thedynamic ram BDC adjustment.

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20810-07-013_az_apmen_205x275 23.02.2007 9:30 Uhr Seite 1

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Grand Scale

The rapid development in Asia has ushered in a period of construction boom. Singapore’s construction

demand (exclude reclamation projects) for 2010 is projected to reach between S$21 billion and S$27 billion (US$14.9 and 19.2 billion) according to a media release by the Building and Construction Authority of Singapore. This is a continuation of a sustained workload from last year’s S$21 billion worth of contracts awarded.

The bulk of this year’s demand will come from the public sector, which is projected to form 65 percent of total demand. It is expected to range between S$14.0 billion and S$17.9 billion and will largely be fuelled by higher growths in most categories of building construction demand and strong civil engineering projects led by Land Transport Authority’s MRT (Mass Rapid Transit) projects for Downtown Line Stage 3 and major road projects.

Elsewhere throughout Asia, the heavy machineries are all out in force with bridges, dams, railways

Of Things

Ivan Prole, Belgrade, Serbia

In The

From power generation to major infrastructure overhaul, the heavy industries are generating big movements that can even be felt in the metalworking community. By Joson Ng

Grand Scale

industryspotlight



47

Jarik, Kyiv, Ukraine

and airports propping up the heavy industry. Such as the scale of this industry, it not only touches on construction of infrastructures, it also covers power generation and even space exploration.

C o n s t r u c t io n o f m a jo r infrastructure requires plenty of raw materials like steel bars, which ultimately benefits the metalworking industry where various fabrication works are necessary to ensure the quality of the product supplied.

Apart from constructions of buildings or other large-scale projects, metalworking technology is very much in demand in power generation where large turbines are produced.

Power GenerationElectricity is essential in modern life. Following industrialisation in major parts of the world, the demand for electricity is higher than ever. There are many ways to generate electricity. Coal burning power stations are still available even with cleaner alternatives like wind power and hydroelectricity.

Although the main source of propulsion (ie: wind, water, natural gas or coal) is different, the way to generate electricity is still somewhat the same. Take a nuclear power station for example, the steam is generated in boilers heated by nuclear reactors. The steam subsequently is captured by turbines to convert mechanical

energy to electricity.Players in heavy industry

have long been involved in power generation. Mitsubishi Heavy Industries (MHI) has completed the construction of a manufacturing facility at its Takasago Machinery Works in Hyogo Prefecture, Japan, that is dedicated to production of forged turbine blades for Nuclear Power Plants (NPP), a core component of nuclear power generation systems.

The facility can integrally perform all processing required for blade production and enhances the company’s capability to supply forged blades, including one of the world’s largest 70-inch class turbine blades, for NPPs in Japan and other countries, according to the company.

T h e f a c i l i t y a c h i e v e s expanded unmanned machining in blade shaping and surface processing, enabling both quality enhancement and cost reduction.

NPP turbines are a key component of nuclear power generation systems that efficiently convert thermal energy produced by ste a m generators into rotational energy. The turbine, a rotating body, is composed mainly of forged blades and a rotor that functions as the turbine shaft or axis into which the blades are set.

See Where The Wind BlowsStaying in the common area where heavy industry, wind energy

Following industrialisation in many parts of the world, the demand for electricity is higher than ever

and metalworking converge, manufacturing of energy harnessing turbines is looking to move up like the wind. According to the American Wind Energy Association, in 2010, over 1,000 wind turbines larger than 2 megawatts (MW) are already in commercial operation in the US, and the year-end order for 338 GE 2.5 MW wind turbines for the Shepherd’s Flat wind project in Oregon, signals a big shift in orders toward such larger turbines.

T h i s fore c a st a s su me s that inventory will have been exhausted and that there will be a growing market for wind turbine orders in 2010 and beyond. The trend towards larger turbines is driven by economics – taller turbines with larger swept areas produce more power at a lower cost per kilowatt-hour.

As wind penetrations grow higher in the US and Europe in 2010, utilities and grid operators should become more comfortable with this new source of power. Several major wind integration studies slated for release in 2010 are expected to add further evidence that wind can be reliably integrated with the grid at low cost.

The colossal infrastructure construction and energy generation projects are only two areas where heavy industry are making its presence felt in Asia and beyond. Be it turbine manufacturing, railway or building constructions, there are no lack of opportunities for the metalworking community to make a big splash into the pool of heavy industry. MEN

Enquiry No. 2401

The trend towards larger turbines is driven by economics

Mad

mic

k99,

UK

industryspotlight



When in 2001 the first fibre lasers of severa l hundred w a t t s w e r e

introduced to the market , the init ia l interest of R& D depa r tments for th is new technology was followed by interest from industry. The economical and technological advantages compared to other lasers sources were obvious and the potential for future applications could be shown in research results for fibre laser materia ls processing. These advantages drove rapid acceptance of these lasers in the market and enabled new applications or replaced other laser technologies by fibre lasers.

The range of applications starts from micro-processing with pulsed and continuous fibre lasers of highest beam quality – single mode or Gaussian beam – to high power applications in cutting and welding of thick metals. Laser cutting as the largest market of laser technology today has come to a change due to the availability of fibre laser cutting systems of numerous machine builders, who realised the technological advantages in cutting.

The waveleng th of 1.07 micrometer has a significant higher absorption on all metals compared to CO2 lasers, which leads to higher processing speeds and lower required laser power.

Within a very short time the modular fibre laser concept allowed the development of ultra high power fibre lasers (Figure 1). Today lasers of 50 kW are already introduced and higher power is only a question of market demand.

Fibre Laser TechnologyFibre lasers are diode pumped solid state lasers with an active fibre doped by rare earths such as Ytterbium, Erbium or Thulium.

With the availability of high power fibre lasers of more than 10 kW, new application fields in thick section welding could be developed, especially in the heavy industries. By Michael Grupp and Karsten Klinker, IPG Laser and Stefano Cattaneo, IPG Photonics

Thick Section Welding

Fibre LaserWith

industryspotlight



49

Figure 1: Time scale of fibre laser development for multimode high power fibre laser

The main advantages are very good beam quality together with wallplug efficiency of about 30 percent. The use of passively cooled single emitter diodes for pumping the active optical fibre results in very high power stability and maintenance-free long-term operation.

Multi mode fibre lasers for high power materials processing applications have a modular design. This a llows almost unlimited power generation by the combination of multiple single mode modules to a multimode system.

Applications In ShipbuildingThe f irst 10kW fibre laser, introduced in 2004, generated a great interest in the shipbuilding industry. The main advantage of thick section welding, in addition to significantly higher welding speed is the reduction of weld distortion from reduced heat input.

In the combined ‘hybrid’ process of laser and Gas-Metal-Arc (GMA), welding speeds of more then 1 m/min can be obtained for sheet thicknesses of more tha n 10 mm. The combination of processes results in a stabilisation of the electrical arc at high speeds together with a gap tolerance that can be wider

than the laser beam diameter. The advantage of fibre lasers

compared to CO2 lasers was seen in the simple beam delivery by optical fibres, this reduces costs and avoids the technological limits of a solid beam delivery by mirrors as used by CO2 lasers. Due to long process fibres (>50 m) there is no need to move the laser along the axis of travel and no adjustment of beam guiding systems in these large area welding systems is necessary.

Concerns about laser safety for the wavelength of 1,07 μm were overcome by intensive research and development of local shielding of the radiation at the processing head. Meanwhile two panel lines with 6 and 10 kW laser power are installed in European shipyards.

The other main technological advantage of fibre lasers is the high beam quality, which is defined by a very small process fibre diameter and allows the focussing of the beam to very

small spot sizes. Fibre lasers up to 10 kW can be equipped with fibres of only 100 μm core diameter, corresponding to a beam parameter product (BPP) <4.5 mm*mrad.

This small spot size together w i t h h i g h we l d i n g sp e e d results in very narrow needle shaped welds with low heat input. Welding depth and weld seam shape are comparable to electron beam welds.

