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M.I.C.A. (P) No. 119/12/2008 May-June 2009

Aerospace Supplier eXchange 2009 Aerospace Industry: The Sky’s The Limit

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

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

CV MULTI TEKNIKJL. Balikpapan Raya No. 28 Jakarta Pusat 10140 Indonesia Tel + 62 21 6307303Fax + 62 21 [email protected]

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

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

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

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Think smart | Work smart | Earn smart.

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ContentsMay-June 2009

SOFTWARE & MEASUREMENT32

22 FIRST CUTGoing The Exotic Way Machining exotic metals is difficult but it can be very rewarding as they often bring superior properties. By Dr Moshe Goldberg, marketing technical advisor, Iscar

Cool Under FireDrilling at high temperature is both a challenging and precise undertaking. By Kalle Schenning, product manager, Seco Tools AB, Sweden

TECHNOLOGY UPDATE30

Die Casting & Mould Processes: The Soft & Hard TruthIntroduction of software and improvements in hardware combine to bring a traditional industry to new heights. By Augustine Quek

CMM Technologies & Advances: Time For A Face Lift?A peek into the past of CMMs and its relevance today as the grand father of metrology goes for a makeover. By Joson Ng

36

38

Deep Sea RatedLaser scanning and design softwares provide a fast and efficient route from prototype to production for the smaller boat builder. By Deri Jones, MD, Deri Jones & Associates.

Blast From The Past, Or Is It?Profile projectors are maintaining its relevance in the fast changing world of metrology. By Tom Groff, North American sales manager, Optical Gaging Products Inc

26

JETSTREAM TOOLINGTM

DIRECTED COOLANT STRAIGHT TO THE EDGE.

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

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

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

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MILLING NEWS:

INTRODUCING: SQUARE 6TM

2009 Jetream combo ad.indd 1 3/19/2009 4:45:31 PM

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• RefeR to AdveRtising index... foR AdveRtiseRs' enquiRy numbeRs

Regulars• 8 Business News• 20 Business Statistics• 73 Product Finder• 79 Exhibition Programmes• 80A Product Enquiry Card

Pg 80

Metalworking Fluids: Bigger Bang For Your BucksThe changing operating climate facing automotive component manufacturing is placing increasing demands on metalworking fluids. By Laurent Barnagaud, global marketing manager of Shell Metalworking Lubricants.

Contents

66

70

62

FEATURES58

44

50

52

56

INDUSTRY SPOTLIGHT46

FAB & FORM42Sheet Metal Advances: Old Ideas, Move Over!Processing thin sheets of metal can be more economical if innovative designs and fresh process selection are used. By Melvin Tham, product manager, bending technology, Trumpf Asia Pacific

Sheet Metal Advances: High Speed Stamp Of ApprovalThe faster, the better — this simple notion takes on a complex view in high speed stamping. By H Pecik, marketing manager, Bruderer

A Quick FixDimensional measurements are sometimes complicated matters where special fixtures are required to aid the operators. By Maren Roeding, PR manager, Witte Far East.

Sky WorksMachining of aero components is in the class of it’s own where special requirements and advanced technology are quite simply, the industrial norm. Contributed by Bernhard Weihermüller, Walter Tools

Aerospace Supplier Exchange 2009

Aerospace: The Sky’s The LimitAsia Pacific sees emerging aerospace manufacturing plants despite the economic slowdown. By Syahril Shariff, consultant, Asia Pacific aerospace & defence practice, Frost & Sullivan.

EVENTS & EXHIBITIONS

Remanufacturing: A New Lease Of LifeOften misunderstood, the concept of remanufacturing brings crystal clear benefits. By William C Gager, president, Automotive Parts Remanufacturers Association

Tech & TactIt is worthwhile to identify new approaches that would help tool shops minimise pains which technology alone cannot help alleviate. By Hari Sridharan, VP of Engineering, Cimatron

Machine Tool & Manufacturing Indonesia 2009 • Precision Engineering Business Forum 2009 • MTA Vietnam 2009 HCMC

30% Morep r o D U C T I V I T yTurning Intelligently

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Aerospace Supplier eXchange 2009 Aerospace Industry: The Sky’s The Limit

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editor’snote

6 metalworking equipment news May-Jun 2009

Joson NgAssistant Editor

There are many different types of love in this world. Be it between friends or between family members, wherever they may be, people in love share a connection transcending distance and time. Like lovers with a special bond, precision engineering and the aerospace industry go hand in hand, each a subset of the other. In the recent Precision Engineering Business Forum in Singapore, this is all the more evident when the aerospace industry is in one of the core threads along with medical technology.

The high regard for safety in the aerospace industry naturally brings about a higher standard in part tolerancing and machining. This leaves very little room for error and heralds the introduction of precision engineering. With tolerances often in the micron level these days, there is no better time to put precision engineering in the spotlight.

Although airlines have had their wings clipped by the global economic turbulence, the aerospace industry is stil l maintaining an acceptable

cruising altitude in Asia, with the big boys in the industry like Rolls Royce and Honeywell Aerospace setting up shop in this region. Supported by the pent-up demands accumulated over the past few years, things are not as bad as initially thought.

Focussing on the aerospace industry in this issue, we have put together plenty of evidence to support this optimism. From industry spotlight where the outlook of the aerospace industry is discussed in- depth, to technical articles in precision engineering, they can be found in this issue of Asia Pacific Metalworking Equipment News.

Also in this issue, the notion of re-manufacturing is visited, as we hope to bring the interesting idea to your attention. Often misunderstood and confused with recycling and repair, we hope to clear the misconception of this concept, so manufacturers and buyers can make the most informed choice and stretch their money to the maximum in these trying times.

Blue Skies

The Haas SL-10 Turning Center Includes aSpecial Feature You May Not Notice Right Away...

Haas Automation, USA | www.HaasCNC.com | CNC Technology Made in AmericaMachines shown with optional equipment.

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a Lot of Machine for the Price.

Intl09_AsiaPacific.qxd 12/1/08 9:50 AM Page 4

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Businessnews

Bielefeld, Germany: Gildemeister has signed a cooperation agreement with the Japanese machine tool manufacturer, Mori Seiki. The cooperation covers production, purchasing and the development of machines, as well as sales and services in selected markets.

This strategic partnership allows both companies to extend their business activities. They will both benefit from short and long-term mutual advantages.

The aim of this ‘win-win’ partnership is to achieve synergies of about €15 million (US$20 million) per

Gildemeister Cooperates With Mori Seikiyear for both sides. To strengthen the alliance, a cross shareholding has been agreed. Investment in five percent of the shares each, confirms the long-term character of the cooperation.

Gildemeister has already purchased two million Mori Seiki shares and will increase this up to a total of 4.4 million shares (five percent). Mori Seiki will purchase 2.3 million (five percent) Gildemeister shares, arising out of a capital increase in authorised capital excluding share options.

Gullegem, Belgium: LVD and Hubei Tri-Ring Metalforming Equipment (HD) have formed a joint venture company in Huangshi City, Hubei Province, China.

The joint venture company will produce LVD sheet metalworking equipment, including turret punch presses, laser cutting systems, and CNC press brakes, as well as HD’s own design machinery, for the Chinese and export markets.

Production from the new joint venture will complement LVD’s existing production facilities in Belgium, USA, France, Slovakia and Romania and will provide key capacity for LVD and HD’s strategic growth plans.

HD is a state-owned enterprise employing over 1,000 people in three plants. The company specialises in manufacturing CNC precision equipment.

Its main factory is equipped to manufacture specialised large press brakes up to 10.000 ton – 12.5 m in capacity, geared toward offshore, energy, oil and gas applications.

LVD & HD Establish JV In China

Singapore & US Institutes Collaborate In Sustainable Manufacturing Technologies

Singapore: Singapore Institute of Manufacturing Technology (SIMTech) has signed a Memorandum of Understanding with the Golisano Institute for Sustainability (GIS) of the Rochester Institute of

Technology (RIT), USA, to advance the development of sustainable manufacturing technologies.

The two-year collaboration between the institutes will build on the collective and complementary research capabilities in sustainable manufacturing technologies in SIMTech, and expertise in the areas of sustainable development and design combining real world experience with a strong academic and research background in GIS.

Specific research collaboration areas include joint R&D in sustainable manufacturing technologies, renewable energy and fuel cells, clean production process technologies, clean technologies, reverse logistics and green supply chains, intelligent testing and diagnostics and sustainable design for remanufacturing.

Sustainable manufacturing technologies will shape future living as they open up manufacturing possibilities to create new environmentally friendly products. These products can be produced cost-effectively to improve quality of life minimising or minus the costly repercussions of pollution, damage to the environment and depletion of resources among others.

Sustainable manufacturing technologies can be used in multiple industries for clean production and services.

May-Jun 2009 metalworking equipment news


9

Businessnews

ABB Sets Up Manufacturing Facility Near Bangalore

Bangalore, India: ABB in India has inaugurated its greenfield automation products facility near Bangalore. This facility is one of many initiatives that ABB has taken up in India to build and expand capacity to meet the needs of the future.

Spread over 18 acres, the factory will manufacture products such as air circuit breakers, switch fuse units, moulded case circuit breakers, low and medium voltage drives and systems, MCC & PLC products, high power rectifiers, static excitation systems and main & auxiliary traction converters. A ‘Demo Room’ showcasing ABB products was also inaugurated on this occasion.

Aluminum Association Sees Increase In New Orders

Virginia, US: The Aluminum Association recorded an increase of 4.5 percent in January after declining for eight consecutive months.

Orders for flat roll products (including can stock and foil) increased 8.0 percent while order receipts for extruded products rose 10.7 percent. Orders for ‘other’ mill products, including drawing stock, electrical conductor and forgings, fell 22.4 percent. Compared to January 2008, new orders were down 26.9 percent from the previous year.

Canada: Bombardier Transportation and joint venture partner, Downer EDI Rail, have been awarded a contract valued at approximately €104 million (US$131 million) by the Queensland government in Australia to build 20 three car electric commuter trains. The company’s share of the contract will be about €48 million. Deliveries are scheduled to start in August 2010 and continue until December 2011.

This order is a follow on from an order for the SMU260 vehicles currently entering service with QR (Queensland Rail).

Assembly of the new trains will be carried out at the manufacturer’s facility and EDI Rail’s facility in Maryborough, Queensland. Propulsion and traction equipment will be manufactured at the company’s plants in Västerås, Sweden and Pittsburgh, USA. Testing and commissioning will be carried out jointly. This order builds on over 600 narrow gauge carriages already in service in Brisbane and Perth.

Bombardier Awarded Contract For Queensland Rail

Jim Southwood, president of CRU Risk Management said: “In our last industry survey, extruders reported that January shipments were better than December. With the Aluminum Association reporting that orders were up 11 percent in January over December, it appears February shipments may mark the bottom of the US aluminium demand decline. A quick recovery is not likely, but it is reasonable to expect that business will stabilise.”



Businessnews

Guangzhou, China: Located on the grounds of the Baiyun International Airport at Guangzhou, China, FedEx will make it the centre of its operations in the Asian-Pacific area for the next 30 years.

The Guangzhou facility replaces the one at Subic Bay. Although that will be decommissioned, FedEx maintains presence in the Philippines where Manila and Cebu are integral components in its AsiaOne network.

A first for an international air express cargo carrier is the Guangzhou facility’s ramp control tower that permits FedEx to manage and control movements of aircraft. The facility also offers dedicated customs clearance. As it begins operations, the facility’s package and sorting systems can handle 24,000 packages per hour.

Some 136 weekly flights will move into and out of the new hub, connecting it to the 220 countries and territories served by the company.

FedEx Opens US$150m Asia Hub Facility

Delcam To Set Up SEA Base Camp In Singapore

B i r m i n g h a m , U K : Delcam has established its Professional Services Group in Singapore and the group’s services will be featured for the first time at MetalTech (Kuala Lumpur, May 6 - 10).

E v e n t h o u g h t h e company’s software has been sold throughout Asia, the Singapore site is the first office in the region for the Professional Services Group. Like the existing team based in the UK, the new office will provide process development and prototyping services based on the company’s range of CADCAM software.

A s i m i l a r f o c u s on helping companies with the manufacture and repair of aerospace

components will be the main priority, although the Singapore team will also provide its services to other industries.

Most of the projects undertaken by the group involve the development of turnkey work cells using the company’s machining technology. It uses a combination of machining and inspection technology to allow the production of complex components to a consistent level of accuracy and quality. Typically, the systems involve automation, allowing them to be operated by lower-skilled staff.

Mumbai, India: Siemens Building Technologies has set up a Graphics and Engineering Centre of Competence (GECC) in Chennai. This is the first competence centre of Siemens building technologies in the Asia Pacific region. The GECC will provide engineering design services for the Indian market and also for the Asia Pacific Region.

The centre will also have capabilities to provide need based, on-site support. In the initial phase, the GECC will have about 30 engineers and the employee strength will be ramped up in line with business demands.

Siemens Sets Up Centre Of Competence In India

Bejing, China: With 138 machines sold at CIMT, Gildemeister posted an order intake of €22.4 million (US$29.5 million). The company presented itself in Asia in a dimension comparable to its European exhibitions with 25 exhibits on an area of more than 1,000 sq m,

A particular highlight of this show was the special concentration on the industry sectors: aerospace, medical, die & mould and energy.

Gildemeister at CIMT 2009



11

Singapore: Invensys Process Systems (IPS) has opened its latest and largest facility in Asia to meet China’s growing development and energy demands as well as to serve as the company’s regional sales and operations headquarters.

The 18,300 sq m technology showcase centre in Shanghai, China comes with an engineering excellence centre, a staging area, and a training and customer support service centre.

The opening coincides with the company’s recently signed US$250 million contract with China Nuclear Power Engineering (CNPE) to develop and implement four large-scale, fully digitised nuclear control rooms, equipped with the latest simulation technologies, critical control and safety systems, for two nuclear power plant sites in Fujian and Zhejiang.

Some of Invensys’ major clients in China include the country’s largest electricity producers, China Nuclear Power Engineering, China Nuclear Power Operation Technology, China Huaneng Group, PetroChina and Datang Yungang Power Plant.

Businessnews

Canton, Ohio: Timken, manufacturer of bearings headquartered in the US has signed an agreement to supply wind turbine gearbox bearings for Nanjing High Speed Gear Manufacturing (NGC), a manufacturer of wind power, marine, construction, and industrial gear transmission equipment based in China.

Under the terms of the agreement, the company will supply tapered and cylindrical roller bearings for use in NGC’s wind power gearboxes. Revenues in the first phase of the agreement are expected to be worth an estimated US$30 million to Timken, with additional growth anticipated after 2010.

Timken To Supply WindPower Equipment Manufacturer

IPS Opens Shanghai Facility

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Messe DusseldorfAsia

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Businessnews

Farmington, USA: The industrial laser market will fall 32 percent in 2009, to the level of 2004, if sales stay at current levels. Sales will return to 2008 levels by 2013, helped by military, biomedical instruments, and energy related applications.

Many materials processing applications spanning laser marking to metal cutting and welding will take longer to recover. Fibre laser suppliers will see a shallower decline of 24 percent to $US 230 million, and will experience faster recovery than other types of lasers. These are some of the conclusions of a report from Strategies Unlimited, market research firm.

Coherent and Trumpf remain at the top of the list in market share. While the industrial laser business is highly fragmented, the top 10 suppliers earn about 86 percent of the laser revenues, while many dozens of small suppliers share less than five percent of the market.

IPG Photonics continues to dominate fibre laser sales. Yet, the recession is so severe that every supplier will be forced to pick and choose the laser businesses in which it wants to continue to compete. Afterward, not only will there be fewer players, but the remaining players will play in fewer niches.

MHI, Wartsila & CSIC To Establish JV In ChinaTokyo, Japan: Qingdao Qiyao Wartsila MHI Linshan Marine Diesel Company (QMD), a company jointly established by Mitsubishi Heavy Industries (MHI), China Shipbuilding Industry Corporation (CSIC) and Wartsila of Finland to manufacture and market large low-speed marine diesel engines, completed construction of a manufacturing plant in Shandong Province.

The pla nt wa s completed at the Ha ix iwa n shipbuilding base in Qingdao, where QMD has its main office. Under license from MHI and Wartsila, QMD has begun manufacture of two-stroke low-speed marine diesel engines with a cylinder bore of up to 960 mm. The plant has an annual production capacity of about 1.2 million bhp, with potential to expand to near 3.5 million bhp.

At a time when the global market for marine diesel engines is lackluster amid the worldwide economic slowdown and financial crisis, the trend of cargo volume has already begun showing signs of recovery in the Chinese market. Completion of the QMD plant signifies that the JV is now structured to meet future demand from the Chinese market, which is expected to expand over the medium to long term.

Industrial Laser Sales To Fall 32 Percent In 2009

DHL Partners Makro In ThailandSingapore: DHL Supply Chain plans to build a US$4.6 million automated warehouse with Makro. Located in Wang Noi on the northern outskirts of Bangkok, the warehouse under construction spans 14,500 sq m and has handling capacity of more than 80 million cases per annum. It offers a lead-time of six hours from the moment the supplier’s goods arrive at the warehouse to the time they reach the retail stores in Bangkok, an improved in efficiency of up to 50 percent in lead-time.

The automated warehouse, slated to commence operations in July of this year, will enhance the efficiency for Makro’s supply chain and reduce the time-to-market for its dry products.

The increased throughput of the automated warehouse is made possible by an Autosort system, which can handle more than 9,000 cases per hour.

World Crude Steel Production Lower In March

Brussels, Belgium: World crude steel production for the 66 countries reporting to the World Steel Association (worldsteel) was 92 million metric tons (mmt) in March. This is 23.5 percent lower than March 2008.

World steel production in the first quarter of 2009 was 264 mmt, a decrease of -22.8 percent compared to the first quarter of 2008.

In the first three months of 2009 Asia produced 173 mmt of crude steel, a decrease of -8.9 percent over the first quarter of 2008.

