APMEN September 2013

www.iscar.com

Machining IntelligentlyISCAR HIGH Q LINES

www.iscar.com

Machining IntelligentlyISCAR HIGH Q LINES

ADVERTISEMEN

T

www.equipment-news.com

September 2013

‘MIll/TuRNINg’ INTo HIgH MIx PRoDucTIoN VENTuRINg INTo PE PRoDucTIVITy: Do MoRE WITH lESS

www.iscar.com

•ITA(IscarToolAdvisor)•CMSElectronicCatalog•InteractiveCatalogforTablets•InsertConverter•ProductID•MachiningCalculator•YouTubeTechTalks

Your Machining Mentor

SINO TOOLING SYSTEMBlk502,JurongWestAve1#03-813Singapore640502Tel + 6565667668Fax+ [email protected]

ISCAR THAILAND57,59,61,63SoiSamanchan-BabosSukhumvitRd.PhraKhanong,KhlongToeyBangkok10110Tel +66(2)7136633Fax+66(2)[email protected]

CV MULTI TEKNIKRukoGsaBlcokBNo.8BN-BP,PodomoroCityJL.LetjenS.parmanKav.28JakartaBarat11470IndonesiaTel +622129206242/44/45/[email protected]

ISCAR JAPAN 1-5-3Shinsenri-HigashimachiToyonaka-shi,Osaka560-0082Tel [email protected]

MESCO RelianceCornerBrixtonSt.PasigCityMetro-ManilaPhilippinesTel + 6326311775Fax+ [email protected]

ISCAR TAIWAN395,DaDuenSouthRd.Taichung408Tel+886(0)424731573Fax+886(0)[email protected]

ISCAR VIETNAM (RepresentativeOffice)RoomD2.8,EtownBuilding,364CongHoa,TanBinhDist.,HoChiMinhCity,Tel + 84838123519/20Fax+ [email protected]

ENQUIRY NO 171

MACHINING COMPETENCEAT YOUR SERVICE.

WWW.SECOTOOLS.COM/SG

COMPETENCE

TECHNOLOGY

PASSION

PRECISION PERFORMANCE

FLEXIBILITY

STRENGTH

EFFICIENCY

RELIABILITY

NEW TURBO 10 SHOULDER MILLHigh performance square shoulder milling for all materials. Machine it faster and consume less power. NEW DOUBLE OCTOMILLTM 05 FACE MILLSmall 16-edged inserts. 1 edge in use and 15 waiting to perform.

NEW SMALL SQUARE 6TM SHOULDER MILLSmall 6-edged, double sided inserts. A new level of performance and economy for small machines.

MACHINING DNAYes, there is a common DNA string that connects these milling cutter systems: it is performance and cost efficiency. High cutting data, smooth cutting action and the most edges per insert. Deployed with our application support & machining competence, these tools will make a measurable difference in your production environment.

Milling ad 1 EQN mag 2012 new Corp ID V2.indd 1



COMPETENCE

TECHNOLOGY

PASSION

PRECISIONPERFORMANCE

FLEXIBILITY

STRENGTH

EFFICIENCY

RELIABILITY







COMPETENCE

TECHNOLOGY

PASSION

PRECISION PERFORMANCE

FLEXIBILITY

STRENGTH

EFFICIENCY

RELIABILITY





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

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

30 Opinion: Michael Grimm On PEAsia Pacific Metalworking Equipment News (APMEN) caught up with Michael Grimm, director of Sales, (Key Accounts, Asia Pacific) Kennametal Singapore and spoke with him on the issues surrounding PE. By Joson Ng

36 Case Study: In-Line Quality Inspection For Engine ManufacturingAn in-process inspection system has allowed more accuracy and operational reliability. By Jarrad Morden, NDI

24 Improve Processes With Turn-Milling & Less ChatterAndrei Petrilin of Iscar dissects the world of milling, starting with turn-mill, and looks at how chatter can be reduced by conducting milling intelligently.

