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SECO TOOLS (SEA) PTE LTDTEL +65 68412802FAX +65 [email protected] ENQUIRY NO 129

www.equipment-news.comasia pacific metalworking equipment news October 20132

38 Adapting To CompositesAdaptive machining, with its ability to use in-process measurement, has emerged as a suitable technology to machine composite materials. By Peter Dickin, Delcam

46 Staying Cool Under Fire Cutting and bending systems play an instrumental role in the manufacture of armoured command-and-control vehicles. By Yoichi Shimatsu, for Bystronic

26 Gearing Up To Better Chamfering & Deburring ProcessesThe chamfering and deburring of gears is an often undervalued process in gear production, but it has a great influence on the usage characteristics of the workpiece. By Karl Schäferling, Gleason

CUTTING EDGE20Deburring With Abrasive Filament BrushesAbrasive filament brushes can selectively deburr and provide an effective and efficient way for deburring parts. By D Mark Fultz, Abtex Corporation

SOFTWARE & METROLOGY34 Cut Out The CrashesMachine simulation is the five-axis programmer’s constant companion. By Karlo Apro, CNC Software

TECH TALK30 Clean Up Your ActLike many processes in the metalworking industry, cleaning techniques have not stood still. By Augustine Quek

CONTENTSOctober 2013

FORM.JOIN.CUT44Quick Draw With AutomationAutomated control system can play an influential role in the cycle time of a deep drawing press. Contributed by David Chia, Beckhoff Automation

INDUSTRY FOCUS50 Messerfabrik Neuenkamp Slits Its Way Into AsiaAsia Pacific Metalworking Equipment News (APMEN) caught up with Ruediger Uhlitz, GM (Sales) of the company to shed some light on the world of slitting and his business endeavour in Asia. By Joson Ng

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ENQUIRY NO 193


CONTENTS

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58Case Study: Pressed For TimeAn enforced regulatory requirement has given rise to the implementation of a hydraulic press line that produces parts for various models at Renault Truck. By Simon Scherrenbacher, Schuler

70Event Review: Iscar Seminar DayProductivity was high on the agenda in this one-day seminar. By Joson Ng

52 Automakers Driving Into ASEANASEAN offers significant opportunities to global automakers in near to medium term. By Vijay Rao, Frost & Sullivan

68‘Piping Hot’ GrowthSteel tube production is on the rise with China leading the way. By Petra Hartmann-Bresgen MA, Press Department of Tube 2014

60The Best-Laid PlansCraig Charlton of Epicor Software Asia shares how the right ERP system can help customer retention in the automotive manufacturing industry.

62Optimised For SpeedOn-time delivery is one of the most important parameters in the production of assembly components in the automotive industry. Contributed by Jaslin Huang, Walter AG Singapore

FEATURES64Delcam Asian Technical Summit 2013The arrows are pointing up and this trend looks set to continue well into 2014. By Joson Ng

EVENTS & EXHIBITION 71Event Preview: Oil & Gas Indonesia 2013 Event Preview: Metalex

ENQUIRY NO 017

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The ASEAN (Association of Southeast Asian Nations) Economic Community (AEC) aims to have regional economic integration by 2015. Besides establishing a single market and production base, the community aims to be a region of equitable economic development and to be fully integrated into the global economy.

The ASEAN Leaders adopted the ASEAN Economic Blueprint at the 13th ASEAN Summit back in 2007 to serve as a coherent master plan in guiding the establishment of the AEC.

Although the AEC is slated to be ready by 2015, there is much work to be done between now and then, said Singapore’s Foreign Affairs and Law minister K Shanmugam. He also added that the masterplan on ASEAN connectivity needs a lot of attention.

Likewise, two American business groups have voiced their concerns. In a recent survey jointly conducted by the American Chamber of Commerce

in Singapore and the US Chamber of Commerce, 475 senior US business executives from the region, or 52 percent of the respondents, said they do not think that the AEC’s goals will be realised by 2015. Of which, nearly 60 percent think that ASEAN will not reach the AEC’s goals until 2020 or later.

While the formation of the AEC might be facing some headwinds, the group, which comprises Brunei, Cambodia, Indonesia, Laos, Malaysia, Myanmar, the Philippines, Singapore, Thailand and Vietnam, has some stars which are shining brightly, in economic terms. They are namely Thailand, Vietnam and Indonesia.

Whether the 10 nations have what it takes to make the deadline of 2015 is anyone’s guess but one thing is certain, if the AEC succeeds in aligning the ‘stars’, the organisation will be better-placed to compete against larger economies in China and India.

Joson NgSenior Editor

chairman Stephen Taygroup executive director Kenneth Tan

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ENQUIRY NO 084

Delcam’s 45,000th Customer Is PT Astra Honda Motor From Indonesia

Birmingham, UK: Delcam is pleased to announce that it has added the 45,000th customer for its range of CAD/CAM software — PT Astra Honda Motor in Indonesia. The customer recently ordered seats of the PowerMill CAM system and PowerShape design software from the Delcam Indonesia subsidiary,

HE Mark Kent, British ambassador to Thailand (right), presented a plaque to Bambang Nugroho, GM of Delcam Indonesia, to mark Delcam’s 45,000th customer

plus the Delcam Electrode and FeatureCAM Wire EDM programs.

A plaque marking this landmark sale was presented by HE Mark Kent, British ambassador to Thailand, to Bambang Nugroho, GM of Delcam Indonesia, during the Delcam Asian Technical Summit held in Bangkok.

P T A st ra Honda Motor is a pioneer of the motorcycle industry in Indonesia. The type of Honda motorcycle that was first in production was the S 90 Z, which had a four-stroke engine with a capacity of 90 cc. Total production in the first year was only 1,500 units, but it has now jumped to around 30,000 each year and continues to grow today. Motorcycle usage continues to increase as they have become a mainstay of transport in Indonesia.

Currently, the company has three main plants in Indonesia employing about 18,000 people, with a combined production capacity of 4.2 million motorcycles per year. The total volume of motorcycles produced by the company reached 35 million in 2012.

Mr Nugroho said: “We are extremely pleased to have made the sale that takes Delcam to 45,000 customers. We look forward to working with the staff at Astra Honda Motor to help them produce motorcycles that are fun to ride, safe and economical, and so meet the expectations and needs of the people of Indonesia.”

Business Climate In Germany Improving

Munich, Germany: The business climate for industry and trade in Germany is on the ascendency, according to the Ifo Business Climate Index. The index revealed that companies are more satisfied with their current business situation. Their optimism regarding future business developments — although slightly cautious — also grew.

T h e b u s i n e s s c l i m a t e indicator in manufacturing rose significantly to its highest value since April 2012. Assessments of the current business situation were considerably better than last month. Business expectations also continued to brighten. Finally, firms expect stronger impulses from export business.

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ENQUIRY NO 177

Emerging Markets Stand Out As M&A Picks Up

Mu n ic h , G er m a ny : A m id signs that global Mergers and Acquisitions (M& A) activity is accelerating, the emerging markets remain a hotbed of M&A activity and will remain so for some time to come, according to a report by The Boston Consulting Group (BCG).

The so-called BRIC countries of Brazil, Russia, India, and China are leading the charge, accounting for 60 percent of all emerging-market deal activities.

Today, one in four M&A deals involves a buyer or seller from an emerging market. Emerging-market M&A tracks three broad investment themes: dealmakers from the developed countries are searching for energy and natural resources to fuel their economies, as well as opportunities to meet the surge of middle-class demand for consumer goods.

Emerging-market dealmakers are focused on acquiring technology

Sigurd Decroos, Oudenburg, Belgium

and management know-how from developed economies. In fact, veteran dealmakers and advisors increasingly report that BRIC-based acquirers are now seeking targets in developed economies that can serve as platforms for global expansion.

“The search for advanced management knowledge in combination with market access is emerging as a major motivation for outbound acquirers from the BRICs, especially China,” said Jens Kengelbach, a BCG partner and a co-author of the report.

Fast-Growing Consumer Markets Lure AcquirersAcquirers f rom developed countries, meanwhile, have widened their acquisition focus in the BRICs and other emerging markets. No longer merely seeking resources or low-cost labour, they are seeking growth in regions where the middle class is

expanding rapidly and disposable incomes are rising.

Cardinal Health, Disney, and Unilever are just three of the companies from developed economies that have recently made acquisitions in the BRICs, and the success of their deals is likely to spur activity by other consumer-facing companies.

Success in emerging-market deal making does not come easily, however. New research undertaken for the report reveals that, with one key exception, acquirers from emerging markets generate higher returns on emerging-market deals than acquirers from developed economies.

Emerging-market acquirers are generally more familiar with the cultures, languages, and markets of their targets than acquirers from developed markets, and that greater familiarity translates into a deal-making advantage.

As a result, emerging-market companies that acquire other emerging-market companies earn an average abnormal share-price return of 2.1 percent on their deals, compared with 1.0 percent for acquirers from developed economies.

But that advantage almost disappears if the developed-country acquirer has deep experience in emerging-market deal making. BCG’s research shows that serial acquirers from developed economies with a track record of six or more emerging-market transactions under their belts generate an average abnormal share-price return of 2.0 percent. The more deals a developed-country acquirer makes, the more it learns, and the more it learns, the better its chances for success.

Extracting Clean Materials From Coal In MongoliaSeoul, Korea: Posco is speeding up the clean CTL (Coal to Liquid) project with Mongolia’s largest private company, MCS. The CTL process produces a liquid-type fuel from coal that can replace oil, and has

greater cost competitiveness over imported diesel oil. Furthermore, less sulfuric acid and nitric acid are produced than when coal is directly burned, while most of the carbon dioxide formed can be collected


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Daimler Trucks Asia Building Presence In Growth Markets

Stuttgart, Germany: The two commercial vehicle subsidiaries Mitsubishi Fuso Truck and Bus Corporation (MFTBC) and Daimler India Commercial Vehicles (DICV) are working closely together under the umbrella of Daimler Trucks Asia.

Their shared objective is to sell 290,000 units worldwide by the year 2020. The export markets in Asia and Africa are key growth drivers, which Daimler Trucks Asia is addressing with an extended product range. Since May 2013, the DICV production plant in Chennai is making five new Fuso truck models intended for export.

“With Daimler Trucks Asia we are bringing our operations to the next level in order to support our existing and new customers with the right products and the best service in Asia and Africa,” said Dr Albert Kirchmann, head of Daimler Trucks Asia and MFTBC president & CEO.

US Manufacturing Sector Expands: ISM Tempe, US: Economic activity in the manufacturing sector expanded in August for the third consecutive month, and the overall economy grew for the 51st consecutive month, say the nation's supply executives in the latest Manufacturing ISM Report On Business.

The PMI registered 55.7 percent, an increase of 0.3 percentage point from July's reading of 55.4 percent. August's PMI reading, the highest of the year, indicates expansion in the manufacturing sector for the third consecutive month.

T he New Orders I nde x increased in August by 4.9 percentage points to 63.2 percent, and the Production Index decreased by 2.6 percentage points to 62.4 percent.

The Prices Index registered 54 percent, increasing five percentage points from July, indicating that overall raw materials prices increased when compared to last month. Comments from the panel range from slow to improving business conditions depending upon the industry.

Kostya Kisleyko, Moscow, Russia

and recycled for industrial use, having an effect of reducing air pollution.

This project utilises low quality coal that is abundant in the Mongolian region, ranked in the top 10 countries in size of coal reserves, to produce a compound gas of hydrogen and carbon monoxide, and applies clean CTL technology to remove pollutants. The companies plan on producing 450,000 tons of diesel oil and 100,000 tons of dimethyl ether annually.

Of these, dimethyl ether, a compound material extracted from the compound gas made from pyrolysing coal, is lower in price than LPG and causes less carbon dioxide and ash, and is in the spotlight as an environment friendly fuel to replace fossil fuels.

The Mongolian government is proactively supporting the project because, although it is one of

the world’s top 10 resource-rich countries, it imports most of its oil from Russia.

With the rapid economic development of Mongolia, the current annual 800,000 ton fuel consumption is expected to reach 3.5 million tons by 2020. As fossil fuel usage increases, Mongolia’s environmental pollution has also become a social issue. Air pollution in Ulaanbaatar, the country’s capital where about half of the population resides, has already reached serious levels.

Through this project, Posco also plans to lead the global clean energy plant business based on accumulated coal processing and energy production technology and operation management experience, and in the mid- to long-term, take an advantageous position in securing natural resources in Central Asia, including Mongolia.


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Tungaloy Singapore Pte. Ltd.31 Kaki Bukit Road 3#05-19 TechlinkSingapore 417818Tel: (65) 6391 1833 • Fax: (65) 6299 4557www.tungaloy.co.jp/tspl/ENQUIRY NO 187

Fuji Electric Establishes Myanmar Branch OfficeTokyo, Japan: Fuji Electric has established a branch office in the city of Yangon, Republic of the Union of Myanmar. The country is presently in the process of developing large-scale special economic zones, and the construction of public infrastructure along with capital investment by foreign corporations, including Japanese companies, is expected to pick up in the future.

Fuji Electric has been supplying various products including electric substation equipment to Myanmar since the 1980s. As recently announced in its medium-term management plan, the company intends to boost sales by capitalising on demand for social and industrial infrastructure in Asia, which it has positioned as a key market. By establishing this branch office in Myanmar, the company is aiming to expand its business while contributing to the country's economic development moving forward.

The main business activities of the office are to collect and distribute information on market trends, infrastructure investment plans, and other matters. Its establishment is also there to build relationships with Japanese companies such as trading companies and manufacturers in Myanmar, as well as subcontractors, construction companies, and local customers. Last but not least, the office will also provide local support for sales promotion for Fuji Electric.

Kennametal & Haimer Sign Agreement Latrobe, US: Kennametal has granted Haimer the license to provide its new KM4X spindle connection solution throughout the latter's global markets.

“ T h e K M 4 X s p i n d l e connection is the most rigid system in the world today. This design enables manufacturing companies to maximise their capital investments. It enables

higher metal removal rates, which facilitates higher machine tool utilisation and reduced cost per part, while increasing the manufacturer’s available capacity,” says John R Tucker, VP and president of the Industrial Business Segment for Kennametal.

“This agreement is a perfect fit because it confirms both Haimer and Kennametal as leaders in high-end innovative technologies for world manufacturing,” says Andreas Haimer, director and member of the executive board of Haimer.

The spindle connection, the interface between the machine tool’s spindle and toolholder, has to provide the torque and bending load capacity compatible with machine-tool specifications. Cutting forces, particularly in roughing or machining high-strength materials, generate bending moments that will exceed the interface’s limits prior to reaching torque limits.

By combining high clamping force and optimised interference levels, KM4X provides a robust connection, high stiffness, and bending load capacity for improved performance in machining high-strength alloys and other materials. This means high metal removal rates and more completed parts per day.

Epicor Partners CyberM Information Technology Limited For Asia Pacific Retail Sector

Dublin, US: Epicor Software C o r p o r a t i o n h a s s i g n e d a partnership with CyberM I n f o r m a t i o n Te c h n o l o g y Limited (CyberM), to resell E p i c o r r e t a i l te c h n o l o g y solut ions a nd prov ide in -country implementation and support services within the Asia Pacific (APAC) region.