For this reason fibre lasers can replace EB-welding in a wide range of applications such as welding of gear box parts (differentials, shafts, gears) and other components with no need of a vacuum chamber. Especially for high volume production and large parts this results in shorter processing times and cost reduction.

Ultra High Power Fibre LasersSince ultra high power fibre lasers of more than 10 kW are available, welding of more than 20

The first 10kW fibre laser, introduced in 2004, generated a great interest in the shipbuilding industry.

Development Of Low Order Mode Fibre Laser

industryspotlight



Figure 3: Penetration depth vs. laser power. Experimental limit and potential increase in welding depth with higher power

Figure 2: Welding performance of 30 kW fibre laser YLR30000. Bead-on-plate weld on stainless steel 1.4301 and X70 alloy steel

mm thickness became possible. This is of high interest in tube fabrication/pipeline construction, heavy industries and power plant construction.

F i g u r e 2 s h o w s t h e performance of the 30 kW fibre laser YLR30000 equipped with a fibre of df= 200 μm. All welding tests were done in bead-on-plate arrangement with the same optical configuration. A welding head with f= 320 mm focal length and an optical magnification of M= 2.1x was used. This results in a spot diameter of 420 μm on the workpiece.

F i g u r e 2 s h o w s t h a t penetration depths of more than 25.4 mm could be achieved with 20 kW at a speed of 1 m/min. Increasing the power to 30 kW enabled a speed of 2 m/min at the same thickness. The cross sections of the welds show that at a speed of below 1 m/min the typical V-or Y-shape of the weld geometry occurs, while at higher speed the weld is very narrow with almost parallel flanks.

Outlook & SummaryRegarding the increase of welding depth with increased laser power, it is obvious that up to the actual experimental limit of 30 kW, an almost linear increase of penetration depth could be achieved (Figure 3). This leads to the expectation that with further increase of the power, welding depths of more than 50 mm could be achieved in single-pass welding. Welding applications in this thickness range are known in power plant and reactor construction, as well as in heavy industry.

One example is the construction of the international thermo-nuclear reactor ITER where wall thicknesses of more than 60 mm have to be welded on large sections of the reactor.

Within a very short time fibre lasers have become an efficient

tool in welding of thick section materials. The power and flexibility allows the integration of fibre lasers in large production lines for the shipbuilding and offshore industry, tube and pipeline production and other areas of heavy industry.

Today material thicknesses of more than 30 mm can be welded by the fibre laser with weld seam geometries which are

very similar to electron beam welds, but with the advantage of no use of vacuum chambers and no limit to workpiece size. Today’s experimental results show the potential of fibre laser welding for future applications for thicknesses of more than 50 mm. MEN

Enquiry No. 2402

Welding Speed m/min

Laser Power kW

industryspotlight

SINGAPORE PRECISION ENGINEERING& TOOLING ASSOCIATION114 Balestier Road, Singapore 329679Tel: +65 6291 6430 Fax: +65 6292 4517Email : [email protected]

Organised by In Collaboration with:

CONTACT USFax: +65 6292 4517Email: [email protected]

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ENQUIRY NO 032




Un v e i l e d to the public late last year, SIMTech’s (Singapore Institute

of Manufacturing Technology) Susta inable Manufactur ing Centre (SMC) is already actively col laborat ing with severa l gover nment a genc ie s a nd companies.

SMC director Dr Song Bin reveals that the setting up of the centre has been a long time coming. For many years, SIMTech has been developing sustainable technologies, but on an ad hoc basis and did not use terms like ‘sustainability’ or ‘environmental’.

According to Dr Song, the centre was set up “with the belief that the manufacturing industry is undergoing a paradigm shift towards green manufacturing to minimise the emissions, waste and the toxicity in the manufacturing process”. To achieve such an objective, he believes that the key will be “technology innovation and

the implementation in the industry”.

“Since 2007,” says Dr Song, “we have started to put in a more systematic effort to research into technologies for sustainability in manufacturing. Included are tools that can help companies to quantify sustainable performance like carbon footprint, depletion of resources and the impact on human health from a manufacturing process; and technologies that reduce toxicity, increase energy/resource efficiency, recovery and recycling waste, and processing and application of eco-friendly materials.”

Open To All IndustriesThere are many industries in which sustainability can play a huge role, suggests Dr Song. In the aerospace and automotive industries, weight reduction is crucial; in the food industry, manufacturers want to reduce energy consumption and improve packaging in terms

SMC’s Dr Song Bin discusses his vision for the newly launched centre. By Joson Ng and Derek Rodriguez

Sustainability:

Take It,It’sYours!

of environmental impact. Other industries, he says, include machinery, moulding, stamping, electronics and mechanical.

Companies that are interested in sustainability but are unable to pursue it due to lack of resource can still consider sustainability as a viable avenue.

Says Dr Song: “We don’t provide funding but there are organisations in Singapore that will support companies to innovate technologies that help to reduce waste and improve energy efficiency. For example, SPRING have this capability development fund, companies that have the need or idea to come up with new capabilities can apply for this funding, which can be around 50 percent or higher, to offset the cost. NEA have this 3R fund; companies that want to implement some sort of technology or process to reduce waste can apply for funding from NEA. And IE Singapore can help companies that wish to carry out some sort of technology upgrading that can help them to export their goods overseas.”

Enquiry No. 2501

features



53

features

Quantifying Carbon Footprint“To help companies quantify their carbon footprint, we are developing our own methodology and software toolkit embedding relevant international standards like PAS 2050, ISO 14064, and the coming 14067.

More and more companies are very keen to do this with us. Companies are very keen to improve their carbon emissions and reduce wastage. They are looking for ways to reduce the consumption of resource in manufacturing process. That will help the companies to be more competitive, and open a lot of opportunity for research.”

Remanufacturing“We have all these precision engineering companies, they’re quite strong in their core competence, but the electronic industry which they have been supporting, is declining in Singapore. However, their capabilities are very suitable and provide the base requirement for remanufacturing.

In the meantime the EDB is attracting large remanufacturers in Singapore and these manufacturers need support. We also have a strong trading industry distributing products and components worldwide. Through taking-back schemes and partnering with precision engineering companies, used products/components can be remanufactured and marketed. All these open up opportunities for business growth with environmental benefits.”

Packaging“Packaging is often the first area for a company to improve their environmental performance while gaining cost benefits. We are looking into the use of sustainable materials for packaging, eco-design of packaging, and technologies to reduce costs. Most of the materials used in packaging are not renewable and some are not even recyclable, so we can improve through the use of new materials.

To maximise the results, we need to rethink about packaging design from the viewpoint of energy and material optimisation. Once you use the new material you have to develop a new and efficient manufacturing process. This includes preparing the industry to apply the materials and looking for potential applications.” MEN

Enquiry No. 2502

Dr Song On SMC’s Three Areas Of Focus:



Die DuplicationDie DuplicationAccelerating

Aveo’s tailgate, the tryout process is a 16-week endeavour.

The challenge in duplicating an operational die is that the handmade adjustments created an as-built condition that no longer matches the original CAD data. Therefore, the 16-week tryout process is repeated for each replacement or duplicate die set.

The alternative can eliminate this costly redundancy by measuring the die and documenting the modifications in the CAD data. The carmaker’s stamping die engineers had considered both CMM and 3D scanners for the task but found each to be impractical.

CMMs required too much time and labour to capture all necessary measurements. 3D scanning resolved this issue, but the scanning software could not produce surfaces sufficient for tool path creation. This lead to

and lead time would be enormous. Culminating a three year search,

the team found and implemented a 3D scanning procedure that uses Rapidform XO scan-to-CAD software. By documenting the as-built condition of operational dies, the company slashed die tryout times by five weeks. It also ensured that the Polish-built Aveos would have the same fit and finish as the South Korean-made Kalos.

Die Tryouts Fol lowing CA D design and simulation, stamping dies go through a r igorous tr yout process. Samples are stamped, measured and scrutinised to uncover tolerance deviations and surface defects.

