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

Visit us at MaNufacturiNg iNDoNesia 2011 Booth NumBer A-242

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 Block B No.08 BN-BP, Podomoro CityJl. Letjen S.Parman Kav.28 Jakarta Barat 11470 - IndonesiaTel +62 21 29206242/44/45Fax +62 21 29206243 [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 8123 519/20 Fax + 84 8 8123 [email protected]

www.iscar.com

For more information, view this interactive ad at www.iscar.com

Heavy Grooving and Turning with the Best!

TAGB 1260 6 – 12 mmGrooving and Profiling

GIF 8.00E - 0.80 4 - 10 mmGrooving and Turning

TAGB 1008 6 – 14 mmGrooving and Turning

GIMF 808 4 - 8 mmGrooving and Turning

GDMM 8CC 7 - 8 mmGrooving

TIGER 14CW 14 -20 mmGrooving

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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 Block B No.08 BN-BP, Podomoro CityJl. Letjen S.Parman Kav.28 Jakarta Barat 11470 - IndonesiaTel +62 21 29206242/44/45Fax +62 21 29206243 [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 8123 519/20 Fax + 84 8 8123 [email protected]

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For more information, view this interactive ad at www.iscar.com

Heavy Grooving and Turning with the Best!

TAGB 1260 6 – 12 mmGrooving and Profiling

GIF 8.00E - 0.80 4 - 10 mmGrooving and Turning

TAGB 1008 6 – 14 mmGrooving and Turning

GIMF 808 4 - 8 mmGrooving and Turning

GDMM 8CC 7 - 8 mmGrooving

TIGER 14CW 14 -20 mmGrooving

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ENQUIRY NO 200

DOUBLE OCTOMILLTM

16 GOOD REASONS TO CHANGE YOUR FACE MILL.

EASY CUTTING. DOUBLE SIDED INSERT WITH HIGHLY POSITIVE GEOMETRY

Double OctomillTM is a performance face mill for roughing and finishing applications. Suitable for normal and large machine tools, Double OctomillTM is a very economical face milling solution for steel, cast iron and stainless steel machining.

PRECISE. HIGH PRECISON INSERT LOCATION

Double OctomillTM insert pocket seats are equipped with unique, hardened insert reference pins. Insert indexing is easy and secure. What’s more, the precise HSS pin ensures a high quality surface finish and a very long life for the pocket and cutter body.

ECONOMICAL. 16 CUTTING EDGES PER INSERT

Whatever your industry, Double OctomillTM with 16 cutting edges per insert and a highly positive insert geometry, can make a unique contribution to milling performance. Test Double OctomillTM for better face milling performance and economy.

Singapore Tel + 65 68412802, Malaysia Tel + 60 3 90591833Thailand Tel + 66 2 7467801, Vietnam Tel + 84 8 9144393

Indonesia Tel + 62 21 80888122, Philippines Tel +63 9 178298719

www.secotools.com

High precision insert location pins

Coated and pre-hardened cutter body

Positive insert geometry for light and smooth cutting action

Wiper flats for very good surface finish

16 cutting edges per insert

Precision ground contact surface

Precise insert reference support

Double Octomill ad 1 EQN mag.indd 1 09-Dec-10 14:52:04

ENQUIRY NO 001

2 metalworking equipment news Nov-Dec 2011

ContentsNovember-December 2011

Using Modern Tools For Sheet Metal Reverse Engineering & Inspection

software & Metrology

Three-dimension self-positioning laser scanners can provide full, accurate and fast assessment of the sheet metal, which guarantees the quality control of vehicle parts and assembly of full-sized vehicles. By Robert Wang, Creaform Shanghai

36

Wet & Dry MachiningAugustine Quek explores the different issues involving wet and dry machining

28

Hold It Right There!fab & forM

Circular vacuum chuck allows tension-free clamping for turning. By Wolfgang Klingauf, Klingauf PR and Maren Röding, Witte

38

Hold On TightThe ‘seat belt’ for cutting tools allows heavy metal removal. By Wolfgang Klingauf, k+k-PR, for Haimer

40

The Search For A Better Ecological Solution

first Cut

Strict regulations and economic reasons have resulted in the rise of the concept of machining without metalworking fluids. By Dr Moshe Goldberg, Iscar

26

teChnology insightsGreen Shipbuilding: Benefiting The Builders & The EnvironmentThe green measures imposed on shipbuilders not only help in reducing harmful emissions but also act as a sustainable building measure, which results in the production of more reliable ships. By Amreet Singh

32

Transforming Business Through Digital ManufacturingFrom automotive and aerospace, to fabrication and assembly, even shipbuilding, companies require the right digital infrastructure to define, plan, create, monitor and control all processes. By Samson Khaou, Dassault Systèmes (ASEAN)

34

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Best choice.We support you.Laser | Bending | Waterjetbystronic.com

ENQUIRY NO 195

ASIA PACIFIC METALWORKING EQUIPMENT NEWS (M.E.N.) is published 8 issues per year by Eastern Trade Media Pte Ltd1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 Tel: (65) 6379 2888 Fax: (65) 6379 2806.

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

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

Federation of Asian Die & Mould Associations (FADMA)

China Machine Tool & Tool Builders'

Association (CMTBA)

Indian Machine Tool Manufacturing

Association (IMTMA)

Federation of Malaysian Foundry & Engineering

Industry Associations

Singapore Precision Engineering and Tooling Association (SPETA)SPETA

inDustryendorsements

Machine Tool Club(MTC)

IMPORTANT NOTICETHE CIRCULATION OF THIS MAGAZINE

IS AUDITED BY BPA WORLDWIDE.

THE ADVERTISERS' ASSOCIATION

RECOMMEND THAT ADVERTISERS

SHOULD PLACE THEIR ADVERTISEMENTS

ONLY IN AUDITED PUBLICATIONS

metalworking equipment news Nov-Dec 2011

ContentsNovember-December 2011

featuresWalter In Asia The CEO of Walter Asia Pacific talks to Asia Pacific Metalworking Equipment News in this exclusive interview to dissect the company’s performance in the past year. By Joson Ng

50

58 events & exhibition

80pg08 Business News74 Product Finder

79 Exhibition Programmes80A Product Enquiry Card

regularsRefer to Advertising Index

For Advertiser's Enquiry Numbers

Newline And Makino Technology Center Grand OpeningFive years in the making, the technology centre in Malaysia opened to much fanfare and optimism. By Joson Ng

52

Moving ForwardKennametal recently moved its office in Singapore, and Asia Pacific Metalworking Equipment News spoke to John Chang, the company’s VP and MD of Asia in an exclusive interview to find out more about the move and also the company’s plans for Asia. By Tjut Rostina and Joson Ng

54

Taiwan Association of Machinery Industry (TAMI)

inDustry foCusAutomation: Cutting Away ConstraintsIt is now possible to process G-code directly with the integrated CNC kernel on the robot controller. By Alexander Bay, Kuka Roboter

42

Sensible Use Of Sensors In IndustriesShahnawaz Abdul Hamid investigates the use of sensors that improve safety in the metalworking industry.

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• Special Report: From The World Of Metalworking

• CAD/CAM Partnership Continues To Blossom With Product Launch

SeaCAD and Dassault Systèmes SolidWorks release the 2012 version of the design software. By Shahnawaz Abdul Hamid

• Event Review: Vietnam Manufacturing Expo 2011

• Event Review: Wire/Tube Southeast Asia 2011

ENQUIRY NO 111


editor’snote

EastErN traDE MEDia PtE LtDPublished by:

(a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

Head Office & Mailing address:1100 Lower Delta Road,EPL Building #02-05, Singapore 169206 Tel: (65) 6379-2888 Fax: (65) 6379-2806

etm EasternTrade Media Pte Ltd

an Eastern Holdings Ltd company

EastErn HOLDInGs LtDExEcutIvE BOarD

managing director Kenneth Tan

editor Joson Ng [email protected]

business development manager Randy Teo [email protected]

editorial assistant Sharifah Zainon [email protected]

graphic designer Jef Pimentel [email protected]

circulation executive Irene Tow [email protected]

contributors Dr Moshe Goldberg Augustine Quek Amreet Singh Samson Khaou Robert Wang Wolfgang Klingauf Maren Röding Alexander Bay Shahnawaz Abdul Hamid Tjut Rostina

board of consultants Wäinö a Kaarto AB Sandvik Coromant

Dr Moshe Goldberg ISCAR

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

Printed in Singapore by Fabulous Printers Pte Ltd

MICA (P) No. 053/06/2011PPS 840/09/2012 (022818)ISSN 0129/5519

chairman Stephen Tay

group executive director Kenneth Tan

financial controller Robbin Lim

A quick flip through the financial section of any major newspapers today and what you are likely to find is probably news that make you cringe in your seat. From the impending bankruptcy of an entire nation to the imminent reduction in credit ratings in several others, the world economy seems to be heading towards more uncertainties.

Instead of threading carefully with a tinge of trepidation, the people in the metalworking industry are predicting great things in the coming year. Even the more conservative ones feel the current positive climate should continue well into 2012.

The general consensus among those in the metalworking industry is that the financial cycle runs differently from the business cycle. Despite some European countries operating dangerously in the red, the mood at EMO Hannover was entirely different. Good crowds and solid results defied the financial wet blanket draped across the Euro Zone.

Emphasising the point, Dr

Wilfried Schäfer, executive director of the German Machine Tool Builders’ Association said: “The machine tool industry continues in full swing. In the course of the past six days (at EMO), the order volume reached a minimum of €4.5 billion (US$6.0 billion).”

Though the financial and business cycles are not entirely independent of each other, there is no reason to panic as of now. This overall positive mood is summed up nicely by Klaus Ludwig, VP of Hwacheon Machine Tool.

He pointed to the orders currently available in the market and there are no pertinent signs or talk that indicate an impending downturn. Even if there were to be one, he feels it is important to remain positive but till then, there is no reason to hold back on developments or investments because businesses go on, even in the worst of times.

Finally, as the year slowly winds down to a close, we at Asia Pacific Metalworking Equipment News would like to wish you happy holidays and a fantastic year ahead.

Joson NgEditor

Let’s Bank On

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Walter AG Singapore20 Science Park Road, #01-04A / 05, Teletech ParkSingapore Science Park II, Singapore 117674

www.walter-tools.comwww.youtube.com/waltertoolswww.facebook.com/waltertools

wal-0001-015_AZ_PRODUCT_Turning_T-TecSilver1_SPG_205x275_RZ.indd 1 06.09.11 15:25

ENQUIRY NO 170

Bystronic Celebrates 25 Years Niederönz, Switzerland: The supplier of complete solutions for the processing of sheet metal is this year celebrating its 25th anniversary. It was in the light of this that during a three-week period in September, the Bystronic Competence Days were held at its headquarters in Niederönz. During the total of 11 individual events, some 1,000 guests from almost 50 countries participated.

The prog ra m consisted of technical presentations and

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discussions about the current issues in the field of sheet metal processing, of live presentations, and a tour of the production plant.

At t he va r ious event s , Bystronic’s CEO Ferdi Töngi expressed his opinion that the company will continue to maintain its track record, but at the same time pointed out that challenges will not decrease in the future. “In a changing environment, our task will continue to be the satisfaction of the requirements of a discerning

group of customers,” said Mr Töngi.In Niederönz the prime output is

laser and waterjet cutting systems for the worldwide market. Other development and production centres are based in Gotha (Germany), Tianjin (China) and Brasov (Romania). Gotha and Tianjin share the responsibility for the production of pressbrakes. Tianjin is additionally responsible for the manufacture of laser cutting systems for the Chinese market. In Brasov, on the other hand, secondhand machines are refurbished for sale on the secondhand market. Additionally, the company has sales and service subsidiaries in 25 countries.

www.equipment-news.com


Businessnews

ENQUIRY NO 122

CBN Engineering Sdn. Bhd.No, 20 Jalan 51/205Highway Centre, 46050, Petaling Jaya Selangor Darul Ehsan, MalaysiaTel: 60-3-77852333 • Fax: 60-3-77883318E mail: [email protected]

Sutton Tools Singapore Pte LtdNo. 1, Ubi View#03-18 Focus OneSingapore 408555Tel: +65 6745-6388 • Fax: +65 6745-5080E mail: [email protected]

Represented by:

German Qualityfrom Europe s No.1!

www.hoffmann-group.com

PT. Rukun Sejahtera TeknikKomplek Ruko Glodok Jaya No. 80-81Jl. Hayam Wuruk Jakarta 11180, IndonesiaTel: 021-628 1615 (Hunting) • Fax: 021-626 5559E mail: [email protected]

Engineering Innovation Co.,Ltd.3/279 Moo 9 Suvintawong Rd.Lumpakchee NongchokBangkok 10530, ThailandTel: 662-9984045; 662-5435734 • Fax: 662-9984047E mail: [email protected] [email protected]

Bon Industrial Sales35 Macopa St., Quezon City, PhilippinesTel: 781-2740; 749-3672; 740-0458 • Fax: 712-4771E mail: [email protected]

Manila Branch:554 Rizal Ave., Cor. Raon St.Sta. Cruz, Manila, PhilippinesTel: 734-2740; 733-1532 • Fax: 733-1534; 733-1569

■ 50.000 quality tools■ More than 500 leading brands■ The System Partner – always by your side■ Exclusive premium brand GARANT

EMO Hannover Stimulates Business In The Machine Tool Industry

Hannover, Germany: Staged under the motto of ‘Machine Tools & More’, the six-day event in Hannover featured the latest machinery, solutions and services for every aspect of metalworking. Some 2,037 exhibitors from 41 different nations took part in the event.

“The machine tool industry continues in full swing. In the course of the past six days, the order volume reached a minimum of €4.5 billion (US$6.1 billion),” said Dr Wilfried Schäfer, executive director of the German Machine Tool Builders’ Association (VDW), the organiser of the event. “Against the backdrop of an upswing in orders over the past few months, EMO’s positive outcome means an even stronger market footing for exhibitors,” said Dr Schäfer.

With nearly 40 percent of all attendees coming from abroad, exhibitors were delighted with the event’s international turnout. “ T he st rong inter nat iona l

appeal makes the show unique throughout the industry, and is a key factor in its success,” said Dr Schäfer, adding that he saw the show as a reflection of ongoing globalisation.

This accounted for a shift in foreign attendance, with an increase of more than 6.5 percent in the ratio of foreign visitors from outside Europe, particularly Asia and South America, which in turn led to record-breaking figures for the duration of stay per visitor: “One out of every four attendees spent more than three days at EMO 2011,” Dr Schäfer emphasised.

Among foreign visitors, this figure even reached 75 percent. Around half of all attendees said their investments were targeted at expanded capacities, while 20 percent were planning to make first-time purchases of machine tools. The show attracted some 140,000 visitors from more than 100 countries over six days.

Vero Software & Planit Holdings Merge

Gloucestershire, UK: Vero Software, a provider of CAD/CAM/CA E solutions for the tooling industry, has merged w i t h P l a n i t H o l d i n g s , a developer of CAD/CAM software for the production engineering, sheet metal, metal fabrication and woodworking sector.

The combination of Vero and Planit creates the third largest CAD/CAM vendor — only behind Dassault Systèmes and Siemens PLM*. The merger o f t he t wo o r ga n i s a t io n s will provide the platform to build even stronger products through enhanced development capabilities and further extend a growing inf luence on the global market. * Source : CIMData

India: Ford India has opened its 76,000 square feet (7,060 sq m) Parts Distribution Centre near Gurgaon in Haryana to support its growing sales. Despite challenging market conditions, the company’s sales have increased by 35 percent so far this year. Earlier, the company broke ground for its new plant in Sanand, Gujarat.

Ford India Breaks Ground For Second PlantThe company sold 90,612

wholesale and export vehicles from January to September 2011, compared to 67,253 units sold during the same period last year – a 35 percent increase year-over-year.

In September 2011, the company had combined wholesales and exports of 10,270 units.

T he comp a ny ha s a l so inaugurated a warehouse for spare parts in northern India near Gurgaon in Haryana state. To support its growing sales, the company is set to expand its sales and service network to more than 200 outlets in 120 and beyond cities by the end of this year.



businessnews

Make a lot more parts in a lot less time with a high-performance Haas Drill/Tap Center. The DT-1 swaps tools in 0.8 seconds, and its 15,000-rpm spindle allows rigid tapping to 5000 rpm, with up to 4-times retract speed. And, 2400 ipm rapids and 1 G accelerations combine to reduce cycle times even further. All this – for a great price.

Simple. Innovation.

Singapore DKSH Technology Pte Ltd. Singapre Phone: +65 6471 9248 Malaysia A Division of SPC Machinery Sdn Bhd Kuala Lumpur | 603 5569 5901 Penang | 604 3801581

Haas Factory OutletThailand A Division of Machine Tech Co., Ltd. Bangkok | 66 2 726 7191 Chonburi | 66 3811 2700Philippines A Division of Gaylan Technologies Manila | 63 2 915 8725

Vietnam Bao Son Technology Production & Trading Co. Ltd. Ho Chi Minh City | +84 8 38 44 71 92 Indonesia Pt Balindo Inti Machinery Jakarta Utara | +6221 56982718

Time is money.g e T m o r e o f b o T h .

