apmen may-june 2014

from DMG MORI

METALTECH 201421st – 24th May 2014Hall 1, Booth 1140

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May - June 2014

3D TECHNOLOGIES: SEE HOW THEY MEASURE UP

Machining IntelligentlyISCAR HIGH Q LINES www.iscar.com

SINO TOOLING SYSTEMBlk 502, Jurong West Ave 1 #03-813 Singapore 640502Tel + 65 6566 7668 Fax + 65 6567 7336 [email protected]

ISCAR THAILAND57, 59, 61, 63 Soi Samanchan-BabosSukhumvit Rd. Phra Khanong, Khlong Toey Bangkok 10110Tel + 66 (2) 7136633Fax + 66 (2) [email protected]

CV MULTI TEKNIKRuko Gsa Blcok B No. 8 BN-BP, Podomoro City JL.Letjen S.parman Kav.28Jakarta Barat 11470 Indonesia Tel + 62 21 29206242/44/45/59Fax + 62 21 [email protected]

ISCAR JAPAN 1-5-3 Shinsenri-HigashimachiToyonaka-shi, Osaka 560-0082Tel + 81 6 835 5471Fax + 81 6 835 [email protected]

MESCO Reliance CornerBrixton St. Pasig CityMetro-Manila Philippines Tel + 63 2631 1775Fax + 63 2635 [email protected]

ISCAR TAIWAN395, Da Duen South Rd. Taichung 408Tel + 886 (0)4 247 31573Fax + 886 (0)4 247 [email protected]

ISCAR VIETNAM (Representative Office) Room D 2.8, Etown Building, 364 Cong Hoa, Tan Binh Dist., Ho Chi Minh City, Tel + 84 8 38123 519/20 Fax + 84 8 38123 [email protected]

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SECO TOOLS (SEA) PTE LTDTEL +65 68412802FAX +65 [email protected] ENQUIRY NO 070

www.equipment-news.comasia pacific metalworking equipment news May-Jun 20142

SHOP TALK22 Composite Materials Breaking Traditional BoundariesThe phrase ‘pushing the envelope’ may be insufficient to describe the magnitude of the technological breakthrough when people start claiming that they have manufactured a wingless plane made of composite materials. By Michael E Neumann

30 Taking The 360º Approach In MeasurementA metrology solutions provider has decided to cover all angles in order to provide automotive production lines actionable information that are essential in their operations. By Joson Ng

42 Back To Basics: We Have Got To Stick TogetherWelding is perhaps the most common joining process in metalworking. The strength of a weld is often dependent on the welding method employed, but what are the pertinent welding methods for metalworkers in Southeast Asia? By Shahnawaz Abdul Hamid

24 Compositing The FutureDespite substituting metal in a growing number of applications, machining composites is a vastly different affair that requires a whole new approach altogether. By Sherlyne Yong

MAKING THE CUT20Drill Productivity Into Your Manufacturing ProcessesGeometry, polished surface and the ability to keep the drilling process cool can go a long way in drilling composite materials, aluminium or other difficult materials. By Joson Ng

DESIGN & MEASUREMENT26 3D Technologies: Not Out Of Our LeagueLaser scanning technologies may seem too advanced for some in the metalworking industry in Southeast Asia but attitudes are changing. By Joson Ng

FABRICATOR'S NOTE34Submerged Arc Welding Technology Provides Up To 100% Increase In ProductivityAn integrated cold electrode is said to bring about better deposition rate while maintaining mechanical properties. By Hannes Raudsepp, ESAB Global Automation

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CONTENTS May-June 2014

48 Medical Industry: What’s New?Augustine Quek takes a look at the advancements in the world of medical devices and its manufacturing process.

INDUSTRY FOCUS44 Bringing Better Smiles Faster Matt Bailey, international correspondent for Haas Automation takes a look at how a part producer successfully moves into the world of dental parts manufacturing.

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58Beyond Simple Manual DeburringWhile deburring may be thought by many to be a fairly simple process, it has gone through some modern enhancements in recent years, saving money and time. By Shahnawaz Abdul Hamid

FEATURES54Taking The Measured Approach By AccessorisingCMM accessories are important. Pairing inferior accessories with a good CMM can be likened to putting cheap fuel into a Ferrari. By Joson Ng

PARTING SHOT72Want A Bike? Print It!Manufacturers can now add printing to their list of manufacturing techniques in making bicycle frames. By Robin Weston, Renishaw

EVENTS & EXHIBITION 62 Event Preview:

MTA Vietnam 2014 Event Preview: EMTE-Eastpo Machine Tool Exhibition Event Preview: Taiwan Machinery Launch Event Event Preview: Vietnam Manufacturing Expo Event Preview: Metalex Vietnam Event Review: MTA Hanoi 2014

CONTENTS May-June 2014

52 Manufacturing To Be Future-ReadyManufacturers need to be ready for the fourth industrial revolution. By Joson Ng

MANAGER'S TAKE50 Lean Manufacturing In 8 StepsIdentifying areas of wastage can go a long way in achieving a streamlined and well-managed warehouse. By Petros N Zenieris, The Business Criterion Consulting & Training Office

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54 Damian Searles, Brisbane, Australia

ENQUIRY NO 012

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The third industrial revolution is widely believed to have started in the 1970s. While the last 40 years have seen unprecedented technological advancements across all fields, (namely computers taking over the workplace) it is likely that this revolution is on its last leg and we are close to the start of a new revolution.

Although it is difficult to put a finger on the exact date of the birth of Industry 4.0, also known as the fourth industrial revolution, it is fair to say that the more we hear about terms like digitalisation, smart devices, 3D printing, cloud computing or arguably anything that sounds abstract or exotic, we are getting closer to Industry 4.0.

In the spirit of Industry 4.0, we are featuring 3D technologies in this issue of Asia Pacific Metalworking Equipment News. 3D technologies have been used to aid metrology for a number of years now. Even when people are beginning to think that the

technology has reached its maximum potential, there are still incremental improvements to be made. Anyway, that is what innovation is all about isn’t it? It is about taking an existing product and making improvements on it, producing something better as a result. We will be exploring the issue of innovation in 3D technology and how mindset plays an important role in convincing people to upgrade to a better product.

We will also take a look at how a company has combined its product portfolio to produce a comprehensive system to transform an ordinary shop floor into a ‘gigantic measuring room’.

The examples have shown us there are actually plenty of ways to reinvent the wheel and companies are pulling out all the stops to make themselves and their products relevant to the future. I guess this is what it is all about at the end of the day, regardless of which industry revolution we are in now.

Joson NgSenior Editor

chairman Stephen Taygroup executive director Kenneth Tanexecutive director Lum Kum Kuen

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ENQUIRY NO 076

Japanese Machine Tool Orders Soared In March: JMTBATokyo, Japan: The total value of Japa ne se machine tool orders in March increased some 25.8 percent compared to February and marked the second consecutive month of increase, according to numbers from JMTBA.

Standing at JPY128.30 billion (US$1.25 billion), this figure also represented an increase of 41.8 percent compared to the same month of the previous year, with March posting the sixth consecutive month of year-on-year growth.

The total amount of orders has now topped JPY100 billion for seven consecutive months and has also passed JPY120 billion for the first time in 33 months, driven by the end-of-the-fiscal-year effect and spot orders.

Domestic orders also showed positive gains in the month of

Röhm Opens Office In Singapore

Singapore: Germany-based chucking tool manufacturer Röhm has opened an office in Singapore. The company started its operation on March 3, 2014 and spearheading it is Roberto Bencina, MD of Röhm Asia Pacific.

According to him, the opening of the office is a strategic plan to be more engaged in the region of Asia Pacific. “We want to have more of the cake and I think it’s the right time to be in Asia now,” he said before adding that the new operation will play a supporting role to the company’s distributor network in the country, forged some 35 years ago.

In terms of technical service, Mr Bencina intends

to “close the time gap.” He hopes in the future, they will be able to send out a technician immediately should the need arises. “We can be there in hours, rather than in weeks,” he said.

Finally, he revealed that the establishment of the office in Singapore is only a start. There are tentative plans to expand their operations in the country to include a warehouse to stock up on inventory and a technical/sales centre to provide technical and sales support. He added that the company’s product range is divided into nine groups and they have every intention to bring the whole range to the region because of “the diversity of the need here.”

Röhm is located at the German Centre

Roberto Bencina

March. The association reported a r ise of 11.4 percent over February, amounting to JPY37.88 billion. This marked the first month of increase in four months. The figure was also an increase of 12.7 percent over the same month of the previous year and marked the ninth consecutive month of year-on-year growth.

Foreign orders stood at JPY90.42 billion in March, a 33 percent increase over the previous month. This marked the second consecutive month of growth. Foreign orders also showed an increase of 58.9 percent over the same month of the previous year, with March posting the fifth consecutive month of year-on-year growth.

By reg ion, orders f rom Asia rose by 60.5 percent over February to JPY49.67 billion. This was also an increase of 103.6

percent over the same month of the previous year.

Orders from North America also rose in March. The only blip in March came from Europe, with orders falling by one percent from February to JPY15.21 billion. However, this was an increase of 30.9 percent over the same month of the previous year.

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APEC Recovery Gaining Traction

Singapore: Economic recovery is gaining traction in the Asia-Pacific but higher production efficiency, supported by more innovation-friendly conditions for businesses, is needed to help put economies on an improved growth path and bridge gaps in employ ment a nd l iv ing standards.

T h i s i s t he u nde r ly i n g message of the latest APEC Economic Trends Analysis report which reflects the direction of partnership between APEC member economies.

“Economies in the APEC region are recovering and we expect

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Italian Machine Tool Orders Up 15.2% In Q1Italy: In the first quarter of 2014, the machine tool index of orders, issued by UCIMU-Sistemi Per Produrre, registered a 15.2 percent increase when compared with the January-March period of the previous year.

According to the association, the result is due to both international and domestic markets. In terms of exports, the index showed a 5.7 percent increase when compared with the same period of the previous year, confirming the positive trend recorded starting from the last quarter of 2013.

The situation in Italy is even better. The index of

Italian manufacturers showed a marked increase of 79.3 percent in the domestic market, when compared with the first quarter of 2013.

Looking at the figures, Luigi Galdabini, president of UCIMU-Sistemi Per Produrre said the numbers showed a general recovery in the demand for Italian machine tools, with the increase appearing more evident on the domestic front.

However, he cautioned that the upturn, while “a great signal”, must be interpreted taking into account that the big increase appeared because of comparisons to a negative period.

this to accelerate,” said Dr Alan Bollard, executive director of the APEC Secretariat. “Our priority now is to ensure that the region moves to a higher medium-term growth path. To achieve that, APEC economies are laying the groundwork for a rebound in trade and productivity.”

The 21 APEC economies account for about half of global trade and 60 percent of total gross domestic product. Economic growth among them is forecast to increase from 3.7 percent in 2013 to 4.2 percent in 2014. A further uptick to 4.4 percent is expected in 2015.

Nonetheless, macroeconomic imbalances linked to the global financial crisis and post-crisis uncertainty continue to moderate economic performance across the Asia-Pacific.

“APEC trade is at high levels in global terms but exports remain sluggish and are not contributing to growth in an optimal way,” explained Dr Bollard. “At the same time, the region is facing the twin challenges of decelerating labour productivity and employment growth.”

“ P ro d u c t i o n e f f i c i e n c y ha s dropped a mong f i rms in emerging and developing economies while companies in industrialised economies have increasingly turned to layoffs,” noted Quynh Le, a macroeconomist at the APEC Policy Support Unit and lead author of the APEC Economic Trends Analysis. “Economic turnaround is a pre-requisite for a revival in productivity and employment but that in and of itself may not be sufficient.”

“ S u s t a i n a b l y r a i s i n g productivity and ensuring robust job creation requires higher production efficiency based on greater innovation across different business sectors,” Mr Le added. “Technological innovation, for example, can cultivate markets for new products and, in turn, seed employment opportunities and expand production frontiers.”


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Shapegrabber Joins The Quality Vision International FamilyRochester, New York: Quality Vision International (QVI) has acquired ShapeGrabber Incorporated, a manufacturer of automated 3D scanners for industrial applications.

As a wholly-owned subsidiary of QVI, ShapeGrabber will gain access to new markets and customers for its 3D laser scanners. On the other hand, QVI adds another technology to its portfolio of dimensional inspection systems for manufacturing quality control. ShapeGrabber is a provider of 3D laser scanners that are suitable for measuring and inspecting complex-shaped parts that are otherwise too time consuming, costly, or difficult to measure.

The scanners are used for quality control in automotive, aerospace, medical and other industrial markets to help manufacturers reduce defects, rapidly conduct first-article inspections, troubleshoot fit problems, and provide documented proof that components meet design specifications.

Birmingham, UK: Delcam’s Vortex area-clearance strategy was the winner in the Best CAD/CAM or Control System category at the MWP Advanced Manufacturing Awards.

In selecting the product for the award, the judges commented: “The winner has developed a method of controlling the tool’s angle of engagement, which optimises the tool speed, extends tool life and produces a faster overall cycle time.”

Vortex gives the fastest safe metal removal from solid carbide tooling, in particular designs that give deeper cuts by using the full flute length as the cutting surface. It can be used for two- and three-axis roughing, three-plus-two-axis area clearance and for rest machining.

Delcam Wins CAD/CAM Award

Renishaw Acquires US Metrology Specialist

UK: Renishaw has purchased the business of Advanced Consulting & Engineering (ACE), a US-based supplier of dimensional measurement products and services focused on the automotive industry.

The acquisition of family-owned ACE, based in Rochester Hills, Michigan, provides Renishaw with further specialist programming capabilities using industry packages and will help to support the company’s sales of CMM probing systems and Equator gauges in the USA.

Embraer Delivers 14 Commercial & 20 Executive Jets In 1Q14São José dos Campos, Brazil: Embraer has delivered 14 jets to the commercial aviation market and 20 to the business aviation market, for a total of 34 aircraft, compared to 29 aircraft delivered in the same period of 2013. On March 31, 2014, the firm order backlog totaled US$19.2 billion, an increase of US$1 billion over December 31, 2013.

The backlog for the first quarter of 2014 includes a firm order for 50 E-Jets E2 aircraft from Air Costa, an Indian airline, in an acquisition that is comprised of 25 E190-E2s and 25 E195-E2s, as announced during the Singapore Airshow.


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WENZEL Asia Pte Ltd 26 Boon Lay Way, #01-84 TRADEHUB21, Singapore 609970Tel : +65 6795-2327 Fax : +65 [email protected] www.wenzel-group.com

Haas Reaches Milestone

US: Haas Automation has reached a major milestone in the company's history as a machine tool builder — the production and installation of the 150,000th Haas CNC machine.

The 150,000th machine — a DS-30SSY dual-spindle turning centre with Y axis — rolled off the production line in January and was installed at Swedish company Claesson Engineering in March.

Leica Microsystems Opens Experience Lab In Japan

Wet z la r, Ger ma ny : L e ica Microsystems ha s opened a n E xper ience L ab in the headquarters of its Japanese office in Tokyo, Japan. The laboratory is dedicated to product demonstrations of Leica microscope systems and workshops.