When flaws are discovered, the die is hand worked to fine-tune it so that stampings match print specifications. For parts like the

GM Daewoo of South Korea, which is now part of General Motors’ family, replacing or

duplicating a stamping die leads to unnecessary costs, inefficiencies and delays. Even though the original die has been put through an exhaustive quality check, making duplicates involve more than another round of machining and assembly operations.

I n s te a d , s t a m p i n g d i e engineers must repeat the entire die tryout process to produce quality stampings.

W h e n G e n e r a l M o to r s announced a second Chevy Aveo production facility in Poland, the stamping die engineers at the GM Daewoo facility sought an alternative that would condense, or eliminate, the multi-week tryout process. With more than 25 large die sets for the Aveo, which is called Kalos in South Korean markets, the gains in efficiency, cost reduction

www.equipment-news.comFeatures

Difficulty: Replacing or duplicating stamping dies – time consuming

Solution: Adopting reverse engineering process, utilising 3D scanner and software programs.

concluSion: Shorten die duplication tryout processing time by 30 percent

The process of duplicating a stamping die is generally painstaking and time-consuming. Through 3D technology and software programs, it is considerably shortened. By Sophia H Jeon, business partner manager, Rapidform



55

Features

a cumbersome and convoluted effort that divided the point cloud processing and solid modelling efforts between two separate software programs. In the end, there was little benefit because the time saved in die tryouts was offset by the time and effort to generate the as-built CAD data.

Parametric Modelling The Chevy Aveo’s tailgate was the first sheet metal part to be stamped from a die that was duplicated using a 3D scanning methodology. GM Daewoo converted 3D scanner point cloud information into a full-function CAD model using Rapidform XOR/Redesign.

According to the stamping die engineers, correcting the CAD data to as-built conditions in XOR yielded an 85 to 90 percent time savings, when compared to p re v io u s 3 D s c a n n i n g attempts. This time savings gave them a viable solution for

die duplication with minimal die tryout delays. The company’s engineers noted that the key to making this possible was the program’s combination of point cloud processing tools with parametric, solid modelling.

In previous 3D scanning attempts, surface data was exported from the 3D scanning software and imported to UGS NX, where it was used as reference data for the manual recreation of the CAD model.

In contrast, the program performed the CAD modelling functions. It created parametric solids, with the full history tree, that drove the automated update of GM Daewoo’s UGS NX models.

In XOR, the die engineers used a variety of CAD correct tools for refitting and redesigning the original UGS NX files. These functions were supported by the Redesign Assistant that aids in

interpreting the design intent of features of the hand worked, and slightly worn, dies.

3D Scanning For As-Built CAD T he c a r ma ker se le c te d a CogniTens Optigo scanner for the Chevy Aveo project. The scanner captured dense point clouds that documented measurements for both the untouched and hand worked features of the tailgate die set. For the four-operation stamping process, there were eight die components for drawing, punching and bending. Following scanning, the point cloud data and original UGS NX solid models were imported into Rapidform XOR. The point clouds were then cleaned, merged and aligned to the CAD model.

The first step in the CAD refitting process was identifying ‘regions of interest’, which are the areas where the scan data does not match the CAD model. To do so, the carmaker’s die engineers used Accuracy Analyzer, which is a visual tool that highlights

The original dies of Kalos were duplicated using 3D technologies and software programs

Redesign Assistant aids interpreting the design intent of features of the hand worked, and slightly worn, dies



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discrepancies between the two die descriptions. As the redesign progressed, the tool also monitored the changes, in real time, to confirm that the modifications were within user-defined tolerances.

Another tool the die engineers used was Redesign Assistant. This XOR function automatically extracts the design intent of individual features. For example, it determines the radius and centre point of fillets even if there are slight changes in curvature resulting from imprecise, hand grinding or tool wear. Having

extracted the design intent, the die engineers remodelled features with CAD-like solid modelling functions such as sweep, extrude and revolve.

While the standard CAD modelling functions were used throughout the project, the bulk of the time savings came from automated tools that have been developed specifically for 3D scanning.

Manufacturing Duplicate Stamping Dies After completing the modification of the CAD data to reflect the as-

built stamping die, the parametric model, with its history tree, was transferred to UGS NX. Although time reduction for the CAD refitting process was important, the true test of this new approach to die duplication was the quality of the surfaces for machining of the production die.

Machined from the XOR-generated solid model, the Aveo tailgate stamping die is now in operation in Warsaw, Poland. It is an exact duplicate of the Kalos die that has been stamping parts in South Korea.

Replicating all of the original hand worked modifications, this duplicate die is producing stampings that match the quality of the Kalos tailgate, and it is doing so without duplicating the lengthy tryout process.

Using 3D sca nning a nd software programs, GM Daewoo cut five weeks from the tryout and approval process. For the tailgate, this 30 percent reduction resulted in an estimated savings of US$200,000. Extended over all large die sets for the Aveo, the company estimated total saving of US$5 million. MEN

Enquiry No. 2503

The diagram shows a summary of the duplication process

GM Daewoo engineer scans original die with 3D scanner

ENQUIRY NO 164



I n a n ever- compet it ive manufacturing environment, it is important and crucial to make prudent investments.

For a typical job shop or a manufacturer, making investments in machineries is arguably one of the most significant decision. It requires serious considerations and even analyses.

The purpose for buying any machine is to make money with it. If you buy nothing, it costs nothing, but makes no money. If you buy a premium machine it costs more than a low grade machine but it is more productive. Finally, the machine must match the work it is intended to do. A buyer must strike the balance between price, productivity and machine capability.

Matching Machine To The WorkA job shop and a manufacturer have slightly different considerations

Economic considerations in purchasing a jet cutting machine are just as important as the machine’s capabilities. By John H Olsen, VP Operations, Omax Corp

when choosing a machine. The manufacturer knows exactly what type of parts he will be making and the production volumes. Some factors for the manufacturer to consider are:

1. A small machine with low accuracy may perfectly match the work to be done.

2. A large machine can achieve material savings via nesting and lower unit cost of material in large sheets.

3. An accurate machine can often eliminate secondary operations.

The job shop owner is concerned with these factors as well, but he also worries that his machine will be too small for the work his customers may request. He tends to buy a machine for the largest imaginable part.

Machine accuracy is sometimes overlooked, but customers prefer

precise parts that require little or no secondary processing. The revenue of the shop depends on the ability to produce parts the customer wants.

Costs Of Jet CuttingCosts are of two kinds: the costs of capital that are fixed no matter how much the machine is operated and those that depend on the operating time of the machine. We will consider two shops to see the effect of these two kinds of costs.

The first will be a shop that only operates the machine part time about 24 hours per week. The second operates two shifts and runs the machine 70 hours per week. These hours will be used to calculate the hourly cost of capital for comparison with the other hourly operating costs.

• Capital CostsConsider a machine that costs US$100,000 and is financed with a five-year loan at 8.5 percent. The monthly payment is US$2,052. At 24 and 70 hours per week operation, the hourly costs of capital are US$19.73 and US$6.76 respectively.

• Labour CostsAn operator might be paid as

Costs of a jet cutting machine running 24 hours per week

Costs of a jet cutting machine running 70 hours per week

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much as US$20 per hour with a fringe rate for vacation and health insurance of 40 percent. That would result in an hourly cost of US$28.

But, the jet cutting machine runs more or less by itself after the initial set up is done and one operator can either run multiple machines or perform some other useful task while the machine is completing its work. For this example, we allocate half of these costs (US$14/hr) to the part making costs.

• AbrasivesAbrasives represent the largest consumable cost in abrasive jet cutting. Prices for garnet abrasive are very transportation dependent and range from a low of about US$0.10 per lb to as high as US$0.72 per lb.

Costs are also somewhat dependent on the grade of garnet and can vary by a factor of three based on quality.

It is generally not a good idea to run with low grade garnet full of dust and dirt particles because these impurities cause frequent nozzle plugging and lost production. A moderate price for garnet is about US$0.30 per lb.

Garnet flow rates range from about 0.5 lb per minute to about 1.5 lb per minute in the larger nozzles in use today. At an average flow of 1 lb per minute with US$0.30 per lb garnet, the hourly cost is US$18 per hour.