China showed a slight increase of 1.4 percent while all the other major steel producing countries showed a decrease in the first quarter of 2009.

China’s crude steel production for March 2009 was 45.1 mmt, -0.3 percent lower than March 2008. Japan produced 5.7 mmt of crude steel in March 2009, down by -46.7 percent compared to the same month last year. South Korea showed a decrease of -21.2 percent from March 2008, producing 3.7 mmt of crude steel in March 2009.

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BusinessnewsOIL & GAS

Yuzhno-Sakhalinsk, Russia: Sakhalin Energy Investment Company signed a sale and purchase agreement (SPA) for liquefied natural gas (LNG) supply to the Japanese company Osaka Gas. The deal calls for the supply of approximately 0.2 million tonnes per annum (mtpa) of LNG for a period of more than 20 years.

As the second largest gas company in Japan, Osaka Gas manages over 56,000 km of gas transmission pipelines, serving nearly seven million gas customers in the Kansai region.

Sakhalin II In Partnership With Osaka Gas

Sindh, Pakistan: OMV has started to test a well located in the Latif block – about 100 km from Sukkur in southern Pakistan’s province of Sindh with its joint venture with partners ENI and PPL. The company’s current production in Pakistan amounts to approximately 17,000 boe/d.

As part of the fast track development, the gas is routed via a 23 km long pipeline to the Kadanwari gas plant, which is operated by OMV Pakistan.

During the first three quarters of 2009 the testing gas rate from Latif-1 will be around 1,000 boe/d whereas in the fourth quarter 2009 additional gas from the second well Latif-2 will be available starting with approximately 4,000 boe/d.

Helmut Langanger, OMV executive board member responsible for exploration and production said: “Our investments in international exploration and production projects have once more strengthened OMV’s position as a reliable partner for energy supply. Furthermore, this success with Latif-1, contributes to the gas supply in Pakistan as well as to OMV’s position within the Middle East core region”.

After the testing phase a field development plan will be submitted to the government of Pakistan for approval and will, after execution, further increase Latif gas production from 2011 onwards.

OMV Starts Test In Pakistan

Vietnam: Total Exploration and Production Vietnam (Total), has signed a production sharing contract with Vietnam Oil and Gas group (PetroVietnam) for the exploration blocks DBSCL-02 and DBSCL-03.

The blocks, which are located in the Mekong delta area onshore, will be operated by Total with a 75 percent interest, PetroVietnam Exploration Production (PVEP) holding a 25 percent interest.

Block DBSCL-02 covers an area of nearly 14,850 sq km and block DBSCL-03 covers an area of almost 13,800 sq km. Under the terms of the agreement, the first exploration phase will cover the acquisition of 2D seismic on each block.

Having created a partnership in 2007 with PVEP and the South Korean company SK on offshore block 15-1/05, the company continues to develop its presence in Vietnam.

The company’s experience in managing the environmental impact of its activities will be important in the Mekong delta. Exploration activities will be carried out without disruption of the community’s activities.

Total Exploration & PetroVietnam In Partnership

Florence, Italy: GE Oil & Gas technology has been selected for one of the largest gas transmission projects in the world. The company will be the primary supplier of compression equipment for the western section of China’s second West-to-East gas pipeline.

The second West-to-East pipeline will be part of the ongoing natural gas pipeline infrastructure in China that, when completed over the course of the next five to six years, will total approximately 20,000 km. This second pipeline, 8,700 km in length, will be 2,000 km longer than the Great Wall.

This pipeline will snake through 13 provinces and autonomous regions, and will play a role in supporting the country’s energy security and economic development. Existing Chinese natural gas pipelines total 30,000 km in length.

PetroChina is the developer and owner of the West-to-East pipeline in China. The second West-to-East project features pipes with 48-inch diameters, some of the largest in the industry. When completed, it will add 30 billion cubic meters of capacity of natural gas transmission per year, half of China’s annual total natural gas production, allowing 400 million people access to natural gas.

This will bring China’s primary energy consumption rate of natural gas to five percent, up from 3.5 percent. The compression stations in phase two of the second West-to-East gas pipeline are expected to go into commercial operation between the second half of 2010 and the end of 2011.

Since 2005, GE has been awarded bids by PetroChina worth over US$600 million.

Largest Gas Transmission Project For GE Oil & Gas

Miroslav Saricka, Slovakia

The globalized economy has created new responsibilities for companies such as TaeguTec.We measure our success by customer satisfaction.

This success sees an ever-increasing number of machine tools all over the world being commissioned with TaeguTec’s cutting tool product lines.

innovative cutting tool solutions for the metalworking industry

world headquarters304, Yonggye 4-ri, Gachang-myeon, Dalseong-gun, Daegu, 711-864, Korea

Tel: +82-53-760-7640 Fax: +82-53-760-7660 Web: http://www.taegutec.com

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BusinessnewsAEROSPACE

Singapore: GE Aviation has increased its ownership of Airfoil Technologies International-Singapore (ATI-Singapore), a jet engine components repair operation, from 49 to 100 percent by purchasing Teleflex ownership stake.

By completing the acquisition, GE Aviation will enhance the repair capabilities key to its global base of airline and industrial customers. Also, the acquisition supports GE’s growing services operation, which had revenues approaching US$7 billion in 2008, and expands the company’s investments in Singapore, where it operates several aerospace facilities.

ATI-Singapore repairs compressor airfoils. The facility was built in 1998 to service CF6 and CFM56 engines, but has expanded to include all GE commercial aviation, marine and industrial engines as well as Pratt & Whitney and Honeywell components. Located in Loyang industrial park, ATI-Singapore has about 535 employees who repair more than two million compressor airfoils a year.

GE Aviation also operates a 30,000 sq ft (2,787 sq m) material distribution and sales centre in the Changi area of Singapore. The centre’s used-serviceable parts and components improve material availability and support for customers in the Asia-Pacific region from China to New Zealand. This is one of only three GE Aviation used-serviceable parts distribution centres in the world.

GE Aviation Completes Acquisition of ATI-Singapore

Connecticut, USA: Hamilton Sundstrand has extended its Comprehensive Asset Repair and Exchange (CARE) programmes with SIA Engineering (SIAEC), a Singapore-based aircraft maintenance company, to provide repair services and asset management for engine and airframe components on Airbus A320 and Boeing 777 aircraft.

The deals consist of support for Hamilton Sundstrand and other suppliers’ equipment, including support for up to 105 Airbus A320 and 13 Boeing 777-300 aircraft. The agreement also includes spare parts support for electric power and air management assets for the Boeing 777-300s, and support for V2500 engine accessories, electric power and emergency power equipment for the Airbus A320s.

Total repair and inventory support services and is fully supported by key OEM accessory suppliers.

Hamilton Sundstrand Extends CARE Programme

Boeing Opens Research & Technology Centre In IndiaBengaluru, India: Boeing has opened its Research & Technology-India centre. This is the company’s third advanced research centre outside the US, the others being in Europe and Australia. The centre will also coordinate the work of more than 1,500 technologists, including 100 advanced technology researchers, from across India on projects that will help define the future of aerospace.

Ruth Canton, UK

Singapore: Singapore Technologies Aerospace (ST Aerospace) has conducted the groundbreaking, together with its JV partner, Xiamen Aviation Industry (XAICO) of its new engine facility to be located at a 28,500 sq m plot of land near the Xiamen Gaoqi International Airport in Xiamen, China.

Construction commenced immediately following the groundbreaking. Completion and operations commencement of the facility is expected around 2010. ST Aerospace Technologies (Xiamen) Company (STATCO) will have a total investment of US$78m. The company will initially provide MRO and total support services for the CFM56-5B and CFM56-7B engines that power narrow-body aircraft such as the Boeing 737 next generation aircraft and the Airbus A320 family of aircraft. ST Aerospace owns an 80 percent stake of STATCO, while XAICO owns 20 percent.

ST Aerospace In JV With XAICO

www.big-daishowa.com

Equipment news Singapore May-June 2009

Improved surface finishExtended tool lifeMinimized thermal displacement

Outstanding dynamic runoutaccuracy

Ceramic ball bearing type For micro drills and endmills

Available upon request with air supplied through the spindle.

AluminumA2017

Prehardened steelHRC40

0.065mm

4mm ø0.5mm Rib-endmill

70,000min-1

1,500mm/minAd=0.02mm

CutterSpindle speed

FeedD.O.C

R0.1mm Ballnose endmill80,000min-1

400mm/minAd=0.01mm

CutterSpindle speed

FeedD.O.C

20mm

Outstanding runout accuracy permits super thin wall cutting.

Drastic time reduction by ultra high speed rotation.Excellent dynamic runout accuracy makes DOC of 5 m clearly visible.

Patented; USA, Canada, Germany, UK, France, Italy, and South Korea

PAT.S P I N D L E S Y S T E M

D U A L C O N T A C T

R

ENQUIRY NO 081



Businessnews

Hyundai-Kia To Develop Eco-Friendly CarsSeoul, South Korea: Hyundai-Kia Automotive Group (HKAG), which includes Hyundai Motor and Kia Motors, will focus on the development of eco-friendly cars and completing the construction of an integrated steel mill.

This is in line with the group’s intension to overcome current economic difficulties by maintaining 2008’s investment levels, to secure competitiveness and create jobs.

HKAG forecasts that demand for fuel-efficient and eco-friendly cars will rise when the global economy recovers, and therefore plans to strengthen its investment in these areas, including training and nurturing talent.

In order to achieve these goals, HKAG will invest a total of about nine trillion won (US$6.8 billion) this year, similar to last year’s levels. Of this figure, six trillion won will be invested in facilities, including a two trillion won investment into an integrated steel mill being built by Hyundai Steel. The other three trillion won (of the nine trillion won) will be invested in R&D.

Separately, HKAG will invest 2.4 trillion won into the development of eco-friendly cars in phases and expand the R&D workforce to as many as 1,000 in the future. The two trillion won investment in Hyundai Steel will be made this year for the 5.84 trillion won project, which is 58 percent completed.

Ja k a r t a , I ndone s ia : Honda Prospect Motor, H o n d a’s a u to m o b i l e manufacturing and sales joint venture in Indonesia, is planning to produce and sell the Freed model in

Indonesia, starting June 2009. Exports to multiple countries in the Southeast Asia

region are scheduled to begin before the end of this year. Indonesia will be the first country in regions outside Japan where the Freed will be produced and sold.

In Indonesia, demand for multi-passenger vehicles, categorised as Multi Purpose Vehicle (MPV) is high and increasing to the point where it accounts for approximately 40 percent of total auto sales in that country.

In the case of the Freed, parts and components will be procured in multiple countries, mostly in the ASEAN region including Thailand, Malaysia and the Philippines, to enhance the competitive advantage of the product.

Honda To Begin Production In Indonesia

Volkswagen Opens Plant In India

Pune, India: With a total financial commitment in India amounting to €580 million (US$ 782 million), the plant represents the largest investment to date by a German company in the country. The facility has a maximum annual production capacity of 110,000 vehicles destined for delivery to the Indian market.

Despite the impact of the financial and economic crisis the desire for individual mobility in India remains high. Experts predict that the Indian automobile market will grow from the present 1.2 million vehicles to over 2 million vehicles by 2014.

The Pune plant will begin building the Skoda Fabia compact car in May 2009. Production of a hatchback version of the Volkswagen Polo developed for the Indian market will be added from 2010. The plant has a high level of vertical integration and a large share of local suppliers. It is the only production plant operated by a German automaker in India that covers the entire production process from press shop, body shop and paint shop to final assembly.

AUTOMOTIVE

Master Chemical Gets CFO

Ohio, USA: Cary R Glay has joined

Master Chemical as Chief Financial

Officer. In this role, Mr Glay will have

global financial responsibility for the

corporation to direct and oversee all

f inancial and information systems

functions assuring compliance and

continuous improvement.

APPOINTMENTS

Cary R Glay

Michi



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FOUNDRY

Essar Steel Inaugurates US$16.8 Million Service Centre

Chennai, India: Essar Steel inaugurated its steel service centre facility at Oragadam near Chennai, India. The service centre has been set up at a cost of Rs 750 million (US$16.8 million) and has a capacity to process 2.5 lakh tonnes of steel per annum.

Located at one of largest auto hub of the country and including a CR slitting line, CR narrow cut to length line, CR wide cut to length line and HR cut to length line. It will

enable Essar Steel to cater to even single sheet customer, provide small lot and customised deliveries for ready to use steel.

Essar’s service centre is backed by its 4.6 MTPA steel plant at Hazira. This will ensure the consistent supplies and quality of the products. The company has three more service centres one each in Hazira, Pune and in Bahadurgarh near New Delhi.

Businessnews

C M Y CM MY CY CMY K

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2007 Steel Can Recycling Data

Country/RegionRecycled

(‘000 tonnes)Recycling Rate 2007

(Percent)Recycling Rate 2006

(Percent)

Brazil 284 49 47

Canada 109 66 62

China 1,597 75 75

Europe * 2,560 69 66

Japan 707 85 88

South Africa 155 70 68

South Korea 101 69 73

Turkey 101 35 33

USA 1,592 65 63

Total 7,206 68 67

* Europe here includes EU 27, Norway and Switzerland.

Global Steel Can Recycling Reaches Highest Recorded LevelBrussels, Belgium: The World Steel Association (worldsteel) announced that 7.2 million metric tonnes (mmt) of steel cans were recycled across the 37 countries reporting in 2007. This avoided approximately 13 mmt of CO2 emissions.

The global recycling rate for steel cans was 68 percent in 2007, a slight increase from 67 percent in 2006. This is the highest level ever and is the third consecutive year that the steel can recycling rate has increased.

Amongst countries covered by the 2007 statistics, Belgium and Germany topped the league with the highest recycling rates of 93 percent and 91 percent. Of the

individual countries that reported directly to worldsteel, Japan had the highest recycling rate at 85 percent.

Europe, North America and South Africa have been particularly consistent in gathering good data and increasing recycling rates year-after-year. South Africa recorded a recycling rate of 70 percent in 2007, a two percent increase compared to 2006. Europe recycled 2.5 mmt of steel cans in 2007, a recycling rate of 69 percent. In the US, 1.6 mmt of steel cans were recovered for recycling in 2007, an increase to 65 percent compared to 63 percent the previous year.

Arlington, USA: While the global economic picture will remain troubled for the near term, slightly improved US economic data could be a harbinger of positive signals for a grim world landscape, according to a new report.

In the Manufacturers Alliance (MAPI) quarterly forecast of US exports, global growth, and the dollar: second quarter 2009 through fourth quarter 2010, economist Cliff Waldman writes that signs of firming demand in the US economy, along with a global move towards historically accommodative monetary policies, suggests that a weak rebound in industrialised country output and a modest acceleration of developing country output could begin in the later months of 2009.

“While the rare financial underpinnings of the current global crisis make it more difficult than ever to assess the impact of policy, it is difficult to believe that rock-bottom prices for fuel and commodities, the lowest interest rates in a generation, and a growing effort to repair bank

Possibility For Slow Recovery Says MAPI

Businessstatistics

balance sheets won’t eventually be sufficient to restore at least weak positive activity,” Waldman said.

Aggregate developing country growth is expected to be a sluggish two percent during the second quarter of 2009 and accelerate to 2.5 percent during the third quarter, to three percent during the fourth quarter of 2009 and the first quarter of 2010, gradually followed by further gains to 3.7 percent by the fourth quarter of 2010.

“Developing country prospects are mixed, with China appearing to sidestep the feared ‘hard landing’ scenario, but the Indian economy slowing more than expected,” Waldman said. “Developing and newly industrialised economies in East Asia have turned surprisingly weak, but prospects are seen as being good for modest recoveries both in economic and in manufacturing growth during 2010.”

Most advanced economies are expected to experience weak recoveries in Gross Domestic Product (GDP) and in manufacturing output during 2010. GDP in non-US industrialised countries are expected to contract by three percent during the second quarter of 2009 and further contract by one percent during the third quarter. MAPI forecasts growth to resume during the fourth quarter of 2009.

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FIRSTcuT

The ongoing pursuit for lighter aircraft and better fuel-efficient jet engines brought about the development of

new grades of materials, such as new nickel based alloys, titanium alloys, composites and high strength aluminium alloys.

Aerospace metals, which are light and strong, are hard to machine, yet remain popular due to their basic properties that are ideal for this industry. Machineability assessments on these materials regarding tool wear, productivity, materia l removal rate, cutting forces, chip disposal and workpiece integrity have indicated poor results.

A s a g u i d e , m a c h i n i n g a component in an advanced alloy can be five to ten times more expensive than machining standard ferrous or nonferrous material. This results in lower productivity, the need for specialist tooling, high specification machines, advanced cutting fluid and supply systems, operator skills and tighter quality procedures.

While abrasive carbon fibre reinforced metal matrix composites can be cut effectively with PCD and carbide tool materials, a solution for Ni and Ti alloys is difficult to obtain.

The Nickel Family Nickel-based superalloys appeared in the early 1940s. This group includes nimonics, renes, inconels,

Going The

Exotic Way Machining exotic metals is difficult but it can be very rewarding as they often bring superior properties. By Dr Moshe Goldberg, marketing technical advisor, Iscar

Exotic Way



FIRSTcuT

recommended for machining these materials, as they literally cut the metal rather than push it forward. To achieve an idea l shear ing mechanism, sufficient feed rate and depth of cut are also essential, while attention should be given to the tool geometry in order to prevent friction.

Even under the best conditions, stress could occur, which might cause distortion of the work. The best practice for maximum dimensional stability is to apply a roughing operation to the part, bringing it almost to size, to stress relieve it, following by finishing it to size. It is important to note that stress relieving

has little effect on dimensions, but could affect mechanical properties.

Having a discontinuous chip, or breaking the chip into small manageable segments is often impossible when machining inconel. This condition occurs due to the high wear resistance of the material, leading to a very high temperature at the cutting interface.

During operation, where there is continuous contact of the tool with the material, the heat and generated pressure could lead to plastic deformation on the cutting edge. Therefore, a sharp edge minimises stress on the material and improves chip formation.