Additionally, it serves as a showroom for microscope users who wish to get to know the instruments and accessories like cameras, illumination and software. Users are free to bring their own samples to observe with the systems and can also take advantage of a sample preparation service for industrial samples to be observed and analysed there and then.

The laboratory is equipped with microscope systems for industria l, cl inical and l i fe science applications.

LVD To Bring Its Sheet Metalworking Solutions To Malaysia

Malaysia: At Metaltech Malaysia, LVD will showcase their products in each of their product groups: punching, bending and laser cutting. In punching, the Strippit VX-1530 is said to be capable of delivering high productivity. With high cutting speeds, the Electra FL-3015 fibre laser cutting machine cuts thin sheets up to three times faster than a CO2 laser cutting machine.

Finally, the company is bringing two press brakes to the show. The first is the compact Dyna-Press, which is suitable for the quick bending of small parts. The ToolCell is an automated tool changing press brake, which allows users to improve the throughput of their bending shop. In addition, the company will also demonstrate the power of its CADMan offline programming system for use with all LVD machinery.


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Boeing Business Jets Market Growing In ChinaShanghai, China: Five Boeing Business Jets have entered service in China in the last year where the market for ultra-long range business jets continues to grow, the company announced.

“China continues to be a strong market for us as more Chinese companies increase their international presence,” said captain Steve Taylor, president, Boeing Business Jets. “The BBJ is the right business tool for this market with the range capability to go farther non-stop, and the size for large business teams to travel more comfortably.”

BBJ had a big year in China with five BBJs entering service since last April; two new BBJs and three pre-owned jets. In addition, three more BBJs for Chinese customers were delivered to completion centres, including the first BBJ2 for the China region. The order book for Chinese customers increased by two in the same timeframe.

Captain Taylor also announced BBJ’s worldwide orders and deliveries. In total, the program has booked orders for 216 airplanes and delivered 195 since launching in 1996.

Worldsteel: Global Apparent Steel Use To Increase Albeit At A Lower Rate

Lév is , Canada: Crea form, a producer of portable 3D measurement solutions and 3D engineering services, has won two awards with its optical portable CMM, the HandyProbe.

The first award was won at the MWP Advanced Manufacturing Awards, a bi-annual event that is held in conjunction with the MACH exhibition in Birmingham, UK. The measuring dev ice won in the Quality Control Equipment category.

One week before, the same product won recognition at the Prix du Copeau 2014, awarded by a French magazine, at the Industrie Paris tradeshow.

The Prix du Copeau honours suppliers’ innovation in helping improve the competitiveness and quality control performance of machining companies. The product also bagged second place in the general ranking and first place in the Quality Control Systems category.

London, UK: The World Steel Association (worldsteel) has released its Short Range Outlook (SRO) for 2014 and 2015. The association forecasts that global apparent steel use will increase by 3.1 percent to 1,527 Mt in 2014 following growth of 3.6 percent in 2013. In 2015, it is forecast that world steel demand will grow further by 3.3 percent and will reach 1,576 Mt.

Cha irma n of worldsteel Economics Committee, Hans Jürgen Kerkhoff said: “In 2013, world steel demand grew higher than our previous forecasts due to a stronger than expected performance in the developed world in the second half of the year.

In particular, the recovery in the US gained strength. In addition, the downturn in the EU bottomed out and we now expect that steel demand in the Eurozone will move into positive growth in 2014. On the other hand, many emerging economies continue to struggle with structural issues and financial market volatility. This, along with China’s deceleration,

Creaform Wins Quality Control Awards

is the reason for our slightly lower global growth rate forecast for 2014.

In 2015, growth in most parts of the world will accelerate thanks to a continuing steady recovery in the developed economies and an improvement in the situation for the emerging economies. But China’s steel demand will further decelerate and this will prevent the broad recovery momentum from registering a higher global growth rate for 2015.

We continue to see challenges. The recovery in Europe is still only mild and constrained by high debt and unemployment. Structural problems in the emerging economies are less likely to be resolved in the short term leaving them fragile and susceptible to external shocks.

We are still seeing unexpected unstable political situations in many emerging economies. In this regard, the development involving Crimea raises a high downside risk for our outlook for the CIS region. Finally, issues remain surrounding China’s debt and real estate bubble.


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In short, the global steel demand recovery continues but growth is stabilising at a lower rate with continued volatility and uncertainty leading to a challenging environment for steel companies.”

After a growth of 6.1 percent in 2013 with support from government in frastructure investment, apparent steel use in China is expected to slow to 3.0 percent growth in 2014 to 721.2 Mt as the Chinese government’s efforts to rebalance the economy continues to restrain investment activities. In 2015, steel demand growth is expected to further decelerate to 2.7 percent.

In India, steel demand is expected to grow by 3.3 percent to 76.2 Mt in 2014, following 1.8 percent growth in 2013, due to an improved outlook for the construction and manufacturing sectors, even though this will be constrained by high inflation and structural problems.

Despite uncertainties relating to the impact of upcoming elect ions, steel demand is proje c te d to g row by 4 . 5 percent in 2015 supported by the expectation that structural reforms will be implemented.

Fol lowing a 2 .0 percent increase in 2013 due to the moderate GDP recovery as a result of ‘Abenomics’, apparent steel use in Japan is expected to contract by -1.0 percent to 64.6 Mt in 2014

G e r m a ny : Wa l te r i s now launching its smarthone app ‘Tools & More’ also as a desktop version for Windows PCs. New features include an optimised user interface, a print and export function and also the name: ‘Tools & More’ has been renamed the ‘Machining Calculator’.

Walter Launches Its Smartphone App For Desktops

Zeiss Committed To Raising Metrology Competency In Thailand

Ayutthaya, Thailand: Zeiss has conducted a two-day metrology seminar on CMM, CMM Measurement and GD&T inspection on CMM. The seminar was held at DMG Mori Seiki's main Thailand office and technical centre and it was attended by some 125 participants. During the seminar, they shared various metrology topics like material inspection, enhancing productivity of CMM, GD&T form and measuring strategies. The seminar also included a hands-on session.

Educational institution and government agencies such as Rajamangala University of Technology Suvarnabhumi (RMUTSB), National Institute of Metrology Thailand (NIMT) and Thai-German Institute (TGI) also took part in the event.

due to the consumption tax hike affecting the construction and automotive sectors negatively. In 2015, steel demand is expected to increase by 0.5 percent.

O ve ra l l app a re nt s te e l use growth in the developed

economies will be above two percent in 2014 and 2015. However, the developing and emerging economies will continue to grow faster than the developed economies despite their more subdued performances.


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Visit us atMetaltech Malaysia 2014 May 21-24Booth 1210 - Hall 1

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ENQUIRY NO 086


Productivity is king. It is an average measure o f the e f f i c iency o f p r o d u c t i o n a n d a

key driver of growth. In the metalworking world these days, productivity is an important issue and most significantly o f a l l , product iv i ty se l l s . Well aware of the situation, cutting tool manufacturers are designing their tools specifically to increase productivity.

Whether it is turning, milling or drilling, the manufacturers are keen to fly the productivity flag. In drilling, greater productivity is typically achieved by higher cutting speed, higher material removal rate, longer tool life and shorter cycle times. While these factors are possibly intertwined and common, the journey taken by every drill manufacturers can be vastly different.

Get In ShapeS e c o ’s c o n c e p t t o b e t t e r p r o d u c t i v i t y i n d r i l l i n g composite materials revolves around shapes — specifically a dome and a cap. According to the manufacturer, the CX1 and CX2 solid polycrystalline diamond-tipped drills bring increased tool life, productivity and quality to manufacturers machining holes in composite materials.

For effective drilling through ‘plain’ composite materials, the third flute on the CX1 provides high levels of stability in the hole as well as decreased vibrations

and improved roundness . Furthermore, the dome-shaped tip of the drill offers a double-angle geometry. This geometry reduces uncut f ibres and delamination in composite-only applications.

G r i n d i n g t h e s e h i g h l y complex types of geometries was previously impossible using conventional brazed or similar PCD techniques. In addition, the dome cap makes it possible for the drill point to be reconditioned and resharpened up to three times.

As far as the cap shape goes, the CX2 has a flat geometry drill point for machining stacked composite materials with layers of aluminium or titanium. With this geometry, a PCD cap is used because the drill point is a 180-degree point angle that provides efficient chip breaking and evacuat ion qua l i t ies . This reduces the risk of metal

chips damaging the hole when transitioning between layers of metal and composites. As a result, the CX2 keeps the surface finish of the composite intact.

The CX1 and CX2 drills offer what the company deems the sharpest and strongest cutting edges currently available. This performance is possible because the drills use solid PCD tips that can be much sharper than diamond coated drills where the coatings wrap around a drill’s cutting edges and actually create a dulling effect.

Other benefits of the solid PCD tipped drills include high cutting speeds, low friction, good heat transfer, multiple re-sharpening and high process reliability.

Aluminium: Smooth OperatorOperating in a smooth manner can go a long way in improving productivity. Take a highly polished surface on a dril l

Drill ProductivityInto Your Manufacturing Processes

Geometry, polished surface and the ability to keep the drilling process cool can go a long way in drilling composite materials, aluminium or other difficult materials. By Joson Ng

The shape of a drill can dictate its performance and productivity.

MAKINGTHE CUT

May-Jun 2014 asia pacific metalworking equipment news www.equipment-news.com 21

and what it does is it reduces friction on flutes, margins, and cutting edges. This results in good chip evacuation and ultimately good metal-removal rates and better productivity.

The Beyond solid carbide drill by Kennametal is said to have adopted this philosophy to achieve good results in drilling aluminium.

In a time when maintaining crucial production schedules whi le control l ing costs is extremely hard when it comes to making high-precision holes in aluminium, the HPS solid-carbide drill comes with design features including a proprietary 135-degree high-performance drill point for good centring capabi l i t ies and improved feeds. In addition, it has sharp cutting edges that lower cutting forces and extend tool life. An enlarged spiral flute design further speeds chip evacuation and reduces cutting forces.

C o m p a r e d t o i t s P C D counterparts that are widely

deployed in up to 80 percent of transportation industr y a p p l i c a t i o n s t o d a t e f o r c y l i n d e r b l o c k s , c y l i n d e r heads, gear boxes, suspension parts, and many other critical components, the solid carbide drill comes at a comparatively lower cost.

Stay Cool When Going DeepDelivering more coolant, taking the heat away and keeping the process cool seem simple enough and simplicity in this case has reaped dividends.

TaeguTec’s DrillRush 12xD drill is capable of strong delivery of coolant through its twisted body channels. This enables a widened gullet design and keeps the drill and workpiece material cool at all times while minimising cycle times when drilling diameters from 12 mm to 22.9 mm. The cycle time can also be minimised with the introduction of chamfer rings.

Other important factors t h a t a r e i n t r o d u c e d a r e repeatability, smooth surface finish and high productivity. All these additions, according to the manufacturer are now achieved without the need for pecking cycles. To promote machining convenience in hole making applications, the new 12xD body can be accentuated with the company’s chamfering rings. Together, they drill and chamfer in a single operation in order to minimise cycle times as well as inventory and tooling cost for improved cost effectiveness.

To m m y S u n g , p ro d u c t manager (hole-making) of the

developer said: “Drilling up to 12xD depth is a

tough application, not only for solid carbide dril ls but for head c h a n g e a b l e

drills as well.”

He revealed while HSS drills are still a common solution for deep drilling over 10xD depth, they do not result in high productivity.

Making a compelling case, he began to compare the performances between a HSS drill and the DrillRush. He said in a drilling test between the two, on a work piece made out of alloy steel (AISI 4140), a hole size of D16 mm X L190 mm would take the HSS drill (D16) a cycle time of 63 s per hole and the tool life is 120 holes. The drilling was conducted at speed (Vc) of 30 m/min, feed (f) of 0.3 mm/rev and table feed of 180 mm/min.

The DrillRush (D16) on the other hand took 13.6 s to finish drilling the same hole. The tool life has also increased to 250 holes. He added the speed (Vc), feed (f) and table feed have increased as well to 120 m/min, 0.35 mm/rev and 835 mm/min respectively.

ENQUIRY No. 4001Turn to page 80a or log on to www.equipment-news.com to enquire

Got a Question? Make An Enquiry.

Good chip evacuation is possible thanks to a highly polished surface on the drill.

Keeping the drilling process cool can help achieve better productivity.

MAKINGTHECUT


What is a plane without its wings? The short answer is a slightly awkward and naked

looking fuselage with a lonely looking tail. After clearing the initial mental image, the next question would naturally be: how is it going to fly?

Answering the question is VX Aerospace with its VX-1 KittyHawk. The advanced composites manufacturing and design company has combined the fuselage and wings into one shape called a ‘lifting body’ or ‘blended wing’ aircraft.

Capable of carr ying out manned or unmanned operations, the design of the aircraft is said to triumph over traditional designs with greater useable internal volume, greater payload capability, better structural efficiency, better durability and better manufacturability. The construction will also have fewer parts and is therefore easier to assemble.

The aerospace industry is of course no stranger to composite materials. In the commercial

aircraft segment for example, the new generation aircraft like the B787, B777-9X and A350-900 all use composite materials to achieve better fuel efficiency, lower emissions and ultimately lower operating costs. The design of the VX-1 KittyHawk is also following this trend.

“The volume wi l l a l low KittyHawk to lead the way in adopting CNG as an aviation fuel. Existing technology CNG tanks fit inside the aircraft with no aerodynamic compromise. At less than 1/3 the cost of avgas, the KittyHawk will have unparalleled operational economy with emissions that are 40 percent cleaner,” says Bob Skillen, VX Aerospace’s CEO.

Using The Right FabricThe effort to reduce the weight of the aircraft saw the manufacturer forge a working relationship with Chomarat, a producer of composite materials and engineered textiles. The first VX Aerospace aircraft was manufactured with C-Ply, a carbon multiaxial product or

Non-Crimp Fabric (NCF). The producer of the material said the NCF is made up of unidirectional layers that are mechanically sewn together. This particular NCF can have plies with a tow spreading process resulting in thickness as low as 75 gsm per ply.

Featuring a gap free technology, there is no resin rich corner. The material also supposedly has better mechanical properties. Finally, with the optimised layer construction, cost savings can be achieved. In this case, the C-Ply was prepregged with Cytec Industries’ resin system MTM 45-1 to create a low density, high damage tolerant prepreg material. The usage of the composite material allows the aircraft to be structurally efficient.

The C-Ply is the enabling material for the manufacturer to use their hand lay-up and oven curing processes to achieve properties similar to autoclave cured UD (uni-directional) prepreg and automatically placed tape prepreg. The material is durable to handle during lay-up, drapable to accommodate the compound curvatures, and can be manufactured to fully optimise the design relative to fibre angles and ply weights to ultimately yield a low weight, high performance, and low cost final solution.

“C-Ply is the first true advance in carbon fabrics in a long time. It is designed to optimise fibre performance. Chomarat capitalised on the low-angle, thin ply, non-crimp laminate concept. The result is a fabric that allows for cost effective production of open mould parts with the same (or better) performance characteristics of ATP parts. This is a game changer for small business,” says Mr Skillen.