• MaintenanceAbrasive jet machinery has a higher maintenance cost than most other machine tools. The flowing abrasive wears out all parts that it touches and in particular the mixing tube where the abrasive is accelerated to high speed by the water wears out in about 100 hours. Between US$1 and US$2 per hour should be allocated for replacing parts worn by the abrasive.

The high-pressure pumps and plumbing systems that provide the high-pressure water to the nozzle are also maintenance items. The higher the pressure, the higher the maintenance costs.

Normal maintenance items are seals and check valve seats. Occasional failures of other high-pressure parts from metal fatigue occur. A good budget for pump maintenance is about US$5 per hour giving an overall maintenance cost of up to US$7 per hour.

24 Hrs/Wk 70 Hrs/Wk

Cost Category Hourly Cost Cost Category Hourly Cost

Capital US$19.73 Capital US$6.76

Abrasive US$18.00 Abrasive US$18.00

Maintenance US$7.00 Maintenance US$7.00

Power US$2.48 Power US$2.48

Water US$0.60 Water US$0.60

Labour US$14.00 Labor US$14.00

Total US$61.81 Total US$48.85

Total costs for operating an abrasive jet 24 and 70 hours per week

• ElectricityMany shops would regard electric power as an overhead cost like building rent, but it is a real cost of operating an abrasive jet cutting system. The cost is dependent upon the type of pump being used. At US$0.10 per kwh, a 0.014” orifice operating at 55,000 psi with a crank drive pump costs about US$2.48 per hour whereas the less efficient intensifier pump costs about US$3.26 per hour in electricity.

• Water & SewerMany utilities charge a fixed rate for water usage that also includes the sewer charge. A price of about US$0.01 per gallon is typical. The 0.014” orifice operating at 55.000 psi mentioned above draws just under 1 gallon per minute for a cost of US$0.60 per hour. An intensifier pump is often cooled with an additional 2 gpm of giving a total cost of US$1.80 per hour.

Productivity & CostThese costs are much greater than the costs for most other machining processes. So, why is this process the fastest growing segment of the machine tool industry? The answer is productivity!

Job shops charge US$100 per hour and up for nozzle time that costs no more than US$65 per hour. Yet, the customer feels that the part price is low because the part time is low.

The major factor affecting

Figure 1: During cutting, the jet exit lags the entry by an amount dependent on speed

Figure 2: Colours ranging from white (fast) to blue (slow) show the speeds in an optimum tool path



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part time is the software driving the machine. The jet is not a rigid tool and an optimum tool path is one that varies the speed according to the shape being cut. The jet exit point lags the entry point by an amount depending on the cutting speed. (Figure 1) A large lag is fine on straight lines, but causes major accuracy errors on arcs and corners.

Modern control software automatically adjusts for this effect and does a much better job than a human can. (Figure 2) The part time difference between a control that runs at a constant compromise speed for corners and arcs and one that properly varies the speed everywhere along the path can be more than a factor of two.

Software also handles the taper in the kerf to make a square edge. As the jet slows down, the kerf goes from widest at the top through parallel to widest at the bottom.

There is a speed at which the taper is minimum. However, cutting the entire part at this speed will take a very long time. Through software, a two dimensional flat part is input, but the machine automatically moves in five axes to compensate for and remove the edge taper. Again, the precise part is made much more quickly with the taper removing software.

Why is part time so important? Consider a part that takes 10 minutes to make on a premium machine and only 30 percent longer or 13 minutes on a lesser machine. Suppose that both machines operate at a US$60 per hour or US$1 per minute cost. The part cost in the first case is then US$10 and it is US$13 from the other machine.

Now suppose that the entire 24 hours per week of the two machines are spent making these parts or parts like them. The premium machine will make 7,488 parts in a year. The other machine will make only 5,760 in a year with the same cost. To make the same

quantity as the premium machine, the other machine would have to run an additional 374.4 hours (7.2 hours per week) at an additional cost of US$22,464. A manufacturer would consider that he saved this amount by purchasing the premium machine.

An ever-greater difference is apparent if the gross margin generation is considered. Suppose that the customer is willing to pay US$20 for this part. The premium machine makes 7,488 of these parts at a margin of US$10 each giving a total margin of US$74,880.

The lesser machine makes 5,760 at a margin of US$7 each for a total of US$40,320. The difference is US$34,560. The premium machine owner could pay US$30,000 more for his machine and get all his money back in less than one year. All these numbers get even better if the machine is used more than 24 hours per week.

Omax: Large-Scale Abrasive Waterjet Machining

The 120X JetMachining Centre is designed for manufacturers with large-scale abrasive waterjet requirements. Four specific models are available from Omax, with lengths of 13 feet (3.96 m), 20 feet, 26 feet and 32 feet. Each of the models is 10 feet in width and features work envelopes capable of handling standard international sheet material sizes.

Applicable for large-scale precision machining from manufacturers serving a variety of industries, including aerospace, petroleum, food processing and equipment fabricators. It features a pending drive system with closed loop, high pole vector drives, to achieve accurate and precise movement. MEN

Enquiry No. 2505

Sadly, many buyers never take the time to do time studies on the machines they are considering. Some even get a part made on a premium machine and then buy on price alone without making a part on the lower cost machine. They learn what they have missed only when they are forced to compete with a premium machine.

Conclusion: Importance Of Time StudyJet cutting machines are more expensive to operate than many conventional machines, but they are productive.

The productivity is highly dependent on the software that manages the jet. Buyers are urged to compare actual part times and make an economic analysis before purchasing a machine.

Enquiry No. 2504

ENQUIRY NO 170




In an increasingly competitive market, major savings are still possible with new approaches to old methods. By Scott Crump, CEO, Stratasys

ViableAlternative

Direct Digital Manufacturing:

Over the past 20 years additive fabrication t e c h n o l o g y h a s mig rated f rom use

in rapid prototyping to a full-fledged manufacturing solution, which is referred to as Direct Digital Manufacturing or DDM. Increasingly, companies are applying it to manufacturing applications, and with each success, they prove that it is a viable alternative.

While the general concept of additive fabrication is the same as when it was introduced 20 years ago, the change is in its intended use, ie: production, not just prototyping. So while the concept has been around for a while, in the minds of many, it is a new thing and difficult to understand.

Additive fabrication is the generic name given to processes that create a part by building it up in layers – as opposed to milling or machining, which are subtractive processes. Additive fabrication was developed as a way to automate the creation of prototypes, and it was therefore originally known as rapid prototyping. It also goes by various other names, including 3D printing.

Direct Digital ManufacturingThere has been some confusion about DDM in part because of the many terms that have been used synonymously with it. To most people it is synonymous

with rapid manufacturing, additive manufacturing, or layer manufacturing, although others make subtle distinctions among these terms.

DDM is the process of using CAD or other data to drive an additive fabrication machine that makes usable parts. Examples are the components that go into sellable products, pieces of production machinery, replacement parts, or manufacturing tools, such as jigs and fixtures.

Besides CAD data, which is the majority of data used, other types of data may be used to drive additive fabrication machines. Among others it includes 3D scan data (for reverse engineering) and DICOM data (for making a physical representation of 3D medical imagery).

The process e l iminates moulding, machining, casting and forming. Instead of material removal or shaping, a company’s finished goods are produced by adding material one layer at a time.

Other than a few minutes of pre-processing to prepare a production run and some light post-processing to clean up a part, DDM progresses directly from CAD data to final part. Eliminating the upfront and back-end operations common to traditional methods mean that there is no extraneous time, cost,

or labour.Due to the elimination of tooling,

the process can save tens or hundreds of thousands of dollars on a single project. Using our FDM additive fabrication process for DDM, Stratasys eliminated about US$200,000 in tooling costs for one of our newer machines.

We did this by direct ly manufacturing 32 components rather than having them produced via traditional means. From our customers, we hear similar stories with varying degrees of savings regularly. The savings on one project can outweigh the cost of the machine purchase.