The rigidity of the tooling system and the ability to deliver coolant at the cutting edge also plays a significant role. Too-low a cutting speed may lead to a built-up-edge phenomenon that has a direct effect on the tool, reducing its life.

Lighter feed rates combined with tighter control of cutting speed have proved to work well, when using endmill cutters with more than four teeth, to support higher removal rate without increasing tooth load and material stress.

Cutting Fluids:Water-based fluids are preferred in high speed turning and milling, due to their greater cooling effect. These can be soluble oils or chemical solutions. For slower operations, such as drilling, boring, tapping,

incoloys, hastelloys, waspaloys and udimets ranging from 150 to 450 HV depending on heat treatment. Super-alloys constitute about 50 percent of the weight of aircraft engines and provide resistance to oxidation, corrosion and creep, while maintaining strength at expulsion up to 1,000 deg C.

Nickel alloys are both tough and ‘adhesive’, demonstrating temperature and wear resistance. From a machineability perspective, nickel alloys tend to work harden rapidly. The high pressure produced during machining causes high tooth loadings, as well as residual deposits build up on the cutting edge.

The work-hardening phenomenon has an adverse a f fect on the machining process, calling for slow down, and in cases of small parts, leads to distortion. The preferable option for machining is a workpiece at cold - drawn stress -rel ieved conditions. Hot-rolling conditions are a less desirable alternative, while annealed condition is the least preferred for most applications.

Making The CutIn general terms, cutting tools with a positive rake cutting edge are

The ability to deliver coolant at the cutting edge plays a significant role.

Aerospace metals, which are light and strong, are hard to machine but they remain popular.



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FIRSTcuT

The combination of the cutter, collet, adapter, spindle and

machine rigidity all have a directly influence on precision

machining. In most cases the precision is defined or

characterised in terms of runout parameters.

That explains the growing development of the tooling

system that aims to compensate for this discrepancy. The

runout phenomenon not only damages the surface finish

but also produces inconsistent dimensions, and significantly

shortens tool life.

The phrase runout has become a catch-all word for

the sloppiness, flexibility, non-repeatability or just plain

‘poor quality’ of a machining job, with various meanings

to different people. In the strict sense of the word, runout

means the amount of deviation from the theoretical position.

The term can be applied to rotary or linear motion, static

or dynamic.

One large cause of runout is due to manufacturing

defect, or damage. A bent shaft will not run ‘true’, even if it

was very stiff and had no free play. If a machined rail is not

produced/set up straight, then the rolling carriage will deviate from the theoretical

straight line – causing runout. If a 4-flute endmill is placed into a dirty collet, which

could cause it to sit slightly askew, a dial indicator will get different readings from

the flute edges – meaning runout.

Enquiry No. 4002

In a world where one micron can make all the difference, various collet chucks and adaptors are deployed to ensure everything falls within tolerance.

Precision Machining

One way of combating runout inconsistency is to use the

Iscar Shortin tooling system. This short holder is available for

ER32 spring and shrink collets, providing rigidity and improved

cutting conditions.

Among the advantages is the short overhang. The short

collets provide high gripping force, thereby reducing cutting

vibrations and improving runout and repeatability. Each chuck

is balanced to 2.5G at 20,000 rpm and has a symmetrical

design for high speed machining, where a balanceable collet

chuck system should be employed.

The Balanceable Collet Chuck System utilises a simple

balancing procedure on all types of balancing machines.

Furthermore, it provides direct readings from its rings for balance, with added

features to compensate for unbalance up to 61 g/mm.

Enquiry No. 4003

Iscar: Runout Correcting Equipment

and broaching, heavy lubricants and very rich mixtures of chemical solutions are needed.

Turning:Single-point turning tools used for cutting nickel alloys must have positive rake angles so the metal is cut instead of pushed, as would occur if negative rake angles were used.

A secondary function of the rake angle is to guide the chip away from the finished surface. It must be large enough to provide clearance, but small enough to give adequate support to the cutting edge. The nose radius, which joins the end and side cutting edges, strengthens the tool nose and helps to dissipate the heat generated in cutting.

Chip Control: Nickel alloys present a minimum of chip disposal problems when cut with carbide tools that have properly-designed chip curlers or breakers. The lip should include the proper rake angles for the alloy and should be wide and deep enough to cause the chip to curl and break but not to force it into a tight knot.

With these devices, tool rake angles are plane surfaces that terminate at the chipbreaker wall. The radius joining the wall of the chipbreaker and the rake angle plane must be kept very small. A small radius and the proper angle will usually prevent the chip from adhering to the chipbreaker. Width and depth of the chipbreaker depend on the feed rate used.

Milling:The essential requirements of milling are accuracy and smooth finish. Therefore, it is imperative to have sharp tools, rigid machines and fixtures. Since milling involves an interrupted cutting action, the correct feed and speed are important. Too light feed, nearly rubbing the surface, will cause an excessively work-hardened layer. MEN

Enquiry No. 4001



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3D Laser ScanningUsing ShapeGrabber Ai310 System

ShapeGrabber will make short work of measuring:

Systems are available in various configurations to accommodate different part sizes, automation and quality control requirements.

• Full surface inspection (shape)• Louvers and stampings• Cross-sections• Holes (size, center to center, true position)• Angles• Diameters & Radii• Flush & Gap• And more…

• Fully automated industrial 3D scanners

• Ideal for rigorous, full surface 3D quality control

• Easy to use without CAD training

• Go/No-Go and back to production

• Inspect whole part in minutes

www.smartscope.com.sgOptical Gaging (S) Pte Ltd

Co. Reg. No. 199508828C

21 Tannery Road, Singapore 347733

Tel: (65) 6741 8880 Fax : (65) 6741 8998 E-mail: [email protected]

Singapore • Malaysia • Thailand • Indonesia • Philippines • Vietnam • Hong Kong • Taiwan • South China • India • Australia • New Zealand

Complex shapes are our specialty

Ai810

The term ‘superalloy’ describes a broad range of nickel (Ni), iron (Fe), and cobalt (Co), alloys developed specifically

fo r a pp l ic a t io n s d e m a n d i n g exceptional mechanical and chemical properties at elevated temperatures.

S o m e 7 0 p e r c e n t o f a l l superalloy production is consumed by the aerospace industry for t h e m a n u f a c t u r e o f p o w e r turbines (jet engines) and related components. Unfortunately their superior mechanical and chemical properties at elevated temperatures do have significant negative impacts on their machinability; superalloys are genera lly challenging and costly to machine.

As high temperature strength increases, the alloys become harder and stiffer at cutting temperature. This results in increased forces on the cutting edge during machining. Edge breakdown by chipping or plastic deformation often appears.

Because of the material’s high strength, toughness and ductility at elevated temperatures, chipbreaking can be difficult during the machining process. As the alloys are mostly heat-treated to modify the as-cast or solution-treated properties, abrasive carbide precipitates or other second phase particles are often formed. Such particles may also cause rapid abrasive wear at the cutting edge.

Most superalloys work-harden like austenitic stainless steels, which

Cool Under

FireDrilling at high temperature is both a challenging and precise undertaking. By Kalle Schenning, product manager, Seco Tools AB, Sweden

means that during machining, a harder surface is created. As the thickness of this zone is normally larger than the feed per revolution (drilling) the cutting edge will cut continuously in areas much harder than the bulk material.

Rapid cutting edge wear follows and it can be difficult to maintain precision tolerances or critical meta l lurg ica l integr ity of the component surface. A damaged surface may also compromise fatigue strength. Tool material properties as well as cutting edge conditions are of utmost importance when machining superalloys.

Titanium AlloysA group of materials closely related to superalloys are Titanium (Ti) based alloys selected for their superior strength to weight ratio and advantageous chemical properties.

Ti-alloys appeared first in the 1950s when it became clear that the requirements of airframe and engine components were exceeding t h e c a p a b i l i t i e s o f e x i s t i n g lightweight alloys.

Ti, with its low density and high melting point appeared to be a good solution. Not only are Ti-alloys used in aircraft applications, but because of their excellent corrosion resistance, they are also applied in other challenging chemical and structural environments.

W hi le somewhat ea sier to machine than superalloys, Ti-alloys

firstcut www.equipment-news.com


firstcut

the tool must be able to cut at ‘0 m/min’, which complicates the process since modern tool materials generally require high cutting speeds (high temperatures). In other words, specific compromises are necessary to reach good drilling performance.

The elastic modulus as well as the hardness and acceptable amount of plastic deformation and even frictional properties of the tool material are to be balanced with the geometrical strength of the cutting edge. The right combination of cutting conditions and tool properties is of decisive importance to the machining costs when drilling in superalloys as

compared to drilling operations in normal steels and cast irons.

‘Classical’ DrillingDrilling in superalloys, Ti-alloys or stainless steels today is still sometimes performed with tools made of High Speed Steel (HSS). Typically cutting speeds then hover around 5 m/min and feed rates are up to 5 mm/min.

Wit h to o l s made o f so l id carbide, 20 m/min and 90 mm/min are acceptable values. For smaller diameter holes, if solid carbide drills are used, secondary machining - reaming - can be eliminated since the

can still be challenging. More difficult to machine than steels with the same hardness, Ti is a poor conductor of heat. Most of the generated cutting heat is concentrated at the cutting edge. Like superalloys and austenitic stainless steels, Ti-alloys work-harden during machining.

Ti has a low modulus of elasticity and component deflection can be serious, often resulting in chatter. Ti is also more reactive than other high temperature alloys.

In fact, some Ti-alloys can ignite during the machining process. This reactive nature of Ti results in chemical interaction with the cutting tool material and cratering wear may be a typical symptom.

Drilling DissectedThe drilling operation has much in common with turning operations; the cutting edge is continuously engaged. However, essential differences exist. Whilst in turning considerable effort is focused on chip breaking, chip guidance is more essential in drilling.

Cutting speeds in turning are constant while they vary in drilling (0 in the drill centre, maximum at the periphery). For turning applications, cutting data is generally specified within narrow limits, in drilling

Some 70 percent of all superalloy production is consumed by the aerospace industry for the manufacture of jet engines.

ENQUIRY NO 075



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firstcut

Seco:High Pressure Coolant Tooling

To improve the machin ing of

difficult alloys, Seco has developed

Jetstream tooling.

A high-pressure coolant supply,

when pumped through a small nozzle,

produces an acute, high velocity

jetstream, which penetrates the friction

zone between the cutting edge and

the workpiece, providing lubrication,

cooling, and chip removal.

There are three pressure based

coolant delivery systems. Low pressure, the standard system supplied today with

most machine tools having up to 20 bar pressure, high pressure, ranging from

20 to 70 bar pressure and ultra high pressure, from 70 bar pressure and higher.

In addition, chip control can be improved by using the tool. Coolant

is applied to the cutting edge, lifting the chip away from the rake face and

preventing crater wear. The resulting chips are smaller enabling them to be

removed from the cutting area without damaging components and tooling.

Enquiry No. 4004

surface integrity requirement is often achieved with the solid carbide drill tool. Using carbide tools, production rate as well as machining costs can be radically improved.

New Drilling Programme Studying of superalloy worn drilling edges, clearly shows two areas that are heavily affected, the centre and the periphery of the drill. Wear at the centre is mainly a consequence o f l ow c u t t i n g sp e e d s ( l ow temperature) and high hardness (deformation hardening) of the work material.

The wear at the periphery stems from the heat induced at higher cutting speeds.

In superalloy machining, special consideration is given to the drill centre wear. The edge hardness of conventional drill materials needs to be increased.

This is achieved with new drill generation made of submicron carbide grains (grain size < 1 um). Decreasing the grain size of the tungsten carbide (WC) grains improves the hardness of the composite material and the hardness/transverse rupture strength ratio. This improves the drill performance even at lower temperatures, which are prevalent at the centre of the drill.

High speeds at the periphery cause high temperature wear – crater wear, f lank wear and deformation of the edge. The best solution to overcome this type of rapid wear is a thin wear resistant coat ing t hat lowers f r ic t ion , temperature and as a consequence; tool wear.

Low temperature PVD coating-technique s ( Physica l Vapour Deposition) allow for sharp and evenly coated cutting edges.

This type of edge can give outstanding results in superalloy drilling.

PVD-TiN, titanium nitride, is known to generate high toughness wh i le t he ‘A l ’ pa r t prov ide s outstanding high temperature wear resistance to the coating. The

final coating consists of nearly 70 percent Al, probably the highest Al-content of today’s popular coating materials. The thickness of the coating is controlled within narrow limits reducing tool life variation to a minimum.

It is possible to produce a homogeneous structure of the three components Al, Ti and N. The toughness can be kept high with the absence of pores and other crack nuclei. A low friction surface is created. Slow, even wear is achieved, as large particles are not likely to be worn away.

A thin, yel low TiN - coat ing finishes the coating process.

Since the main coating, (Ti,Al)N is dark in colour, the TiN top coating makes it easy for the user to determine when a drill has already been used. However, it is stressed that the tool life is set by the black (Ti,Al)N-coating. This layer wear has to be studied before deciding to change the tool.

Drill GeometrySuperalloys as well as Ti-based alloys have high tensile and yield strength.

High amounts of energy are required to machine these materials. Most of the energy is transformed into heat.

To address this energy-heat issue, drills are usually designed with light cutting geometries.

To provide a light cutting action, an edge sharpness of radius 0.015 mm with extremely narrow tolerances (+/- 0.005 mm) is achieved with new production techniques.

The use of sub-micron cemented carbide was a given since coarse grain sizes and sharp edges are incompatible. The front clearance angle is increased from 10 to 12 degrees to further reduce the work hardening effects in the component material.

To minimise friction and heat generation, the flute back taper size is double that of a standard drill. A broad periphery land margin can increase edge temperature and frictional work and affect the quality of the machined surface. The width of the land was also reduced for the aerospace drill package. MEN

Enquiry No. 4005



M YC K

While every effort has been taken to carry out instruction to customers satisfaction NO RESPONSIBILITY liablilty will be accepted for errors CUSTOMERS ARE THEREFORE URGED TO CHECK THOROUGHLY BEFORE AUTHORISING PRINT RUNS DALIM

11 2 3 4 5 6 7 8 9 10 OK TSMcCann CN CN1845CN225980 DL-MAC2 OSX 08.06.2007 150#

ESS0000943 APMEN-Insert Back July 2007Size:275H x 205Wmm 150# Film+CD

ENQUIRY NO 157



technologyupdate

Die Casting & Mould Processes:

The Soft & Hard TruthIntroduction of software and improvements in hardware combine to bring a traditional industry to new heights. By Augustine Quek

Die - ca st ing i s a ma ss production process which manufactures designed metal parts through high-

pressure injection of molten metal into reusable steel moulds. The moulds, also called dies, are designed to produce almost any shape with a high degree of accuracy and complexity.

Parts can be highly well defined, with smooth or textured surfaces, and are suitable for a wide variety of attractive and serviceable finishes. The metal is usually forced into the mould under a pressure of 10 to 210 Mpa (1,450 to 30,500 psi). The result is usually a uniform part with good surface finish and dimensional accuracy of up to 0.2 percent of casting dimension.

For many parts, post-machining can be totally eliminated, with some very light machining required occasionally to bring dimensions to size.

Hot Or Cold?Die-casting can be done using a cold or hot chamber process. Cold chamber machines are used for alloys such as aluminium and other metals with high melting points that alloy easily with iron at higher temperatures.

The molten metal is ladled into the cold chamber, or cylindrical sleeve, manually or automatically. A hydraulically operated plunger seals

the cold chamber port and forces metal into the locked die at high pressures. Time exposures of the melt to plunger walls are low.

In contrast, hot chamber machines are used primarily for zinc, copper, magnesium, lead and other low melting point metals of high fluidity.

These meta ls do not a l loy easily with steel at their melting temperatures. The molten metal is exposed to the plunger and cylinders for a longer time since these metals do not erode the casting equipment. Therefore, in this process, the die cavity is immersed permanently in the molten metal.

The inlet port of the pressurising cylinder is uncovered as the plunger moves to the open (unpressurised) position.

This allows molten metal to fill the cylinder and at a faster rate than the cold chamber process. As the plunger moves to the close position, it seals the port and forces molten metal into the die cavity. After the metal has solidified in the die cavity, the plunger is withdrawn.

Software InvasionThe advent of computers and their rapid increase in information processing capability has helped the die-casting industry. Many companies now use software modelling to improve their die and mould processes. Some

programming software and existing CAD can even reduce typical lead times for producing die-casting moulds by 30 percent.

According to MK Tool and Die, such a time saving feat is possible. The manufacturer of low-pressure moulds and gravity fed dies for cast aluminium components uses SolidWorks CAD software to create a manufacturing model for customers. The software allows changes to be made and provide the customer with an accurate visual aid to assess the finished component.

It also helps visualise the positions of shut lines, air bleed vents, feeders and risers. Creation of cutter path directly on the computer model is possible. No features, layers or component data are lost through the use of translators and programming errors are eliminated.

A similar experience was seen in Swiss electric motor component maker, Stanzwerk. By modelling tooling for stamping and die-casting, they claimed it has cut its development time in half for tool design and parts production. The company uses CoCreate OneSpace Suite modelling software to design the stamping tools, die-casting moulds and equipment that shape the components.

T hey have a l so re l ie d on the modelling and management software to speed tool design and



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technologyUpdate

In hot chamber machines, the molten metal is exposed to the plunger and cylinders for a longer time.

map complex die-casting moulds. The software simplifies reuse of existing designs and offers support for the development of new tools and processes due to its modelling based approach to product development.

Designers can split work on models during the detailing phase and later merge them regardless o f t he c re at ion h i s tor y a nd parametrical dependencies.

In the recent past, the company also put an automated assembly line for aluminium casting into operation.

A robot arm puts six laminations simultaneously into one master mould, and the mould’s elements can be changed on the machine within 20 minutes. This has allowed company engineers to use stamping technology on very narrow parts with the smallest of diameters, and can reliably produce millions of such pieces.