Composite MaterialsBreaking Traditional Boundaries

The phrase ‘pushing the envelope’ may be insufficient to describe the magnitude of the technological breakthrough when people start claiming that they have manufactured a wingless plane made of composite materials. By Michael E Neumann



SHOPTALK

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ENQUIRY NO 027


Despite substituting metal in a growing number of applications, machining composites is a vastly different affair that requires a whole new approach altogether. By Sherlyne Yong

One unique thing about composi tes is that their properties can be tailored differently

depending on the fibre layering techniques, resins and curing processes used.

However, this also leads to inconsistency in manufacturing and assembly, which could result in manufacturing defects such as fibre misalignment, delamination, broken fibres, a cracking matrix, knots and excessive porosity.

F ibres are the hear t of composites and are essentially what gives it strength alongside other unique properties. However, the sheer variety of fibres ranging from chopped to woven or continuous strands of carbon, polyaramid, silicon carbide, polyethylene or boron also serve as a machining challenge due to its non-homogeneity. This too results in greater abrasiveness, which increases with the strength of the fibre.

As a resu l t , machin ing composites could lead to rapid tool wear. Surface quality is also another area that could be

affected by delamination when the different layers are separated. These defects are largely dependent on fibre attributes.

For instance, small pieces of fibre delaminate easier, while those with a larger diameter will also have a lower tensile strength. The layout of the fibre also affects its anisotropy, where delamination occurs more frequently in unidirectional layouts than in a two-dimensional fabric weave. With these characteristics, it is imperative for operators to have a suitable tool design when working with composites.

Tool DesignThe benchmark of quality in composite machining lies in the holes it produces. Hole quality indicates when the tool needs to be changed or indexed. It is also where delamination and splintering occurs, of which tool geometry has a significant influence on. In milling for example, end mills tend to lift the workpiece because cutting forces are generated in a single direction, which leads to damage on the top edge.

The non-homogeneity of composites calls for flexible machining strategies that can be optimised according to specific applications. This begins with using tools with the right geometry. For milling, compression style routers are better suited as cutting forces are concentrated on both the top and bottom of the workpiece. This stabilises the cut and prevents damage to the edges.

For drilling however, the type of damage that might occur include a peel-in effect on entry due to the torque twisting action, as well as delamination or fibre breakout caused by the thrust action.

In this case, positive geometry can help to minimise stresses while sharp tools are essential for creating a cleaner cut. Because top and bottom surfaces tend to be different, hole quality may differ between entry and exit.

Tool material should also be strong enough to support sharp geometries, and in both milling and drilling, the material must be hard enough to resist the inherent abrasiveness of composites.

Alternatively, adding a coating or surface layer on the carbon fibre could also make the CFRP easier to machine. For instance, higher feed rates can be achieved with a fine or coarse copper mesh.

In addition to maintaining the quality and precision of the machined piece, tool geometry also helps with chip and dust evacuation — a common problem and vital component of the machining process.

Dust & Chip-FreeChip breaking is a challenge that can create a butterfly effect across the areas of surface finish, precision and machine downtime. Long chips can damage the workpiece and create uneven surfaces. It may also erode the material and compromise hole tolerances in the process. Furthermore, chips can accumulate on the tool holder and jam up

The FutureCompositing

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SHOPTALK


the entire machining process, causing machine downtime as well as additional costs.

Other methods include using specific machining methods such as micro-peck drilling, where periodic low frequency axial motions are paired with an automated drilling unit or CNC machine during drilling, to produce smaller and more manageable chips. Using pauses during programming, or adding a chip breaker to the tool would also aid the machining process.

Dust accumulation on the other hand, poses a safety hazard as it is combustible and conductive (when from carbon fibre). Carbon fibre dust not only poses the risk of damaging the machine, accelerating machine tool wear and short circuiting electronics, but also makes cleaning a challenge and is an irritant to skin and the health of workers when inhaled.

To c i r c u m v e n t t h e s e consequences, dust must be vacuumed frequently and workers should be wearing proper gear (ie: gloves, dust mask) during machining. Having a dust free surface would also help in achieving maximum adhesion when joining components made of composites.

At other times, composite parts are machined dry to prevent the swelling of material that might occur when it is exposed to and absorbs coolant during cutting. Undoubtedly, dry machining also makes dust containment and removal an easier process.

Working Efficiently With CarbonUltimately, the benefits of CFRP and other composite materials can best be harnessed by thoroughly understanding its properties and learning how to work around it.

For instance, carbon fibre has a low thermal conductivity and as a result, the majority of heat remains in the part. If left uncontrolled, too high a surface temperature

can cause damage to the material, softening and depolymerising the matrix. Coolants may also not be an option since dry machining is the preferred method for this material.

However, heat can be kept under control through the right configuration of tool paths and tools. For instance, feed rates can be adjusted to minimise heat generation. In particular, carbon fibres require higher spindle speeds but lower feed rates when compared to metals.

Tooling with a specific resilience is also needed as fractured fibres create a large amount of abrasion on the cutting tool. This in turn can cause a tool to catch on fibres and pull them from the part, which severely decreases the quality of cut. It is therefore important to ensure that the tool is sharp during machining.

To fulfil this requirement, most of the tools used for composite machining are made of carbide or Polycrystalline Diamond (PCD). Both materials provide good wear resistance; the former is better suited for smaller jobs, but the latter costs more.

Diamond coatings have also been found to increase tool life by as much as 10 times, as opposed to an uncoated solid carbide drill. Alternatively, veined PCD drills — where PCD is sintered directly

onto carbide drills — are also available that enable geometries with complex shapes.

By using vein technology to position PCD in exactly where the user wants it to be, it is a more flexible option compared to brazed PCD, and works best in repeatable and defined processes.

N o n e t h e l e s s , a n o t h e r technology has been gaining traction in the world of diamond tooling. CVD diamond coatings are lauded for having a higher hardness than PCD. It is suited for composites and difficult-to-machine materials that are non-ferrous, due to its abrasion-resistant nature and high thermal conductivity. These properties not only help to remove heat from the cutting edge, but also aid in reducing damage to heat sensitive materials.

Despite having qualities that are similar to metal parts, especially in terms of strength, composites are evidently different when it comes to machining. With applications for the material growing continuously, it is pertinent that the industry is prepared for a future where composites are slated to take centre stage.



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Chip evacuation is important in drilling

SHOPTALK


3D documentation has a futuristic twang that sets the mind racing 20 to 30 years into the

future. While this may ironically consign the technology to the KIV folder as a ‘curious interest’ in the metalworking world here in Southeast Asia, it is important to play devil’s advocate and show that the technology has a place in the metalworking arena here.

The concept of taking a scan of an object or surrounding and presenting it as a 3D model may only be an enabler for 3D documentation, it is a good idea to study what these enablers or 3D scanners can do in the metalworking world.

First produced sometime in the early 90s, 3D scanners have been making incremental improvements over the years . However, technological advancement may have worked against it in terms

of adoption in this region because like 3D documentation, 3D laser scanning is perceived to be out of reach for many in the metalworking industry, particularly those in the emerging economies where there is an affinity for more traditional methods of measurement. This is a misconception that metrology solutions providers are eager to dispel.

Insisting that 3D laser scanners have a place in Southeast Asia’s metalworking arena, Mak Poh Fatt, Asia Pacific business line manager of Faro said: “Given the sophisticated nature of 3D laser scanning technology, many people automatically assume that it is costly to adopt. However, with technological advancement, 3D laser scanning has become much more affordable, making it possible to pack more features in a compact device.”

T h e re s t o f t h e w o r l d seems pretty convinced with this argument. According to MarketsandMarkets, global sales in the 3D scanning market is expected to grow from an estimated US$2.06 billion in 2013 to US$4.08 billion by 2018 at an estimated compound annual growth rate of 14.6 percent.

With such market potential, it is no surprise that developers are willing to invest significant resources into R&D to bring out better products year after year.

In Southeast Asia however, things are not so straightforward. T h e n o t i o n o f a d v a n c e d technology is well and good but not quite enough to convince people to open their cheque books. For smaller players to seriously consider adopting such technologies, it must be seen as ‘attainable’ and ‘feasible’.

The Tide Turning?In order to persuade people that the technology is ‘attainable’ and ‘feasible’, the issues of affordability and productivity must be addressed. Metrology solution providers are working on it and one of them is sensing a change in mindset slowly gathering pace in Southeast Asia.

“The adoption of laser scanning technology in Southeast Asia has been rapid across a number of industries. From our experience, once manufacturers understand how the technology can work for them, the conversion rate is high. For them, the benefits of productivity, ease of use and portability are clearly attractive,” said Mr Mak.

This trend is showing no sign of abating as far as he is concerned.

“Based on our observations, the market is hungry for information and manufacturers are ready to invest. Often, they are interested to learn about 3D technology and how they can adopt it. As mentioned, conversion rates are high and it

Not Out Of Our League

3D Technologies:

Laser scanning technologies may seem too advanced for some in the metalworking industry in Southeast Asia but attitudes are changing. By Joson Ng

DESIGN &MEASUREMENT


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does not take them too long to decide to purchase the device. For those reasons, we think that numbers for Asia will climb rapidly in the next three years.”

Improvements In 3D Laser ScanningMr Mak’s colleagues at the R&D department seem to agree with him because Faro has developed a 3D laser scanner that has a scanning range of almost three times more than the previous models. With the faro Laser Scanner Focus3D X 330, it can now scan objects up to 330 m away and in direct sunlight.

With its increased range and scan accuracy, the scanner reduces the effort involved in measuring and post-processing. The 3D scan data can be imported into all commonly used software solutions. Finally, the developer

added that distance dimensions, area and volume calculations, analysis and inspection tasks and documentation can be carried out quickly, precisely and reliably.

3D Laser Scanning For MetalworkingThe improvements look good on paper but how can the technology be used in a meaningful manner in the metalworking arena? The answers may well lie in the non-tactile nature of the operation that is capable of generating accurate readings in the most inhospitable places or surfaces.

“It (Focus3D X 330) is suitable for users who need high levels of detail and precision in their 3D models, as well as for users who require a non-contact form of measurement for objects of interest that cannot be touched (eg: objects at extreme

temperatures, objects of extreme plasticity or malleability, or objects of large scale).

Typically, manufacturers who require dimensional inspections of large or complex components, rapid prototyping, or reverse engineering of products will find the technique of 3D documentation helpful and accurate,” said Mr Mak.

Scanning Across IndustriesFar from being an exclusive item only for experts in surveying or metrology, Mr Mak went on to highlight the technology’s versat i l i ty across var ious industrial verticals.

“Laser scanners have a mul t i tude o f appl icat ions in a variety of industries. Improvements on 3D laser scanners have made them versatile, able to withstand both indoor and outdoor conditions.

DESIGN&MEASUREMENT


3D laser scanning is often deployed for welding analysis in the shipbuilding sector.

Within the Asia Pacific region, our laser scanners are more intensely used by customers from the oil & gas and shipbuilding industries at the moment,” he said.

Quoting an example, he revealed that in the shipbuilding segment, 3D laser scanning is deployed for welding analysis of ship components. It also allows the accuracy of constructed steel hull checked against the CAD design.

Staying in this industry, 3D laser scanners also play a role in the retrofitting of ballast water treatment systems in international ocean-going ships. Typically, the ballast water treatment system goes into the engine room or pump room of a ship. The installation of a new and large system to a functioning ship involves a great deal of time and effort because of the complicated piping systems and machinery already present.

The traditional method of creating detailed drawings requires manual measurements to replicate the actual site layout. Any remodeling to accommodate the new system will have to be done based on these manually-produced drawings. This entails numerous on-site inspections of the ship, and enormous amounts of design time. In addition, l imitations that come with manual measurements mean that

a slight error on paper can turn out to be a much larger design fault during execution.

According to him, the use of Focus3D reduces the amount of on-site measuring time. The technicians used to take days to measure existing piping and facilities manually, but with the 3D laser scanner, it now takes them several hours to complete the task. In addition, the measurement points collected can be converted into 3D CAD data, making it possible to create 3D design drawings directly from the CAD data.

A New Way To Measure?In the automotive industry where the usage of the laser scanner is not “as intense in the manufacturing process”, the application has been more



prevalent in plant installation and verification purposes.

In fact, 3D laser scanning can trigger some kind of revolution in this segment. Mr Mak said Magnus Ronnang, a technical expert from the Volvo Cars Group spoke about the usage of 3D laser scanning in virtual manufacturing.

Mr Ronnang asserted that a paradigm shift is imminent, where reverse engineering from point clouds to CAD would no longer be necessary. Instead, point clouds would be used directly for a variety of manufacturing engineering purposes. CAD data would be used to represent new, non-existing artifacts.

With versatility that stretches across industries, and signs of changing attitudes in users in the region, it is anyone’s guess if 3D laser scanning will make an even bigger splash here in the near future.

While there may be a list of other reasons for not adopting 3D laser scanning technology in a typical measuring room in this region, the notion of the technology being ‘out of our league’ should not be on that particular list.

With 3D technologies, it is possible to create an accurate representation of a constructed steel hull.

DESIGN&MEASUREMENT

ENQUIRY NO 077


Taking The

In Measurement360ºApproach

DESIGN&MEASUREMENT


In a world where data or information is crucial for any successful business ventures, the way to collect data or

having the means to provide ‘actionable information’ becomes high on the agenda of any top executives. Some observers say actionable information is specific, consistent and credible. If you were to look at the very nature of such information, you would notice it has some striking similarities to what metrology stands for.

I t m a y b e r e l a t i v e l y straightforward to produce accurate data on a single part, but when metrology solutions providers are to scale up measuring performances to fit a large-scale automotive production line, a more holistic approach is needed to do the job.

Teaming UpA quick check at what is available in the market today will reveal a good number of metrology equipment designed to carry out a specific task. Although they all have their own application range, it is not difficult to imagine the potential in bringing them together. In fact, by doing so, it is possible to form a modular, large scale metrology solution that can transform the production floor into essentially a large measuring room.

Engineers or operators can now be creative depending on the applications. For short-range applications, white light scanners, laser scanners, portable CMMs (arms) or CT scanners can be deployed. For something a little longer in range, portable CMMs (trackers) or optical trackers may be more suitable.

In a nutshell, putting these equipment together can help cover up whatever limitation one par t icu lar measur ing equipment might have. This is of course a very simplistic view but it is the basis of producing

A metrology solutions provider has decided to cover all angles in order to provide automotive production lines actionable information that are essential in their operations. By Joson Ng

a robust measuring system that grows along with expanding manufacturing operations.

With a wide selection of measuring equipment at its disposal, Hexagon Metrology has developed the 360° Smart Inline Measurement Solutions (360° SIMS), a family of measurement solutions that can be fully integrated into automotive production lines.

They enable full surface inspection and critical features measurement of up to 100 percent of the produced car bodies, parts and sub-assemblies within production cycle time. By leveraging its metrology methods, software and sensor technologies, the company has created an advanced means of process control.

Cutting Down Time“Our vision was to extend our reach into the production environment and combine our measurement abilities with the in-l ine process control methodologies. This way, we can create a bridge between the quality department and our other measurement systems like the bridge and horizontal CMM and the quality efforts of production during new vehicle launch, ramp-up and steady state production,” said Tal Vagman, director of Automated Solutions strategy of Hexagon Metrology.