One Process, Many TechnologiesDDM is a process, not a technology. It can be performed with various additive fabrication technologies with diverse capabilities. The additive fabrication technologies that perform the process share the fundamental technique of producing parts directly from a CAD data file.

They do so by adding material layer-by-layer. However, the many

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DDM is a process of using CAD or other data to drive an additive fabrication machine that makes usable parts

processes vary greatly, so in order to determine if the process is suitable for a project, it must be evaluated with respect to a specific technology.

The most often cited advantages of DDM are:

• Eliminate investment in tooling• Eliminate lag time between design and production• Eliminate design constraints• Eliminate penalty for redesign• Eliminate lot size minimums

Collectively, these benefits translate to efficiency, flexibility, responsiveness and affordability. DDM is a manufacturing process that introduces alternatives in product design, manufacturing methodology and business operations.

As an added benefit, many additive fabrication technologies are fairly ‘green’ processes. They have very little waste material as compared with milling processes because only the needed material is used.

No unnecessary inventory is produced because there is no benefit to building more than you need at any time. Most additive processes require no harmful chemicals and vent no harmful fumes into the environment. Among a list of other green benefits, is the relatively small amount of electricity that is required to produce parts via additive fabrication.

Application DiversityIn the manufacturing environment,

it often performs one of two roles. Companies will use the process to manufacture the products it sells or to make the devices that aid in the manufacturing of the products.

When first introduced to the process, the application most people envision is the production of finished goods. The word manufacturing conjures images of high-volume production of consumer products. People often jump to the definition ‘the making of goods on a large scale’, even though manufacturing also means ‘the making or producing of anything’.

This process is suited for low-volume manufacturing – not mass production, but before you think ‘We can’t use it because we do mass-production’, keep in mind every manufacture has low-volume needs in the production of manufacturing tools, such as jigs, fixtures, gauges and hand tools.

Producing manufacturing tools presents the opportunity to try DDM. These tools are deployed to

make manufacturing and assembly fast, efficient, repeatable and cost effective.

In this manufacturing context, the process becomes a low-risk, high-return alternative to standard practices. Because the tools are used by the company, not the customer, and the time and cost to produce them is small, an unsuccessful attempt has little consequence. But when successful, it has a major impact on productivity, quality and the cost of producing parts.

P e r f o r m i n g D D M o f manufacturing tools is currently greater than DDM for end-use parts. That is partly because it is such a low-risk opportunity, and partly because every manufacturer has a need for such tools.

Manufacturing can also be a bit of a misnomer when the entire spectrum of industries using the process is considered. Some of the greatest successes are not in the manufacturing industry. Because of the inherent need for custom fitting devices, the medical and dental professions have been early adopters of the process.

Orthotics, prosthetics, hearing aids and dental bridges have all benefitted from DDM. Companies have discovered that this process is a powerful alternative, rather than a direct replacement, to the conventional manufacturing processes. MEN

Enquiry No. 2506

Because the tools are used by the company, not the customer, and the time and cost to produce them is small, an unsuccessful attempt has little consequence. But when successful, DDM has a major impact on productivity, quality and the cost of producing parts.

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The latest technologies in rapid prototyping reduce cost and usher in the digital age in a big way. By Augustine Quek

The latest developments in 3D technologies for metalworking include 3D scanning, modelling,

rapid prototyping and rapid manufacturing.

Today’s digital 3D scanners, modellers and rapid manufacturing technologies has reduced not only manufacturing costs and time, but also accelerated advances in innovation. A whole product approach can now be taken for any metal work, from 3D scanning to digitising to rapid prototyping or manufacturing.

3D Scanning A 3D scanner is a device that interacts with a physical object through various means to collect data of the object’s physical parameters, such as its size, shape and possibly its appearance (ie: colour). The collected data can then be used to construct digital 3D models, useful for reverse engineering and prototyping, quality control and inspection.

Many different technologies can be used in 3D scanning devices; ranging from touch trigger probes to

XYZOfThings

GettingInto The

3D Technologies:

optical digitisers to laser scanners. Each technology comes with its own limitations, advantages and costs. Most 3D scanners offerings now comes with software programs for control, image capturing and even 3D rendering and modelling.

Applications include reverse engineering, inspection, 3D a rchiv ing, complex shape acquisit ion, measurements archiving, damage assessment, digital models and mock-ups, packaging design and rapid prototyping. They can also be classified as either contact or noncontact measurement.

3D Modelling & VisualisationThe data obtained from 3D scanners can be used to make 3D models, which are mathematical representations of the real objects. Programs used to convert such data into models are part of Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).

There are five popular ways to represent a model: polygonal modelling, splines and patches, Non-Uniform Rational B-Splines (NURBS), primitives modelling,

and sculpt modelling. Polygonal modelling uses points in 3D space, called vertices, to connect line segments to form a polygonal mesh.

The majority of 3D models today are built as textured polygonal models due to their flexibility and fast rendering. However, polygons are planar and can only approximate curved surfaces using many polygons. NURBS are mathematical representations of 3D geometry that can accurately describe any shape. NURBS surfaces are defined by spline curves, which are influenced by weighted control points.

Sculpt modelling, a fairly new method of modelling 3D sculpting,

Did You Know?Research from the Aberdeen Group shows that manufacturers that use digital prototyping build half the number of physical prototypes as the average manufacturer, get to market 58 days faster than average, and experience 48 percent lower prototyping costs.

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uses a dense model of subdivided polygon control meshes and stores new locations for the vertex positions through use of a 32bit image map that stores the adjusted locations. This method allows for very detailed reproductions as new topology can be created over existing ones.

One pa r t icu la r popula r application for 3D models is in digital prototyping, where designs can be built and tested digitally on a computer without the need for building a physical prototype. 3D models not only give the ability to virtually explore a complete product before it is built, it also enables one to design, iterate, optimise, validate, and visualise products digitally throughout the product development process.

Reverse Engineering,Rapid Manufacturing Technologies also exist to produce physical models and prototypes using metal from 3D scanned and model data. The entire process from scanning to modelling to 3D printing has typically been part of reverse engineering, rapid prototyping and manufacturing.

Rapid prototyping technologies that use metallic materials include selective laser sintering, electron beam melting and now, 3D printing. The common feature shared by these technologies is the ability to produce freeform, complex-geometry components directly from a computer-generated model.

Layerwise shaping and feedstock consolidation, considered as direct fabrication techniques, (eg: powder, wire, ingot, paste, or melt) were adopted to form complex shapes

having full or near-full density without the use of intermediate binders, furnace densification cycles, or secondary infiltration steps. Minimal thermomechanical post-processing or machining are required to obtain a desired geometry, structure, and properties.

3D technologies have already redefined the way companies design and build products. Future developments are likely to be impacted by improvements in computer processing speeds. Faster computers are not only able to produce more complex objects, but also more accurate designs, increase manufacturing speeds which lowers build times. As a result, the rise of 3D technologies in metal products manufacturing is inevitable. MEN

Enquiry No. 2509

Rapid Prototyping TechnologiesBesides 3D printing, there are a few other rapid prototyping techniques around.

Selective Laser Sintering (SLS) technology fuses meta l powder in to a solid part by melting it locally using a focused laser beam. The laser s e l e c t i v e l y f u s e s powdered material by scanning cross-sections generated f rom a 3D digital description of the part on the surface of a powder bed.

Af te r each c ross-s e c t i o n i s s c a nne d , t h e p o w d e r b e d i s lowered by one layer thickness, a new layer of material is applied on top, and the process is repeated until the part is completed. Even highly comp lex ge omet r i e s can be created this way without any tooling. It is a net-shape process,

producing par ts wi th high accuracy and detail resolution, with good surface quality.

Medical ImplantsSimilarly, Electron Beam Me l t ing (EBM) me l ts metal powder in a layer-by-layer process to build the physical part, using an electron beam in a high vacuum.

This solid freeform f a b r i c a t i o n m e t h o d produces fully dense metal parts directly from metal powder with characteristics of the target material. Since titanium alloys are suitable and widely used with this technology, EBM is also widely used for making medical implants.