Hardware Improvements Several die-cast and mould making hardware have also improved in recent years, due to the increasing stringent requirements in the final parts and products.

For example, Haas Automation has expanded its line of vertical machining centres (VMC) designed for the mould making and tool and die industries. Its large-frame VM-6 is a VMC that provides the accuracy, rigidity and thermal stability required for precision work.

It has 64in x 32in x 30in travels, a 12,000 rev/min spindle driven by a 30 hp vector dual-drive system, a

24-pocket side-mount tool changer and a high-speed control with full look-ahead capability.

The VM-6 features massive cast-iron construction, with extensive internal ribbing on the castings to increase rigidity and damp vibrations.

To fur ther ensure thermal stability, coolant is circulated through the VM-6’s head casting to remove heat generated by the spindle. To prevent radiated heat from affecting the casting, the headstock is insulated and cool air is circulated through the entire assembly.

A n e l e c t r o n i c t h e r m a l -compensation algorithm in the Haas control accurately models ballscrew heating from high-duty cycles and automatically corrects for any expansion that could cause positioning errors.

TaeguTec has the Chase F-Ball. Designed for the mould and die and aerospace sector, the tooling insert holder has a wide prism contact between the insert and holder to provide a stable structure. It has a maximum run-out of 0.01mm and a repeatability of 0.01mm. The guide roll of the prism shape provides easy clamping between the insert and holder, supported by a high tensile screw, providing a strong clamping structure.

This structure is further supported by a carbide shank that, according to the maker, allows the product to machine deep mould cavities.

The company claims this rigidity is the same as a solid carbide end

mill, improving tool life, surface finish and accuracy in comparison to steel shank tooling. They also claim the system is suitable for semi-finishing and finishing operations.

The casting of metals to produce smaller dimensions and greater accuracies is also now possible. The latest die-casting machines are able to produce a thin-walled, yet warp resistant magnesium alloy die-casting with a very high surface quality. This requires an optimum interaction between the die-casting tool and the machine control.

Frech hot chamber magnesium die casting machine range is an example. Its DAM200F magnesium hot chamber diecasters are used for the supply of thin-walled housings for the handsets of several cellular phone manufacturers.

These machines can also be upgraded to complete diecasting cells, with optimisation of multi-cavity die design. Other features include automatic spraying devices and casting extraction units for fully automatic production. Its DAW-C Series have locking forces of 200, 500, 800 and 1250 kN, with a Meltec single-chamber furnace with a stainless steel crucible. The hydraulics on the injection end is fully proportional, allowing the first and second phases to be programmed from the control panel.

Die-cast products are now the most common mass-produced items in the metalworking industry. They can be found in thousands of consumer, commercial and industrial products, ranging from automobiles to trinkets, from as simple as a sink faucet to as complex as a connector housing. Improvements continue in the alloys used in die-casting, software algorithms, simulation strategies, and the machining processes.

Once limited to simple lead type, today’s die casters now produce castings in almost any known size and shape, with applications in almost every known market. MEN

Enquiry No. 4101



CMM Technologies & Advances:

A peek into the past of CMMs and its relevance today as the grand father of metrology goes for a makeover. By Joson Ng

Time For AFace Lift?

Co ord inate Me a su r ing Machine (CMM) is a device used for measuring the physical dimension of an

object. Coming in the form of bridge, gantry and arm types, an operator may manually control this machine or it may be computer controlled.

From a report from Wenzel, the machine first appeared in the early 1960’s. The earliest CMM was a 3D device with a simple DRO displaying the XYZ position of the XYZ Machine.

Fundamentally a metrology equipment that requires contact between the probe and the object before measurements can be made, it has been the dominating force in terms of parts measurements in the manufacturing industry.

The moving axis of the CMM produces a series of X, Y and Z coordinates of the contact points. The algorithms in turn interpret these data.

What’s In Between The C-M-M?A typical CMM comprises three axes, an X, Y and Z. These axes are

perpendicular to each other in a three-dimensional coordinate system.

The operator or programmer directs the machine while it reads inputs from the probe. It then uses the X, Y and Z coordinates of each of these points to determine size and position. Location of the axis is indicated by a scale system on each axis.

There are different types of CMMs in the market today. A bridge type is a type of measuring system with a horizontal beam holding the probe. It is also the most common type. The gantry type is essentially similar to the bridge type but the difference is in size.

Gantry type CMMs, some big enough to measure cars, has two legs and is often called a bridge. They can move along the granite table with one leg following a guide rail and the other leg resting on the granite table following the vertical outline.

In order to minimise unnecessary vibration and jerking, air bearings are deployed to achieve friction free travel. The base of fixed CMMs is also cushioned this way. A point to note is the discipline of the operator

– who must ensure no external disturbances are introduced while measurements are taking place ie: the measuring platform to be clean and free of stray objects, and the temperature of the room.

In the air bearings, compressed air is introduced via series of small holes in a flat bearing surface to provide a smooth but controlled air cushion on which the machine can move. The movement of the bridge or gantry along the granite table forms one axis of the XY plane.

The bridge of the gantry is movable and it traverses between the inside and outside legs and forms the other X or Y horizontal axis. Z-axis is supplied by the addition of a vertical spindle, which moves up and down through the centre of the carriage. The touch probe completes the basic structure of the CMM.

While they provide accurate measurements, the integrity of results must be verified if the technician is not properly trained. A qualified CMM technician should perform the machine installation. In addition, accuracy needs to be checked

software&measurement



33

innovation occurs, the machine will remain the focal point of quality laboratories.

The current trend is to move CMM measurements to the production floor and many new designs have come to the market in recent years specifically aimed at this application. CMMs have also gotten faster over the past decade although few customers need speed to be achieved at the expense of accuracy.

Enquiry No. 4201

MEN


periodically; the typical CMM calibration interval is 12 months.

Technology AdvancesMost advances in personal computers today are in processing speed and memory space. Computers of the near future are likely to feature a monitor and a keyboard still. This is the same for CMMs, where it is difficult to see much advances in terms of hardware designs.

Apart from the traditional three axis machines, CMMs have evolved to include arms that mimic the action of a human arm in order to measure difficult to reach places. Such CMMs are often used where their portability hold an advantage over traditional fixed bed CMMs.

F l u c t u a t i n g o p e r a t i n g env ironment a lso resulted in the proli feration of automatic temperature compensation, which is now standard on most machines, such as the advances in the technology. Improvements however, are an on-going process. CMMs will continue to evolve, along with advances in computer technology, electronics and materials. Together they will make the machines more flexible, faster and more accurate.

For the case of CMMs, advances will come in the form of integration. The ma rr iage of non - contact measurement devices with existing probing systems will be used in both portable and fixed CMMs.

Co nve rge nce o f av a i la b le technologies, ie: the incorporation of a laser tracker with a portable CMM to provide accurate measurements over large distances and volumes will prove to be the way forward.

In addition, with the increasing use of nanotechnology, machines can now measure below a sub micron, giving manufacturers the ability to measure smaller volumes with higher accuracy.

Probing Into The FutureIn addition to the contact probe CMM; video CMM is becoming more common. The multi-sensor machine

with a combination of touch and video has become popular with Wegu, Mahr, and OGP who are the main suppliers. Scanning sensors using laser scanning technology have also being integrated to the CMMs.

According to a report from Wenzel, the future of the CMM is difficult to predict. Many are suggesting that the technology will become obsolete in the coming decade. CMM products however continue to dominate the manufacturing inspection arena and unless a major technological

Hexagon Metrology has developed Leitz PMM-C infinity,

a version based on its previous Infinity-class PMM-C.

The company claims that the machine has an accuracy

specification of 0.3 microns and repeatability of 0.1 microns.

The machine’s body is a closed-frame structure, which

is stiff due to the fact that the main components are all

made of granite and cast iron. Its probing unit is LSP-S4,

which can measure form and profile on every probing point

based on 3D scanning; normal to the surface with low force

of 0.5 to 0.16 N.

Use of very small diameter probing styli is allowed.

Moreover, the maximum permissible surface pressure

is not exceeded even on softer materials. The remaining

stylus bending is compensated by a built-in bending

correction. In addition, by the attached high-resolution

glass ceramic scales, it allows a metrological resolution

of four nm.

Enquiry No. 4202

Hexagon Metrology:High Precision Measuring System

Advancement in CMM – the Leitz PMM-C infinity by Hexagon Metrology incorporates drive components design to improve driving forces from the moving axes.




Product HigHligHts

The Smart 500 mobile by

Wenzel is based on the

coord ina te measur ing

mach ine Smar t CMM,

where the difference to the

conventional machine is in

its mobility.

A s a 3 D s h o p

measurement machine, it is designed to measure small to

average-size work pieces and can also change its location with

the help of a lift truck. In addition, the machine offers a range of

application due to its design.

A cantilever arm design offers a measuring volume that can be

accessed from three sides. The high temperature tolerance and

all protected guides facilitate measurements even under rough

environmental conditions.

Enquiry No. 4203

Wenzel: Mobility Induced

Metris: Inspection Software

Focus Scan 5.2 sof tware

speeds up the preparation

a n d exe c u t i o n o f CM M

laser scanning inspection

jobs. The product by Metris

allows automatic scan path

programming and virtual point

cloud simulation, resulting

in acquisition, analysis and

reporting workflow.

Besides laser scanners’ inherent advantage of requiring

simpler motion paths, automatic scan path programming in the

product reduces measurement preparation time. One click on

the CAD surface area and a scan macro is generated to define

scanner path with probe angles.

Scan path visualisation helps metrology engineers to validate

scan programming before going live. These visualisations include

collision detection between scanner and part and an estimation of

CMM execution time, taking into account the actual scanner type.

Enquiry No. 4206

Tesa: Portable Measuring Equipment

Tesa Multi-Gage is a portable tool that provides the user with

measuring possibilities for dimensional inspection. A manual,

modular gauge featuring a six-axis configuration is designed for

checking complex work pieces.

User requires little initial training due to its easy to use

interactive interface. The equipment is available with different

probe and optional WiFi wireless connection. Initial setup is not

required.

The product has an accuracy of E = 5+L/40≤18 R = 8 (µm)

according to ISO 10360-2.

Enquiry No. 4204

Carl Zeiss: Gantry Type CMM

The accuracy of parts for wind turbines determines the efficiency

of the system. Carl Zeiss supports the rising quality requirements

for these components with MMZ 3D coordinate measuring

machines.

The machines are for the measurement of large parts. They

can deliver reproducible measuring results as the measuring

machines and software are matched. Applications are found in

production and measuring laboratories to measure and document

machined prismatic and round parts, as well as freeform surfaces.

Each MMZ gantry measuring machine, such as the MMZ

G200 with linear measuring tolerance of 2.8 + L/400 µm, features

the required accuracy. The company offers the machine with

measuring volumes of up to 4,000 x 8,000 x 4,000 mm.

Enquiry No. 4205

“Made by BRUDERER” is a guarantee that has,

over the past six decades, become a worldwide

synonym for outstanding precision, perfor-

mance, reliability and highly efficient stamping

technology. BRUDERER customers also profit

from the unequalled durability of the stamping

machines. The proof of this is a large number of

satisfied customers – who have been using our

products for decades – from diversified fields,

including the connector industry, watchmaking,

automotive and lamination industries. No matter

how complex your application is, the worldwide

BRUDERER team will find a solution that serves

your needs efficiently and effectively.

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

BRUDERER PRESSES(Far East) Pte Ltd.65 Loyang Way · Singapore 508 755Tel.+65 65 46 81 21 · Fax:+65 65 46 81 [email protected]

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

Welcome to the world of high performance stamping.

Welcome to BRUDERER.

www.bruderer-presses.com

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

BSTA 200

Small in size but huge in precision andperformance! The compact machinedesign of the new BSTA series guaran-tees the best possible cost /benefit ratioand is the perfect choice for small butprecise stamped parts like connectors,contacts, watch parts or razor blades.

Different parts used in the communica-tion industry require an extremely highlevel of accuracy arising from complexbending and coining stages. The BSTAseries offer not only accuracy but alsounsurpassed repeatability and high performance for increased output andreduced manufacturing costs.

BSTA 500

BSTA 250

N E W

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Deep SeaRated

It is possible to capture existing structures for reverse engineering by working on a variety of software packages.

Point cloud data are converted to marine modelling and surface models.

Based on the island of Islay, Stormcats are producers of commercial fibreglass boats in Scotland. They

approached Glasgow based naval architects Marine Design Int’l (MDI) for advice on improving the flexibility of the existing hull range and creating the next generation of hull moulds.

MDI are long term associates of Deri Jones & Associates (DJA), having worked on many marine projects together, from fishing boats to superyachts. Their awareness on the use of laser scanning on larger projects and a discussion on cost reduction led them to recommend laser scanning on these smaller vessels.

was continually checked against the original point cloud data, giving confidence in the supplied data.

CAD model/point cloud mapping also allowed MDI and Stormcats access to information on the symmetry of the hulls – critical when dealing with fast vessels and allowing improvements in performance and efficiency.

Enquiry No. 4207

The Scanning ProcessGeospatial Solutions (GSS) and DJA suggested scanning the existing range of hulls using Faro Laser Scanner LS880, producing a resolution point cloud model of the hull shape, accurate to +/-5mm. A method of scanning the hulls was devised, allowing the entire range of hulls to be scanned in one session. A total of 18 scans were carried out, capturing an average of 17 million points per vessel.

The Art Of ModellingHull shapes varied from a simple rowing boat to a complex, high-speed hull shape known as a ‘Cathedral’ hull. Traditional naval architecture techniques for capturing hull shapes using plumb bobs, tape measures and optical levels would have required many hours of patient measurements and would not have been able to provide the level of detail achievable with the laser scanner.

On return to the office, the laser scans were cleaned and separated to create point clouds for each of the hulls in Faro’s Scene software. Aligned to a common centreline and vertical axis, the point data was imported to Pointools and then to Rhino 3D CAD software.

The software is recognised for marine modelling and for creating accurate 3D NUR BS surface models from point cloud data. It allowed GSS/DJA to supply MDI with clean CAD data. Accuracy of the 3D CAD model

Laser scanning and design softwares provide a fast and efficient route from prototype to production for the smaller boat builder. By Deri Jones, MD, Deri Jones & Associates

MEN


chip forming geometrylight cutting action

thick insertsecurity

more corner for your moneyeconomy

detail chip breakerchip control

modern coatinghigh productivity

bigger insert screwlow maintenance

optional wiper insertbest surface finish

flat contact surface with holderimpact stability

angled center screwprecise and strong clamping

16 cutting edgesand more......

LMT - THE PERFORMANCE TEAM

Leitz Metalworking Technology Asia Pte. Ltd.1 Clementi Loop #04-01, Clementi West DistriparkSingapore 129808

T (65) 6462 4214 F (65) 6462 4215E [email protected] www.lmt-tools.com

wavy wiperlight cu

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Profile projectors are maintaining its relevance in the fast changing world of metrology. By Tom Groff, North American sales manager, Optical Gaging Products Inc.

Blast From The Past,

Or Is It?

www.equipment-news.comsoftware&measurement



39


Th e p r o f i l e p r o j e c to r, a lso k nown a s opt ica l co mp a rator ha s b e e n used for quality control

inspection for more than 70 years. Despite its maturity, the projector is still around and going strong. Its lasting value comes from its versatility in today’s manufacturing environments. The eye of the operator provides the precision.

Although the fundamental design is essentially unchanged, over time, the role of the projector has changed along with manufacturing technology. As its descriptive names imply, one of the earliest uses for the projector was the measurement of contours on a workpiece, its straight, curved or varying edges.

Simple SolutionsAll projectors offer a large viewing screen capable of displaying an enlarged profile image of features on the part at an exact optical magnification.

This allows the magnified profile of the feature to be directly compared to a matching master profile printed on a customised chart gauge that is placed over the viewing screen. The typical chart gauge shows not only the nominal feature shape but also the min/max profile tolerances specified for the feature.

The chart gauge allows relatively unskilled users to easily determine the conformance of the part to its specifications. This optical technique is called measurement by comparison, commonly used on lead screws.

While the projector offers a quick go/no -go evaluation, providing quantitative numerical data when measuring by comparison can be difficult. The measurement process is always subjective since the user’s eyesight and degree of care can both enter into the evaluation of the part.

With the advent of digital position readout systems (DROs) for the projector’s table motion, the primary tasks that projectors perform today

have slowly changed from full screen measurement by comparison, to measurement by translation relative only to the screen centreline.

Video Measuring SystemsToday nearly every manufacturer of projectors also offers several models of automatic v ideo inspection equipment. Modern video measuring systems use solid-state cameras to electronically evaluate optical images projected into the camera. Computers are programmed to analyse the camera images for the location and size of pre-selected features on the part as they are brought into view.

The system’s software detects edges automatically and evaluates pre-selected feature size and location numerically. When nominal values and tolerances for the feature are supplied, deviations from nominal and out of tolerance conditions can be generated automatically. CNC video measuring machines can automate inspections and eliminate user variability.

If video measuring systems work quickly and automatically and provide numerical evaluations of features on the part without subjective human intervention why use a projector? This

is where the projector’s versatility comes into play.

Easier On A ProjectorThere are a few tasks that are more efficiently performed on a projector than on a video inspection system. Measurement by comparison of parts that fit within the field of view with a chart gauge is fast and easy. The eye is excellent at determining parallel ism and spacing when aligning a chart gauge and a part.

As the illustration shows, the shadow of the part is within the minimum and maximum profile tolerances shown as the dashed l ine s. There is a n impor ta nt technica l considerat ion when measuring by comparison. Since this measurement uti l ises the entire screen area, it requires accurate, distortion-free images across the full screen.

H i g h - q u a l i t y o p t i c s a n d illumination sources play critical roles in making effective measurements with this technique. Precision assembly and manual alignment of miniature components are easier on a projector because orientation and adjustment are more easily performed when the user can see a large area on the viewing screen.