Under the terms of the agreement, CyberM will provide sales, services and support to assist local retailers and meet the globalisation requirements o f mu lt inat iona l re ta i le rs looking to expand into APAC.

The partnership is the latest development in a multi-year strategic plan to grow Epicor retail technology market share and expand its global footprint in APAC, Latin America and Europe, Middle East and Africa (EMEA). To service the exploding growth in the Asia Pacific retail market, the company has been readying its end-to-end retail technology suite for deployment in the region.

In addition to double-byte character set support in the product suite, the company created a new international business team dedicated to t he deploy ment o f Epicor R e t a i l s o l u t i o n s i n n e w geographies, and hired in -region retail channel managers to assist in facilitating partner relationships; the first of which will focus on furthering the CyberM relationship and forging additional key relationships with Asian Pacific retailers.

Luiz Fernando Pilz, Sao Paulo, Brazil


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ENQUIRY NO 178

Nissan US Manufacturing On Track To Nearly Double Export Markets By End Of 2015

Irvine, US: With increasing production capacity in the US, Nissan projects its US plants will nearly double the number of export markets it will be able to serve by 2015.

In August, the company shipped the first of more than 900 US-built, right-hand drive Pathfinders to Australia and New Zealand. With the addition of these two new markets, the

automobile manufacturer is now able to export vehicles from its Smyrna vehicle assembly plant to 61 markets around the world.

In 2014, Nissan’s Canton vehicle assembly plant will become the global source for Murano production, creating export opportunities in as many as 119 markets.

“Shipping right-hand drive vehicles half way around the world from Tennessee at one time may have seemed exotic to us, but now it’s an increasingly common event on our path to becoming a net exporter,” said Bill Krueger, senior VP of manufacturing, purchasing, production engineering and supply chain management, Nissan Americas.

The expansion to Australia and New Zealand is an aggressive and growing export strategy for the company, with 12 percent of US production going to export markets in 2012. Export volumes are expected to approach 14 percent of US production in 2013 as the company continues to localise global products to the US and launch in new markets around the world.

Mr Krueger said: “While we quickly increase our capacity to satisfy local demand in the region, Nissan’s US plants have been charged to take a lead role in the production of some of our most important global models. As a result, more American-built Nissan vehicles will make their way to more global markets than ever before.”

Ground-Breaking Ceremony Held For Toyota

Tianjin, China: Toyota Motor C o r p o r a t i o n ( T M C ) h a s announced that FAW Toyota Research & Development (FTRD), a joint-venture R&D company between TMC and China FAW Group Corporation (FAW), held a ground-breaking ceremony for its facility in the Western Zone of the Tianjin Economic-Technological Development Area (TEDA).

FTRD will move to the 110,000 sq m site in 2015, when the design building, laboratory building and other major facilities are scheduled for completion. FTRD is a base for vehicle-body development in China and carries out development of cars for the Chinese market.

Aerium, South Africa

Strong Automotive Division Drives Business For SchaefflerHerzogenaurach, Germany: International automotive and industrial supplier Schaeffler looks back on a successful first half of 2013. At €5.6 billion (US$7.3 billion), revenue for the first six months of 2013 remained flat with the prior year period, albeit with revenue trends differing between the automotive and industrial divisions.

The automotive division grew its revenue by about six percent to approximately €4.1 billion, while the industrial division's revenue

declined by about 14 percent to €1.5 billion.

“We are very pleased with the performance of the automotive division. It has held its ground very well despite the challenging market environment in Europe. Due to the current uncertainties in the various industrial sectors, the industrial division was unable to maintain the very encouraging results of the prior year. However, our EBIT margin of 12.9 percent shows that we continue to maintain our high earnings

quality,” stated Dr Juergen M Geissinger, CEO of Schaeffler.

The company generated EBIT of €724 million (prior year: €780 million). Net income for the period was €561 million (prior year: €504 million). Operating cash flow increased by about 22 percent to €606 million (prior year: €495 million) and includes €162 million in dividends received from Continental (prior year: €80 million). Cash used in investing activities amounted to €220 million, falling short of the prior

Automotive

Julien Hoste, Bruxelles, Belgium


Businessnews

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Harbin, China: Harbin Embraer Aircraft Industry (HEAI), Embraer’s joint venture with Aviation Industry Corporation of China (AVIC), announced that the first Legacy 650 large executive jet assembled in China successfully completed its maiden flight. Delivery of the jet is scheduled for the end of 2013.

“The successful maiden flight of HEAI’s first Legacy 650 marks an important milestone not only in the Embraer-AVIC partnership, but also in the history of the Chinese executive aviation industry, as the jet is also the first large executive jet assembled by a joint venture in China,” said Guan Dongyuan, senior VP of Embraer and president of Embraer China.

First China-Assembled Legacy 650 Completes Maiden Flight

Evendale, US: GE Aviation has begun testing on its composite fan blades for the GE9X, the next-generation GE90 engine that will power Boeing's 777X aircraft. This validation test is the first of several testing programs GE has planned this year for the GE9X fan module

The first round of fan blade tests occurred in June and the company is planning a second round of tests to further validate the fan blade composite material and a metal material for the fan blade leading edge.

"The GE9X fan blade will feature high-strength carbon fibre material and a steel alloy leading edge," said Bill Millhaem, GM of the GE90 Program at GE Aviation. "This material, along with a higher fan tip speed, will improve the efficiency of the low-pressure turbine and deliver more than 1.5 percent fuel efficiency improvement compared to the GE90-115B engine."

The fan module incorporates several features. The front fan will be the largest of any GE engine at 132 inches in diameter and include a durable, lightweight composite fan case similar to the fan case on the GEnx. Compared to a metal fan case, the composite fan case will lower the weight by 350 lbs. per engine.

The GE9X engine will have 16 fan blades, which is fewer blades than the GEnx and the GE90-115B engines. This fan blade reduction is possible as a result of advancements in 3D swept design that enables engineers to create a more swept design and large fan chord.

The high-strength carbon fibre material allows the blades to be thinner than blades made from current carbon fibre material, with the same strength and durability. These improvements will drive fuel efficiency improvements and hundreds of pounds of weight reduction from fan blades and the structure needed to support them.

GE Aviation Puts Composite Fan Blades To The Test

Rolls-Royce Installs Syncrolift In VietnamVietnam: Rolls-Royce announced t hat t he la rge st capac it y Syncrolift shiplift to be built in Vietnam is now officially open for service. The Syncrolift has been installed as a key element of a major new shipbuilding and ship repair development at New Song Thu shipyard.

The company designed and supplied the system, which acts like a large elevator that raises and lowers vessels in and out of the water for dry-docking ashore. It has a docking platform 98 m long with a width of 20 m, and a maximum net lifting capacity of more than 4,500 tonnes.

year level of €465 million as expected. These trends are the basis for free cash flow of €386 million for the first six months of 2013 (prior year: €30 million).

Outlook For 2013Given the considerable decrease in revenue in the industrial sector in the first six months of 2013, the sluggish recovery of the global economy so far and weak economic momentum in China, the Schaeffler Group is now forecasting revenue for 2013 as a whole to grow by one to two percent.

“We continue to expect sustainable above market revenue growth for the automotive division. However, we probably will not be able to offset the weakness in revenue experienced in the industrial division to date,” explained Dr Geissinger.

The group is maintaining its ambitious profitability target. “Due to the stable earnings situation in the automotive division we currently continue to expect the group to generate an EBIT margin of approximately 13 percent for the full year 2013,” Dr Geissinger said.

Automotive/AerospAce


Businessnews

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ENQUIRY NO 197


De b u r r i n g r e m o v e s residual material left as a resu l t o f par t process ing through

machining, stamping, grinding and fine blanking. The process of deburring typically accounts for a large por t ion of the overall manufacturing cost, but ineffective deburring can lead to part failure, injuries, or system damage.

Part material and geometry, burr location(s) and severity, production rate and other var iab les ge t f ac tored in when determining the most effective and efficient means to deburr a part. Matching the strength of one of the many deburring process technologies

available with the many part and production variables will yield the most effective and efficient process.

This article addresses the qualities of an abrasive filament brush as a tool to be employed by an automated system, to effectively eliminate burrs in high-volume manufacturing applications.

Selective & ControlledAbrasive nylon filaments are produced by co-extruding heat stabi l ised nylon and abrasive grains (eg: silicon carbide, ceramic, etc.) into a monofilament. The result is a homogeneous, flexible structure containing up to 40 percent abrasive by weight. In the brush manufacturing process, filament diameter, style (crimped or straight), abrasive grit size, type and loading percentage can all be varied.

The advantages of abrasive filaments over traditional wire brushes are their flexibility, durabi l i ty, sel f -sharpening feature and the limit of their aggressiveness. An abrasive filament is typically applied where a surface contamination, sharp edge, or burr needs to be removed without negatively impacting the critical geometry or structure of the work piece.

Simply stated, the abrasive f i l a m e n t i s s e l e c t i v e a n d contro l led in i ts abras ive action. Unlike a wire brush, which uses sharp tips rotating at high speeds to knock/cut a burr off, abrasive filament brushes work at slower speeds.

This allows the side of the filaments to strike and drag against an edge, acting like many f lexible f i les. As the nylon begins to wear away, new abrasive particles are cont inua l ly exposed . The f i lament is therefore se l f -sharpening as it wears.

Abrasive filament brushes

DeburringWith Abrasive Filament Brushes

Abrasive filaments are flexible and are therefore compliant and forgiving in application

Abrasive filament brushes can selectively deburr and provide an effective and efficient way for deburring parts. By D Mark Fultz, president, Abtex Corporation

CuttingEdgE

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Figure 1: Radial Brush Figure 2: Disc Brush Figure 3: Planetary Head

Figure 4

are not considered material removal tools . In general , abrasive filament brushes are used in applications where a part is precision ground, cut, or machined and the burrs created by the process need to be removed without further damaging or altering the part geometry.

The force of the filament is expended on the targeted edge, with little abrasive action occurring on other part features. Because the filaments are flexible and compliant, they can work on parts with complex geometries.

Common applications for abrasive filament brushes are the end deburring of saw cut aluminium extrusions, surface deburr ing o f double d isc ground steel parts, precision ground powdered metal parts, fineblanked parts, machined aluminium automotive wheels, honing of carbide inserts and tools, as well as various other machined parts.

Radial, Disc Or Planetary?An abrasive filament brush should be thought of as an engineered tool. For a successful application, the brush maker needs to analyse the specifics of the part to be deburred and then select/design a brush to maximise effectiveness and

efficiency. With the proper br ush des igned , the next challenge is how to present the part to the brush.

As descr ibed , abras ive f i laments are f lex ible and t h e re f o re c o m p l i a n t a n d forgiving in application. They are relatively easy to apply to get desired results in the short term, but much more difficult to apply effectively and efficiently in the long term. Builders of machinery who apply abrasive filament brushes tend to believe that their forgiving nature means that machine design tolerances are not that critical.

C o n v e r s e l y , f o r t h e performance typically demanded, the smallest misalignment or inaccuracy in machine design will be greatly magnified in performance. Design oversight or error will result in an out of spec edge break on the part and/or decreased brush life.

To maximise the performance of an abrasive filament, the machine must apply the part to the brush in a manner that allows the filaments to strike the desired edge at a perpendicular angle. As this perpendicularity is reduced, abrasive action (deburr ing) marg ina l i ses . Filaments dragging parallel to an edge have little to no effect on burrs or surface finish.

Applying a radial style brush (figure 1) results in the filaments wiping in a single (typically downward) direction. Since the filaments need to strike, and drag against the desired edge, effective presentation method of the burred surface to a radial wheel brush is obvious.

For flat parts, a disc brush prov ides a more e f f ic ient presentation format. A disc brush (figure 2) can provide 360 degree wiping action if employed properly by the machine builder.

In designing a machine to apply disc brushes, the builder must consider how to present the part to the brush so that each surface receives proper fi lament impact. Often, the most effective and efficient way to accomplish this is to independently rotate a group of brushes in a planetary manner.

A planetary brushing head

CuttingEdgE

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(figure 3) makes achieving a uniform and consistent edge radius possible. The pictured head utilises three 254 mm diameter disc brushes. Through this design, more than 129,000 mm2 of abrasive surface area is acting on the part. Providing variable brush rotational speed and direction, independent of the turret (head) rotational speed and direction, offers the ability to fine tune the process for each specific application or part.

With abrasive f i laments continually moving in multiple directions throughout the head, parts being conveyed through benefit from a uniform amount of abrasive action from all possible directions. This result of the planetary action yields the consistent edge radius demanded on today’s precision parts.

Deburring SystemsPlanetary head based deburring systems are commonly used for processing flat surfaces that have been precisely ground, lapped, or machined. Ferrous par ts a re o f ten ‘ f i x tured ’ magnetically as they are being

brushed. Par ts are loaded onto a continuously moving conveyor which has a magnetic platen under the belt.

The advantage of this system is that it will accept any ferrous metal part without the need for unique tooling, securing each part in place while being deburred. A demagnetiser is typically incorporated into the exit conveyor to remove any residual gauss from the part.

Because of the efficiency of a planetary head, machines employing this technology can be relatively compact. Figure 4 shows a machine which uses a single planetary head to deburr both sides of a flat part.

Parts are loaded and then conveyed through one side of the planetary head. After traveling under the head, the parts are inverted and shuttled onto a parallel conveyor which brings them back through the planetary head. Before exiting the machine, they travel over a demagnetiser, through a coolant rinse and air knife.

P ro d u c t i o n r a t e s w i t h planetary head systems are

To max imise the performance of an abrasive filament, the machine must apply the part to the brush in a manner that allows the filaments to strike the desired edge at a perpendicular angle.

variable. Part type, burr severity, and desired edge break will impact the speed at which they can be processed. Adding additional planetary heads wil l increase productivity. With multiple heads, conveyor belt speeds up to 18 m/min are possible.

A competent deburr ing machine builder will have an applicat ions laborator y to test parts. Through this, they will demonstrate the finish provided by abrasive filament brushes and show how different filament and grit combinations wil l alter edge break. This testing will also determine the optimal machine design necessary to meet productivity and quality requirements.

Abrasive filament brushes have the ability to selectively deburr desired surfaces without dimensionally changing the part. Applied on an automated system engineered for specific application, they provide an effective, efficient, and safe means for deburring parts.

CuttingEdgE

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As with any machining process, the preprocessing of gears by hobbing or shaping results in burrs

on the front edge. These burrs must be removed because they are hazardous to machines, tools, operators or the process in general.

For instance, the hardened burrs can break off inside the gearbox and lead to failure of the gears and bearings. Residual burrs in the tooth gap after hardening are extremely sharp and will quickly destroy the grinding or honing tools during hard-fine machining.

The operators handling the workpieces run the risk of injuries caused by the sharp and pointed edges of the burrs. Other risks include the potential overcarburising of pointed front edge of the tooth during case hardening. This results in breakage under load.

Gears must therefore be chamfered and deburred for all these reasons. The chamfering and deburring process is often technically undervalued and does not receive the attention it deserves. However, ignoring the issue can lead to inevitable production downtimes (Figure 1).