Enquiry No. 2507

3D Modelling In ActionAutodesk Productstream software are used by Swiss watches maker Ulysse Nardin to manage design data. As such, it is now easier for other workgroups to work together with the design team. This also allows watch designers to visualise how gears

and springs fit with other components as they design.

It is not only easier to spot and eliminate inter ferences early in the design process; the positions of mechanical parts that integrate with ex te rna l por t ions of

the watch can also be optimised. Enhancements to designs can also be made by anyone who spots an opportunity. This allows watchmakers to create more innovative watches faster.

Enquiry No. 2508 It is now possible to visualise how gears and springs fit with other components with 3D modelling

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Features



The 14th Seoul International Machine Tool Show 2010 (SIMTOS2010) is making its return this year at

KINTEX from April 13 – 18. With an exhibition space of 53,541 sq m, the hall is expected to be thronged by some 80,000 visitors. The number of exhibitors stands at some 426, occupying 3,390 booths.

The event aims to showcase metal cutting machines, metal forming machines, CAD/CAM, cutting tools, robots and factory automation and precision measuring machines and instruments.

In terms of machine types, metal cutting machines lead the way, taking up 31 percent of the total number of exhibitors. The next in line are the component/parts exhibitors coming up to 22.7 percent. Exhibitors dealing with toolings round up the top three spots with metalforming machines, industrial robots, automation, measuring equipment, CAD/CAM and other exhibitors making up the full 100 percent.

Foreign ExhibitorsAmong the foreign exhibitors, Germany boasts the largest contingent with 60 companies. Japan make up the biggest foreign contingent from Asia with 56 companies taking part.

The internationality of the event can be seen with some 20 foreign countries taking part in this year’s event. They come from all corners of the globe including USA, China, Spain, Turkey and Australia, just to name a few.

Show HighlightsAlthough the main focus is expected to go to the exhibits, there are other activities going on concurrently at the venue for visitors of different interest. Among those events is the machine tool symposium by Korea Society of Machine Tool Engineers.

For those who are interested in CNC repair and maintenance, there is a workshop held from April 14 – 15. A seminar on advanced

SIMTOS 2010Event Preview:

industrial robot technology will also be conducted for visitors with an eye on automation. Other highlights include machine tool coordinating meeting among Asian MT associations, a CAD/CAM conference and an international machine tool technology seminar.

KINTEXSeoul, South KoreaApril 13 – 18, 2010

Enquiry No. 2601

EVENTs&ExhibiTioNs

ENQUIRY NO 034



An event that will create o p p o r t u n i t i e s f o r exhibitors and visitors alike, Intermach 2010 is

a platform for business into the whole ASEAN region. It is an event where decision makers gather to meet, talk shop and do business on the spot.

Giving visitors VIP access to many important seminars, conferences and related activities affecting Thai industry, as well as global economic issues – the event allows access to inside information that can provide a big competitive advantage.

What Can You ExpectIn this year’s event, visitors can expect to see a full display of high-tech machinery from the world’s leading international manufacturers

Intermach 2010Event Preview:

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In addition, Sheet Metal Asia 2010, an important sub show at the event, will display sheet metal machinery including hot-stamp presses, water-cutting equipment and the latest laser technology – much of it being shown in Asia for the first time.

Power Of 1Sanchai Noombunnam, UBM project director for the event says: “The 4th quarter of 2009 showed a strong recovery underway in Thailand for the automotive, subcontracting, electronics and electrical industries. In 2010, Thailand expects to export around 600,000 cars – an increase of 14 percent over 2009.”

Riding on the wave of optimism, a strategy has been developed to help increase business opportunities as Mr Noombunnam concludes: “We have been working hard with the Thai Board of Investment (BOI), the co-organiser of Subcon Thailand, and other government agencies to develop our strategy, ‘The Power of 1’ – is focused on helping Intermach customers increase business opportunities with major manufacturers in Thailand and other countries.”

BITECBangkok, ThailandMay 13 – 16, 2010

Enquiry No. 2602

who will be arriving from over 30 countries. Major country pavilions and displays featuring over 4,000 individual pieces of machinery and equipment will also add internationality to the show.

For those looking to cast their net in the field of business, the business matchmaking opportunities with buyers from the automotive, electronic appliance and electronics industries will be made available.

Other Events Running ConcurrentlySubcon Thailand runs in conjunction with Intermach and helps manufacturers and suppliers form mutually beneficial partnerships. Over 300 local and international subcontractors will be at this year’s event, according to the organiser.

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Medtech manufacturing 2010 will be held in Suntec Singapore from March 18 – 19,

2010. Organised by SPETA in collaboration with IE Singapore and SPRING Singapore, the inaugural event will play host to some 50 exhibitors.

The exhibitors hail from industries specialising in optics, plastics processing technology, precision metal finishing technology and machine tools, just to name a few.

The profile of visitors ranges from heads of quality control, technical procurement managers, medical packaging designers and medical equipment procurers amongst others.

Conference & Other HighlightsJointly organised by Singapore Institute of Manufacturing Technology and SPETA, the conference focuses in manufacturing opportunities and challenges, manufacturing of medical device and emerging technologies for medical devices fabrication.

Another highlight of the event is the Global-Asia Trade Exchange (GATE). It is a procurement event in Asia that seeks to connect global buyers and regional suppliers in

Medtech Manufacturing 2010Event Preview:

EVENTs&ExhibiTioNs

the electronics and precision engineering industry. GATE was first launched in 2004 by International Enterprise (IE) Singapore, as a platform for Singapore companies to meet with key global procurement decision makers from global OEMs.

GATE 10 caters specifically to buyers from the medical technology industry. It is a global buyer- centric platform that allows international buyers to source for a wide range of products and services from end-to-end precision engineering and electronics solutions such as product design and development, prototype testing, production and assembly, to supply chain and distribution services.

Through a process of pre-qualification, this business- matching event is designed to be focused and targeted such that buyers will be matched with the most suitable suppliers based on their requirements.

Accelerating Medical Technology Innovation In AsiaAsia presents new growth opportunities with a growing base of ageing population and rising affluence. In 2050, the United Nations expects Asia’s population aged 60 to grow beyond 100 million. Alongside this development, Asians’

growing purchasing power will fuel the demand for better quality healthcare systems and solutions.

This growing market in Asia presents a window of opportunity for medical technology companies to venture into new frontiers and new geographies.

Key Global Manufacturing Site Today, 30 global medical technology companies have invested in commercial-scale manufacturing plants in Singapore. They develop and manufacture a wide range of medical products, such as contact lenses, scientific analytical equipment, implantables, syringes, stents, catheters and hearing aids as well as research instruments.

In research tools and diagnostics instruments, Singapore is one of the leading global sites that supplies 70 percent of the world’s micro-arrays and 50 percent of the global demand for Polymerase Chain Reaction (PCR) instruments.

Indeed, as companies seek to outsource their manufacturing a c t i v i t i e s t o e l e c t r o n i c manufacturing services and precision engineering companies, they can tap on the capabilities and expertise of our local suppliers.

These suppliers adhere to strict standards of IP protection and regulatory requirements stipulated by US FDA and European EMEA. They have also received ISO 13485 certification and have established a strong track record amongst leading medical technology corporations.

Suntec SingaporeSingaporeMarch 18 – 19, 2010

Enquiry No. 2603



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Automechanika ShanghaiEvent Review:

The f i f th ed i t ion o f Automechanika Shanghai was held from December 9 – 11, 2009 at the Shanghai New

International Expo Centre, China.Exhibitor numbers increased by

nearly 22 percent to 2,414 from 24 countries and regions, compared to the 2008 event. Showing an even larger increase were the visitor numbers with 38,551 visitors from 132 countries and regions attending the show. This is an increase of nearly 25 percent compared to the previous show.

Automechanika Shanghai has further confirmed its position as an international show with 29 percent of the visitors coming from overseas, compared to 16 percent in 2008. The top 10 visitor countries and regions outside China were (greatest first) Taiwan, South Korea, Malaysia, Iran, Japan, Russia, Turkey, India, the United States and Hong Kong.