He added that the concepts and technologies have been developed with industry partners and customers.

This technology may not have been in use for a long time but he revealed that the system has managed to help users identify problem(s) during launch and ramp up period. This has cut down on the time taken to understand the root cause of the quality problem.

Lastly, production and line quality are more self-sufficient and can react faster. A large part of this can be attributed to a touchscreen

DESIGN&MEASUREMENT


interface, where operators with basic training can supervise the measurement process, visualise results and identify root cause for quality concerns.

The main point to take away here is probably the time saving. In fact, according to Mr Vagman, users have reported savings mostly coming from the measurement of parts/car bodies in the CMM, as well as the time and cost of logistics to move parts from production to measuring room. Finally, reporting and analysis time is saved in these new methods of measuring and analysing dimensional quality where the real assembly operations take place.

Adapting To Various EnvironmentsAlmost like a mixed bag of solutions put into one, the system can involve a number of robot arms and it is modular and adaptable. The modularity of the system sees it adapted to various environment and targeted industry applications. Installations typically include white light area measurement sensors and point cloud-based software tools. 360° SIMS is compatible with commonly used industrial robots,

PLCs, automation devices and safety equipment.

Cel l conf igurat ions wi l l include in-line, near-the-line and offline options to support a variety of customer applications throughout stamping, body shop and final assembly sub-plants. The measuring cells can be positioned anywhere along production lines and production bays to support a customer’s dimensional control strategies.

According to Mr Vagman, the system was designed as such after intensive market studies. He said: “We identified the industry trend of moving from dedicated hardware platform to using common industrial robots which are already used in their hundreds across the automotive plant. By using industrial robots and other automation devices, we achieved high flexibility and being future ready to model changes.

We do integrate various different technologies including o u r p a t e n t e d f i x t u re f o r repeatable alignment, white light sensor, 3D point cloud processing, automation and analysis software, etc. The installation is planned as yet another cell on the line or near the line and can achieve similar

timelines as other body shop assembly cells.”

He also touched on the flexibility of the system, which allows future work with line builder and OEM interested in introducing the new technology. The system also allows the definition of control and automation strategy in advance to help simplify on-site implementation process.

Finally, he added that in some cases, it is possible to integrate the solutions into existing or renovated lines where down-time for commissioning will be limited to three to four months.

Wide Reliable CoverageApart from the obvious advantage, which is reduction in time, the

The system allows automotive manufacturers to take the next step towards the digital factory of tomorrow.

DESIGN&MEASUREMENT




for the complex geometries of car bodies and automotive components. The industr y solutions we’re targeting in the first stage usually have quality tolerance of +/- 0.5 mm which we’re able to support without an issue.

We usually correlate our results to a CMM after commissioning and then when the measurement and process control cell becomes independent. In addition to accuracy and repeatability, the system also needs to be fast and comes with high detection rate for the critical features,” he said.

Describing the 360° SIMS as a system that enables automotive manufacturers to take the “huge step towards the digital factory

of tomorrow,” Mr Barilà said the system is designed to answer the growing need for insightful and actionable information to accelerate production launches and monitor quality.

If he is right then the system may have provided new insights into quality control for the automotive OEMS and tier-one suppliers. This further adds to the philosophy that harnessing the merits of several metrology equipment can produce a powerful measuring system that is scalable and reliable.

holistic, accurate coverage is other point worth talking about. For one user, using a set of measuring sensors has effectively taken away the reliance on a CMM. The system has become a primary measurement tool in his production line. He added that the mix of reliability and speed in measurement has made it possible to carry out inspection 100 percent in-line.

Giacomo Barilà, head of the automated solutions product line of Hexagon Metrology said white sensors play a big part in making this possible.

“We use white sensors for providing both critical features inspection along with full area measurement. This is very helpful

DESIGN&MEASUREMENT


Until recently, twin welding has been the most productive single power source Submerged Arc

Welding (SAW) process in terms of deposition rates. Twin welding is accomplished using two wires connected to the same power source and same polarity.

The latest advancement in SAW is a patent pending technology that uses a third electrically insulated cold wire (integrated cold electrode) which is added in between and parallel with the two hot wires in the same contact device.

The cold wire feed speed is controlled independently from the hot wires with integrated software resident in the control unit. The cold wire melts from the excessive energy generated by the arcs from the two hot wires. This technology, known as ICE, engineered by ESAB, increases deposition rates up to 50 percent compared to twin welding and as much as 100 percent compared to welding with a single wire.

Feeding Cold WireSAW using an additional cold wire is not a new method to increase welding deposition rates. In fact, there are many technical solutions for feeding cold wire with different performance and application areas. Most of these solutions add the cold wire to the process from the side, in an angle to one hot wire. There are a number of challenges with this method, process stability being the most significant.

For example, if the stick out changes or the arc is unstable, the melting point of the cold wire will change. This makes the welding process very sensitive to any changes that will affect the arc. In production environments, solutions in which the cold wire is added from the side require

highly controlled conditions to be effective. Experience has shown that these solutions are not robust enough to be considered for the vast majority of applications.

Improved Process Stability Integrating the cold wire into the same contact jaw and placing it in parallel with the hot wires adds to process stability and robustness.

The arcs and melt pool calm down as a result of adding the cold wire using this technology, making the process more robust and less sensitive to changes in the arcs and stick out, as the melting point of the cold wire always adapts to the two arcs. The improved stability makes the process easier to adjust and adapt to different joint types.

Submerged ArcWelding Technology

The previously held view that the cold wire was ‘cooling’ the weld or creating a ‘heat sink’ is no longer relevant.

An integrated cold electrode is said to bring about better deposition rate while maintaining mechanical properties. By Hannes Raudsepp, welding application manager (SAW/FSW), ESAB Global Automation

Provides Up To 100% Increase In Productivity

FABRICATOR'SNOTE

ENQUIRY NO 049


This stable welding process enables operation at higher parameters and higher welding speeds than convent ional SAW, generating significant process benefits.

Weld Bead Profile & Mechanical Properties MaintainedWhen compared with twin welding using the same active parameters, and a cold wire feed ratio of 10 to 100 percent of the hot wire feed speed [cwfr], the weld bead penetration profile does not change when using different amounts of cold wire.

Because the active parameters are unchanged when adding the cold wire, the weld characteristics are maintained. This means unchanged penetration and weld width compared to conventional twin SAW.

The weld bead height or reinforcement height is increased, ensuring an even distribution of metal in the weld. The increase in flare angles reduces double heating in the flare area with improved mechanical properties from reduced grain size.

When using the same heat input, the mechanical properties in joints welded with an integrated cold electrode are at the same level as those welded using conventional SAW. When using the integrated cold electrode process to modify the penetration profile, mechanical properties can be improved.

Increasing Deposition Rate Without Adding Heat In SAW, as with other welding processes, heat input limits productivity. The heat input the parent material can stand always sets the upper limit for productivity.

Using an integrated cold electrode, there is no need to change the total heat input to increase the deposition rate or to realise other benefits provided by this SAW process. This technology uses the excessive energy in the SAW process to melt more wire and thereby increase deposition rate.

The heat input remains unchanged when adding different amounts of cold wire. The way heat input is calculated does not take into consideration the amount of cold wire added.

The heat input formula is:

Extensive research and testing has shown that heat input does not change when adding cold wire to the process. The previously held view that the cold wire was ‘cooling’ the weld or creating a ‘heat sink’ is no longer relevant.

Using the integrated cold electrode process in place of a single wire, the deposition rate can be increased up to 100 percent, and up to 50 percent compared to twin welding with the same heat input and welding speed. The maximum deposition rate this process can

produce connected to one power source is 34 kg/h.

When the integrated cold electrode process is connected in parallel to two AC/DC inverters, deposition rates of 40 kg/h can be reached. Table 1 indicates the limits in deposition rates (yellow) for different setups versus commonly used deposition rates (green). Commonly used deposition rates can be considered as comfort zones for this process. Table 1 is based on using similar heat input.

The integrated cold electrode process using a single power source can deposit more than a tandem with single wires. In fact, replacing the trailing head in a tandem configuration with an integrated cold electrode can double deposition rates.

Higher Welding SpeedsThe stabilising effect of the integrated cold electrode allows welding speed to be increased while either maintaining or reducing heat input.

SINGLE WELDING TORCH

Single 4mm

Twin 2”2.5mm

ICE (cwfr 70%) 3”2.5mm

TANDEM WELDINGTandem Single 4mm + Single 4mm

Tandem Single 4mm + Twin 2”2.5mm

Tandem Twin 2”2.5mm + Twin 2”2.5mm

Tandem Single 4mm + ICE 3”2.5mm

Tandem ICE + ICE 3”2.5mm

Deposition rate kg/h0 10 30 6020 5040 70

8

12

22

18

27

32

40

50

ESAB’s ICE 3*2.5 mm 800A 35V 50% cwfr

Table 1: Comparison of deposition rates

Fillet, throat size 5 mm, welding speed 1,700 mm/min. Deposition rate 24 kg/h, heat input 1.19 kJ/mm

FABRICATOR'SNOTE

Ingersoll-Rand South East Asia (Pte) Ltd42 Benoi Road Singapore 629903 Tel: +65 6861 1555 Fax: +65 6862 2086Sales Hotline: +65 6860 6734 | Service Hotline: +65 6860 6857Email: [email protected] | Website: www.ingersollrandproducts.comAustralia • Indonesia • Malaysia • Philippines • Thailand • Vietnam EN

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In conventional applications and joint types, welding speed can be increased to above 1,000 mm/min while maintaining heat input and process stability. The integrated cold electrode process is able to achieve welding speeds up to 1,700 mm/min.

High Deposition In Root RunsThe stabilising effect of the integrated cold electrode also enables high productive welding in root runs. This process achieves deposition rates above 25 kg/h without the need to remove tack welds or sealing runs.

Using the integrated cold e lectrode technology in a tandem setup with a leading single wire, the user can modify the penetration profile to the joint geometry in the root. The integrated cold electrode process will change the weld bead profile as well as change the direction of the solidification front, providing the ability to control the penetration profile in a new and dynamic way.

Reduced Flux ConsumptionAs the integrated cold electrode technology makes welding more productive, completing welding jobs in fewer runs, flux consumption can be reduced significantly. The improved process stability also adds to reduced flux consumption, melting less flux per kg wire deposited.

In tandem setups using this

technology as a trailing head compared to a tandem setup with a twin trail, flux consumption is reduced by approximately 20 percent, while maintaining the heat input at the same level. When comparing a tandem integrated cold electrode setup to a single wire, the reduction in flux consumption can be as much as 45 percent.

When increasing welding speed, flux consumption is also reduced. The amount of this reduction varies by application.

In addition, slag release using the integrated cold electrode process is independent of flux basicity and produces a smoother top surface compared to conventional SAW.

Flat Cap ControlA flat cap on a weld is not new. However, achieving a flat low cap with the integrated cold electrode process is much easier than with conventional welding

processes. Because the cold wire is not an active parameter, it can be adjusted during welding without changing the energy in the process, meeting the validity range in the WPS.

Traditionally, if the welder has filled just below the parent material level, they will need to add an extra run. This extra run may need to be grinded because of the risk of overfill and not meeting the cap requirements.

The welder can slow the welding speed but this results in higher heat input and reduced mechanical properties. A flat cap is achieved using the integrated cold electrode process by simply fine tuning the amount of cold wire while welding.

Less Distortion With Reduced Heat InputThe increased deposition rate achieved using the integrated cold electrode process combined with its stabilising effect permits faster welding using a lower heat input than twin and single wire setups.

When setting the integrated cold electrode process to the same level of productivity, the heat input will be lowered. The cold wire adds to productivity enabling lower welding parameters to be used at the same productivity level. Lowered heat input results in less distortion, which is a significant benefit when welding thin plates and parent material sensitive to high heat input.

One sided welding in 10 mm thick plate, welding speed 1,400 mm/min. Deposition rate 23.9 kg/h, heat input 2.03 kJ/mm

High deposition root run, 30.2 kg/h Heat input 3.2 kJ/mm, plate thickness 25 mm, heat input 3 kJ/mm

Tandem welding in root pass: Deposition rate 25 kg/h. Flux: OK 10.72

FABRICATOR'SNOTE

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Welding with lower heat has additional advantages. When welding in objects that require waiting between runs for the object to cool down to the correct inter pass temperature, the cooling time will be reduced or eliminated because of the lower heat input.

Energy SavingsThe integrated cold electrode uses the heat available in the SAW process to melt more wire. This means that energy consumption and energy costs are reduced compared to completing the same job using conventional methods.

The integrated cold electrode process can lower energy consumption and cost as much as 33 percent when compared to twin welding. Compared to single wire welding and using the integrated cold electrode in tandem (single DC + integrated cold electrode AC), the energy reduction can be up to 50 percent.

Standard Wires & FluxesThe wire and flux combinations used with the integrated cold electrode are typical offerings for each industry and application. No special or unique wire and flux combinations are required to use the integrated cold electrode technology.

Significant Overall BenefitsComparing the integrated

cold electrode as trailing in a tandem setup (4 mm single wire + integrated cold electrode) to a tandem with two 4 mm wires, the overall benefits are significant:

• Increase deposition rate by 150 percent

• 30 kg/h average deposition rate

• Welding speed 1,000 mm/min

• Reduce flux consumption by more than 20 percent

• 50 percent less energy used seven percent less wire used with 1 mm lower cap height

The stabilising effect of the integrated cold electrode process enables h igh product iv i ty welding in narrow joints with high mechanical requirements. Using the integrated cold electrode, it is possible to weld productively in narrow joint configurations

with included angles down to eight degree and deposition rates up to 30 kg/h, maintaining a heat input below 3 kJ/mm and meeting requirements down to -60 deg C.

Many narrow joints are today welded with a single wire or tandem with two single wires. Comparing a single 4 mm wire with the integrated cold electrode as trailing head in a tandem setup (4 mm single wire + ICE), in a S355G8+M plate, 22 degrees included angle, and a heat input limit at 3.5 kJ/mm, the integrated cold electrode process can increase productivity significantly in filling runs:

• Increase deposition rate by 250 percent

• 28 kg/h deposition rate

• Welding speed 850 mm/min

• Reduce flux consumption by 45 percent

• 10 percent less energy used

The integrated cold electrode technology provides a productive SAW process solution from a single partner, making it easy to introduce the technology and realise the benefits.

Flat cap control, 0.5 mm reinforcement height

40 mm S355NL welded with Tandem 4 mm DCEP 3*2.5 mm integrated cold electrode AC; Heat input 3.3 kJ/mm

OK 10.72 Slag Weld surface

FABRICATOR'SNOTE

ENQUIRY NO 071


Stick Together

While the process of joining parts together might be eas i ly described, and may

seem simple to accept in theory, its practical application can often be complicated. Surface roughness, impurities, fitting imperfections, and the varied properties of the materials being joined make the process far from straightforward. Fortunately, the development of welding processes and procedures have managed to overcome some of these difficulties.

Barring a few exceptions, most welding processes require the application of high levels of heat. The heat serves to bring atoms to the edge of one piece of material or part, close enough for interatomic interaction to occur with atoms from the other material or part.