Typical Haas Ingenuity.Haas Automation I HaasCNC.com | USA MadeECO CNC

ENQUIRY NO 189

Gildemeister Sold 847 Machines At EMO

Bielefeld, Germany: With order intake of €207.6 million (US$282.7 million) and 847 machines sold, Gildemeister takes positive stock of the EMO 2011. This trade fair was the most successful EMO of all time for the company with the highest order intake at a trade fair in its history. Moreover 5,746 follow-up offers could be triggered, building the basis for a successful order intake within the next few months.

The company also exhibited energy solutions and presented live how companies can generate and even store a part of their energy needs themselves by solar and wind technology.

SolidWorks 2012 ReleasedSingapore: DS SolidWorks has unveiled the SolidWorks 2012, a 3D design solution that enables users to work more efficiently and have the data they need to make better design decisions t h r o u g h o u t t h e p r o d u c t development process. The 20th release of the CAD software provides more than 200 new functions to users.

B e n e f i t s t a k e s h a p e throughout the software with a variety of improvements in areas such as assembly and drawing capabilities, built-in simulation, design costing, routing, image and animation creat ion and product data management that will positively impact design teams each and every day.

“SolidWorks 2012 focuses on the areas that will help o u r c u s t o m e r s d r i v e their businesses to higher productivity and profitability,” said Sharon Toh, GM, South Asia for SolidWorks.

Nissan Sets Global Benchmark Yokohama, Japan: Nissan Motor announced the world's first* ultra high tensile strength steel rated at 1.2 gigapascals (GPa) which is highly formable, to the extent that it can be used for cold pressing structural body parts. To be deployed globally in models across the company's lineup from 2013, it will reduce vehicle body weight by up to 15 kg, representing a step in improving environmental impact as well as driving performance.

Developed in collaboration with Nippon Steel Corp and Kobe Steel, the ultra high tensile strength steel will be used for centre pillar reinforcements, front and side roof rails and other key structural components. By exceeding the

structural body performance of previous materials with less thickness, the steel will contribute to increased dynamic performance and fuel economy.

T he mate r ia l w i l l a l so contribute to lower total costs including that of manufacturing, as superior cold-pressing formability supports mass production.

This breakthrough overcomes significant obstacles. Until now, high tensile strength steel involved a critical trade-off: increased strength came with increased rigidity and a consequent reduction in press formability. Traditionally, only high tensile steel rated up to 980 MPa can be used in cold pressing structural body parts, requiring complex press work.

The 1.2 GPa steel, combined with Nissan-developed advances in welding methodology, overcomes both obstacles.

Development of the material was realised by a breakthrough in the ability to control its structural formation at the sub-micron level in combining hard and soft layers to achieve both strength and formability.

Once t he mater ia l wa s d e v e l o p e d , e x t e n s i v e experimentation was required to develop an optimal spot-welding methodology. This has been achieved with a proprietary process that involves optimisation of welding pressure, current volume and power distribution.* For use as structural body parts in cold pressing



Businessnews

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Klas Forsström Is The New President Of Sandvik CoromantKlas Forsström has taken over the position of president of Sandvik Coromant.

Mr Forsström has been with the Sandvik Group for about 17 years, mostly at Sandvik Coromant. His work has included leading positions in R&D, product development, marketing, business development and sales. Most recently he held the position as president of Sandvik Hard Materials.

APPOINTMENTS

Klas Forsström

John J Mroz

Berry Metal Names John Mroz As VP Of Sales & Marketing

Be r r y Me ta l Company ha s announced the addition of John J Mroz as VP of Sales and Marketing.

Mr Mroz will be responsible for providing customers with technical support and service in the use of injection lances for steelmaking. Prior to joining the company, he was employed by Heraeus Electro-Nite Company as sales manager, steel products and by LTV Steel Corp as part of their Steel Producing Operations Management team.

Fraunhofer: Laser Polishes Components To A High-Gloss FinishGermany: Fraunhofer researchers will be presenting a machine tool that uses laser polishing to give even complex 3D surfaces a high-gloss finish. In collaboration with the companies Maschinenfabrik Arnold and S&F Systemtechnik, researchers at the Fraunhofer Institute for Laser Technology ILT have developed a type of machine tool, which can polish both simple and complex surfaces using laser beams.

“Conventional methods remove material from the surface to even it out. Our method is different: It uses a laser to melt a thin surface layer roughly 20 to 100 µm deep,” says Dr-Ing Edgar Willenborg, section head at the ILT. “Surface tension — a property that applies to all liquids — ensures that the layer of liquid metal solidifies evenly.”

Depending on the material, the project team can already produce surfaces with an average roughness (Ra) of between 0.1 and 0.4 µm. “Hand polishing can still get better results than that,” Dr Willenborg admits, “but the point is that in many applications — for example moulds for glass-making, forming and forging tools — a medium-quality surface is all that is needed.”

The machine has the potential to save considerable amounts of time and money in these areas:

The machine polishes surfaces up to 10 times faster than a hand polisher and is an option for serial production and for polishing small batches.

How it Works• Laser melts thin surface layers• Surface tension ensures the layers

of liquid metal solidifies evenly

NX 8 EnhancedSingapore: Siemens PLM Software has announced the release of NX software, the company’s integrated computer-aided design, manufacturing and engineering a n a l y s i s (C A D/C A M /C A E ) solution. The software includes enhancements to its CAE offering — including its NX Nastran software for solving simulation problems.

NX 8 for simulation offers solutions for optimisation and multi-physics analysis, along with

methods for analysing complex assemblies. Enhancements to NX Nastran include improvements in nonlinear and dynamic analysis, as well as increases in computational performance and modeling ease-

of-use. The new and existing functionality in NX CAE helps reduce the time spent preparing and solving analysis models by up to 70 percent when compared to traditional CAE tools.

Siemens PLM



Businessnews

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Flow Asia Opens New Office

Hsinchu, Taiwan: Flow Asia Corp has invested some US$500,000 (remodeling work) in an office at Hsinchu Science Based Industrial Park in Taiwan. The company is the subsidiary of Flow International Corp, which develops and manufactures ultrahigh pressure waterjet technology and also a provider of robotics equipment headquartered in Kent, Washington.

With this 1,200 sq m facility, the company has added a demonstration laboratory centre providing equipment demonstrations, application R&D and a higher standard of technical training program to continue support to associates based in Taiwan, India, South Korea, New Zealand, Australia and South East Asia.

Over the last two years, the company has established its marketing alliance relationship with local agents and distributors to expand its business in SE Asia, India, South Korea, and Australia.

Manufacturing Technology Orders Up 101 Percent From 2010USA: August US manufacturing technology orders totaled $460.61 million according to AMT — The Association For Manufacturing Te c h n o l o g y a n d A M T DA , the American Machine Tool Distributors’ Association.

This total, as reported by companies participating in the USMTO program, was down 9.4 percent from July but up 88.5 percent when compared with the total of $244.35 million reported for August 2010. With a year-to-date total of $3,439.21 million, 2011 is up 101.0 percent compared with 2010.

“Despite news reports that wider economic growth may be stagnating, the manufacturing technology industry is sustaining its momentum,” said Douglas Woods, AMT president. “With orders still up substantially over last year, there is clearly optimism within the industry as firms are seeing future growth opportunities that merit new capital investment.”

SKF Committed To Sustainability

USA: SKF announced that the company has been selected to be a member in both the Dow Jones Sustainability World Index (DJSI) and the pan-European

sustainability benchmark for the Industrial Engineering sector. The DJSI represents the leading global companies from 57 sectors in the area of sustainability.

“Sustainability is a long-term commitment for SKF and I am very proud that we have been recognised for our efforts, particularly in the areas of promoting sustainable products,” says Tom Johnstone, president and CEO.

T h e c o m p a n y d e f i n e s sustainability as SKF Care, which encompasses Business Care, Environmental Care, Employee Care and Community Care. It has a strategy called Beyond Zero, which focuses on both reducing the environmental impact of its own operations and on helping its customers reduce the environmental impact in their operations and in the use of their products.

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Businessnews

ENQUIRY NO 197

GE To Provide Power Boost For Indonesia

Jakarta, Indonesia: GE’s aeroderivative gas turbine technology has been selected for an Independent Power Plant (IPP) that will help meet an urgent need for more electricity in the rapidly growing East Kalimantan region of Indonesia.

The project also supports the Indonesian government’s initiative to increase the overall supply of reliable power for the country, where approximately one-third of the population has no access to electricity.

The company will supply two 41-megawatt LM6000-PG aeroderivative units to PT Kartanegara Energi Perkasa (KEP), owner of the Senipah Power Plant, located 70 km from Balikpapan, East Kalimantan. This will be the first installation of the technology in Asia and the second in the world, following a project at Turlock, California, which recently was commissioned.

“In East Kalimantan, which is experiencing rapid growth, the availability of a reliable electricity supply can be a catalyst for the development of new industries, housing and other commercial enterprises. The availability of gas in the Senipah region makes electricity production very cost-competitive. In addition, the project aligns with one of the power plan targets set by the government, which is to have all of the new IPP plants in Indonesia based on non-oil fuels, such as coal, natural gas, geothermal, hydro and solar,” said general (Ret) Luhut B Pandjaitan, majority owner of PT KEP.

In simple-cycle operation, the Senipah facility will generate 82 megawatts of power, with a plant availability of 85 percent. The company plans to upgrade the Senipah plant from simple cycle to a combined-cycle operation in the next phase of development, scheduled for 2013, which will enable the facility to deliver even higher power output and efficiency.

Objet Makes Materials Available In More Territories & 3D Printers

Rehovot, Israel: Objet has announced that the 3D printing materials it released in the first half of 2011 are now available on additional 3D printing platforms and in more territories.

Objet VeroWhitePlus, a rigid white material with enhanced dimensional stability is now available worldwide for all Objet 3D printers. Objet VeroClear, a water-clear transparent material is now available for all Objet Eden and Connex 3D printers. Finally, Objet ABS-like Digital Material (RGD5160 -DM), a composite material for simulating ABS-grade engineering plastics is now available for all Objet Connex 3D printers, including the multi-material Objet260 Connex.

Commenting on the new material availability, Zehavit Reisin, head of Consumables Line of Business at Objet said: “By widening our material availability to additional platforms and regions we are constantly enhancing the prototyping capabilities for all our customers on all our platforms, both new and old.”

Posco In Agreement With ShellSouth Korea: Posco signed a l o n g - t e r m E n t e r p r i s e Framework Agreement with m u l t i - n a t i o n a l o i l m a j o r company Shell on the thick steel plate supply for offshore plant. Accordingly, the company will

be the sole steel plate supplier for various structures on all the offshore plant projects ordered by Shell until 2016, with an opp or tu n it y to renew t he contract for another five years depending on performance.

Through this agreement, Posco plans to secure global leadership in the steel market for offshore structures and become a global steel major company by developing high value-added steel for energy.



Businessnews

www.hexagonmetrology.com

MalaysiaHexagon Measurement Technologies Sdn.Bhd11 Jalan PJS 7/21 (758921-A) Bandar Sunway 46150 Petaling Jaya, Selangor, MalaysiaTel : +603 5632 8900Fax : +603 5632 [email protected]

ThailandHexagon Metrology (Thailand) Ltd.3 Soi, Bangna-Trad 34, Bangna-Trad Rd.Bangna, Bangna, Bangkok 10260Tel : +66 2361 3695 to 9Fax : +66 2746 [email protected]

SingaporeHexagon Metrology Asia Pacific Pte. Ltd.2 Woodlands Sector 1#01-10 Woodlands Spectrum 1Singapore 738068Tel : +65 6463 6242Fax : +65 6463 [email protected]

VietnamHanoi Representative Office5th Floor, Regus Hanoi Press Club,59A Ly Thai To Street, Hoan KiemDistrict, Hanoi, S.R. of VietnamTel: +84 4 3936 7935Fax: +84 4 3936 [email protected]

ENQUIRY NO 142

MACHINE TOOL INDONESIA 2011Stand No: 3417 Nov 30 - Dec 3, 2011Jakarta, Indonesia

LiuGong Opens APAC HQ In Singapore Singapore: LiuGong, a wheel loader manufacturer, has opened its Asia Pacific headquarters in Singapore. The 45,000 square feet (4,180 sq m) facility will support corporate functions and serve as the company’s sales hub, technical support and trading hub for Asia Pacific, excluding China. The facility is also the first spare parts distribution centre for Southeast Asia and the Pacific islands.

The company expects its Asia Pacific headquarters in Singapore to generate more than US$50 million in revenues in the first year of operations, with expected annual growth rates of 30 percent. The office will serve Southeast Asia, New Zealand, Papua New Guinea and other islands in Pacific.

Toyota To Start Vehicle Exports From IndiaToyota City, Japan: Toyota Motor Corp (TMC) announces that its production and sales subsidiary in India, Toyota Kirloskar Motor ( TKM ), is to begin export of the ‘Etios’ series sedan and hatchback to South Africa in March 2012. Although TKM has been manufacturing vehicles for sale in India since 1999, exports of the Etios will mark Toyota’s first vehicle exports from India.

In line with its Global Vision released in March of this year, TMC is positioning emerging markets as a priority and is aiming to increase sales in those markets. To match the growth of India’s automobile market, TKM’s annual production capacity is scheduled to increase from its current 160,000 vehicles to 310,000 vehicles in 2013. The start of vehicle exports from India represents an expansion beyond India’s domestic market for TKM and a commitment by TMC to developing India into a global production and supply base for vehicles and transmissions.

Delcam Summit Celebrates 15 Years & 2,000 Customers For China Subsidiary

Zhuhai, China: Delcam held its a n n u a l A s i a n Technical Summit in Zhuhai, China, from September 6 – 8, 2011 as part of the celebrations o f t h e 1 5 t h a n n ive rsa r y o f the founding of its Delcam China subsidiary.

The summit is held each year to

present the latest developments from the company to its customers, academicians and the technical media in the region. This year’s meeting, which was sponsored by HP, was the 11th in the series and the second to be held in China. Close to 200 delegates attended, mainly from China but also from 10 other countries.

The summit featured presentations on the latest versions of the company's range of CAM systems before their official launch at the EMO exhibition. Updates were also included on the other software in the company's portfolio, including the company’s design and inspection programs, plus the dedicated software for the footwear, orthotics and dental industries.

The summit comes at a time when the company is setting new records for its business in China. Sales of software have increased by more than 50 percent in the first half of this year compared to the first six months of 2010.



Businessnews

www.bilz.de

SETTING THE STANDARDwww.bilz.de

SETTING THE STANDARDwww.bilz.de

SETTING THE STANDARD

ENQUIRY NO 046

LMT Asia Pte Ltd1 Clementi Loop #04-01, Clementi West Distripark129808 SingaporeTel: (65) 6462 4214 Fax: (65) 6462 4215Email: [email protected]

Airbus: More Aircraft Needed In RussiaAerospAce

Passenger traffic in Russia is expected to increase at a rate of 5.6 percent per year on average over the next 20 years.

Toulouse, France: Russian carriers will need more than 1,000 passenger aircraft over the next 20 years in response to the strong traffic growth, according to the latest Airbus Global Market Forecast (GMF).

The forecast ranks Russia sixth in the top 10 countries for passenger aircraft demand after US, China, India, Germany and UK. The Russian passenger aircraft fleet of 100 seats or more is expected to grow strongly from 519 aircraft in service in 2010 to 1,058 by 2030. This means that over the next 20 years Russian airlines will need 1,006 aircraft, valued at US$95 billion to meet fleet growth as well

Paris, France: WorldAutoSteel, the automotive group of the World Steel Association, pressed the need to shift the basis of vehicle emissions regulations from tailpipe emissions to a total Life Cycle Assessment (LCA). LCA considers emissions from all aspects of a vehicle’s life, from material production to end-of- life -recycling, and shou ld play a n impor ta nt role in current regulations in discussion around the world.

“When vehicle emissions assessment is focused solely on emissions produced during the driving phase (tailpipe), this encourages the use of g re e n hou se ga s - i n te n s i ve

Steel Industry Calls For Shift In Vehicle Regulationsm ate r ia l s i n a n e f for t to reduce vehicle weight and fuel consumption,” said Cees ten Broek, WorldAutoSteel director. “However, this may have the unintended consequence of increasing greenhouse gas emissions during the vehicle’s total life cycle.”

Alternative materials, such as aluminium, magnesium and carbon fibre, produce emissions during their manufacture that are five to 20 times greater than steel.

T h e U S i s c u r r e n t l y examining further fuel economy and emissions requirements for 2017-2025. And while the mid-term review of EU legislation on

emission standards for new cars is expected for next year, in many Asia Pacific countries vehicle efficiency standards also are being assessed. In light of these developments, the industry is calling for a shift from tailpipe emissions regulations to a life cycle assessment approach that effectively measures the carbon footprint of today’s and future cars.

