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Grinding OutResults

Software Programs Deliver In Cylindrical Grinding

Strong Arm TacticsRobots:

Event Review: Metaltech 2012

Executive Zone: Mid Year Report

September 12 – 14, 2012 • Suntec, SingaporeMedical Manufacturing Asia

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ContentsJuly-August 2012

2 metalworking equipment news Jul-Aug 2012

48From Design To ManufacturingCAD technology for sheet metal allows the designing of sheet metal parts in an intuitive way, taking manufacturing constraints into account. By Samson Khaou, Dassault Systèmes Asia Pacific South

42Maximising Availability For Better Productivity Coupling shop management software with a tool-vending unit pushes productivity to a new level. By Raoul Rapke, IMC Group

34Handling The LoadA robot loading system adds productivity to a machining centre. By Stefanie Senft, Kuka Robot

28Grinding Out Results With SoftwareThe IT experts of Fritz Studer have developed a grinding software which delivers results during cylindrical grinding and simultaneously reduces the processing time by approximately 25 percent. By Erhard Kämpf, Studer

44Cloudy Issues Explained Anubhav Saxena and Stanimira Koleva dispel some misconceptions on cloud computing. By Joson Ng

softwAre & Metrology38Streaming IT Solutions Into FactoriesIncorporating a Manufacturing Execution System (MES) in factories can ease movement of data and production. By Natalia Tee

teCh tAlk30Robots Can Be For You TooA common perception places robots in high-tech futuristic assembly facilities. But the fact is that the usage of robots is applicable to traditional processes like welding and they can find a place in small job shops too.By Joson Ng

Cutting edge26Vertical Support For Better GrindingThe development of synchronous support grinding allows high feed speeds for grinding delicate workpieces such as a crankshaft or camshaft. By Oliver Hagenlocher, EMAG

sheet MetAlworking46 Watch Sheet Metal Designs UnfoldMichael E Neumann takes a quick look at what is available in the market today for sheet metal designing.

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Contents

61Making Parts AirworthyAugustine Quek investigates the various production processes in aerospace part manufacturing.

54Case Study: Arming The QC DepartmentA Malaysian automobile producer brought in an extra pair of arms to improve their inspection process. Contributed by Emily Tay, Faro Asia-Pacific.

events & exhibition 64• Adding Precise Value

Precision engineering can be developed in tandem with the rise of high growth industries, which has propelled the shift towards complex and high volume, low mix manufacturing. By Sherlyne Yong

• Event Review: Metaltech 2012• Event Review: CIMES 2012• Event Review: Hannover Messe 2012• Event Preview: EuroBlech 2012• Event Preview: JIMTOF 2012

metalworking equipment news Jul-Aug 2012

80pgregulArs08 Business News75 Product Finder79 Exhibition Programmes80A Product Enquiry Card

Refer to Advertising Index

For Advertiser's Enquiry Numbers

4

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exeCutive Zone56Mid-Year ReportAs we cross the halfway mark of the year, it is a good time to take stock of the happenings in the first six months of 2012. In this special APMEN feature, we catch up with leaders of the metalworking industry to see how their company fared and what their plans are for the rest of the year.

feAtures60Thailand’s Automotive Industry Controls Its Welding Equipment & Consumables MarketRising eco consciousness could lower the demand for welding in the automotive industry. By Krishnan Ramanathan, Frost & Sullivan

industry foCus50Hear Me OutThe use of acoustics in non-destructive testing and inspection promises to yield faster, more accurate results. By Shahnawaz Abdul Hamid

Visit Our Website

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Grinding OutResults

Software Programs Deliver In Cylindrical Grinding

Strong Arm TacticsRobots:

Event Review: Metaltech 2012

Executive Zone: Mid Year Report

September 12 – 14, 2012 • Suntec, SingaporeMedical Manufacturing Asia


July - Aug 2012

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53Touch Free Is Now The Perfect Touch It is time to change that default setting on the CMMs as the influence of non-contact metrology sweep into the traditional realm of tactile measurement. By Michael E Neumann

ENQUIRY NO 036


editor’snote


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contributorsOliver HagenlocherErhard KämpfStefanie SenftNatalia TeeMichael E NeumannShahnawaz Abdul HamidEmily TayKrishnan RamanathanAugustine QuekRaoul RapkeSamson KhaouSherlyne Yong

board of consultants Wäinö A Kaarto AB Sandvik Coromant

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The world of robotics reaches far and wide in the manufacturing industry and its growing influence is here for all to see. At the recently concluded Automatica 2012 show held in Munich in May, some 31,000 visitors from more than 100 countries attended, according to the organiser. The figures released also revealed good economic conditions for automation technology. Following growth of 35 percent in 2011, the VDMA Robotics and Automation expects further growth of four percent in the current year.

Whether complementary or competitive, there is no doubt the usage of robots is here to stay. For those in the metalworking industry who view the usage of robots as a complementary technology, they can point to stories where robots lend a hand in processes like welding or assist in the loading of parts.

For those who fear being replaced by robots one day, they can take heart that there are certain areas where human intervention is still required. For example, in welding, robots are

not 100 percent effective in identifying gaps inside a welding part whereas a welder can see that and correct the part accordingly.

At the end of the day, the decision to adopt robots in a factory is made based on its merits. Whoever makes the business more money is always going to have a more compelling case. In this issue of Asia Pacific Metalworking Equipment News, we will bring you articles on robots and their applications in metalworking to help you decide what is best for your business.

Apart from robots, we also put the spotlight on NDT, an inspection technique used to evaluate the properties of a material, component or system without causing damage.

On the business front, we are glad to bring you our mid year report, where the bigwigs of the metalworking world come together and assess their companies’ performances for the first half of the year and how they will fare for the rest of 2012.

Joson NgEditor

chairman Stephen Taygroup executive director Kenneth Tan

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ENQUIRY NO 039

Munich, Germany: In 2011, Tüv Süd set new records for revenue, income and headcount. The international service corporation increased its revenue to almost €1.7 billion (US$2.2 billion) (2010: €1.55 billion). Earnings before interest and taxes (EBIT) rose by 12 percent to around €160 million (2010: €143 million).

Dr Axel Stepken, chairman of the Board of Management of the company, emphasised: “Tüv Süd is increasingly turning into a global player: our revenue from international activities increased by more than 13 percent in 2011.” The company generated around 35 percent of its revenue abroad in 2011 — a year-on-year increase of two percentage points.

In addition, the company also further reinforces its already strong position on the fiercely competitive domestic market, increasing its revenue in Germany by 5.5 percent in 2011.

JTC Breaks Ground For CleanTech Two

Singapore: JTC kicked off the construction of CleanTech Two at CleanTech Park to meet the demand from industry players for cleantech-related R&D activities. The building will offer 22,300 sq m of office spaces, laboratories and workshop spaces on a 0.9 ha site. Construction work is estimated to be completed by third quarter of 2014. The building will house the Advanced Remanufacturing Research Centre (ARTC), its anchor tenant.

The partnership agreement was signed by JTC CEO, Manohar Khiatani and Dr Lim Ser Yong, CEO, ARTC and executive director of SIMTech. The centre is a collaborative effort between public sector research labs, the academia and the industry players to advance remanufacturing technologies in Singapore and will be led by A*STAR, NTU, MNCs and SMEs.

Mr Khiatani said in his speech that the partnership between JTC and ARTC brings JTC closer to its vision of advancing Singapore’s position as an innovative cleantech and sustainability hub in the global marketplace.

Guest of honour Lim Chuan Poh, chairman of A*STAR touched on the importance of remanufacturing in his speech at the groundbreaking ceremony. He said: “In certain instances, remanufacturing can save up to 85 percent of the energy that would otherwise have been expended in making a product from scratch.” He also quoted a study that showed the total energy savings from current remanufacturing activities worldwide is equivalent to about 16 million barrels of crude oil, which is the energy needed to fuel six million cars for up to a year.

Tüv Süd Improves Revenue & Income

Posco Named The World’s Most Competitive Steelmaker South Korea: The World Steel Dynamics, an agency specialising in the analysis of the steelmaking industry, announced that Posco has won the first place in the assessment of competitiveness o f s te e lma kers worldw ide this year.

In this year's assessment, it evaluated top 35 steelmakers worldw ide in ter ms of 23 criteria including production output, profitability, technical innovation, price power, cost-cutting measures, f inancial soundness and securement of raw materials.



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www.equipment-news.comM.I.C.A. (P) No. 053/06/2011

April 2012

OFFICIAL MAGAZINE OF METALTECH 2012

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Manufacturing Technology Orders Up 10.2% In AprilUS: April US manufacturing technolog y orders tota l led US$410.42 million according to AMT — The Association For Manufacturing Technolog y. This tota l , a s repor ted by companies participating in the USMTO program, was down 17.0 percent from March but up 2.9 percent up when compared with the total of US$398.73 million reported for April 2011.

With a year-to -date total of US$1,763.77 million, 2012 is up 10.2 percent compared w ith 2011. The se numbers and a l l data in this report are based on the tota ls of a c t u a l d a t a r e p o r te d b y companies participating in the USMTO program.

“ Ye a r- to - date orders o f ma nufactur ing technolog y are up a solid 10 percent over 2011,” said AMT president Doug Woods. “Manufacturing firms continue to hire, with year-over-year unemployment down from nearly 10 percent in 2011 to a little under seven percent this year. In the first quarter, US manufacturing technology exports rose consistently and factory productivity increased five percent. What remains to be seen is whether overseas instability and possible cooling of domestic investment will disrupt continued growth,” he added.

Delcam Advanced Manufacturing Facility Expands Metrology & Machining

Birmingham, UK: Delcam has expanded the range of equipment within the Advanced Manufacturing Facility at the company’s Birmingham headquarters with the addition of a GOM ATOS ScanBox inspection cell for 3D metrology and reverse engineering, and a Hermle C50 UMT five-axis machining centre.

These latest additions form part of a more general expansion of the Delcam Professional Services subsidiary as demand grows for its process development and prototype manufacturing services.

Marcell Marra, SJ Campos

Irvine, US: CGTech and DP Technology have developed an Esprit-to-Vericut Interface. The interface launches Vericut NC verification, machine simulation and optimisation software from within Esprit 2012 CAM software.

“Accurately simulating the CNC machine and material removal with the actual NC code that will run on the machine is a requirement for the complex CNC machines and machining processes supported by Esprit users,” said CGTech’s product marketing manager Bill Hasenjaeger. “Working together, the combination provides a solution to help prevent errors from being forwarded to the shop floor — avoiding material scrap, machine damage, broken tools and wasted time.”

By simulating CNC programs on a computer without using the actual machine tool, the users are able to realise savings and efficiencies by reducing machine cycle time, improving work quality and maximising throughput. Possible programming errors are identified sooner without putting the actual machine tool at risk.

CGTech & DP Technology Develop Direct Interface



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Singapore: The global economy started the year on a firmer footing compared to the second half of 2011, with gains in manufacturing activities supported by increased consumer demand in major economies such as the US and China. Alongside the improvement in macroeconomic conditions, Singapore’s growth momentum has picked up, anchored by a strong upturn in the manufacturing sector.

Nevertheless, the recovery in the global economy remains fragile and vulnerable to downside risks. The US labour market remains sluggish with unemployment rate still at a high level. The Eurozone economies will remain weak, as ongoing fiscal austerity and bank deleveraging continue to dampen domestic demand in the region.

In Asia, notwithstanding the support from rising domestic demand, growth will be curtailed by lacklustre export performances amidst the external headwinds.

In addition, there is increased uncertainty surrounding the Eurozone’s political climate and fiscal outlook. A disorderly sovereign debt default in the Eurozone cannot be ruled out at this stage. If it materialises, there will be considerable downsides for the global economy and Singapore’s externally oriented industries. In view of these factors, MTI is maintaining the economic growth forecast for 2012 at 1.0 to 3.0 percent.

Singapore’s GDP Growth Forecast Between 1.0 To 3.0 Percent

Honda Begins Construction Of Auto Plant In Indonesia

Jakarta, Indonesia: PT Honda Prospect Motor (HPM), Honda’s automobile manufacturing and sales joint venture in Indonesia, has held a groundbreaking ceremony to mark the start of the construction of its automobile production plant in Karawang Industrial Park in the suburb of Jakarta.

With annual production capacity of 120,000 units, the auto plant is scheduled to begin production in 2014 in order to continue meeting demands in the growing automobile market in Indonesia. In addition to BRIO, which was developed especially for Asian markets, HPM is planning to produce a MPV (Multi-Purpose Vehicle) model at the plant.

The plant, an investment of approximately 3.1 trillion Indonesian rupiah ( US$329 million), will employ approximately 2,000 associates at the start of production. Combined with the current capacity of 60,000 units, the company’s annual production capacity will total 180,000 units.

Moreover, HPM will strengthen the local product development function, establish an efficient production system, and increase local content to approximately 80 percent from the current level of approximately 50 percent. Through these efforts, the company will provide high-quality products to its customers with speed and affordability.

MOU Signed To Conduct Joint Research For Manufacturing Technology & ProcessesTokyo, Japan: Boeing and its three major Japanese airframe partners — Mitsubishi Heavy Industries, Kawasaki Heavy Industries and Fuji Heavy Industries — have signed a memorandum of understanding with Institute of Industrial Science (IIS), the University of Tokyo. Under the MOU, the parties will commence joint research and work to create a consortium to develop industrial-scale manufacturing technology and processes, in a new model of academic-industry cooperation.

Efforts initially will focus on the development of machining and drilling process technology for titanium, aluminium and composite materials. The parties' aim is to form a consortium for manufacturing innovation within IIS to tackle manufacturing issues common across different industries in current and future production.



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UCIMU: Machine Tool Orders In Q1 Increased By 10.5 Percent

Italy: During the first quarter of 2012, the machine tool index of orders, processed by the Studies Department of UCIMU-Sistemi Per Produrre has recorded a 10.5 percent increase when compared with the same period of last year.

The index relating to foreign orders has in fact increased by 12 percent in comparison with the same period of last year, for a total absolute record value of 158.9.

On the other hand, the index relating to internal orders, ‘increased’ by 0.1 percent in relation to the first quarter of 2011, for an absolute value of 69.3, shows all the weakness of the home market, which demand remains stagnant.

Giancarlo Losma, president of UCIMU-Sistemi Per Produrre, said: “The continuation of this condition of investment freeze in production technology, forces us

Three Predictions For Industrial Automation & Process Control

all to a careful assessment of the risk of loss of competitiveness of the industrial network of the country, at all levels within the production chain.”

“On the other hand,” added Alfredo Mariotti, general director of the Association, “machine tool compa nies, including foreign ones, still believe in the Italian market, and know the unexpressed potential of the demand. This is demonstrated by the figures for the attendance to BI-MU, the bi-annual exhibition of the sector, which will take place next October in Milan. To date, the figures show a 26 percent increase in purchases of exhibition space when compared with the space purchased by the same period in 2010 (the previous edition). The hope is that the positive trend will continue in the next few months, and that it will be confirmed in the final event results of the event.”

London, UK: Frost & Sullivan released its three big predictions for the industrial automation and process control market. Energy efficiency and sustainability, smart technologies and the influence from BRIC and other emerging economies will be the key topics in 2012 and beyond.

Based on a survey of several hundred companies conducted in December 2011, this research paper highlights areas of growth. “Energy efficiency, advanced technology and geo-economics will transform the face of industrial automation in the future. Along with sustainability, these factors are set to influence product design, project cost and service capabilities of industrial automation vendors in the next-generation enterprise,” comments Muthukumar Viswanathan, director for Automation and Process Control at Frost & Sullivan.

Energy Efficiency & SustainabilitySustainability, in terms of energy and resource efficiency, will be a key ingredient for the success of the global manufacturing industry. The growing focus on the implementation of energy efficient solutions in both process and discrete industries will also promote sustainable manufacturing. Energy efficiency concerns will dominate business in the electric motors market, with class IE3 energy efficiency — a stricter requirement compared to class IE2 energy efficiency — required in 2015.

Smart TechnologiesFactories of the future will be driven by megatrends such as cloud computing, cyber security a nd mobi le a nd w i re le ss communication technologies. The need for higher productivity and greater efficiency will drive

organisations to implement greater interaction between the factory floor and enterprise across all end-users. This will be achieved also by leveraging on technology to provide automation solutions enabling end-users to gain a competitive edge in the global market.

BRIC & Other Emerging EconomiesBR IC a nd other emerg ing economies across the globe are likely to sustain high growth in industrial automation markets. The strongest growth is expected in emerging markets, especially in the Middle East, South East Asia, and Eastern Europe.

Opportunities connected with the modernisation of old infrastructure also exist in developed regions such as North America and Western Europe. In addition, flexible manufacturing will aid regional customisation by aligning the product portfolio to suit market demands.



businessnews

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Businesses Say Sustainability Is Vital to Growth: Study

London, UK: The vast majority of businesses say that sustainability is vital to their future growth, but almost half say that margins are currently lower on sustainable products and services, according to research by Accenture.

The survey of 250 senior executives in eight leading mature and emerging economies reveals that 44 percent think sustainability is critical to their business and 78 percent say it is vital to their future growth. Nearly two thirds (62 percent) of respondents claim their sustainable investments are motivated by customer expectations for sustainable products and services and 60 percent by the opportunity to drive growth. Only 41 percent of those surveyed are motivated by regulatory compliance and only 29 percent by the need to reduce energy and material costs.