The projector (left) images the magnified view of the part directly on a large frosted screen. The video measuring system (right) images the part on a solid-state detector that is typically smaller than an inch across and contains numerous, individual pixels. The electrical signals of all the pixels, corresponding to different light levels, are analysed by software to determine feature locations and presented on a video monitor.




A field of view of three inches is available at a magnification of 10 times on projector with a 30-inch diameter viewing screen.

An entire three-inch workpiece magnified 10 times in a single scene on the screen makes position and alignment easy to see. Projectors with a horizontal viewing axis are particularly convenient to use for tasks requiring a lot of manual manipulation because the user is located directly in front of the screen with the assembly easily at hand on the worktable.

O p e n s e t - u p s p o t c h e c k measurements require less time and less skill to perform on a projector. In fact, the projector can have the answer before the video system has

even initialised. This is particularly true for angle measurements, which can be done in a couple of ways.

A chart gauge with the specific angle on it can be measured by comparison as above. Most projectors offer a rotating viewing screen with a protractor assembly for angle measurement.

Aligning the screen crosshairs to an angled edge takes only a matter of seconds and is simple and easy for any user to do. An example of newer technolog y applied to projectors is the use of digital rotary encoders that make angle measurements even easier. The procedure is the same, but the angles are digitally displayed in 0.01-degree increments on a DRO.

Projectors allow evaluation of subtle characteristics in an image

The alternative procedure on a video measuring machine or CMM requires acquiring points along each side of the angle, then fitting and intersecting those lines to get the angle.

Tool presetting for adjustment of cutters used for metal removal on numerically controlled machine tools is a common example of both the manual assembly and alignment functions, and the open set-up functions using the protractor and measurement by translation available on projectors.

Projectors offer a means to evaluate subtle characteristics in an image such as colour, texture, and roughness. These subjective eva luat ion s ca n b e done by comparing the part against a known standard part or, with experience, by making the required evaluations d i r e c t l y b a s e d o n s e l e c te d characteristics in the image.

Tasks like inspection for flaws and measuring features that are indistinct because of roughness, dirt, low contrast, or poor focus are often easily accomplished with projectors.

Finding a burr can be a side benefit during any inspection. Random f laws and indist inct, variable features are difficult to programme on an automatic video system, and essentially impossible on a CMM.

Projecting The FutureIt is true that the modern projector can have electronic edge detection located at the centre of the viewing screen that will detect high contrast backlighted edges. The projector may also have a DRO for the table movement with geometric feature computation functions built in.

While these capabilities can significantly extend the projector’s usefulness the projector is still not nearly as capable of full automation as the modern video inspection system.

So why is the projector still with us? With a projector we, the user, can easily and accurately perform a wide variety of tasks without



41


The operator is the source of the projector’s versatility.

Not Lost In TranslationBefore moving worktables were incorporated into projectors,

special slide fixtures with accompanying chart gauges were

used to measure long parts that did not fit within the field of view.

Eventually, micrometer heads were incorporated into worktables

to track changes in position.

Higher end projectors now use glass scales integrated into

a geometric processor with a DRO for making measurements.

There are two main advantages to measuring by translation.

First, because part features are measured at the screen

centreline, there is no need to image the entire part at once.

This means that large parts that could not possibly be imaged

all at once no matter how large the projector can be measured

easily. Second, projectors can operate in CNC mode when

worktables are combined with motor drives, edge detection and

automation software. This significantly increases productivity and

reduces operator subjectivity.

In order to measure accurately using worktable motion,

optical stability and mechanical accuracy are paramount. In

addition, when measuring in CNC mode, edge detection must

be repeatable.

Using A Profile Projector? Read On...

Appropriate Screen Size & MagnificationProjectors range from small benchtop units to floor models with

screens of 30 inch diameter or more. Lenses from 5x to 100x are

typically available. The field of view (size of the area being magnified)

equals the screen diameter divided by the lens magnification. Here

is the calculation for a 20x lens on a 20 inch projector:

20”/20 = 1”

This means that one inch of the part will fill the screen at 20

inch. Therefore, a feature that is 0.01 inch will image as 0.2 inch

on the screen. That same lens on a 30 inch projector will image

an area of 1.5 inch on the part.

Projectors make it easy to satisfy the 10:1 rule for

measurement. Use a 10x lens and the image is ten times larger

than the field of view. Quick-change lens mechanisms make

it easy to use different magnifications on a projector allowing

different levels of resolution for a particular inspection, or different

magnifications per part.

Enquiry No. 4209

programming anything. We are the source of the projector’s versatility. Over our lifetime each of us interacts with our surroundings primarily through our eyesight. The human eye and brain naturally provide critical judgments in the context of the measuring task at hand just by looking at the viewing screen.

I t is our exper ience, when applied to the images we see on the screen of the projector that helps us extract information well beyond just dimensional relationships. This capability far exceeds even that of the most advanced video inspection systems.

Projectors and video measuring systems will continue to co-exist because each is good at what it does. When and where you use each one depends on what you need, and how fast and often you need it.

In any case, it is a safe bet that the big round projector screens would continue to be seen in manufacturing operations everywhere.

Enquiry No. 4208

MEN



Sheet Metal Advances:

Old Ideas, Move Over!

The ma ximum allowable cost of a sheet metal part is determined before designing work begins. Naturally,

the more economical the part is, the better. There are two ways of achieving this. You can either save on material or cut costs in production.

‘Economical’ however, is not the same as ‘cheap.’ The goal is to combine the various production factors – the type of materia l, m ate r ia l co n su mpt io n , t i me , machines, and tools – in the best way possible.

Production factors influence each other. One change can often times have a positive effect on a number of different areas. For example, a reduction in the number

it is always a good idea to check whether an attached part can be substituted by simply bending another section. This eliminates the need for welding along with all the associated preparation work such as setting up, aligning, and clamping the parts.

When welding is unavoidable, new designs and methods to doing things do have its benefits. For instance, cleanup work can be reduced by eliminating welding seams entirely, by welding sections from the inside, or by designing edges so that they are straight and smooth after welding. New manufacturing techniques such as laser welding also help to reduce cleanup work.

of single parts used to create a module not only saves material, but it also concurrently reduces production time.

Change In ThinkingAs a general rule, it is better if components comprise a small number of complex parts than a large number of simple parts. Today’s manufacturing techniques and programming software make it easy to produce complex single parts but the joining process on the other hand are usually very time consuming.

W h y w e l d w h e n y o u c a n bend? Welding not only takes up valuable time, but also generates heat that could potentially distort the workpiece. For this reason,

Processing thin sheets of metal can be more economical if innovative designs and fresh process selection are used. By Melvin Tham, product manager, bending technology, Trumpf Asia Pacific

Fab&Form



43

fab&form

The ‘New’ WeldingGenerally welding application is for less precision parts. Welding process distorts the profile and therefore will not be considered for precision construction. TruDisk technology however, solves this problem. The laser application is able to apply welding process without distorting the sheet metal and therefore able to maintain within tolerance and reduce the cleanup work.

Laserwelding sheet metal yields required flatness on sheet metal after welding. In addition, the sheet metal is water and airtight after the process. The salient point here is also the cosmetic effect on the product.

Bent On TechnologyGreat design must be accompanied with the support of technology.

Initial design (top) and further optimisation steps result in a reduction of 40 percent in manufacturing cost.

While considering the design, we also need to explore whether the technology of our machine can support and complete the process.

For air bending, it reduces 5 to 10 t imes of work ing force required as compared to bottoming method (depending on the material thickness).

For example, air bending can bend mildsteel of 10mm with

a force of 607kN/m. Bottoming the mildsteel on the other hand, requires 4,400kN/m.

Air bending has the advantage to bend different angle required.

Coin ing / bottoming is a lso required at times but generally, we use it for forming purposes (eg: simple lourve, embossing).

Enquiry No. 4301

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fab&form

High SpeedStamp Of Approval

The faster, the better — this simple notion takes on a complex view in high speed stamping. By H Pecik, marketing manager, Bruderer

The term ‘high speed’ in c o n n e c t i o n w i t h t h e s t a m p i n g p r o c e s s i s absolutely relative. Where

block-cutting tools allow for the safe stamping of small parts with up to 2,000 strokes per minute, industrial applications often reach their limit at 100 strokes per minute. Depending

on the application and complexity of the part geometry, limits vary widely.

It goes without saying that higher speeds are also in demand for the stamping sector. The constantly increasing cost pressure often creates temptation for users to raise the production speed. In many cases, however, the existing operating

facilities are simply running at higher speeds neglecting the fact that they are not designed for the higher number of strokes per minute.

This invariably leads to problems and less than satisfying results. The entire stamping line must be attuned to the higher output if the direction for a higher production speed is taken.

Sheet Metal Advances:



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fab&form

There are also different approaches to increase productivity. More parts per stroke are more effective than mere speed boosting in most cases as it causes less wear and less unforseeable problems.

Cutting Speed & QualityIn the past, several automatic punching presses with speeds of up to 4,000 spm were offered. Heralded as the latest trend at the time, it has however, fallen from grace as the problems with periphery, tool technology and heat influence led to unsatisfactory results. Additionally, such machines are only available with short fixed strokes and small clamping areas, which turns them into mere single-purpose machines.

The machine speed is one criterion, but the resulting cutting speed of the punching tool is something quite different. Next to the machine speed, the cutting speed also depends on the set stroke height and the angle at which the tool hits the material.

Depending on the individual applicat ion, the user needs a higher or slower impact speed with which the tool hits the band material. Low speeds are mainly suited for embossing and bending, high speeds of fer advantages in cutting processes. In general smaller strokes are preferred as the dynamic influences are reduced and tool wear is minimised.

But how does the material react to the different cutting and impact speeds of the punching tools? Internal tests at the university of Darmstadt in 1990 showed that better results are achieved with cutting speeds above 0.8 m/sec in terms of burr formation and cut surfaces. They become better when increasing the ram speed up to 5 m/sec.

In order to achieve this goal, however, the machine must allow for adjusting large strokes while the impact angle of the cutting tool must lie way below reaching the Bottom Dead Centre (BDC). To at least realise the said 0.8 m/sec, the

following adjustments would be necessary for instance: machine speed 1,000 spm, 30 mm stroke, impact point 2 mm before BDC.

In case of smaller stroke heights, as they are to be found with fixed stroke machines for high speed applications, the speed would thus have to be raised to the extreme in order to achieve the same effect. This again leads to problems with the dynamic accuracy and the life of machine and punching tool.

In contrast to most machines with longitudinal shafts, machines equipped with adjustable stroke allow for the adjustment of long strokes for high cutting speeds on the one hand, but also for setting small strokes suited for lower speeds on the other. With a machine concept offering the desired flexibility, the toolmaker may aim at the perfect compromise between tool life and part quality by an optimised tool design and construction.

Stamp Fast, Stamp Safe?How to increase the speed of stamping without compromising the safety of the process is the challenge which automatic punching press manufacturers are facing today.

Bruderer offers machines, which may be operated at up to 2,000 spm. In cooperation with the press control, almost everything may be monitored, measured and where necessary, controlled with BSTA

type machines. The so-called first and last hit

accuracy is also of importance in this context, as it must be granted that the ram speed upon reaching the BDC is high enough not to produce any noticeable variations in the stamping depth of the punched parts.

Fur thermore , i t i s just a s important to stop the ram as quickly as possible as soon as an error is detected in the system. What good does high speed do if the ram continues to run through the BDC 10 times after detecting a mis-stroke thus breaking the complex punching tools? The resulting damage would be substantial.

A n a u t o m a t i c p u n c h i n g press must comply with these requirements on the whole. Which is why mechanics and electronics must be harmonised with each other without thereby abandoning the high flexibility, accuracy, and a long machine life.

The topic of high -speed in stamping processes might be elaborated on in much more detail at this point. The essence is to understand, however, that the forces do not rise linearly to the speed increase but quadratically. This means that a small cause may have a big effect.

Enquiry No. 4302

A well-balanced load distribution is key for desired results.



IndustryspotlIght

Gl o b a l a e r o s p a c e manufacturing revenue in 2008 was estimated to register more than

US$337 billion with growth below 7.0 percent, lower than the previous years. Frost & Sullivan estimated Asia Pacific’s revenue at US$47.9 billion or 14.2 percent of the global output, a slightly higher growth rate than the global average.

Year 2008 has been a challenging year for the aerospace manufacturing industry with the record breaking oil price hike in decades, which has seen amplified logistics costs due to the globalised nature of manufacturing supply chain.

This has resulted in many business experts disagreeing in the idea of expanding a company network of suppliers to other low costs countries because in the end they will still have to pay extra on the logistic costs.

Prior to the oil price hike, Airbus in 2006 transferred their A320 aircraft assembly into Tianjin, China due to the expected high demand in the region. The choice was made as they already enjoy a strong network of suppliers in the Asia Pacific region. The plant started operations in 2008 and is currently assembling four A320 aircraft with expected delivery this year.

Asia Pacific sees emerging aerospace manufacturing plants despite the economic slowdown. By Syahril Shariff, consultant, Asia Pacific aerospace & defence practice, Frost & Sullivan.

Taking A New RouteIt is going to be tough for OEMs this year to sustain the growth that they have been enjoying in the past few years due to the current slowing economies.

On Jan 9, 2009, Boeing said it would cut administrative manpower in its commercial aircraft division by 6.6 percent or 4,500 workers; however it will still retain the production work force due to the huge backlog orders in the pipeline worth more than US$270 billion.

Manufacturing costs in North America and Europe is high. With the worsening economy, costs structures will need to be re-examined to face stronger competition which drives the industry to strategically re-align their business model to be able to sustain regionally and globally in the long term.

Lea n ma nufactur ing today becomes more important for most

OEMs with the right sizing of their operations. A lot of OEMs today are adopting Six Sigma, Kanban, Kaizen, JIT, performance based logistics and any other best practices to reduce cost of operations and increase their efficiencies.

The North American region currently commands about 49.0 percent of global revenue. With increasing cost structures in the region, we may see a reduction of revenue shares from North America shifting towards emerging and lower cost regions such as Asia Pacific, South America and Eastern Europe as OEMs shift their supply chain networks.

Many OEMs integrators such as Airbus and Boeing are shifting their production facility to low labour cost countries in Asia Pacific. OEMs are also actively seeking ways to reduce manufacturing costs by outsourcing more ‘design to build’

TheSky’sLimitThe

Mic

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Aerospace:

Contact us for more details.

Mitutoyo (Malaysia) Sdn. Bhd.Tel: (60)3-7845 9318 Fax: (60)3-7845 9346E-mail: [email protected]

Mitutoyo Asia Pacific Pte. Ltd.Company Reg No. 892/1978-N24 Kallang Avenue, Mitutoyo Building, Singapore 339415 Tel : (65) 6294 2211 Fax : (65) 6299 6666 E-mail : [email protected] http://www.mitutoyo.com.sg

Mitutoyo (Thailand) Co., Ltd.Tel: (66)2-521 6130 Fax: (66)2-521 6136E-mail: [email protected]

Philippine Representative OfficeTel: (63)2-842 9305/6 Fax: (63)2-842 9307E-mail: [email protected]

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Ho Chi Minh City Rep. OfficeTel: (84)8-3517 4561 Fax: (84)8-3517 4582E-mail: [email protected]

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packages rather than just ‘build to print’ to tier one OEMs. This has led to tier one OEMs to be responsible for the maintenance programmes for assemblies and parts that they design and manufacture.

Friendly Skies Asia Pacific will see or rather is already seeing the emergence of new aerospace manufacturing plants despite the economic slowdown.

Examples of new manufacturing plants that are star t ing their operations in Asia Pacific in 2009 are Honeywell Aerospace and Spirit Aerosystems in Malaysia, Rolls Royce in Singapore and few other OEMs.

Entrance of prominent primes or OEMs into the region will not only increase the work packages of Asia Pacific manufacturers but will also attract existing suppliers of OEMs from North America and Europe to invest and enter the Asia Pacific market.

While other industries are cutting down manpower, job opportunities s t i l l e x i s t i n t he ae ro sp ace manufacturing in Asia Pacific due to expansion. Most OEMs are also replacing high paying employees and expatriate with lower cost, local fresh graduates.

Countries that are expecting to experience growth in aerospace manufacturing activities in the region are Malaysia, China, Australia, Taiwan, Singapore and a few other countries.

Air Turbulence Ahead?The price of oil dropped tremendously in the past few months. In addition, OEMs are bearing the brunt of the global economic slowdown. Total air traffic growth expected to reduce to below 6.0 percent per annum with air cargo market experiencing the highest decline in growth rates.

Airlines have been the most affected industry due to the reducing air traffic demand resulting in capacity cut down and aircraft orders being cancelled or delayed.

Some Asia Pacific Low Cost Carrier (LCC) is expected to bear losses with declining passenger demand in

certain sectors as consumers tighten their disposable income to prepare for the economic slowdown despite declining fuel price.

Nevertheless, the stronger LCC players in the region are expected to sustain growth for 2009 as business travellers shift to LCC from legacy airlines in the move to cut their companies’ operational costs.

Along with lower traffic volumes, another point to note is the effects of fuel hedging. During the price hike in June to July last year, a lot of major airlines hedged their fuel expecting jet fuel prices to stay

high. Right now they are suffering from this hedging as prices have dropped lower than expected.

We estimate the global aircraft fleet will reduce by 2.0 percent due to the economic slowdown with Asia Pacific delivery reducing to 17,000 new aircraft within the next 21 years.

Ending on a good note, there are very few airlines today cancelling orders, as air travel has become a commodity service in most Asia Pacific countries with few deferred deliveries.

Enquiry No. 4401

MEN

Aerospace Manufacturing Revenue Forecast(Asia Pacific), 2008 - 2020

South KoreaJapanChina

India

Taiwan

MalaysiaSingapore

Indonesia

Australia

More Work PackagesOutsourced To Asia

Pacific Manufacturers

North America

EuropeCountries Expected To

Experience Growth In Aerospace Manufacturing (Asia Pacific),

2008 - 2020

$0

$10

$20

$30

$40

$50

$60

$70

Airframe Engines Components Avionics Others

2008 2020 Source: Frost & Sullivan

Rev

enue

, US

$Bill

ion

IndustryspotLIght

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IndustryspotLIght

Exhaustive control checks a n d m a i n te n a n c e o f sensitive aircraft parts must be carried out regularly.