The ProcessesThe most important processes used in practice are briefly described in the following section.

Manual chamfering and deburring with hand tools:This is a difficult and quite imprecise process that is primarily used for low volume or large gears.

Impact milling: In impact milling, the rotating milling tool is moved axially to the point of processing with a plunge cutting feed, stays there for an instant, and is then retracted to the starting position.

Grinding with disk-shaped grinding wheels and/or milling with rotary cutters:These processes generally work with one or more swinging grinding/milling tools that use adjustable contact pressure to

probe the edges of the teeth. The chamfering quality depends on these forces and the rotational speed selected for the workpiece.

Chisel method:In this process, a specially formed chisel is used for chamfering. The spacing between teeth is generally continuous in this case.

Rotary chamfering and deburring:In this process, a specially formed gear-shaped tool engages with the workpiece. Their axes are parallel and there is only a radial plunge. The desired chamfering is obtained after a few turns. The process itself is chip-free. The material removed from the plane sides is then cut off with a simple tool, such as turning tools.

All the processes l isted have their particular areas of application. For large-series production, however, in addition to the shapes and qualities that can be produced, determining factors include processing times, tool cycle times, and automation options. Rotary chamfering and deburring is currently assuming the dominant role in the automotive and motorcycle industry, and we will now examine it in more detail.

The chamfering and deburring of gears is often an undervalued process in gear production, but it has a great influence on the usage characteristics of the workpiece. By Karl Schäferling, director of Product Management (Shaving, Honing & Chamfering/Deburring), Gleason Corporation

Gearing UpTo Better Chamfering & Deburring Processes

Figure 1: Gear before and after chamfering.

Gear after hobbing without chamfer Chamfer and deburred gear

CuttingEdgE

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The ToolsThe technology of rotary chamfering and deburring is primarily in the tool itself. It is adapted to the specific processing task and is therefore workpiece-specific in most cases. The diameter of the tools is generally between 150 and 200 mm, and it is beneficial to choose a prime number as the tooth count.

Both sides of the tooth must generally be deburred and chamfered. As such, the tool consists of two chamfering wheels. These are combined into a compact unit by the synchronisation gear in the middle.

D u r i n g t h e p ro d u c t i o n operation, the chamfering wheels do the shaping work to form the chamfers. The synchronisation wheel ensures their exact guidance and this results in consistent chamfer form and quality.

Since the synchronisation gear is narrower than the workpiece by twice the desired chamfer width, the flanks of the chamfering wheels will engage in those of the workpiece during radial positioning. The synchronisation gear also fills in the tooth gaps

of the workpiece, preventing material from penetrating the gap (Figure 2).

For special applications, the tool package can be modified. If the chamfering quality requirements are lower, it is sufficient to replace the synchronisation gear with a spacer disk. This is particularly the case if shaving is to be done afterwards or if the chamfering is carried out between two cuts during hobbing.

The synchronisation gear can also be provided with a burnishing sector. This means that over the space of about 180 degrees, it is broader than the workpiece and ground hollow in the direction of the flank lines. The result is that only those zones on the tooth flanks of the workpiece are contacted in which a secondary device can enter the tooth gap.

These minimal, but sharp, burrs are then rolled down by the burnishing sector. The remaining sector of the tool then handles the chamfering work. This variation is especially practical if there is to be subsequent hard finishing of the tooth flanks. If the secondary burrs are not removed, they will be extremely hardened and sharp after hardening. To protect hard finishing tools such as grinding wheels or honing rings, it is therefore essential to remove them (Figure 3).

The MachinesRotary chamfering and deburring can be carried out either with individual machines or by units integrated into hobbing or shaving machines. The latter solutions have become more widespread over the past few

Figure 2: Rotary chamfer/deburring tools: tools are specially designed for each application.

Figure 3: Principle of rotary chamfering

workpiecechamfer tool

synchronisation gear

burnishing “end zones”

secondary burrworkpiece

Rotary chamfering and deburring is currently assuming the dominant role in the automotive and motorcycle industry.

CuttingEdgE

October 2013 asia pacific metalworking equipment news www.equipment-news.com 29

years for cost and space reasons. The control, chip removal and automation can all be handled by the base machine.

The deburring machines or units are relatively simple and consist two parallel spindles whose centre distance is reduced during processing. It does not matter whether the workpiece or the tool is driven.

Speeds generally range from 100 to 150 rpm at the tool, and the processing itself takes only two to four seconds.

The material pressed to the face by the chamfering process is then cut off in the last work step by chisels or deburring disks positioned by spring force. This compensates for the width tolerances of the workpiece. The positioning itself can be done using a controlled axis or even hydraulically (Figure 4).

Chamfering ShapesIn all cases, at least the sharp front edge should be provided with a chamfer. However, this is the exception, since generally both the sharp and the blunt edge must be chamfered. Corresponding design of the tool permits a variety of chamfering shapes to be obtained with a defined chamfering angle.

Experience shows that a comma-shaped chamfer down into the root of the tooth is recommended when chamfering on both sides. However, a parallel chamfering shape can also be produced. Normally, the chamfering angle at the foot of the tooth is about 45 degrees. Measured from the flank, it should ideally not exceed 30 to 35 degrees. Here, up to module 4, a chamfering width of less than 0.7 mm should be the goal. The size of the chamfer is thereby distance checked under 90 degrees to the gear faces (Figure 5).

Tool ConditioningRoller deburring tools can be

reconditioned after use. Generally, the tool life when processing an automobile gear should be up to 10 million workpiece teeth when working with oil. In dry processing, which is also possible, a tool life of about 2.5 million teeth can be assumed.

If the costs are converted into cost per workpiece produced, it is quickly apparent that the cost per workpiece for chamfering with the described deburring process is low. However, it is obvious that the process can only be cost-effective when working with large unit counts, that is, in series production.

SummaryThe chamfering and deburring of gears is often an undervalued process in gear production, but it has a great influence on the usage characteristics of the workpiece. It is important to distinguish between the processes of chamfering and deburring.

However, in practice they are always used together. In large-series production, rotary chamfering and deburring is the process most frequently used, because it is fast and cost-effective.


Figure 4: A working chamber of a hobbing machine with an integrated chamfer unit.

Figure 5: Determination of

chamfer sizes

A = chamfer sizeE,F = chamfer angle

under the tip chamfer plan surface

plan surface

tooth gap

loader

chamfer tool

deburring disks

work spindle

CuttingEdgE


Part cleaning is an integral step in many operations and industrial processes. Seen as a prelude to

surface finishing or a way to protect sensitive components, most industrial and commercial businesses perform some form of part washing on a routine basis, be it critical cleaning applications, repair and maintenance tasks or teardown or rebuilding processes.

More than a process to remove various undesirable materials from parts or components, the cleaning process is also used as an inspection step to prepare surfaces for further processes and as a final finish. All in all, part cleaning equipment can be used for the processes of metal cleaning, metal surface cleaning, component cleaning and degreasing.

Methods Of CleaningThere are various cleaning p ro c e s s e s a v a i l a b l e a n d therefore, specificity is the name of the game when it comes to cleaning. With a plethora of cleaning processes available, including solvent cleaning, hot alkaline detergent cleaning, electrocleaning and acid etch, among others, it is important to choose the right one.

To complicate things, there are also manual, mechanical, robot supported, automatic techniques, and other processes that do not use any media in part cleaning.

Cleaning Without MediaIn processes without cleaning media like laser ablation and vibration cleaning, only the removed dirt has to be disposed

of as there is no cleaning agent. Take for example, dry ice blast cleaning, which uses a solid form of CO2 that is non-abrasive and can be used on both hard and delicate surfaces.

Recycled CO2 in the form of solid dry ice particles run through a hose and high-velocity nozzle to create micro-explosions upon the surface to be cleaned. Because CO2 particles have a temperature of -105 deg F, the combination of the kinetic and thermal shock effects of dry ice blasting cleans the surface, blasting away residue. The dry ice particles vapourise into a gas upon impact.

Little waste is generated in processes like CO2 blasting, and it is usually less labour–intensive as compared to other manual methods. The dry process also reduces equipment downtime with no waiting time for parts drying. However, higher energy costs can be expected, including energy consumption required to make dry ice.

A ‘Sound’ MethodAnother common technology being used is ultrasonic cleaning. A combination of mechanical, chemical and ultrasonic methods is usually used today, and part cleaners are usually built with these combinations in mind.

For example, the Ransohoff rotary basket cell washers utilise a combination of spray, rotation, immersion, and ultrasonic technologies.

This immersion cleaning uses only filtered wash and rinse solution in the cleaning chamber. To further minimise cross contamination of the wash solutions, a divert drain system, which handles inter -stage solution management is used. This feature is combined with quick release drain actuators to rapidly discharge contaminant-laden solution into the tanks.

Clean UpYour Act

Like many processes in the metalworking industry, cleaning techniques have not stood still. By Augustine Quek

Tud

or,

Do

rche

ster

, UK

TechTalk


ENQ

UIR

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19

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In another example, the Kerry Microsolve M250/2M cleaning s y s t e m i s P L C - c o n t ro l l e d and works in two stages. The stainless-steel-mesh component baskets are first lowered into a unit by a single-axis transporter. Ultrasonic cleaning is then carried out in the stage-one

tank, which is fitted with base-mounted ultrasonic transducers operating at 38 kHz. Stage one also has electric solution heating with electronic temperature control, digital indication and a pump and filtration system.

The solvent is brought to a boil in the second stage. During

which, the vapour rinses the components, and they are then dried by a dwell in the freeboard zone. Condensation occurs when the solvent vapour passes through the primary reflux cooling coils. The condensate is collected in the integral distillate trough.

Now, the solvent begins the journey back to the stage-one ultrasonic tank via a dual-purpose gravity or molecular sieve-type water separator, where the contaminated solvent is displaced into the boiling sump. Distillation, together with filtration of the solvent, ensures that the ultrasonic tank is maintained at a controlled level of cleanliness.

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TechTalk


the IRB 940 Tricept robot, it is developed for robotic cleaning.

The design is based on a parallel kinematics framework, which can be described as an up-side down camera stand, featuring three linear actuators with a centre tube in the middle and three additional axes on the wrist. The system has an acceleration of approximately 1G, an absolute accuracy of approximately 0.2 mm, and a repeatability of about 0.02 mm.

Cleaning Media In addition to equipment and energy source, cleaning media plays an important role as it removes the contaminants from the substrate. These include aqueous (water-based) agents, s e m i - a q u e o u s a g e n t s ( a n emulsion of solvents and water), hydrocarbon based solvents and halogenated solvents.

H o w e v e r, t h e c l e a n i n g industry is always looking to replace halogenated solvent degreasing with ‘environmental friendly’ means of cleaning. Although water-based, semi-aqueous and hydrocarbon-based chemistries are available

as substitutes, they are often less effective as cleaners than halogenated solvents, and sometimes require the addition of mechanical energy (such as agitation and ultrasonic) to achieve the required levels of cleanliness.

Aqueous cleaners are mostly a combination of various substances like surfactants, alkaline builders and sequestering agents. In the

case of ferrous metal cleaning, rust inhibitors are built into the aqueous cleaner to prevent flash rusting after washing. In the group of hydrocarbon based solvents, there are some newly developed agents like fatty acid esters made of natural fats and oils, modified alcohols and dibasic esters.

A class of cleaning media c o n t a i n i n g e n z y m e s a n d microorganisms has also been developed. The microbes are able to bond with organic molecules, and release enzymes that break down the hydrocarbon structures into more water soluble, digestible materials that are subsequently absorbed through the cell wall and digested further. This type of media enables the conversion of oil, grease, fats and other simple organic molecules into carbon dioxide and water.

Going BioUs i ng b io log i ca l ly a c t iv e agents to clean, also known as bioremediation, can now be performed on an industrial scale for parts washing. One example is from US-based ChemFree Corporation, which produces the OzzyMat, a particulate trap impregnated with

A common cleaning technology today is ultrasonic cleaning

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TechTalk


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microbes. These microbes remain dormant in colonies and start to multiply when placed in the SmartWasher.

As the OzzyJuice (degreasing solution) begins circulating within the washer, the microbes move throughout the solution, breaking down grease, oil and other organic products. There are also catalysts mixed with the microbes to speed up the organisms’ rate of reproduction and digestion.

In most plants, the cleaning media are circulated until their cleaning power has decreased and reached the maximum tolerable contaminant level. In order to increase the time of media change as much as possible, there are downstream treatments deployed, removing contaminants and the used up agents from the system.

At the same time, fresh cleaning agents or parts have to

be supplemented, which requires a bath control. The latter is increasingly facilitated online and this allows a computer aided adjustment of the bath. Almost no wastewater is generated when downstream units such as oil separators and demulsifying agents are used.

For most parts, cleanliness can be gauged visually. In the industry, the most common cleanliness test is the water break test, in which the surface is thoroughly rinsed and held vertical.

Hydrophobic contaminants such as oils cause the water to bead and break up, allowing the water to drain rapidly. Perfectly clean metal surfaces are hydrophilic and will retain an unbroken sheet of water that does not bead up or drain off. However, this test does not detect hydrophilic contaminants.

To A Cleaner FutureTechnology is in a state of change. New materials are constantly introduced and replacing old materials in parts. Plastics and composite materials are increasingly used in automobiles instead of metals.

Cleaning media are also evolving. Vapour degreasing using chlorinated and fluorinated solvents, which had long been the standard for many industries, was phased out in the interest of a cleaner environment.

At the same time, cleaning re q u i re m e n t s h a v e b e e n continually increasing. As a result, part cleaning can only get more sophisticated, requiring not just higher levels of operator training, but also planning and vigilant process control.


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TechTalk


Machine shops of all sizes are purchasing r e c o r d n u m b e r s o f f i v e - a x i s C N C

machines, and for a good reason. These machines enable single-setup manufacturing strategies, which are much more productive than conventional machining using several pieces of equipment. Keeping manufacturing to one setup also eliminates stack-up errors and the resulting scrap.

Also, many advanced, complex part designs are impossible to produce on anything but a five-axis machine. To quote those parts, shops must invest in the equipment, and as such, prices for reasonably accurate five-axis systems have dropped significantly.

A l o n g w i t h t h e m a n y opportunities five-axis machining creates, there are substantial risks. Five-axis CNC programs are geometrically more complex than three-axis programs, which can create more opportunities to damage cutting tools, toolholders, equipment and the part itself via a crash. For example, if a shop has put hundreds of hours into a complex piece made from a single piece of stock, a crash would be extremely costly.

On the other hand, time on a five-axis machine is far too valuable to be wasted by having operators hover over the machine as it cycles through its operations, to verify they are safe and correct. This is especially true for small runs.

With so much to gain — and

lose — various forms of machine simulation have become the five-axis CNC programmer’s constant companion. Simulation is the first line of defence against damage and lost productivity. It also gives the programmer additional tools to solve fixture design-for-manufacturability challenges and make parts more productively.

Manufacturers that have previously not used their CAM systems’ simulation capabilities often become converts as soon as they install their first five-axis machine. They are frequently surprised at the depth of simulation resources provided.

Program SimulationHigh-end CAM software has built-in simulation capabilities that allow programmers to ascertain that the program they have written will perform cutting operations exactly as they had in mind when they wrote them.