CUTTING EDGE20Feature Story: ‘Mill/Turning’ Into High Mix ProductionFacing increasing complexity and more varied products, a contract manufacturer in Singapore has turned to machines that add versatility and flexibility to their production capability. By Joson Ng

SOFTWARE & METROLOGY32 Optical Technology Showing Good Measuring TouchGOM’s Dr Carsten Reich gives his take on optical measuring techniques. By Joson Ng

TECH TALK28 The PE VentureAsia Pacific Metalworking Equipment News (APMEN) sat down with Dr John Yong, director of the Precision Engineering Centre of Innovation (PECOI) to find out more on Precision Engineering (PE) and its importance in Singapore. By Joson Ng

CONTENTSSeptember 2013

FORM.JOIN.CUT38More Multi-Axis Processing Expected In AerospaceIn the aerospace industry, smaller components with a higher accuracy requirement will facilitate the usage of more laser cutting systems that have the ability to move into the realm of multi-axis processing. By Mark W Barry, Prima Power Laserdyne

Best choice.

Make it easy

Carl is clever. Thanks to the BySoft 7 software package he maintains a complete overview and executes orders fast, economically and reliably. He constructs parts in 3D and 2D, generates cutting and bending plans, prepares and monitors his production. Take a leaf out of Carl’s book. Make it easy.

Laser | Bending | Waterjetbystronic.com

ENQUIRY NO 162


CONTENTS

80pgREGULARS08 Business News72 Product Finder79 Exhibition Programmes80A Product Enquiry Card

Refer to Advertising Index

For Advertiser's Enquiry Numbers

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

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

Federation of Asian Die & Mould Associations (FADMA)

China Machine Tool & Tool Builders'

Association (CMTBA)

Indian Machine Tool Manufacturing

Association (IMTMA)

Federation of Malaysian Foundry & Engineering

Industry Associations

Singapore Precision Engineering and Tooling Association (SPETA)SPETA

INDUSTRYEndorsements

Machine Tool Club(MTC)

IMPORTANT NOTICETHE CIRCULATION OF THIS MAGAZINE

IS AUDITED BY BPA WORLDWIDE.

THE ADVERTISERS' ASSOCIATION

RECOMMEND THAT ADVERTISERS

SHOULD PLACE THEIR ADVERTISEMENTS

ONLY IN AUDITED PUBLICATIONS

Taiwan Association of Machinery Industry (TAMI)

September 2013

INDUSTRY FOCUS44 Medical Industry: In The Pink Of HealthThe medical industry is trending upwards at the moment and this can have a positive impact to even those involved in its supporting industries.

46Metalworking: Helping the Medical Industry Save LivesThe use of metals in the medical industry has greatly expanded the usage of medical devices, many of which are crucial in saving the lives of patients. By Shahnawaz Abdul Hamid

42Five-Axis Waterjet Technology: A New DimensionPrecision waterjet cutting shops around the world are taking their business to the next dimension with advanced five-axis waterjet technology. By Nancy Lauseng, Jet Edge

56Limiting Factors To Prevent Machine Crash The combination of mechanical torque limiters and electronic torque limiting can go a long way in preventing machine crashes. By Niilo Nykanen, R+W Antriebselemente

FEATURES54Special Report: Asia PacificIIW International CongressAsia Pacific Metalworking Equipment News (APMEN) was amongst welding experts from all over the world, to look at recent developments in welding and joining technologies. By Joson Ng

ExECUTIvE ZONE48Do More With Less Asia Pacific Metalworking Equipment News (APMEN) sat down with Dr Moh Chong Tau, chairman of the Singapore Workforce Development Agency (WDA) Precision Engineering Industry Skills & Training Council (PE ISTC) and the president & CEO of Makino Asia to talk about productivity, an issue close to his heart. By Joson Ng

PARTING SHOT 78

EvENTS & ExHIBITION 58Event Review: MTA Vietnam Event Review: JEC AsiaEvent Preview: Wire & TubeEvent Preview: MITF 2013Event Preview: Metalex Vietnam

ENQUIRY NO 017

Editor’sNotE


Published by:

EaStErn tradE MEdia PtE Ltd (a fully owned subsidiary of Eastern Holdings Ltd)