Business OpportunitiesHeads of sourcing and procurement departments from 15 companies including China, France, Italy, Japan, New Zealand, South Africa and UAE attended the Automechanika Matchmaking Forum to meet one-on-one with suppliers.

Dubai company Dynatrade specialises in a diverse range of automotive products such as tyres, batteries and vehicle parts.

Manager, V Rajkumar was very satisfied with the event: “This is the first time that I’ve participated in the matchmaking event,” he says. “Since there are too many companies at the show, the matchmaking forum is like a short-cut for me to quickly make contact with the leading suppliers.”

Latest Industry TopicsOther industry events at the s h o w i n c l u d e d t h e f i f t h International Forum and Showcase

bigger, we see the need for an extra show day. We also received feedback from exhibitors and visitors who wanted to extend the show by one day to further maximise their benefits and opportunities.”

Shanghai New International Expo CentreShanghai, ChinaDecember 9 – 11, 2009

Enquiry No. 2604

of Service Outsourcing in the Manufacturing Industry.

Other events included the Automechanika Academy which was attended by many prominent industry speakers who explored the latest topics.

In 2010, Automechanika Shanghai will become a four day event, instead of a three day event, running from December 8 – 11, 2010.

Jason Cao explains: “As the show is becoming bigger and

EVENTs&ExhibiTioNs



Singapore Airshow 2010

Event Review:

EVENTs&ExhibiTioNs

Asia’s largest and one of the top three aerospace and defence exhibitions in the world, played host

to industry bigwigs, international government and mi l i ta r y delegations, providing them a platform to network and make key announcements.

As the global economy recovers from the recent downturn and the aviation industry is on a slow upswing, the biennial event saw deals and announcements at the show worth about US$10 billion over the first three days. To date, trade visitorship has already exceeded 30,000, which is higher than the inaugural show in 2008.

Overseas visitors have more than doubled from 25 percent to more than 50 percent. There was also a notable growth in the total number of countries/regions represented, with the count moving up from 113 in 2008 to 119 this year.



73

In terms of exhibitors, there was representation from more than 60 countries/regions. Singapore Airshow attracted high-level foreign dignitaries from around the world. The total number of foreign delegations grew from 240 from 61 countries in 2008 to over 250 delegations coming from close to 80 countries this year.

“As the first major airshow taking place at the beginning of the year, the Singapore Airshow is in a position to gauge the pulse of the industry. Although aviation as a whole has taken a hit due to the economic downturn, it is promising that we have witnessed large transactions and major announcements this week, and we look forward to the market picking up further as the industry rides the upturn. For the next Singapore Airshow in February 2012, we have already more than 60 percent of the exhibition space taken up. We are committed to delivering another iconic and strategic event,” says Jimmy Lau, MD of Singapore Airshow & Events.

Changi Exhibition CentreSingaporeFebruary 2 – 7, 2010

Enquiry No. 2605

In terms of exhibitors, there was representation from more than 60 countries/regions

Military aircraft were also part of the draw of the show

EVENTs&ExhibiTioNs



EVENTs&ExhibiTioNs

Bombardier, Bodycote, Rösler, Addvalue Technologies Join A*STAR’s Aerospace ProgrammeT h e A g e n c y f o r S c i e n c e , Te chno logy and Resea rch (A*STAR) has inducted four new members namely Bombardier, Bodycote, Rösler and a local SME, Addvalue Technologies, into its Aerospace Programme. Including the new members, there are now 18 companies in the consortium, of which seven are local companies.

The Aerospace Programme,

l a u n c h e d i n 2 0 07, i s a n ongoing and proactive industry engagement effort that enables members to partake in aerospace R&D by leve rag ing on the agency’s scientific know-how and resources, and is helmed by industry giants. It has invested a total of S$18M on 16 projects to date.

Enquiry No. 2607

A*STAR’s Institute of Chemical and Engineering Sciences (ICES) is entering into a collaborative project with EADS, a global leader in aerospace and defence, to investigate the conversion of algae oil to kerosene for jet fuel.

The objective of this 12-month collaboration is to assess the potential for microalgae to be a renewable source of fuel for aircraft and to investigate the conversion of algae oil to kerosene for use as jet fuel.

Air transportation is a vital contributor to global economic growth. The aviation sector accounts for 2 to 3 percent of man-made CO

2 emissions, and although this may be a small proportion, EADS recognises that growth in air

transportation must be sustainable. There is significant interest

across multiple sectors in the potential of microalgae as an energy source. They have the potential to produce nearly 90,000 litres of oil per hectare per year.

Microalgae grow rapidly (doubling in biomass in as little as a few hours), require limited nutrients to thrive, but technological breakthroughs are needed for them to become viable. Some microalgae contains high levels of oil content which can be used as the feedstock for making jet fuel, for example by separation of fatty acids, hydrogenation and hydro-cracking.

Enquiry No. 2606

Aviation Industry:Into A Greener Future



75

Cognex: 3D Vision Software

Cognex 3D-Locate delivers accurate, real-time, three-d i m e n s i o n a l p o s i t i o n information that enables automation equipment to work with a wider variety of parts, including items that are stacked or tilted.

U s i n g t h e software can improve vision performance for challenging applications such as logistics and robot-guided de-palletising and precision assembly, and it can eliminate the need for expensive mechanical fixtures or measurement devices. The software can also be used in combination with Cognex code reading, gauging, and inspection tools.

Enquiry No. 2701

Extensible CAD Technolog ies, p r o v i d e r s o f CAD and PLM p r o d u c t i v i t y sof tware, has r e l e a s e d t h e Office2PDM. The program is an add-in for Microsoft Office that brings the document management functions of SolidWorks Enterprise PDM directly into Microsoft Word, Excel and PowerPoint.

The product provides access to common Enterprise PDM functions as well as timely access to document status information, all without requiring users to open up a separate interface. It enables SolidWorks Enterprise PDM users to access Enterprise PDM directly through their Microsoft Office environment by way of a simple and intuitive ribbon interface as well as an easy to use task pane.

Enquiry No. 2702

Extensible CAD Technologies: Easy Assess Program

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ProductFinder



ProductFinder

Master Chemical: Low Cost Metalworking Fluid

Master Chemical has developed a low-cost and low-odour semisynthetic metalworking fluid. Trim SC520 uses a proven EP-additive package to control built-up edge and improve tool life. It performs well in multi-metal, multi-operational job shops.

The fluid has the wetting and cooling c h a r a c t e r i s t i c s necessary for good

machining results on high-speed milling and turning operations. It provides sufficient lubricity to do down-the- hole operations in aluminium, cast iron, and most steels, including many stainless steels.

It controls chip welding on soft, gummy materials like aluminium and will reject tramp oils rapidly which will help provide good sump life in ‘stand-alone’ machine tools.

Enquiry No. 2705

Mate: 5-In-1 Tooling Kit

The EasyMark 5-In-1 tooling kit from Mate Precision Tooling allows fast and rel iable method for marking fabricated parts in five different ways during the punching process.

It is a thick turret application tooling system for machines without a bottom s t r o k e f o r m i n g feature. Using the programming software in a CNC punch press, this tool system can be set up to automatically perform any of five marking operations.

The operations include writing numbers, dates and other identifying information on a part surface, etching the sheet metal surface with permanent marking information, cut or scribe protective film on sheet metal surfaces, create cone-shaped indentations (centre point down) on the part surface and perform high-speed dot-matrix marking.

Enquiry No. 2706

Iscar: Inserts With PB Chipformer

I s c a r h a s developed Penta 34 inserts with a PB chipformer. The PB chipformer features a single cavity with a positive rake, neutral shoulder angle, and a honed edge. It is actually a C-type chipformer with a different frontal edge.

The chipformer is designed for machining soft materials. It is a solution for parting bearing steel and other very ductile materials. It can be used at low feed: 0.03 to 0.10 mm/rev. The combination of the chipformer and IC908 grade provides good chipbreaking and tool life results. The insert is available in a 1.5 to 3.0 mm width range, made from the IC908 PVD coated grade.