•BackplotsimulationAlmost every CAM programmer relies on on-backplotting — an on-screen geometrical ‘tracing’ of the contact point — to visualise tool movement through various CNC manufacturing operations.

Backplotting provides fast, visual confirmation that a tool is performing the desired cutting operations in the most efficient sequence. As the backplot simulation progresses, information about the tool choices appears in a separate window. Backplot simulation serves as a sequential template for checking the appropriateness of tools and settings at each stage of the process.

The backplot simulation also generates a close approximation of machining time (not including tool change time). This can be invaluable for estimating costs, especially when they involve CNC cutting programs that will run for many hours, if not days.

Machine simulation is the five-axis programmer’s constant companion. By Karlo Apro, multiaxis product manager, CNC Software

Cut OutTheCrashes

Software &MeaSureMent


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If the programmer and machinist are different people, conferring over the backplot simulation helps them get on the same page. The machinist will have a clearer understanding of how they should set up and run a process and the programmer can confirm that the strategies he has chosen are appropriate for the equipment and shop conditions.

•Stock-removalsimulationThis type of simulation provides an accurate 3D visual representation of the amount of stock removed from a virtual workpiece at any stage of the cutting process. This representation may be colour-coded to indicate if material removal falls within the specification or it may automatically highlight areas where too much or too little material has been removed.

Skilled five-axis programmers frequently run the stock-removal simulation at high speed as if it were time-lapse photography, dynamically zooming in and out of the areas of concern on the fly.

Those who program five-axis machines find themselves using backplot, verify and full-blown machine simulation after programming ever y

operation. This makes them better programmers because they quickly learn what will and will not work. It also gives them powerful tools that allow for safe experimentation with different manufacturing strategies. Used this way, machine simulation is the safest and most effective way in creating effective and efficient production methods.

Simulation provides an accurate 3D visual representation of the amount of stock removal from a virtual workpiece at any stage of the cutting process.

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Beyond The BasicsSimulation may be used to e f fect ive ly prove out the manufacturing process for individual parts, as well as the whole manufacturing process cycle of a work cell, as parts move from machine to machine.

When better strategies are discovered via simulation, they frequently become part of a manufacturer’s mix of proprietary competitive advantages. The following are some of the advanced features in simulation programs.

•FiniteelementanalysisFEA is not actually a CAM software feature but it is offered by some software vendors that create CAD models. Ideally, the CAD and CAM software are so tightly integrated that the design and manufacturing engineers can work back and forth with each other to concurrently modify and improve design elements and manufacturing strategies.

W h e n d e s i g n a n d manufacturing strategies are developed concurrently, FEA can determine if the changes made to improve manufacturability will not only meet part specifications but also determine that the stresses generated during manufacturing will not damage the product, tools, fixtures or machine.

•SurfacefinishinspectionInspecting critical surfaces via stock-removal simulation at high magnification provides an accurate visualisation of the surface finish that will be imparted. Most nicks and scratches produced by awkward tool movements actually appear in a magnified simulation.

A manufacturer of injection tooling for micromolded medical parts, for instance, said this approach to verification is like taking an EDM tool the size of a

pea and blowing it up to the size of a basketball to find critical surface imperfections.

•ChamferingvisualisationMany five-axis parts are used in high-precision assemblies, and, therefore, must not have any cosmetic defects that can compromise the durability or performance of wear surfaces. For these parts, chamfering may be used extensively to eliminate the need for costly secondary deburring operations.

In this case, both backplot and stock-removal simulations ensure that the tools can get into tight spaces without crashing, and that chamfering does indeed produce the desired effect. Verification at high magnification can show if chamfering removes potentially abrasive nicks and burrs.

•SafetoolentriesandexitsBackplot simulation shows if

a tool is getting dangerously close to or hitting impinging surfaces. It is possible to specify precise entry and exit curves during toolpath creation, but a manufacturer of aerospace parts takes this process one step further.

The CAM software’s ‘save as geometry feature’ is used to turn the backplot into an exact representation of the problematic cut’s location. Then, geometry is added to allow for safe tool entry and exit at the beginning and end of the operation. This allows the navigation of a tool into and out of confined areas without damaging nearby surfaces.

Machine SimulationIn the five-axis world, it is sometimes necessary not only to simulate the CAM software’s intermediate code, but also the G code, driving specific individual machines with unique

Machine simulation of an insulator bracket being cut.



kinematics. This higher level of verification, known as machine simulation, proves out machining strategies in a virtual five-axis environment that ensures part geometries, tools, fixtures and machine components will not interfere with each other during the cutting process.

There are two varieties of machine simulation. The first takes the intermediate code (APT, NCI, CLS) generated by the CAM system prior to post-processing into G code for the machine’s control, and uses that code to drive a virtual replica of the specific five-axis machine.

A small number of CAM developers have taken this approach, with some even refining it to the point where a separate, simplified stream of code is generated to drive the five-axis machine simulation process.

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The second, even more meticulous approach drives a precise virtual replica via the G code generated by a CAM system’s post-processor. This program allows the user to choose from a variety of machine and control options and effectively simulates any G code language.

The good news is that either of these approaches will accurately simulate machine behaviour if an accurate model of the machine has been created and the simulation program has been properly configured.

Correctly configuring a virtual replica and the simulation process requires an in-depth knowledge of the specific five-axis machine, simulation software and post-processor.

Setting up an effective machine simulation program can be time consuming and expensive, but

it will protect a five-axis CNC machine investment and improve the manufacturing process. The alternative is to labouriously step through first-piece manufacturing operations sequentially at the machine, and wasting machine time and labour — unacceptable in today ’s manufac tur ing environment.

Simulation also provides a safe, relat ively low-cost virtual environment for testing competing ‘what if’ scenarios, so simulation-derived, five-axis machining strategies can become a competitive advantage.

For those who have purchased, or are about to purchase the five-axis CNC equipment, simulation is or will soon, become a core competency. It is not a question of if, but when.


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Mo s t c o m p o s i t e components require some kind of machining after they have been

formed. This might include trimming any excess material from around the part, machining of pockets within the shape, and drilling of holes for assembly.

Like most other areas of its manufacturing operations, the composites industry has traditionally relied on manual methods for these tasks. While it is generally acknowledged that this approach is both slower and less accurate than the more automated techniques now used in most finishing operations for metal components, the industry has been able to continue with its more traditional methods for two reasons.

Firstly, the volumes of parts are usually much lower than are typically found in the metalworking industries. This makes it harder to justify the cost of the introduction of more automated methods. Secondly, the expectations of many customers remain low, with final adjustment of individual components still accepted as part of the assembly process.

Wind Of ChangeBoth of these factors are now decreasing as part volumes increase and demands for higher quality become more intense. The expansion of the use of composites in the aerospace industry and, to a lesser extent, in the mainstream automotive industry means that components now need to be produced in much larger volumes

than before. As a result, any expenditure on automation can be spread over a much greater number of parts.

At the same time, companies that receive higher-quality components from their more technically-advanced suppliers are starting to question why all their parts cannot be supplied to the same standard. This later trend is being reinforced by a general increase in concern over quality control. As times get harder and companies become more cost-conscious, anything that can reduce waste will be welcomed.

This increased use of automation is more difficult to achieve within the composites industry for three reasons. Firstly, composite components tend to be more flexible that their metal equivalents and so are more difficult to locate in a fixed position. This is especially true for larger components that are commonly found in the aerospace, marine and rail industries.

S e c o n d l y , c o m p o s i t e components tend to have less consistency within their production, whether this is undertaken within an autoclave or in a closed mould. These variations make high-precision finishing operations more challenging.

Thirdly, the act of cutting the component can change its shape because of stress relaxation within the part. These changes must be taken into account during any subsequent operations to obtain the required level of accuracy.

Adaptive MachiningThe traditional relationship between manufacturing and inspection is that machining is completed first on the company’s machine tools and the components are then transferred to dedicated inspection equipment to be approved or rejected.

However, as machin ing techn iques become more sophisticated, and as components become larger and more complex,

Adaptive machining, with its ability to use in-process measurement, has emerged as a suitable technology to machine composite materials. By Peter Dickin, marketing manager, Delcam

Adapting ToComposites



there are a growing number of cases where closer integration is required to give the highest productivity and the biggest reductions in scrap.

Instead of a simple linear progression from CAD to CAM to machining to inspection, a more complicated series of steps is needed, with extra data needed to fill any gaps in the information available at the various stages. These new processes can be grouped under the heading of ‘adaptive machining’.

The programming of most machining operations, whether for metals or for composites, is based around knowing three things: the position of the workpiece on the machine, the starting shape of the material to be machined, and the final shape that needs to be achieved at the end of the operation.

A d a p t i v e m a c h i n i n g techniques allow successful machining when at least one of those elements is unknown, by using in-process measurement to close the information gaps in the process chain. It also allows any errors to be spotted earlier in the manufacturing process, so helping the problems to be resolved faster and at lower cost.

With adaptive machining, additional information about the initial part shape and location must be collected after the component has been placed in position and before machining starts. Further inspection and adjustment may then be needed at the various stages of the machining process. A final round of inspection may also be required at the end of the complete process to confirm that the part has been produced to the specified tolerance.

Electronic FixturingThe most common cases where adaptive machining techniques are needed are those where the exact position of the whole area of the workpiece on the machine

is not known precisely. With larger composite components, such as aerospace or marine structures, or blades for wind turbines, achieving the correct position and orientation of the part on the machine is a major challenge, taking many hours of checking and adjustment.

This can be overcome with a jig to hold the parts but jigs can be expensive and time-consuming to

manufacture. Furthermore, if the component design is modified, the jig will need to be adjusted or even remade. Even the best-made jigs can be a source of errors through incorrect operation.

For example , i f c lamp-type fixtures are used, the part can be distorted if the correct clamping sequence is not followed. These problems can be further

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compounded with larger composite parts because of the flexibility of the materials. This makes it possible for the centre of the part to sag out of position, even if all the edges are located correctly.

With electronic fixturing, the toolpaths are adjusted to match the actual position of the whole surface of the workpiece, rather than trying to align the complete area of the part into exactly the nominal position specified in the CAM system. This approach has been used in the machining of geometric features into metal parts for some time. An equivalent solution for the manufacture of complex shapes and surfaces is now available that gives the same benefits of shorter set-up times and improved accuracy.

The first stage in this approach is to create a probing sequence in the inspection software, preferably using off-line programming so there is no interruption to the machine tool’s cutting time. This sequence is used to collect a series of points from the complete area of the workpiece, which can be used to map the surface of the part.

Any mismatch can then be calculated between the nominal position used in the CAM system to generate the toolpaths and the actual position of the workpiece surface in relation to the machine-tool bed. A modified set of

toolpaths can then be created within the CAM system.

The measurements are normally undertaken using a probe fitted to the machine tool but the data can also be collected with a portable inspection device positioned on or beside the machine. Typically, this will be an inspection arm for medium-sized components or an optical device for very large items. Using an independent inspection device is more flexible as the same inspection equipment can be used on a number of machine tools, in addition to its normal inspection duties.

As mentioned, the edges of the part can normally be held in the required positions by the fixture. Therefore, for trimming operations, the adjustment can be done on a whole-part basis to overcome any differences between the theoretical and actual position of the fixture and the component.

However, individual machining operations can be modified on a feature-by-feature basis. As such,

the position of the surface in the appropriate area can be checked when cutting each pocket into the surface. An example where this approach could be needed would be cutting the holes in a marine panel. The measurements can be taken around the area where each hole will be cut and then any differences between the nominal and actual positions can be taken into account.

Overcoming InconsistencyMany composite parts need large numbers of holes to be drilled into them for assembly. Often, these holes need to include a counter-bore so that the top of the rivet or bolt can be flush with the surface of the part.

In these cases, any variation in the material thickness can be a significant problem. If the counter-bore is not deep enough, the appearance and aerodynamics of the part will suffer. If it is too deep, there might not be sufficient material remaining around the bolt to give a durable joint.

Unfortunately, the processing of composites offers a number of areas where inconsistency can arise in the thickness across the finished component. This can happen for a variety of reasons, especially if the parts are laid up manually and cured in an autoclave.

The errors will be more serious on the back surface of

Did You Know? Civil aviation has been increasing composite content in aircraft since 2005.

Composite components tend to be more flexible than their metal equivalents and so are more difficult to locate in a fixed position.

Adaptive machining techniques allow successful machining by using in-process measurement to close the information gaps in the process chain.


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ENQUIRY NO 192


the part. Even with closed-mould processes, there is the potential for variation in the temperature and pressure throughout the mould that can cause localised distortions. While such errors may be small in the overall dimensions of a large part, they can cause holes and pockets to be machined to an incorrect depth.

As described above, adaptive machining can overcome these variations by providing a map of the actual surface of the part, either across the whole component or in the areas where drilling is to take place. The drilling toolpaths can then be adjusted to compensate for any variations in thickness found and so give the required depth for all the holes and any associated counter-bores.

Another problem in the machining of composites is that the materials tend to relax as the composite fibres are cut. This is not as serious at first glance because any pockets tend to be undersize and so can be corrected with an extra machining operation.

However, the effect is difficult to predict because the fibres will not lie in the same orientation when they are cut. This means that the degree of distortion will vary in different directions. To overcome this problem, the initial

machining operation should be followed by an inspection on the machine tool using the inspection techniques described above. This will show how much more material needs to be removed and enables the required extra toolpaths to be generated in the company’s CAM system.

For more complex components, with 20 or more pockets, a further cycle of inspection and machining may well be needed to produce all the dimensions to the required tolerance. However, for subsequent parts in a series, the complete machining sequence can be repeated and the results checked with a final inspection.

A similar problem can arise when drilling holes as the relaxation of the surface can alter their final dimensions. Also, changes induced by the initial drilling operations might alter the component such that holes towards the end of the sequence are incorrectly located.

One solution is to use a two-stage drilling operation. The first sequence is done using an under-size drill, typically half of the size required for the final hole. The surface of the part is then scanned and the results used to create a second drilling routine with the correct size of tool. Any distortion of the part will be picked up by the scan and the centres of the second series of holes can be adjusted accordingly.

ConclusionsThe adaptive machining methods described in this article offer the potential to improve quality and reduce waste in a variety of composite manufacturing operations, especially for larger components.

Productivity and quality are now key issues for all manufacturing companies, including those in the composites industry. For firms wishing to target the aerospace industry in particular, anything that can reduce waste or improve efficiency must be worthy of further investigation.

However, companies wanting to use the adaptive machining processes described in this article must understand that they tend to be much more complex and process-specific than conventional CAM programming.

Most adaptive machining projects will require some specific consultancy and customisation work by the software supplier as part of their implementation.

The most common cases when adaptive machining techniques are needed are those where the exact position of the whole area of the workpiece on the machine is not known precisely.


Another problem in the machining of composites is that the materials tend to relax as the composite fibres are cut.


ENQUIRY NO 189


With its Advanced Deep Drawing Press (ADP), Denmark-b a s e d K i e r m a r

Technology developed a press that is characterised by the horizontal movement of the upper tools. The actual pressing procedure takes place from bottom to top. The upper tool only has to move 5 mm in a vertical direction before it drives horizontally out of the press and the finished product is placed on the conveyor belt by means of an ejector.