However, this high heat causes the metal to oxidise, and this oxidation can result in a weakening of the outer microstructure of the part. Nevertheless, should sufficient protection from oxidation be included in the welding process, this problem can be prevented. When examining each welding process, it becomes important to consider how much heat is produced, and the manner in which it is produced.

Apart from the application of heat, some welding methods will also require that pressure be exerted as well, while some achieve the weld through pressure

alone, without any external heat supplied. As mentioned earlier, in some weld processes a filler material is added to facilitate the joining of these two parts.

For welding methods under the pressure processes subheading, a joint is made by applying pressure to the area of contact of the two parts, which may or may not be heated to a molten state. For methods under the fusion processes subheading however, no pressure is applied and only heat is used to melt the contact area.

GMAW & GTAWIn Gas Metal Arc Welding (GMAW), an arc is generated between the solid or flux-cored, consumable wire electrode and the base metal. The arc is protected with a shielding gas or gas mixture, which is sometimes carbon dioxide or a combination of argon and carbon dioxide. This shielding gas is blown out through a nozzle which lies parallel to the arc formed, covering it from all sides.

GMAW has several advantages as a welding process. For a start, it uses a higher current density, which allows higher deposition rates and faster welding. This increased rate of welding and higher deposition rate translates to lower welding costs.

GMAW is suitable for a multitude of weld joints of various orientations: straight, curved, long or short. It is also suitable on both thin sheets and thick plates. This

makes GMAW extremely versatile, allowing it to be used in many situations without the need for much planning.

The one drawback of GMAW, however, is the weld porosity which forms when an ambient wind disrupts the shielding gas’s ability to protect the arc.

Gas Tungsten Arc Welding (GTAW) is also commonly known as Tungsten Inert Gas (TIG) welding. Here, an arc is generated between the non-consumable tungsten electrode and the base metal. The shielding gas used is pure argon, and a filler rod or wire is fed into the arc to deposit the additional filler material, although this is optional in some cases.

GTAW is often known for its versatility; it can be used for welding all types of metals, and is particularly suitable for welding sheet metals and tubes. Welds can be made on very thin materials of less than a millimetre and all weld positions can be joined.

GTAW can also be used in automated or robotic applications. Unlike GMAW, weld control for this process is excellent, given the establishment of a molten pool during welding and the addition of filler material when required. This control yields good fusion and wetting at the beginning of the weld. It therefore avoids incomplete fusion, which can be the case with consumable-electrode welding.

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Welding is perhaps the most common joining process in metalworking. The strength of a weld is often dependent on the welding method employed, but what are the pertinent welding methods for metalworkers in Southeast Asia? By Shahnawaz Abdul Hamid

Back To Basics:

We Have Got To

FABRICATOR'SNOTE




3M has developed a high-altitude upgrade

to its Adflo Powered-Air Purifying Respirator

(PAPR) system. The Adflo Turbo Assembly with

High-Altitude Upgrade provides continuous

filtered air to welders working at altitudes of up

to 10,000 feet.

The high-altitude upgrade was designed

specifically to compensate for air-density changes that occur

with an increase in elevation. It comes with a lithium ion battery — reducing the battery

weight in previous models by approximately 50 percent and the overall respiratory

system weight by approximately 20 percent.

3M: High-Altitude Welding Protection

Future Developments In Arc WeldingA l t h o u g h w e l d i n g c a n certainly be considered a very established technology, its time in the sun is by no means over. While many predict that its usage will continue to grow in emerging economies of the world, its growth in specialised areas in developed countries cannot be discounted.

Areas that will see continued expansion include welding automation. Given the shortage of skilled welders, it comes as no surprise that the arc welding industry will have to rely heavily on robots. Already, automated machinery is used in spot and seam welding and it seems simply a matter of time before such technology w i l l m i g r a t e t o t h e a r c welding sector.



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Whatever the direction the industry takes, one can be sure that these developments in the sector will bode well for those who take full advantage of them.

CT 20

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FABRICATOR'SNOTE


Based near Amsterdam, Holland, Cyrtina BV has evolved from a milling centre (using three-axis

machines to produce simple parts, such as copings) into a provider of more complex crowns and bridges that can be supplied directly to the dentist, without the intercession of a dental technician.

Copings — frameworks for crowns or bridge abutments — can be made easily on a three-axis machine. “However,” explains Siebe van der Zel, the company’s chief operating officer, “to produce more complex dental parts efficiently, we knew we had to move up to five-axis machines.”

The company started building up their machine tool lineup progressively with an initial purchase of a five-axis CNC machining centre with a 30,000-

rpm spindle. They also added a vertical machining centre, primarily to machine zirconium dioxide, an inorganic metal-based material commonly employed in modern dentistry.

Moving OnWith the advent of high tech CNC machine tools, the days of hand crafting prosthetic teeth is rapidly coming to an end. Looking back on how things used

to be done and how things have since changed, Mr van der Zel says: “Then, dental technicians, who would typically produce full restorations by hand from porcelain, started thinking they could invest in machine tools and make the copings themselves. We knew we had to evolve and also produce crowns. And so, we developed and patented a product called Primero, a layered crown created by CAD/CAM.”

Bringing

BetterFaster

SmilesMatt Bailey, international

correspondent for Haas Automation takes a look at how a part producer

successfully moves into the world of dental parts manufacturing.

The days of a traditional dental technician taking a coping and building it up by hand with porcelain are well and truly numbered

— Siebe van der Zel

INDUSTRYFOCUS


He c la ims the product offers better aesthetics than convent iona l s ing le -p iece monolithic items, which makes it popular with patients.

“Our crowns are very accurate and have a chameleon affect, because they are transparent, reflecting the light from adjacent teeth,” he adds.

Challenges From AbroadOf course, like many industries, Cyrtina faces stiff competition from China. For example, crowns in the Netherlands average around €250 (US$345) each, whereas Chinese crowns cost €160 to €200. As a result, around 40 percent of crowns in the Dutch market originate from China. However, there are drawbacks.

“Our lead time is four days, but from China, it’s more like two or three weeks,” says Mr van

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With the advent of high tech CNC machine tools, the days of hand crafting prosthetic teeth is rapidly coming to an end.

INDUSTRYFOCUS


der Zel. “Secondly, dentists like consistency; their core business is treating patients, so a good-fitting, impeccable crown is imperative. They don’t want to have to send back a crown if it’s faulty. It means more time and another appointment with the patient.”

Machine Shop + Dental LabThe company now supplies 30 percent of its business directly to dentists, and this percentage is growing fast.

“We started out as just a milling centre, but now we are a cross between a milling centre and a dental lab creating crowns. Milling companies are becoming labs,” he says.

The company can produce 150 layered crowns with a single set of diamond-coated cutting tools (the biggest tool is 3 mm diameter) on the Haas OM-2. Although zirconium dioxide is soft, it is extremely abrasive. The crowns produced here are essentially a two-part system: the lower part is zirconium, while the outer layer is porcelain.

“We mill the coping and place it in a milled block where we create the stump,” he explains. “Around this stump, there is a milled



cavity that is filled with a liquid porcelain material that we have created ourselves. The crown is then placed in a compression system and compacted, before being dried to create a crystalline structure, almost like sugar.

We then use the OM-2 to mill it in ‘green’ shape, before it goes into the oven. Afterwards, it has the exact same characteristics as hardened steel. It’s practically impossible to break, and can withstand extremely h igh pressures. We call it ‘ceramic steel’, and for this reason, our crowns come with a five-year warranty.”

Automated ProcessThe company adopts an unmanned process called Collaborative Computerised Dentistry where almost every aspect of the business and manufacturing function is automated.

Orders, for example, arrive digitally. The dentist either sends an intraoral scan or an impression that is scanned by the company’s ScanDesignCenter. The design work can then commence, using the company’s self-developed CAD system. Finally, models are created using a 3D printer. Once the design is finalised,

automated production of the crown can commence.

“Orders pass automatically through our workflow, which includes a calculated mill path program created using Delcam’s PowerMill CAM software for the Haas VF-2,” he says. “Some of the parts we machine, such as indexed posts for example, require holes drilled at different angles, which is why we use 3+2-axis machining on all three Haas machines.”

The company is aiming to capture at least 10 percent of the Dutch market by the end of 2016. To achieve this goal, the company has just signed a contract with an investor group that will be involved in marketing its products.

“The days of a traditional dental technician taking a coping and building it up by hand with porcelain are well and truly numbered. The future is automated machining of dental restorations. The costs will come down, and restorations will be accessible to many more people,” he concludes.

Siebe van der Zel says his company is now a cross between a milling centre and a dental lab creating crowns.

The company now supplies 30 percent of its business directly to dentists, and this percentage is growing fast.

INDUSTRYFOCUS

Taiwan New Product Launch■ Date: 21 May, 2014■ Time: 10am to 12pm■ Location: Kelantan Room,

Level 2, PWTC

Taiwan Machine Tools Processing Technology & Know-How Forum■ Date: 22 May, 2014■ Time: 1:30pm to 4pm■ Location:Johor/Kedah Room,

Level 2, PWTC

4220 4120

1170

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12601430

HALL 4HALL 1

TAIWAN MACHINE TOOLSSHAPING THE WORLD

Welcome to the Taiwan Pavilion at Metaltech

Ministry of Economic AffairsSupported by :

Ad. by Bureau of Foreign Trade

Organized by : Implemented by :

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ENQUIRY NO 079


Medical devices cover a w i d e r a n g e o f medical instruments, apparatus, or similar

article that is used to diagnose, mitigate, or treat diseases. They v a r y i n c o m p l e x i t y f ro m s i m p l e p ro d u c t s s u c h a s tongue depressors, surgical sutures and contact lenses, to more complex devices such as implantable defibrillators, prosthetic heart valves and diagnostic imaging systems.

The manufacture of such devices is set to increase rapidly to meet demands. However, traditional manufacturing methods typically depended on cutting and moulding technologies to create a limited number of structures and shapes. This is the reason why parts with more intricate designs and requirements have to be formed from a number of parts and assembled together, giving rise to the need to adopt advanced manufacturing processes.

Advancement In CuttingEven with the avai labi l i ty of advanced manufacturing t e c h n o l o g i e s , t h e r e a r e advancements in conventional methods of medical device manufacturing.

The age-old process of cutting, for example, has seen improvements in precision. For instances, Personna Industrial has precision blades for cleanroom

environments and medical device manufacturing. The blade systems include a single-edge blade safety dispenser unit that holds up to 100 single-edge blades. The dispenser features a storage compartment for storing of used blades.

S p e c i a l t y m a c h i n e s manufacturer Schober Technologies has a precision pressure cutter that uses a counter surface. The cutting pressure is actively regulated by electronic controls, especially when the die cutting head is driven into a position against an anvil cylinder by a servomotor.

F e e d b a c k s i g n a l s f ro m the servomotor are constantly monitored to maintain a constant cutting force between the die cutting head and anvil cylinder. This means that the cutting quality is not affected by fluctuations in the speed of the web. According to Schober, the system increases productivity and provides reproducible setting data and fast change-overs.

Inspecting Medical PartsInspection of finished medical products has also taken a more critical role. With its stringent quality requirements, medical device inspection systems have sought unconventional means to achieve its requirements. One particular area is in industrial x-ray technology.

I n a d d i t i o n t o x - r a y s , conventional optical measurements have also improved. Non-contact 3D

optical profiling of surface topology, nanostructures and film thickness can be achieved with resolutions of 0.1 micrometer laterally and 0.01 nanometers vertically.

Sensorfar’s PLu neox, for example, uses a combination of confocal scanning, phase shift interferometry, vertical scanning interferometry and spectroscopic reflectometry techniques in the same single sensor head.

The design features several improvements and technology advances, such as a high-resolution CCD sensor with 50 percent larger field-of-view. Another system, the Q-six system for implantable medical device inspections uses both 2D and 3D imaging for analysis of stent structures. Other functions of Q-six include assessing edge features, enabling automatic defect detection and classification.

The FutureThe medical device manufacturing industry is an ecosystem, where medical technology advancement pro pe l s i mpro v emen ts in manufacturing systems, and new manufacturing technologies open possibilities for new devices. The emergence of new materials or even sub-industries would increase the speed and complexity of technological evolution further.

For example, the mobile health sector has opened new markets in wearable diagnostic/therapeutic devices for manufacturers. Due to these advances, production systems are keeping pace with advances in medical devices and meeting the ever-changing needs and requirements of a demanding industry sector. Constantly evolving production capabilities will provide a richer and more varied medical device landscape in the foreseeable future.

What’s New?Medical Industry:

Augustine Quek takes a look at the advancements in the world of medical devices and their manufacturing process.



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3D printing, also called additive manufacturing,

is the process of creating 3D objects from a

digital model. This technology is able to

produce parts that have higher structural

integrity, durability and flexibility.

The element of flexibility has enabled

additive manufacturing to be used in many

aspects of the medical field, including

surgical equipment, prosthetics, implants and

tissue engineering. Creating objects through

additive manufacturing is also faster and more

3D Printing In The Medical Industry

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responsive to consumer needs compared

to other technologies. Technically complex

bespoke solutions can be provided rapidly

using CAD data. This advantage is more

critical in medical device manufacturing than

other types of product manufacturing.

An example of the technology's speed

was demonstrated by surgeons at the

University of Michigan, who have successfully

designed and developed a 3D printed tracheal

splint that has saved a baby’s life. They

created a 3D model of the patient’s airway

and specially designed splints for a custom

fit on the baby’s bronchi.

From the model, they created a unique,

patient-specific tracheal splint via laser-

based 3D printing using the biopolymer

polycaprolactone. The 3D printed splints were

then implanted to support the trachea and

bronchi, creating viable airways.

The demand for accelerated production

of custom implants is also set to increase.

According to a new research report from

Transparency Market Research, the global

market for 3D printing in medical application

was valued at US$354.5 million in 2012 and

is expected to grow at a Compound Annual

Growth Rate (CAGR) of 15.4 percent from

2013 to 2019 to reach US$965.5 million

by 2019.

Currently, 3D printing uses a variety

of metal and plastic materials, but

research is already underway on more

advanced technologies and materials, such

as biodegradable ceramics. In fact, the

possibility exists that stem cells might be used

on biopolymers for organ printing. Printing

arteries, skin and even an entire heart or

kidney might be possible in future.



INDUSTRYFOCUS


It has been described that the correct application of the lean process in the warehouse environment will ensure the

optimisation of the three important elements in any warehouse such as space, equipment and personnel. It will also provide the needed assistance for achieving warehouse excellence by the continued elimination of the waste.

An essential component in the application of lean process towards the warehouse excellence would be the ability to identify ways for the continued elimination of the waste, which will lead to the improvement of the entire warehouse operation.

Defining WasteWaste can be defined as any activity that does not add value to the product. In addition, any material or resource beyond what the customer requires and is willing to pay for can be referred as waste. Finally, any material (finished, semi-finished or raw & packing), which unnecessarily occupies vital space in the warehouse is also considered as waste.