When respondents were asked if their sustainable investments are primarily aimed at aiding growth or improving efficiencies and cost cutting, almost twice as many pointed to growth over efficiencies (41 percent to 22 percent). In emerging markets, the distinction was greater still, exactly half of surveyed executives opting for growth over cost savings (18 percent).

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Gothenburg, Sweden: The SKF Group has received the Sustainable Supplier Award from Bombardier Transportation for integrating CSR in business principles and in management standards.

"Bombardier Transportation has been a strategic customer to SKF for many years and we are pleased to accept this award

While the vast majority (83 percent) of responding senior decision makers see spending on sustainability as an investment rather than a cost, a majority (56 percent) say it is currently more expensive to be a sustainable business. Forty-nine percent say that margins are currently lower on sustainable products and services. The figure rises to 54 percent of surveyed businesses in the US and 58 percent in emerging markets.

“The good news is that companies now systematically see sustainability as being vital to their future growth and core to their business,” said Bruno Berthon, MD, Sustainability Services at Accenture. “Sustainability has broken free from the realm of regulatory pressure and reputation management, and is now rising into a virtuous circle of commercial opportunity and investment growth. Businesses must now industrialise and scale production in order to drive higher levels of productivity, operational discipline and cost optimisation into what can often be immature operating models in high growth sustainable markets.”

Premium PricesThe concern over lower margins may be explained by the survey’s finding that businesses think consumers are reluctant to pay more for sustainable products and services. Almost half (47 percent) of respondents say that consumers are not willing to pay a premium for them (exactly a quarter of respondents believe that they are willing to do so).

Nevertheless, 60 percent admit to charging premiums for sustainable products and services and the largest proportion of those that do so (68 percent) claim they can charge between 5 and 20 percent premiums. Seventeen percent claim they can charge premiums of between 20 and 50 percent. Yet, despite charging higher prices, over one third (37 percent) of surveyed businesses say they cannot keep up with customer demand for sustainable products and services. This figure rises to 44 percent in emerging markets.

SKF Receives Award From Bombardier Transportationthat recognises the work we do to integrate CSR into all areas of our business," says Henrik Lange, president, SKF Industrial Market, Strategic Industries. "SKF Care, our sustainability program, drives how we integrate sustainability into our business, into our environment projects, into how we suppor t ou r employees, and how we work

with the communities where we do business."

P i e r r e A t t e n d u , c h i e f procurement officer of Bombardier Transportation, presented the award in Berlin with the statement that SKF is going beyond industry standard. He further stated: "The excellence of integrating CSR in the business principles has been successfully achieved by SKF."



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APEC Economies Remain The World’s Fastest Growing

Kazan, Russia: The growth of APEC’s 21 member economies is expected to buck global trends and outpace the rest of the world in 2012 despite the uncertain environment, according to a report issued by the APEC Policy Support Unit ahead of the Meeting of APEC Ministers Responsible for Trade in Kazan.

APEC economies’ growth

New York, US: Bauxite mining in Australia, China, India and Kazakhstan is expanding rapidly due to an eager end-use market and gigantic reserves, but regulations may prove a hindrance to ambitious miners, according to natural resources experts GBI Research.

The report shows that while Asia-Pacific is estimated to hold the second-largest reserves of bauxite in the world, with Australia and China ranking as the top bauxite-producing countries globally, practicalities may get in the way of future profits.

Asia-Pacific accounted for around 64 percent of global bauxite production in 2011, and levels are expected to shoot up further as a result of the growing regional

Aluminium-Intensive Industries To Boost Bauxite Production In Asia

before rebounding to 4.1 percent in 2013.

“ T h e r e l a t i v e s t r o n g performance of APEC economies within the current economic climate is significant,” said Raymond Greene, the APEC Economic Committee’s chair.

GDP growth of industrialised APEC economies is expected to show resiliency with a 2.1 percent pick-up in 2012 while industrialised economies outside the region are facing the prospect of a mild recession.

Developing and emerging APEC members’ GDP growth is meanwhile forecast to soften to 6.3 percent in 2012. Yet they will remain the world’s fastest growing economies, contributing more than 50 percent of global real GDP growth.

APEC’s developing and emerging economies are furthermore predicted to regain ground in 2013 on 6.9 percent growth although external factors remain a cause for concern for all APEC members.

moderated from 5.9 percent in 2010 to 4.1 percent in 2011 but

kept ahead of the 3.9 percent global growth rate in 2011, the APEC Economic Trends Analysis reveals.

The moderation of APEC economies’ growth partly reflected weaker investment and exports amid the

intensification of the Euro area debt crisis

and disruptions to the APEC region’s supply and

production chains caused by a series of natural disasters.

Private domestic consumption within APEC economies was robust, however, supported by strong income growth and improved employment opportunities.

In 2012, the APEC region’s growth is forecast to accelerate to 4.3 percent and climb further to 4.7 percent in 2013. By comparison, world growth is projected to decelerate to 3.5 percent in 2012

demand for aluminium. Asia-Pacific consumed an estimated 160 MMt of bauxite in 2011, as the construction, automobile, electrical appliances and packaging industries in the rapidly developing economies of China, India and Australia began to source more bauxite with which to expand their businesses.

China’s 12th Five-Year Plan will also see more bauxite imported into the country to support the State Grid Corporation of China’s plans to build a network of aluminium ultra-high voltage electricity transmission lines to enhance transmission capacity in remote areas.

However, regulatory issues imposed on the mining industries of many Asian countries may

damage bauxite production levels in the region. Australia’s national parliament announced plans in November 2011 to impose a US$23.6m-per-ton tax on carbon emissions for the biggest industrial polluters from mid-2012, while the Kazakhstani government’s Mineral Extraction Tax and Excess Profit Tax has been an important fund-raiser for the government, but an object of criticism from the mining companies.

Asia-Pacific produced an estimated 136 Million Metric Tonnes (MMt) of bauxite in 2011, against a consumption of 160 MMt. Production is expected to increase during 2012-2020 at a Compound Annual Growth Rate (CAGR) of 6.7 percent, to reach approximately 249 MMt. Similarly, consumption is expected to grow at a CAGR of 6.3 percent to reach 276 MMt in 2020.

g-point, Czech Republic



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Soaring Commercial Aviation Market Drives Aerospace & Defence Industry

expected to rise for the sector overall, there is a significant risk that return on sales could drop due to supply chain inefficiencies.”

C o m m e rc i a l a e ro sp a ce companies predominantly reported strong revenue growth and delivered a record number of large aircraft in 2011, exceeding 1,000, driven by a record backlog and increasing production rates. The strong order activity was largely led by the launch of two new single-aisle aircrafts, the A320Neo and 737Max. These re-engined versions of existing models, which promise at least 15 percent efficiency improvement, have unleashed a flurry of orders, both in the expanding Asian market and among US carriers.

Mr Hampson said: “2012 is already off to a great start, but the industry will continue to face challenges such as rising production rates, raw materials shortages and

late deliveries. Despite these issues, times are good for the A&D sector. In fact, many are debating whether there’s a bubble in the industry. However, current backlog levels provide ample cushion between demand and production rates, likely absorbing any reasonable softening in demand near-term.”

One area of opportunity for defence contractors has been exports, where growth led to a record backlog of $327 billion at mid-year 2011. However, defence companies are and will continue, to face more pressure than ever to improve productivity, increase transparency and respond to increasingly complex government regulations, especially given uncertainty over longer-term prospects including looming budget cuts, the growing threats of Iran’s nuclear weapons program and the US military’s role in world affairs.

As the report highlights, the industry must overcome three challenges to thrive in the future: preserving innovation, improving productivity and abiding by the regulatory environment.

He said: “The current focus remains on affordability, so contractors need to stay dedicated to improving productivity, where they’ll start seeing the shift from new platforms to platform upgrades and sustainment. The industry also needs to recognise the value of innovation and research and must invest in knowledge retention and training.”

London, UK: The Aerospace and Defence (A&D) industry experienced a record year in 2011 on the strength of a surging commercial aviation market, according to the Aerospace & Defence 2011 year in review and 2012 forecast report from PwC. In 2011, the top 100 A&D companies reported $677 billion in revenue, a five percent increase compared to the previous year, and $60 billion in operating profit, an increase of two percent from 2010.

Neil Hampson, global aerospace and defence leader, PwC, said: “This year, we expect continued growth in commercial aerospace resulting from strong and steady demand for global aviation and increased commercial aircraft production. Conversely, defence revenues should continue to remain low, but recent cost-cutting actions should mitigate the impact on company bottom lines. While revenue is

Times are good for the A & D sector

East Hartford, US & Riyadh, Saudi Arabia: The Middle East Propulsion Company (MEPC), a joint venture between Pratt & Whitney’s parent company United Technologies Corporation, Saudi Arabian Airlines, Mohawearean Aviation Services Company and MTU Aero Engines has opened an aircraft-engine maintenance facility in Riyadh, Saudi Arabia, to handle

Pratt & Whitney Inaugurates A Propulsion Company Facility In The Middle East

increasing needs for maintenance and repair of military aircraft engines in the region.

The 194,000 sq ft facility will accommodate forecast growth in both existing and new product lines. MEPC has been the overhaul provider of choice for the Royal Saudi Air Force’s F100-PW-220/220E engines since it opened in 2001. Growth plans include expanding

the facility’s portfolio to include engines for military helicopters, tanks and others vehicles.

MEPC, which provides military engine maintenance, repair and overhaul (MRO) services for the Middle East, is part of a larger network of Pratt & Whitney military MRO solutions, offering a range of services.



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Scanning With Terahertz Waves

Germany: Radio signals reach pilots on board an aircraft through the ‘radar dome’, the rounded nose of the aircraft. But if errors occur during the production of this ‘nose’, — tiny foreign particles, drops of water or air bubbles — this can impede radio traffic.

Researchers at the Fraunhofer Institute for Physical Measurement Techniques IPM in Kaiserslautern are working with partners in industry and research to develop a new testing system: the system uses terahertz waves to completely scan the aircraft nose, which is several centimeters thick, and immediately identify any flaws.

The frequency of terahertz waves falls between that of microwaves on the one hand and infrared light on the other. They are completely harmless

to humans. The waves are generated in a rolling cabinet not unlike those found in many offices: it contains a microwave source and all electronics to control the system and to collect the data. A frequency mixer multiplies the frequency of the microwave radiation generated into the terahertz range.

Researchers have connected the actual measurement module to this container by means of electrical wires. This module emits the teraher tz waves toward the radar dome. The material reflects the radiation, and the detector integrated in this module analyses the reflected terahertz radiation. If there are any air bubbles or little imperfections embedded in the material, they turn up in the reflected signal.

The main challenge facing researchers was to find out which terahertz frequencies they would have to use to bombard the material to achieve the most effective results for the various imperfections.

Higher frequencies create better resolution, while lower frequencies have less difficulty penetrating the material. The researchers select from a range of different frequencies depending on the errors the researchers are looking for in the case concerned. The scientists have already developed a prototype of the testing system.

Around a year from now, the scanner will have advanced to the point that it will scan and analyse aircraft noses automatically. Cuurently, simple scanners for level and rotations symmetrical objects are available.

Rio de Janeiro, Brazil: Embraer and Aviation Industry Corporation of China (AVIC) have signed an agreement to build Embraer’s Legacy 600/650 executive jets in China, using the infrastructure, financial resources and workforce of their joint venture Harbin Embraer Aircraft Industry (HEAI), which started operations in 2002.

The agreement is based on

Embraer & AVIC In Joint Venture To Build Executive Jets In Chinathe understanding of both parties about the potential demand of China’s flourishing executive aviation market, and their wish to extend their decade-long strategic partnership. HEAI’s first executive jet is expected to be delivered by the end of 2013.

To date, Embraer has 154 firm orders from China market, with 116 aircraft already delivered.

The company accounts for around 78 percent of China’s regional aviation market and is gaining strength in its executive segment with 18 firm orders for executive jets in the year 2011. The cooperation with AVIC on Legacy 600/650 program further consolidates the company’s presence in China’s executive aviation market.

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Domestic Orders Holding Up For Germany’s Machine Tool Industry

Frankfurt am Main, Germany: In the first quarter of 2012, order bookings in Germany’s machine tool industry fell by seven percent. Domestic orders were one percent down on the preceding year’s equivalent figure. Orders from abroad fell by nine percent compared to the historical highs of the previous year.

“Capacity utilisation is still holding up well in Germany’s i n d u s t r i a l s e c to r, w h i c h is inve st ing in addit iona l capacit ies for coping with its orders,” says Dr Wilfried Schäfer, executive director of the sectoral organisation VDW (German Machine Tool Builders’ Association), Frankfurt am Main.

Domestic demand for forming technology, in particular, has had a stabilising effect. Forming technology is used primarily in longer-term project business for larger customer groupings like

the automotive industry. So very sizeable orders in the first quarter of 2012 led to yet another rise in order bookings of more than one-fifth.

“European demand, too, is still looking good,” he says. Although the debt crisis is being reflected in declining orders from Southern Europe, other European countries like the Scandinavian nations, the UK or France have continued to place substantial orders, a trend already foreshadowed at the METAV 2012. Exhibitors at the trade fair had confirmed a continuingly high propensity to invest in Europe’s industrial sectors.

The order backlog, at nine months in February of this year, is at a similar level to October of

last year. Capacity utilisation, at 95.1 percent in April 2012, was likewise almost unchanged. In February of this year, the sector was employing 68,200 people, 6.4 percent up on the preceding year’s equivalent figure.

“The German machine tool industry is still performing well. By reason of the order backlog, a rise in production output for 2012 is virtually assured,” predicts Dr Schäfer. The VDW is forecasting growth of five percent. Although demand is quietening down, this has already been factored into the pricing, and will give the companies a breathing space for addressing strategic issues, like expanding their business operations in Asia.

German Machine Tool Industry - Moderate fall in demand during the first quarter of 2012Note: Index basis shipments 2005=100, data until March 2012

Sources: VDW,VDMA

Dr Wilfried Schäfer

Nashville, US: In all materials, process, and market sectors, the North American Powder Metallurgy (PM) industry has built on the growth momentum begun last year, said Matthew Bulger, president, Metal Powder Industries Federation.

Traditional press-and-sinter PM, Metal Injection Moulding (MIM), Hot Isostatic Pressing (HIP), and other specialty PM technologies are thriving. PM is an interconnected technology that innovates and

Maintaining The Growth Momentum In PMgrows by leveraging its different sectors. Looking back at the past two years clearly suggests that the industry’s recovery is sustainable.

Ironpowder shipments soared in 2010 after a terrible previous year. Total iron-powder shipments grew modestly in 2011 to 363,831 short tonnes, a three percent increase. This increase was also achieved despite the shutdown of a major powder supplier’s main plant for two months.

Shipments of copper and copper-based and tin powders gained almost 19 percent in 2011 to 17,002 short tonnes. Stainless steel–powder shipments increased about five percent to an estimated 7,000 short tonnes.

Shipments of North American MIM grade powders, including imports, jumped nearly 40 percent in 2011. The MIM process continued to garner greater acceptance in the materials marketplace. Some interesting R&D programs include developing MIM ultrasonic



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dentalscaler tips and endodontic tips, and titanium and cobalt–chromium alloys for medical-implant applications.

The HIP business has also experienced robust growth in 2011 due to a general surge in manufacturing, and gains in the oil and gas, tool-steel, and aerospace markets. The HIPing of MIM parts continues to be a growing market.

Sustained Growth AheadMr Bulger noted that 2012 began on a very positive note, with rising confidence levels. First-quarter shipments of metal powders are up, as are volumes of PM parts and MIM parts. US light-vehicle sales are expected to top 14 million units, up substantially from the 12.8 million units sold in 2011.

Iron-powder shipments through April this year rose by 11.25 percent to 134,925 short tonnes. Copper and copper-base and tin powder shipments have remained stable. One of the key issues facing the entire industry is the serious need for experienced production workers and PM engineering professionals. Industry-wide employee reductions during 2008–09 have not been easy to reverse as the industry has rebounded.

Another issue is capacity constraints: will the industry be ready to meet rising demands, part icularly driven by the automotive industry, in the next several years? As was the case with staffs, rationalisation moves

during the same 2008–09 period included several plant closings and the scrapping of older equipment. Because it can take upwards of 10 to 12 months to build a high-end press and put it into production, Mr Bulger cautioned, the equipment investment bandwagon must begin rolling sooner rather than later.

Within the automotive sector, PM is approaching a saturation point in auto-engine content with existing technology. The average

auto engine now contains up to 50 PM parts weighing more than 18 pounds, including connecting rods, bearing caps, valve-seat inserts, and VVT parts.

With the average North America–built engine containing up to 170 individual parts, PM parts currently represent about 30 percent of the content. Potential growth appears more likely in transfer-case and transmission applications.

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25Jul-Aug 2012 metalworking equipment news

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Th e i n t e r n a t i o n a l automobile market is still in the middle of a period of dynamic growth. The

number of automobiles sold on a global basis rose by three percent in 2011 compared to the figure for 2010 according to the American market research institution, Polk.