Certain parts, such as landing gears, on which strong demands are made, are given to special repair companies.

Dimensional measurements are sometimes complicated matters where special fixtures are required to aid the operators. By Maren Roeding, PR manager, Witte Far East.

As those companies often do not have the original drawings of the components available, dimensional checking in the range of quality control is often very extensive. They have to work according to basic data supplied by the manufacturers.

Position and diameter of bushes often fall into that category. Time and again it is not known in which alignment the part was measured.

However, when it is a matter of highest accuracy, the alignment of a part and the support points must be

AQuick Fix



51

taken into account for dimensional measurement.

As these details are often not available, checking of complex parts proves to be problematic. To get around this, part fixturing is used, especially with heavy parts, which are often the case in the aircraft industry. Part fixturing has considerable influence on the measuring results.

Getting Your FixIn order to achieve comparability of results, measuring must always take place with the part in the same situation eg: in installation position, horizontally or vertically.

After successfully measuring the data, results are sent to the part manufacturer for comparison purposes. If deviations are established, measuring with different alignment must be done again. Problems ensue when dedicated measuring fixtures cannot be adapted and therefore are no longer of any use for changed support situations.

Additionally, it is mostly small quantities which have to be checked, whereby the manufacture of a new dedicated fixture is often not cost-effective, especially if they have to be made two or three times. In such cases the use of modular fixturing systems

is called for, whereby individual and highly accurate measuring fixtures are built on the spot.

Modular SystemsThe user remains independent of fixture builders, which can lead to considerable savings. Modular systems such as A luf ix a l low precision and reusability of almost all components.

It enables adaptation of finished f ix tures, catering for updated measuring requirements at the customer’s plant. When the fixture is no longer required, it is completely disassembled and all components are free to build a new fixture.

Investment in a modular fixturing system pays for itself after only a few applications. As parts in the aircraft industry to be checked are often large and require corresponding coordinate measuring machines, many repair companies in Singapore work together with measuring laboratories.

Witte Far East provides individual measuring fixtures for each part to be measured. Even for large parts up to 6 m, modular fixtures are built at short notice, whereby all special support requirements are taken into account.

Enquiry No. 4402

Made out of high-tensile aluminium for measuring fixtures,

checking gauges, assembly or welding fixtures, cubing,

gauges, meisterbocks, blue bucks, data control models,

Alufix by Witte Far East is a modular fixturing system.

Deployable in design, R&D and prototyping areas where

a lot of changes take place, this modular system for holding

workpieces is available in six sizes.

The different system sizes can be combined with each

other. After use, fixtures can be disassembled and the single

components can be used for new fixtures.

Enquiry No. 4403

Witte Far East:Modular Fixturing System

MEN

Modular systems allow flexibility as all components can be disassembled and made available to build a new fixture.

IndustryspotLIght



IndustryspotLIght

The mechanical machining of aero engine parts can hardly be compared with other areas of machining.

There are very special requirements associated with hard-to-machine materials and comprehensive quality management.

While automobile suppliers or machining companies use new tools and machining methods to optimise their general mechanical engineering processes, production processes especially for sensitive components in the aero engine industry have largely stopped. The reasons for this are far-reaching quality regulations, and in the end, safety.

Under these circumstances, technolog ica l innovat ions in machining are usually applied to the aero engine industry some time afterwards. However, if new aero engine projects are being engineered, this of course is based on the most up to date machining technology.

Fine MarginsDue to the long life cycle terms of single aero engine types (up to 40 years), many individual processes remain valid throughout this time. The customers only permit a specified range in which the supplier can move within the procedures without permission.

This range is very small, with rotating parts inside the aero engine. With stationary parts on exterior surfaces, (eg: with casings) it is greater. The latter also applies to pre-machining which becomes critical when close to the final contour.

(Top)There is only a fine margin in machining aero parts

(Bottom) Tools used in aerospace technology are almost all special tools

Machining of aero components is in the class of it’s own where special requirements and advanced technologies are quite simply, the industrial norm. Contributed by Bernhard Weihermüller, Walter Tools

SkyWorks

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Mitutoyo (Malaysia) Sdn. Bhd.Tel: (60)3-7845 9318 Fax: (60)3-7845 9346E-mail: [email protected]

Mitutoyo Asia Pacific Pte. Ltd.Company Reg No. 892/1978-N24 Kallang Avenue, Mitutoyo Building, Singapore 339415 Tel : (65) 6294 2211 Fax : (65) 6299 6666 E-mail : [email protected] http://www.mitutoyo.com.sg

Mitutoyo (Thailand) Co., Ltd.Tel: (66)2-521 6130 Fax: (66)2-521 6136E-mail: [email protected]

Philippine Representative OfficeTel: (63)2-842 9305/6 Fax: (63)2-842 9307E-mail: [email protected]

PT. Mitutoyo IndonesiaTel: (62)21-898 0841 Fax: (62)21-898 0842E-mail: [email protected]

Ho Chi Minh City Rep. OfficeTel: (84)8-3517 4561 Fax: (84)8-3517 4582E-mail: [email protected]

Hanoi Representative Office Tel: (84)4-3768 8963 Fax: (84)4-3768 8960E-mail: [email protected]

M(M)S.B. - Penang Branch Tel: (60)4-641 1998 Fax: (60)4-641 2998E-mail: [email protected](M)S.B. - Johor Branch Tel: (60)7-352 1626 Fax: (60)7-352 1628E-mail: [email protected]

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with end, cylindrical and face milling cutters, in terms of projection lengths, corner radii, number of teeth and above all also with regard to the fine geometry of the cutting edges,” says Reinhold Sanhieter, technical consultant at Walter.

Extremely sharp cutting edges tend to chip faster if there are vibrations. The cutting edges are rounded off at the µ level specifically for this reason. How much, and in which way, depends on the material.

The tooth geometry also varies; Inconel needs a more stable cutting edge and consequently a smaller rake angle than in titanium alloys. Standard tools are a minority and are mainly confined to drills and taps.

To the variety of the tool variants grouped together for the reasons mentioned, you can add that the milling cutter, indexable insert etc. are not used up until the end of their tool edge life, but are in use up until a permitted wear point on the cutting edge.

“We replace tools much earlier than in other areas,” explains Mr Kirbach, “this again has to do with the continuity of the material structure; as wear on the cutting edge increases, unwanted surface compression also increases,” he concludes.

Aero-ing Into The FutureAero engine parts are predominantly turned parts, but the need for milling cutters is increasing. Years ago, the ratio for turning/milling machining was 80:20; today it is about 70:30. This follows the trend of more complex turning parts; the best examples are the casings, which have to be machined with many slots and flanges.

On the other hand, the proportion of orders at Aerotech for static components is increasing steadily. The reason for this development is that aero engine manufacturers are steadily reducing the number of their suppliers.

“This has also further increased t he i mp or ta nce o f comple te machining using mult itask ing machines with as few clamps as possible,” explains Mr Zimmer. In turn, this requires a correspondingly flexible tool strategy.

As a result, the number of indexable insert tools is increasing. It is precisely the stationary components with less strict approval procedures that provide a greater opportunity to implement a machining strategy that uses new tool types.

Enquiry No. 4404

“During machining, material can become compressed, and this can cause structural changes leading to the build -up of unintended tensions,” explains Michael Kirbach, purchasing manager at Aerotech Peissenberg, a manufacturer of aero engine components.

“In thermally and mechanically stressed components such effects must be avoided, that is, specific limit values must not be exceeded,” he adds. The workpiece and its machining therefore requires authorisation from the customer. To attain this, the components are examined thoroughly in the laboratory before they go into production.

For the aero engine specialists this means that changes to tools and cutting values, once fixed, are associated with a renewed a u t h o r i s a t i o n e f fo r t . I f , fo r productivity reasons, you wish to dev iate f rom t he de f ine d manufacturing specification, the release procedure (eg: laboratory tests) must be initiated again.

Examining The CutDemands for up to date machining technologies give manufacturing e x p e r t s t h e o p p o r t u n i t y to contribute. Most components almost always have low wall thicknesses and high cutting forces increasing the tendency to cause distortion.

As such, special fixtures and brainstorming sessions are often required. “We sit down at a table with the aero engine designers to work out production-oriented solutions together,” reports Manfred Zimmer, production manager at Aerotech.

Materials used for machining include high-temperature chrome nickel alloys, nickel based alloys and titanium alloys. People who work with such materials need a reliable tool partner.

“The tools used in aerospace technology are almost all special tools which are produced according to customer specifications. The special features become evident during roughing and fine finishing

WITh the Paradur ECO-CI tap for pocket and through-holes, Walter has

now managed to speed up the job of making threads in cast iron.

The reason behind the increase in productivity is to be found

concealed in the technical details of this threading tool. On the one

hand it is down to Xtra treat surface treatment ensuring that coating

is a controlled process.

On the other hand, a composite layer is given here which,

together with the graded TiCN multilayer hard-materials coating,

will ensure high cutting speeds and a long tool edge life.

The product is suitable for making threads down to a depth

of 3.5 x d in short-chipping cast-iron materials.

Enquiry No. 4405

MEN

Walter:Designed For Cast Iron

IndustryspotLIght

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eXchangeAerospace Supplier

2009

The inaugural Aerospace Supplier eXchange (ASX), a regional conference and exhibition that mainly showcases the aerospace suppliers in tier 3 and 4 of the industry — where they provide support

to the aerospace OEMs and after market maintenance, repair and overhaul (MRO) companies.

The conference similarly focuses on the aerospace supply industry, looking both at macro issues as well as micro issues such as supplier certification and regulatory requirements.

Organised by the Association of Aerospace Industries (Singapore) in partnership with IIR Exhibitions, the event will take place at Singapore Expo from May 27 – 29, 2009 from 1030 to 1800hrs.

An estimated 3,000 trade professionals and visitors will network with some 50 exhibiting companies who are showcasing their most innovative products and services.

Exhibitor & Visitor ProfileSupported by the Singapore Economic Development Board, IE Singapore and SPRING Singapore, ASX 2009 is a full two-day conference complemented by a three-day exhibition. It serves as a platform for the industry to meet, network, and participate in seminars by esteemed speakers, as well as understanding the procurement and quality needs of major OEMs.

Intended to be a biennial event, the ASX aims to be the event for all tier 3 and 4 aerospace companies to exhibit their products and services, and one whereby buyers from the tier 1 and 2 suppliers and OEM will view as important to their sourcing needs.

Major exhibitors range from materials suppliers, machine tooling, jigs and fixtures, technology suppliers, logistics and supply chain management, asset management, fasteners and plastics, design and manufacturing. Supporting industry in areas of training and development, trade compliance and more will also be part of the exhibition.

Amongst the expected crowd will be procurement managers, quality assurance personnel, operations personnel, managers and supervisors and R&D heads of department.

In conjunction with this event, Singapore suppliers can also look forward to meeting key aerospace procurement decision makers in one to one business meetings at the Global Asia Trade Exchange (GATE) 09 Aerospace.

Co - orga n ise d by I nter nat iona l E nter pr ise ( IE) Singapore, GATE 09 Aerospace pre -matches aerospace buyers with the most suitable suppliers in a

IndustryspotLIghtEVENTS & EXHIBITIONS



57

prequalification process, to facilitate efficient sourcing of end-to-end solutions for the industry.

To coincide with ASX 2009, the first Singapore Aerospace Awards (SAA) supported by the Agency for Science, Technology and Research (A*STAR), Civil Aviation Authority of Singapore (CAAS), Singapore Economic Development Board (EDB), International Enterprise (IE) Singapore, SPRING Singapore, Singapore Workforce Development Agency (WDA) and Workforce Safety & Health (WSH) Council will also be held to celebrate the outstanding achievements of companies in the Singapore aerospace industry in areas such as innovation, technology adoption, workforce development, safety and fast growth.

Aviation Hub As an aviation hub, the Singapore aerospace industry is a mature one with strong projected growth over the next few years. According to a research study released in 2007, Singapore is the number one Asia Pacific MRO hub with comprehensive MRO capabilities and key infrastructure.

Contributing over three percent of Singapore’s GDP last year, and with a strong compounded annual growth rate of more than 12 percent over the last 15 years, this industry is a stable and increasingly dynamic one, commanding strong local supplier support, and providing over 19,000 jobs locally.

In the past three years, a growth area has been in the arena of aerospace manufacturing. Singapore has benefitted from major investments in this area in recent years which include Rolls Royce’s location of its S$320 million (US$213 million) aero engine assembly and test facility plant in Seletar Aerospace Park and Pratt and Whitney’s setting up of their component workshops here, employing more than 2,500 employees.

The ASX underscores this critical mass of aerospace activities in Singapore, with the spotlight now on promoting and further growing the pool of local aerospace manufacturers who are vital towards supporting the tier 1 and 2 giants.

ASX 2009Singapore Expo Singapore27 – 29 May 2009

Enquiry No. 4406

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The changing operating climate facing automotive component manufacturing is placing increasing demands on metalworking fluids. By Laurent Barnagaud, global marketing manager of Shell Metalworking Lubricants.

Metalworking Fluids:

Bigger Bang For YourBucks

Major countries have made clear commitments to reduce their country’s gasoline consumption

in the coming years. For example, the US has committed to reduce their consumption by 20 percent in the next 10 years. The reduction in consumption would be met, in part, by raising fuel economy standards for cars.

As a result, vehicle manufacturers are looking to manufacture more economical vehicles. Achieving this without compromise to performance and design has presented automotive manufacturers with a particularly difficult R&D challenge.

Manufacturers will have to begin to produce higher fuel efficient and lower carbon emission producing vehicles.

To achieve this, while retaining and increasing the market appeal of their vehicles, many manufacturers are investing in new production techniques and technologies.

Changing ProcessesT r a d i t i o n a l l y a u t o m o t i v e manufacturers have been focused on lowest price technology to deliver financial savings to customers but the increasing demand for fuel efficient vehicles, coupled with growing competit ion from Far Eastern manufacturers are leading many to realise that investment now can have a major positive impact on future profitability. There is an evolution taking place at the moment – from unit cost reduction to overall manufacturing cost reduction.

One method that automotive manufacturers have utilised to improve overall vehicle efficiency i s t he pro duc t ion o f l i g hter components.

R e d u c i n g t h e w e i g h t o f components such a s veh ic le t ra nsmission , body work a nd gearboxes lowers the total weight of the finished vehicle and the demand placed on the engine during acceleration. Therefore, lower total vehicle weight equals less fuel consumption dur ing engine combustion, increasing fuel performance.

To make components lighter, manufacturers have switched from using basic steel compounds to various a lloys and other l ight n o n - fe r ro u s m a te r i a l s . T h i s



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switch provides a component of comparative durability to steel, so that manufacturers do not have to alter vehicle design or performance. Furthermore, vehicle safety can be improved as the new alloys offer greater resistance to failure during impact.

However, increasing the strength of the metal that is being machined will lead to an increase in cutting duration, temperature and chipping. As the majority of cutting fluids are developed to operate within certain temperature parameters, manufacturers must ensure that the fluid used is able to perform even with harsher demands of machining stronger metals.

Alternative MaterialsUsing these alternative materials for component production can help reduce total vehicle weight by around 25 percent, offering manufacturers a cost effective way of significantly improving vehicle efficiency and environmental performance.

However, to reap the full financial benefits of this production solution, manufacturers need to ensure that their tools and metalworking fluids are able to cope with the pressures and issues related to machining tougher metals.

I f not, they risk facing long periods of unscheduled stoppages and high levels of component and equipment damage. One particularly successful method of protecting against these risks is by using a fit-for-purpose metalworking fluid.

For example, lighter aluminium alloys are notorious for staining during the metal working process, leading to poorer quality finished product and wastage, which impacts on profitability. As these alloys are used more and more in the

automotive industry, a coolant is used to address these problems. Shell Lubricants Companies have developed a coolant for aluminium machining to offer lubricity and minimise staining.

Shell Sitala D 3403 has resistance to foaming in soft water, limiting the number of production stops required and allowing high pump pressure and flow rate.

Automot ive ma nufacturers using the coolant can benefit from reduced operational costs as a result of limited fluid maintenance requirements and extended fluid stability, in addition to the reduced waste disposal costs resulting from extended oil life.

All this makes manufacturers more profitable overall even though the product may be more expensive when judged by unit cost.

Fluid OverviewMetalworking fluids play an important role in the smooth and efficient running of automotive component manufacturing equipment as well as the successful formation of the finished part.

The extreme temperatures, high level of chipping and long continuous operational hours of metalworking processes, such as deep hole

Automotive manufacturers have reduced the weight of transmission and gearboxes to increase performance.

Metalworking fluids play an important role in the successful formation of the finished part.



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drilling, turning and broaching, place multiple demands on the fluid. It must provide lubrication, flushing and cooling properties to protect the tool part from accelerated wear and the finished part from surface damage and deformation.

All metalworking processes generate intense heat as the metals or non - ferrous mater ia ls a re processed. However, the heat must be dissipated across the part surface and the friction must be reduced to avoid part damage and poor surface finish, which can be extremely costly for operators in terms of wastage and delays in production.

Selecting The Right FluidWhen it comes to metalworking fluids, there is no one size fits all and selecting the right fluid for the right application is key to protecting against tool failure or part damage. I f manufacturers are changing t he i r pro duc t ion pro ce ss to accommodate new, tougher metals or nonferrous materia ls, they should always consider reviewing the performance properties of their metalworking fluid.

In many cases, an experienced meta lwork ing f lu ids prov ider will be able to assist automotive manufacturers in auditing the cutting processes and identifying fluid

The Shell Ensis fluid range of corrosion preventatives, suitable for the protection of

ferrous and non-ferrous metal surfaces, has been expanded with the addition of Shell

Ensis PL 1608, a prelube using a micro-wax free technology.