Reg No: 199908196C

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

etm EasternTrade Media Pte Ltd

an Eastern Holdings Ltd company

managing director Kenneth Tan

senior editor Joson Ng [email protected]

business development manager Randy Teo [email protected]

senior sales manager Derick Chia [email protected]

sales manager Melvin Wong [email protected]

editorial assistant Sharifah Zainon [email protected]

graphic designer Jef Pimentel [email protected]

circulation executive Samantha Tan [email protected]

contributorsAndrei PetrilinMichael GrimmJarrad MordenMark W BarryShahnawaz Abdul HamidNancy LausengNiilo Nykanen

board of consultants Wäinö a Kaarto AB Sandvik Coromant

dr Moshe Goldberg ISCAR

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

Printed in Singapore by Fabulous Printers Pte Ltd

MCI (P) No. 050/06/2013PPS 840/09/2012 (022818)ISSN 0129/5519

Many industry vert ica ls are now enjoying growth, especially in the region of Southeast Asia. For example, the automotive industries are driving t he economie s o f T ha i la nd a nd Indonesia forward; Singapore has been looking skywards in pursuit of the aerospace sector and is now beginning to taste the fruits of her labour; meanwhile, other countries in the region like Malaysia are dipping their feet into medical device production.

Behind any high-flying segment is an indigenous support industry to help prop up the multinational big boys. The unsung heroes in this case are the contract manufacturers or job shops.

I n t h i s i ssue o f A sia Pac i f i c M e t a l w o r k i n g E q u i p m e n t N e w s (APMEN), the manufacturing landscape of Singapore is very much in focus. We look at the challenges contract manufacturers are facing now in the ever- changing manufacturing environment, and how they continue to find relevance by forging a meaningful relationship with their customers. For our main feature, we v isited Disk Precision, a Singapore -based

contract manufacturer, to see how they made the transformation to a high mix production model by using multitasking machines.

In the area of precision engineering or PE, we spoke to Dr John Yong, the director of the Precision Engineering Centre of Innovation (PE COI), to see how the country identifies industries with high growth opportunities and shores up weaknesses in its manufacturing structure, in order to execute a precise and comprehensive strategy to attract multinationals to invest in the country.

Lastly, we spoke with Dr Moh Chong Tau, chairman of the Precision Engineering Industry Skills & Training Council (Workforce Development Agency), to tap on his considerable experience in helping the workforce achieve a higher level of productivity.

For many big countries, manufacturing is a numbers game. Blessed with a big pool of labour or resources, they hold all the trump cards. For smaller countries like Singapore, skill, productivity and resourcefulness are perhaps the only cards they get to play in the globalised game of manufacturing.

Joson NgSenior Editor

chairman Stephen Taygroup executive director Kenneth Tan

EastErn HOLDInGs LtDExEcutIvE BOarD

SingaporeManufacturing

win

terg

erst

& fa

iss

powered by Tiger·tec® Silver

The new generation of mills from WalterBlaxx™ stands for a reliable system which captivates the user with its absolute precision and stands out through its extremely high productivity. The Blaxx™ F5041 and F5141 shoulder mills are therefore based on a newly developed, incredibly robust tool body, which is fitted with the most efficient of Walter indexable inserts, powered by Tiger·tec® Silver.

Find out more about the unbeatable combination of Blaxx™ and Tiger·tec® Silver now: www.walter-tools.com

Walter AG Singapore Pte Ltd20 Science Park Road#01-04A/05, Teletech ParkSingapore Science Park IISingapore 117674Tel: +65 [email protected]

Watch trailer:

PoWerfuL, PreciSe, reLiAbLe.

AZ_W_Mi_Blaxx_EN_WSG_205x275_RZ_000dpi.indd 1 19.09.12 10:37

ENQUIRY NO 084

Bombardier To Deliver Technology For Metro Line In RiyadhBerlin, Germany: Bombardier Transportation, as a member of the ArRiyadh New Mobility Consortium (ANM), has won a contract to deliver technology for the metro line three in Riyadh, Kingdom of Saudi Arabia. The contract involves system interface management, project management and design, as well as the delivery of 47 two-car driverless Bombardier Innovia Metro 300 trains equipped with Bombardier Mitrac propulsion technology. The total value of the consortium’s contract is approximately US$5.9 billion with the company's share valued at approximately US$383 million.