There are typically two types of waste. They are visible waste and hidden waste. The former is self-explanatory, they are things we can easily see, monitor and identify. For example, they are rejected or damaged goods in any warehouse. Hidden waste on the other hand, are things we cannot easily see,

monitor or identify immediately in the warehouse operation. In most cases, hidden wastes may be more significant and costly in warehouse operations.

According to Taiichi Ohno, the father of the Toyota Production System, there are seven types of hidden wastes. They are over production, inventory, waiting, motion, transportation, rework and over-processing.

Although these seven hidden wastes were initially aimed, designed, established and applied in the manufacturing environment, they could easily be applied to other essential areas as well such as in the warehouse operational environment.

OverproductionIt occurs when more than needed products are produced or produced earlier than they are required.

Overproduction ties up money and warehouse space, as excess stock produced has to be kept in the warehouse and it could remain unsold for long periods of time. It is advised to adopt the (JIT) or Just In Time approach to help mitigate the problem. JIT mandates the production to produce only what the customer wants and when they want it.

InventoryInventory refers to finished and semi-finished goods or raw and packing materials. It is any kind of

stock with additional quantity than it is needed for a smooth progress from production to distribution to sales to the customer.

Excess stock kept in the warehouse could easily create other types of wastes, as such stock might require people’s extra time and effort to move it around, to count and to keep it in good condition.

It could also occupy vital space in the warehouse for other products that are actually needed by customers. It is not advisable to hold ‘comfort stocks’, those that do not add value to the business. Stocks can easily go obsolete due to age related deterioration, change in design or fashion or the emergence of new trend.

WaitingWaiting refers to cases where people are waiting for a work cycle to be completed before a new one is to commence. Typical examples are when people are waiting for pallets to place products on or when products are waiting to be transferred to a pallet or to be moved away.

Bulk stacking or palletised stock can also cause a certain amount of waiting because they have to be re-arranged before new stock can be placed on it. Waiting is a productivity killer and represents a major source of aggravation among customers in any warehouse operation.

Lean Manufacturing In

8 StepsIdentifying areas of wastage can go a long way in achieving a streamlined and well-managed warehouse. By Petros N Zenieris, owner of The Business Criterion Consulting & Training Office Meilinda01, Indonesia

MANAGER'STAKE


MotionIt refers to all unnecessary movements of people during any warehouse operation. Most of the time it is confused with the waste of transportation.

Waste in motion typically occurs during delivering or supplying times. It happens during work which involves lots of stretching or climbing on a bulk stack of products. Finally, waste in motion also refers to unnecessary movements in trying to locate equipment (forklifts, hand pallet trucks etc) left by other people in non-designated areas.

It is important to minimise fatigue by arranging people and their respective tools and equipment around the work station in such way so as to minimise unnecessary motion.

TransportationTransportation waste refers to the unnecessary movement of materials, products and information within an operation. For instance, unnecessary distance between products’ release for loading or unloading and documentation point(s) is considered as a waste.

Collection of print outs or copies of invoice(s) from different offices is another one. Lastly,

placing vehicles’ parking lots far from the unloading or loading bay is deemed a waste.

Re-WorkA c t i v i t i e s re p re s e n t i n g a duplication or replication of a process are usually considered as re-work and that is defined as a waste. Incorrectly packaged goods, damaged products, wrong invoicing, wrong stocks’ documentat ion are widely believed to be a waste.

Preparing and loading a customer’s order with wrong products would lead to stock returns, resulting in a re-work.

Over-ProcessingAs the name suggests, over-processing refers to a warehouse process beyond any necessary standards. A long chain of labourers passing or stocking products in the warehouse is one typical example.

Carrying out activities in a complicated way when there is a simpler way can also be considered as over-processing. Finally, moving a pallet with the hand pallet truck for some distance and then handing it over to a forklift for further

t ranspor tat ion wi th in the warehouse area is also an instance of over-processing.

Recently, a great number of sources, mostly in the US have now established the eighth waste and have labelled this as the ‘Unused human potential’. This waste refers to the unused employees’ minds and creativity. In other words, it refers to the under-utilisation of peoples’ skills and expertise.

It is important as managers to determine how you could better involve your people in the warehouse continuous improvement process and how you could possibly make best use of their valuable time in your effort to provide excellent results.

ConclusionAll seven or e ight wastes mentioned in this article represent a real threat to optimum and successful warehouse operation if proper care is not applied.

A careful and systematic application of lean process and especially the correct identification and elimination of all wastes from your warehouse environment will ultimately provide the needed solution for your long-term optimum operation.

Over the years, it has been observed that more companies (SMEs and MNCs) have adopted the lean process and the application of the seven wastes in their warehouse operation. By doing so, they have achieved significant long-term results.

It has been said and it is worth mentioning again that in any warehouse operation, it is essential to organise your warehouse in a lean and well-functioning way. In doing so, it will lead you to better managing your space, equipment and personnel.



Unnecessary use of forklifts are deemed to be a wastage.

Alfonso Romero, Pasadena, US

MANAGER'STAKE


Th e n e x t i n d u s t r i a l revolution is coming. T h e y e v e n h a v e a f u t u r i s t i c n a m e fo r

it ca lled Industry 4.0. This concept is the brainchild of Germany, a country that is trying to stay relevant in the manufacturing world.

T h e k e y t o r e m a i n i n g relevant according to Satish Lele, VP of Frost & Sullivan, requires a certain amount of rethink and readjustments, as in the case of Germany.

He said: “To stay relevant over the next 15 to 20 years as far as manufacturing is concerned, they (Germany) have to think

about manufacturing in a very different perspective.”

T h e r e s u l t o f t h i s considerat ion is of course Industry 4.0, which encompasses the Internet of Things ( IoT), susta inable manufacturing, cloud platform and big data, among others. As Germany is a highly developed country with matured manufacturing industries, many countries in a similar situation like Singapore can try to adopt this strategy to their advantage.

Time To Be Different The notion of the next industrial revolution and some of the

terminology that comes with it can be thought-provoking for some but downright scary for others. Whichever camp you choose to be in, it is best to prepare for it and the first place to start is the inner reaches of your own mind.

“Think about manufacturing differently in order to stay relevant,” said Mr Lele, as he gave his take on manufacturing trends and opportunities in ASEAN at the TCI Forum held at SIMTech recently.

Thinking differently in this case requires a total change in mindset. Currently, most things are mass produced

Manufacturing To Be

Future-ReadyManufacturers need to be ready for the fourth industrial revolution. By Joson Ng

MANAGER'STAKE


Did You Know?

AFTA: Zero Tariff RatesCome 2018, there is expected to be zero tariff rates across all 10 ASEAN nations. This means companies within ASEAN are free to manufacture in any ASEAN country without trade barriers.

their R&D and perhaps more importantly, their IP in Europe.

We are also hearing more of terms like ‘cloud’, ‘big data’ and the ‘IoT’. While it is true that many of Southeast Asia’s manufacturing markets are still not highly developed or matured compared to Germany’s, it is probably wise to take a good look at Industry 4.0 as it might provide valuable insights or opportunities in the future.

ASEAN Manufacturing

The 10 nations in Southeast Asia are collectively a rising star in the manufacturing

world. By the looks of it, they will be even greater in the future. Observers have said

by 2030, ASEAN could be the 4th largest single market in the world.

Having the size or critical mass however, does not mean everything will be

smooth sailing. ASEAN, being a diverse region, has its unique set of challenges

as the countries are in different stages of economic development. Factors like

minimum wage policy, exchange rate, productivity and capability development will

be obstacles but will also provide opportunities. The important point here according

to Mr Lele is to not be overly reliant on foreign technology. He said home-grown

technology is the key for manufacturing in ASEAN.

To conclude, Mr Lele spent some time in dispelling myths on manufacturing.

First of all, he said it is a fallacy that manufacturing will go away. He believes ASEAN

can be a manufacturing powerhouse as long as they integrate as one in order to

realise its potential.

We take a look at the manufacturing climate of this region and its future development.





and manufacturers charge a premium for customisation and slap on a longer lead time for good measure. According to Mr Lele, this will have to change.

“We need to look at customers as individuals,” he said. This change in thinking can have a tremendous impact on the current manufacturing climate. He said presently, manufacturing locations are centralised in a few locations globally.

F r o m t h o s e l o c a t i o n s , producers distr ibute their p ro du c t s to a l l ov e r t h e world. The movements of raw materials and finished goods along the value and supply chains, according to him, create a large carbon footprint as far as the manufacturing process is concerned.

In the future, factories are envisaged to be smaller in size. In addition, manufacturing will also be more distributed, resulting in manufacturing activities closer to customers. Only the design segment will remain centralised.

The Future…Looking ahead, he said the three main pillars of future manufacturing centres around being ‘green’, ‘intelligent’ and ‘flexible’. Green refers to reusing resources, while intelligent

is actually about embedded devices that command, respond and control. F lexible refers to the ability to respond to individual customers.

Some people may not want to believe it but we are beginning to see the effects of Industry 4.0 in Asia. Many European companies are setting up plants in China to supply to the large Chinese market, while keeping

MANAGER'STAKE


By Accessorising

Taking TheMeasured

ApproachCMM accessories are important. Pairing inferior accessories with a good CMM can be likened to putting cheap fuel into a Ferrari. By Joson Ng

A top range CMM is a b ig inve st me nt for many companies. Their benefits are often well-

documented and well-understood. For a QC department, such marque acquisitions may even be considered a crowning glory for them. While CMMs can no doubt improve the quality of a company’s products, accessories like extension bars and stylus do play an important role too. It is therefore important to address this issue to make sure the CMM fulfils its true potential.

FEATURES


“Our accessories increase the productivity of your CMM,” said Andreas Holowitz, global business development manager of Zeiss when he spoke at the company’s user meeting in Singapore.

Focu sing on t he st y lu s extension bars, he said the materials used to make those bars must be considered thoroughly. He added that there are different extension bars available in the market. They are typically made of steel, aluminium, titanium and carbon fibre. The first thing to note according to him is that extension bars should be lightweight, bending resistant and thermally stable.

Materials Matter“Steel is stiff and stable but it is also very heavy. If you have a long extension, it is not ideal. ( You) need counter weight, which is again not ideal for the whole balance of the system,” he said.

Thermally stable extension bars can contribute to a more reliable reading

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Aluminium extension bars, while described as “very popular”, may yet prove to be difficult to manage due to its reaction to heat. After all, it is consistency and reliability that most QC engineers are going after.

“You don’t want materials (in the measuring system) to be any different than it was one hour ago. You want a stable process,” he said. Using aluminium as an illustration, he added: “Aluminium has a high temperature coefficient of 23.8. That means 1 m of aluminium is expanding by 23.8 µm with 1 degree of temperature change. If you have a 100 mm extension, 1 degree temperature change would see 2.5 µm (of expansion). Most measuring rooms I see have at least one degree temperature change, some have two, three or four degrees of temperature change in the course of a day.”

According to h im, i t i s possible to lose up to 4 µm of accuracy with one extension.

This loss could be multiplied w ith compl icated systems because it is made up of more than one extension. However, he conceded that if the cycle time is short, aluminium extension bars are reliable because there is not enough time for the effects of heat to kick in.

Finally, titanium has fewer problems with temperature but the wall of the extension wa s de sc r ib e d a s “p ap e r thin”, making it susceptible to instability when large bending force is experienced.

Higher Speed Better SavingsThe issue of materials is related to the scanning speed and ultimately the productivity of the whole measuring process.

At a ver y low sca nning speed of 2 mm/s, there is not much need to choose between extension bars made out of various materials. However, at higher scanning speeds, the carbon fibre extension bar

FEATURES


displays the least form deviation. In other words, if an operator uses a different material, he/she has to measure at a slower speed in order to achieve the same level of accuracy and repeatability.

Linking scanning speed to operating cost, Mr Holowitz said: “If the cycle and measuring time is 20 minutes and 10 percent reduction can be gained by using the right materials (extension bars), it works out to two minutes per part and six minutes in an hour. After three hours, you can measure one part more and after 10 hours, you have gained an hour in productivity.”

This point is particularly pertinent given that the hourly operating cost of CMMs typically fall in the region of US$100 to US$200. One hour saved can potentially be quantified a s US$150 (on average) of productivity gained.

Using the bicycle a s a n analogy to sum up the issue of materials, he said a bike frame made of steel is cheap; an aluminium frame represents an upgrade as it is l ighter. However, if someone is going to race, he would need a carbon fibre frame.

Interface — When Less Is BetterA stylus system is made up of various accessories l ike adapter p late s , e x te n sion bars and joints. Although this modular system or approach offers flexibility, the interface where two accessories meet is an area of weakness.

“A n inter face may come a l i t t l e l o o s e o v e r t i m e , becoming a potentia l weak point in your stylus (system),” said Mr Holowitz. Based on his argument, reducing the number of interfaces would theoretically make the system more reliable and accurate.

Diamond — Metrology’s Best Friend?

Another important part of the stylus system is the point that is in contact with the part.

When scanning soft parts made out of aluminium, there is a possibility of material build-

up at the ruby tip. According to Mr Holowitz, this is a problem because operators have to

spend time cleaning up the ruby tip and recalibrating the system. He said using a diamond

tip can solve this problem as it apparently does not pick up materials from soft parts even

though it is a very hard material. Allaying fears that diamond, given its hardness, may

scratch parts, he said the developers have done testing on copper and the diamond tip

did not deform the copper part.

Be Mindful Of Heat Sources Around Your CMM

“You bought a wonderful machine and there are things you need to do to keep it wonderful,”

said Mr Holowitz. According to him, some measuring rooms are not sensitive to the

conditions that CMMs require in order to do what it is designed to do properly.

For instance, he said thin walls and windows of the measuring room can potentially

be sources of heat and that can in turn affect the performance of the CMM. He also

discouraged having non-essential personnel in the measuring room and placing a CMM

too close to a door. As minute as the issue may seem, activities like that could affect air

flow, resulting in fluctuating temperature. He recommends keeping track of the temperature

on an hourly basis or investing in a temperature tracking system that can provide live

monitoring of temperatures.

Other Tips For More Reliable Measurements

This forms the basis for the ThermoFit technology, which according to the developer, saves operators from the problems that come with connecting interfaces. In addition, the system based on this technology is some 25 percent lighter and has nearly double the st i f fness of the stylus system.

At the end of the day, modern metrology is all about getting

the tiny deflections right. High-end CMMs promise unrivaled accuracy but having a correct mindset and paying attention to details like using the right accessories ensure reliable results and higher productivity.

Andreas Holowitz sharing his expertise at the company’s user meeting in Singapore.





FEATURES

In our annual Vietnam Guidebook, we feature Metalworking Equipment and bring you the latest in the industry, all in Vietnamese.

Don’t miss your last chance to tap into the dynamic Vietnamese market. Book your ads now!Advertising booking will close on June 6.

• Vietnam’s GDP reached US$141.7 billion in 2012, four times higher compared to figures from 10 years ago.

• Vietnam’s annual GDP growth rate from 2001 to 2010 was 7.3 percent, higher than its more established neighbours like Thailand, Singapore, Indonesia and Malaysia.