According to the producer, the two in one product with anti-rust properties

has been designed to deliver key benefits to both the metal sector and its car-

manufacturing customers.

The micro-wax free technology also reduces the chances of filter blockages, which

can lead to regular cleaning requirements as well as unplanned maintenance and

downtime. In addition, up to 25 percent less prelube is required when using the product.

Another key benefit for car manufacturers is the product’s compatibility with

processes further down the line, including adhering and degreasing.

Enquiry No. 4502

Shell Lubricants:Micro-Wax Free Preventatives

demands. This approach helps determine the required EP rating, wetting, cooling, anti-corrosion and flushing performance of the fluid.

The right metalworking fluid, suppor ted w ith the re leva nt application expertise, will help automotive manufacturers protect their processes against expensive tool and component damage, while

maintaining uptime. In a market that continues to demand more value from the finished vehicle in terms of efficiency and environmental compliance – this could help manufacturers to ensure that their process remains productive and profitable.

Enquiry No. 4501

features

Selecting the right fluid for the right application is key to protecting tool and part from damages.



27-29 MAY 2009 (10.30am - 6.00pm DAILY)SINGAPORE EXPO

AEROSPACESUPPLY SHOW

OF CHOICE

THE

WHY YOU SHOULD ATTEND:

• Meet potential business partners in a highly effective and efficient business environment• Learn latest trends and developments in the Aerospace Sector• Network with the global industry professionals • Attend a comprehensive conference that provides valuable knowledge on safety and risk

management, business strategy, procurement, aerospace supply chain, certification and regulations, and many others. Topics will focus on the aerospace industry’s interest in general, encompassing requirements and topics for both the MRO and Aerospace Manufacturing community. Conference speakers will come from esteemed companies such as Aerostrategy Management Consulting, CAA International, Federal Aviation Administration and Civil Aviation Authority of Singapore.

SINGAPORE’S FIRST AEROSPACE SUPPLIERS EVENT

For more information on ASX 2009, you may contact:

Ms Michelle Tan, Project Coordinator

Email: [email protected] Exhibitions Pte Ltd205 Henderson Road,

#03-01 Henderson Industrial Park, Singapore 159549

Tel: (65) 6319 2668

SEND VIA FAX TO (65) 6319 2669� Yes, I will be attending ASX 2009, please send me more information � I am unable to attend at this time but please include me in your mailing list

Name: Job Title:

Company:

Address:

Tel: Fax:

Email: Business Activities:

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Main Organiser: Co-Organiser:1 Changi Business Park Avenue 1#03-03, Ultro Building, Singapore 486058Tel: (65) 6787 5227 Fax: (65) 6783 9129

205 Henderson Road #03-01 Henderson Industrial Park, Singapore 159549Tel: (65) 6319 2668 Fax: (65) 6319 2669

SN: APMEN MAY/JUNE 09

Virtual Management Partner:Official Media: Held In:

Official Conference Content Partner:Supported by:

Supporting Media:

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Like many manufacturing sectors, the tooling industry continues to experience mounting global competition,

placing ongoing business and operational challenges on tool shops across the industry. Those that thought these challenges were temporary in nature have either gone out of business or realised that ‘change is here to stay’.

Delivery, quality, and cost are the top three challenges facing tooling companies, according to a recent survey conducted by CIMdata, an industry research firm. These findings

become the standard mode of operations at most shops.

When faced with a challenge, the common reaction is to grab for the most immediate solution – be it purchasing a new machine, e x t e n d i n g b u s i n e s s h o u r s , outsourcing, or adding a new detached software solution.

As a result , many of these solutions fail to address the root causes of the problem at hand. More than 50 percent of tool shops polled in the CIMdata survey indicated that their first priority was to implement advanced technology.

prompted CA D/CAM solutions providers to identify new approaches that would help tool shops eliminate or minimise these pains.

As with any practical framework, th is is work- in -process. I t is continuously used and honed as more tool shops are engaging in this effort.

A Common PitfallW h e n t a l k i n g t o t o o l s h o p executives, it became apparent that many do not take the time to analyse their business processes. Working in a highly competitive env ironment, f i re f ight ing has

TechTact&

It is worthwhile to identify new approaches that would help tool shops minimise pains which technology alone cannot help alleviate. By Hari Sridharan, VP of engineering, Cimatron

features www.equipment-news.com


features

Measuring result is an important part of the optimisation process.

Another analysis revealed that many of these implementations failed to solve the problems for which they were acquired, as the following examples show:

• Facing the need to expeditedelivery times, a tool shop invested a significant amount of money to purchase additional machines. While the investment helped speed up machining, it created new bottlenecks throughout the process and ultimately fell short of reducing overall delivery times.

• A nother tool shop that hadtrouble meeting delivery times began outsourcing their design work. Not only did the outsourcing increase their cost, the need for greater communication between parties negated any improvement in delivery times.

Investment in technology alone fa iled to deliver the expected results. It became clear that tool shops needed to look for other ways to improve operational results and examine the entire business processes.

Tool Shop OptimisationThe starting point in any improvement is a clear understanding of the business goals. They are: increase productivity,

shorten delivery times, reduce costs, increase customer satisfaction as well as employee motivation.

The more difficult question was how to get there. To help tool shops with this undertaking, an eight-step methodology was developed.

1. Identify The Best Process & Flow: All too often, companies invest in new technology or software, but oftentimes this merely moves bottlenecks from one area to another or creates other burdens in translation, as seen in the case studies above. The first step is to establish a streamlined process that covers all deliverables and milestones – from the initial price quote to the finished product.

Inputs and outputs for each step in the process must be clearly identified, along with quality expectations and the value added to the finished product. Only once the entire process has been laid out can specific technologies and methods be considered for individual tasks; these would be evaluated based on their impact on the entire process, not just the task at hand.

2. Streamline Internal & External Communications: Direct data transfer with the customer, the design team, shop f loor and

purchasing not only saves time by minimising the need for multiple data translations, it also increases data reliability, reduces errors and repeat work and minimises engineering changes.

To get started, reduce the use of printed documents, with the eventual goal of operating as a paperless company.

3. I m p l e m e n t 3 D D e s i g n & M a n u f a c t u r i n g : S t r i v i n g towards concurrent processes, implementation of 3D data reduces downtime and eliminates the level of redundancy caused by manually entering data into the machines, as is the case with 2D design work.

4. Re-examine Outsourcing: Including your outsourced activities in your process design may reveal opportunities to bring work back in-house and reduce costs, eliminate communication obstacles, and speed up delivery times in order to be more competitive.

If certain activities must be outsourced, focus on improving the communication process with these partners and better integrating them into the overall process.

5. Pla n For Succes s : A so l id implementation plan is the key to the success of the entire process. The implementation plan should consider all factors and constraints and include a contingency plan for unplanned events such as fluctuations in the shop’s workload. To shield customers from any negative impact during the implementation, maintaining and even improving delivery times throughout the transition should be a priority.

6. Acknowledge The Cost Of Change: The cost of change must be acknowledged and quantified.W h a t w i l l b e t h e l o s s o f productivity during the initial implementat ion? When is it



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3D visualisations help mouldmakers plan out their job.

Quoting is another area identified for process improvement.

Craig Mog, founder and co-owner of Cam Tool, launched an

effort to improve operations in his shop. He upgraded both his

equipment and software.

These new capabilities have enabled the company to operate

more efficiently. For example, a job which previously required

90 percent burning could be done without any electrodes —

everything was cut — generating time and cost savings.

Similar process improvements have been realised on the

design side, where a project that took 177 hours now takes

about 55 hours to complete. These savings translate to faster

delivery times that give the company an advantage over

overseas manufacturers.

Streamlining the entire process, which owner Craig Mog

refers to as ‘Screen to Machine’ brings the company additional

benefits. The ability to read customers’ files and do the design,

NC and electrodes all within the same software means there

is nothing lost in translation, which makes the entire process

efficient and cost effective.

As a result, the company has reduced the number of steps

involved in their tool making processes, allowing them to cut

costs and reduce delivery times while improving accuracy and

expanding their product offerings.

Enquiry No. 4504

Cam Tool & Engineering is a small tool and die shop facing

increased competition from larger tool shops and overseas

manufacturers. The company knew that in order to remain

successful, they would have to remove all bottlenecks from their

operations by reorganising their processes and employing the

latest technologies.

gained back? At what point does productivity surpass previous levels through the optimisation?

7. Get Buy-in: The optimisation plan results in a more streamlined operational approach, usually with fewer steps in the tool making process. Resistance to change is natural, so getting all parties involved in the process early on is crucial to its success.

8. Measure Results: Measuring success is an important part of the optimisation process. Using this approach, the company has been able to help tool shops achieve tangible and measurable results, with over 30 percent increase in productivity and up to 50 percent design cost reduction.

Enquiry No. 4503

Case Study: From Screen To MachineStreamlining operations give small companies big competitive edge.

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Often misunderstood, the concept of remanufacturing brings crystal clear benefits. By William C Gager, president, Automotive Parts Remanufacturers Association

Remanufacturing is the disassembly of products during which parts are cleaned, repaired or replaced then reassembled to sound working condition. A product is considered

remanufactured if its primary components come from a used product.

There are also other instances whereby a product is deemed remanufactured. When a product is dismantled to the extent necessary to determine the condition of

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its components, when its components are thoroughly cleaned (made free from rust and corrosion), when all missing, defective, broken or substantially worn parts are either restored to sound, functionally good condition, or when they are replaced with new, remanufactured, or sound, functionally good used parts.

Remanufacturing puts the product in sound working condition – such machining, rewinding, refinishing or other operations are performed as necessary. They are reassembled and determined that it will operate like a similar new product.

Other terms may be used interchangeably with remanufacturing in certain specific industry segments. One such term is rebuilt. Rebuilt is synonymous with remanufacturing when used in connection with motor vehicle parts and systems but not the entire vehicle. Recharged is synonymous with remanufacturing when used in connection with imaging products, such as laser toner cartridges.

Dispelling The Fallacy The definition of what remanufacturing is describes a process. If a product goes through this process it can be considered remanufactured. There are many terms, which may be confused with remanufacturing; including the following:

Recycled - A ‘recycled’ product may very well meet the minimum remanufacturing requirements; and

It may come as a surprise, but office equipmentlike toner cartridges are remanufactured as well.

many legitimate remanufacturers use this term to describe their product. However, many times a recycled product may be, as in the automotive sector, removed from a scrap vehicle and resold with little or no work performed on it.

Some recycled products are superficially cleaned, boxed and sold. Obviously, as described, recycled would not be considered remanufactured and its reliability is questionable.

Repaired - This is not a precise term. Essentially it means that the product has had enough work done to it to make it operational again, but this would probably not be considered remanufactured. A holistic root cause analysis is generally not performed in the repair process, which means the product may not perform like a new product.

Restored/Reconditioned - These are generic terms generally applied to antique or classic goods as opposed to a mass market consumer product.

Used - Generally, this is a product that has been subjected to previous use and is not new. Nothing has been done to repair it or correct any problems it may have. Therefore, its useful life is unknown.

In summary, when determining if a product is or is not remanufactured, it is imperative to consider first

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and foremost the process utilised. Some products are remanufactured more than others. They are motor vehicle parts, compressors, robots and aircraft parts.

Ultimate RecyclingInherently, remanufacturing has positive environmental ramifications. In fact, many organisations are now using the concept of remanufacturing, if not the term, in their environmental literature.

But why is remanufacturing considered the ultimate form of recycling? First, one must consider the definition of recycling. The term recycling is generally applied to consumable goods: such as newspapers, glass bottles and aluminium cans.

However, recycling can also apply to durable goods – such as an engine. Once these goods are consumed, they may be recycled, meaning they are removed from the waste disposal stream, returned to their original raw material form and serve as raw materials for a manufacturing process.

The environmental benefits of recycling are easy to comprehend; recycling reduces the quantity of waste headed for landfill space. If an engine were to be recycled, the steel from the item would be saved from the landfill space and could be used to produce another item requiring steel.

However, rema nu factur ing o f fers a bet ter alternative. According to an entry by professor Robert T Lund of Boston University in the book, ‘The American Edge: Leveraging Manufacturing’s Hidden Assets’, remanufacturing differs from recycling because remanufacturing ‘recycles’ the value originally added to the raw material.

According to professor Lund: “Remanufacturing differs from recycling also, most importantly because it makes a much greater economic contribution per unit of product than does recycling. The essential difference arises in the recapture of value added.”

“Value added is the cost of labour, energy, and manufacturing operations that are added to the basic cost of raw materials in the manufacture of a product. For all but the most simple durable goods, value added is by far the largest element of cost.”

He went on to say: “Even in a product as simple as a beer bottle, the cost of the basic raw materials (sand, soda, and lime) is much less than five percent of the cost of a finished bottle. The rest is value added. For a product such as an automobile, the value of the raw materials that can be recovered by recycling is only in the order of 1.5 percent of the market value of the new car.”

“Value added is embodied in the product. Recycling destroys that value added, reducing a product to its elemental value – its recoverable raw material constituents. Furthermore, recycling requires added labour, energy, and processing capital to recover the

raw materials. When all of the costs of segregation, collection,

processing, and refining are taken into account, recycling has significant societal cost. Society undertakes recycling only because, for all nondurable and many durable products, the societal cost of any other disposal alternative is even greater,” he concluded.

Other Environmental Benefits According to studies performed at the Fraunhofer Institute in Stuttgart, Germany, energy savings by remanufacturing worldwide in a year equals the electricity generated by five nuclear power plants or 10,744,000 barrels of crude oil which corresponds to a fleet of 233 oil tankers.

They also determined that raw materials saved by remanufacturing worldwide in a year would fill 155,000 railroad cars forming a train 1,100 miles (1,770 km) long. Because products that are remanufactured are kept out of the waste stream longer, landfill space is preserved and air pollution is reduced from products that would have had to be resmelted or otherwise reprocessed.

A product can always be recycled. Extending product life through remanufacturing though, is the key to leveraging the earth’s natural resources.

Enquiry No. 4505

Rebuilt is synonymous with remanufacturing when used in connection with machine parts.

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control solutions, cutting and welding gear, test and measurement equipments and tooling.

Supported by the Department of Industry, Indonesia and the Indonesian Moulds and Dies Industry Association, Surabaya, the opening hours are from 1100 – 1900 hrs.

Grand City Convention & Exhibition CentreSurabaya, IndonesiaJune 3 – 6, 2009

Enquiry No. 4601

EVENTs&ExhibiTioNs

Machine Tool & Manufacturing Indonesia 2009

East Indonesia’s manufacturing show is moving to a bigger venue this year. To be held at the Grand City Convention & Exhibition Centre, Surabaya, Indonesia from June 3 - 6, 2009, the 2,442 sq m

venue will showcase 239 exhibiting companies. Some 6,000 visitors are expected to attend this event.

The 2008 show experienced growth over the show in 2007 and with the investment in East Indonesia’s economy on the increase, the decision was made to move the show to a larger venue.

Exhibits on display will range from machine tools and metalworking technologies to automation and

Precision Engineering Business Forum 2009

Held over two days, on March 26 - 27, 2009, at Raffles City Convention Centre in Singapore, the event saw an participation of over 150 senior management and executives from

contract manufacturers, fabricators, semiconductor manufacturers and personnel from R&D and academia.

The key objective of the forum was to provide firms in the high-tech manufacturing sector with the momentum and know-how to increase their business channels through improved manufacturing strategies and R&D. Covering topics on aerospace, medical equipment, automotive and sustainable energy, the speakers and panelists addressed a spectrum of issues, including the required precision engineering capabilities and the necessary compliance of international standards and regulations for companies to penetrate these sectors.

These insights offered companies with the inroads to capitalise on the mid- and long-term growth potential of these strategic industry segments.

Desmond Goh, consultant at Frost & Sullivan, Singapore spoke on the opportunities in precision engineering for the aerospace industry in the Asia Pacific region. Despite the estimate that air traffic

growth will slow to six percent per annum, the strong showing by low cost carriers looks set to sustain growth in 2009.

Asia is poised to reap a larger part of the global aerospace manufacturing pie as “many OEMs are shifting production facilities to lower cost regions such as Asia Pacific,” said Mr Goh.

An ageing population and a rising middle class have also been identified as critical factors contributing to the rapid growth of the medical devices market in Asia – estimated to be worth US$65 billion in 2008 and growing by 10 – 12 percent.

Speaker Fredrik Nyberg, managing partner and co-founder of Biomedical Strategy Consultants said: “established products with well-defined manufacturing processes and low margins are strong candidates for outsourcing.”

Raffles City Convention CentreSingaporeMarch 26 - 27, 2009

Enquiry No. 4602

Organized by :

Truly world-class metalworking event for your stronger, more resilient manufacturing!• Get new technologies! Touch and see how over 1,000 new machinery and technologies save costs and increase productivity through live demonstrations.

• Expand your business into new markets! Bond new overseas relations in International Pavilions from China, Germany, Japan, Singapore, Thailand, Turkey, and the UK, that are bigger than last year!

• Achieve business and personal goals with new know-how and wider horizons in Conferences and Technology Presentations

• Special feature! Catch on with new tech and meet new people in electronics manufacturing industry in “Electronics Assembly 2008” offering the latest Surface Mount Technology from Singapore and more.

Thailand and Vietnam’s leading exhibition and conference organizer

Forging Vietnam’s Manufacturing

Excellence

www.metalexvietnam.com

Important Note! “METALEX Vietnam 2009” is open to trade visitors only. Please dress in business attire. Those wearing shorts and/or sandals and minors under the age of 15 will not be permitted into the exhibition

hall. The organizer reserves the right to refuse admission to anyone without cause or explanation.

Co-located Show:

Vietnam’s Only Machinery Expo for Electronic Parts and Components Manufacturing – 2nd Edition

Register to visit the show to get instant badge and show directory today at www.metalexvietnam.com.

For more information, please call Contact Center: (08) 842 7755 or e-mail: [email protected].