“Legislation that focuses only on one part of the vehicle’s life cycle will become immediately out of date as the electric vehicle becomes more prominent on the road,” said Mr ten Broek. “We are only shifting the problem to other vehicle life cycle phases.”

as aircraft replacement. These additional aircraft will include some 839 single-aisle aircraft which are currently prominent in the region’s fleet, 145 wide-bodies and some 22 Very Large Aircraft (VLA) to satisfy strong international travel growth.

The growing demand for aircraft is the consequence of the increase of passenger traffic in Russia driven by consistent economic growth and

All New, In Bahasa Indonesia

IndonesIa

the ongoing airline consolidation. According to Airbus forecast,

passenger traffic in Russia is expected to increase at a rate of 5.6 percent per year on average over the next 20 years, which is much faster than the world average of 4.8 percent. The biggest traffic growth is expected to be on international destinations from Russia to Asia-Pacific (+7 percent) and CIS regions (6.7 percent).



businessnews

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With more than 50 years of experience in the development and production of high-performance tools, WIKUS is Europe‘s largest manufacturer of band saw blades and global technology leader in metal sawing.Precision band saw blades from WIKUS represent innovation and productivity with the objective of higher effi ciency for the customer.

WIKUS is offering you:· Innovative band saw blades, optimised for all kinds of sawing tasks· Competent and individual customer service in the entire sawing process· Cutting tests directly on location of the customer

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WIKUS_AnzAsien_09|11_rz.indd 2 16.09.11 14:21

ENQUIRY NO 187

ST Aerospace Unveils Engine Facility In XiamenSingapore: ST Aerospace and Xiamen Aviation Industry Co (XAICO) announced that their joint venture company ST Aerospace Technologies (Xiamen) Company (STATCO) has unveiled its engine Maintenance, Repair and Overhaul (MRO) facility in Xiamen, China.

Boeing Opens China Service Centre In BeijingBeijing, China: Boeing opened a service centre in Beijing to provide enhanced product support to China’s growing commercial aviation industry.

“We are bringing Boeing’s world-class airplane services and support closer to our China customers, providing them a competitive edge in their markets,” said Lou Mancini, senior VP of Commercial Aviation Services.

The service centre comprises qualified pilots and experts in flight operations, spare parts and maintenance engineering who are serving in airlines in China. With Beijing-based experts who are fluent in Chinese and knowledgeable about customers’ concerns and issues, the team will enhance the company’s day-to-day support of more than 800 Boeing airplanes currently in service in China.

The service centre also will work closely with the company's engineering teams in Seattle and Long Beach, on unique customer requirements and to develop products and services to further the reliability, efficiency and safety of the Chinese commercial airline fleet.

The company projects that China’s demand for air travel will grow at an annual rate of 7.6 percent during the next 20 years, creating the need for more than 5,000 new airplanes by 2030.

AAIS Launches Its Aerospace Productivity Drive

Singapore: The Association of Aerospace Industries (Singapore) (AAIS) launched its aerospace productivity drive at the Singapore AeroIndustry Annual Meeting, held at the Singapore Aviation Academy.

Themed ‘AeroProductivity — it’s everyone’s business’, AIAM 2011 provided the ignition for the association’s drive for higher productivity this coming work year. The event included a conference focusing on productivity in the areas of human capital, technology adoption, processes and capabilities upgrading, as well as an AeroProductivity showcase.

From initiatives which were undertaken to understand the manpower gaps and needs of the industry in the Association’s 2010 work year, the AAIS affirmed the need for companies to focus on enhancing manpower capabilities to increase productivity in order to maintain Singapore’s sustainability as an aerospace hub.

In the Singapore Aerospace Manpower Study commissioned by the association in 2010, it was found that the industry’s average revenue per employee in 2009 was about S$439,000. The study revealed that this is expected to grow by about 13 percent, to S$496,000, by 2015. Productivity growth rates differ by subsectors, with avionics and manufacturing leading the pack at an increase of S$425,000 and S$252,000 per employee respectively.

At AIAM 2011, three memorandums of understanding were also signed. These would seal partnerships that will lead to the implementation of initiatives that aim to enhance workforce, organisation, and industry capabilities. The event was graced by Guest-of-Honour, minister for Transport, Mr Lui Tuck Yew.

AErOSPAcE

The US$78 million facility has a capacity to support up to 300 engines annually. It will initially provide MRO and total support for the CFM56-7B and CFM56-5B series of engines that power narrow-body aircraft such as Boeing 737 next generation aircraft and the Airbus

A320 family of aircraft. The facility is located on a 38,620

sq m plot of land, near Xiamen Gaoqi International Airport in Xiamen. With a build-up area of 29,860 sq m, it houses an engine shop designed to operate with a streamlined production flow system.

Cylonka bsg, Poland



Businessnews

UCIMU: Orders Grew By 58.2 Percent In The Third QuarterItaly: The machine tools index of orders has grown significantly with an increase of 58.2 percent in the third quarter 2011 compared to the period of July-September 2010, for an absolute index value of 73.9 (base 2005=100). This emerges from the survey drawn up by the Studies Department of UCIMU-Sistemi Per Produrre, the association of Italian machine tools, robots and automation manufacturers.

The positive trend, which started at the beginning of 2010, consolidates the recovery of the Italian industry in this sector that, as emerges from the survey, has obtained positive feedback both from the domestic and the foreign markets.

For the first time, after four consecutive quarters of decrease, the index of orders for the domestic market sets off again marking an increase of 96.8 percent. Nonetheless the absolute value is still low reaching a quota of 30.3.

The performance of the orders placed in foreign markets was excellent, marking an increase of 32.3 percent compared to the same period of the previous year, for an absolute vale of 114.3.

Giancarlo Losma, UCIMU president, says: “Despite the particularly uncertain context, the Italian industry of the sector has recovered a good share of the ground lost during the 2009 crisis, by strongly increasing its activity in foreign markets.”

During the first six months of the year machine tools exports increased by 27.8 percent compared to the same period of 2010. Deliveries grew in Germany (+67.3 percent), which regains its position as main outlet market for the Italian products of this sector. Sales in China slightly decreased (-1.3 percent) Positive results for deliveries to United States (+100.9 percent), France (+6.3), Brazil (+63.4 percent), India (+40 percent), Russia (+8.7 percent) and Turkey (+113.1 percent).


25Nov-Dec 2011 metalworking equipment news

Businessstatistics

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In the current, competitive manufacturing environment, end users of metalworking fluids are looking to reduce

costs and improve productivity. T he cost s o f ma inta in ing and eventually disposing of metalworking fluids, combined with health and safety concerns, have led to a heightened interest in either eliminating metalworking fluid altogether or limiting the amount of metalworking fluid applied. The former process is known as dry machining while the latter is referred to as near-dry machining or minimum quantity lubrication.

During machining, 70 percent of the generated heat originates from plastic deformation of the workpiece. The remaining

30 percent of the heat arises from friction at the chip/tool and tool/workpiece interfaces.

Without metalworking fluid, excessive tool wear and inferior surface finish may occur during machining because the use of fluids during machining can result in effective lubrication and cooling at the tool/workpiece interface, as well as effective flushing of the chips.

T a k i n g e c o n o m i c a l considerations into account, manufacturers are turning to dry or nearly dry machining solutions, with the intention to benefit from coolant cost savings or improved tool life.

Dry Machining Supported By Substrate & Coatings The method of dry/near-dry machining is backed up by some of the technology available in cutting tool materials, such as advanced coated carbide, ceramics, cermets, cubic boron nitride, and polycrystalline diamond.

For coating, the technologies comprise coatings based on Titanium Nitride (TiN), Titanium Carbon Nitride ( TiCN ) and Titanium Aluminium Nitride (TiAlN), which were developed to withstand more severe operating conditions.

The TiAlN, in particular, has emerged as a coating that exhibits thermal stability up

Regulating Metalworking Machining Fluids

Metalworking machining fluids have undergone intense regulatory scrutiny

throughout the last two decades, led by the United Auto Workers in USA who

petitioned the Occupational Safety and Health Administration (OSHA). Their aim

is to lower the permissible exposure limit for metalworking fluids from 5.0 mg/m3

to 0.5 mg/m3.

Consequently, OSHA established the Metalworking Fluid Standards Advisory

Committee (MWFSAC) in 1997, which developed specific standards and guidelines

related to metalworking fluids.

In its final report in 1999, MWFSAC recommended that the exposure limit be 0.5

mg/m3 and that medical surveillance, exposure monitoring, system management,

workplace monitoring and employee training are necessary to monitor worker

exposure to metalworking fluids.

Enquiry No. 8001Turn to page 80a or log on to www.equipment-news.com to enquire

Ecological SolutionBetter

ForASearchThe

Strict regulations and economic reasons have resulted in the rise of the concept of machining without metalworking fluids. By Dr Moshe Goldberg, marketing technical advisor, Iscar

FIRSTcuT

Nov-Dec 2011 metalworking equipment news


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to a temperature of 900 deg C. The coating displays a very low friction coefficient, enabling its use under almost all dry machining conditions.

Dry Machining LimitationsWhile the technology to carry out dry machining has improved, metalworking fluids are still needed to ensure that higher speeds and feeds can be used and to ensure that the surface f inish of workpieces meets expectations.

Certain dry machining trials have indicated that new tool coatings have been helpful. However, the absence of cutting fluids cannot solve the problem of dry machining at a rate needed to achieve high productivity.

Industry has not seen any increase in dry machining beyond its current use for cast iron. Dry machining, presumably, cannot overcome the positive benefits of using metalworking fluids. The tradeoff in using metalworking fluids is normally a compromise between fluids disposal costs and productivity.

Near-Dry MachiningNear-dry machining incorporates the application of small amounts of lubricant to the tool/workpiece interface. The key to the process is atomising the lubricant, with air as the carrier, into a fine aerosol.

The lubricants used are vegetable oil-based products, which are priced relatively lower than conventional cutting fluids (synthetic oils). While the price is higher than most coolants used in conventional applications, the consumption rate is minimal.

I n ne a r- dr y mach in ing , though the lubricant is applied directly through a nozzle pierced through the cutting tool, the coolant applied by the flooding method cannot be used in near-dry machining. That brought about the development of the

minimum quantity lubrication technology, a system, which del ivers a ir and oi l mixed together as closely as possible to the cutting tool.

Tria ls using this system have indicated that near-dry machining demonstrates most effective performance on cast a luminium alloys and steel alloys in various metalworking

operations such as turning, milling and hole making.

While dr y and near- dr y machining will not, in the near future, replace wet machining, these two techniques will provide cost-effective alternatives in niche applications. MEN

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GLUEING

PLASMACUTTING

POLISHING

SPOT WELDING

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ARCWELDING

Welding, Cutting, Stamping, Bending, drilling, joining, milling, handling, monitoring, measuring, folding, polishing pot lids, sharpening knives. No matter what processes are to be mastered, KUKA has a solution for the metal industry.The versatility of KUKA robots makes them interesting for any type of metalworking application.

KUKA ROBOT AUTOMATION (M) SDN BHDNo. 5, Jalan BP 4/9, Bandar Bukit Puchong, 47120 Puchong, Selangor, MalaysiaTel : +60(0)3 8063 1792, Fax : +60(0)3 8060 0631, Email: [email protected], Website: www.kuka.com.my

THAILAND OFFICE111/1, Moo 12, Rachatheva, Bangplee Samutprakarn,10504, ThailandTel : +66(0) 2312 4954, Fax : +66(0) 2750 4399, Email: [email protected], Website: www.kuka.com.my

FIRSTcuT



Metalworking processes such a s cut t ing, grinding and milling, involves materia l

removal primarily through plastic deformation and/or friction. Most of the energy used in the processes is dissipated as heat. Therefore, a common practice in metal machining is to use a range of oils and liquids known as metalworking fluids to reduce the amount of heat in the cutting zone, reduce tool temperature and increase tool life.

In addition to cooling, metal cutting f luids a lso provide lubrication at the interface between the tool and workpiece, and facilitate chip removal. Faster fluid flow helps improve the quality of the workpiece by continuously removing the fines, chips, and swarfs from the tool being used and the surface of the workpiece.

Dry MachiningDry machining avoids the use of these fluids during metalworking operations. This is based on the fact that some machining operations are more amenable to dry machining. The heat generated from open-faced operations such as milling and boring can be easily managed and the resulting chips can be easily moved away from the tool-workpiece interface, reducing the need for lubrication. There are other advantages of dry machining, including the elimination of coolant and its disposal costs, thermal shocks created by flood coolant, and no danger in igniting oil coolants from hot chips.

Coatings applied to cutting tools have also improved to the extent that made dry machining possible. Instead of aluminium oxide, Titanium Nitride (TiN), Titanium Carbon Nitride (TiCN) and Titanium Aluminium Nitride (TiAlN) have been developed to withstand more severe operating conditions. The use of TiAlN has been particularly attractive for dry machining due to its thermal stability up to a temperature of 900 deg C, and its very low friction coefficient.

Coated cutting tools can be used without metalworking fluid in hard turning. This finishing process is used on steels with hardness ratings above 60 HRC at cutting speeds two to four times higher than those used for conventional cutting tools. Milling is another operation that can be run dry, because tool life can be superior under dry as opposed to wet conditions. Coolant use in milling leads to higher fluctuations in the temperature of the cutting edge as the tool goes in and out of the cut. This effect can cause thermal cracking, leading to premature tool failure by edge microfracture.

Tool l i fe a lso increases because coated carbide, ceramics, cermets, Cubic Boron Nitride (CBN ), and Polycrysta l l ine Diamond (PCD) are all brittle, they are susceptible to the chipping and breaking caused by thermal stresses. This is especially so during face-turning and milling operations, and can be aggravated by the introduction of coolant.

For continuous cuts, the high

tool tip temperatures that occur in dry turning serve to anneal (soften) the pre-cut area, which lowers the hardness value and makes the material easier to shear. As such, dry machining can be feasible and environmentally friendly in certain metalworking processes.

If dry machining processes are integrate correctly, manufacturing can realise improve work piece accuracy, reduced manufacturing cost, and other related benefits associated with high speed dry machining. Recent research reveals that trend in manufacturing is to minimise or eliminate the use of metal working fluids in manufacturing processes. Dry machining has the potential to reduce environmental pollution, health hazards, and costs associated with the use of metal working fluids.

Dry Vs Wet MachiningDry machining has certain limitations, which must be compensated for. Many stages of machining still cannot be done dry at the rate needed to achieve the productivity found with using metalworking fluids. Another reason is that the lubricious coatings on cutting tools do not last long enough to deliver the productivity needed in today’s manufacturing environment.

Removal of metal working fluids in manufacturing processes can give rise to a variety of machining problems related to heat, tool life, and chip removal. In dry machining, the functions of metal working fluids must be assumed by alternative methods. The challenge of heat dissipation without coolant requires a completely different approach to manufacturing.

Different types of material being worked also influences wet to dry machining. Eliminating coolant from steel and cast iron machining operations typically can be accomplished with little problem. Stainless steel machining can be done dry, but special attention must be given to surface finish.

Dam

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MachiningAugustine Quek explores the different issues involving wet and dry machining.

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29

Mould steels such as 4140 and 4340 can be milled and shaped with coated tooling. These alloys typically have Rockwell hardness ratings (HRC) ranging from 52 to 58 HRC. But there are limitations because metals such as titanium and stainless steel are not amenable to dry machining. Titanium has a very low thermal conductivity rating, which means that heat cannot be effectively carried away from the workpiece during the process.

Stainless steel machining typically produces long chips that extend the contact length between the chip and the tool and, as a consequence, increases the amount of heat in the cutting zone. However, dry machining of superalloys (cobalt-, nickel-, chromium-, molybdenum-, or tungsten-based alloys that are able to withstand high stress at high temperatures) may not be possible due to the extremely high amount of heat generated during metal removal operations.

As mentioned, certain types of operation are more easily done dry without the use of coolant, such as turning and milling. Most of today’s tools, such as coated carbide grades, ceramics, cermets, polycrystalline cubic boron nitride, and polycrystalline diamond, are brittle. They chip, fracture, and crack, especially in facing and milling operations where rapid repetitive thermal fluctuations lead to expansion and contraction of the cutting tool edge. Keeping the tool hot is beneficial, because a hot tool is often a tougher, more reliable tool. In this case, the presence of coolant may actually exacerbate the tool cracking problem.

Certain processes, especially closed-face machining operations such as drilling and tapping cannot be efficiently run dry because the metal chip remains in close proximity to the tool-workpiece interface. Such proximity increases the prospects of chips damaging the tool and the workpiece surface because there is no other mechanism in place for chip

removal other than fluid flow. Cutt ing f luids are of ten

necessary while drilling because they provide lubrication at the drill tip and flush chips from the hole. Without fluids, chips can bind in the hole, and the inner surface roughness can average twice as high as when machining wet. Cutting fluids also can reduce the required machine torque by

lubricating the point at which the drill touches the hole’s wall.