The deep drawing press is said to challenge traditional concepts of size, speed and energy efficiency. It has a significant pressing force but it weighs only 26 tons. Its overall height, including the crane for tool handling, is 4 m. Fast cycle times is also one of the characteristics of the machine that is based on fast tool and integrated material handling.

As a result, the press cycle

for the production of a sink takes less than 15 seconds. “A complete pressing cycle is around 30 percent faster than other hydraulic deep drawing presses,” explains Martin Hansen, MD of the company. The electrical and hydraulic servo drives are controlled by a Beckhoff C6920 Industrial PC with TwinCAT

automation software and the EtherCAT communication system.

The Reason Behind The SpeedThe speed of the press can be attributed to the automation system working in the background. One Beckhoff C6920 Industrial PC is required to handle the PLC and motion control. PC-based control ensures that both the pressing procedure and the horizontal tool movements operate precisely and smoothly. The press is equipped with three electrical and three hydraulic servo axes. As they are controlled differently, this poses a challenge.

Hans Christian Pallesen, application engineer from Beckhoff Denmark says: “In the case of electrical axes, a certain operating profile can be created in advance on the basis of ramps, position and speed. That is not possible with hydraulically-controlled axes, since they change their profile during operation. In addition to that, the hydraulics behaves very differently, depending on the valve type, oil flow, oil temperature, etc.”

The hydraulic axes are ‘path controlled’, ie: the position controller is active only when at a standstill. The set value generator controls the cylinder according to ramp and speed, while its current


Apart from speed, another attribute of the machine is said to be its energy efficiency. The

small movement of the upper tool means that only minimum vertical movements are required

in the subsequent process in order to develop the sheet metal holding force. Therefore,

the ADP press requires hydraulic pumps with a power rating of 118 kW compared to the

usual 300 kW.

“In conventional presses, all movements take place vertically, which means that the tool

must be raised in accordance with the height of the finished product in order to remove the

product from the press. Raising the tool requires considerable expenditure of force and,

correspondingly, large amounts of hydraulic oil.

Our deep drawing press concept runs with two hydraulic pumps: A large one for the

actual pressing procedure and a small one for opening and closing the pressing tool. The

pressure and flow rate of the hydraulic axes are precisely closed during operation in order

to save energy,” explains Mr Pallesen.

Easy On Energy Consumption

Quick DrawWith Automation

Automated control system can play an influential role in the cycle time of a deep drawing press. Contributed by David Chia, MD, Beckhoff Automation

Martin Hansen

FORMJOinCut


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position is constantly checked via the encoder signal. Once the set value position is reached, the position controller is activated again in order to maintain the current position.

While the electrical axes are controlled by the automation software, the hydraulic axes are controlled via the TwinCAT Hydraulic Library.

It is said that with the aid of the standard software library, the engineers were able to master the challenges of the ADP deep drawing press, such as the movement of 2,000 kg horizontally by 2 m for discharging the work piece — in less than two seconds and with an accuracy of ± 0.1 mm.

The automation software forms the cornerstone for the execution of the PLC program. The PLC data performance enables fast execution while at

the same time handles demanding travel movements. The entire PLC program is updated every 2 ms, ie: 500 times per second. To do this, EtherCAT is used for communication with the servo

drives and I/O components. The fast update rate gives rise to a fast control system, which contributes to the precise positioning.

Fast cycle time is one of the characteristics of the ADP.

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Hak Poh Lim is fully aware of the challenges and risks of military operations, as a former major in the Singapore army’s signals corps assigned to electronic engineering and

communications. After spending some 19 years in the army, the

experience enabled him to master the multiple skills needed to design and build Command-and-Control (C2) units that are the ‘brains’ behind the brawn of advanced warfare. Inside, huddled under the protection of a steel armour shell, officers analyse the incoming signals and messages before issuing orders to their troops to engage or hold fire.

After his military service, Mr Lim invested his personal savings in 1993 to start up HPH, which stands for Hybrid Project Hub. The name reflects his vision of integrating diverse technologies into a nerve centre that can control complex systems.

To respond to crises anywhere in the world, military command systems and emergency/rescue services need to be compact and versatile. Starting with the externals, Mr Lim explains: “Since military vehicles face the risk of coming under hostile fire, they are protected by armour plate of between 1-inch and 2-inch thickness (25 to 50 millimeters) that can deflect incoming rounds from, let’s say, a heavy machine gun.”

Piercing ArmourIn the production of armour plate components, the technical obstacle is that the tempered metal cannot be cut with a burning torch because heat alters the crystalline structure of the exotic alloy of steel and cobalt or magnesium. “Heat damage to the edge of cuts creates a point of vulnerability to explosive blasts,” he adds.

Thick aluminium, used to make light-but-strong support beams or the arms of lifting cranes, has similar problems. Neither can a punch be used to make bolt holes because, as Mr Lim says, “the metal is too thick, and in any case, the pressure would bend the aluminium.”

The traditional method for cutting armour plate or thick aluminium has therefore been to use a metal saw equipped with superhard blades. The machine tool process is extremely time-consuming because of the long hours required for setup and the slow operating speeds due to friction, which causes heat buildup. Another difficulty for fabricators is that larger sizes of metal sheets require much bigger equipment.

“That’s where the Byjet solves all of these problems,” he says. The waterjet cutting system carries an abrasive that abrades the otherwise stubborn metal. “The procedure is much like sandblasting, but finer, and it allows the cutting of nested parts — which saves

Hans Sautter

Hak Poh Lim

Under Fire Staying Cool

Cutting and bending systems play an instrumental role in the manufacture of armoured command-and-control vehicles. By Yoichi Shimatsu, for Bystronic

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material and costs,” he adds. “The plate dimensions are also no problem, since the cutting head can move anywhere on the machine bed.”

All Terrain, All WeatherIt is not only the military and police forces that use mobile cabins; there is also a growing market for them in the civilian sector. In a global economy, energy companies and construction firms have to be ready to set up operations in extreme environments from deserts to permafrost.

That is where HPH comes in. “The basic work is to design, build, and mount a customised cabin onto a truck or an all-terrain vehicle,” explains Mr Lim. “After being driven to the site, these cabins are expandable, like the drawer of a dresser, to provide indoor meeting space or living quarters.”

“My initial business was to produce better electronic components for communications networks,” he says. “Then, these separate pieces of equipment had to be mounted on a frame that fits neatly inside a cabin.”

At that time, semiconductor manufacturers also needed steel frames for their computer racks and chip-making equipment inside clean rooms, while emergency services wanted their ambulances to contain more types of life-saving equipment.

Mr Lim’s push into fabrication meant relocating his garage-sized electronics workshop to bigger quarters at Woodlands Sector, an industrial estate in the northern suburbs of Singapore.

The Art Of Metal OrigamiIn addition to laser cutting machines, Mr Lim was also on the lookout for bending machines. “Instead of welding two, three, or more metal shapes to make a single part, multiple bending enables our engineers to make a complex part out of a single piece,” he explains. “That not only eliminates welding and grinding, but also results in a stronger part that’s less likely to break.”

Complicated metal folding is required to fit components of different shapes into the most compact configuration inside a cabin. In the design

“Customising the design for and with the users is necessary to achieve the practicality of the product so that it can better serve their needs.”

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customisation process, the company usually makes a working model so that different types of users, such as radio operators and radar analysts, can rearrange the equipment for optimal efficiency in a tight space. “Customising the design for and with the users is necessary to achieve the practicality of the product so that it can better serve their needs.”

Due to the precision requirements, he decided to invest in a pressbrake and purchased a Hämmerle 3P. The pressbrake can bend with a tolerance of +/– 15 to 20 arc minutes and supports maximum repetition accuracy.

Artisan EngineersIn the military market, the company is a subcontractor for ST Engineering, which delivers armoured personnel carriers to the defence ministries of Singapore and the UK. Speed is a priority, especially when it comes to such military clients. “For my first vehicle order, the time between order and delivery was just four months,” he says. “Products for the defence industry have to be error-free and done quickly. Military customers are impatient for delivery, because human lives depend on these systems.”

Whenever clients want their complex orders delivered “yesterday,” quality control checks have to be streamlined. “Every engineer must be able to act independently in design, production, and checking on their own work.


“They must be skilled and trustworthy,” he asserts. “The company culture should be constantly taught and ingrained.”

At the company, the senior engineers have passed the most rigorous tests of skill and character. Even the less senior workers at the company are each required to learn at least two skill sets so that employees can be deployed flexibly to the task at hand. The learning curve, Mr Lim notes, varies with individuals. ”Some talents are hidden and can be found only through long hours of practice, therefore we give each applicant an opportunity for a tryout.”

Global FactorsSingapore is one of the most globalised economies on the planet. Globalisation is pushing further changes, as the escalating costs of manpower and space have put enormous strains on Singapore's industry.

As such, in addition to establishing a factory on a one-acre site in Johor, Malaysia, the Singapore headquartered operations are now shifting toward a focus on “design, development of prototypes, and upgrading of the manufacturing process,” says Mr Lim.

His strategy is to stay ahead of any potential competition with intelligent and motivated engineers designing new products. He says: “We anticipate what a client wants and then draw up a design with the user to create better high-quality products.”

Hans Sautter

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Speed is a priority when it comes to producing military parts.

Mr Lim feels his machines have a combination of speed and precision

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ENQUIRY NO 184


APMEN: Please share with our readers your latest product offerings related to metalworking and the pertinent technologies behind it.R u e d i g e r U h l i t z ( R U ) : Messerfabrik Neuenkamp offers precision slitter tooling for the metal and non-ferrous metal industries. With knife materials and tool tolerances of +/- 0.001 mm, our customers can achieve quality output in their production.

The slitting applications have become more difficult in the last two years, as the demand for higher quality, together with new material developments have presented the customers with new jobs to work on.

For example, we have many customers in the pipe industry who follow this growth trend. For proper welding of their pipes, they need a consistent perfect cutting performance in order to ensure that material edges are of the required standard, which facilitates high standard welding.

APMEN: It is said that the three important considerations in slitting are: material thickness, the type of material and the required tolerances. Do you agree with this statement?RU: Yes, because the type of materia l and the materia l thickness are the most important points to set up the correct

slitting clearance. The clearance in combination with the required strip tolerances clearly indicates the standard required for the slitter tooling set.

Steel materials and non-ferrous materials have completely different values of clearances and the tool set must fulfill several parameters according to the application. High performance knife materials, smooth surface grades, precision tool tolerances and the ideal combination of slitting tools guarantees a stable and continuous quality output of strips.

APMEN: In your opinion, what is the technological trend in slitting for the next five years?RU: After 2009, we have seen that the trends change much faster than before. Because of the steel crisis in 2009, the market and the companies operate in a much more flexible way, with a higher degree of ‘just on demand’ production. The growing automotive, oil & gas and electronics industries provide a clear guideline for closer tolerances in slitting.

Higher material strength, more narrow strips, or a clear definition of burr will drive the need to use more high precision tools than before. During the next few years, it will be necessary to bring the slitting quality in the Asia Pacific area up to international standards, because more and more companies

are interested in investing here. So we see a clear trend that demands for more special slitting applications with higher accuracy to grow here, besides the ‘normal’ steel slitting jobs.

APMEN: How will you assess the business potential (for slitting) in Southeast Asia? What are your short and long term plans?RU: The business potential in Southeast Asia is huge because nearly all countries here are able to grow in this field. The domestic and the international automobile industry is starting to build more production plants here, and this in turn is a basis for more strip and sheet cutting facilities near to their plants.

We have been doing business in different Asian countries since 2003 and we renewed our business development efforts for the Southeast Asia region last year.

With our representative, Citoforte Asia Pacific, based in Malaysia and Singapore, we have confidence that we can provide slitting products and services to our customers in the region. In addition, we look for agents in every country for a good and close communication with our customers. Our long term plan is to have a stable group of customers and business.

Into Asia

Messerfabrik Neuenkamp

Slits Its WayAsia Pacific Metalworking Equipment News (APMEN) caught up with Ruediger Uhlitz, GM of sales of the company to shed some light on the world of slitting and his business endeavour in Asia. By Joson Ng


Ruediger Uhlitz

IndustryFocus

ENQUIRY NO 138


The importance of ASEAN as a cluster cannot be denied as the region is likely to be the fifth largest

automotive market in the world by 2019. This region presents a significant opportunity to global automakers in the near to medium term.

The low level of motorisation in ASEAN offers strong growth potential for the automotive market, while the heavily-motorised regions of Western Europe and North America represent a saturated ‘replacement’ market.

The ASEAN market is likely to grow at CAGR of 5.8 percent from 3.18 million units in 2012 to 4.71 million units in 2019, driven mainly by rapid market expansions in Indonesia and Thailand.

Passenger vehicle segments are likely to dominate the market. Thailand, the key pickup market in the region is shifting to passenger vehicles with an increased consumer preference for compact,

environment-friendly eco cars. Automot ive demand in

Thailand is also expected to grow, driven by an improved economy, more disposable incomes, capacity expansions by automakers, and the launch of several new vehicle models. The Malaysian market is expected to grow, supported by foreign model proliferation at competitive price points and by price reduction as a result of market liberalisation.

Indonesia is expected to emerge as the largest automotive market in the region by 2019, accounting for 2.3 million units. The country’s rise is driven by sustained economic growth in the country, growing middle classes with larger disposable incomes, increased investments in the automotive sector, and the introduction of automotive regulations supporting market growth.

Thailand Automotive Sector Thailand is one of the key emerging

economies in Southeast Asia with a free enterprise, modern and well-developed infrastructure, and positive investment environment with a focus on exports.

Thailand also has a skilled workforce, a high literacy rate, and one of the lowest unemployment rates in the world. Besides, it has relatively low labour costs in the manufacturing sector compared to those in other Southeast Asian countries, making it a preferred production hub, especially for the automotive industry.

After coping with devastating floods, which paralysed the economy in 2011, Thailand restored itself with a 5.6 percent GDP growth in 2012. It is expected to witness a sustained growth of 4.9 percent in 2013 as well.

T h e T h a i a u t o m o t i v e component market has nearly 1,800 automotive component manufacturers, of which 700 are OEMs. Several of these are the preferred automotive parts

Driving Into ASEANAutomakersASEAN offers significant opportunities to global automakers in the near to medium term. By Vijay Rao, research director (Asia Pacific), Automotive & Transportation Practice, Frost & Sullivan

Peter Suneson, Norrköping, Sweden

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manufacturers of the Japanese auto OEMs, which dominate the Thai automotive industry. However, several locally based Thai conglomerates also operate in this segment.

Thailand has approximately 690 local and multinational Tier I auto parts suppliers and also 1,700 Tier II and III suppliers. However, a majority (more than 50 percent) of the Tier I suppliers in Thailand are large multinational companies comprising the top auto parts manufacturers in the world.

With a majority of international automotive parts manufacturers having a base in Thailand, the quality of parts manufactured in Thailand is considered one of the best in ASEAN.

T h e T h a i a u t o m o t i v e component industry is therefore well equipped to supply the entire range of automotive parts from

engine parts to interior and body parts required by the auto OEMs in Thailand.