Co-organized by:Minh Vi Exhibition & Advertisement Co., Ltd.

• Vietnam’s Premier Machine Tool & Metalworking Event

• 500 global brands, 25 countries

• 7,000 buyers

• 20 Conferences & Technology Presentations

• Part of “METALEX,” Largest Event in ASEAN

The 3rd International Machine Tools and Metalworking Technology Exhibition

MXV2009_Visitor Ad_for APMEN_NN.1 1 3/30/09 2:24:53 PM

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8-10/10/099.00-17.00 hrs.

Saigon Exhibition and Convention Center (SECC)

Nguyen Van Linh Parkway, District 7

Ho Chi Minh City, Vietnam

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EVENTs&ExhibiTioNs

Vietnam’s manufacturing solutions trade event, MTA Vietnam, is scheduled to return to Ho Chi Minh City for its sixth edition from July 8 – 11, 2009 to a new venue, the Saigon Exhibition &

Convention Center (SECC) located on Nguyen Van Linh Parkway in the heart of Phu My Hung New City.

The previous edition in 2008 attracted over 7,700 local and overseas visitors to view exhibits showcased by 220 exhibiting companies from 26 countries/regions. According to a survey conducted with participating exhibitors and visitors, over 80 percent of exhibitors felt that their participation at the event was worthwhile.

More than 80 percent of visitors indicated that the show met their expectations, for its internationality of exhibitors, scope and range of exhibits, and potential for investment and business opportunities.

This year, the event will offer international exhibitors an avenue to promote their brand and achieve high visibility for their products and solutions in the Vietnamese market. Vietnamese buyers will gain direct access to a wide range of machine tools and solutions, as well as acquire valuable industry intelligence through networking with local and international business leaders and industry professionals.

More than 400 exhibiting companies from over 25 countries/regions (85 percent from overseas) will occupy over 9,000 sq m of exhibition space. The event this year will also feature a strong international presence with seven international group pavilions from Germany, Korea, Japan, Italy, Singapore, Taiwan and Thailand

MTA Vietnam 2009 will also incorporate Metrology Vietnam 2009, Tool Tec Vietnam 2009, Sub Con Vietnam 2009 and Automation Vietnam 2009. Opening hours are from 0900 – 1700hrs.

Saigon Exhibition & Convention Center (SECC)Ho Chi Minh City, VietnamJuly 8 – 11, 2009

Enquiry No. 4603

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productfinder

The By Spr int Pro 3015 is a high speed laser cutting system de s i g ne d for o p e r a t i o n a l and economic eff iciency. Its laser power has been increased to 4 .4 kW i n

addition to other improvements, making it an efficient laser cutting system for thin sheet metal applications.

Able to record speed when cutting thin metal sheets, the machine achieves the shortest part production times through the combination of high speed plasma cutting with machine dynamics.

Additional factors are compressed air cutting, the 3.75-inch cutting head and the short start-up time of the laser source.

Enquiry No. 4701

Bystronic: High Speed Laser Cutting System

Tailift: Punch Press Machine

Tailift has developed MAX1250X, a thick turret punch press with Advanced Servo Hydraulic System (ASHS) employing the Complex Multi Auto-Index Tools (CMAIT). The machine’s efficiency and flexibility ensures quality CNC turret punch press for your sheet metal processing needs.

ASHS allows fast punching, nibbling and forming of components while maintaining low noise emissions. The turret design is solid with minimal inertia and fast response speed. CMAIT offer the flexibility of 24 various sized tooling stations including four auto index D stations for multi tools 3B or 8A, giving more user options on the interchangeability of the tools used.

As a result, the number of auto index can be as much as 6 to 16 times that of conventional punch press machines.

Enquiry No. 4704

To date , 5 - a x i s m a c h i n i n g h a s o f te n f a i l e d to deliver visible cost-effective benefits. The machine by Makino puts an end to that issue.

T h e a i m s o f the D500 concept are crystal clear. T o o v e r c o m e cumulative error due to the increased number of axes and to provide acceleration performance unaffected by heavy table loads.

Only by resolving these issues can a 5-axis machining centre be a solution for production innovation.

Productivity in parts machining is achieved through multi-face machining and continuous unattended machining compatible with many automation systems.

Enquiry No. 4703

Makino: Cost Effective 5-Axis Machining Centre

The Super Mini Mill 2 from Haas Automation provides a combinat ion of high -speed capabilities, generous t r a v e l s a n d c o m p a c t footprint in an affordable package.

Despite its compact size, the mill offers extended

travels of f 20 inch x 16 inch x 14 inch (xyz) – a four inch increase on each axis over the standard milling machine. The machine comes equipped with a 15-hp vector drive spindle that spins to 10,000 rpm, and a 40 inch x 14 inch T-slot table that provides room for multiple fixtures or a single- or dual-axis rotary table.

The machine also comes standard with a coolant system, rigid tapping, a 15 inch colour LCD monitor and a USB port. High-productivity options include a 15,000-rpm spindle, a high-speed 24+1 tool side-mount tool changer, 4th- and 5th-axis drives and more.

Enquiry No. 4702

Haas Automation: High Speed Milling Machine



T h e L y n x s t e r e o microscope by Vision E n g i n e e r i n g , t h e U K he adqua r tere d manufacturer of stereo microscopes and non-contact mea sur ing systems utilises the Dynascope technology to offer ergonomics by removing the need for restrictive eyepieces. This system is meant for intricate tasks requiring high-resolution stereo viewing.

Aerospace components inspection tends to be challenging, as the components are complex and reflective, with curved and flat surfaces presenting reflections and glints. The machine uses a true, optical head, which presents a clear, sharp image without glare.

Enquiry No. 4708

Ma nu fac t u re rs o f c a s t i n g s , w e l d e d tubes, and numerous other complex parts, now have a more a f fordable way to i m p r o v e q u a l i t y control in their visual inspection process with the expanded line of Hawkeye Pro Flexible Borescopes

from Gradient Lens Corporation (GLC). The borescopes provide images of cracks, burrs,

voids, flash, surface-finish irregularities, and other defects that can affect the quality of a range of mission-critical products like fuel & hydraulic systems, engine blocks and medical equipment.

Key feature includes high-resolution, 18,000 fibre, acid-leached, optical-glass imaging bundles that produce images and give the scope flexibility to reach into twisting, narrow paths. The fibre bundles are engineered to reduce crosstalk between the fibres and increase image contrast.

Enquiry No. 4706

SmartScope Flash 1500 is a floor model measurement machine where the instrument head moves in the X axis across a steel bridge while the entire bridge moves on parallel tracks in the Y axis. The large measurement range of the machine accommodates large parts, such as LCDs, plasma displays, circuit boards, and multi-component fixtures.

The machine is multisensor capable. Its design allows the additional precision of multiple sensors; including touch trigger probes, micro-probes, and laser scanners.

Enquiry No. 4707

Optical Gaging Products: Multisensor Measuring Machine

T h e M i t u t o y o D T -10 hardness tester is economical and suitable for material testing of a variety of hard and soft metals.

A m a n u a l a r m actuator, which will start the ha rdne ss te st ing process, is one of the main features of this measuring equipment.

In addit ion, it a lso fe at u re s a ma x i mu m achievable workpiece height using a flat anvil of 170 mm with an adjustable dial indicator for zero-setting and fast throughput.

The unit is applicable for both Rockwell and Super Rockwell (scale N,T) testing.

Enquiry No. 4705

Mitutoyo: Economical Hardness Tester

Vision Engineering: Stereo Viewing Systems

Gradient Lens: Cost-Effective Flexible Borescope

productfinder



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ESI Group: Weld Planner

ESI Group, a supplier of digital simulation software for prototyping and manufacturing processes, has released Weld Planner, an enabling software to evaluate and control welding distortion engineering at the early stage of design and planning.

Said to reduce time-to-production, the new planner is simple to use for the uninitiated in finite elements simulation. Training to be fully operational can be done in a day as the planner offers fast generation or automatic finding of weld seams between parts; convenient definition of the welding sequence as a robot plan; typical industrial clamping conditions; and versatile possibilities for the visualisation of computed distortion.

Enquiry No. 4709

Mori Seiki: Interactive Training Software

productfinder

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In recent years, the number of customers who face difficulty in providing technical trainings for their employees has been growing due to the advancement and complexity of machine tools.

Education On Demand (EOD) by Mori Seiki is a human resource development tool, which reproduces machine operation systems by using interactive graphics, and allows anybody to learn a basic knowledge and technical skills for machines tools at anytime, anywhere.

Features of EOD include an online training system, interactive graphics and comprehension quizzes at the end of each chapter to help users acquire the consistent quality of knowledge.

Enquiry No. 4710

�

With the TORNOS/ALMAC SOLUTIONS, benefit froma single provider for all your high precision machiningneeds in MEDICAL and DENTAL applications!

TORNOS TECHNOLOGIES ASIA LTDUnit 4, G/F, Transport City Building1-7 Shing Wan Road, Tai WaiShatin, N.T., HONG KONGTel. +852 2691 2633 / Fax +852 2691 [email protected]

TORNOS S.A. THAILANDREPRESENTATIVE OFFICETel. +66 2 662 3908 / Fax +66 2 662 [email protected]

TORNOS TECHNOLOGIES ASIA LTDMALAYSIA REPRESENTATIVE OFFICETel. +60 4 263 0118 / Fax +60 4 262 [email protected]

For more information, please logon to www. tornos.com

Almac CU1007Versatility, Modularity

TORNOS Sigma 20 IIAccessibility, Simplicity

TORNOS DECO 13a/eConstant Production,Very Complex Parts



productfinder

Kennametal: Modular Drills

KSEM Plus modular drills, which combine the feed rates and length/diameter capabilities KSEM modular drills are known for with the speed and low consumable costs of indexable drills.

The tools consist a steel body coupled to a high-strength steel head. Kennametal designed the drill body to feature a central coolant hole that maintains rigidity while allowing maximum coolant flow through the tool.

A margin and relieved clearance eliminate trapping of chips between the drill body and hole wall to increase tool body life and improve hole surface finish, while differential helix flutes smooth chip evacuation and maintain rigidity.

Suitable for holemaking in steel, stainless steel, cast iron, and nonferrous alloy workpieces, the single tool body can handle a range of drill head sizes.

Enquiry No. 4712

MMC has manufactured a n i n d e x a b l e f a c e milling cutter series, the AHX640W for machining of cast irons. Cast iron that offers high durability and vibration absorption properties is used for

various components such as diesel engines, automotive suspension components and machine cases.

The AHX640W face milling cutter was designed to offer improved productivity and cost efficiency when machining both cast iron and ductile cast iron parts.

This is possible due to the design of the cutter itself, the use of a CVD tool grade MC5020 and the use of heptagonal neutral inserts. This grade offers increased weld chipping resistance and wear resistance. This leads to stable cutting edge wear patterns and assist in achieving higher machining productivity.

Enquiry No. 4714

MMC: Face Milling Cutter

VX Corp: Scalable Entry Level CAD

The VX Innovator was designed to put high-end CAD/CAM within reach from a cost, learning and scalability standpoint. Innovator by VX Corpof Florida, USA, is value-priced, comes pre-loaded with built-in tutorials and can be upgraded to any level of CAD/CAM including full mould & die, design and manufacturing.

Billed as a true hybrid modeller, it uses modelling tools which work with surface and solid geometry. It can import and work with poor geometry while its healing and surface editing tools are available to work with non-solid geometry.

It also allows the addition complex sweeps, lofts and domes to models as it comes with an entire suite of detailing and layout tools.

Enquiry No. 4711

Wenzel: CT Solution For Industrial Applications

Wenzel presents the integrated Computed Tomography workstation for the industrial applications. With this solution, contactless 3D measurements of inner and outer structures can be performed.

This enables non-destructive and timesaving inspections for many industry processes like quality control, test engineering and reverse engineering.

The manufacturer offers the full product range of this technology – the manufacture of the systems, software, services, trainings and consultation. With the workstation, the maker sets a standard in the price-performance-ratio. The integration of mechanical engineering from Wenzel and image quality detectors gives quality.

Enquiry No. 4713



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Tel: 65 6747 8946 • Fax: 65 6744 6687Email: [email protected] • Website: www.isatech.com.sg

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The Kestrel Non-contact Measuring Microscope• 2-axis non contact measuring• Eyepieceless Dynascope technology• High resolution high contrast images• Intuitive, user friendly microprocessor• Accurate and simplifed results

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May-Jun 2009 metalworking equipment news 79

ExhibitionProgrammEs2009maY

6 – 10Metaltech 2009Putra World Trade CentreKuala Lumpur, MalaysiaTrade-Link Exhibition [email protected]

6 – 10MTA Malaysia 2009Putra World Trade CentreKuala Lumpur, MalaysiaMalaysian Exhibition [email protected]

13 – 17Intermach 2009 BITECBangkok, ThailandCMP Media (Thailand)[email protected]/intermach/

28 – 30 Intermold Vietnam 2009Hanoi International Center for ExhibitionHanoi, VietnamReed Tradex [email protected]

27 – 29Aerospace Supplier eXchangeSingapore Expo SingaporeIIR [email protected]

JUnE2 – 5Die & Mould China 2009Shanghai New International ExpoShanghai, ChinaShanghai International Exhibition [email protected]

3 – 6Machine Tool & ManufacturingIndonesia 2008Surabaya Convention HallSurabaya, Indonesia PT Pamerindo Buana [email protected]

10 – 12Oil & Gas AsiaKuala Lumpur Convention CentreKuala Lumpur, [email protected]

25 – 28 Intermold ThailandBangkok International Trade and Exhibition CentreBangkok, ThailandReed [email protected]

25 – 28Automotive Manufacturing 2009Bangkok International Trade & Exhibition CentreBangkok, ThailandReed [email protected]

JUlY

8 – 11MTA Vietnam 2009 HCMCSaigon Exhibition & Convention Center Ho Chi Minh City, VietnamSingapore Exhibitions [email protected] www.sesallworld.com

15 – 18Eastpo 2009Shanghai New International Expo Center (SNIEC)Shanghai, ChinaEastpo International [email protected]

16 – 19MachinExpo Bangladesh 2009Bangladesh - China Friendship Conference CentreDhaka, [email protected]

24 – 27India Machine Tools Show 2009Pragati MaidanNew Delhi, IndiaK & D [email protected]

aUgUst

5 – 82009 Taipei International Mold & Die Industry FairTaipei World Trade Centre Nangang Exhibition HallTaipei, TaiwanChan Chao [email protected]/tw

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BIG DAISHOWA SEIKI CO LTD 17 081

BRUDERER PRESSES (FAR EAST) PTE LTD 35 197

DEES HYDRAULIC INDUSTRIAL CO LTD 77 190

DELCAM PLC (INTERNATIONAL DIVISION) 05 137

EVERISING MACHINE TOOLS 49 079

EXXON MOBIL ASIA PACIFIC 29 157

FRITZ STUDER AG 13 066

HAAS AUTOMATION INC 07 061

HORST WITTE GERATEBAU BARSKAMP E.K 43 080

IIR EXHIBITIONS PTE LTD 61 072

ISA TECHNOLOGY PTE LTD 77 078

ISCAR LTD FGC/IFC 085/069

KENNAMETAL INC BC 052

LEITZ METALWORKING TECHNOLOGY (ASIA PTE LTD 37 082

MESSE DUSSELDORF ASIA 11 076

MITSUBISHI HEAVY INDUSTRIES (THAILAND) CO LTD 55 086

MITUTOYO ASIA PACIFIC PTE LTD 53/47 073/074

MORI SEIKI (S) PTE LTD IBC 070

OPTICAL GAGING (S) PTE LTD 25 068

PREMIER EXHIBITION SERVICES SDN BHD 69 084

REED TRADEX COMPANY 71 067

SANDVIK SOUTH EAST ASIA PTE LTD (COROMANT DIVISION) 01 063

SECO TOOLS (S.E.A) PTE LTD 03 062

SINGAPORE EXHIBITION SERVICES PTE LTD 65 065

SM COMPONENT 77 031

SOFIMU SRL 19 083

TAEGUTEC LTD 15 064

TORNOS TECHNOLOGIES ASIA LTD 75 071

TRUMPF PTE LTD 21 077

WENZEL ASIA PACIFIC PTE LTD 27 075

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INTERMEDIA PARTNERS GMBH Tel: 49-202-271 6913 Fax: 49-202-271 6920 E-mail: [email protected]

JAPAN Ted Asoshina EcHo JAPAN coRPoRATIoN Tel: 81-3-3263 5065 Fax: 81-3-3234 2064 E-mail: [email protected]

KOREA Young-Seoh chinn JES MEDIA INTERNATIoNAL Tel: 82-2-481 3411/3 Fax: 82-2-481 3414 E-mail: [email protected]

SWITZERLAND Rene Bachmann MEDIALL SA Tel: 41-56-442 14 40 Fax: 41-56-442 27 77 E-mail: [email protected]

TAIWAN Robert Yu WoRLDWIDE SERvIcES co., LTD Tel: 886-4-2325 1784 Fax: 886-4-2325 2967 E-mail: [email protected]

U. KINGDOM Eddie Kania RoBERT HoRSFIELD INT'L MEDIA REP. Tel: 44-1663-750 242 Fax: 44-1663-750 973 E-mail: [email protected]

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❑ 315 Stamping

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❑ 304 Drilling/Boring

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©2009 Kennametal Inc. l All rights reserved. l A-09-02006

BY KENNAMETAL

FREE Insert OfferTo experience substantial cost savings, greater efficiencies, and improved productivity for yourself, contact your local Kennametal sales representative or authorized distributor

or visit www.beyondtooling.com.

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In recent controlled tests, Kennametal’s newest tooling platform beat the competition’s best 85% of the time! In 1,302 conducted experiments, BeyondTM proved to be 30%–300% more productive an astounding 1,100 times. That’s advanced engineering that is built to outperform — at any speed, on any application. And metalcutting innovation that delivers increased productivity leading to greater profitability.

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ENQUIRY NO 052

MEN May_Jun09

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