Enquiry No. 2703

A generation of digital microscopes – Leica DVM5000, DVM3000, and DVM2000, has been developed by Leica Microsystems. With the DVM line, the microscopic image is displayed directly on a high-resolution monitor. The zoom optics reach difficult-to-access surfaces for nondestructive inspection of even the largest stationary parts, which could only be examined with great effort using traditional microscope techniques.

Leica digital microscopes not only feature high-quality optics, they also offer a variety of quantitative analysis options – whether 2D analysis or advanced 3D surface measurements.

Enquiry No. 2704

Leica Microsystems: Digital Microscopes



77

ProductFinder

Mori Seiki has expanded its NV Series by adding the NV7000 with a table size of 1,700 mm x 760 mm and Y-axis travel of 760 mm. The VMC features a high-rigidity structure, which has been inherited from the MV Series, as well as versatility and simplicity equivalent to those of the DuraVertical Series. The machine is also equipped with the operating system, MAPPS IV.

The machine improves rigidity by increasing the width of guideways 2.4 times wider than the conventional machine. It offers good damping performance with the use of slideways in all axes.

Enquiry No. 2708

Mori Seiki: High-Precision VMCMikron Tool: Back Chamfering Without Re-Clamping

Mikron Tool has developed a milling cutter, which is designed for back chamfer milling of contours and bores in small dimensions. Compared to other products available on the market it has up to 50 percent more teeth, according to the company.

The toolmaker claims this results in better surface quality at high cutting speeds. Used for the smallest holes and micro machining, starting from diameter 0.4 mm and depths of 5 x d, where it c a n b e optimally u s e d , t h e main applications can be found in the watch industry, medical engineering and automotive.

Enquiry No. 2707

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Mastercam X4 is here, delivering dozens of new tools

based on input from users like you. From dramatically

fi ner machine fi nishes and effi cient dynamic milling to fast

multi-core computer processing, Mastercam

X4 provides maximum productivity at a great

value. Find out how the world’s most widely-

used CAM software* can maximise your

shop’s machining.

See Mastercam X4 in action at www.mastercam.com/X4

Mastercam X4 is here, delivering dozens of new tools

based on input from users like you. From dramatically

fi ner machine fi nishes and effi cient dynamic milling to fast

multi-core computer processing, Mastercam

X4 provides maximum productivity at a great

value. Find out how the world’s most widely-

See Mastercam X4 in action at

Techtown Pte Ltdwww.techtown.com.sg • [email protected]: +65 6741 3318 • Fax: +65 6741 0181

CAD/CAM SYSTEMS

*Source: CIMdata, Inc. 2009



ProductFinder

Witte: Vacuum Clamping System

Flip-Pod vacuum system was conceived for clamping large work pieces in wood, aluminium or plastic parts for different manufacturing processes. These plates can also be modular and by joining them together, for instance with a guiderail system, a larger clamping surface can be achieved.

This vacuum system by Witte comprises of a base chuck with integrated Flip-Pods elements in a pre-selected layout. Non-active pods remain inside the chuck, only Flip Pods required according to work piece contour and geometry are flipped over and thereby activated.

Enquiry No. 2712

The Widia Victory Top Drill M1 Modular Drill gives users the best of both worlds by combining the economic benefits of modular drilling systems with machining performance and hole quality comparable to solid-carbide tools.

Available over a standard diameter range of 8.00 to 20.99 mm, and in length/diameter ratios of 3× and 5×, drill bodies come in either flanged-shank (metric) or round-shank (inch) configurations.

They feature solid coupling for consistent performance from insert to insert and easy insert changes on the machine due to a front-clamping mechanism.

Enquiry No. 2711

Widia: Combining Modular & Solid-Carbide Drills

Sentry Protection Products: Portable Versatile Bollard

Machine shop, foundry and metalworking plant managers and material handling supervisors seeking simple ways to demarcate plant walk-through paths can now use a portable, versatile bollard from Sentry Protection Products. The Sentry Guard Post , a re - design of the tradit ional bollard for a wide r a n g e o f b o t h indoor and outdoor applications.

The lightweight product is 1,219 mm, tapering from 125 x 125 mm, with a 355 mm diameter round base. Each side of the post has a 63 x 500 mm inset available to place reflective tape or other signage.

Watertight and hollow, the product can be filled with ballast (eg: sand or water) to increase stability. It can also be attached with fasteners into a floor, dock, or any other flat base.

Enquiry No. 2710

Stäubli: High Speed Machining Robot

S t ä u b l i R o b o t i c s , m a nu fa c t u r e r s o f advanced industrial and cleanroom robots, has

developed a machining robot, the RX170

HSM (High Speed Machining).

T h e r o b o t features several te chnolog ica l

innovations. This robot has a Fischer Precision high-speed spindle integrated directly into its forearm, an adaptation that enhances rigidity. In addition, the harness containing the unit’s

power supply, cooling system and lubrication is completely inside the arm, with no external ducting. The robot‘s pressurisation also enables it to operate in difficult and wet conditions.

Enquiry No. 2709

www.equipment-news.com March 2010 metalworking equipment news 79

ExhibitionProgrammEs

2010march18 – 19MedTech Manufacturing 2010Suntec [email protected]

24 – 27INAPA 2010JIExpoJakarta, IndonesiaGlobal Expo Managementwww.inapa-exhibition.net/contact_us.phpwww.inapa-exhibition.net

25 – 26China Commercial Aircraft Summit 2010InterContinental Pudong Shanghai Shanghai, [email protected] www.opplandcorp.com/aero/index.htm

aPril13 – 18SIMTOSKINTEXSeoul, S [email protected]

14 – 17Intermold 2010Intex OsakaOsaka, JapanJapan Die and Mold Industry [email protected]/im/english/index.html

19 – 23Hannover MesseExhibition GroundsHannover, GermanyDeutsche Messewww.hannovermesse.de

21 – 24Japan Int’l Welding Show 2010Tokyo Big SightTokyo, JapanJapan Welding Engineering [email protected]/english

may5 – 9MTA Malaysia 2010Putra World Trade CentreKuala Lumpur, MalaysiaMalaysian Exhibition [email protected]

5 – 9Metaltech 2010Putra World Trade CentreKuala Lumpur, MalaysiaTrade-Link Exhibition [email protected]/metaltech

8 – 11MT DuoTaipei World Trade Center (TWTC) Exhibition HallTaipei, TaiwanTAITRA & [email protected]

13 – 15Subcon Thailand 2010BITECBangkok, ThailandUBM Asia (Thailand) [email protected]

13 – 16Intermach 2010BITECBangkok, ThailandUBM Asia (Thailand)[email protected]

13 – 16 Sheet Metal Asia 2010BITECBangkok, ThailandUBM Asia (Thailand) [email protected]

20 - 22Vietnam Manufacturing Expo 2010ICE HanoiHanoi, VietnamReed Tradexvietnammanufacturingexpo@reedtradex.co.thwww.vietnammanufacturingexpo.com

JunE2 – 5Manufacturing Surabaya 2010Grand City Convention & Exhibition CentreSurabaya, IndonesiaPT Pamerindowww.manufacturingsurabaya.com

24 – 27Automotive Manufacturing 2010BITECBangkok, ThailandReed [email protected]

24 – 27Intermold Thailand 2010BITECBangkok, ThailandReed [email protected]

July6 – 9 MTA Vietnam 2010Saigon Exhibition & Convention Center (SECC)Ho Chi Minh City, Vietnam [email protected]

80

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From turning, holemaking, and indexable milling to solid carbide end milling, solid carbide drilling, and tapping, the most powerful tools in the business now proudly wear WIDIA brands. When you buy WIDIA products, you’re not just purchasing speed, power, and precision, you’re investing in quality and complete satisfaction.

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Documents

t ee s

n s h3p

high productivity sumoturn

high toughness

improved mtcvd ticn

chipping resistance

high speed machining

thick alpha al2o3 cvd