The production situation at many automobile manufacturers as well as their suppliers is characterised by a great deal of enthusiasm. The ‘just in time’ quantities of a component that are required are also increasing rapidly. Quality is also being tested right now.

The fact that new mechanical engineering technologies can meet these challenges with ease is demonstrated by a particularly demanding application that has a major influence on the quality of the entire engine, the grinding of crankshafts and camshafts. A synchronous support grinding technology developed allows productivity in the production of the components to be improved by up to 70 percent.

Crankshaft & Camshaft Machining The production of crankshafts and camshafts are at the heart o f eng ine product ion and their extraordinary geometry demands complex production processes. Grinding has a special

role to play in the overall process because it must ensure that the components are true to size.

At the same time, the process is often time-consuming and demanding — in particular, shafts which are very slim are not very strong in the machining direction which often means that sophisticated stabilisation methods must be used with multiple trailing steady rests.

C o n s e q u e n t l y , o n l y comparatively low feed rates can be used — particularly to e l iminate t rue running inaccuracies. This naturally results in long cycle times and low output.

“ We d e c i d e d t o t a c k l e this problem head on in our development of a new grinding technology based on the vertical clamping of the component. Our idea was to reduce the forces, which act on the component during the grinding process. Ultimately that will allow higher feed speeds,” explains Dr Guido Hegener, CEO of Emag Salach Maschinenfabrik.

Low Forces Acting On The ComponentThe development of synchronous support gr inding marks a breakthrough by developers in this sensitive application. The principle is based on the use of two grinding wheels, which act on the crankshaft

Vertical SupportFor Better Grinding

The development of synchronous support grinding allows high feed speeds for grinding delicate workpieces such as a crankshaft or camshaft. By Oliver Hagenlocher, head of marketing, EMAG

CuttingEdgE

Jul-Aug 2012 metalworking equipment news


27

Enquiry No. 5001Turn to page 80a or log on to www.equipment-news.com to enquire

or camshaft from two sides moving in different directions.

The normal forces, which occur in the feed direction are compensated by the fact that the grinding wheels are mounted opposite each other and machine the component simultaneously. At the same time, a simple NC-controlled support is used to press against the workpiece from one side.

T h i s m e a n s t h a t t h e workpiece cannot move in any direction and also eliminates tangential forces. “This design therefore has multiple positive effects,” says Dr Hegener.

“On the one hand, extremely high feed speeds for grinding delicate workpieces such as a crankshaft or camshaft are possible due to the rigid clamping operation. On the other, two grinding wheels are used simultaneously. This drastically reduces the machining time compared to the conventional grinding processes in use today.”

Vertical DesignThe design principle of a grinding machine is another major factor in ensuring that the components can be ground at low cost. Using the Emag grinding machine (VTC 315 DS) as an example, the shaft is clamped vertically inside the VTC. The workpiece spindle is at the top, the tailstock is at the bottom. The entire grinding process on the shaft

takes place in this position. The vertical position of the

component also assists in producing good chip flow. This means that the removed material can be removed particularly easily and efficiently together with the cutting fluid. In addition, the cutting fluid does not flow over the structure of the machine and its temperature is not subject to fluctuation at any time during the process.

“This is a point which ultimately has a direct bearing on machining quality because the whole subject of heat management in the system is insignificant,” says Dr Hegener.

Shorter Grinding Time, Better Accuracy What have been the experiences of users of the synchronous support grinding principle? “The responses that we have had have been positive,” says Dr Hegener. “The principle can also be used for transmission shafts, propeller shafts, pump shafts and compensating shafts with a maximum length of up to 600 mm. In every case, there has been a leap in productivity. In some cases, the machining time has been cut by up to 70 percent compared to traditional grinding.”

On the other hand, the machining quality is improved. One example of this is the experience by a user in the production of a cast four-cylinder camshaft for a car.

The machining of the main bearing takes place in several sequences, each with a grinding time of five seconds. Despite the short grinding time, true running inaccuracy levels of less than 10 mm have been recorded. This is much lower than the maximum tolerance limit and marks a clear improvement compared to the grinding process used in the past — in other words, a leap forward in quality.

Doubling The BenefitsSynchronous support grinding is not just appropriate for circular grinding but also produces positive effects for non-circular applications. Pairs of cams on four-cylinder camshafts can be machined simultaneously which means that four grinding wheels can grind a single camshaft at the same time.

This process on the one hand results in drastic reductions in machining times while on the other increasing the quality of the cam shape. This produces double benefits for the user.

Major Market OpportunitiesThe fact that this process has major opportunities on the market will certainly not come as a surprise. In addition, there are many in favour of synchronous support grinding due to the fact that the shorter machining times also mean considerably lower energy costs.

“The energy per piece cost is much lower. This also means lower costs for the user,” confirms Dr Hegener. Furthermore, there is the fact that the vertical systems require less space than machines with a horizontal design.

“Economical processes, simple handling, high quality — the many benefits of synchronous support grinding compared to traditional grinding process will quickly become established on the market,” says Dr Hegener. MEN

Principle of synchronous support grinding

CuttingEdgE



•Automaticcalculationanddesignofthe

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programs

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ofset-upplans, tool lists,additional

comments,andimages

•Timeandcostcalculation,quoting

•Reductionoftheset-uptimes

•Shortergrindingtimesbyapproximately

onequarter

•Reduction of the optimisation time

towardszero

•Reductionoftheerrorcosts

Today’s cameras make it easier to shoot good pictures when compared to the past. As opposed

to 20 years ago, today’s cameras are able to automatically select settings such as the aperture, the light sensitivity, or the exposure. There is now a similar development for cylindrical grinding machines.

E v e r y c o m p o n e n t manufactured on the machine depends on the correct settings. First, the user must select the corresponding grinding wheel. Furthermore, the cutting speed, the cooling lubricant, the stability of the workpiece, critical speed ratios, and the influence of the grain size on the grinding wheel must be checked.

Even if an operator has a

wealth of experience, he does not usually manage to instantly set the machine in an ideal manner. The optimum would be the setting with which the machine precisely achieves the desired grinding result and simultaneously works most efficiently. Normally, this setting can only be found by means of systematic tests.

This takes time and so it is only reasonable when producing in large numbers. For a few hundred units or even smaller production volumes up to single- item production, the operators do not normally have the time to slowly approach the perfect setting.

Therefore, they mostly rely on their gut feeling regarding the values for dimensional, shape, and position tolerances, as well as surface quality. This results in the

The IT experts of Fritz Studer have developed a grinding software which delivers results during cylindrical grinding and simultaneously reduces the processing time by approximately 25 percent. By Erhard Kämpf, head of software department, forms and threads, Studer

Grinding OutResults With Software

Grinding Technology Calculator:

Advantages At A Glance

CuttingEdgE



29


following problem: the majority of users underestimate the machining output of a grinding wheel and, therefore, rarely dare to approach the limits of what is possible.

They often adjust the machine too cautiously and do not utilise its full potential. As a result, the production runs at a speed, which is much slower than what is possible. This way, the companies waste large amount of time and money.

Monetary SavingsA software solution called the StuderTechnology, which is essentially a grinding technology calculator, is available as a practical module of the CAM system StuderGrind. This program contains the entire near-100-year experience of the Swiss cylindrical grinding company.

The engineers supplied the software with the data from countless grinding tests, for which they approached the optimum for the most diverse workpieces again and again. This results in a machine that makes many decisions for the operator. The module determines the most important process-relevant influencing variables and the corresponding values automatically for each processing step.

I n t h i s w a y, i m p ro v e d results can be achieved while simultaneously shortening processing times. A calculation revealed that the processing time, in most cases, could be reduced by at least a quarter with the technology.

For example, using an average universal grinding machine operating in two-shifts, productivity can often be increased to such an extent that a company can save large amount of money each year. In this way, the purchase of the module often pays for itself after a short period of time.

One Software, Two VariantsRecently, the grinding technology calculator has become available in two different versions. For customers operating their own programming office within their company, the full version of the software is available. Using this version, it is not only possible to program the machines on a PC to an ideal standard, but also to display simulations graphically, to calculate unit costs, or to generate operation schedules.

As the latest development, StuderTechnology integrated has now been added. In this version, the software is no longer located on a separate computer, but directly on the machine control system. Using this variant with a range of functions, which is reduced to a workshop level , Fr i tz Studer provides the machine operators with more freedom in their everyday work.

They need only enter the material and will immediately be provided with a suggestion regarding the correct grinding material and the ideal process parameters. Without tedious trial and error, an ideal result can be achieved at the push of a button. MEN

The technology includes years of experience from Swiss cylindrical grinding experts

As with a camera, automatic programs adjust the most important grinding parameters

StuderTechnology determines the appropriate values for each workpiece

CuttingEdgE



When a person is asked to think about robots, it is a good bet that some would conjure

up images of R2D2 and C3PO from the film Star Wars, or many other robots that have graced the silver screens of Hollywood. With the tag ‘advanced technology from the future’ invariantly placed on robots by popular culture, many tend to dismiss the relevance of robots in his/her business without even giving it the same consideration that is given to other technologies.

The perception of robots that is of advanced technology and more importantly, unreachable for most people is slowly changing. In today’s industrialised world, the usage of robots is no longer rocket science or reserved for the top scientists of the world. In fact, it is down to simple logics and economics. It is about whether you need it for your business, and how robots can benefit it.

More Robots To AsiaThe applications of robots are far and wide today. It ranges from assembly, load bearing and even carrying out dangerous tasks like bomb disposal. It is therefore not surprising that robots have found their way to the metalworking industry as well. Whether a business needs the help of robots

depends largely on the intent, according to Alexander Wick, GM, Reis Robotics Singapore.

“The usage of robots depends on the type of products you have and your intention. Why are you using robots? If you are looking for high quantities, and high repeatability, robots are inevitable for bigger mass manufacturing companies. But even if you are a smaller shop producing highly specialised parts, robot applications can be suitable for you as well. Robots can get you consistent quality, a stable production and an all-time availability that in most cases you cannot achieve manually,” he said.

A common perception places robots in high-tech futuristic assembly facilities. But the fact is that the usage of robots is applicable to traditional processes like welding and they can find a place in small job shops too. By Joson Ng

Can Be For You TooRobots

It seems that many in Asia are agreeing with Mr Wick. He revealed to Asia Pacific Metalworking Equipment News in this exclusive interview that Asia

If you are a smaller shop producing highly specialised parts, robot applications can be suitable for you too.

- Alexander Wick

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is witnessing a rise in the take-up rate of robots, no doubt due to changing mindsets and also notably, the issue of labour cost.

“It (the take-up rate) is coming along well. In the beginning, there is no necessity in using robots. This is because the cost of manpower is very affordable. But a lot has since changed. If you look at a market like China for example, the cost of living is increasing year after year and for the first time it makes sense to use robots to save on labour costs,” he said.

There are other reasons for the popularity of robots in Asia. Mr Wick said: “In the past, a lot of the companies were just selling to local markets. Awareness for quality was probably not that big. Now you see the companies selling more internationally. As such, the necessity for a certain level of volume and quality is

there. So I see the markets for robots picking up in Asia.”

He added that China is currently his company’s best performing country in Asia in terms of sales, attributing to some 35 to 40 percent of the company’s

worldwide sales. An increase in demand can also be seen recently in Southeast Asia. On the whole, Asia has grown significantly over the past six to seven years to become the company’s second most important market.

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As far as industries are concerned, the automotive industry is responsible for some 40 to 50 percent of the company’s total sales. Mr Wick was, however, quick to point out that they are a company specialising in turnkey solutions customised to the customers’ requirements rather than ‘just selling’ a robot.

“ O u r t y p i c a l c u s t o m e r is looking to improve and/or modernise his current production processes and we offer him the total solution from the planning stage until the final handover, all out of one hand,” he said. The company’s main customers in the automotive industry are tier 1 and 2 suppliers to the automotive manufacturers.

Robots In MetalworkingWith more Asian companies using robots, Mr Wick spoke at length on

how robots can be incorporated into metalworking processes. “In general, we offer a variety of vertical and linear robots giving us flexibility to cater for different possibilities. Depending on the applications, for example if you are in an environment where you need a lot of space, a great freedom of movement or a high reach, linear robots can be very helpful. If you have more stringent applications, vertical robots are more suitable,” he said.

Like in any other businesses, productivity and safety in metalworking are of utmost concern and he felt that robots could be a big help in these two areas.

He said: “If you look at safety, a robot can do a lot of things humans cannot do. You have applications that have a lot of hazardous risks. For example, someone could be blinded by the welding light or get

sick by taking in the poisonous fumes. Next thing is productivity; humans get tired, and make mistakes but not robots. They work 24 hours a day and seven days a week without any interruption. Finally, if you look at quality, that is another big thing. A welder, once he gets tired, starts making mistakes. A robot always has consistent quality and also high repeatability.”

Limitations & CorrectionsMr Wick did admit that even with many advantages, robots do have limitations as well. He said: “In many cases, people make the mistake of thinking that a robot can do exactly what a human can do. A human can see for example, the deviation or gaps inside a welding part. A human can see that and correct the welding part. For a robot, this is much more complicated.”

One way to avoid this is part preparation. Using welding as an example, he said: “If you want to automate, you need a certain tolerance on parts and they need to be well prepared. Once you have a good clean preparation of the parts, then you do not have any issues. If you look at pipe and mandrel welding and you have two parts that are very clean, you do not have any issues if you want to weld them together. On the other hand, if the tolerances on the part become too big, it is very difficult or almost impossible to do it.”

In summary, the usage of robots is coming to Asia in a big way, and more people would identify it as a good assistant to help in keeping good productivity levels and process consistency. But at the end of the day, humans are still required to make certain decisions. The best way forward for now is probably the combination of consistency and guile, which means the usage of robots with occasional human input. MEN


Man’s new best friend? Robots lending a hand in welding

techtalk

ENQUIRY NO 076



Ma s c h i n e n f a b r i k Berthold Hermle, based in the Swabian town of Gosheim

(Germany), is a manufacturer o f m i l l i n g m a c h i n e s a n d machining centres. In the RS 4 manufacturing system, the company has opted for the KR 1000 titan industrial robot.

T h e 1 , 0 0 0 k g p a y l o a d capacity of the robot is suitable for fully-automatic loading and unloading of Hermle machining centres with heavy workpieces, such as those found in tool and die-making or in mechanical engineering.

Robotic Application Increases Service Life Of SpindleAll C series machine models f rom Hermle can be fu l ly automated with robots. The RS 4 machining centre combines a robot, a pal let magazine and one or even two five-axis C 50 U machining centres to form a production system. The robot system can transport loads weighing 1,000 kg and is used in production for the fully-automatic machining of heavy castings and aluminium workpieces.

A s e n s o r - m o n i t o r e d

TheHandling

LoadA robot loading system adds productivity to a machining centre. By Stefanie Senft, press relation officer, Kuka Robot

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35



changeover station allows the manufacturing system to be loaded and unloaded without interrupting the machining process. The robot is responsible for loading and unloading the pallets with clamped workpieces.

In addition to its automatically exchangeable grippers, the robot can also directly handle the most varied workpieces with ease. Pallet handling and workpiece handling are therefore possible in an ‘on-the-fly’ changeover without the need for operator intervention. The robot is positioned in front of the machining centre and safeguarded by means of a door safety system.

“The robot system and the machining centre can each be operated manually, without disturbing the automatic sequence of the other unit,” says Rainer Kohler, MD of Hermle-Leibinger Systemtechnik, a Hermle subsidiary that specialises in the automation of machine tools. Two operations can therefore be executed in parallel: while one machine tool is machining a workpiece, another can be upgraded.

“The end result is longer service life of the spindles. And that, of course, is the whole point of the automation,” Mr Kohler adds.

Depending on customer requirements, the system can also be expanded to include a variety of heavy-duty racks for workpieces. Prototype manufacturers, for example, can use this robot system for mixed operation: during the day, prototypes or high-quality parts are produced in small batches. During the night, the system

is run in automatic mode and large batches or series parts are manufactured.

Achieving ROI With Flexibility“The robot is a flexible element in the machine tool,” explains Mr Kohler. The unlimited degrees of freedom of the robot make it possible to load and unload a range of pallets and workpieces of any size in a cell. The flexibility allows the operator to convert the system quickly to meet new challenges.

The robot ensures utilisation of the machining centre in three-shift operation — even at the weekend. Automation of the machine tool with the robot boosts the productivity of the system, reduces unit costs and shortens the payback period. “In many cases, integration of the robot into the machine tool has paid for itself in just under a

year,” says Kuka key technology manager Andreas Schuhbauer.

Safe Robot Technology Safety is of paramount importance in machining centres. Where operator and robot work together in close proximity, it must be ensured that the robot cannot move out of its defined workspace. ‘Kuka.SafeOperation’ ensures just that — without the need for mechanical axis range monitoring or expensive, specially reinforced safety fences.

The software transfers safety-relevant control tasks directly to the robot controller, thereby eliminating the need for an external safety PLC. It monitors the position and velocity of the robot and is responsible for operator safety.

“Anyone developing workpiece changing systems today can no longer dispense with robots,” affirms Mr Kohler. “The key factor in the face of global competition is to increase the service life of the machine. A robot system therefore will always be cost-effective.”