ADVE

RTIS

EMEN

T

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GIẢI PHÁP MỚI CHO LƯỠI CƯA VÒNGLưỡi cưa vòng cắt được tất cả các loại vật liệuChi phí thấp cho mỗi lần cưaThời gian sử dụng lâu, đường cắt đẹpCó đội ngũ kỹ thuật chuyên nghiệp

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To advertise, please contact:

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The process of removing burrs from the edge of a workpiece, commonly known as deburring,

has been used for more than a century in the metal workshop. When a piece of metal undergoes a machining process, such as cutting, drilling, boring or turning, it forms jagged edges and protrusions, which are commonly known in the industry as burrs.

Deburring not only improves the aesthetics of the finished product, it also prevents safety issues from arising. Such burrs have the potential to cause complications, with the severity of these complications dependent on the environment where these workpieces may finally find themselves.

For example, a metal tube may

compromise the glued sealings and overall integrity of a HVAC (heating, ventilation and air-conditioning) system if it has not been thoroughly deburred.

Perhaps more seriously, a similar metal workpiece used in a pharmaceutical clean room can inadvertently result in the

introduction of foreign particles into the drug manufacturing process. As a result, pharmaceutical companies have been known to operate a strict quality control system, making it increasingly challenging for fabricators of metal products and articles to get away with imperfect surface finishes.

While deburring may be thought by many to be a fairly simple process, it has gone through some modern enhancements in recent years, saving money and time. By Shahnawaz Abdul Hamid

Beyond Simple Manual

DeburringDamian Searles, Brisbane, Australia

FEATURES


Better Machining, Less BurrsWhile deburring may seem a rather straightforward and simple process, it is anything but. In recent years, new deburring tools have been introduced which seek to make the process of removing burrs more cost-effective and efficient.

Traditionally, most deburring is accomplished through the use of a simple manual deburring tool, one with a curved sickle that quickly removes any burrs which may be perceptible to the naked eye. Alternatively, one may use an abrasive substance like sandpaper. While this is a tried-and-tested method, it is difficult if the workpiece has surfaces which are difficult to reach. Also, it may not be feasible for large workpieces, or those made from tougher metals.

In such cases, the use of more sophisticated deburring equipment may be needed. Nevertheless, it may be premature to speak of such equipment without first asking if today’s machining environment is aware of the need for lesser burrs to be formed after a certain machining process. One should consider the cutting tools available which help in reducing burrs from forming. After all, the main objective of deburring is for the metal surface to be free from protrusions and edges.

In this regard, non-traditional metal removal processes may be looked at. Abrasive jet machining, chemical machining, ultrasonic machining and water jet machining are just some of the non-traditional meta l removal processes , introduced since the 1960s, that have saved tens of thousands of hours of deburring.

T h e s e n o n - t r a d i t i o n a l p ro c e s s e s a re k n o w n t o consistently produce high quality burr free edges. However, some of them, such as chemical machining, have been known to result in undesirable environmental effects, preventing widespread use.

Metal components need to be thoroughly deburred to prevent any complications

Michael & Christa Richert, Berlin, Germany

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19A Hillview Ave., 01-06 Hillview Park, Singapore 669554

phone +65 8112 6550mail [email protected] www.heimatec.de

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In contrast, better cutting tools within the realm of traditional processes, invented over the last decade, have also been influential in preventing burr formation. Perhaps no improvement in cutting has been more significant than the introduction of replaceable carbide insert tools. These tool tips, which allow for easy, convenient replacement, ensure that tools are always sharp, and minimises the formation of burrs.

New Age DeburringDespite the advancements in cutting and other machining processes, burrs still exist, making the deburring process as important today as it was years ago.

According to a white paper entitled ‘Your Burr Technology Efforts Changed The World’ by LaRoux K Gillespie, there are now a total of 117 deburring processes, up from 17 in 1973. In the year 2000, over 1,000 companies made and supplied deburring products and services.

Three deburring processes

are particularly seen as major contributors to this new era of enhanced deburring effectiveness. They are on machine brush deburring, mass finishing and robotic deburring. All three have witnessed process enhancements which make them critical to today’s manufacturing process.

On machine brush deburring refers to the use of a brush attached to the rotating machine spindle to remove and smoothen a workpiece. This usually results in lesser deburring time, as compared with manual deburring by hand. It also allows for a better finish on the workpiece. This process requires the operator to move the workpiece in a back and forth motion along the moving brush.

In recent years, the use of bristle-disc brushes as opposed to wire brushes has reduced the pressure needed from the operator, resulting in lesser vibrations being transferred to the hand of the operator.

Unlike on machine brush deburring, mass finishing does

sulaco229, Slovenia

Will robots of the future make workers like these obsolete?not require an operator to hold the workpiece while it is being deburred. It is more automated, with workpieces being put through a mechanical process to attain a certain surface finish. While the cost of such deburring machines may be expensive, the savings in terms of time can be rather substantial. These machines are now commonplace in factories which produce metal parts for applications in the fields of medicine, defence and optics.

Like other metalworking processes which have since turned to robots to alleviate manpower constraints, robotic deburring is no different. However, deburring robots are also useful in a sense that they are able to handle and deburr parts which may prove a challenge for human operators: hot, heavy, with many sharp edges. In addition, robots are valued for their accuracy and consistency.

What Next?While the technology of deburring has gone through much expansion in recent decades, there still lies many opportunities and areas for constant improvement.

The use of software to determine where burrs are formed, the codification of edge standards, as well as the continued need for burr minimisation are some of the areas that future scientists and researchers will have to look at.

There is even talk today of microscopic raised edges and deformities, or micro-burrs, which will require higher levels of sophistication in terms of detection and removal. Only time will tell how these subtopics will impact the study of surface integrity and finishing, as well as the ancient art of deburring.



FEATURES

ENQUIRY NO 033


MTA Vietnam will return to the Saigon Exhibition & Convention Center (SECC) in Ho Chi Minh

City from July 8 – 11, 2014. According to the organiser, the show will once again be showcasing metalcutting and metalforming machinery as well as tooling systems that cater to Vietnam’s robust manufacturing industry.

Since its inaugural edition back in 2005 in Ho Chi Minh City, the show has established itself as an annual event for Vietnamese manufacturing professionals. It continues to see strong support from international trade bodies and government agencies. This year, the show will see the participation of group pavilions from Germany, Japan, South

Korea, Singapore, Taiwan and Thailand, as well as a line-up of local supporting government organisations.

“MTA Vietnam has supported the manufacturing industry in Vietnam through the years, by offering the platform for the showcase of the latest technologies and solutions, as well as business networking and idea exchange opportunities.

W i t h t h e V i e t n a m e s e manufacturing capabil it ies gaining momentum this year, the show is set to play an even more important role in bringing international technology know-hows to Vietnam. We look forward to a strong line-up of exhibitors, many of which are returning exhibitors — a testament to the relevance and importance of the show,” says William Lim, project director for the show from Singapore Exhibition Services (SES).

The organiser’s optimism can partly be fueled by the growing economy in the country. The Vietnamese manufacturing sector has gained momentum this year, with January seeing the strongest rise in output since April 2011.

There is a sharp increase in pledged FDI, reflecting well on the country’s competitiveness in labour-intensive manufacturing, which may drive the Southeast Asian country to become an a l ternat ive to China as a manufacturing base.

SECCHo Chi Minh City, VietnamJuly 8 – 11, 2014

Event Preview:

MTA Vietnam 2014



EVENTS&EXHIBITIONS

ENQUIRY NO 073


The EMTE-Eastpo Machine Tool E x hibit ion w i l l be held in Sha ngha i at the Shanghai New

International Expo Centre from July 14 – 17, 2014. The joint exhibition will leverage on the combined strengths and expertise of three partners. According to the organiser, Eastpo alone covered 80,000 sq m of gross exhibition space in 2012, and the addition of EMTE is expected to increase the exhibition space covered by the four-day exhibition.

The event aims to provide manufacturers and suppliers of machine tools with a key business platform to increase

Event Details• Product Launch Date: May 21, 2014 Time: 10:00 am - 12:00 pm Location: Kelantan Room, Level

2, Putra World Trade Center

• Taiwan Machine Tool Processing Technology Forum

Date: May 22, 2014 Time: 1:30 pm - 4:00 pm Location: Johor/Kedah Room,

Level 2, PWTC

Event Preview:

EMTE-EastpoMachine Tool Exhibition

Event Preview:

Taiwan Machinery Product Launch

productivity in today’s globalised and highly competitive world. It also serves as a sourcing platform for agents, distributors and buyers to meet some 1,000 manufacturers worldwide for their sourcing needs.

To-date, the exhibition has secured support from industry associations representing the major end-user sectors of the machine tool industry in Asia. They include the association of Yuhuan Machine Tool Industry, Australian Manufactur ing Technolog y Institute, Chinese Mechanical Engineering Society, Ho Chi Minh City Association of Mechanical Engineering, Indonesia Foundry

Industries Association, Jiangsu Machinery Industry Association, Jiaxing Mould Trade Association, Philippine Die & Mould Association Shanghai Mechanical Engineering Society, Shanghai Society of Automotive Engineers, Vietnam Associat ion of Mechanica l Engineers and Zhejiang Machinery Industry Federation.

National pavilions are also going to be out in numbers. Represented at this year’s exhibition are country groups from Czech Republic, Ita ly, Germany, South Korea, Spain and Switzerland.

Shanghai New International Expo CentreShanghai, ChinaJuly 14 – 17, 2014





Happening at Metaltech is the ‘Taiwan Machinery Products’ Launch. To be held on May 21,

2014 at the Putra World Trade Center, the event will highlight the technological strengths of Taiwan’s metalworking and machine tools industries.

This event aims to enhance the manufacturing sectors’ competitive edge and business o p p o r t u n i t y i n M a l ay s i a . Organised by the Bureau of Foreign Trade (BOFT), Ministry o f E conom ic A f fa i r s , a nd implemented by the Taiwan External Trade Development Council (TAITRA), the product

launch will serve as a platform to showcase the technologies that have been driv ing the metalworking market forward.

Of the lathes and turning machines Malaysia imported (US$80 million) in 2013, Taiwan accounted for 37.5 percent of such imports, which is valued at US$30 million. As for machining centres, Malaysia imported a total of US$100 million during the same period, with Taiwan accounting for 20 percent of the shipments, which is valued at US$20 million. Exports of machine tools from Taiwan to Malaysia were the third highest in 2013.

Looking into the future, Taiwan will assume the role of a major supplier of machine tools and parts to the global market, meeting increasing demand in Asian countries, particularly Malaysia.

EVENTS&EXHIBITIONS

ENQUIRY NO 006


• The Stars of Technology Pavilion: A special showcase of high-tech machinery,

technologies and live robot demonstrations.

• See leading technologies from these International Pavilions: Japan Pavilion,

Singapore Pavilion, Taiwan Pavilion, Thailand Pavilion and Vietnam Pavilion

• Engineer Master Class & Technology Presentations: The knowledge- and technical-

based sessions will unveil new business insights and introductions of new

technologies. It will also offer a three-session-training course for local engineers at

Engineer Master Class. Participants will be trained on leadership, visions, as well as

creative management towards manufacturing excellence. Participants must attend

all sessions to gain a certificate.

• The First Hand Soldering Championship: IPC (Association Connecting Electronics

Industries) and Reed Tradex will bring the competition to the exhibitions. This is a

series of activity organised in many countries to highlight skills of local electronics

manufacturers. The competition will take place during the three-day show.

• Business Matchmaking Program: A designated meeting place to match businesses

with the right traders, agents and suppliers in metalworking, automotive and

supporting industries.

• Agent Wanted: The meeting point for global providers of industrial machinery and

technologies to look for agents to represent their products in Vietnam.

Key Highlights At The Show



Vietnam Manufacturing Expo 2014 will showcase manufacturing machinery and technologies for the

supporting industries. With 200 brands from 20 countries, the organiser has made good their promise to present something more this year. Industrial part-making factory owners, engineers, production managers, and industrialists will be able to use this event as a community platform to source solutions, parts, suppliers, partners, and knowledge to keep up or lead the change.

The organiser hopes that this year’s edition will build on last year’s success. The event in Hanoi last year was the fifth and the largest edition of the show ever.

The exhibition broke its own records in several areas. It was larger in terms of space. It was bigger in terms of collaborations between participating parties. Not surprisingly, the total number of attendance during the three days reached 13,614.

ICEHanoi, VietnamAugust 27 – 29, 2014

Vietnam Manufacturing ExpoEvent Preview:



EVENTS&EXHIBITIONS

Organized by :ECMI Services Sdn Bhd

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MALAYSIATel : +60 3-56361788Email : [email protected]

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26 - 29 August 2015The 7th International Metalworking Technologyand Tooling Exhibition on Machine Tools and

Related Machinery For Indonesia

Where Market

Leaders Converge

to Unveil Latest

Technologies

to Provide Solutions

& Alternatives

to Meet Every

Manufacturing Need

RidOpportunit

Promis

de OnRid

PWTCKuala Lumpur

27 - 30August

Book Your Space Now

O

Organized by :ECMI Services Sdn Bhd

Ride On Opportunities to Clinch

Promising Dealsand Enjoy

Rewarding ROI

MALAYSIATel : +60 3-56361788Email : [email protected]

OVERSEASTel : +65 65709007Email : [email protected]

Book Your Space Nowwww.mtt-kl.com

to Secure Good Location

Rewarding ROI

26 - 29 August 2015The 7th International Metalworking Technologyand Tooling Exhibition on Machine Tools and

Related Machinery For Indonesia

Where Market

Leaders Converge

to Unveil Latest

Technologies

to Provide Solutions

& Alternatives

to Meet Every

Manufacturing Need

RidOpportunit

Promis

de OnRid

PWTCKuala Lumpur

27 - 30August

Book Your Space Now

O

ENQUIRY NO 080


This year, Metalex Vietnam and NEPCON Vietnam will return from October 9 -11, 2014 at the Saigon

Exhibition & Convention Center (SECC). According to the organiser, the show will be a meeting centre of the manufacturing community, which opens doors for Vietnamese industrialists to discover how they can heighten their product quality and productivity.

The show will feature new machine tools, metalworking technologies, and electronics manufacturing technologies from 500 brands from 25 countries. The show is also co-located with NEPCON Vietnam 2014, the country’s only exhibition on assembly, measurement and testing technologies for the electronics manufacturing industry.

Duangdej Yuaikwarmdee, deputy MD of Reed Tradex said that the positive movements are happening in ASEAN’s automotive manufacturing industry. These movements indicate good heath for both the auto and supporting industries. These movements are also happening in countries such as Indonesia and Vietnam,

which are attracting more investment from giant car makers in order to possess the level of competitiveness that will yield success in the region.

As seen from general statistics, there was a significant increase in Vietnam’s gross domestic product in 2013, with the electronics industry playing a key role in boosting the country’s economy. The high-tech exports were on the rise, increasing

21 percent and exporting to nearly 50 countries worldwide.

Saigon Exhibition & Convention Center (SECC)Ho Chi Minh City, VietnamOctober 9 -11, 2014

Reed Tradex has joined forces with the Investment & Trade Promotion Centre (ITPC) and

Japan External Trade Organization, Ho Chi Minh Office (JETRO) to organise the Vietnam

Supporting Industries Forum #10 on May 22, 2014 under the theme of ‘How to Develop

Vietnamese Supporting Industries: Sharing the Best Practices — The Guideline for your

Sustainable Success’. As supporting industries play a key role in promoting the development

of Vietnam’s main industries, Vietnam cannot afford for it to be undeveloped.