In 2012, Thai automakers introduced 10 new and face-lifted models. This trend is expected to continue in short to medium terms with several OEMs planning to launch either new or upgraded models across segments.

Toyota plans to launch its eco car and a new version of the Toyota Corolla in 2013. Several other models are expected to be introduced in 2013, including offerings from Mitsubishi and Nissan. The Mazda2 eco car is also to be introduced in short to medium terms. Availability of new and upgraded models are expected to push up new vehicle sales.

However, uncertainty in the global economic prospects, particularly related to the Eurozone crisis, is likely to be a key restraining

factor for Thailand’s economic growth in short to medium terms. To improve growth in the long term, the country needs to prioritise skills development and reduce inequalities in incomes and human development outcomes. Lapses in these areas are expected to hinder economic growth and affect the automotive market growth in Thailand.

The popularity of the Thai government’s first-time car buyer incentive scheme (from September 2011 to December 2012) prompted a massive upsurge in vehicles sales volumes in 2012.

This trend is likely to continue in early 2013 as automakers complete pending orders . However, the vehicle sales are expected to witness a deceleration or slowdown from 2014 onwards, as spillover orders from 2012 are fulfilled and the market stabilises.

IndustryFocus


Indonesia Automotive Sector Currently, Indonesia is one of the largest economies in the world with the fourth largest population. It is expected to emerge as one of the top five economies by 2025.

The country has maintained an economic growth above six percent in the last three years, mainly driven by increased domestic consumption. It has emerged as one of the countries that registered a positive growth during the global economic crisis.

More than two-third of the population in the country resides in the Java island, making it the centre of economic, social, and political activities. An imbalance in population density and economic conditions across the nation is one of the key challenges before the country. It is therefore one of the key focuses under the country’s long-term development master plan.

The number of households in Indonesia with an annual d isposab le income above US$10,000 is expected to reach 25 million by 2018, with an

expected three to five percent growth per year. This reflects an increase in consumption levels. The trend also indicates a shift in consumer spending from food-related expenses to non-food items such as transportation, increasing the probability of first-time car purchases.

The Indonesian economy has sustained positive growth in recent years, despite the effect of the global economic crisis.

Supported by a stable inflation rate, steady loan interest rate, and new finance terms for vehicle purchase up to six years, the market demand for new vehicles is expected to grow.

More than 60 percent of Indonesia’s population is within the productive range of age 20 to 60 years. With a young population, the country has potential in terms of production and income to support more consumption. The so-called ‘golden age’ period is predicted to be maintained until 2030.

However, with the growth in consumption levels and other socio-economic issues, the government is expected to regulate a number of restricting policies such as minimum down payment on vehicle financing.

Although not directly affecting the market, natural disasters are among the key concerns for the industry in Indonesia, as it is located in an area susceptible to natural disasters such as floods, volcanoes, and earthquakes. In addition, the Indonesian auto industry must also watch out for any natural disasters in countries such as Thailand and Japan, where automotive components are sourced.

With the developed countries leading the way to provide a greener

Ning Nung, Thailand

The government of Indonesia is expected to implement a number of restricting policies such as minimum down payment on vehicle financing.

Osei May, MA, United States

Thailand has relatively low labour costs in the region, making it a preferred production hub, especially for the automotive industry.

IndustryFocus

ENQUIRY NO 182


environment, Indonesia is following suit. The country is committed to reducing emissions by implementing higher fuel standards. This will prove to be an obstacle due to concerns with the availability of fuel, infrastructure and facilities. Moreover, the costs and prices needed to cope with the new standards are likely to restrain the market, as nearly 70 to 80 percent of the vehicles in Indonesia continue to rely on cheaper subsidised low-standard fuel.

Malaysia Automotive Sector Malaysia is currently the third largest economy in Southeast Asia, and the 29th largest economy in the world. The country’s Gross Domestic Product (GDP) reached 5.6 percent in 2012.

From an economy dependent on agriculture and primary commodities, Malaysia has

progressed into a manufacturing-based, export-oriented economy driven by advanced technology and capital-intensive industries.

The New Economic Model (NEM) to be achieved through an Economic Transformation Programme (ETP) initiated by the Malaysian government constitutes a key pillar that will propel Malaysia to becoming a high income advanced nation with inclusiveness and sustainability, in line with goals set forth in Vision 2020.

Malaysia’s automotive market is in its mature stage and is likely to grow at a CAGR of four percent during 2012 to 2019. To promote the country as a regional hub for hybrid vehicles and electric vehicles, along with ensuring sustainable development of the nation, full exemption of import duty and excise duty on hybrid vehicles and electric vehicles will continue to

be given to franchise holders for vehicles below 2,000 cc.

The special incentives offered has helped boost sales of hybrid vehicles, from 332 units in 2010 to 8,334 units in 2011, and a subsequent increase of 84 percent to 15,355 units in 2012.

However, the tax exemption is scheduled to end on December 31, 2013. The government has not given any confirmation if there would be a further extension.

The hybrid segment will continue to be a bright spot with the extended duty exemption, new models in the pipeline, and growing customer acceptance. To meet Euro 4M implementation requirements, the government has requested the country’s oil companies to upgrade its refineries to produce lower sulphur fuels from 2015 onwards.


Cluster 1 (C1): Markets nearing stagnation

Brunei, Singapore

Cluster 2 (C2): Markets witnessing

steady growthMalaysia

Cluster 3 (C3): Growing MarketsThailandIndonesia

The Philippines

Cluster 4 (C4): New MarketsVietnam, Laos

MyanmarLaos, Cambodia

Automotive Market: Position of ASEAN Countries on Market Growth Curve, ASEAN, 2012Position of ASEAN Countries on Market Growth Curve

Indicates the position of the countries Note: All figures are rounded. The base year is 2012. Source: IMF and Frost & Sullivan analysis.

Motorisation Levels in ASEANAs a market, ASEAN is currently at the cusp of a high growth phase, along with the BRIC markets

Note: The size of the bubble represents the total industry volume (TIV).Note: All figures are rounded. The base year is 2012. Source: ASEAN Automotive Federation and Frost & Sullivan analysis.

Automotive Market: Motorisation versus GDP per Capita in Key Countries, Global, 2012

• Growing Middle Classes

• Vehicle ownership grows twice as fast as per capita income

The low level of motorisation in ASEAN offers strong growth potential for the automotive market, while the heavily-motorised regions of Western Europe and North America represent a saturated ‘replacement’ market.

Malaysia is currently the third largest economy in Southeast Asia, and the 29th largest economy in the world.

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Organized by:Of cially Supported by:

For more information:Tel. + 66 2686 7222, email: [email protected]

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ENQUIRY NO 172


With the introduction of the Euro 6 emission standard for trucks on January 1, 2014,

the permissible nitrogen oxide emissions for trucks weighing over 3.5 metric tons will fall by 80 percent. This standard has some wide-ranging effects on truck manufacturers.

One of them, Renault Trucks, is using the upcoming amendment to revise its complete range. This revision project started in France in June 2013 and will continue in countries where the company is represented over the coming months. Some of the parts used to construct the company’s trucks are produced on a hydraulic press line where its particular strength is its productivity and flexibility.

Easy & Fast ChangesThe flexibility of the line is particularly important when there are different sets of dies involved. Dr Martin Habert, MD of Schuler SMG, the company that supplied the hydraulic press line to the truck manufacturer says: “Renault Trucks can use both the existing dies of an older press line and specially developed dies for the production of the new truck cabins.”

Dr Habert, also the head o f t h e Te c h n o l o g y F i e l d (Hydraulic Presses) of the press manufacturer adds that the line

Case Study:

Pressed For TimeAn enforced regulatory requirement has given rise to the implementation of a hydraulic press line that produces parts for various models at Renault Truck. By Simon Scherrenbacher, Corporate Communications, Schuler

Ren

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enables the customer to exchange die sets quickly. With the aid of an automatic changing system, machine operators can exchange the complete press die set and robot tooling in less than five minutes. All in all, more than 80 different die sets are used on the line, making producing even the smallest batch sizes both simple and economic.

The company not only supplied the hydraulic lead press with 2,000 metric tons of press force and the three hydraulic follow-up presses with 1,000 metric tons of force each, but also the blankloader and other automation equipment. The entire line can achieve speeds of up to 11 strokes per minute with bed-slide surfaces of 4.1 by 2.5 m. With two parts per stroke, the line can produce 22 parts per minute.

Well-Oiled Process“In terms of precision and reliability, the process is like a Swiss watch,” says Dr Habert. “Everything runs like clockwork.” First of all, the blankloader separates the individual blanks from each other with the aid of fanning magnets so that the robot only picks up one blank from the pile to place on the conveyor belt.

In the subsequent optical centring station, individual blanks are captured on camera and their coordinates sent to the loading robot. The latter then

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places the blanks centrally and in the correct position into the die of the lead press, ready for deep drawing. The parts are then given their final shape in the follow-up presses. Robots transport the parts from station to station before they are laid on one of the exit conveyors.

The complete l ine was tailored to the exact dimensions of the Renault Trucks production

hall. The use of robots also means small distances between the presses as the parts are moved in a linear direction and transported from station to station without the usual 180-degree turn. This reduces the line’s overall footprint.

ConclusionTotal Productive Maintenance or TPM is a specialist term used

to describe the strong influence which maintenance has on a line’s overall productivity.

“Renault Trucks has a press l ine which corresponds in full to the principles of TPM,” concludes Dr Habert. “The line’s accessibility ensures that maintenance remains easy, minimising downtime.”


Both existing and the newly developed dies are used to produce the new truck cabins.

Automation equipment can be found in the hydraulic press line.

Schuler Schuler

IndustryFocus


To d a y ’s a u t o m o t i v e industry is generating revenue in many aspects. For one, it has helped

create a sustainable impact for many countries by developing opportunities for other areas such as human resource and research development. As such, automotive manufacturers strive to develop a favourable business environment to help them enhance this sustainable impact by improving and integrating international standards with today’s technology.

This trend is further reinforced in a recent IDC study conducted with over 460 manufacturers across multiple sectors around the globe, which includes manufacturers that provide components to the automotive industry.

It is noticed that while the business focus of manufacturers of today continues to evolve around costs and profitability, many are starting to understand the importance of improving customer experience and the options available to them to achieve this.

Now that the automotive industry has proven to provide quantum leaps of profit for Asia, automotive manufacturers are constantly looking out for new ways that they can boost market competitiveness through the use of appropriate technologies. These

technologies have to adhere to the stringent requirements of vehicle safety but also at the same time ensure production capacity has been met.

Keeping Up With ChangesTraditionally, the many methods technology can help enhance market competitiveness for automotive manufacturers is to introduce optimised global manufacturing methods. They can help reduce cost and improve operational efficiency and manage operational risks related to the manufacturer’s supply chain management for improved responsiveness.

In this era, where there are more emphasis in controlling cost and employee productivity than before, manufacturers need to start going deeper into how technology can help them focus on product innovation, ensure production capacity is met and sustain long term customer relationships.

So the question remains, how can today’s technology help automotive manufacturers keep up with these changing priorities at a cost effective manner?

The answer to this is to work with technology providers that can help automotive manufacturers achieve the goal of producing vehicles that are compliant to international standards and at the same time develop an infrastructure that is

not only capable of keeping up or exceeding production demands, but also provide automotive manufacturers with the essentials of sustaining customer retention for future business growth. On top of that, the deployment process of this IT infrastructure has to be easy to implement, adaptable and flexible to future business process changes.

Incorporating ERPF o r m o s t m a n u f a c t u re r s , Enterprise Resource Planning (ERP) has now become a necessity in running their business processes. It has been proven over the years that manufacturers have benefited greatly in terms of improving productivity and reducing operational costs with a good and strong ERP system in place. But how about improving customer experience? What role does an ERP solution play in the aspect of improving customer experience?

Based on the same IDC study, manufacturers whom are on their way to improving customer experience appear prone to a simplistic approach that sees IT as the fundamental tool to achieve that goal. The truth is, IT is only an enabler. In order for automotive manufacturers to see how the true benefits of an ERP solution is as an enabler, they have to align their ERP strategy along with their objectives.

The Best-Laid PlansCraig Charlton, senior VP & GM (Asia Pacific) of Epicor Software Asia shares how the right ERP system can help customer retention in the automotive manufacturing industry.

IndustryFocus


A good system can go a long way in improving operational efficiency.


Investing in a single ERP package will provide more flexibility and integration across the organisation. Key features to look for include SOA/middleware openness, ease of use, mobile features to streamline service operations, open choice of deployment, and functional agility. As cost management will still overshadow business expenditure, look for a solution that will help achieve a rapid return on IT investment.

With a single ERP package in place, automotive manufacturers get to match their needs with vendor modules’ and enjoy more flexibility in selecting specific features and modules from their software supplier.

In addition, tablet sales are predicted to eclipse laptop sales in the near future. Combining that with smartphones, which have become an ubiquitous business-productivity tool, they can help automotive manufacturers accommodate multinational trade, simultaneously deal with make-to-stock and make-to-order supply-chain strategies, improve scheduling of production facilities and resources, better handle complex costing processes and provide better financial reporting.

Case StudyTake for example Guangdong Hongtu Technology Company. The organisation is a manufacturer of

aluminium alloy die castings and serves as the national automotive parts export base and produces 22,000 tons of precision aluminium alloy die castings annually. In order to extend its business beyond Guangdong province and also internationally, a decision was made by the management to invest in technology in order to build a global brand and adhere to international standards.

The key ob ject ive was to streamline and improve its business processes to foster innovation and to be prepared to compete on the world stage. They also wanted to grow, and at the same time retain existing customers. The company felt that an ERP solution would be helpful for onsite production management & scheduling/planning and customisation.

The results saw the efficiency of production planning and scheduling improved, in addition to reducing cost of procurement through better collaboration between the procurement and production departments. In addition, the company gained full operational visibility in production, field management, and reporting.

As such, the company is able to save cost by eliminating redundancy and increase productivity and efficiency by complying to governmental and industry standards in production

and field management. The system has also been useful in simultaneously supporting and supplementing its R&D initiatives and capturing new products into the system in real time. The sales team was also able to provide real time and accurate information to all customers in an efficient manner with the use of the ERP solution, which as a result, more trust was placed in the organisation amongst their customers.

ConclusionTo sum things up, the role of a modern IT infrastructure is crucial. With a better integration and more flexible IT environment, it facilitates an improved experience for customers. With a strong strategy and execution plan, it is possible to identify and prioritise areas to improve customer experience as well as monitor and measure performance benchmarks against competition to sustain success.

It is also crucial that the IT infrastructure is adaptable to new business conditions. Last but not least, involve every user and third party supplier in the decision making process. In that way, the IT infrastructure will be able to cater to each department and supplier requirements, making business processes even smoother than before.

IndustryFocus


In summer 2012, a British v e h i c l e m a n u f a c t u r e r commissioned L Schaible to carry out the modified

production of its ‘tappet screw left hand and right hand’.

During the first production stage of this turned part, made from 42CrMoS4 bar material with a tensile strength of 1,100 N/mm2, all conical inner drilling was carried out by indexable insert drill with indexable drilling insert.