Kuka: Agile Small Robot

Automation of the machine tool boosts the productivity of the system.

Kuka Roboter has added to its small robot family

with the KR Agilus robot series. The basic model, KR 6

R900 sixx, weighing 51 kg, can carry a maximum payload of 6

kg. The energy supply system is integrated into the robot to save

space and includes a 100 Mbit Ethernet cable, three 5/2-way

valves (compressed air), a direct air hose, six digital inputs and

two digital outputs.

In addition, the robot is operated with the universal KR C4

controller technology. The robust controller is designed for

low maintenance and optimised energy efficiency. Finally,

it is the only robot in its class to operate with the Kuka

SafeOperation function, simplifying and improving human-

robot cooperation.

In the coming months, it will be followed by further

payload variants in the standard, food, cleanroom and

waterproof versions. MEN

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techtalk

The ExoHand from Festo is a solution for future human-machine cooperation in industrial environments based on soft robotics. It is an exoskeleton that can be worn by an operator like a glove and designed to meet the challenge of an ageing population by functioning as an assistance system for assembly tasks in production.

The fingers can be actively moved and their strength amplified; the operator’s hand movements are registered and transmitted to the robotic hand in real time. ExoHand can simulate all the major physiological degrees of freedom of a human hand. As a result, it supports the various possibilities for gripping which a human hand has. As a force feedback system, it can extend people’s scope of action in production environments.

Adept Technology has developed the Adept Viper s1700D, a six-axis robot. Featuring motors that are faster and more efficient, the robot delivers higher speed motion and increased productivity. Like the previous Viper 1700 robot, the s1700D offers a long reach and high payload capacity within a small footprint.

With a reach of 1.7 m and a payload capacity of 20 kg, the robot is designed for applications that require fast and precise automation and can be deployed for material handling, machine tending, packaging, cutting and assembly.

Toshiba Machine’s TV800 six-axis robot offers fast cycle times due to a low mass design. It however still exhibits rigidity and durability. The robot is also easy to program.

The TV800 model has an arm length of 800 mm, a reach of 920 mm and a composite maximum speed of 8.06 m/s. It has a maximum cycle time of 0.4 to 0.5 seconds, repeatability of ±0.02 mm and a maximum payload of 5 kg. The six-axis robot uses an absolute position detection system and a AC motor at its heart.

The electrically driven small parts gripper EGP by Schunk proves that mechatronic modules by no means have to be complicated. With respect to the mechatronics, it focuses on the essential and places hardly any demands on the user.

For example, it is controlled by the sensor distributor. It

also allows conversion from pneumatic to electric gripper

modules in a flash. An added advantage is that the sensor system of the pneumatic small parts gripper MPG-plus can be transferred 1:1 to the EGP.

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Adept Technology: High Speed Motion Robot

Schunk: Electrically Driven Gripper

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Streaming

Frost and Sullivan, companies find it a challenge to drive operational improvement, optimise energy consumption, and reduce carbon footprint without impacting on profitability. Such issues can be resolved through shop floor to top-floor connectivity, which is an MES feature.

Previously, MES used to operate as self-contained systems; they are increasingly being integrated with Enterprise Resource Planning (ERP) software suites. The goal of the MES is to improve productivity and reduce cycle-time, whereby the latter refers to the total time to produce an order. As such, through the integration of MES and ERP, delivery of quality products in a

Incorporating a Manufacturing Execution System (MES) in factories can ease movement of data and production. By Natalia Tee

FactoriesIT Solutions

timely manner is ensured.Real-time data collected by

the MES for any production step can be called in, and can also be aggregated as Key Performance Indicators (KPIs) in terms of performance of individual plant parts and downtimes. Therefore, it provides a basis for continuous improvement along the entire production chain.

To further illustrate the point, Saint-Gobain Sekurit, an automotive supplier, faced both pricing pressure and increasing productivity demands from suppliers. Their customers requested a price reduction of automotive products by six percent, at the same time, simultaneously

Into

Ma n u f a c t u r i n g Execution System (MES) software is able to manage and

monitor manufacturing operations in factories. This software can be used to support collaborative manufacturing strategies that are designed to integrate disparate data streams from a company’s supply chain and factory floor.

This allows movements of intermediate and finished products to be scheduled, controlled and checked, thereby increasing transparency and enabling management to make decisions based on reliable data.

Optimising Productivity Without Impacting On ProfitsAccording to a market report from

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delivering 10 percent improvements in productivity.

In order to address these pressures, the company had implemented a platform that includes MES to provide real-time visibility and control for manufacturing operations. With this platform, the company is able to achieve standardisation on how product costs and KPIs are measured across the various plants.

In addition, the company is also able to identify areas where yields are best or time is lost as well as realising continuous improvement through best practices.

Furthermore, Rockwell Auto-mation states that companies can use MES to manage energy as a form

Supports Extended Enterprise

Merging Manufacturing Execution

Sys tems and Product L i fecyc le

Management enhances integration of

data and processes.

According to CIMData, a consulting

firm that provides information on PLM

technologies and services, PLM is

defined as:

• A strategic business approach that applies a consistent set of business solutions

in support of collaborative creation, management, dissemination, and use of

product information

• Supports extended enterprise such as customers, design and supply partners

• Spans all phases of product-development, from front-end concepts through

manufacturing and on to maintenance, support, logistics, and eventual disposal

• Integrates people, processes, business systems, and information

Companies choose to leverage on this strategic approach so as to stay competitive

in an unpredictable economy. In the coming years, companies will continue to face new

sets of challenges and opportunities including more complex regulations and customer

expectations for eco-friendly products. As such, in meeting these issues, the broad

range of PLM technologies will continue to expand to encompass areas like social

media, cloud computing and open source platforms.

CIMdata partitions the PLM market into the following primary segments:

Despite 2008 being a record year for the PLM market, there had been a decline

in PLM investments growth due to the global recession in 2009. Although the market

has not yet recovered, the uprising trend is earlier than expected. Coming out of the

recession, many companies are investing in PLM possibly due to a delayed funding of

projects that were previously approved.

Tools • Applications used to create, analyse and stimulate products and plants, and associated documentation

• Examples: Mechanical Design Automation (MDA), Simulation and Analysis (S&A), Computer-Aided Software Engineering (CASE)

Collaborative Product Definition Management

• Manages product or plant definition lifecycle

• Examples: Compressive Technology Suppliers, Focused Application Suppliers

Digital Manufacturing • Supports simulation and analysis of the processes and manufacturing environments used to produce a product

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Due to its complexity and variety, it

is recommended that MES software

to be custom-configured for specific

manufacturing situations. For example,

a MES software package for an electronics maker would not be the same for a

canned food processing plant. The applications should be customised for the specific

manufacturing steps needed inside a plant through add-ons, custom code and layered

applications, depending on the requirements and vendors involved.

Therefore, selecting MES software requires a detailed analysis of capabilities

and features. While some products provide operator instructions for each stage of

production, other products provide finite scheduling, workflow management and quality

analysis features.

Machine monitoring sensors and shop floor data collection terminals transmit

production data from the factory floor to MES. This is made possible when supervisory

control and data acquisition features are part of the MES software. In turn, software-

based algorithms send real-time instructions to devices like a programmable logic

controller (PLC).

Proper Schedule Of Tasks

MES software can also be used to schedule tasks by facility, work entre, machine, and/

or employee skill set. Products that include planning features allow schedulers to load

jobs against an organisation’s total production capacity.

Advanced Production Scheduling (ASP) offers finite scheduling options and a

visual representation of projected workloads. Production Requirements Planning (PRP)

and Material Requirement Planning (MRP) allow schedulers to define processes with

multiple tasks. This way, MES software that integrates PRP and MRP with inventory

management and procurement can generate a schedule that specifies when required

materials should be ordered.

According to Solarsoft, in order to run the plants effectively, it is crucial for

manufacturers to collect data from every piece of equipment in real time. When the

company’s Mattec system is connected to all the machines in the plant, manufacturers

are able to automate the collection of scrap counts and downtime reasons.

Likewise, Siemens Metals Technologies Simatic IT Production Suite enables

production of the entire plant to be planned and monitored in real time. Stage-by-stage

implementation is made easier with the modular structure of the MES.

FlexNet Production from Apriso has combined MES capabilities and FlexNet

applications. By adopting a platform-based approach, the software can reach across

various manufacturing processes at various locations to offer unified integration

of the product supply network. This is often called as Manufacturing Operations

Management (MOM).

MES covers the complete gamut of production activities from order launch to

finished goods. Using current data from the shop floor activities, this helps in rapid

response, thereby reducing waste and errors. As such, the deep focus on the plant

floor has made manufacturer look upon MES as a competitive edge rather than a

technology investment.

The scope of MES tools may drive process improvements and optimisation

efforts pertaining to resources and equipment. However, data analysis tools as

such may also drive regulatory compliance in industries that require detailed record

keeping for traceability. MEN

of resource. For instance, a certain plant in a brewing company’s rising energy costs became a problem, evidently shown in the impact on production costs. In spite of implementing production optimisation measures, energy efficiency still suffered due to constant machine breakdown, lack of spare part tracking and insufficient fault diagnostics. By implementing an integrated MES solution and control-system solution, the plant can achieve reductions in machine downtime and gains in productivity.

Restrained Growth From 2010 OnwardsHowever, since MES has bundled functionalities, MES providers face competition from participants with extended functionalities and homegrown solutions. It is anticipated that there will be a restrained growth for MES from end 2010 onwards.

This i s par t ly because end-users gradually transit to Commercial-Off-The Shelf (COTS) pre-integrated solutions offered by system integrators and niche solution providers. In turn, system integrators are capitalising the market potential by developing in-house solutions targeting niche customers. Moreover, MES solution providers and system integrators may work together to enter markets that were previously out of reach for them.

One emerging trend is the convergence of MES with solutions like Product Life Management (PLM), compliant and quality management, and warehouse management on unified platforms to reduce complexity while driving performance-based reliability. It is expected that the transition of market to pre-customised solutions with extended interfaces will bolster growth for MES markets.


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Industrial vending has been around for over 20 years. However, it only took off in a big way in the US in the

past seven years or so, and has since spread to Europe, South America and Asia Pacific. As multi-nationals diversify their geographic manufacturing base, a host of best practices migrate across borders, including the vending of cutting tools to the shop floor.

To better understand the growth of this phenomenon, we should look at both the sellers and buyers of cutting tools, and how their respective interests are served.

Sellers, and in particular distributors and integrators, are keen to provide customers with easy and reliable access to their

products, as a guarantee of return business and to explore growth opportunities. A vending machine on the shop floor stabilises the business relationship with the target customer and can ward off predator suppliers who still deliver in the traditional, less convenient method.

Buyers are looking to maximise availability of tools so their production does not stop. They also want to minimise cost and risk of ownership of stock, by optimising stock levels or leaving ownership with the supplier through consignment arrangements.

Gaining In PopularityIn the last few years, we have seen an exponential growth in the vending business, with some of the

Maximising AvailabilityFor

major players investing heavily in new equipment installations. The ROI is estimated to be 6 to 18 months with data showing that vending based distribution returns double the growth rate of non-vending based business.

The type of systems in the market vary from the basic helix style machines for simple vending and replenishment tasks, to the high end systems that provide full control over hundreds of stock items in one unit, coupled with powerful tool management software.

The latter is particularly attractive to more advanced users and the medium-to-large customers, seeking a range of functionality, flexibility and reporting, not offered by the basic machines.

Better Productivity

Coupling shop management software with a tool-vending unit pushes productivity to a new level. By Raoul Rapke, director CTMS Division, IMC Group

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A Thinking Vending MachineThe high-end systems have a number of key advantages. The machines are based on drawers or carousel, with multiple individually locked bins per drawer or shelf. Each bin can store a different stock item, suitable for a large variety but low-to-medium quantities. This facilitates broader management of stock, as many more items can be securely stored, and the issue of tools is controlled and monitored. Space is fully utilised, so less hardware is needed, keeping capital costs down.

The advances in software functionality also provide huge benefits to end users. First, the high-end systems deploy clever logistics algorithms to maximise availability of tools while minimising stock levels and obsolescence. In a manufacturing environment, the importance of this cannot be understated.

Machine tools, which cost hundreds of thousands of dollars are chosen for their speed and performance. Suppliers compete for orders based on speed of delivery. If the required cutting tools are not in stock, spindles are left idling and promised delivery dates are endangered. The indirect costs and risk of inefficient tool management are unacceptable.

Recent AdvancementsAlthough predictability is a key factor in ensuring availability, the newer software packages offer clever tools that allow users to customise stock levels for items that are used infrequently. This can be done by overriding the calculated minimum stock level, or inputting changes in relevant parameters like frequency, usage and lead time, that

will automatically generate changes to the calculated minimum stock level. Changes can be effected on the spot, rather than waiting for a weekly or month end process, so the system is always up to date.

There have also been advances in a range of other areas that make these new generation systems intelligent. It is of vital importance that only the right tool is selected for a job. While the bill of materials may designate the cutting tools, to be sure that this is respected, a limitation can be defined in the software, so that at the time of issue, the user is required to input the part number, after which only those tools authorised for use will be available.

The issue of items based on cost centres, like a part, has other important implications. It allows production planners and shop floor managers to track the ‘real’ cost per unit, rather than basing decisions on a theoretical cost.

When interfaced with the customer’s ERP, production batch data can be imported, and the software not only presents the CPU data, but can also report deviations from a benchmark CPU. In this way, changes in tool life, due to the cutting tool, coolant management, machining parameters or maintenance, can be identified and corrected in a timely fashion.

As customers look for new ways to improve their productivity, the intelligent vending solutions that incorporate easy to use, yet sophisticated management software, will become more popular and gradually supersede the simple traditional systems that have been popular until now. MEN

more pics (?) and/or possible odd size ad location

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The indirect costs and riskofinefficient tool management areunacceptable.

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APMEN: HCL and Cisco have launched a joint Customer Experience Management (CEM) Lab. Tell us how the venture came about?Stanimira Koleva (SK) MD, partner business group, Asia Pacific, Japan and Greater China, Cisco Systems: We have partnered with HCL for 16 years, so we see this as a new chapter in our partnership. If you look at us, we are a technology vendor that has been supplying network infrastructures and servers in the horizontal market. But now with IT increasingly running businesses, we have to be much more business-relevant.

I need to have a way to stay in touch with the business process. Being an infrastructure provider, you do not have many options to do that unless you go into much tighter integration with applications with a player who has knowledge of that vertical domain.

Anubhav Saxena (AS) VP and global head, Marketing and Alliance, HCL Technologies: We are getting more proactive. Instead of wait ing for the customers, we are proactively identifying the need for changes that are happening in the market, ie: pre-integrating of solutions (eg: routers, smart grids and switches). We go to customers who are going through changes and ask if they want solutions from us. We are pre-integrating solutions in our labs so that the customers do not have to go through the pain of the integration happening over on their side.

Once you set this solution up, you have a reference architecture that works. As a result, you can replicate it, and you can become more successful as partners in the industry.

APMEN: Cloud computing — some might say the name is quite superficial. What is your

opinion on this and how would you define cloud computing in your organisation? SK: Cloud is a combination o f e x i s t i n g t e c h n o l o g i e s , n o t n e c e s s a r i l y a n e w technology. Cloud computing became poss ib le because o f a d v a n c e m e n t s i n t h e telecommunications sector a l l o w i n g c u s t o m e r s t o

consume services remotely in a virtualised manner, and with much more flexibility.

To that end, we view cloud computing more as a new business model rather than a new technology. However, there are new capabilities we need to build within the technology i n l i n e w i t h t h a t m o d e l of delivery.

Cloudy IssuesExplained

Stanimira KolevaAnubhav Saxena

Anubhav Saxena and Stanimira Koleva dispel some misconceptions on cloud computing. By Joson Ng

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45



Now there is a business model on how IT gets consumed. Therefore, it starts presenting a completely different set of problems on the consumer side, to the extent that instead of integrating technologies, customers are looking at how to integrate services that are delivered through various vendors or from cloud to private, hybrid cloud. It is really how we are changing the way we deliver technologies and services in line with the evolution of the business model, and the evolution of the process the customers are going through.

There is a lot of attractiveness in cloud. There is the availability and the flexibility. It is a great environment for us to make solutions widely available. We hope this is an environment that is going to underpin greater business efficiency.

AS: It is a new service delivery model. It impacts business services and SLAs (Service Level Agreements). Cloud computing on its own would not be the answer to CIOs (Chief Information Officers), but only a part of the answer.

I think the adoption of cloud will come in waves. The first wave will include the infrastructure applications, eg: e-mail, DNS (Domain Name System) and active directories. The reason why it (cloud) is cost competitive is because it leverages heavily on shared services; the basic foundation is that it can be shared across users, and has got all levels of security built in.

T h e s e c o n d w a v e w i l l b e b r o u g h t o n b y

applications like CRM (Customer Relationship Management) for example. Salesforce (a global enterprise software company) is doing well in this respect compared to its competitors because it has got cloud and APIs (Application Programming Interfaces) for easy integration.

However, there are some systems that would not work in a cloud. Enterprise Resource Planning (ERP) is one example b e c a u s e o f t h e l e v e l o f customisation required.

The level of localisation and centralisation is also very different. So if someone tries to make ERP available as a service on a cloud platform, they would not be able to make it cost competitive. The level of customisation would not allow the sharing to take place.