Dry But Not QuiteAnother practice in the use of metalworking fluids is near-dry machining. Near-dry machining involves the application of small amounts of lubricant to the tool-workpiece interface. The key to the process is atomising the

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Additive Examples

Biocides triazine compounds, oxazolidine compounds

Sulphurised or chlorinated compounds, extreme pressure additives

sulfurised fatty materials, chlorinated paraffins, phosphorus derivatives

Corrosion inhibitorscalcium sulfonate, sodium sulfonates, fatty acid soaps, amines, boric acid

Emulsifiers triethanolamine, sodium petroleum sulphonates, salts of fatty acids and non-ionic surfactants

Anti-mist agents polyisobutylene polymer

Alkanolamines, stabilisers, and dispersants

N/A

Although metalworking fluids will generally vary in composition, formulations have

traditionally been based on a petroleum feedstock, raising concerns about environmental

degradation and toxic substances release to the environment throughout the life

cycle. They may also contain up to eight additives that are harmful to human health

and are toxic to the terrestrial and aquatic ecosystems. The table below lists these

possible additives. MEN


Metalworking Fluids: What’s In Them?

lubricant, with air as the carrier, into a fine aerosol.

A recent development in near-dry machining is the application of the lubricant directly through a hole in the cutting tool, much like delivering the metalworking fluid through the spindle in wet machining. In contrast to dry machining, the lubricant is available to facilitate machining operations. Suitable applications for near dry machining are operations such as drilling and sawing.

Heavy lubricants such as oil work best in difficult operations (drilling, grooving, parting-off) and on difficult materials such as stainless steels and high-temperature alloys. Cutting speeds and feeds are usually low and do not generate high cutting temperatures. The oil is used to lubricate (not cool) and resist metal buildup. Under these conditions, it may be possible to remove the lubricant.

Increasing the sharpness of the cutting edge, increasing rake angle, and adjusting the lead angles may result in lower friction, eliminating the need for added oil. Under conditions where lubrication is needed, minimum quantity lubrication, which consists of drops or droplets of oil suspended in compressed air, may be all that is needed.

Near-dry machining is most effective on cast aluminium alloys and steel alloys in operations such as gun drilling and deep hole drilling. Japanese machine maker Horkos Corp for example, has a near-dry machine that uses a combination of gravity drop and vacuum remove fines and chips.

However, there are several limitations for near-dry machining. Coolant applied by the flooded method cannot be used in near-dry machining, as is high-volume machining. If multiple operations are done in a short period of time, then more nozzles must be employed to direct sufficient metalworking fluid to the working interface of each operation.

The cost of near-dry machining

is also higher than conventional machining because the lubricant is used neat and is utilised in one pass instead of recirculated. In addition, near-dry machining may not offer better protection for the health of the worker. A recent study on near-dry machining indicated that the mist generated by this technique was higher than that with wet machining.

Versatility The Answer?Given the limitations and constraints faced by both dry and wet machining, multi-purpose, or all-in one machines have become popular, All-in-one machines such as Makino’s S56 vertical machining centre with graphite package have wet and dry hardmilling capabilities but can also be configured for graphite milling.

Mounting pressure to minimise costs while improving machine and spindle utilisation has forced many shops to consider replacing their dedicated machines with all-in one machines. Using these machines, die and mould shops can lower costs by reducing downtime, training and maintenance spend. In

addition, shops can decrease lead-times and improve machine and spindle usage.

While dry and near- dry machining will not, in the near future, replace wet machining, these two techniques will provide cost-effective alternatives in niche applications. The function of the metalworking fluid when used with coated tooling may also change. While the need for dry machining may be apparent, most manufacturers are still concerned with issues such as the perceived inability to transfer heat while cutting dry, change over cost and finishing quality.

Special tooling utilising high performance coatings, heat resistant materials and through spindle air are now tilting the balance in favour of dry machining. By examining the manufacturing processes capable of dry machining, it becomes apparent that the key is a balance between advanced metal cutting strategies, special tooling and the machine tool specifications.


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ENQUIRY NO 173

The shipbuilding industry remains highly dynamic and competitive coming out of the recent financial

crisis. Both the European and Asian Shipbuilding powerhouses are constantly seeing an increase in demand in the number of ship orders and stakes are only getting higher. With improvements in technology and increase in ship demands, the industry looks set to bolster ahead amidst current fears of the global financial industry dipping into yet another recession.

Shipyards continue to remain an important and strategic asset in many shipbuilding countries and play a great role in their industrial infrastructures. Complex vessels such as ferries, cruise ships, dredgers as well as oil tankers continue to dominate alongside vessels such as those required for naval purposes.

Also, alongside the main

chassis building of ships, internal equipment requirements as such propulsion systems, diesel engines as well as systems to operate electronics and cargo handling push the demand for such shipyards. Annual turnovers run into the billions and this industry plays important roles in the countries they operate in by providing hundreds of thousands of jobs.

Emission Sanctions Being IntroducedThe future of the industry remains bright in Asia as there are forward-looking plans being announced to develop the shipbuilding arena. For example, the South Korean government is investing heavily in green technology due to sanctions on greenhouse gas emission values by the International Maritime Organization (IMO).

A report by the IMO stated

that global shipping industries carbon dioxide emission values have surpasses one billion tonnes, making it a contributor of 3.3 percent of total global emissions. IMO amended the MARPOL Annex VI Regulations, which prevents air pollution from ships and also added a new chapter to its regulation on ship energy efficiencies. This has made it mandatory to implement Energy Efficiency Design Index (EEDI), for new ships, and the Ship Energy Efficiency Management Plan (SEEMP) for all ships.

These systems are being put in place so that SOx emissions can be reduced by 95 percent and NOx emissions by 85 percent. The South Korean government has responded by investing more than US$267 million over the next 10 years to ensure these measures are put into place.

Building A Sustainable ShipThe green measures not only help in reducing the emissions they produce but also act as a sustainable building measure which pushes for a more reliable ship as well. According to the Guangzhou Shipyard International Company, green ship building technology does more than reduce end product emissions. Emissions during the design, manufacturing and service processes also add to the overall level of harmful emissions. The idea of green shipbuilding is extended to having a green shipyard as well. By doing so, air, water and soil pollution is reduced and as a result,

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The Builders &The Environment

Benefiting Green Shipbuilding:

The green measures imposed on shipbuilders not only help in reducing harmful emissions but also act as a sustainable building measure, which results in the production of more reliable ships. By Amreet Singh



technology InsIghts


Marine Industry On The AscendancyThe marine industry in Singapore is following the same upward trend that the global

shipping industry is heading towards. Sembcorp Marine for example has recently

posted a first half profit of S$300.5 million (US$249.2 million) for the year 2011. The

profit is attributed to new rig building projects which were secured in the fourth

quarter of the previous year.

Similarly, Sembawang Shipyard, a subsidiary of Sembcorp Marine, has seen

positive growth in the current year with S$215 million worth of contracts being

secured through newbuilding and upgrading contracts. The contracts come from

companies such as Teekay Shipping (Australia) for the engineering, procurement

and construction and commissioning of a blue water research vessel. MEN


resources can be saved alongside improvements in economic and social benefits.

The idea of the green shipyard focuses of reducing consumption of materials and energy and environmental pollution in the ship manufacturing and service processes and also on the recycling of parts and accessories in ship maintenance, as well as the reusing of materials in the building process. Selection of marine equipment now holds a focus on low energy consumption, low pollution and high efficiency as to achieve the guidelines laid out above.

For example, there is a strong emphasis on the rationality of load factor of the main engine as well as the generator and air condition systems among others. These equipment selections also are driven based on the amount of vibration and noise that is produced as these are contributing factors to noise pollution and efficiency.

Technologies IntroducedElectric propulsion systems as opposed to conventional ones are also being introduced. These technologies bring about better manoeuvring, lower vibration and noise levels as mentioned above as well as produce a higher reliability rate. Their small volume and lightweight arrangement also

means that these ships can be equipped with middle-high speed diesel generators with gear boxes and shafts that are of small volumes, which in turn makes it easier to increase loading capacities.

Efficiencies within the shipping industry are not capped at the shipyard itself. Other factors such as fuel choice are also shaping the current shipping climate. Examples include the choosing of vapourised natural gas instead. This can bring about a savings of up to 35 percent. These savings goes to the price of fuel as well as the reduction of emissions.

Benefits For Builders Green shipbuilding is a viable option today for any shipbuilder and goes beyond fulf i l l ing mandatory requirements set by the IMO. In reality, by embracing the new technologies presented, shipyards as well as clients can find themselves with a less costly and more reliable product in the long run.

Furthermore, with the ship’s more reliable nature, maintenance costs will also be reduced alongside costs factored in for downtime. All in all, the direction in which the shipbuilding climate is entering is one that is beneficial to all parties involved.



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Digital manufacturing runs from initial process planning and assembly simulation to modeling

welding lines, robot and cell programming, to a complete definition of the production facility and equipment.

It enables customers to achieve exemplary levels of innovation, quality, cost control and time-to-market that are revolutionising the way they do business, whether they manufacture jumbo jets or mobile phones. A global environment for authoring and managing digital knowledge translates into control over the definition of products, the virtual manufacturing processes and the simulation of production factories.

PLM, A Prelude To AutomationEvery detail can be worked out before the implementation stage by using 3D visualisation and the manipulation of digital content. As a result, all departments — from design through marketing to maintenance — can seamlessly share, reuse and enhance product information in the pursuit of an

optimal strategy. Enterprises large and small can now work with a digital representation of their intellectual property. It is a key manufacturing asset and is becoming the natural vehicle to drive success.

To truly achieve business transformation with digital manufacturing, it is vital that Product Lifecycle Management (PLM) is practised extensively to make it a reality. The next natural progressive step to extend beyond a PLM strategy is automation. It allows you to simulate total production systems in a completely virtual environment and to explore as well as optimise processes for effective manufacturing operations.

Automation In ManufacturingAs PLM amalgamates design, simulation and execution in the production processes, automation b e c o m e s a c o l l a b o r a t i v e programming solution to digitally define, control, and monitor automated systems.

Control engineers can design automation systems and describe the PLC program in a logic

modeler language, then validate the logic against the 3D model of the cell, machine, or an entire line. Automation also provides a synergistic workspace for control and mechanical engineers to share knowledge, react to changes and communicate within the same digital environment.

For manufacturers to survive and be competitive, it is becoming increasingly important to ensure that the organisation follows the best standards and employs the best methodologies across the entire network to meet the needs of their industry. As manufacturers are working in a much more diverse and complex environment, typically including global sites and their suppliers, demand for faster responses and higher levels of integration are applying increased pressure on the industry today.

Programming RobotsIn order for manufacturers to confidently meet the needs and challenges of OEM suppliers, a comprehensive and role-based robotic programmer solution that offers advanced simulation capability with dedicated offline programming tools is required to mirror accurate real world processes.

Ideally, this solution will provide detailed forecasting, calibration, and post processing tools to allow users to accurately program robotic systems offline for specific welding applications. Companies wil l be able to significantly reduce production ramp-up time and costs due to the manual programming of robots tasks and motions by validating the complete process and ‘what-if’ scenarios in a 3D digital environment before any actual physical deployment.

By utilising systems simulation in a 3D virtual environment, an advantage will be gained as the 3D direct manipulation shortens the user’s learning curve and improves

From automotive and aerospace, to fabrication and assembly, even shipbuilding, companies require the right digital infrastructure to define, plan, create, monitor and control all processes. By Samson Khaou, GM, Dassault Systèmes (ASEAN)

Digital ManufacturingTransforming Business Through

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35

Digital manufacturing enables customers to achieve exemplary levels of innovation, quality, cost control and time-to-market from the manufacture of jumbo jets to mobile phones


Wanting to improve design-to-manufacturing productivity and enabling real-time product

data visibility, STX Shipbuilding embarked on a Process Innovation (PI) project, which

is a company-wide management innovation system that the shipbuilder adopted to

organise its efforts to develop new engineering methods, ensure that change requests

can be easily incorporated into the final data, and improve its production processes.

“Shipbuilding takes a long time and accordingly, continuity is the key to successful

production,” said Hyo-Gwan Leem, senior VP of STX Shipbuilding.

Streamlining Operations

Central and Engineering Central products, enables the company to create a Master bill

of materials (BOM) for each ship under construction. The Master BOM is then broken

into ‘Project BOMs’ that detail all the parts for that particular project.

“In particular, we used a Master BOM to better integrate disparate data between

the 120,000 to 150,000 parts per ship building project and to share this data among

engineers. The fully integrated product lifecycle management platform is mission critical

for improving organisational collaboration and best practices,” he said.

As such, the company streamlined its business process by eliminating

inefficient tasks and currently expects to reduce costs by KRW 100 billion (US$70

million) in five years. MEN

With 21 shipyards around the world, South Korea’s STX Shipbuilding has played a key role in the development of the shipbuilding industry since its inception.


the user’s efficiency in designing and programming.

Service organisations and tooling supplier play a vital role in today’s marketplace, providing automated manufacturing systems, designing flexible workcells and robot programming for OEMs. As such, these contenders in the industry can likewise, capitalise on this technology in their daily operations.

Ensuring ManufacturabilityThe goal of any manufacturing company is to develop a product that meets market demand with exceptional quality and with a profitable return on investment. Even the most innovative product will fail if it is not ‘manufacturing ready’ and produced both effectively and efficiently. Improved quality and shorter time-to-market for new programs is increasingly important for many modern manufacturers, with the ultimate goal that designs are ‘100 percent manufacturing ready’ as a standard design and engineering deliverable.

Ensuring this level of product manufacturability and profitability is, however, extremely difficult in a mainstream environment. Digital manufacturing strategies can offer radical solutions to meet these challenges and goals. The technology will help to ensure a solid business model for any enterprise and revolutionise the product lifecycle by creating new value and innovation at each stage of the process.

Through the sheer nature of technology, simulation is the conduit for unleashing ideas in an already capable workforce. Not only is it an effective way to visually plan, define, validate and optimise, it allows employees to take it a step further: to explore forward-thinking ideas and experiment without physical constraints.

Gavin Spencer, Lancing, West Sussex, United Kingdom

Digital Manufacturing: Continuous R&D Leads To Growth

technologyInsIghts



No w a d a y s , t h e intense competition prompts automobile m a n u f a c t u r e r s t o

expedite the development of new car models to compete for market shares and profits. As the design and manufacture technologies on engine and chassis mature, the new car model focuses mainly on the development of vehicle body styling and electronic devices.

During its development, the sheet metal of the vehicle body has multiple characteristics including complex shape, large-size structure, high accuracy and high quality surface. Statistics show that 40 percent of designers and engineers are undertaking sheet metal-related work in new car model development. The quality of the sheet metal is crucial to the success of new car model development, which raises new challenges for the inspection of sheet metal.

However, the traditional gauge and 3D CMM cannot provide full assessment to the spatial surface shape of the sheet metal due to its own limitations. Their efficiency is low and cannot totally meet the inspection requirement for large-scale automobile production. How to provide quick, precise and convenient inspection of sheet metal has become a key issue for the automobile manufacturers to address.

Adding Mobility To InspectionThree-dimensional laser scanning technology can be a solution to that issue, as it allows free movement of the parts while scanning, and enables data acquisition from hard-to-reach areas. One of those products, the Handyscan, can generate a data accuracy of up to 0.04 mm, acquire point clouds fast and allows easy operation and no limits in terms of size according to the manufacturer. It can be used for new car model development, parts quality control as well as for

UsingModernTools


full-sized vehicle assembly.The main applications of 3D

laser scanners in automotive industry include inspection of the surface, boundary and holes of the vehicle parts, and reverse engineering of the vehicle parts and full-sized vehicles.

Using the 3D laser scanner and the accompanying software in sheet metal inspection can help in measuring the actual spatial error of

the parts quantitatively and present the results visually. It performs well in the quality control management, and avoids the limitation of traditional gauge and 3D CMM that can only inspect limited cross sections. It helps to reduce the cost of new car model development, shorten the development cycle and smoothly assemble full-sized vehicle.

Case StudyUsing a left-side inner panel welded assembly of a developing electric motor car as research object, the following illustrates the complete process of quality analysis of automobile sheet metal using non-contact technology.

Scan The Sheet Metal

Scan the parts with the laser scanner,

including the surface, hole positions and

boundaries. The scan result is shown in

figure 1.

Figure 1: Scan data of sheet metal

For Sheet Metal Reverse Engineering & Inspection

Three-dimension self-positioning laser scanners can provide full, accurate and fast assessment of the sheet metal, which guarantees the quality control of vehicle parts and assembly of full-sized vehicles. By Robert Wang, applications engineer, Creaform Shanghai

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Figure 2: Results of 3D compare

Figure 3: Results of compare features

Figure 4: Results of compare boundary

points during the quality control, and is suitable

for inspecting automobile sheet metal with self-

positioning features such as holes and slots.