In the second production stage, the outer diameter was turned. Ralf Ferrero, operations manager of L Schaible explained that previously, other products did not provide any process reliability because the chip breaking was not consistent. He added that it caused repeated interruptions to the machine cycle and was leading to production stoppages.

Chipping Away At The ProblemIn a bid to improve the process, the company decided to speak with cutting tool supplier Walter.


Following a discussion, the parties agreed to run optimisation trials. Within the scope of this internal improvement project, the teams analysed and discussed the special requirements. In this case, it was about process reliability, tool life, chip formation and cycle time optimisation.

“The chips were the headache at the time,” explained Mr Ferrero. “The machine ran practically on its own, and the operator had the task of monitoring the machine, carrying out tool changes and making the necessary adjustments and maintaining the machine.”

The Walter employees involved developed a solution and presented their proposal on site. During subsequent implementation, several tools were tested, documented and evaluated within the scope of a cost/benefit analysis. The test phase lasted for two weeks.

Savings Achieved “Our most important goal was installing a more reliable production

process,” explained Markus Bilger, head of the CNC production department. “This goal was surpassed. All other parameters that have to be considered during production had automatically improved as well. The machining time reduction came virtually on its own accord. This saves us almost a full working month per year. We previously used to have stop times of one or two hours on the machines every day, which doesn’t happen anymore.”

Since the ‘tappet screw left hand and right hand’ is produced in quantities of up to 120,000 units per annum, the use of the mentioned tools resulted in process improvement and a more favourable cost structure.

When the drilling is complete, the workpiece is parted off and transferred to the second clamping facility in order to cut the thread.

First, the outer thread diameter is pre-turned. A new geometry used has improved the cutting data and reliable chip breaking behaviour. In the next stage of production, the thread (M24x3) is then turned using the indexable insert. Here too, the cutting data has been improved.

“The feeds have been modified in such a way that significantly better chip control takes place during this operation as well,” emphasised Mr Bilger.

The total amount of time saved using the various modifications at L Schaible amounted to 13 seconds per workpiece. Exact delivery times and on-time delivery are currently the most important parameters in the industry for successful existence in the market.

“Thanks to optimisation with the latest generations (of cutting tools), we can now manufacture our products in a shorter time,” summarised Mr Ferrero.

On-time delivery is one of the most important parameters in the production of assembly components in the automotive industry. Contributed by Jaslin Huang, Marketing, Walter AG Singapore

OptimisedFor Speed

Tappet screws

IndustryFocus

ENQUIRY NO 201


Recently crowned the world’s leading CAM software specialist for the 13th year, Delcam’s secret

to success in the complex world of CAM is actually quite simple, as aptly summed up by their chief executive, Clive Martell.

“Our po l icy i s to keep reinvesting in our products to make sure that we have good products coming through next year or the year after. We also ensure the core of our work is transferred throughout our products,” he said, in an one-on-one exclusive interview with Asia Pacific Metalworking Equipment News (APMEN) during the Asian Technical Summit (ATS).

Good products, combined with their business strategies are causes for optimism as Mr Martell told APMEN that he expects his business to grow.

“I expect to continue to increase the level of support and bring in more customers and grow our business around the world. We have seen recently, not just growth in the developing markets but also in the more matured markets. My expectation is that both areas will continue to grow,” he said.

Growth In Asia Expected To ContinueThis year’s ATS was held in Thailand, over at the Hotel Dusit Princess in Bangkok from August 20 – 22, where it was attended by users and Delcam’s executives alike. One of those executives was Sandy Moffat, business development manager of Asia, who like his chief executive, also predicted growth to continue well into 2014.

“I see continued growth throughout the region. A slight change here is that healthcare has become much stronger. We are also seeing the effect of FeatureCAM, which was relatively new five years ago, becoming stronger,” he said.

Delcam

Asian Technical Summit 2013The arrows are pointing up and this trend looks set to continue well into 2014. By Joson Ng

Echoing this sentiment was another business development manager of Asia, Chai Kok Hoe. He said: “We do foresee a steeper growth (next year).” In terms of percentage, he said growth would likely be “more than five percent” for the region of Vietnam, Thailand, Malaysia, Singapore, the Philippines and Indonesia. In order to achieve that growth, he told APMEN

that product improvements and seminars are important. However, the key is to support their customers.

Marketing EffortsIn terms of marketing, Asia remains a key growth area for the company, according to Peter Dickin, the company’s marketing manager. He said that growth in the manufacturing industry in

Clive Martell

Features


Asia is significantly greater than in Europe or the US.

“In terms of fast growth, Asia is still the most important. We are putting more materials onto the internet and are focusing on videos. The visual aspect (of videos) is much more attractive to people to watch and there is less of a language barrier as well. You can get an idea of what is going on even if you cannot understand the commentary. On the other hand, one thing we are trying to do is to get more multi-language videos. We hope to get more dedicated content for the Asian community in their native languages,” he said.

In spite of more activities online, Mr Dickin revealed that they are still carrying on with the more traditional types of marketing.

“We will still have case studies and product reviews. In addition, exhibitions, particularly in Asia

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Mr Chai sees steeper growth in 2014.

Mr Dickin believes face-to-face communication is a vital part of marketing.

Features


are important. Face-to-face communication is a vital part of marketing as you need to build relationships before you can sell anything,” he said.

Staying Ahead, Plowing New GroundsStanding atop the podium in the CAM software world for 13 straight years is an achievement, but also an enormous challenge that gets greater with each pass ing year. Wi th larger c o m p a n i e s l i k e D a s s a u l t Systèmes and Siemens in the background and others busy acquiring to expand their market share, Delcam faces a real fight on their hands to stay on top.

Refusing to get carried away, Mr Martell said the company’s ambition is to keep growing market share and doing that organically seems to be the order of the day.

“We have made M&A (in the past), but we believe we can convince companies using our competitors’ products that they can make productivity gains by using our products. That sort of approach will help us continue growing,” he said.

He also told APMEN that part of the strategy to achieve organic growth is to take the traditional approach. The company has been looking at some of the markets, which have large growth, such as Turkey and Mexico.

“We like to be direct,” said Mr Martell. “We want to increase our resources across our reseller channels around the world to make sure we have more capacity to support our customer base.”

Whether the company extends their run to the 14th year is anyone’s guess, but with their investment in R&D, ethos in constant product improvement, and their ability to listen to clients, Delcam looks set for a good 2014 and beyond.


ATS In Pictures

(From left) Joe Zhou (GM, Greater China Delcam plc), C W Chung (MD, Delcam Malaysia), Chai Kok Hoe, Sandy Moffat, Y Bambang Nugroho (GM, Delcam Indonesia), Buranang Suksamitti (MD, Delcam Thailand)

A trip to Mazak was part of the agenda during the summit

The visitors to Thai Summit Group were treated to a live demonstration on how a scanner picks up measuring points for metrological purposes.

Features

E&E’14 APMEN(205x275mm)p 9/5/13 10:46 AM Page 1

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‘Piping Hot’Growth

Steel tube production is on the rise with China leading the way. By Petra Hartmann-Bresgen MA, Press Department of Tube 2014

Worldwide steel tube production reached new record levels after growing six

percent to 150 million tons in 2012 (full year). Main growth factor was disproportionate growth in China, where steel tube production rose by 11 percent to 74 million tons. As a result, China’s share of the overall global steel tube production rose to 49.5 percent, declared Frank Harms of the German Steel Tube Association (WVS).

Steel tube production without China grew 2.3 percent, hitting 76 million tons. Despite increased demand from third countries, production within the EU27 contracted from 14.1 to 13.8 million tons. Weak economic conditions in Southern Europe are to blame. In Germany, the production output fell to 3.14 million tons, a decrease of three percent.

Mr Harms expects worldwide demand for oil & gas to continue rising, which will lead to increased demand for steel tubes. Increased exploitation of unconventional oil and gas deposits through fracking is set to stimulate steel tube demand.

Cont inued development of infrastructure in emerging markets, especially China, is a l so e x p e c te d to h ave a positive impact on demand for steel tube products. European manufacturers are cautious with their outlook for 2013, due to the

persisting economic situation, adds Mr Harms.

Bot h t he f ina nc ia l a nd sovereign debt crises in Europe and the US however should have less of an impact due to state intervention in the mid-term. Inventory-cycle effects could lead to growing demand, if market expectations rose over the course of the year, as stocks would be increased.

Growth Markets For Steel PipesSteel pipes will find growth elsewhere. Growth markets here include engineering, oil & gas, automotive, medical engineering, and aerospace.

The aircraft sector is booming in the age of globalisation. Demand is high due to fleet modernisation and the need to decrease costs.

Large-scale pipeline projects, such as South Stream and Nabucco, also result, if realised, in major orders for the pipe industry. In the case of South Stream, the pipeline will be 3,600 km long — around 63 billion sq m of gas would be pumped through the Black Sea from Russia to Southern Europe. However, this would only happen in 2015 at the earliest.

The Nabucco pipeline, planned to reduce natural gas dependency from Russia, requires pipes for a total length of 3,300 km from the Caspian region to Western Europe.

Markets In BRICS Countries The entire pipe sector has high hopes for the dynamically growing BRICS countries: Brazil, Russia, India, China and South Africa. In Russia and China, there are efforts to create an own aerospace industry. In Russia, its oil & gas industry is of great importance.

The BRICS countries do not exclusively rely on imports. China exports great amounts of steel pipes itself. China is increasingly changing from a former steel pipe importer to a country that can satisfy its own demand, and more. In addition, the country is increasing its export activities, WVS noted.

A similar, less obvious picture can be seen for welded pipes of up to 16”. Chinese producers are in a dominating position, even if this is not as evident as in the market for seamless pipes. According to the WVS, the largest producers in the large-diameter arena (over 16”) are China, the Far East and the CIS. However, the role of Indian producers is increasing.

Specialisation & QualityMore than a few Western pipe producers are brooding in view of the current developments. How can they withstand competition from Asia? “Increasing international competition makes specialisation a necessity,” says Mr Harms.

Features


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Companies that can offer products with higher material quality, better tolerance levels, and cost efficient production will have better chances of prevailing. In addition, buyers of steel pipes expect low fault tolerances, a consistent level of quality, and delivery reliability. Low temperature properties are also an increasingly important issue.

A further trend is to lower wall thickness, as thinner walls save weight. Sectors such as the car and plane industry want lighter products, which require less fuel. It also means less CO2 emissions. In the case of electric cars, less weight translates into higher ranges.

Weight Loss Is In VogueBuyers pay attention to pipes that have low weight. This tips the scales towards the current trend to reduce weight. Due to reducing

weight by saving on materials, pipes are not produced as classic seamless or welded pipes, but as tailored blanks, which are rounded and welded.

Companies are also expanding subsid ia r ie s in impor ta nt industrial nations. Vallourec & Mannesmann Tubes is expanding its plant in Youngstown, US, with a new production area. It produces small-diameter pipes, mainly for shale gas extraction. A facility is put into operation in Changzhou, China. A Vallourec & Sumitomo Tubos do Brasil steel pipe factory is beginning to operate in Jeceaba, Brazil.

New Strategies & Future OutlookInternet-based network and sales structures are becoming increasingly important for the pipe sector. In 2007, a company

247TailorSteel.com took an innovative approach.

The start of the website in the Netherlands marked the beginning of the internet age for laser cutting. After offering internet-based procurement of 2D flat cuts in the market, the website started to offer tube and sheet metal processing by laser in early 2011.

Looking ahead, the sector has to pay heed to elements of uncertainty. Rulings by the European Commission concerning climate policy are worrying. According to WVS, these will lead to higher costs in the medium term, from which competitors outside of Europe remain exempted. These concerns are also shared by other industries — despite an otherwise good outlook.

Features


The Singapore leg of the Iscar Seminar Day was held on August 23, 2013, at York Hotel. Some 158

attendees were present to witness the IMC Group president and CEO of Iscar, Jacob Harpaz give his take on productivity — the buzzword of the manufacturing world.

Tying productivity to the notion of growth, he skillfully used his company as an example. He told the audience that with the ethos of producing products that enhance productivity, the company grew from less than US$50 million in 1982 to an entity valued at around US$3 billion in 2012.

Mr Harpaz is not only a firm believer of productivity, he is very confident of producing it. “We guarantee a reduction of 15


percent in cost in the first year (of using their products),” he said, urging the audience to pursue a higher level of productivity.

Dissecting ProductivityWhile flying the flag of productivity, Mr Harpaz also emphasised the importance of staying focused on what companies want to achieve, ie: higher long term productivity over short term price reduction.

He explained that in a typical manufacturing setup, cutting tools account for some three percent of overall production cost. The rest of the costs are raw materials (22 percent), manpower, machining and overhead (75 percent). Should there be a 20 percent reduction in tool price, overall savings will amount to a mere 0.06 percent, dispelling the significance of cutting tool discounts.

On the flip side, by machining intelligently, a 20 percent increase in productivity (speed or feed) would roughly translate to 15 percent overall production cost reduction, according to him.

New ProductsWith some five to six percent of the company’s annual revenue invested in R&D, it is no surprise that Mr Harpaz had a slew of new products to present to the participants.

The tool families under the HighQLine campaign assist the user to increase profitability by employing engineering solutions to achieve the notion of ‘machining intelligently’.

Some of the toolings are:

• Dove IQ Turn — a dovetail pocket combined with a lever clamping mechanism providing firm and rigid insert clamping for heavy turning.

• Dove IQ Grip — this tool has a frontal locking mechanism designed for deep heavy grooving applications and unobstructed chip flow.

• Heli IQ Mill 390 — these milling inserts with three cutting edges and advanced cutting geometries function with reduced cutting forces and lower power consumption.

• Dove IQ Mill — this milling insert features a design with eight cutting edges for a range of face milling applications.

Productivity was high on the agenda in this one-day seminar. By Joson Ng

Event Review:

Seminar DayIscar

Did You Know?IMC Group is the first company outside of the US to be acquired by Berkshire Hathaway.

The Dove IQ Turn is said to be suitable for heavy turning.

Features


Event Preview:

Oil & Gas Indonesia 2013

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Th e 2 0 1 3 e d i t i o n o f Indonesia’s oil and gas exploration, production and refining exhibition —

Oil & Gas Indonesia 2013, will return on November 13 – 15, 2013 at the Jakarta International Expo, Kemayoran, as a standalone industry exhibition.

Held for the ninth time, the exhibition has once again registered record growth in tandem with the industry developments. In total, over 140 exhibiting companies from 15 countries will converge at the event, including group pavilions from Australia, China, Germany,

Italy, South Korea, Singapore and UK, providing a definitive industry platform covering an area of over 9,000 sq m.

With key industry solution providers from the oil and gas sectors committed to showcasing their latest technologies, products and services, the event serves as a key focal point to address on Indonesia’s evolving industry needs.

“We are indeed delighted with the growth progress attained, both with companies in Indonesia and internationally, since introducing it as a dedicated standalone event. It reflects on the dynamism of the

market as well as recognition on our initiative to provide for a dedicated industry platform,” said Maysia Stephannie, senior project manager of PT Pamerindo Indonesia, the exhibition organiser.