APMEN: One of the advantages of cloud computing is widely believed to be cost savings. However, the skeptics are saying no, citing expensive monthly subscription fees. What are your thoughts on this?

SK: One of the characteristics of cloud is its economy of scale. You can see for example customers who are more cost-conscious adopting cloud services more readily. SMEs kicked off that trend three to four years ago and you can see the market penetration today.

With the larger organisation, t h e p i c t u r e i s n o t s o straightforward in terms of cost implications because what you need to keep in mind is the risk to the business, various regulations and governance that come into play. So it is probably dependent on each individual case, on how the services got implemented.

Also, the savings stem from the fact that you are minimising and managing the risk to the business in terms of much more availability during disaster recovery. Another point is the security you get around the data. All these have to be taken into account.

AS: Ultimately, it comes down to the ability to put cash on the table. Would you want to build a data centre, or would you want to use existing technologies? This has become more of a financial decision today. The kind of rate of return you can get, based on other investments, versus putting the money into a data centre, will kill the business case of the data centre completely. MEN

What Is Cloud Computing?

Providing software applications, data access and storage resources without users knowing the computing infrastructure, cloud computing is the delivery of computing as a service rather than a product. A network like the Internet usually supports it.

Advantages Disadvantages

Reduce CAPEX Service reliability

Increase competitiveness Regulatory compliance

Increase flexibility Security & privacy

Cloud is a combination of existing technologies, not necessarily a new technology.

-Stanimira Koleva

software&Metrology



Ma c h i n i n g a n d designing a normal metal part typically involves a machine

tool and CAD/CAM software programs. When it comes to sheet metal, it is a whole new ball game altogether. There is a complete range of machine tools specially designed for sheet metal fabrications. Bending, punching and even waterjet machines come into mind.

Sheet metalworking arguably runs on its own, w ith its idiosyncrasies and machining intricacies. Even for designing, there are specialised sheet metal design suites or add-on options available for most CAD software programs.

According to a report titled

‘Sheet Metal Industry In The US’, which can be found in Research and Markets, sheet metal demand in the US is forecast to cross US$20 billion by 2016. This suggests more sheet metal projects will be available and as a result, there will be more demand for competent software suites for the designing of sheet metal parts.

Software Programs AvailableWith the race well and truly on to produce the authoritative sheet metal design software program for designers to transform what they have in mind to the drawing board, we take a look at what is available today.

• Unfolding & FlatteningRadan is a CAD/CAM solutions

provider for the sheet metal industry. It develops solutions to design, manufacture and control production of sheet m e t a l c o m p o n e n t s a n d products.

One of its design solutions, Radan 3D, is a 3D modelling package for sheet metal design and engineering assembly modell ing. The modell ing package provides an avenue to create 3D objects from 2D, allowing design flexibility at the same time.

While it is di f f icult to visualise a bent part in its sheet metal form, useful features are found in software programs to ‘unfold’ parts, to allow designers to see or make modifications to their designs.

UnfoldMichael E Neumann takes a quick look at what is available in the market today for sheet metal designing.

Watch Sheet Metal Designs

SheetMetalWorking



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These unfold/fold functions a r e v e r y i m p o r t a n t , o r even essential. It helps to temporarily flatten bends in order to place certain features, such as cuts across bends. Unfolding in the software is automatic and flexible.

In Radan’s solutions, parts can be unfolded directly and ready for onward processing. The unfolder can flatten models, such as intersecting cylinders, producing complex profiles in the developed shape.

• Maximising EfficiencyA nother design sof tware developer, Autodesk, has its sheet metal design environment in the form of Autodesk Inventor. This sheet metal design tool

allows users to maximise their efficiency and cost savings.

Manufacturing engineers can tweak flat patterns to minimise engineering cost. In addition, they can use the lofted f lange command to design transition shapes for press brakes fabrication of parts such as, hoppers, ducts and exhaust hoods. It is also possible to define a sheet metal punch library to standardise punch usage and reduce CNC tooling cost.

Another pertinent point to note in the software program is its design automation tools. It works by basing mechanical relationships rather than geometric descriptions and constraints to achieve faster

programming. The program combines a 3D mechanical de s i g n e nv i ro n me nt for creating parts and assemblies with design tools that enable engineers to focus on design function.

• Simulation ProwessS o l i d E d g e S T4 a l l o w s simulation for sheet metal designers. Engineers can now test design ideas as they work. The program has made it easier to optimise designs with mesh refinements, more mid surface and assembly design capabil it ies for improved analysis, especially with sheet metal components. In addition, simulation can be used to analyse stress, strain, force, displacement and more.

• Combine OperationsLantek has developed its sheet metal and steelwork solutions for 2012. The Lantek Expert CAD/CAM software now includes a manufacturing browser, which optimises the selection of tool options, while algorithms for automatic machining of multi-parts and the 3D simulation of punching operations improves efficiency and clarity.

Automation with pre-nesting, nesting of kits of parts and the linking of a series of operation enables programming to be completed with one mouse click. Whole sequences from importing CAD data to nesting, material selection, programming, and report generation can all be integrated into one operation.

Families of parts can now be automatically machined through parametric control, resulting in improved quality and increased productivity, while combination machines with milling capability are also supported in the new version. MEN

There is a complete range of machine tools specially designed for sheet metal fabrications

SheetMetalWorking



Can you imagine what it must have been like for our predecessors all those years ago when it

came to designing anything from cars, ships to even buildings? CAD was a revelation for engineers and designers globally who now have the power to create virtually anything they can think of.

Undoubtedly, the economic importance of CAD is significant. It is now applied in almost every industry including automotive, shipbuilding, aerospace, industrial and architectural design and prosthetics.

Better Manufacturing Starts In Design In the aerospace industry, CAD is used for multiple purposes with sheet-metal design being an important function. For example, Catia Aerospace Sheetmetal Design is a product used to define sheetmetal parts used in the aerospace industry (hydro-pressed or break-formed). It enables the capture of company


knowledge, including design, and manufacturing constraints.

This solution is based on feature modelling techniques, using a pre-defined set of features used for sheet metal parts designed in the aerospace industry.

Based on both specification-driven and generative approaches, this solution will allow typical hydro-formed aerospace parts to be specified, the system taking care of creating both 3D and flattened part geometry. Where such parts are designed or modified with basic modelling tools within hours or days, this solution allows the same result to be achieved in minutes.

The software program provides a function to design sheetmetal parts in an intuitive way, taking manufacturing constraints into account. It provides the flatpattern of the sheetmetal part, and allows easy incremental design (from

preliminary to detailed stages) and modification both in 3D and flattened conditions.

Whenever initial specifications are changed (eg: the aircraft skin on which a frame has been designed is modified), this product will allow a new part to be automatically rebuilt, based on the new specifications.

One aspect that significantly impacts aerospace sheetmetal design is the differential between the weight and centre of gravity from preliminary design to that during manufacturing.

To overcome this, the software program allows for the inspection and analysis of the weight of the different parts directly in 3D, with realistic physical properties. It is also possible to validate compliance regulations pertaining to weight criteria at the product level. MEN

FromTo

ManufacturingDesign

CAD technology for sheet metal allows the designing of sheet metal parts in an intuitive way, taking manufacturing constraints into account. By Samson Khaou, MD, Dassault Systèmes Asia Pacific South

SheetMetalWorking

Organized by :

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www.metalexvietnam.com

Exhibit Pro le: • Machine Tools and Machining Centers • Sheet Metalworking • Welding Technology • Factory Automation • Pump and Valve • Material Handling • Mold and Die • Wire, Tube, Cable Technology • Control Measurement • Tools and Tooling

Special Feature: • Plastic & Rubber Manufacturing Machinery • Mold and Die Manufacturing Technology • Automotive Parts Manufacturing Machinery • Automation and Assembly Technology

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ENQUIRY NO 092



For several years now, non-destructive testing or NDT has been used e x te n s i v e l y i n t h e

metalworking sector, g iven its ability to detect flaws or a predominant metallurgical condition in a particular product or work piece, without impairing the said work piece’s future usability and usefulness.

As its name would suggest, the NDT test process does not result in changes to the structure or material of the test specimen itself. Therefore it will not inadvertently reduce the lifespan of the specimen during its operation.

NDT processes are common in quality assurance departments in manufacturing companies, where a sample of a particular batch may be inspected using NDT methods, to determine if it meets product requirements. Alternatively, defects in a particular piece of equipment, such as a boiler onboard a vessel or oil rig, can be sought and rectified using NDT.

Rise In PopularityGiven this, it comes as no surprise that NDT has risen in popularity from its early, humble beginnings. According to a market report from BCC Research, the market value of technologies related to NDT in the US alone was US$2.5 billion in 2010. The same report also states that NDT techniques play a crucial role in manufacturing, with sales of NDT equipment estimated at US$422 million in 2010, and predicted to grow at a rate of seven percent per annum.

This rise in popularity has also brought the best minds in physics and engineering

to the sector, allowing NDT technologies to rise in stature, reaching new frontiers. One such technology that has developed recent ly is Acoust ic Pulse Reflectometry (APR), promising to reduce the time taken in detect ing defects in meta l tubes and pipes in a particular piece of equipment, such as a heat exchanger, vis-à-vis other inspection methods.

Another technique within NDT that uses acoustics is Acoustics Emission (AE) analysis. This technique allows a qualitative and, under certain conditions, quantitative assessment of the integrity of the test part or structure, such as the chassis of a car, or the rotor of a helicopter.

Techniques UsedBefore delving into how exactly acoustic technology is used in such inspection and monitoring, let us briefly review the other techniques available in the world of NDT. Within the umbrella of NDT exists a wide range of techniques that serve a broad spectrum of meta lwork ing industries: marine, aerospace, defence and oil and gas.

Most of these techniques focus on using principles of physics such as electromagnetic radiation, acoustics and magnetism in churning out meaningful results for the tester. To achieve this, however, requires that the right method be chosen for a particular application, given that some principles have little or no relevance to certain applications.

Hear Me OutThe use of acoustics in non-destructive testing and inspection promises to yield faster, more accurate results. By Shahnawaz Abdul Hamid

Artur Bienek, Poland

It may be early days, but it would not be far-fetched to suggest that acoustic technologies such as APR and AE will be making inroads into the world of metalworking inspection

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Here is a l ist of current available NDT techniques:

• Penetrant Testing Uses a penetrant solution

(or dye) to determine cracks, porosity or other defects in the surface of the test specimen.

• Magnetic Particle Testing Magnetic flux leakages from a

ferromagnetic test specimen highlight the presence of surface flaws and breakages.

• Ultrasonic Testing High frequency sound waves

sent into the test material allow defects to be located.

• Eddy Current Testing Eddy currents generated from

a coil located near the test specimen allow the user to detect surface and near-surface flaws.

• Radiographic Testing X-rays are used to produce

images of objects using film or other radiation-sensitive detectors. Variations in radiation show the internal features of a test object.

The Science Of AcousticsThe realm of acoustics often deals with the marrying of various scientific disciplines, including noise, vibration and wave behaviour. Primarily, one has to understand that sound is produced and propagated through the vibration of particles, whether through the air when people speak to each other, or through surfaces, from a vibrating piece of machinery for instance.

Depending on the frequency, and wavelength of the wave itself, sound waves react differently to changes in the environment in

which they travel. Some waves reflect off surfaces, while others bend around them. This probably explains why controlling noise is more art than science, with no one-size-fits-all solution.

Nevertheless, this unique property inherent in acoustic pulses gives APR a distinct advantage over other NDT methods when used in the inspection of tubes and pipes. The technique uses acoustic pulses to detect faults such as leaks or holes in the tube or pipe wall, or bulging and constriction, often indicated by increases or decreases in the tube or pipe diameter.

Details Of APRThe acoustic pulse is typically injected into a semi-infinite, straight-walled tube. Assuming the tube is free from defects, it should propagate down the tube without generating any reflections.

IndustryFocus



is evident that much time can be saved from the use of APR.

Given that APR does not use a probe in the inspection process, breakdowns are often few and far between. When tubes are not cleaned regularly, probes from other NDT methods, such as eddy current or magnetic flux leakage, are known to get stuck, adding to inspection time. Bends in the tubes and pipes also add to the complexity of inspection with probes.

A Short Word On AEAnother NDT technique that uses acoustics is AE analysis. In AE, sensors are attached to the surface of parts or structures being monitored. These sensors

record elastic sound waves caused by microscopic processes happening within the structure, such as cracks.

This allows the engineer an intimate look into part failure process, without having to be present throughout the inspection. Subjecting the test specimen to multiple load cycles while these sensors are affixed to monitor AE also forms the basis for many safety inspections. In particular, those within the metalworking industry can use AE to study the structural rigidity of welded joints, and recommend improvements based on their findings.

For all the benefits of AE and APR, it is clear that not everything in metalworking can be inspected using these two techniques. AE and APR serve a distinct, niche sector within metalworking, and it would be naïve to expect the companies that provide their services to detract from doing what they do best.

It may be early days yet, but it would not be far-fetched to suggest that acoustic technologies such as APR and AE will certainly be making inroads into the world of metalworking inspection, if they have not already. MEN


Alexander Abolinsh, Latvia

The aerospace industry is one of several industries to have benefited from the use of NDT.

Acoustic emission analysis can be used in checking the integrity of welds in a particular structure.

This can be confirmed through the use of a small microphone, positioned flushed with the tube wall, which should measure the pulse once only.

However, should the pulse encounter a discontinuity in the tube or pipe’s cross-section, a reflection is produced, and its amplitude and form studied to analyse the type of discontinuity encountered. Genera l ly, a larger amplitude corresponds with a bigger discontinuity. A constriction creates a positive reflection, while a dilation or bulge creates a negative one.

Holes in tube walls, on the other hand, result in the subsequent re f le c t ion hav ing a more complicated shape, affected by the hole’s size and radiation of sound energy to the outside of the tube.

AdvantagesThere are several advantages that APR offers over other NDT methods. The biggest advantage it provides is the speed at which it inspects, given that it does not require the use of a traditional probe. Instead, the non-invasive nature of APR ensures that the measurement time of one particular tube can be reduced to as little as 10 seconds. Multiplied over the many hundreds of tubes and pipes a particular heat exchanger has, it

IndustryFocus

September 2011 metalworking equipment news


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A c o r n e r s t o n e o f metrology, the CMM has evolved with time and even as the basic set up

of the equipment has largely been unchanged over the years, new developments are still available although they fundamentally exist as an ‘add-on’. These auxiliary attachments generally improve the whole system by bringing in new applications that open up new possibilities.

The adopt ion o f these accessories not only makes the CMM more versatile, it also helps the age-old machine cross the threshold between contact and non-contact metrology. In today’s

surfaces, this technology may be worth adopting.

Increasing PerformanceAttachments like laser scanning probes increase the CMM’s base of operation. However, CMM can be retrofitted with vision probes to magnify its range of accuracy as well.

The QVP Vision Probe from Mitutoyo brings functions to the CMM when it comes to measuring flat surfaces, elastic materials and small dimensions.

With its vision processing speed, the probe improves the total throughput time of inspection, thereby improving efficiency and cost effectiveness. According to the manufacturer, when used together with a CMM, the equipment can measure a hole less than 1 mm in diameter. This feature is typically out of range for traditional contact type probes. MEN

Dav

id J

one

s, L

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on,

UK

It is time to change that default setting on the CMMs as the influence of non-contact metrology sweep into the traditional realm of tactile measurement. By Michael E Neumann

PerfectThe

Touch

Touch Free Is Now

Did You KnowThe CMM first appeared commercially in the 1960s


world of metrology, the newly acquired versatility has high significance as advancements in electronics, computers and sensors have indirectly set the bar higher for manufacturing tolerances. This ultimately translates to a need for a more flexible CMM.

Breaking New GroundsWhen mounted to a Bridge CMM, a laser scanning probe is suitable for situations where there is a need to inspect similar parts repeatedly. These probes, such as the ScanShark V4ix laser scanning probe by Brown & Sharpe works by laser triangulation according to the manufacturer.

Where multiple measurements on certain features are required us ing tact i le probes, th is technique allows certain features to be measured in a single pass as typically a laser line consisting of several hundred points are reflected off the surface to the camera chip. On easy to dent

Industryfocus



A common advice that many would dish out in the business world is ‘dream big, start small’. Indeed,

it is a useful saying that is tried, tested and true. One such company that followed this path to success is Proton Holdings (Malaysia), part of the Proton Group.

Known as the ‘National Car Project’ in Malaysia, Proton started in May 1983. Today, the car manufacturer has close to 12,000 staff worldwide engaged in manufacturing, sales, service and other operations.

Much of the company’s success lies in the emphasis placed on pursuing its core values. It should therefore not come as a surprise that ‘quality’ is listed as the first building block of the company’s ability to achieve business excellence.

Zulhasni Bin Abdul Rahim, senior executive (Group Quality — head of project for Quality Digitisation and Quality Metrology Innovation Program) of the company in the Shah Alam plant shared: “Our quality control procedures call for precise metrology in applications such as alignment, calibration, installation and most importantly, the inspection process. We are

glad that with portable solutions, we have been able to perform our quality checks with much more ease and efficiency.”