This forum will offer visions, best practices and experiences by government and private

sectors to keep participants updated on business opportunities and business development

of Vietnamese Industries. It also offers guideline in building up the sustainable growth

of Vietnamese Industries through the strong network and collaboration of supporting

industries. Vietnamese manufacturers will get ideas on what to do to upgrade their products

to meet Japanese manufacturers’ quality standards and get guidelines on how to improve

Vietnam’s supporting industries.

Vietnam Supporting Industries Forum

Event Preview:

Metalex Vietnam





EVENTS&EXHIBITIONS

27-29

August 2014International Center for Exhibition (I.C.E) Culture Palace - 91 Tran Hung Dao

Hanoi, Vietnam

4,500 Sq.m. 200 Exhibitors, 20 countries 11,000 Buyers Business Matchmaking Technology Presentations

As more investment projects are pouring into Vietnam, business opportunities continue flowing towards manufacturers in the supporting sectors. Their needs for better technology and know-how will increase, and technology providers like you will be able to answer their needs with the right technology just in time at Vietnam Manufacturing Expo 2014.

Upgrade Production Technology.Upscale Business Opportunities.

The Most Comprehensive Machinery & Technology Event for the Manufacturing and Supporting Industries - 6th Edition

Organized by:

Co-located with:

Local partner:

www.vietnammanufacturingexpo.com

Space is open for reservation. Contact Us:In Vietnam: Tel. +84 8 3520 7756/57/58 Fax: +84 8 3520 7604The rest of the world: Tel. +66 2686 7299 Fax: +66 2686 7288

ENQUIRY NO 084


This year’s edition of MTA Hanoi was held from April 1 – 4, 2014. According to the organiser, thousands of

interested buyers explored the halls over the three-day event, seeking to forge business relations with key global and local industry players.

The machining, tooling and measuring technologies and solutions from all over the world gave visitors the opportunity to bring their knowledge closer to international manufacturing standards. In addition, the show also featured some group pavilions, one of them hailing from Czech Republic.

“Vietnam’s hearty investment landscape and local manufacturing sectors has positioned the region as one of immense growth potential in the minds of Czech’s industry players. Our participation at MTA Hanoi 2014 has made it possible for us to promote our home-

grown brands and capabilities and through the multiple networking opportunities available during three show days, we were able to gain valuable knowledge of Northern Vietnam’s bustling manufacturing community and its prospects for future growth,” said Petr Zemanek, GM of the Association of Engineering Technology, Czech Republic.

Visitors From All OverIn all, more than 4,000 industry attendees, including exhibiting staff, trade visitors, conference speakers and delegates and members of the media came to the trade event, with the bulk of visitors coming from Vietnam, followed by Singapore and Japan. Within Vietnam, majority of visitors came from Hanoi, followed by Bac Ninh and Hung Yen.

“We are pleased to see that MTA Hanoi serves the manufacturing industries in Hanoi and the

Northern region well. Positive comments received from exhibitors shows that our attendees have made full use of the opportunities presented at the event to review the latest manufacturing products and solutions, and network with exhibitors.

As the region’s manufacturing industry continues to grow and flourish, MTA Hanoi will continue to provide the tools and technology needed to take it to the next level,” says William Lim, project director (machinery events) of show organiser, Singapore Exhibition Services.

ConferencesIn addition to the exhibition, nearly 250 delegates registered to listen and learn at conferences organised by the Vietnam Associat ion of Mechanical Industr y (VAMI), the Multi Engineering Solutions Laboratory (MESLAB) and the Vietnam Welding Society respectively.

Through these sessions, industry experts were able to share with delegates their insight into the cooperation and development of local mechanical enterprises; technical knowledge of total productive maintenance, laser technology and 3D scan technologies; the various aspects of welding, such as automation, robotic systems, international standards; and also the processes in nuclear power plants. The next edition of the show will be held in April 26 - 28, 2016.

ICEHanoi, VietnamApril 1 – 3, 2014



Event Review:

MTA Hanoi 2014

EVENTS&EXHIBITIONS

ENQUIRY NO 040

Renishaw has collaborated with a British bicycle design and manufacturing company to create the

world’s first 3D printed metal bike frame. Empire Cycles designed the mountain bike to take advantage of Renishaw’s a d d i t i v e m a n u f a c t u r i n g technology, allowing them to create a titanium frame that would be both strong and light using topological optimisation — the new frame is some 33 percent lighter than the original.

The frame has been additively manufactured in titanium alloy in sections and then bonded together. This offers advantages in design freedom, construction and performance.

The Strength TestTitanium alloys have a high Ul t imate Tensi le S trength (UTS) of more than 900 MPa when processed using additive manufacturing and near perfect densities of greater than 99.7 percent are achieved; this is better than casting and, as any porosity is both small and spherical, it has little effect on strength.

The project’s aim is to produce a fully functioning bicycle, so the seat post bracket was tested using the mountain bike standard EN 14766; it withstood 50,000 cycles of 1,200 N. Testing continued to six times the standard without failure.

Topological OptimisationFrom the Greek word for place, ‘topo’, topological optimisation software is the term given to programs that are used to determine the ‘logical place’ for material — normally using iterative steps and finite element analysis.

Material is removed from areas of low stress until a design optimised for load bearing evolves. The resulting model is both light (due to the low volume) and strong. The historical challenge in manufacturing these shapes can now be overcome with additive manufacturing, enabling physical 3D models to be realised.

How Light Is It? Titanium alloys are denser than aluminium alloys, with relative

densities of around 4 g/cm3 and 3 g/cm3 respectively. Therefore, the only way to make a titanium alloy version of a part lighter than its aluminium alloy counterpart is to significantly alter the design to remove any material not contributing to the overall strength of the part.

The original aluminium alloy seat post bracket is 360 g and the hollow titanium version is 200 g, a weight saving of 44 percent. This is however just the first iteration; with further analysis and testing it could be reduced further.

The original bike frame weighs in at 2,100 g. Redesigned to make use of additive manufacturing, the weight drops to 1,400 g, a 33 percent weight saving.



Manufacturers can now add printing to their list of manufacturing techniques in making bicycle frames. By Robin Weston, marketing manager, Additive Manufacturing Products Division, Renishaw

Want A Bike?

Print It!


PARTINGSHOT


ENQUIRY NO 085


Got a Question? Make An Enquiry.ENQUIRY No. 4901Turn to page 80a or log on to www.equipment-news.com to enquire





Ewag: Grinding Machine With Integrated Robot

The Compact Line five-axes CNC tool grinding machine by Ewag is suitable for grinding indexable inserts made of hard metal, cermet, ceramic, PCB and PCD.

According to the manufacturer, the machine has a ‘three-in-one’ dressing unit responsible for a true runout of the grinding wheel and high process repeatability. It enables dressing, regeneration and crush dressing on the same unit.

In addition, the machine possesses a fully integrated six-axes robot that supports various plug and play clamping systems, which enable flexibility on the machine.

Finally, in terms of control and usability, the manufacturer said all grinding programs can be programmed on the touch screen panel. The input masks are supported by 3D graphics.

EOS: Using AM To Produce Large Metal Parts

Heimatec: High-Speed Tools For Drilling & Milling

EOS has developed the EOS M 400, a modular and extendable platform that gears additive manufacturing up for application in industrial production environments.

According to the manufacturer, the volume of the building chamber, which measures 400 x 400 x 400 mm, is big enough so that larger components can now be produced.

The additive manufacturing system also has a laser that has a performance of up to 1,000 watts. It allows the use of new materials that require more powerful lasers. Finally, it has a touchscreen user interface to further simplify the system usability.

In an increasingly competitive environment, no company engaged in manufacturing of high-tech tools can afford to remain idle. Therefore, Heimatec has developed drilling and milling heads for axial and radial machining on different lathe machines.

With a transmission ratio of 1:4, these tools can reach a speed of 24,000 rpm, according to the manufacturer. In addition to internal cooling of 70 bar for the axial drilling and milling head, and 140 bar for the angle-drilling and milling head, the tools are supplied with an ER16 AX u-tec change system.

Guhring: Versatile Taps

Guhring’s PowerTap range provides taps for the most popular threads. According to the manufacturer, it is suitable for materials like cast iron, aluminium and aluminium alloys. In addition, it can be used on stainless and acid-resistant, high-strength or general steels.

The geometry of the taps enables a broad application range and good machining results. Long and constant tool life is achieved due to the optimal cutting edge geometry. Its performance reliability with straight-fluted taps for through holes as well as with spiral tools for blind holes is achieved through optimised geometries.


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Sutton Tools: Better Productivity With Lower Inventory

Sutton Tools has developed its multipurpose Black Magic Tap range. According to them, it enables component manufacturers to achieve productivity while minimising tap inventory. In addition, they claim that the product can eliminate many common problems encountered during tapping.

Using a premium three percent vanadium grade of powdered metallurgy high speed steel (PM-HSSE) base material, the design also features a ‘Hardlube’ (TiAlN+WC/C) coating.

Finally, the manufacturer said the taps are suitable for tapping of stainless steels, alloy steels, general steels, low-alloy steels, as well as copper and aluminium alloys, across a broad spectrum of industrial applications from small-scale jobbing shops through to high-volume component production.

Walter: Insert Drill

Walter has enhanced its Xtra•tec Insert Drill family to include modular shanks with Walter Capto clamping and indexable inserts with Tiger•tec Silver. The advantages for the user are, on the one hand, faster tool changing and, on the other, higher transmission of force via the polygonal Walter Capto interface.

According to the manufacturer, the indexable inserts have four genuine cutting edges that enable high cutting parameters as well as providing reduction in the number of additional operations.

The ground indexable inserts are also fitted with a wiper edge, which means that they ensure good hole surface finish. High process reliability is ensured by the positive locking of the indexable inserts with TorxPlus screws.

Sandvik Coromant: Secure & Efficient Parting Off

CoroCut QD, the system from Sandvik Coromant for deep grooves and parting off with long overhangs is now expanded to offer inserts and durable tools. The system is supported with plug and play adaptors for easy handling and efficient coolant supply.

For bar feed manufacturers, process security in terms of good chip control and reliable tool life is the key to an efficient production. To meet these needs, the system combines strong tools and inserts with rigid clamping and efficient coolant supply.

Renishaw: Optical Encoder

Renishaw has d e v e l o p e d t h e

Atom, a non-contact optical linear and

rotary incremental encoder system that

combines miniaturisation with dirt immunity, signal stability

and reliability. According to the manufacturer, the encoder achieves the performance as a consequence of a design which avoids the many compromises traditionally associated with miniaturised encoders.

The encoder is available in sizes as small as 6.8 mm x 12.7 mm x 20.5 mm and is said to be the world’s first miniature encoder to use filtering optics with Auto Gain Control (AGC) and Auto Offset Control (AOC).


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Diameter 0.60 to 20.05mm in 0.01mm incrementsTolerance: -0, +0.004mm

Straight shank Machine Reamers starting from

For enquiry, please email: [email protected]

Swiss-Made Precision Machine Reamers

(HSSE, TIN-coated, TIALN Coated and Solid Carbide)



EXHIBITIONPROGRAMMES2014

19 - 22Intermold Thailand 2014BITECBangkok, ThailandReed [email protected]

9 – 11Aluminium China 2014Shanghai New Int’l Expo CentreShanghai, ChinaReed Exhibitions Greater [email protected]

14 – 17EMTE EastpoShanghai New International Expo CentreShanghai, ChinaMP [email protected]

27 – 30Taipei Int’l Industrial Automation Exhibition 2014TWTC Nangang Exhibition HallTaipei, TaiwanChan Chao [email protected] www.autotaiwan.com.tw

27 – 30Taipei Int’l Mold & Die Industry Fair 2014TWTC Nangang Exhibition HallTaipei, TaiwanChan Chao [email protected] www.odm-dmi.com

27 – 30MTT Expo 2014 MalaysiaPWTCKuala Lumpur, [email protected]

SEPTEMBER9 – 11Medical Manufacturing AsiaSuntec SingaporeSingaporeMesse Dusseldorf [email protected]

MAY21 – 23Indorenergy 2014Grand City Convex SurabayaSurabaya, IndonesiaPT Napindo Media [email protected]

21 – 24MetaltechPWTCKuala Lumpur, MalaysiaTrade [email protected]/metaltech

JUNE11 – 14Manufacturing SurabayaGrand City Convention & Exhibition CentreSurabaya, IndonesiaPT Pamerindowww.pamerindo.com

18 – 22CIMESNCIECBeijing, ChinaReed [email protected]

JULY8 – 11MTA VietnamSECCHo Chi Minh City, [email protected]

AUGUST27 - 29Vietnam Manufacturing Expo 2014ICEHanoi, VietnamReed Tradexcontactcenter@reedtradex.co.thwww.vietnammanufacturingexpo.com


EXHIBITIONPROGRAMMES

11 – 13IndometalJI Expo Kemayoran JakartaJakarta, IndonesiaMesse Dusseldorf [email protected]

OCTOBER2 - 4Manufacturing MyanmarMyanmar Convention CentreYangon, [email protected]

9 - 11Metalex Vietnam 2014SECCHo Chi Minh City, VietnamReed [email protected]

29 – 31Indonesia Mining & EngineeringJakarta International ExpoJakarta, IndonesiaReed Mining Eventshanung.hanindito@reedpanorama.comwww.miningandengineeringindo.com

Oct 30 – Nov 4JIMTOF 2014Tokyo Big SightTokyo, JapanJMTBAwww.jimtof.org

NOVEMBER5 – 8Indo Aerospace 2014JI Expo Kemayoran JakartaJakarta, IndonesiaPT Napindo Media [email protected]

5 – 8Indo Marine 2014JI Expo Kemayoran JakartaJakarta, IndonesiaPT Napindo Media [email protected]

5 – 9TMTS 2014GTIECTaichung, [email protected]

12 – 14Welding Busan Korea 2014BEXCOBusan, South KoreaMetal Network Korea Companywww.weldingasia.org

DECEMBER3 – 6Manufacturing IndonesiaJakarta International Expo KemayoranJakarta, IndonesiaPT Pamerindowww.pamerindo.com

19 - 22MetalexBITEXBangkok, ThailandReed [email protected]

29 - 31Intermach MyanmarTatmadaw Exhibition HallYangon, MyanmarUBM Asia (Thailand)[email protected]

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

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


ADVERTISINGINDEX

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The closing date for placing advertisements is not less than FOUR WEEKS before the date of publication. Please contact our nearest advertising office for more details.

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Knowledge and Performance in ConcertImagine running in perfect, synchronized harmony. Any project, any challenge, optimized and refined using digital intelligence to fundamentally transform your workflow into seamless, elegant, simple production. From art to part — to profit.

With NOVO™ you can now have the right tools on your machines, in the right sequence. This enterprise-wide solution ensures that you execute flawlessly to accelerate every job, maximize every shift. And that should be music to your ears.

That’s Different Thinking. That’s Kennametal.TM

ENQUIRY NO 011

apmen may-june 2014

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