Therefore, this paper uses the RPS to align the

scan data with the CAD model.

Error Evaluation Of Parts

Figure 2 shows the colour-coded deviation

spectrum between the scan model and CAD

model, from which operator can quickly

browse the distance and error in x/y/z axis

between any corresponding points in scan

model and CAD model.

Figure 3 shows the error of diameter and

centre point on corresponding features such

as round hole and rounded slot between

scan model and CAD model. Figure 4 shows

the boundary error between scan model and

CAD model. MEN

Preprocess The Scan Data

First, import the scan data and CAD model

into a post-processing software, and apply

preprocessing such as noise reduction.

Then, create features such as holes, rounded

slots and rectangular holes in the CAD

model, and create corresponding features

in the scan data.

RPS Alignment Between Scan Data &

CAD Model

The software provides multiple alignment

methods, among which RPS alignment.

The RPS alignment declares a set of

reference points common for development,

manufacture, inspection and batch

assembly. It is a constraint-based reference

point system alignment method, which can

‘lock’ the key points in the model to establish

the relationship between point clouds

coordinate and CAD model coordinate.

This method prioritises the key additional

software&Metrology



DIFFICULTY:Clamping using three-jaw chucks is not always suitable for final machining without deforming the workpieces.

SOLUTION:The adoption of vacuum chucks.

CONCLUSION:The special dampers can now be machined with in the required tolerances, in reasonable time.

Circular vacuum chuck allows tension-free clamping for turning. By Wolfgang Klingauf, Klingauf PR and Maren Roeding, PR manager, Witte

Ma d s e n M a c h i n e Technology from Horsens in Denmark specialises in turning

removal of deep-drawn and rolled parts in metal including stainless steel. Such parts are relatively thin-walled and exhibit enormous material tension due to their manufacturing process. Special know-how is needed to control forces arising during milling and machining finished products with tight tolerances.

According to Morten Helding Madsen, co-owner of the company, they mainly export turned parts for automotive, medical and pump industries. Also responsible for the growth among other things are special orders, for instance from an automotive supplier for 100,000 dampers per year.

These parts are supplied as rolled semi finished products. They weigh around 8 kg and have an outer diameter of approximately 330 mm. It is Mr Madsen’s job to not only machine the reverse flange inside and out, but also to carry

convex because of the tension and we could not maintain the required tolerances.”

So the company went in search of alternative clamping methods. Tests with magnetic chucks were carried out, but because of the pull affecting iron chips, it did not lead to the desired results. During discussions with their machine supplier the idea arose to try a vacuum chuck. Vacuum would allow an even and tension free part clamping process.

Mr Madsen reports: “The first tests have showed that our skepticism regarding holding forces was unfounded. We machined these parts with approximately 2,000 RPMs and clamping was 100 percent reliable.”

He emphasises a further advantage — the system is easily cleaned using compressed air or water. Compared to magnetic alternatives that is an advantage.

out milling of the face ends. Tight dimension and position tolerances are required.

Better Clamping RequiredUntil now clamping parts using three-jaw chucks was sufficient, but this method met its limits for dampers. Mr Madsen described the problem: “For face milling on one end we can clamp the flange inside using a three-jaw chuck. But for the other end the part is too big. Also the surface would become

Better clamping was required to satisfy production needs

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Advantages Of Vacuum Clamping Systems• Reduce clamping time• Universal clamping system for

different parts• Clamping non-magnetisable parts• Oscillation-free machining• Clamp thin parts and foils without

deformation• Problem-free machining of contours

and cutouts• Suitable for many types of machining

and materials

When Not Having Air Is A Good ThingVacuum systems are available in different versions depending on the application and specialities to be taken in to account during clamping, whereby the principle set up is always the same: Vacuum is generated via a modular vacuum unit with integrated liquid separator, vacuum tank and pressure controller.

For applications on turning machines, circular vacuum chucks are the best option, they range from 100 - 630 mm diameter. For larger or smaller parts, special solutions are available. Circular chucks allow fixation of parts with different size inner and outer diameters. Freely adjustable stops ensure accurate positioning of work pieces.

Meanwhile the company is now using four such chucks from Witte. Two are permanently installed on Gildemeister CTX420 linear machines. These machines are used for manufacture of the previously mentioned dampers. The third system is mounted when required on a CTX400 to turn a lid insert, which is required in smaller quantities. Changing the chucks is a fast process. Mr Madsen confirmed that setting up vacuum on a machine takes no longer than one to two hours.

For the 30 employees at the company, it is important to keep an eye open for innovations which will optimise quality, price and delivery time of their products. For the director the clamping systems are an important component of his modern machinery: “Without

this vacuum clamping system we could not machine these d a m p e r s i n t h e re q u i re d tolerances, or only by taking a lot more time.” MEN

Fab&Form



The ‘seat belt’ for cutting tools allows heavy metal removal. By Wolfgang Klingauf, k+k-PR, for Haimer

Productivity of the highest level should be delivered even when faced with challenging conditions like

High Performance Cutting (HPC), in which the capability of the machine tool is exploited to its very limits.

Oliver Sax, manager, Global Solid End Milling Products Portfolio at Kennametal, explains: “Many segments are being subjected to fierce competitive pressure. They are looking for manufacturing solutions that give them the highest possible metal removal rates. HPC is becoming more and more popular, in particular where the proportion of metal removal is high, as it is in the aerospace industry for example.”

The t rend has become increasingly evident in the last few years, ever since high performance cutting tools that facilitate demanding machining operations have been on the market. The tools can withstand the high torques, feeds and forces that occur during machining without breaking.

Tougher Operations Require Better LockingThe danger of the milling cutters being pulled out of the tool holder at extreme forces has significantly increased, particularly during demanding HPC and High Speed Cutting (HSC) processes. This is true for tool holders that offer precision clamping with good concentricity such as shrink-fit, hydraulic expansion or power chucks, for example. The holders work with frictional locking, but their clamping force is often not sufficient for HPC.

It is estimated that about 70 percent of all users are currently forced to use standard Weldon holders for heavy roughing

tools can also be adjusted. In other words the tools can be reground and pre-set as usual.

The lock system adopts the shrink-fit technology and the clamping process is simple. The chuck is heated as usual and the tool inserted with a slightly twisting movement. The locking elements of the system find their own way into the grooves when the tool is turned. A spring can be used to aid in the play-free positioning of the tool. The holder cools down after a few seconds creating the press fit and positive locking.

Concentric accuracy of <3 µm is achieved during shrinking. Stable tool clamping achieved in this way allows users to machine even greater cutting depths with higher feed rates. The tangible benefits at

operations due to security concerns, because the clamping screw of these holders creates a positive locking. This means that any desired torques can be transferred — but combined with the known disadvantages of poor cutting tool run-out, weak clamping due to the shank needing a little space in the chuck and shorter tool life of the expensive HPC cutting tools.

Reliable Milling AchievedKeith Wiggins, leader, Global Tooling Systems Product Management at Kennametal, has been investigating a fail-safe/high-accuracy tool holding system to complement their high performance portfolio for a long time now and is well aware of the problems with aggressive heavy chip removal.

“For years now we have been investigating a holding solution that has best possible accuracy with a fail-safe security clamping system that would gain the full potential from our cutting edge performance. With the Safe-Lock from Haimer we now have a non-slip holding solution to complement our toolholder offering.”

The lock system is a pull-out protection for round shanked cutting tools of all types. The principle is simple and effective: helical grooves are ground into the shank of the tool. These together with the respective pin drivers in the chuck prevent the tool from spinning or even being pulled out of the holder altogether under extreme machining conditions, a malfunction that can be very expensive where such costly tools and workpiece materials are concerned. The trick here: The helical path of the lock system grooves means that the length of the

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the end of the day — time saving, enhanced productivity, lower scrap rates and less vibration.

Better Locking, Better ResultThe lock system has achieved success with high-performance tools for the HSC machining of aluminium (spiral cutters) and the heavy machining of titanium (roughing cutters). According to the maker, companies in the aerospace industry have increased their removal rates by over 30 percent.

In addition, one user in titanium processing was able to increase the tool life of his cutting tools three-fold for roughing and seven-fold for finishing. A medium-sized supplier of the automotive segment reports that his tools now run smoothly, doubling their tool life. MEN

Safe-Lock is a pull out protection in which grooves are ground into the shank of the tool. These together with the respective pin drives in the chuck, prevent the tool from being pulled out of the holder during extreme machining conditions.

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Ma c h i n i n g w i t h industria l robots i s a w ide spre ad appl icat ion. The

flexibility of industrial robots opens up a large range of application that until now has involved primarily the finishing of series products. Taps and fittings are ground and polished under robotic guidance, injection moulded parts are trimmed and cut to size by robots, and castings are finished, fettled or deburred.

While many CAD/CAM-based systems already exist for the offline programming of robots, there has never yet been an integrated approach to process data all the way to the robot controller. The prerequisite for processing programs until now was the compilation of the CNC programs into the corresponding robot language with the aid of an adapted post-processor. This automatically resulted in a loss of information, as functions from

the CNC program were not always supported in the widely differing robot languages.

Out With The Old ConstraintsA program that allows the direct integration of a CNC kernel on the robot controller has eliminated the mentioned limitation. It gives the robotic machining system an inherent range of additional functions.

Kuka.CNC can be used to execute DIN 66025-compliant CNC programs directly with the robot controller. Direct integration of the CNC kernel on the robot controller turns the industrial robot into a machine tool with an open kinematic system that combine s the advantages of an industrial robot with those of a CNC controller.

T he complete sta nda rd code can be interpreted by the program and implemented by the robot. (G functions, M/H/T

functions, local and global subprograms, control command structures and loops) These options broaden the range of applications for an industrial robot , pa r t icu la rly in the following fields:

• Milling of shaped parts made of soft/semi-hard materials, such as wood, plastic, aluminium and composite materials

• Polishing and grinding of shaped parts

• Coating and surface treatment of complex workpiece surfaces

• Trimming and cutting of complex workpieces and workpiece contours

• Laser, plasma, waterjet cutting of complex workpieces

Direct integration of the CNC kernel on the robot controller

It is now possible to process G-code directly with the integrated CNC kernel on the robot controller. By Alexander Bay, product manager, Kuka Roboter

Automation:

Cutting AwayConstraints

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ENQUIRY NO 201




allows the combination of the advantages of an industrial robot, such as the large workspace, high flexibility, low investment costs and six-axis machining, with those of a CNC controller, such as G-code programming, CNC user interface, tool radius compensation, extensive point anticipation, advanced spline path planning and user-friendly tool management.

Integration of the CNC kernel also enables direct processing of the CNC program on the robot controller. Both CAD/CAM programmers and CNC machine operators can therefore program and operate an industrial robot with their existing knowledge.

Advantages For CP ProcessesCNC mode is pa r t icularly advantageous for continuous-path processes. Machining programs with a large number of points on the path can be executed more precisely and with shorter cycle times using the CNC kernel and its sub-functions.

The se improvements in accuracy and cycle times are due to the advanced path planning functions in the CNC kernel. Path planning with point anticipation for more than 500 points makes it possible for the robot to maintain constant velocities during the machining process and to plan optimal acceleration/deceleration ramps.

The path accuracy is also improved by means of various spline interpolations in the CNC kernel. Akima and B -Spline calculations ensure that the robot executes its set path as accurately as possible. These typical CNC functions are combined with the conventional functions of a robot controller. As such, optimal machining results are achieved.

Simplicity Is BeautySimplified robot integration holds adva nta ge s for t he machine operator. Moreover, the use of robots in the domain of

conventional CNC machine tools redefines the possibilities of G-code processing. In automated machining systems, it will in the future be possible to program and operate not just the machine tool, but a lso the robot by means of DIN 66025-compliant code. This facilitates robot integration and offers a crucial advantage especially for the machine operator. In the future, the operator will no longer need robot-specific programming knowledge, but will be able to operate the robot using his existing CNC expertise.

Machine tool and automation system are merged into a single unit. A special case in the field of automated machining is the processing of workpieces handled by the robot. The combination of machining and handling makes this process variant particularly efficient. Since the robot picks up the workpieces, guides them to a m a c h i n i n g s t a t i o n f o r processing and then transfers them to a storage facility, no further transfer or handling kinematic system is required for automation of the process.

In this example, the machine tool and automation system are combined to form a single unit, with a great influence on the aspect of cost-effectiveness.

CNC programming opens up a whole new range of programming systems for robotics. The CAD/CA M system market of fers specially adapted solutions for a wide range of different machining applications. Robot programming and application possibilities will also multiply in the future. CAD/CAM systems are increasingly recognising this development and providing their software with corresponding modules for robot programming and simulation. MEN

Machining with industrial robots is a widespread application

IndustryFocus

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Sheet Metalworking, Our Passion, Your SolutionENQUIRY NO 077



The field of metalworking has come a long way. Today, the cutting and joining of metals to create

individual parts, assemblies and large-scale structures is no longer achieved through brute strength alone but by a combination of robotics, machinery, information systems and electronics working together. This vast discipline of manufacturing technology is known industrially as automation.

The use of automation in metalworking comes as no surprise, in l ight of r ising consumer expectations on quality and quantity. In particular, automation is expected to achieve the following goals:

• Consistency: Although each product is inherently different, there should be a high degree of consistency in terms of quality, regardless of where the product was manufactured. This is especially true in an increasingly borderless world where manufacturing operations may be situated in developing countries to benefit from low labour costs.

• R e l i a b i l i t y : I n a h i g h l y competitive manufacturing environment, being able to work round-the-clock is crucial. Any downtime can translate into high revenue losses. The use of automation reduces the need to depend on manpower, increasing the reliability of the manufacturing system.

• High Performance: The use of robots and machinery on the shop floor allows for the analysis of complex data, the speedy repetition of tasks as well as the completion of multi-functional jobs, all of which could not be achieved through the use of human labour.

• F lexibi l i ty : The need to reduce inventories as well as respond quickly to customer demands make the ability to instantaneously change a production line on the fly a critical asset.

• Safety: Part of the motivation behind the use of intelligent automation is the enhancement of safety, ultimately reducing

the number of man-hours lost and injuries sustained.

Common Elements In AutomationWhat are some of the products that form this huge industry known as automation? To begin, almost all automation systems require what is commonly termed a Programmable Logic Controller (PLC). A PLC is a computer that is used for the automation of electromechanical processes. In metalworking, it is typically used to control factory assembly lines.

Unlike a normal computer, the PLC is easier to program and maintain, consisting of a series of ladder diagrams and electrical symbols commonly used by electricians. There are two types of PLCs available on the market today: fixed and modular. Fixed programmable controllers come as self-contained units with a processor, power supply, and a predetermined number of discrete and analog inputs and outputs (I/O).

Unlike fixed units, modular controllers are more flexible,

Shahnawaz Abdul Hamid investigates the use of sensors that improve safety in the metalworking industry.

Department of Business, Innovation & Skills

Sensible UseOf Sensors In Industries

IndustryFocus

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ENQUIRY NO 134



offering options for I/O capacity, processor memory size, input voltage and communication type. However, these controllers may be significantly more expensive compared to fixed ones.

I/O systems often serve as interfaces between devices and the PLC. To put it simply, they form the connections between wires of devices and controllers. Through the use of a cabling system and network, racks of I/O are placed closer to the process but remote from the controller.

To power many o f the devices in a factory, motors have been introduced, with various configurations that can be used for a wide range of applications. In recent years, motors have become more ‘intelligent’ with energy-efficient designs that reduce the carbon footprint of a process.

The use of sensors in automation systems to detect change has become increasingly common

The automotive industry is one that has benefited greatly from the use of sensors to safeguard workers

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The Art Of SensingAnother common element in automation systems is the sensor. Sensors detect and signal changing conditions, either through contact or non-contact methods. Contact sensors typically detect change through direct physical contact with target object. They are simple and reliable and can usually tolerate power line disturbances.

Non-contact sensors, on the other hand, use photoelectric, induct ive , capac i t ive and ultrasonic technologies to detect changes. Given the lack of physical contact between sensor and target, there is hardly any potential for wear and tear.

Given the ir usefu lness , sensors are used in many aspects of metalworking. It is perhaps with regard to safety

that they are most valued. This is especially because the risks associated with metalworking, such as cutting and turning, cannot be underestimated.

Non-contact sensors, when installed properly, prevent access to a hazard or detect the entry of personnel into a hazardous location. The sensor then, in conjunction with the control system, initiates a shutdown of operations to eliminate the hazard.

Safety Light CurtainsSafety light curtains safeguard entry into a manufacturing cell, given the various dangers associated with quick-moving robotic arms or machine parts. Although safety light curtains have been used for decades, the technology behind it has kept pace with the industry’s ever-changing demands. In recent years, the use of corner mirrors allows the light curtain to protect all sides of an application.

The curtain comprises of two primary parts: a sender and a receiver. The sender unit emits an infrared beam towards the receiver unit. Upon the receiver unit receiving and registering the beam, a light curtain is generated, allowing the machine or robot to move and do work. An interrupted safety light results in a safety stop signal being sent to the machine control circuit, which stops the machine or robot, preventing any possible injury.