Variety In An AssemblyThe automotive manufacturing process typically takes the form of an assembly line, whereby auto parts of a large variety — different in size, shape and nature — are

ArmingCase Study:

The QC Department

On average, it used to take us up to four days to properly inspect one car unit. Now, we only need two days to complete the entire task. Mr Zulhasni on the usage of

measuring arms

A Malaysian automobile producer brought in an extra pair of arms to improve their inspection process. Contributed by Emily Tay, Faro Asia-Pacific.

IndustryFocus



55

fixed together to create the end product, a commercial car.

In ensuring product quality, the company performs routine checks by measuring the assortment of parts used. This includes car parts, stamping parts, plastic parts, as well as jigs that hold pieces in place while they were being worked on. These parts range from a mere 200 mm to a full-sized car body approximately 3 m x 1.5 m x 2 m, with corresponding weights as light as few grams and as heavy as a few hundred kilograms.

It is not difficult to imagine how tedious and complicated the inspection process could get on the shop floor of an assembly line. In an interview with a group quality staff, the team revealed: “In the past, our inspectors used to rely on a host of conventional measuring tools. This ranged from steel rulers and measuring tapes to taper gauges, micrometers, vernier calipers, and also a fixed CMM.”

While these tools fulfilled the company’s measurement needs early on, customers’ growing expectations pushed the company to search for more advanced technology to meet new and higher requirements, especially on results consistency, accuracy, and time.

As demands for precision increased, Proton was gradually faced with issues concerning measurement consistencies. The company wanted to reduce the amount of time spent on inspection, as well as eliminate factors such as human and equipment error that was inherent with the usage of traditional hand tools. Fueled by a personal commitment to improve on quality, Mr Zulhasni and his team went in search for a viable solution.

Enhanced Efficiency & CapabilityIn late 2008, the company purchased a set of Faro Laser ScanArm V3 and a set of FaroArm Platinum, for the QC Body and Jig

Shop departments respectively. These are portable CMMs that enable operators the liberty to perform accurate measurements right on the assembly line. The measuring arm performs contact measurement by means of probing; while the scan arm has the additional ability to obtain scans of objects without making contact.

With the solutions, the car manufacturer achieved higher accuracy levels and repeatability during its inspection checks. It managed to achieve tighter tolerances, with an accuracy of 0.2 mm to 1 mm, for the entire range of measurement volume. The device offers portability and versatility, on top of its efficient and accurate scanning capabilities.

The company also enjoyed time- and manpower-savings with the implementation of the equipment, which boosted the company’s efficiency. “One portable CMM now replaces the multitude of conventional hand tools we used in the past,” said the project head.

“Coupled with the arm’s user friendliness, we have saved plenty of time. On average, it used to take us up to four days to properly inspect one car unit — from measuring, to inspecting and producing reports. Now, we only need two days to complete the entire task.”

In addition, the manufacturer also managed to have manpower-savings on its inspection checks. The company was able to deploy the measuring arm anywhere on the shop floor, whenever required. This eliminated the need to move objects to a fixed machine, which saved the company time and labour. In fact, they managed to free some staff members for other tasks, requiring only one inspector for quality checks, instead of three or four in the past.

Return On InvestmentDue to a high frequency of use in the first two years, Proton managed to achieve full Return On Investment (ROI) in half the time that was originally expected.

“Based on our conservative calculations, we targeted to reach ROI at the end of three years,” indicated the project head. “However, requests to utilise the FaroArm were coming from other departments in the company, as well as from external parties such as research units of the local universities. So with the measuring arm in operation for 75 percent of the time, we promptly realised a positive ROI within the first 18 months.” MEN


The company was able to deploy the measuring arm anywhere on the shop floor, whenever required.

IndustryFocus



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ReportMid-Year

As we cross the halfway mark of the year, it is a good time to take stock of the happenings in the first six months of 2012. In this special APMEN feature, we catch up with leaders of the metalworking industry to see how their company fared and what their plans are for the rest of the year.

How would you rate your company’s performance (sales/overall growth) for the first half of the year? Is there a particular industry/country whereby your company did very well in?

Talking about Asia-Pacific, the first months of the year have shown a positive development compared to the previous year despite a slowdown in China’s economy. South Korea, Thailand and Japan have been the markets developing the most.

How would the rest of the year go?

We expect the second h a l f o f t h e y e a r t o be even better. The automotive industr y in Far East has slowed down lately and needs to come back to higher

levels of production as demand is still there.

What is the most significant news/product launch/event that happened in your company in the first six months of the year?

Our latest innovation is the Tiger·tec Silver ISO P indexable insert range. With it, the average tool life improves by up to 75 percent compared to existing technologies. This is due to both the optimised microstructure of the Tiger·tec Silver coating and the geometries we introduced.

We also launched the Walter Titex XD70, the first solid carbide drill for drilling holes up to 70 times the diameter without pegging. This increases productivity by up to 600 percent compared to the common gun drill technology.

Jean-Paul DissousPresident (Sales Area, Walter Asia Pacific)Walter Asia Pacific




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Teo Tian SengPresident GF AgieCharmilles (Southeast Asia)


Overall, the first half of this year could be very similar to the first half of last year. In South Asia, there were four countries that fared well (as of April 2012). They were Thailand, Indonesia, India,


We hosted an open house in Singapore at the end of April, during which we showcased several key products. One of them was the FO350mS machine, which was specially developed for IC mould making.

In addition, we launched a few new models. Some of them are high-tech machines produced in China. The price advantage brought about by producing in China can be transferred to our customers so they can benefit from lower investments.

Our China plants in Beijing (EDM machines) and Changzhou (milling machines) produce the ‘stable models’ already in serial manufacturing for the world. The European plants produce the very high end machines that are closely linked to on-going R&D.

and Vietnam. These are the four markets that will do well this year.

Thailand and Indonesia in particular, are the fastest growing with at least 25 percent growth year on year. These two countries have a certain resilience that saw them less badly hit by the Euro crisis. This could be due to a huge domestic demand in the automotive industry.

India is also strong, posting 20 to 25 percent growth in sales. The country suffered from currency fluctuation last year, which made the investment climate very unhealthy. The situation has since been corrected with the Rupee now stable. Finally, Vietnam will benefit due to its geographical location because many companies in China are now looking to develop a second base.


If there is no other crisis, I believe this year will be a good year for us. The second half of the year would be better than the first.


Trumpf will meet the challenging targets we defined last year. In Southeast Asia, Indonesia continues to grow and Thailand remains a prospering market despite the flood situation. Finally, Vietnam has a chance to grow if financial and legal system in the country improves.


We are expecting moderate growth. New projects for Laser 3D application (cutting and welding) as well as a number of new machines available

for ASEAN markets at the end of the year are the building blocks of our optimism.


1. Set-up of a local laser marking assembly

2. 20th anniversary of Trumpf in Singapore

3. TruLaser 1030 and TruPunch 3000

4. Skeleton-Free-Processing as a significant measure to cut down cost and reduce waste as well as optimising the usage of energy with a completely new approach.



Dr Hans-Peter LaubscherMD (Asia Pacific)Trumpf



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Klaus LudwigVPHwacheon Machine Tool

Peter DickinMarketing ManagerDelcam

positive feedback from testers who have seen significant reductions in machining times.



Delcam has made a strong start to the year and is on track for a further growth in sales as the global economy continues its recovery. Our subsidiaries in Indonesia and Thailand are continuing their growth but the fastest increase has come in Vietnam, albeit from a low base.


We expect continued growth for the rest of the year, especially in


Southeast Asia. Delcam will be announcing important new releases across our complete range of CAD/CAM software in the coming months, which should help to produce even better sales.


The most important developments have been the addition of direct modelling to our PowerShape CAD software and the new Vortex strategy for rough machining in our PowerMill CAM software.

Even though Vortex is only in beta testing, with a full release some months away, we are getting very

We just had our board meeting for the first quarter. So far I can say our international sales is more than what we had forecasted. We are currently about 15 percent above plan.

Surprisingly, in the first quarter, we received a lot of orders for bigger machines mainly from Europe and the US. It looks like in certain industries, there is a trend for bigger machines. We also have a strong increase in business in the mining and oil and gas industries. As such, we would like to focus more on those growing industries in countries like Australia, England and the Middle East. Our large size turning centres like High-tech 550, 700 and 850 are enjoying good business right now.


I predict our international business unit would have a positive second quarter silmilar to the first one. I think the third and fourth quarters would be even better. We do not foresee an overall slowdown; of course there would be slowdowns in

certain industries, (eg: automobile sales going down in Europe) but positive economies can be seen in many areas. The overall situation is basically positive. We predict to achieve our positive sales forecast set last year plus up to 15 percent more.


1. Smart machine with UA (Ultimate Automation).

2. SIRIUS UM, a smaller version to our SIRIUS UL+.

3. Our ATC solution for our VT 1150 Vertical Turning Centre.

4. Newly designed Hi-Tech 450 series, a Universal Turning Centre available in many variations, centre distance and spindle bore dimensions including Y-axis.



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Taveesak SrisuntisukMDHexagon Metrology (Thailand)


We are doing very well in H1 2012. Our sales are over 50 percent higher compared to the same period in H1 2011. This is the result from the flood disaster in Thailand at the end of 2011. The major industries we are doing well in are the automotive and electronic industries.


We are very confident of seeing continued investment and growth

for the rest of 2012, especially in the automotive industry as it is Thailand’s master plan to achieve 1.6 - 1.8 million cars in these few years.


Hexagon always invests in R&D to develop our products in terms of accuracy and speed. We introduced our silver series CMMs, which are both faster and more accurate. We launched it in a show in Bangkok in June. We also launched the second version of our Absolute Arm recently.


We grew by € 508.9 million (US$630 million) in order intake last year compared to 2010, resulting in the best ever year for us in terms

Dr Jens HardenackeCEO DMG (Asia)

of sales. We did well in the South Korean market, which is responsible for a significant share. We believe it will further increase in the second half of 2012. (Figures based on DMG products only / Gildemeister group)


In Asia, we expect increasing sales revenues. Last year, the share of Asian markets in the overall order intake development for the Gildemeister group had grown again, reaching 19 percent in 2011. We expect to increase at the same level with respect to last year if there are no special projects coming because we have increased our forecast twice. (Figures based on DMG products only / Gildemeister group)


For innovations, the compact machining centre Milltap 700, our first joint development, and the Lasertec 65 Shape for five-axis milling combined with laser surface texturing, have been launched in the South Korean market at this year’s SIMTOS.

Apart from these Korea premieres, we extended our evolution series by bringing the DMU 80 evolution to the market, and launched the new Sprint 50 for high-speed turning with Twin work area concept and modular expansion options for six-sided complete machining with up to three turrets.

Also, we are planning several innovations for the monoBlock series and further extension of the eVo series coming towards the second half of the year. From Mori Seiki, we expect to have the new NLX4000 towards the end of the year.





Global automotive giants are recognising Thailand’s suitability as a R&D hub to manufacture fuel injection

pumps, transmissions, anti-lock braking systems and central locking systems, bringing cheer to the local welding equipment and consumables market.

An analysis from Frost & Sullivan finds that the market earned revenues of US$293.0 million in 2010 and estimates this to reach US$450.0 million in 2017 at a compound annual growth rate of 6.3 percent.

T he gover n ment o f fers exemptions on import duties and excise taxes on cars to attract investors; however, the current thrust on eco cars are likely to dampen the market for welding equipment. If pollution control enforcement becomes stricter or the manufacturing technology changes, auto companies will seek alternate manufacturing bases, taking business away from the welding equipment and consumables market.

Increasing energy costs can play a role in determining the demand for welding equipment and consumables. For instance, if the focus shifts to renewable sources of energy/power generation and automobiles are made to run on batteries, the demand for welding consumables will reduce.

Other FactorsApart from automotive, the oil and



gas and construction industries will also influence the fortunes of the welding equipment and consumables market. The Thai government has been keen to introduce new technologies to accelerate industrialisation in the country. The welding equipment market will certainly be buoyed by its efforts but it still has several issues to address before it can make the most of the initiatives.

Investors will be aware that

standardisation will not be possible in this market, since only appropriate equipment can be used for specific applications. Moreover, technological transfers will be bumpy as the local workforce lacks the skills to develop and use technologies.

Once measures are taken to regulate and ensure quality at several sites, investors will feel more confident about moving their manufacturing to Thailand, thereby boosting the local welding equipment market.

Rising eco consciousness could lower the demand for welding in the automotive industry. By Krishnan Ramanathan, research analyst, Frost & Sullivan

Thailand’s Automotive Industry Controls Its Welding Equipment & Consumables Market

Thailand is home to several multinationals in the welding industry although most of

them operate with Singapore or Malaysia as the base for the Southeast Asia region.

Construction remains the biggest end user sector in terms of revenues in the

Thailand welding equipment market and accounts for close to 30 percent. As more

developments take place in the industrial sector, the market for automated welding

processes is likely to expand. MEN

Summary

Note: All figures are rounded. The base year is 2010. Source: Frost & Sullivan analysis

Market OverviewWelding Equipment and Consumables Market: Market Engineering Measurements, Thailand, 2010

FeatureS

Aerospace manufacturing is a high technology industry that produces aircraft, guided missiles,

space vehicles, aircraft engines, propulsion units, and related parts. Many companies produce technical tools and components such as spaceships and satellites. Some known companies involved in space programs include Boeing, EADS, Lockheed Martin and Northrop Grumman.

Specialty materials such as aluminium alloys and titanium, tight tolerances and the emphasis on precision a nd reduced waste mean that planning and preparation are vital for every plane before it is made. Therefore, considerable forethought is an aspect of every precision part made in the aerospace industry.

An important stage in modern aerospace craft manufacturing is the design and modeling process using CAD and CAE software.

The aerospace industry in recent years have optimised on better design composite parts by improving the communication between CAD engineers and CAE analysts. As such, most software providers in this field concentrate on br ing ing integrat ion of functions between design and analysis.

For example, if a CAE analyst adds changes to the design of a part to help it meet specifications, like adding a layer of fibre, that change is communicated back to the CAD system to propagate it throughout the design.

Therefore, software packages, such as FiberSIM from Vistagy, is integrated into a number of popular existing CAD and CAE systems, like Dassault Systèmes’ Catia, Siemens NX, and PTC’s Pro/E, with analysis integrated with packages from Ansys, MSC.Software, and Siemens NX Laminate Composites.

Next Stage — ProductionMicromachining of f lexible, malleable workpieces used in aerospace craft are especially demanding, as the parts may be distorted or be affected dimensionally in other ways. Cutting, clamping, or applying force s i n a ny way wou ld induce and relieve stresses in unpredictable ways.

At tolerances measured in thousandths of an inch, many of these stress responses can be ignored. But at tolerances measured in ten-thousandths or less, these effects can be significant. Another problem involves large-volume insert use due to the materials involved. The resulting time spent indexing inserts can be a huge drain on productivity over time, especially machining productivity.

Better Techniques AvailableOne example of improved holding tool is the QS Holding System.

Augustine Quek investigates the various production processes in aerospace part manufacturing.

AirworthyMaking Parts P

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Features

Due to evolving aerospace standards in terms of traceability, aerospace companies are marking all strategic parts in line with the latest requirements

Umayr Sahlan Masud, Islamabad, Pakistan

Its high precision coolant not only reduces setup and tool change times, but also improves chipbreaking and performance. Its wedge design allows manufacturers to remove and change inserts in seconds, with coolant pressure as low as 145 psi. The precision nozzles deliver accurate coolant flow, improving component quality and chipbreaking.

A machining technique, helical milling or ramping, can also increase productivity in aerospace applications. The technique uses milling tools rather than drills to more efficiently machine holes and pocket features on the curved and slanted plains common in many aerospace components.

By taking relatively light and fast cuts, the technique requires significantly less force and power compared with a drill. Many milling machines are now built for this purpose.

A ‘Sound’ TechniqueUltrasonic machining is another recent innovat ion for the machining of ceramic aerospace parts. It is a non-thermal, non-chemical and non-electrical machining process that leaves the chemical composition, material

microstructure and physical properties of the workpiece unchanged.

U l t r a s o n i c m a c h i n i n g operations use an abrasive slurry that flows between the workpiece and a vibrating tool. The mechanical high-frequency (~20 KHz) vibration of the tool is produced from low-frequency electrical signals, which are converted by a transducer.

A vibrating tool as small as 0.015 or 0.020 inches in diameter could be used to machine precise features

in very small, hard, ceramic parts. The process is a little like milling and a little like grinding, but is ultimately different from both of these methods.

By rapidly oscillating the tool through a tightly controlled amplitude, the machine chisels the material away using microscopic impacts at the rate of tens of thousands of strikes per second. Machining this way involves at least one parameter that is alien to other processes, because the tool is ‘tuned’ to find a stable oscillation frequency somewhere between 20,000 and 50,000 Hz.

One such machine, being used by the National Aeronautics and Space Administration (NASA), is the Sauer ultrasonic five-axis machining centre from DMG/Mori Seiki. Because the machine has five axes, multiple faces can be accurately machined to produce novel chip structure designs that are space-efficient.

The ultrasonic machine tool is equipped with a 42,000-rpm spindle that accommodates a machining centre’s toolholder and cutting tool. During ultrasonic material removal, the machine also holds an abrasive tool instead of a conventional vibrating tool.