“The focused nature of Oil & Gas Indonesia 2013 will elevate quality engagements between industry engineering stakeholders and corresponding solution specific providers. For which, industry project demands and requirements will be more effectively attended and accomplished over the duration of the event.”

Jakarta International Expo KemayoranJakarta, IndonesiaNovember 13 – 15, 2013


EvEnts&Exhibitions


Metalex 2013 returns t o t h e B a n g k o k International Trade & Exhibition Centre

(BITEC) from November 20 - 23, 2013, with the largest gathering of global brands, according to the organiser, Reed Tradex.

With proven records and strong relationships with global technology providers, the show is recognised as the ‘event of the year’ to promote corporate images and launch the latest o f f e r i n g s t o t h e re g i o n a l market. Visitors can source for technologies to stay ahead of competitors and/or expand their networks.

Fully occupying all six halls, the basement area of BITEC and the expansion zone called Super Dome, the show will be loaded with over 4 ,000 technologies by 2,700 global brands from 50 countries.

Leading brands to participate in the show include ABB, Amada, Brother, Carl Zeiss, Agie Charmilles, Chevalier, Davi, DMTG, Durma, Emuge, Erowa, Euromac, Fanuc, Haas, Haco, Hankwang, Hexagon, Hitachi, Hwacheon, Hyundai, Iscar, Kawasaki , Komatsu, K y o c e r a , M a t e c , M a z a k , Mitsubishi, Mitutoyo, DMG/Mori Seiki, Nachi, Nikon, Noritake, Okamoto, Okuma, Olympus, OTC, Renishaw, Rollomatic, SMT, Sodick, Sumitomo, Takamaz, Taegutec, Toshiba, Toyoda, Trumpf, Tungaloy and Yaskawa.

In addition, there are eight International Pavilions including:

Event Preview:

Metalex 2013

EvEnts&Exhibitions


Visitors can expect many products making their first appearances in Southeast Asia.


• China Pavi l ion by China Council for the Promotion of International Trade (CCPIT)

• German Pavilion by German M a c h i n e To o l B u i l d e r s ’ Association (VDW)

• Japan Pavilion by Japan External Trade Organization (JETRO)

• Korea Pavilions by Korea Association of Machinery Industry (KOAMI) and Busan Economic Promotion Agency

• S i n g a p o r e P a v i l i o n b y Overseas Market Development Association (OMDA)

• Taiwan Pavilion by Taiwan Association of Machinery Industry (TAMI)

• UK Pavilion by Engineering Industries Association (EIA)

Dynamic Learning Platform Immense amount of knowledge and technological experiences will be imparted to the minds of delegates to expand strategic visions with various interesting conference topics to help par t ic ipants gain a better competitive edge and an upper hand in the global arena. The forums are:

• The 3rd Metalex Nano Forum, the nano-enhanced technology for metalworking industry

• The 2nd Metallurgy Forum

• Onsite conference sessions and First-Time-in-ASEAN Technology Presentations

BITECBangkok, ThailandNovember 20 – 23, 2013

EvEnts&Exhibitions

Covering all angles and markets, Asia Pacific Metalworking Equipment News is the metalworking resource centre in both traditional and new media platforms.

[email protected]: (65) 6379 2888Fax: (65) 6379 2805


Social MediaAn interactive way to stay engaged with our readers.

eNewsletters Get regular updates from us and our sponsors with this service that reaches 28,500 subscribers.

WebsiteRead our eBooks as well as business news here.

Print MagazineThe most quantifiable way to reach 9,880 qualified readers.

Vietnam Guide BookAn annual to help our Vietnamese readers (8,000 strong) arm themselves with the latest in metalworking technologies.

MEN IndonesiaWith a readership of 8,000, you will be able to gain a foothold in the rising Indonesian metalworking market with this magazine.


Enquiry No. 7702Turn to page 80a or log on to www.equipment-news.com to enquire EN

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DMG/Mori Seiki: Turn & Mill Complete Machining

The CTX beta 2000 TC is an addition to the CTx TC series and offers an affordable entry into turn-mill complete machining of workpieces with turning lengths of up to 2,000 mm. The machine comes with a large work envelope for workpieces up to Ø550 x 2,050 mm, the biggest Y-stroke in its class and the possibility to use a steady rest for workpieces up to Ø350 mm.

For demanding complete machining applications, the machine offers main and counter spindles with a torque of up to 770 Nm. Furthermore, the powerful turn-mill spindle with speeds of up to 18,000 min-1 offers the machining of complex workpieces and five-axis simultaneous machining.

Heule Precision Tools: Solution For Back Spot Faces & Counter Bores

The BSF tool by Heule extends their range for automated high volume production of back spotfacing and counterbor ing. Now, a counter bore ratio of up to 2.3 x d is possible. The tool is used for diameters from 6.5 to 20 mm without having to turn the workpiece over.

The product ive e f f i c i e n c y i s distinguished by its process capability, proper functioning a n d h i g h c o s t effectiveness, due to fast process cycles and a minimum of secondary time. BSF is specifically designed for CNC machining and is immediately ready for production.


ProductFinder





igus: Measuring System Cable

igus has optimised its chainflex measuring system cables CF113.D and CF11.D. The measuring systems cables have been further developed for smaller radii with a bending radius of at least 7.5 x cable diameter and dispose of accordingly high-quality superstructures. They are available from stock as yard goods or ready-made in 20 manufacturer standards.

Measuring system cables communicate the movement of a motor back to the control. They are used in any manufacturing machines, for example, in wood processing or in machine tools, but also in storage and retrieval units, in semi-conductor assembly or crane applications. For this reason, five different qualities of measuring system cables are available in the chainflex program.

ifm Electronic: RFID System MakerBot: Desktop 3D Scanner

ifm electronic have launched a RFID system for harsh e n v i r o n m e n t s l i ke ident i f y ing tools, monitoring production steps, QA, automotive and conveying industries.

T h i s ro b u s t , IP67 eva luat ion unit is equipped with an integrated Profibus DP interface and a web server. Parameters are easily set via a laptop.

The RFID evaluation unit features four antenna terminals, or digital I/Os. The antenna concept guarantees easy connection of the LF, HF antennas by means of M12 connectors.

RFID system platform is widely used in production for easy use and flexible parameter setting, allowing users to solve each identification task easily and precisely.

The MakerBot Digitizer Desktop 3D Scanner is a fast and easy way for anyone to create 3D models. The 3D scanner is for sale worldwide with shipping expected in mid-October.

The equipment takes a real-life object, scans it using a camera and two lasers, and creates a 3D digital file — without any need for design or 3D software experience. The 3D Scanner is optimised for and works seamlessly with MakerBot’s Replicator Desktop 3D Printers and MakerBot Thingiverse.

The equipment can be used in the office, manufacturing space, workshop, classroom, or in the home to jumpstart the modeling and prototyping process and create artworks, sculptures and figurines, as well as memorialising keepsakes and archiving.

Greenleaf Corporation: Ring-Groove Cutter Line

Greenleaf Corporation has developed an expanded line of Ring Max ring groove cutters to the international marketplace. Designed specifically for the oil and gas industry, the line of ring groove tooling is engineered to finish machine API ring grooves in less than one minute of cut time.

The Ring Max II cutters have been designed to use fewer components for even greater dimensional accuracy and repeatability from groove to groove. Their design ensures accurate seating and secure locking of the insert cartridge into the cutter body. The Ring Max III design includes all of the enhancements of the Ring Max II in a high-precision, two-piece modular system.


ProductFinder

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ProductFinder





TDM Systems: Digital Tool Data For Simulation

Union Tool: End Mill For Cemented Carbide

TDM Systems has developed the TDM release version 4.6, a 3D generator and graphic converter to support improved CAM simulation.

The developers have once more targeted the effort required to implement the tool and resource management system, as well as easy and intuitive usability.

Due to the 3D tools, the company has taken a step closer to their vision of a digital factory and has upped another gear in terms of CAM simulation: A 3D-revolve generator for rotational symmetric tools and a 3D graphics converter for the CAM systems’ accelerate process simulation and collision analysis.

The diamond coating, developed by Union Tool, enables carbide end mills to physically ‘cut’ shapes and features into cemented carbide work material.

By combining optimised cutting geometry, with UDC coating, users can apply direct milling strategies and remove the need for grinding or using EDM techniques to form complex 3D shapes.

This coating, with a hardness of 100 Gpa or 9,000 HV, is able to resist wear and gives a good surface finish, enabling the end mill to produce finished parts without pits or burrs. Also, without the need to make electrodes or form wheels for grinding, the production time can be up to 80 percent quicker.

SKF: Lubrication System For High-Speed Spindles

The SKF Microdosage Lubrication System comprises a compact intelligent lubricant metering unit and a pressurised reservoir for high-speed spindles with speeds above two million n x dm used in machine tools.

The system has four individual outlets and is designed to adjust the minimum amount of lubricant dynamically when spindle speeds cause a change in the lubricant requirements.

With its integrated automatic calibration, the system responds immediately to viscosity changes in the lubricant. These changes are commonly caused by temperature or pressure fluctuations. The system then maintains minimal and precisely metered small quantities of lubricant, with the volume being individually configured.

MPDV: MES Industry Solution For Metals

MPDV’s Manufacturing Execution System (MES) has been customised specifically to cater to the needs of metal processing.

Hydra for Metals is based on the approved functions complying with the VDI 5600 guideline of the MES solution. It has been customised and enhanced by special functions to cater to the needs of metal-processing companies.

The functions range from applications for foundries, rolling mills, heat treatment, coating to mechanical processing and packing. Selected highlights of the solution are functions for composition, roller maintenance and processing centres.


ProductFinder


2013OctOber9 – 12MITF 2013PWTCKuala Lumpur, MalaysiaExpo [email protected]

10 – 12Metalex Vietnam 2013SECCHo Chi Minh City, VietnamReed [email protected]

24 – 26Intermach Myanmar 2013Tatmadaw Exhibition HallYangon, [email protected]

NOvember13 – 15Oil & Gas Indonesia 2013Jakarta International Expo KemayoranJakarta, IndonesiaPT Pamerindowww.pamerindo.com

20 – 23Metalex 2013BITECBangkok, ThailandReed [email protected]

December4 – 7Manufacturing IndonesiaJakarta International Expo KemayoranJakarta, IndonesiaPT Pamerindowww.pamerindo.com

2014march11 – 13JEC EuropePorte de VersaillesParis, FranceJEC [email protected]

19 – 22InapaJI Expo KemayoranJakarta, IndonesiaGEM [email protected]

april1 – 3MTA Hanoi 2014ICEHanoi, [email protected]

9 – 13SIMTOS 2014KINTEXSeoul, South [email protected]

may15 – 17Subcon Thailand 2014BITECBangkok, ThailandUBM Asia (Thailand)[email protected]

15 – 18Intermach 2014BITECBangkok, ThailandUBM Asia (Thailand)[email protected]

15 – 18Sheet Metal Asia 2014BITECBangkok, ThailandUBM Asia (Thailand)[email protected]

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

July14 – 17EMTE EastpoShanghai New International Expo CentreShanghai, ChinaMP [email protected]

2013-2014

exhibitiONprOgrammes

Vis

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Vis

it Us

Vis

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


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


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No. 7 2013

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❑ 221 Basic Metal/Foundaries/Mills

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❑ 222 Telecommunications Equipment Manufacturing

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❑ 318 Shearing

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❑ 324 Inspection/Measuring/Testing

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❑ 317 Automated Assembly

❑ 320 Beading

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TYPE OF BUSINESS (Please ✔ ONE box only)Do you use METAL in your production/manufacturing process? ❑ Yes ❑ NoDo you use machine tools and related equipment? ❑ Yes ❑ NoDo you use automation systems & equipment? ❑ Yes ❑ No

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❑ 021 Senior & Middle Management❑ 023 Maintenance Engineering❑ 025 research & Devt

❑ 028 Testing & Inspection❑ 030 Sales & Marketing❑ 027 OThErS (Please specify)

❑ 022 Production Engineering❑ 024 Quality Control/Assurance

❑ 026 Design Engineering❑ 029 Purchasing/Sourcing

YOUR METAL PROCESS USED ? (Please be specific)

❑ 313 Forging❑ 316 rolling❑ 319 Die Casting❑ 322 Welding❑ 302 Turning❑ 305 Coil Forming

❑ 308 Broaching❑ 311 Plastic Moulding❑ 314 Pressworking❑ 317 Automated Assembly❑ 320 Beading❑ 323 Electroplating

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❑ 321 EDM/ECM❑ 324 Inspection/Measuring/Testing❑ 301 Design with CAD/CAM❑ 304 Drilling/Boring❑ 307 Tapping/Threading❑ 310 Lapping/honing

❑ 300 CNC Machining❑ 303 Milling❑ 306 Gear Cutting❑ 309 Grinding❑ 315 Stamping❑ 318 Shearing

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DKSH Technology Pte Ltd. · 625 Lorong 4 Toa Payoh #03-00, Singapore 319519 · [email protected] Technology Co., Ltd. · E-Town 2 Building 1st fl oor, 364 Cong Hoa Street, Ward 13 Tan Binh-District, Ho Chi Minh City, Vietnam · [email protected] (Thailand) Ltd. · 2106 Fantree 4 Building, Sukhumvit Road, Bangchak, Phrakhanong, Bangkok 10260, Thailand · [email protected] Technology Sdn Bhd · No. 14, Jalan Bersatu 13 / 4 · 46200 Petaling Jaya · Malaysia · [email protected]

THAI METALEX20.–23.11.2013 Booth X41, hall 104

If space-saving is your priority, then the S11 is the right machine for you. In a space of less than 1.8 m2 the S11 produces extremely effi ciently and reliably with a grinding wheel dia. 500 mm. The S11 can be set up quickly and easily thanks to the lean StuderWINfocus software, geared to the most important features. It can also be easily automated with an integrated loading/unloading device.

www.studer.com – «The Art of Grinding.»

The Art of Grinding.

The super-productive machinefor small workpieces.

S11

ENQUIRY NO 194

©2013 Kennametal Inc. l All rights reserved. l A-13-03153

Double-sided insert with up to 12 cutting edges for a more productive cutting process.

Higher clearance angles designed in the cutter bodies to permit pocketing, profiling, and 5-axis machining.

Three different insert sizes and three topography styles per size, cover any type of material, component, and application.

Unique anti-rotation feature for excellent stability with higher feed rates and cutting forces while allowing for user-friendly insert rotation.

RodekaTM double-sided round inserts:

• Three insert ICs: 10, 12, and 16mm.

• Innovative, cutting-edge design increases tool life and reduces cutting forces.

• Also offered, RodekaTM 8, a tailor-made solution for turbine blade machining.

Working harder and smarter. That’s RodekaTM

. That’s Different Thinking.

Kennametal introduces a new and revolutionary double-sided round milling insert — Rodeka.

TM

It’s capabilities span multiple types of milling operations and workpiece materials, providing the latest double-sided insert technology to increase your productivity with the most efficient cost per edge. Now That’s Different Thinking. That’s Kennametal.

To learn more about RodekaTM

and the latest machining technologies, contact your authorized Kennametal distributor, call 800.446.7738, or visit www.kennametal.com.

ENQUIRY NO 068

apmen october 2013

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