Laser Scanners & Vision SystemsSimilar to the safety light curtain is the safety laser scanner, a device designed to provide protection even in the most complex of zones. They emit very short laser pulses, while an electronic timer captures the travel time of the pulse. These laser scanners can be used

IndustryFocus



49

in a wide range of mobile or stationary applications, and are mainly tasked with preventing access into a dangerous area.

Perhaps more relevant to metalworking is the vision system, commonly found in press brakes. The vision system is typically mounted on the ram of a press brake and monitors the hazardous area with a camera image, evaluating the safety field. These fields can be specifically programmed based on a specific folding position.

The fields are constantly monitored for any foreign objects, finger-sized or smaller. Such an intrusion results in the press being stopped immediately. Apart from providing this safety measure, some vision systems also measure the angle of bend being formed as part of feedback, allowing for a more accurate bend.

Selecting An Appropriate SensorThe act of selecting an appropriate sensor to beef up the overall safety of a manufacturing process is dependent on several criteria. National standards usually help manufacturers decide on the level of risk a specific process entails. Next, a risk reduction strategy may be crafted. The risk strategy allows the manufacturer to decide which sensor is most appropriate in the prevention of any hazards.

Part of forming the strategy i n v o l v e s m e a s u r i n g t h e dimensions of the safety zone that require guarding as well as the shape of the zone itself. This will help in determining what type of sensor will best suit the company’s safety strategy. For instance, in the automotive

industry, safety light curtains have often been used to provide a perimeter of security around robotic arms that swing to and fro as they assemble cars and other vehicles.

In conclusion, the advent of industrial automation has allowed the metalworking industry to reach heights once thought of as impossible. Quality, reliability, flexibility and quantity have all improved significantly. However, it is in the field of safety that improvements are perhaps most welcome, especially for workers. The use of sensors has enhanced this, allowing for a reduced number of injuries and a greater peace of mind for those tending to milling and cutting operations. MEN


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IndustryFocus



The metalworking industry performed admirably in 2010 following the preceding years, which

were clouded by woes in the financial markets and in other industries. In 2011, it was widely believed to be the year of consolidation. However for Walter in Asia, it was an improvement from 2010 according to Jean-Paul Dissous, CEO of Walter Asia Pacific.

Said Mr Dissous: “The sales in Asia Pacific have been growing positively in double digits in 2011 despite Japan’s triple catastrophe in March. Against the odds, business in Japan went well for us. As such, we have high expectations.”

Mr Dissous felt that some of the growth in Japan may be due to the rebuilding efforts but it is the normal market demand that is more pertinent in this case. “The demand did not disappear, people still want computers, mobile phones and cars,” he said.

Sales Strategies 2012 Looking forward to the year ahead, Mr Dissous revealed that the company would focus more on two markets: China and Japan.

“We decided to go into these two markets and came up with a fine-tuned strategy. We are not talking about a strategy just for 2012 but rather a long-term one. For Japan,

we are expecting a boost so we need to be prepared. On the other hand, for China, it still represents a big potential even though we have been based there for 15 years. We are happy with the numbers and we hope for even more,” he said.

‘All Systems Go’ In 2012Halfway across the world in the US and Europe, the financial markets are reeling from the credit crunch and the historic downgrade of US bonds. These ripples have reached Asia and though the major Asian bourses took a hit recently, it is not exactly a major cause for concern for Mr Dissous.

He said: “We have been following the situation in Europe and the US closely. While we agree world markets are linked but the timings in business cycles are not the same. I do not see a slowdown in Asia Pacific next year, mainly due to existing demands. Japan is expected to have an excellent development next year and this will be beneficial to this region because there are a lot of Japanese companies based here. The slowdowns in Asia are mainly due to the situation in Japan and China’s decision to slow growth in order to keep inflation in check.”

T h o u g h M r D i s s o u s ’ assessment of the region is positive, he felt it is important to be prepared for any eventuality.

“Whatever the situation, we always try to be ready for two extremes — blooming economy and slowdown. It is a permanent attitude.” Painting an example, he continued: “We are careful with our investments, be it the establishment of new plants, the purchase of new machines and the training of our employees.”

Opportunities & Hot Spots“If the markets are shrinking, it does not mean the possibility for us is shrinking. There is still a lot of market share we can gain,” said Mr Dissous.

This positive thinking is behind many of the company’s endeavours in Asia. There should however, according to Mr Dissous, be a guiding principle, ie: stay focus to avoid going off tangent.

“Though there are a lot of opportunities (in Asia), we decided to focus on specific areas. We concentrate our attention on automotive, energy, aerospace and general engineering. Among them, the energy and aerospace industries will be up and coming. Just look at the aerospace industry, with the number of people flying these days, the flights are usually fully booked,” he concluded.

Walter

Asia


The CEO of Walter Asia Pacific talks to Asia Pacific Metalworking Equipment News in this exclusive interview to dissect the company’s performance in the past year. By Joson Ng

In

FeatureS



51

Share with us your thoughts on your

new appointment

As a newly appointed MD of Walter

Singapore, my aim is to gear up this

company for sustainable business

growth as a competent par tner for

cutting solutions for customers in the

metalworking industries.

Walter Singapore recently appointed Tan Soo Thong as MD. Also holding the same portfolio with Walter Malaysia, Mr Tan gave his thoughts on the appointment and also shed light on his management philosophy.

To achieve this, our main focus

is to develop our employees through

training in order to enhance their skills,

knowledge, application know-how and

expertise level.

Being the MD for both Walter

Singapore and Malaysia, do you see

any obvious differences between the

metalworking industries/clients in the

two countries?

Their expectations for product quality

are similar but however there are obvious

differences. For example, the complexity

of the machining process is one of them.

This is in accordance to the maturity of

the industry. For instance, the aerospace

industry in Singapore is more established

whereas Malaysia has got the automotive

industry, palm oil machinery OEMs and

some general mass production machining

industries, which are not found in Singapore.

What is your management philosophy?

I always believe in people. They are

important assets of the company. It

gives me great joy to be involved in the

development of my employees and see

them progress over the years. MEN


Mr Tan’s aim is to gear up the company for sustainable business growth

In The Hot Seat…Tan Soo Thong

FeatureS

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With more than 100 participants at the opening, Je f f rey Choon, MD, Newline

Machine Tool has fulfilled one of his wishes for the centre by providing a platform for users and experts to come together for technical exchanges. “By starting this technology centre, we hope to provide an education in metal cutting and machining technology,” said Mr Choon.

According to Mr Choon, the facility cost some RM6 million (US$1.9 million) and though the place was bought five years ago, development works started only recently and the company moved into its new home in July this year. For him, though the facility was built to support their clients, and partners, other OEMs are welcomed to use the centre too.

The technology centre was something that

was planned some years ago according to

George Lim, VP of marketing, Makino Asia.

However, due to staff allocation and location

concerns, the plan was put on hold till this

year. Five years on, with infrastructure now

more developed, the concerns of the past

were all but eliminated. This was confirmed

by Mr Lim, who also sought opinions from

guests at the opening. He said: “I asked

Five years in the making, the technology centre in Malaysia opened to much fanfare and optimism. By Joson Ng

Grand OpeningNewline And Makino Technology Center

the customers and they told me it is a good

location and is easy for them to send their

employees here for training.”

Having a technology centre has always

been the company’s focus with its Singapore

facility as a shining example. The technology

centre in Kuala Lumpur aims to emulate the

success its counterpart enjoyed across the

causeway. It also helps reduce any difficulties

faced in documentation when sending

workers over to Singapore for training.

New In 2012

“From the commercial point of view, we

are very much looking at the 3C markets.

They are computer, communications and

George Lim On The Present & Future…

All in all, the future looks br ig ht for Newl i ne a s M r Choon revealed to Asia Pacific Metalworking Equipment News that the company is planning another centre in Penang. The facility is slated to open in January next year. This can be seen as a massive vote of confidence in the economy. Though there are some signs of uncertainties in the US and Europe, Mr Choon felt that his company’s portfolio is well -diversified and as such, the

possible downturn is rated “not critical” by him.

Elaborating the point on diversification, he said: “We serve industries that range from medical device manufacturing to the semiconductor industry. In addition, we are supporting major government projects such as the manufacturing of Proton cars. We have actually provided a few lines of machines for the national car maker.”


consumer electronics. Especially for the

communications devices, parts are getting

more precise and the production volume is

getting higher. As such, we have to produce

machine up to that level,” said Mr Lim.

He used the EDAF as an example. The

EDM machine can produce a depth control

of +/- 2 micron. As for the wire side, the

company is looking to develop technologies

that cut tungsten carbide. For Makino

Asia, Mr Lim said: “We are looking more at

mass volume production. We are looking

at milling machine and machining centres

that can create high-performance and

high-precision. It is easy to produce high

performances but difficult to achieve high

It is all systems go as far as George Lim is concerned

Jiro Makino (2nd from right), president, Makino Milling Machine is very pleased with the formation of the technology centre which is in line with the company’s policy of developing technologies, driven by its extensive R&D program.

Jeffrey Choon

Features



53


For KS Sankaran, COO, Makino Asia, Malaysia

is an attractive country to do business in. He

attributed its relative low cost and the skill

of the workers as positive points. However

should there be a need to upgrade the skills,

the technology centre addresses the issue of

training. He said: “If every customers can take

advantage of this technology centre, it would

be a good thing.”

Looking towards 2012, Mr Sankaran

felt that the dark clouds that are gathering

in the US and Europe pose some cause for

concern but he also pointed out a shift has

taken place and suggested Asia do not have

to be unduly worried. “Today, China produces

more cars than the US. It is an irreversible

change. The high tech consumables are also

being manufactured in Asia. For Makino,

accuracy. We have to look into structural

design in order to satisfy both criteria.”

Positive Future

Looking at the future which is clouded in

some degree of uncertainties, he said: “The

financial problems in the US and Europe have

been there for quite some time now. It affects

Asia because Asians do not understand the

business politics of the West. We tend to

react negatively.” Mr Lim felt the markets in

the US and Europe will affect their business to

a certain extent but he hopes the company’s

sizable business in China can help offset

any blow.

At the end of the day, it is ‘all systems go’

as far as Mr Lim is concerned. “Be it R&D, the

development of any new technology centres

or any HR projects, they will continue. After all,

when business cycle go down, it is also the

best time to invest,” he concluded.

sales figures in Asia have increased. It has

overtaken sales in European countries. It used

to be 1/3 Asia (sales figures) and 2/3 Europe

but now, it has reversed,” he said.

The company has also shifted their

marketing efforts. It is now skewed towards

the Internet. “We are now looking more at

web-based marketing. For example, we are

organising Webinars and other web-based

training,” he said. He felt this is the current

trend and embracing the Internet can increase

reach and lower cost.

Mr Sankaran

Expert Opinion: KS SankaranMr Sankaran on business in Malaysia, the economic situation in the west and also the company’s push into the online world.


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Hong Chek Company (Pte) Limited180 Paya Lebar Road, #09-07 Yi Guang Factory Building, Singapore 409032

Tel: +65 6746 1308 Fax: +65 6747 1760Email: [email protected] Website: www.hongchek.com

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Features



The emerging market of Asia presents a great potential for growth for Kennametal. In order to maximise this

potential, the company has looked into ways to establish a stronger presence in this region. One of its recent endeavours is to move into a new office in Singapore.

“The Asia region is an emerging market that we want to focus on. Also, in order to serve the growing customer base, we decided to pick a more convenient location for our office in Singapore. In addition, this move also allows us to present a brand image consistent with Kennametal on a global basis, that is to establish a much stronger

presence in our emerging markets with Singapore as the centre,” said Mr Chang.

Current ly, there a re 29 employees working at the facility and Mr Chang hopes to increase that number to 40 in the future. He believes that this part of the world continues to be in the growth mode and the company will continue to add selectively in Singapore for growth. He also added that there are investments in infrastructure developments in China and India.

On The Growth BandwagonWith Asia firmly in the crosshair of the company, Mr Chang said they have formulated a strategic

plan in the last five to eight years to capitalise on the growth of the region.

“We have consistently developed infrastructure in the region dating back to five years ago when we built our plant in Tianjin, China for our metalworking business. Since then, we have added engineering capabilities most notably in China where we built an advanced engineering centre. Last year, we opened a facility in China focused on the mining and construction industry,” said Mr Chang.

“In October 2011, we are opening a new furnace for our Conforma Clad business in China. At the same time, we are opening

Kennametal recently moved its office in Singapore and Asia Pacific Metalworking Equipment News spoke to John Chang, the company’s VP and MD of Asia in an exclusive interview to find out more about the move and also the company’s plans for Asia. By Tjut Rostina and Joson Ng

MovingForward

Features

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

Tungaloy Malaysia Sdn Bhd (876763-H)50 K-2, Kelana Mall, Jalan SS6/14Kelana Jaya 47301 Petaling Jaya, MalaysiaTel: +603-7805 3222 • Fax: + 603-7804 8563www.tungaloy.co.jp

ENQUIRY NO 206




a new customer solutions centre in our Shanghai office, which will house the latest technologies. It will also include a demonstration as well as a training facility that can sit more than 80 people.”

Elsewhere in Singapore, Mr Chang revealed the company has consolidated their warehousing and inventory to better serve their customers. They now have a regional hub in the Changi area whereby they are able to provide standard or customised products.

Dark Clouds Ahead?The recent wave of financial uncertainties in the US and Europe has cast a shadow over the stellar economic performance in Asia last year. For Mr Chang, though it is a concern, the fundamentals in Asia are looking solid.

“Firstly, the market in Asia continues to grow. If you look at the GDP growth, even though it is slower compared to last year, the economy continues to be healthy and robust. With respect to growth outlook, there is certainly a lot of concern on sovereign debt and rising interest rate in emerging markets, the obvious indicators of barriers to

growth. We are watching closely at this point with respect to developments in North America, and in Europe where we see challenges,” he said.

Financial markets’ woes, however, are separate from industrial production. He felt that the overall global industrial production continues to be very robust.

Said Mr Chang: “I think it is a matter of which industry and which sector. The global industries have a lot of aspects and cycles; as a result you will find that while certain markets are down, certain industries are up. For example, we have been reading in the press about the number of aircraft that have been launched recently. Within Singapore, we could see aerospace companies making significant investment. Our reaction to that is to place emphasis in businesses that are growing, like the aerospace industry and earthworks.”

Improvements & BeyondMr Chang remains positive when asked about the coming year. “These are exciting times for us, we survived the recession and we reorganised ourselves, upgraded the SAP system and digitised our

operations,” he said. Though the improvements have made the company stronger, he foresees some challenges coming from the workforce side of things.

“My view have always been about getting the technical knowledge and skill set required. New technologies are been developed at such a rapid pace. The rate of change our customers are demanding from us is significant. The limitation as I find over the last few years is getting the right talent, leadership and skill set. That will continue to be the challenge facing the regional markets,” he said.

With that, he said the company would focus heavily on its ability to provide the right training to their employees, distribution partners and customers. Giving an example, he concluded: “We are going to offer courses in Singapore, starting early next year. This is a big need based on what we hear from our customers. When I visited a customer who had set up a facility in Singapore earlier this week, he also said that skill set is the biggest challenge.” MEN

The company aims to establish a strong presence in the region

John Chang

Features

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

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EMO Hannover 2011 was staged under the motto of ‘Machine Tools and More’. The six-day event in Hannover, Germany saw some 2,037 exhibitors from 41 different nations took part and featured the latest machinery, solutions and services for every

aspect of metalworking.

The Drill 300 by AgieCharmilles has a

compact fixed table design with X x Y

of 600 x 400 mm and Z x W

travel of 450 (650 optional) x

450 mm. Its generator and

dielectric unit are integrated

into the machine, and various

automation and additional axis

options are available.

The hole drilling machine is equipped with the ISPG generator with maximum mean current

30A (60A optional) and a pulse duration down to hundreds of nanoseconds. The form of current

pulse is optimised for EDM drilling, with ISPG generator for low electrode wear and an affected

layer less than 10 μm was obtained.

The machine has a range of technologies for various electrode for workpiece materials like

Inconel, titanium, steel and carbide.

WorldOf Metalworking

From The

GF AgieCharmilles gave six milling and EDM

products a world premiere at EMO 2011.

They are aimed at triggering customers’

success in demanding manufacturing areas

from automotive, aerospace and aeronautics,

and medical and dental technologies, to

electronic components and information and

communications technology.