Machining of workpieces used in aircraft are especially demanding, as the parts may be distorted or be affected dimensionally in many ways

Jean Scheijen, Maastricht, Limburg, Netherlands



Features

Marking & MetrologyDue to evolv ing aerospace s t a n d a r d s i n t e r m s o f t r a c e a b i l i t y , a e r o s p a c e companies are mark ing a l l strategic parts in line with the latest requirements, which include conformed 2D marking.

A variety of methods exist for marking a part. Electrochemical etching methods use a low v o l t a g e c u r r e n t to m a r k the object surface, and are commonly used for low volume product runs. Ink jet printing uses small dots sprayed directly onto the surface, and produces high contrast marks, but is not considered a permanent marking method. Lastly, the dot preen process is a percussive marking method, using changes in depth to create marks which can last throughout the part’s lifecycle.

A n o t h e r i n d i s p e n s i b l e component in aerospace part manufacturing is part inspection and verification. Since aerospace components operate in severe conditions where part failure can be catastrophic, accurate and efficient tests are required

for critical parts during the manufacturing process.

For example, laser-based measurements are used at the A380 final assembly site at Jean-Luc Lagardère in Toulouse, France. The final assembly of the aircraft involves different segments and parts, which are to be compared to one another.

Four laser trackers: two for the fuselage and two for the w ings a re inter twined and connected by a common c o o r d i n a te s y s te m . T h i s arrangement a llows for the u n i f o r m n e s s a n d m u t u a l interchangeability of the laser trackers. These laser trackers can record data from a single set-up position on objects with a measurement volume of up to 80 m diameter, with an accuracy level of +/- 10 ppm (μm/m), at a measurement rate of up to 3,000 points per second.

A simplified Human-Machine Interface (HMI) was used as this measurement system was integrated into the fuselage assembly process, controlled by the assembly workers. The HMI features automatic control and

target location, and on-screen result display for determining the correct part positioning.

The basic concept behind the assembly inspection method was to inspect the aircraft’s individual segments in relation to one another rather than to use the tools as a reference system, avoiding the whole issue of compounding tolerances.

The aerospace industry is a culmination of highly technical product ion processes a nd te c h nolog ic a l ly adv a nce d materials being implemented to manufacture over 200,000 components to complete an aircraft.

M a n u f a c t u r i n g t h e s e components are both complex and costly, with everything, from the screws to the engine components having to meet stringent quality controls for safety. Therefore, better tools and machines, with ever greater precision and efficiency will continue to be developed for the fast-growing aerospace industry. MEN


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Ultrasonic machining is another recent innovation for the machining of ceramic aerospace parts.



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Features

The Precision Engineering Centre Of Innovation (PE COI) annual conference was held on May 16,

2012, at the Singapore Institute of Manufacturing Technology (SIMTech). Professionals spanning across various industries were invited to present trends and opportunities in precision engineering, to approximately 250 participants from 150 companies.

While the centre was created to help the local Precision Engineering (PE) industry innovate in terms of technology, manufacturing operations and business model, its recent focus is to help suppliers venture into high value growth sectors through localisation. This includes industries such as oil and gas, medical technology,

aerospace, and engineering design and operation.

According to Tan Kai Hoe, deputy chief executive at SPRING Singapore, the PE industry contributes to 2.4 percent of Singapore’s GDP, and about nine percent of the total manufacturing output.

Meanwhile, Tan Hui Khim, director of Supplier Development, Precision Engineering, EDB, has added that while China remains a popular manufacturing nation, costs are increasing and OEMs are shifting to the ASEAN region. With the depreciation of the Euro and US dollar, cost is no longer the main reason for foreign companies to invest in Asia. Instead, they are doing so due to the close location to growing markets.

Increasing CompetitivenessThe Economic Development Board (EDB) and SPRING Singapore aim to further the industry by helping SMEs to enter the high growth sectors, which have a compound annual growth rate of about 10 percent, said Dr John Yong, director of PE COI.

These organisations are working with MNCs in analysing products that can be localised in Singapore. This includes products and modules that are either new to Singapore, or things that are integral to the end product, such as the type of machines, materials or finishing required.

Joint ventures between MNCs and local companies, or tie-ups with technical experts and the formation of consortiums are alternative ways of enhancing competitiveness. These, in addition to the training of workers (eg: WDA supported courses, seminars and conferences), will help enhance capabilities.

Bridging GapsWith increasing competition within the region, companies can enhance their offerings by focusing on a niche. On the whole, the industry is encouraged to move towards high mix, low volume manufacturing to remain competitive. This is due to the rise of complex manufacturing, and is especially relevant for Singapore as it is a major MRO hub in both Asia and the world.

Dr Moh Chong Tau, president and CEO of Makino Asia, shared that MNCs now require high value and knowledge and not just cost savings or cheap labour, which has led to a greater emphasis on skills and automation. Most OEMs would prefer to outsource manufacturing if possible as it is less costly. For this, they would require a components supplier with the relevant knowledge chain.

Addressing this, Mr Tan Hui Khim has also mentioned the gaps present between researchers,

AddingPrecise ValuePrecision engineering can be developed in tandem with the rise of high growth industries, which has propelled the shift towards complex and high volume, low mix manufacturing. By Sherlyne Yong

Clockwise from top left: Tan Kai Hoe, Dr John Yong, Christian Mutter and Tan Hui Khim



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manufacturers and suppliers. For instance, as researchers come up with a product blueprint and pass it down the supply chain, manufacturers have to work with suppliers to discuss the new product and technological know-how before the parts can be produced.

More synergy is required between researchers and suppliers to streamline the process, which can be achieved when suppliers increase their technical knowledge, and in turn, the ability to make recommendations on how to better the manufacture of a product. In this sense, suppliers are evolving to take on a larger role, by engaging in design for manufacturability and adding valuable input instead of purely producing the part.

Trends & OpportunitiesThere are opportunities abound for both the manufacturing and MRO sector with the rise of high growth sectors that include the oil and gas, aerospace, and medical technology industries.

The oil and gas industry is large in Singapore, in which 70 percent of the world’s jack-up rigs and 50 percent of submersible drilling rigs are produced, and 70 percent of floating production storage and offloading vessels converted, as according to Mr Tan Hui Khim.

Some trends within the local landscape include the formation of tools, process, automation and

partnerships to create a higher value chain. This has led to intersecting and miniature flow- and wire-lines that support unmanned operations, the use of corrosion and wear resistance material (eg: laser cladding Inconel), and the adoption of innovative measurement and inspection methods.

For the aerospace industry, however, the MRO sector takes up a larger share of the market. Meanwhile, manufacturing includes making various parts like engines, casings and bearing nuts.

According to Christian Mutter, business development director, Supply Chain Asia Pacific, Rolls-Royce Singapore, the main goals for the local aerospace industry are strengthening the SMEs’ support to MNCs and localising aerospace manufacturing and MRO. It is pertinent to localise such activities as the growth of

aircraft fleet in the Asia Pacific region has shifted manufacturing efforts closer to home.

In addit ion, MNCs are conservative in making changes to mitigate risks, as high costs are involved for substandard performance. Instead, they tend to stick with existing suppliers on a long-term basis instead of qualifying new ones. As a result, the way forward lies in collaborating with existing suppliers and supporting their operations.

Many have touted localisation as a strategy to tap on the opportunities presented by the various high growth industries. As complex manufacturing takes centre stage, suppliers must equip themselves with the technical knowledge in order to value add the supply chain.

Leaders in the high growth industries came together to share how manufacturing activities can be localised


Jul-Aug 2012 metalworking equipment news 65

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The 18th edi t ion o f Metaltech took place in the Putra World Trade Centre (PWTC), Kuala

Lumpur (KL), Malaysia. The five-day event saw trade professionals from the metalworking, machinery and manufacturing industry come together to source for the latest technology and services from related industries within the 30,000 sq m exhibition area (gross).

Launched by Yang Berhormat Dato’ Sri Mustapa Mohamed, minister of International Trade and Industry (MITI), this year’s event managed to attract some 1,500 local and international participating companies from 35 countries and three international pavilions from South Korea, Singapore and Taiwan.

According to the organiser, the estimated value of exhibits is worth some RM250 million (US$79.7 million) and they ranged from CAD/CAM systems, machine tools, cutting tools, metrology equipment and automation solutions, among others.

Strong GrowthIn his opening speech, Yang Berhormat Dato’ Sri Mustapa Mohamed said the M&E industry is a key sector of Malaysia’s economy and the government’s long term objective is to make the country the regional production and distribution hub for high technology and specialised M&E product and services.

He also mentioned the government will continue to provide incentives to support the growth of the industry. This includes the granting of pioneer status with full tax exemption of statutory income for 10 years to M&E companies that qualify.

Event Review:

Metaltech 2012

In conclusion, he gave the crowd his growth projection for the M&E industry. He said: “Our economic transformation program will generate many business opportunities for the industry. The manufacturing sector is targeted to grow by 5.6 percent annually throughout the rest of this decade and contribute to 28.5 percent of gross product by 2020.”

PWTCKuala Lumpur, MalaysiaMay 15 – 19, 2012



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Speakers from Malaysian Investment Development Authority (MIDA) and Malaysia External Trade Development Corporation (MATRADE) spoke with foreign visitors and exhibitors at Metaltech in a bid to make Malaysia an attractive country for investors.

Held on the sidelines of Metaltech, a

networking session was organised to

bring MIDA and MATRADE together with

potential foreign investors at the show.

MIDA performs the following functions:

they promote, evaluate, plan, and monitor.

The organisation helps in promoting the

country by offering tax incentives in order

to bring in FDI and assist in planning for

various industrial development. They

also assist companies to implement and

operate projects.

At the talk, representatives from

the organisations urged participants to

take advantage of various incentives

Did You Know?Malaysia experienced 5.1 percent of real GDP growth in 2011. Of which, manufacturing contributes 27.5 percent.

In Malaysia, there are:

400 mould and die companies

170 machining companies

300 metal stamping companies

70 metal casting foundries.

One-On-One With Albert LaiAsia Pacific Metalworking Equipment News (APMEN) spoke with Albert Lai, MD of Trade-Link Exhibition Services, to discuss Metaltech’s future as the organiser aims to bring more focus to the show. By Joson Ng

APMEN: This year marks the first year that you are ‘flying solo’ with the absence of MTA Malaysia. What are your thoughts on that?

Albert Lai (AL): Being independent provides us with the flexibility in our decision-making. That gives my team the opportunity to plan our operations, promotions and sales in ways we have never been able to do. In fact, we have managed to

successfully execute several plans for our promotion and exhibition management this year.

APMEN: In an interview last year, you mentioned there are plans to move the show to a new facility. Any updates on that plan?

AL: The construction of the hall was supposed to start last year but it was put on hold and now construction


work has started again. They are targeting the construction work to be completed by 2014. The earliest date for any shows to be held in the new venue is 2015.

APMEN: Looking ahead, will there be any changes in 2013 in terms of show concept, attractions for visitors and the participation of various delegations?

AL: Yes, we have expanded our target audience to include related industries such as oil and gas, aerospace, medical/pharmaceutical, marine/offshore as well as electrical and electronics. The plan is to establish a larger database so we can bring in the right people, as there are a lot of exhibits

offered. For example MIDA offers pioneer

status, which can bring about income tax

exemption ranging from 70 or 100 percent

for a period of 5 or 10 years. They can

also grant an investment tax allowance

(60 or 100 percent on qualifying capital

expenditure) for five years.

In addition, they allow import duty and

sales tax exemption for raw material or

components and machinery and equipment.

Finally they give out a reinvestment allowance,

which is 60 percent of the qualifying capital

expenditure for 15 consecutive years.

Malaysia Targets FDI



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in the exhibition that interest these groups as well.

Next year, we will identify those groups and cater a promotional program to invite them to the event.

On the other hand, we also need the exhibitors to cooperate with us. They have to inform us beforehand the type of machines they are exhibiting and what industries they are suitable for. This way, targeted promotional campaigns can be planned to reach those people. Finally, we hope to work with the Malaysian Investment Development Authority (MIDA) to conduct conferences and seminars on investments.

APMEN: There were some notable absentees this year compared to 2011, with the likes of DMG/Mori Seiki and Makino opting to stay away. What are your plans to attract established machine tool builders?

AL: As we all know, the market economy plays a large part in this. Major brands tend to enhance the show profile and we know that. As much as we would like all of them to be with us this year, it may not be the case as they might have other plans for their company. Nevertheless, we are in close contact with all of them to ensure that they do not miss out on the next edition of the show.

APMEN: This year saw international pavilions from Taiwan, Singapore, South Korea and China. Any plans to bring in other national pavilions next year?

AL: Yes, we are expanding our reach in Europe and the US by cooperating with agents in that region to create new pavilions. We are currently working on bringing a Germany and US group for next year. With 80 percent of our machines from overseas, we have shown that we are a show with internationality.


Mr Lai aims to bring more focus to the show in 2013

With some 80 percent of its exhibits from abroad, the show is one with internationality



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ENQUIRY NO 130

Event Review:

CIMES 2012CIMES 2012 opened at the New China International Exhibition Center in Beijing on June 12,

2012. According to the organisers SinoMAC, CNMTC and Reed Exhibitions, the event covered an exhibition area of 120,000 sq m, with 1,300 exhibitors from 28 regions and countries including Hong Kong, Taiwan, US, Germany, Italy, UK, France, Switzerland, Japan, South Korea, Spain and Czech Republic, among others.

The five-day event received some 55,000 visitors from China and abroad, making it one of the most popular and influential machine events across the globe this year. As a result, the event attracted a full lineup of major players in the industry.

The machine tool industry in China has seen steady progress over the past two decades, with the worldwide highest machine tool consumption numbers in 10 consecutive years and an output value also ranking first in three consecutive years. Now China is the most vigorous machine market in the world, directly driving the boom of automotive, shipbuilding, a e r o s p a c e a n d m a c h i n e manufacturing industries.

Despite these achievements, there is still room for improvement in terms of high-end machine tools and brand image. In order to improve core competitiveness in productivity, reliability, and precision technology, as well as environmental protection, interactivity during the event was improved.

On-Site Expert Consultation ServicesThe event saw the launch of expert ‘ambulant’ service, which was provided by a panel of industry experts. They dispensed consultation services to exhibitors and buyers on a daily basis. Beijing Machine Tool Research Institute deputy chief engineer Sheng

Bohao, China Machine Quality Inspection Center director Zhao Qinzhi, Key Projects Office staff expert Feng Hutian and Chengdu Tooling Institute deputy director Zhao Bingzhen formed the panel of experts.

The event was not only an outsourcing platform, but also a suitable place for learning and sharing information. Based on past experiences and exhibitors’ demands, CIMES 2012 took the

lead in the industry by providing expert ‘ambulant’ service to give in-depth technical and management analysis, and solutions for both exhibitors and buyers.

Apart from the service, the event also featured a number of conferences and technical seminars, including an International Forum on High-Quality and High-End Equipment Manufacturing, the China NC Machine Tool Industry Development Forum, a Military



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CNC Machining Technology Seminar, the Aerospace Difficult-to-Machine Materials and High-Speed Processing Application Seminar, a Smart and Green Manufacturing Summit as well as presentations of the latest products and technologies by more than 20 exhibitors.

Green Development A FocusAccording to the Chinese government’s 12th Five-Year Plan, high-end CNC machine tools will

be the foundation for aerospace, shipbuilding, automotives and power generating equipment manufacturing. Old technologies with high pollution and high-energy consumption are to be eliminated.

As an example, the aerospace industry will feature key parts of titanium alloy, high-strength durable materials, engineering ceramic, and other advanced hard-to-machine materials. These new technologies put high demand on

high speed, precision, composites, and multi-axis gearing. With the launch of a renewable energy automotive strategy, demands are growing for high-speed, high-efficiency CNC machines and flexible production lines.

All these key applications pose new challenges to the machine tool industry, and huge opportunities as well. The show invited top-notch players of the global industry to share green, innovative, smart ideas and drive the green development of the industry in China.

The 2012 edition of the show witnessed majority of exhibitors promoting the green concept. For instance, DMG offered its universal turning machines, universal milling machines, and vertical milling centres that save space and energy and feature high efficiency and versatile functions.

GF AgieCharmilles launched its products through coordinated design in both Beijing and Switzerland. The products can improve efficiency and extend cutting mould life, providing an automatic solution to aerospace customers.

Stimulated by the increasingly segmented market demands, the organisers enhanced their Hosted Buyer program, by inviting not only 1,000 diamond-level buyers from domestic military, aerospace, automotive, shipbuilding, railway, power, metallurgic industries, but also visitor delegations from oversea trade associations and professional organisations from India, Thailand, Malaysia, Japan, and South Korea, who participated in the business matching program with local players.

New China International Exhibition Center Beijing, ChinaJune 12 –16, 2012



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Hannover Messe 2012 showed measurable success even before it came off the starting

block. Around 5,000 exhibitors from 69 countries were registered. The exhibition space grew by two additional halls to more than 172,000 sq m. One highlight was the presence of Partner Country China with 500 exhibitors in around 9,000 sq m.

With its largest ever industrial presence at a foreign event, China demonstrated the importance of Hannover Messe as a barometer for the global economy.

“The perfect themes, greater international reach and satisfied exhibitors — everything was just right at this fair,” said Dr Wolfram von Fritsch, Deutsche Messe’s managing board chairman, at the closing of the fair. “More than 600 companies have already signed on for Hannover Messe 2013, and we look forward to filling up the entire exhibition centre in Hannover next year.”

T h e p r e m i e r e o f t h e IndustrialGreenTec flagship show also exceeded all expectations: some 120 exhibitors from 12 countries attended, with 80 percent coming to Hannover for the first time. IndustrialGreenTec celebrated the most successful launch of any new trade show in recent memory. One visitor in four was interested in industrial environmental technologies.

Seven additional fairs also attracted visitor interest. They are Industrial Automation, Energy, MobiliTec, Digital Factory,

Industrial Supply, CoilTechnica, Research & Technology and the Metropolitan Solutions exhibitor area. Alongside Hannover Messe, Promotion World, the trade show for promotional items and incentives, presented innovations from the promotional items sector.

‘greentelligence’ Focus The show scored full points with its ‘greentelligence’ theme and the IndustrialGreenTec trade show. ‘greentelligence’ encompassed a number of major messages: green technologies are driving business models and growth worldwide, and the industry has market-ready solutions for sustainable production that correspond to this theme — and are profitable, as well.

A Humming EconomyIndustry associations and exhibitors expressed equal satisfaction. “The

mood in the German machine and facilities engineering sector was exceptionally good. As a business barometer for mechanical engineering, the fair gave us a very optimistic feeling about the second half of 2012,” said Dr Hannes Hesse, director of the German Engineering Federation (VDMA).

Friedhelm Loh, president of the German Electrical and Electronic Manufacturers’ Association (ZVEI) went even further: “German innovative power is in high gear. Whether in the exploding area of energy efficiency, or for renewable energies, smart cities or automation — German electrical engineering technologies are in demand everywhere.” According to a ZVEI survey, 93 percent of member companies expect earnings to continue to increase in 2012.

Event Review:

Hannover Messe 2012



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Event Preview:


EuroBlech is the world’s largest exhibition for the sheet metalworking industry. The event is a

trend barometer for this industry sector. With this year’s theme being ‘For a sustainable future’, the event puts a special focus on energy efficient technology, e n v i ro n m e n t a l l y f r i e n d l y manufacturing processes and intelligent use of material.

Currently, a total of 1,340 exhibitors from 37 countries have booked their stands at the show, covering a net exhibition space of more than 84,000 sq m. This is an increase in floor space of more than six percent compared with the previous show.

“This thoroughly positive outlook for this year’s EuroBlech reflects a further recovery of the sheet metalworking industry; and it also shows that the industry sector is inspired by overall trends such as sustainability, awareness of resources, energy efficiency and mobility. Major developments

in sheet metal working focus upon lightweight construction, intelligent use of material, processing of hybrid structures as well as new applications of established production processes,” says Nicola Hamann, exhibition director of EuroBlech, on behalf of the organisers, Mack Brooks Exhibitions.

“Visitors to the exhibition can look forward to discovering a large number of machine demonstrations throughout the eight exhibition halls, as live presentation of machinery and systems is traditionally a major focus for participating companies at the show,” explains Ms Hamann.

International AppealInternational attendance is, once again, high at this year’s exhibition. Almost 48 percent of the companies come from outside Germany, with Italy, Turkey, China, Switzerland, the Netherlands and Spain being the biggest exhibitor countries after Germany.

The show will occupy halls 11 to 17 and 27 at the Hanover E x h i b i t i o n G ro u n d s . T h e exhibition profile represents the entire sheet metalworking technology chain: sheet metal, semi-f inished and f inished products, handling, separation, forming, flexible sheet metal working, joining, welding, surface treatment, processing of hybrid structures, tools, quality control, CAD/CAM systems and R&D.

Exhibition GroundsHanover, GermanyOctober 23 – 27, 2012

EuroBlech 2012



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Event Preview:


Ja p a n M a c h i n e To o l builders Association and Tokyo Big Sight have announced the updated

exhibition scale and number of exhibitors of the upcoming event JIMTOF 2012, to be held in Tokyo Big Sight from November 1 - 6, 2012.

The total number of booths is 5,082 (as of May 28, 2012), which is 118 booths more compared to the 2010 edition. Some 4,800 booths are taken up by domestic exhibitors whereas 282 booths are booked by foreign exhibitors, whose number currently stands at 75.

The 26th edition of JIMTOF marks the 50th anniversary of the inaugural event, which was held in Osaka in 1962. Because machine tools and related products are producers’ goods that form the basis of all industry, it has historically attracted a large amount of attention from Japan and overseas due to its status as a mirror that reflects the technological level of the industrial nation of Japan.

Reaffirming its role as a showcase for technologies that will reshape the production f loors o f the fu ture , the t r a d e s h o w ’s o rg a n i s e r i s approaching this year’s event with the following priorities.

They are actively encouraging participants to exhibit even

more leading edge and new products than in the past. Many exhibitors, particularly J a p a n e s e m a n u f a c t u re r s , s t r u c t u r e t h e i r p r o d u c t development schedules so that they can unveil or announce new offerings at the show, and the event is regarded as a one-stop venue for comparing various companies’ advanced machinery and products earlier than is possible elsewhere.

Conventions & SeminarsThe event also aims to play host to appealing conventions and seminars that offer meaningful experience for participants. While product information will remain the primary reason that attendees visit JIMTOF, many have called on the event to incorporate appealing meetings and seminars.

For example, the subjects for the International Machine Tool Engineers Conference (IMEC), which introduces research findings concerning machine tools and related technologies along with forecasts of future trends, as well as lectures featuring noteworthy engineers and managers and exhibitor workshops, will serve to spark audience interest.

Foreign VisitorsThe organiser will also try to

create bus iness -match ing opportunities with a view toward world markets as overseas transactions account for an increasingly large share of many Japanese companies’ business. As such, the show should play the role of creating new contacts w i th overseas exh ib i tors and attendees.

The number of attendees at recent JIMTOF events from China, Taiwan, South Korea, and other East Asian countries, where brisk economic growth is driving demand for capital investment, has been increasing. Attendance is expected to grow in the future as a result of the relaxation of Japanese entry requirements and revitalisation of air service between the region’s cities and Japan.

Tokyo Big SightTokyo, JapanNovember 1 – 6, 2012

JIMTOF 2012



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Aerotech: Non-Contact Direct-Drive Linear Air Bearing Stage

The ABL1500 direct-drive linear air-bearing stage from Aerotech meets the needs of scanning and inspection applications with fully active pre-load, stiffness and geometric characteristics.

Its positioning tolerances exceed the capability of conventional ball-screw and mechanical-bearing systems. The non-contact design allows years of maintenance-free operation.

The stages are appropriate for critical applications in any industry that requires smooth and accurate linear motion to manufacture, test or inspect a product. These include semiconductor, data storage, medical and genome devices and industries requiring cleanroom operation.

Ametek: Non-Contact Linear Displacement Transducer

A non- contact Linear Displacement

Transducer (LDT) from Ametek Automation

and Process Technologies offers greater durability and

consistency than traditional potentiometers. The magnetostrictive technology of

the Gemco 955 eBrik has no moving parts to wear out and does not exhibit problems common to linear potentiometers.

It is designed to provide accurate continuous position feedback when installed on automated factory and processing machinery. Industry applications include plastic injection moulding and extrusion equipment, tire and rubber and die casting among others.

The sensor offers field programmable zero and span settings, plus electronic diagnostic feedback transmitted through the analog output. It is accurate to ±0.03 percent of stroke with repeatability to 0.001 percent.

Electric PowerSUHNER power tools - robust but handy. High torque and power. For stress-free, effortless working.

www.suhner.com

Shanghai Tong Lee Hardware Pte Ltd.200 Jalan Sultan#01-01 Textile CentreSingapore 199018Phone (65) 6291 7288 (5 lines)[email protected]

SUHNER Abrasive Expert AG P.O. Box CH–5201 BruggPhone +41 (0)56 464 28 80 [email protected]


www.equipment-news.com ProductFinder





HPMT: Anti Vibration Endmills

Krebs & Riedel: Fibre-Reinforced Composites Grinding Wheel Body

As a manufacturer of conventional as well as vitrified-bond CBN and diamond tools, Krebs & Riedel has observed a consistent demand over recent years for dressable, ultra-hard grinding tools.

Many factors have contributed to this development. New materials such as powder-metallurgical steel and high-tensile coatings pose extreme challenges to conventional grinding tools. Tolerance zones are also becoming ever tighter, while there is pressure at the same time for shorter primary and secondary processing periods. The ultra-hard grinding tools, CBN and diamond, offer a much higher potential to reduce unit costs.

The body of a grinding wheel is also an essential component of a grinding wheel system. Wheel bodies made out of fibre-reinforced composites offer particular advantages for specialised usages. As well as a weight reduction of up to 70 percent, they also offer good attenuation and stability characteristics.

Komet Group: Chip-Breaking Topography For Drilling

Komet Group’s SOEX indexable insert topography is generally suitable for all steels, in particular for long-chipping steel materials and stainless steels. Reliable removal of chips, even with high L/D ratios is achievable due to its chip formation.

The PVD coated BK8430 is an all-round cutting material. It is wear-resistant with a universal indexable insert for inner and outer cutting.

It is suitable for use in continuous drilling with KUB Quatron indexable drill with drilling depth 2×D, 3×D; deep hole continuous drilling with KUB Centron Powerline with drilling depth up to 9xD, and Easy Special (special tools).

The Noviano SE45DP range of endmill developed by HPMT is touted by the manufacturer to be anti vibration and anti noise. This is largely due to the anti vibration design on its variable index. Other features include wear and chipping resistance and longer tool life brought about by the PVD coating.

Finally, the endmill gives better surface finishing, higher cutting speeds and a high CNC repeatability within 0.01 mm. They are benefits attributed to the tool’s ability in edge grinding.

Iscar: Economical Solution For High Feed Milling Applications

Iscar is expanding the Helido family of

milling tools by i n t r o d u c i n g

the FF SOF cutters, designed for high feed

milling operations. The cutters feature a cutting edge angle of 15 deg and

can carry the standard double-sided inserts like the S845 SNMU/SNHU 13 and the ONMU/ONHU 05.

They combine the advantages of the design of the FeedMill tools with the effectiveness of the double-sided square and octagonal inserts. These cutters expand the application range of the above standard inserts by applying productive rough face milling with high metal removal rates.

The cutters are designed for machining most metalworking materials. They are available in face mill configurations in the diameter range of 63 to 100 mm, and have coolant holes directed to each individual insert pocket.


www.equipment-news.comproductfinder



ENQ

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4

ENQ

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Mitsubishi Electric: Wire EDM

Mitsubishi Electric h a s d e v e l o p e d the Wire EDM MV Series with DMXS optimisation of WDM technology. The machine is equipped with a linear shaft

motor and automatic wire threading with an annealing system over

300 mm on break point insertion. Other functions and features include a precision

finish circuit, which realises faster machining operation with improved power-supply performance of Rz3.5 µm/Ra0.45 µm with three cuts. The machine also offers easy operation with its natural user interface. It adjusts job schedule and inserts extra job including offset, speed and adaptive control setting. Finally, its built-in long life system reduces power consumption, lowers running cost and in turn, offers energy saving for every machine shop.

Lantek: Sheet Metal & Steelwork Solutions

Lantek’s 2012 versions of its CAD/CAM, management and ERP software for sheet metal and structural steelwork applications speed up daily tasks, increase productivity levels and enhance management transparency and efficiency.

The CAD/CAM software now includes a manufacturing browser, which optimises the selection of tool options, while algorithms for the automatic machining of multi-parts and 3D simulation of punching operations improve efficiency and clarity.

For pipes and steelwork, the company has improved the way in which Lantek Flex3d links with CAD. Its customisable ribbon menus and advances in STEP, IGES, DSTV, CAM and XML interfaces make it easy to import pipe assemblies and work with 3D data.

heimatec® ASIA /PACIFICPhone +65 8112 6550Mail: [email protected]: www.heimatec.com

heimatec® GmbH GERMANYPhone +49 7843 94660Mail: [email protected] Web: www.heimatec.de

andandandandandQuality

excellence!


www.equipment-news.com productfinder





Walter: Maximum Drilling Performance

The increase in performance that Tiger·tec Silver provides for milling and turning is now available for drilling. Walter has developed the Xtra·tec Insert Drill range indexable inserts made of the high-performance silver cutting material.

Tiger·tec Silver Performance is now available for drilled holes of up to 59 mm in diameter and drilling depths of up to 5xD as a standard, while drills for other diameters and depths are possible as special solutions.

The insert is subjected to a surface treatment of the aluminium oxide coating developed that minimises friction and ensures improved resistance to comb crack formation. This results in both higher cutting speeds, as well as further improvements to process reliability in comparison with standard CVD coatings.

TaeguTec: Minimising Down Time

The Drillrush by TaeguTec is a quick-change system cutting tool solution. A key enables simple head indexing with minimised down time and no further set up time. The clamping system provides accuracy and rigidity for all applications.

As a standard or specialised drilling, boring or chamfering solution, its strength lies in its flexibility as a tooling solution. Polished wide flutes allow smooth chip evacuation and high-hole accuracy while the PVD coated drill body means longer tool life.

The range of indexable diameters (10.0 - 19.99 mm) with drill bodies from 1.5XD, 3XD, 5XD and 8XD means consistent performance and high productivity even after multiple head indexing. A further innovation is the addition of twisted through coolant channels for optimal flute geometry.

Schaeffler: High Load Carrying Roller Bearings

Schaeffler is now offering a range of tapered roller bearings with its FAG tapered roller bearing series in X-life quality worldwide. Currently, 30 standard catalogue types of these tapered roller bearings are available in sizes with outside diameters of up to 635 mm.

Within the next two years, the company will increase the number of types to 120 including outside diameters up to 1,200 mm. This will cover the majority of industrial applications.

The roller bearings in X-life quality can achieve a reduction in frictional torque of up to 75 percent compared with conventional standard products. According to the manufacturer, the tapered roller bearings can carry a minimum of 20 percent higher loads compared to any competitors’ product in the standard category.

Siemens PLM: Better Decision Making In Product Development

Siemens PLM Software has released the Teamcenter 9, a PLM system that delivers solutions and enhancements across the portfolio in support of Siemens PLM Software’s HD-PLM vision. The system helps companies deliver complex products while maximising productivity and streamlining global operations.

The release adds an integrated systems engineering solution and tightens the integration across the unified architecture, so companies can make smarter decisions with better visibility into the impact of those decisions.


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ExhibitionProgrammes2012-2013

www.equipment-news.comJul-Aug 2012 metalworking equipment news 79

July3 – 6Eastpo 2012SNIECShanghai, [email protected]

3 – 6MTA VietnamSECCHo Chi Minh [email protected]

September10 – 15IMTSMcCormick PlaceChicago, [email protected]

12 – 14Medical Manufacturing AsiaSuntecSingaporeMesse [email protected]

19 - 21MTT ExpoGrand City ConvexSurabaya, [email protected]

OctOber4 – 6Metalex VietnamSECCHo Chi Minh City, VietnamReed [email protected]

23 – 27EuroBlech 2012Exhibition GroundsHanover, GermanyMackbrooks [email protected]

NOvember1 – 6JIMTOF 2012Tokyo Big SightTokyo, JapanJMTBAwww.jimtof.org

6 – 10China International Industry Fair 2012SNIECShanghai, Chinawww.ciif-expo.com

7 – 9Indonesia Oil & Gas Expo 2012Balikpapan Int'l Sport ArenaBalikpapan, [email protected]

7 – 10Indo Aerospace 2012JIExpoJakarta, Indonesiawww.indoaerospace.com

21 – 24MetalexBITECBangkok, ThailandReed [email protected]

To be considered for inclusion in the calendar of events, send details of event to:

December5 – 8Manufacturing Indonesia 2012Jakarta Int'l Expo KemayoranJakarta, IndonesiaPT Pamerindowww.pamerindo.com

2013JaNuary24 – 30Imtex 2013Bangalore International Exhibition CentreBangalore, [email protected]

February20 - 23IndometalJakarta International Expo KemayoranJalarta, IndonesiaMesse Dusseldorf (Asia)[email protected]

march5 – 10TIMTOSTWTC, TWTC NangangTaipei, [email protected]

april 9 – 12MTA 2013Singapore [email protected]

The Editor (APMEN)Eastern Trade Media1100 Lower Delta Road, EPL Building, #02-05, Singapore 169206Email: [email protected]: +65 63792888

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malleable parts. With its selection

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MACHINEONETOOLStheALL

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ENQUIRY NO 125

WIN WITH WIDIA

How much would you pay for a perfect hole? Not nearly as much as you think.

WIDIA VariDrilltm

• Best price-performance ratio.• Applicable in almost every workpiece material.• Available from 1,0 to 20,0 mm, from 3xD to 8xD.• With coolant or non-coolant.

To learn more about the unmatched benefits of WIDIA VariDrill,tm contact your local distributor or visit www.widia.com.

©2012 Kennametal Inc. l All rights reserved. l A-12-02818-ENENQUIRY NO 128

apmen julaug 2012

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