Some of the products making their debut

at the show were:

- Mikron HSM 600U LP high-speed milling

machine for prototype production, die-

making and fully-automated, low-volume

series production where accuracy and

surface finish are key success factors

- Mikron HPM 450U milling machine with

torque rotary tilting table for unlimited five-

axis machining

- Form 300 vP, a flexible die-sinking machine

for greater autonomy

- Form 200 mS die-sinking EDM machine that

masters the details for geometric quality

- Cut 2000 OilTech, which uses oil as a

dielectric to make surface protection the

top priority

GF AgieCharmilles: Hole-Drilling EDM Machine

Special Report


Fine Cutting: Cut 1000The Cut 1000, though not a new product on show, has been retrofitted with an Integrated

Vision Unit, to deliver optical access to details that a 3D probe does not. The vision

unit now adds in-process measurement to its accuracy and fine cutting ability, cutting

down process and set up timings. Enquiry No. 8601Turn to page 80a or log on to www.equipment-news.com to enquire

Six World Premieres Products Shown From GF Agie Charmilles At The EMO 2011



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ENQUIRY NO 198

Special Report

DMG/Mori Seiki: A Show Of StrengthDMG/Mori Seiki showcased 97 machines at

EMO, including 25 world premieres from all

areas of technology on a total exhibition area

of 7,600 sq m.

Cooperation Sustains Innovation

In the press conference held by the company

during EMO, Dr Ruediger Kapitza, chairman

of the board of Gildemeister and Dr Masahiko Mori, president of Mori Seiki gave some updates

on the cooperation as well as the current economic climate.

On the economic front, Dr Kaptiza said that the machine market worldwide is growing and

the economic woes that happened some two years ago “will not be repeated.” He also cited

Germany as the growth driver for Europe in 2011.

Speaking on the cooperation efforts between the two companies, Dr Mori said cooperations

would be in production components, procurement, R&D, sales & services and customer

financing. The main aim is to make gains in efficiency for the companies’ customers by bundling

resources and expertise.

The pair also spoke at length on the formation of DMG/Mori Seiki Deutschland. The “super

team available” at the new partnership will receive 100 percent support in sales and services.

R&D Efforts

Away from the economics, the two companies also made good their promise at JIMTOF 2010

and presented a jointly developed machine at EMO. Dr Mori revealed the NHX 4000 was a joint

development alongside the CTX 310 Ecoline, which is currently being produced in Shanghai, China

at a rate of 150 to 200 machines a month. The first joint development however was the Milltap 700.

The vertical milling and boring centre achieves top values in all processes with its combination

of work capacity and chipping performance. It also achieves good performance on the tapping

centre market.

Productivity and efficiency were at the core for development of the machine. For this reason,

the companies have concentrated their innovative power and equipped the vertical milling and

boring centre with a series of technical details.

The high machining speed usual in the field of tapping centres is supported by a high-speed

tool changer, which achieves chip-to-chip times of 1.5 seconds and so enables an efficient

process. There is also a special feature: The complete drive of the magazine — it takes 15 or

optionally 25 tools — is integrated into the spindle head.

Ecoline: Quality & Economics Combined The Ecoline turning-milling machines on show came in a new design that ensures functionality

and ergonomics plus an enhanced performance due to faster rapid traverses and more

powerful spindles.

A feature of the design is the Progressline, whose display allows the operator to see at a

glance the remaining running time of the workpiece and the quantities of the machining job.

The introduction of the DMG Slimline Panel with Siemens 840D solutionline with

program navigation and 3D simulation is the fastest control in the entry level, according to the

manufacturer. The control portfolio has been expanded to include the DMG Slimline Panel

with Heidenhain 620 and MAPPS VI from Mori Seiki.

New Products From Ecoline…

CTX 310 Ecoline & CTX 510 Ecoline

The combination of functionality,

efficiency and user comfort make the

two universal lathes in the CTX Ecoline

family an option. The turret equipped

with a servo-synchronous-motor

reported a 100 percent reduced tool

change time (a tool change of two

60 deg tool stations, for example,

in just 0.4 seconds) and hydraulic

interlocking that ensures top dynamics

and stability.

DMU 50 Ecoline

The CNC universal milling machine

DMU 50 Ecoline has an optional

10,000 motor spindle for optimum

surface quality and a 30-piece tool

magazine for more flexibility during

five-sided-machining.






EVENTs&ExhibiTioNs

ENQUIRY NO 192

Koerber Schleifring: On The Up

The upturn in the economic situation, which

started in the second half of 2010, has

also had an impact on grinding machine

manufacturers and has continued into 2011.

The pent-up demand in almost all customer

industries ensured that during the first half of

2011, the Schleifring Group too experienced

an increase in orders of nearly 70 percent,

compared to the same period last year.

The technology division of tool grinding

was the first to benefit from this boom and

now the surface grinding, profile grinding

and cylindrical grinding divisions are also

showing comparable growth rates. This

trend has had a positive effect on turnover,

which rose by almost 70 percent compared

with the previous year.

With its eight corporate brands, the

group is the world’s largest supplier of

Taiwanese OffensiveExecutives from some of Taiwan’s largest

machine tools companies discussed trends

in the industry at this year’s EMO Hannover.

Special Report

Ewag Laser Line

Walter Ewag unveiled the company’s

development for complete tool machining

using laser ablation. Supported by existing

technologies for grinding, electrical

discharge machining, and measuring, the

company is now a full range manufacturer

for tool machining technology.

In deve lop ing the Laser L ine,

application flexibility was a major priority

right from the start. A kinematics concept

was pursued that superimposes three-

axis laser beam guidance (U/V/W) on

a five-axis machine kinematics (X/Y/Z/

B/C). This enables the laser processing

of tool cutting edges as well as the laser

ablation of complex chip grooves to be

performed in one clamping operation.

An integrated 3D measuring sensor is

used to accurately measure the soldered

diamond blank. This enables bumps

created during the soldering process to

be compensated for and guarantees an

accurate lens position.




grinding machines. As a result, it has

established an international market

presence, which is customer-oriented and

efficient. As described by Stephan Nell, the

CEO of Koerber Schleifring, the company’s

major strength is the global presence that

they have and they are a “reliable partner”

who will “improve the competitiveness of

their customers.”

In recent years, the companies of

the group have continued to invest in

research and development resulting in newly

developed machines, like the Ewag Laser

Line, the Blohm Orbit precision surface and

profile grinding machine and the Studer S41

universal cylindrical grinding machine.

A p r o d u c t s l a u n c h f e a tu r i n g

Taiwanese machines took place at a

press conference at the show. According

to recent estimates made by the Taiwan

Association of Machinery Industry,

the total output value of Taiwan-made

machine tools could hit US$4 billion by the

end of 2011, making Taiwan the world’s

third largest machine tools exporter. The

island currently stands at the fourth spot

globally. As the demand of the emerging

Asian markets for national economic

construction continues to increase,

experts predict that Taiwan’s machine tool

exports to the global market will expand

to US$7 billion in 2015.



EVENTs&ExhibiTioNs

ENQUIRY NO 133

The Grob Group embarked upon this year at

the EMO Trade Fair with a range of technical

innovations. They are hydraulic-free CNC

machine tools in five-axis technology with an

additional sixth axis for workpiece clamping,

along with other new developments in

hydraulic-free machine tools.

Loading & Automation Concept With

Part Changer

The part changer is secured to the front of

the machine and has two linear axes. The

first linear axis moves the workpieces with

two loading forks in an X direction from the

raw part position to the loading position, or

from the loading position to the finished part

position. The second linear axis is designed

as a telescopic axis and transports the

workpieces from the loading position to the

working area and back again.

Compact Linear Gantry

The part changer is loaded and unloaded

with the aid of a smaller linear gantry. The

X beam is about 3.2 m above the floor of

the plant, making it much lower than was

previously the case. The vertical suspension

of the carriage and of the loading arm on

large castors underneath the X beam is

another new development.

Program For The

Modular Special Machine

A modular machining unit has been

Developments At Grob

developed by the company, which also

supports clamping positions for two

workpieces — for short cycle times and

during pre-machining processes on the

workpieces. This makes the units and the

combined machines more high-performing

and efficient, and more compact and

more space-efficient in terms of their

dimensions.

Milling, Turning & Machining Centre

Taking the G-module series as a basis, a

type of machine has been developed in

the form of a milling, turning and machining

centre, combining the cutting tasks of milling

and turning in a single clamping action.

In the development of this, the engineers

attached particular importance to the axial

arrangement of the single-spindle five-axis

series G 350 and G 550.

Electromechanical Pallet Changer

As a complementary model to round

off the hydraulic-free machine tool,

the company has developed a fully

electromechanical pallet changer. The

pallet is clamped and held in place

mechanically on the loading/unloading

station and work area side. It also enables

the cycle time of the loading process to

be shortened and accelerated.

Trumpf

Trumpf showcased the laser deposition

welding at the EMO as a manufacturing

method for wear protection, repairs and

prototyping which reduces the usage of

materials and energy.

Two applications for laser deposition

welding were seen at the show. A

deep-drawing tool used in automotive

manufacturing shows how effectively laser

deposition welding can protect surfaces

against wear and tear. This heavy-duty

tool is used for hot-forming and press-

hardening elements such as the B-pillars

on bodyshells. In the case of press-

hardening, the components need to be

quenched; this is done by cooling the tool.

The more efficient the cooling, the shorter

the cycle time.

With this deep-drawing tool, pipes are

integrated in globular gray cast iron. The

advantage is that the pipes can be routed

close to the tool surface. The disadvantage

is that the cast iron is very soft. As such,

the tool needs to be armoured with a hard

wear layer.

Following forming, the components

are so hard that they substantially improve

the safety of the passenger cell. The hard

deposition-welded protective layer ensures

long tool life. This cooling technique

reduces the cycle time of a component by

up to 35 percent.



Special Report



EVENTs&ExhibiTioNs

Mikron Unveils Machining Concept




PamaWith the annual revenue of €147 million

(US$195 million), the Italian manufacturer

large machine tools is going places. With

over 80 percent of production exported

mainly to China, India, Russia, Germany and

the US, the company revealed at the press

conference at EMO that their new plant in

Lingang, Shanghai will be ready in 2012.

With the motto: Winning the challenge

of market, the company showcased its

Speedram 3000 at EMO. It is a floor type

boring and milling machine. The structure of

the machine has been designed to increase

rigidity, without increasing mass, to maintain

the dynamic characteristics of the machine.

Machine is also equipped with a

headstock balancing system that evenly

dissipate the forces acting on the column,

minimising its deflection effect.

In addition, an adaptive system has

been introduced to the machine, which

integrates the spindle absorbed power

reading with signals provided by a tri-axis

accelerometers.Faster, deeper and more efficient — this is

Walter’s motto for EMO 2011. All customers

from the automotive industry, aerospace

industry, energy sector, mechanical

engineering and rail transport sectors, and

also from other metalworking sectors, can

draw benefits from the products.

Tiger·tec Silver On The Advance

Tiger·tec Silver technology can now also

demonstrate its strengths during turning. A

generation of indexable inserts for steel chip

removal during ISO turning was on display

with the Tiger·Tec Silver ISO P generation

for the first time at EMO. According to the

maker, it can give an increase in output of

up to 75 percent.

At the centre of the presentation at EMO was the machining system Multistar NX-24. Presented

under the heading ‘The best of productivity with CNC flexibility’, a machining concept was

introduced, which combines productivity with flexibility and precision.

The company still offers the Rotary Machining System among its line of Transfer Machines.

It achieves up to 150 cycle steps per minute and can produce up to 520 parts per minute when

equipped with four cycles per machine.

The machine is designed for high output, large volume production but because it is

fully mechanically controlled, change-over can take time. The system increases flexibility

and this with only slight reduction in the output capability. Therefore it is especially suitable

where different types of work pieces must be produced in quantities from a few hundred

up to many thousands of parts, within accuracies in the hundredths of a millimeter range.

Records For Speed & Depth

The Alpha 4 XD drill from Walter Titex

has set a world record. The solid carbide

drill with internal cooling is the only

spiral drilling tool which offers a drilling

depth of 70xD, without pecking. The

company is producing solid carbide

blanks by applying a new method,

which makes this type of long solid

carbide twist drill possible. The drill is

suitable for machining steel, cast iron

and non-ferrous metals. It is available in

a range of diameters from 5 - 12 mm as

a special tool. Compared to the gun drill,

the XD drill offers a ten-fold increase in

performance.

Time & Costs Savings

The ConeFit modular solid carbide milling

system from Walter Prototyp has been

gradually extended. With ConeFit Spade

Type, the company introduced a double-

edged, pressed modular tool for the ConeFit

system at EMO. It is suited to copy milling,

plunge milling, chamfering, centring and

spot-facing holes. Also new are versions

that have been developed for graphite

machining.

Walter Demonstrates New Products At EMO

Mik

ron

SA

Ag

no

Special Report


Nov-Dec 2011 metalworking equipment news 65

EVENTs&ExhibiTioNs





Renishaw: Versatile Gauging System

The Equator gauging system from Renishaw is billed as an alternative to traditional dedicated gau g i n g t h a t c u t s purchase, maintenance and fixture costs, can be pre-programmed for multiple parts, and re-programmed in minutes for design changes.

The system, which is capable of high-speed

comparative gauging for inspection of high-volume manufactured parts, has reportedly been developed on the shop-floor in collaboration with industry-leading companies in the auto, aerospace and medical sectors.

The result is a lightweight, fast and repeatable gauge that operators can apparently use with push-button simplicity. Since the solution can switch between parts in seconds, it is seen as suitable for flexible manufacturing processes or accepting parts from multiple machines.

Mitutoyo: High-Speed Scans

Aicon: Simulation Module For Bending Machines

Seco: Making Milling Simpler

With the launch of the software version 4.7, Aicon’s optical tube measuring system TubeInspect will be extended by a practical function: Now the operator has the possibility to simulate the bending process considering individual correction values, and to verify their effect on accuracy to gauge by means of a virtual gauge check.

With the help of high-resolution digital cameras, the system determines the tube geometry within seconds. Beyond that, the system shows in detail which bending points deviate from the desired values, and suggests correction values. These correction values can be transmitted directly to the bending machine, whereby the system allows the connection to up to 100 benders.

Mitutoyo presents a generation of the series of coordinate m e a s u r i n g machines with the models Crysta-Apex S 500, 700 and 900.

Compared with the previous versions, the current models of the series feature a higher scanning rate with a high accuracy. This increase is made possible by the integration of the UC400 controller.

These CNC-controlled coordinate measuring machines, which were designed and built especially for the demands of the European market, are versatile and have a wide range of applications. With their capabilities and comprehensive equipment, they offer much more than usual in this class.

The modern tool system Minimaster Plus by Seco with replaceable fluted inserts makes milling simpler and more productive. A manufacturing technolog y a l lows heav y- duty, versatile usable milling cutters show convincing performance with regard to high precision and long tool life.

The most significant innovation of Minimaster Plus is the precise and secure interface between the replaceable carbide insert and the steel shank. The insert has an

internal thread and external taper, while the shank has an internal

taper with a threaded centre pin both giving additional

reliability as well as high run-out precision and high stability.



Products




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Walter: Solution For Cast Iron Workpieces

T he Xt ra·te c mi l l F4045 is fitted with indexable inserts with 14 cutting faces a nd ha s been optimised for the machining o f c a s t i r o n materials. Walter has adapted this tool with a medium pitch to wea ker machines and unstable clamping conditions.

Stable machines, workpieces and clamping arrangements are required for achieving maximum cutting rates. Only in such conditions can a tool achieve its highest performance. Because workpieces with complicated shapes do not always permit rock-solid clamping, many operators prefer to use less stable, yet movable machining centres due to their flexibility, and so a tool like the heptagon cutter is used to its full potential.

In deep-hole drilling applications up to 30XD, solid-carbide Widia-Rübig deep-hole drills remove between three and four times the metal compared to gun drills, in addition to delivering good hole quality and cycle times.

Length ratios for the deep-hole drills are available in 15XD, 20XD, 25XD, and 30XD. Available diameters range from 3.0 to 13.0 mm.

Along with increased performance, the solid-carbide deep-hole drills increase process versatility by not requiring special drivers or guide bushings. And where gun drilling machines are dedicated to gun drilling only, the deep-hole drills can be used in machining centres, eliminating the need for specialty capital equipment.

Widia: Deep-Hole Drills System 3R: Automation In Pallet Changing

T h e a d d i t i o n t o S y s t e m 3 R ’ s automation program is WorkPartner 1+, a robot characterised by a design that is tuned to match modern tool machines in efficient production cells.

T he system is a compact unit for changing pallets (of up to 50 kg in the standard format) on machine tables and at machine spindles in one or two machines. The served machines may be of the same type and make. They can also just as easily use different machining technologies and come from different manufacturers.

It offers magazine capacity in minimum floor space. The modular magazines give flexibility that can be adapted to each user’s needs.

See Mastercam X6 in action at www.mastercam.com.sg

Design Enhancements

New OptiRough Toolpath

New Dynamic Milling Techniques

Easier Multiaxis Machining

New Plunge Turn Toolpath

Mastercam Machine Simulation

Smart Hybrid Finishing

Techtown Pte Ltdwww.techtown.com.sg • [email protected] : +65 6636 8215 • Fax : +65 6636 8221

Manufacturing Indonesia 2011Stand 8917 Hall D

Metalex 2011Booth 6P04



Products



SeaCAD Technologies, in association with Dassault Systèmes SolidWorks hosted the ‘SolidWorks

2012 Product Launch’ at the Megu Event Hall, located at the Singapore Flyer on October 4, 2011.

The event gave approximately 300 design professionals from 115 companies in industries as diverse

CAD/CAM Partnership Continues To Blossom With Product LaunchSeaCAD and Dassault Systèmes SolidWorks release the 2012 version of the design software. By Shahnawaz Abdul Hamid

SolidWorks 2012 To Help Companies Make Better Cost Decisions

Ms Toh told APMEN: “Prior to launching

SolidWorks 2012, we had a beta testing

exercise. Previously, we told users to

download the beta version and test, and

submit any issues they had to us. But for

this version, we did something different. We

actually organised a group-level test. Our R&D

engineers went to Pune, India to meet a group

of SolidWorks users. The testing of the 2012

software was done in front of these engineers.

This helped the user directly communicate his

concerns to the engineer.”

When asked which new features would

be most exciting to the design engineer, Ms

Toh cited the Feature Freeze and Costing Tool.

The Feature Freeze increases the speed of

designing complex models where rebuilding

specific features is not needed while the

Costing Tool allows designers to make more

informed cost-based decisions throughout

the design process.

“The process of engaging the customer

has led us to realise that design engineers

make a lot of decisions. However, they lack

the tools to make good cost-related decisions.

They don’t see how their decisions impact the

cost of the product. Therefore, in this latest

version, we have a costing module. This

allows the design engineer to accumulate the

company’s costing information when making

design decisions,” she added.

as aerospace and defence to office equipment a sneak preview of SolidWorks 2012.

The event began with the founder of SeaCAD Technologies, Conrad A Montgomery; recounting before the audience the early experiences he had trying to singlehandedly sell a virtually unheard of SolidWorks to the manufacturing industry.

Today, more than a decade later, the company, where he is president and CEO, boasts a 520 sq m office at the Enterprise Hub. It is ‘home’ to 31 specialists; all dedicated to selling the same product, albeit one that has grown more popular over the years. The company, Mr Montgomery is proud to add, has commercial licenses amounting to 3,000.

His opening address was followed by a speech by Kelvin Ang, the territory technical manager for Dassault Systèmes SolidWorks. Mr Ang spoke on the changing world of CAD. “Gone are the days when we only use CAD. We now use product design, together with design validation, together with product data management.”

Indeed, it appears SolidWorks 2012 aims to seamlessly integrate design data across all work functions. Initial reports indicate the 2012 version will continue to do well in the CAD/CAM industry. The product features over 200 customer-driven enhancements.

The event concluded with the SeaCAD technical team demonstrating to the audience the various features of the software.

In an exclusive interview with Asia Pacific Metalworking Equipment News, Sharon Toh, GM of Dassault Systèmes Singapore, shares how her company’s most recent offering will help design engineers make better decisions.

Conrad A Montgomery

Sharon Toh



EVENTs&ExhibiTioNs

ENQUIRY NO 172

Event Review:

For the first time in Vietnam, ‘Industrial Components & Subcontracting Vietnam 2011’, ‘SI Exhibition:

Vietnam-Japan Support ing Industries Exhibition 2011’ and ‘Vietnam Manufacturing Expo 2011’ joined forces at ICE Hanoi and showcased today’s technologies as well as high quality parts to support the growth and improvement of supporting industries in Vietnam.

Over 9,774 visitors came to visit the shows to source for suitable machineries to expand their productivity and diversify their range, while also meeting up with potential partners from many countries including Thailand, Singapore, Japan and others to create a new market.

The atmosphere of the shows was lively and provided a positive sign for the future of supporting industries in Vietnam. Moreover, with more intense level of cooperation among different associations and companies from different countries, the way to the international market for Vietnam supporting industries was opened. The number of visitors this year is an increase of 32 percent when compared to the last.

Voices From The IndustryChanin Khaochan, director of BOI Unit for Industrial Linkage Development (BUILD) said: “There are lots of exhibitors from within Vietnam, Thailand and Japan at these exhibitions with all kinds of supporting industries products to offer. Visitors get the

Vietnam Manufacturing Expo 2011


opportunity to gain access to new technologies and improve their industries. I expect that exhibitors of these shows will get to increase the level of cooperation to produce higher-quality products while visitors can learn new technologies which would help them in their own business.”

Vivien Yen, project manager, International Trade Development S ingapore Manufacturers ’ F e d e r a t i o n s a i d : “ T h e s e exhibitions are very well organised and useful for both exhibitors and visitors. Currently, supporting industries in Vietnam have a lot of advantages and opportunities for future development. Through our participation in these shows, the Singapore Manufacturers’ Federation hopes it will increase the chance for our members to get more exposure and contacts with the local companies as well as Japanese companies here.”

Ronnie Wong, president of The Association of Electronic Industries in Singapore (AEIS) said: “This year, the Association of Electronic Industries in Singapore has brought machines for electronic, connectors and battery as highlights for the electronics industry. We are looking forward for companies from Singapore to network with local companies in Vietnam and promote our products to be known here. Although the supporting industries in Vietnam are now at an early stage, I believe that this scenario will change in the next five years through the set up of factories, purchase of new machines, as well as technologies and human resource training.”

ICE HanoiHanoi, VietnamSeptember 15 – 17, 2011



EVENTs&ExhibiTioNs

ENQUIRY NO 205

Event Review:

Wire / Tube Southeast Asia recorded figures of 392 exhibitors and more than 5,300 trade visitors from about 60 countries, of which some 40 percent

came from outside Thailand. The exhibitions, which took place at BITEC (Bangkok International Trade and Exhibition Centre) from September 13 - 15, 2011, exceeded expectations with visitorship that saw an increase of 20 percent from 2009.

ASEAN visitors’ inclusive of Thailand accounted for about 80 percent of the total visitor attendance, signifying that ASEAN buyers view the event as the forum for trade and business and the gateway to Southeast Asia for product distribution for wire, cable, tube and pipe sectors in the region.

The strong visitor attendance, particularly from Indonesia, Malaysia, Singapore, and even India also further highlighted the increasing significance of ASEAN as a ‘collective whole’ and dynamic common market moving towards a single economic community by 2015. Information ExchangeNumerous discussions took place on the show floor during all exhibition days, together with visiting delegations from China, Malaysia, Japan, Philippines and Vietnam boosted the professional atmosphere of the show.

The response from the local, regional and international sectors to the exhibition this year has propelled it to yet another important stage in its strategic development. Gernot Ringling, MD of Messe Düsseldorf Asia commented: “The results of this year’s wire and Tube Southeast Asia proves that business in the wire, cable, tube and pipe sectors in the region is expanding strongly, driven by continued economic growth in Thailand and the Southeast Asian region.”

Highlights Of The ShowHighlights from this year’s exhibitions, included eight national pavilions and groups from Austria, China, Germany, Italy, Singapore, Taiwan, UK, and USA. There was also a creative design showcase on stainless steel industrial products presented by members of the Thai Stainless Steel Development Association.

The growth in the number of international visitors attending was due in no small part to the success of the technical seminar series held in July this year in Jakarta, Taipei and Seoul which placed a spotlight on leading companies.

Wire/Tube Southeast Asia 2011


Messe Düsseldorf Asia has announced dates for wire / Tube Southeast Asia 2013. It will be held on September 17 - 19, 2013 at BITEC, Bangkok.

BITECBangkok, ThailandSeptember 13 - 15, 2011



EVENTs&ExhibiTioNs

ENQUIRY NO 194





Delcam: Enhancements To Feature-Based Machining Software

Delcam has launched the 2012 version of its FeatureCAM feature-based CAM system, with a range of enhancements to enable faster and easier programming, and produce more efficient toolpaths to give greater machine productivity.

A number of the improvements will make the program even easier to use. For example, a range of keyboard shortcuts has been added, including isometric view options that will allow faster programming. It has been made easier to select multiple items from the operations tree and to move all the features in a group, for example, a network of similar holes or all the operations on a particular spindle.

Autodesk: Cloud Services

Autodesk has developed Autodesk Cloud, a collection of more than a dozen web-based capabilities, products and services. It enables customers to extend their desktops with greater mobility, new viewing and sharing capabilities, and more computing power, helping them better design, visualise and simulate their ideas.

Additional cloud services exclusive to subscription customers give designers, engineers and digital artists new capabilities, such as high-performance 3D visual communication, simulation and collaboration that were once limited to organisations with privileged access to expensive, high-end supercomputing centres.

Faro: Measuring Software

CA M 2 M e a su re 10, the measuring software for the FaroArm, ScanArm and laser tracker has been developed by Faro. The software is built on the foundation of the previous CAM2 Q while also introducing key features like Live Colour Scan for point cloud inspection, Shortcuts and the Easy Move Wizard. These functionalities are designed to improve the measurement processes, whether tactile or scanning.

Designed to make tactile and scanning measurements easier, the software also features an interface that enables users to customise the layout window optimising the measurement workflow.

Heller: Five-Axis Machining With Turning Function

Usually a five-axis machining centre does not provide a turning machine’s capability of horizontal or vertical turning or tilted turning with A and B axis. However, the cutting performance of Heller’s C series will make it possible to perform such operations on a machining centre.

This machine series provides economically efficient cutting data to enable workpiece rotation of up to 1,000 RPM for performance-oriented pre-machining and finishing true to the final contour.

The manufacturer offers the C series in two sizes: C 2000 and C 4000. Options include a version with direct manual loading onto the table of the machine (CT) or with integrated pallet changer (CP) and hydraulic clamping.



ProductFinder



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With the continuing evolution of machining requirements to satisfy new power generation production needs, Mitsui Seiki has developed the HU63-T 5-xis CNC Machining Centre. Typical applications include critical rotating components (blisks, impellers, and turbine disks) for gas turbine power generation systems.

Features and specifications include up to 800 mm work diameter capacity on its vertically oriented table, 300 kg work / fixture weight capacity, variety of increased axis stroke options, high torque spindles (1,081 Nm – 800 lb-ft continuous), tuned structure for heavy cutting in hard metals, and the Fanuc 30iM control with enhanced features for five-axis simultaneous machining.

Mitsui Seiki: Machining Centre For Power Generation Parts

Matrix Machine Tool: CNC Internal Thread Grinder

M a t r i x h a s d e v e l o p e d a small footprint CNC inter na l thread grinder — Model 3060. T h e g r i n d e r

includes features like torque motor driven workhead and HF wheel head motor among others.

The machine, which has a swing capacity of 300 mm and a maximum grind length up to 150 mm makes it suitable for a variety of applications within a diverse range of industries such as the automotive, aerospace, metrology, automation and oil/gas.

The manufacturer has also released the Matrix Profilemate, which is the company’s own thread profile generation software.


www.equipment-news.com ProductFinder





SolidAce: Structural Steel Design & Engineering Application

SolidAce has released the version 2.0 of BuiltWorks, a structural steel design and engineering add-in application for SolidWorks CAD environment.

Version 2.0 fully support the corresponding version of 3D CAD platform — SolidWorks 2011. The maker also decided to continue the support of previous platform version of BuiltWorks 2010 for SolidWorks 2010 due to multiple requests from user community.

Some of the features in the software program are the improved performance in trimming operations and some functions working with plates and full support of cardinal points without changes to offset value in placement of steel members.

Tungaloy: Double-Sided Inserts

Dorec from Tungaloy is a family of double-sided inserts with four helical cutting edges and tools for 90 deg milling. The insert construction is thick and strong, with a wiper, which leaves a good surface finish. In addition, clamping into a dovetail inclined pocket provides rigid clamping.

The tool features durability, low cutting forces and long tool life, due to its strong construction and chip deflector with positive cutting angles. It is suitable for machining steel, stainless steel and cast iron at high machining parameters.

TMT: Turn/Mill Machine

The L-290M from TMT is a heavy duty, precise, versatile CNC turning and milling machine for customers who need machines with comprehensive machining capabilities and accuracy.

The machine’s X and Z axis are box guideways. They present accurate and durable characteristics for various turning applications. The 125 mm X axis and 500 m Z axis allows a maximum cutting diameter up to 250 mm. The spindle uses the NN type bearings (double-row cylindrical roller bearings) for high precision, even under heavy cutting loads, and its 66 mm bore accommodates larger bar capacity up to 52 mm.

Open Mind: CAM Software Program

Open Mind Technologies has released hyperMill 2011. Automated functions and technologies in the release helps to reduce machining costs and times. The features include intelligent macros, 64-bit support, application programming interfaces and customised process features. New strategies such as five-axis shape offset roughing and finishing allows for even more efficient programming.

The programming environment offers forward-looking solutions for 2D, 3D, HSC and five-axis simultaneous machining. Users can draw from a range of functions for optimised processes, time-saving, comfortable workflows and efficient machining.


www.equipment-news.comProductFinder

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1600 tons Front Runner with 2 x 1000 tons and 2 x 800 tons

DEES' Taiwan and China Factories are all ISO-9000 Certified

DEES HYDRAULIC INDUSTRIAL CO., LTD.

www.deesgroup.com.tw

TAIWAN HEADQUARTERS / FACTORY: Tel.: +886-2-2601-8661 Fax: +886-2-2601-8936 E-mail: [email protected]

10 to 6,000 Ton CapacityWanted:

Machine Building PartnerContract ManufacturersQuality Value Toolmakers

[email protected]

We are an Australian medical device company that requires specialized one-off machines to make patented, unusual products. We are seeking to outsource the construction of several machines. We will be providing significant amount of design input. Also, we require manufacturers with ISO 9001 to operate our machines. We will provide all raw materials and training. You will need approximately 500m2 of space, container access and preferably located in Thailand, Indonesia, Vietnam, Singapore or Malaysia.

We are also looking for:• Polyurethane with 14kg/m3 density• PET or Polypropylene 180 micron sheet with high quality optical

properties. Clear without scratches, with coating for a surface tension appropriate to print.

• Service supplier who can print and die cut PET approximately 4-6 tonnes per month.


www.equipment-news.com ProductFinder

Over the course of this year, we have rolled out new initiatives and products to bring you to the forefront of metalworking.

Gives You More


For more information, please contact:

[email protected] tel: (65) 6379 2888 • fax: (65) 6379 2805

Print Media

Online Media

New Magazine


ExhibitionProgrammes

2011-2012NovemberNov 29 – Dec 2EuromoldFrankfurt, [email protected]

Nov 30 – Dec 3Manufacturing Indonesia 2011Jakarta International Expo KemayoranJakarta, IndonesiaPT Pamerindowww.pamerindo.com

December21 – 24MetalexBITECBangkok, ThailandReed [email protected]

2012JaNuary19 – 24IMTEXBIECBangalore, IndiaIndian Machine Tool Manufacturing [email protected]

February 21 – 22SAMPE Asia 2012KL Convention CentreKuala Lumpur, [email protected]

21 – 23Composites 2012Las Vegas, USAACMAwww.acmashow.org

march28 – 30MTA HanoiInternational Center For ExhibitionHanoi, [email protected]

28 – 31Inapa 2012JIExpo KemayoranJakarta, IndonesiaPT GEM [email protected]

april11 – 13Indonesia Oil & WGas Expo 2012JIExpoJakarta, [email protected]

17 – 22SIMTOS 2012KINTEXSeoul, South [email protected]

18 – 21InterMoldIntexOsaka, JapanJapan Die & Mold Industry [email protected]

may9 – 12INAMarine 2012JIExpoJakarta, IndonesiaPT GEM [email protected]

15 – 19Metaltech 2012PWTCKuala Lumpur, MalaysiaTrade [email protected]

17 – 20Intermach 2011BITECBangkok, ThailandUBM [email protected]

July 3 – 6MTA VietnamSECCHo Chi Minh [email protected]

November7 – 10Indo Aerospace 2012JIExpoJakarta, Indonesiawww.indoaerospace.com


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ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing, Automation & Quality Control


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4T TEcHNoLoGIES PTE LTD 33 126

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AGMAcHINE TEcHNo co LTD 75 068

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❑ 324 Inspection/Measuring/Testing

❑ 301 Design with CAD/CAM

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❑ 317 Automated Assembly

❑ 320 Beading

❑ 323 Electroplating

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ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing, Automation & Quality Control

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

Match the most expansive portfolio of precision-engineered products and custom solution services available today with a global, specialized network of authorized distributor partners and you have the tools you need — and the power that only comes from WIDIA brands. For product information, or to schedule an onsite demonstration, call (65) 6265.9222 or visit www.widia.com.

www.widia.com©2010 Kennametal Inc. l All rights reserved. l A-09-02229

Our complete portfolio.Your complete satisfaction.

• Australia 1300.094342 • India 9180.2839.4321 • Japan 813.3820.2855 • Malaysia 603.5569.9080 • Singapore 65.6265.9222 • China 8621.3860.8288 • Vietnam 84.8.38447917.21 • Korea 822.2109.6100 • Taiwan 886.4.23501920 • Thailand 662.642.3455

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