The metro system will comprise six metro lines totalling approximately 176 km, which will form the backbone of the city’s public transport network. All six lines are to be implemented over five years.

Line three, also known as the Red Line, is a turnkey project that includes the civil construction of the 40.7 km alignment, including 22 stations, electrical and mechanical equipment and rolling stock. The consortium comprises two groups that will design, build, construct and commission Line three.

Delcam Rated World’s Leading CAM Software Specialist For The 13th Year

Birmingham, UK: The latest NC Software Market Analysis Report from US analysts CIMdata shows that, in 2012, Delcam had the highest vendor revenues and received the highest end-user payments of all the CAM-centric companies.

This means that the company has completed 13 years as the world’s leading specialist supplier of CAM software and services, having first achieved its global leadership in 2000, despite a number of mergers and acquisitions that have created some larger competitors.

CIMdata found that the company continues to increase its market share. The company’s share of vendor revenues grew from over seven percent in 2011 to 7.3 percent in 2012. A further increase in market share to over 7.5 percent is predicted by CIMdata for Delcam in 2013.

SIA: Quarterly Semiconductor Sales Increased By Six PercentWashington DC, USA: The S e m i c o n d u c t o r I n d u s t r y Associat ion (SIA) has sa id t h a t w o r l d w i d e s a l e s o f s e m i c o n d u c t o r s r e a c h e d US$74.65 billion during the second quarter of 2013, an increase of six percent from the first quarter when sales were US$70.45 billion. This marked the largest quarterly increase in three years.

Global sales for June 2013 hit US$24.88 billion, an increase of 2.1 percent compared to June 2012 and 0.8 percent higher than the May 2013 total. Regionally, sales in the Americas jumped 8.6 percent in Q2 compared to Q1 and 10.6 percent in June 2013 compared to June 2012, marking the region’s largest year-over-year increase of 2013.

“There’s no question the global semiconductor industry has picked up steam through the first half of 2013, led largely by the Americas,” said Brian Toohey, president and CEO, SIA. “We have now seen consistent growth on a monthly, quarterly, and year-to-year basis, and sales totals have exceeded the latest industry projection, with sales of memory products showing particular strength.”


Businessnews

Dual-Turn Edition

The DS-30Y | 4+2 turning & milling | Affordable Haas price.

E-Z setup

Turn X & Z axis

Mill C & Y axis

Singapore +65 6274 1222 Philippines +63 2 915 8725

Malaysia +603 5569 5901 +6019 6631 901

Haas Factory OutletVietnam +84 8 38 44 71 92

Indonesia +6221 29094177

Thailand +66 2726 7191 +66 3811 2700

www.HaasCNC.com ENQUIRY NO 157

UCIMU: Foreign Machine Tool Orders Increased Slightly In Q2

Italy: In the second quarter of 2013, the index of orders for machine tools, developed by the Studies Department of UCIMU-Sistemi Per Produrre, registered a g row t h o f 0 .7 p e rce n t , due to the posit ive results collected abroad.

H o w e v e r, t h e i n d e x o f dome st ic orders recorded a decrease of 21.2 percent co mp a re d to t he a l re a d y di f f icult second quarter of 2012. On the foreign front, the index of orders increased 6.2 percent, interrupting the negat ive ser ie s reg istered beginning with the second quarter of last year.

On a semi-annual basis, the index recorded a decrease of six percent, determined by the poor response obtained by the builders on the Italian market (-29.6 percent) and by the weak foreign demand (-1 percent).

“This latest survey,” said Luig i Ga ldabin i , president o f U C I M U , “ s n a p s h o t s t h e d i f f i c u l t y c u r r e n t l y f o u n d a m o n g t h e I t a l i a n manufacturers of machine tools in dealing with an almost non-ex istent domest ic dema nd in addition to a reduction in foreign demand.”

MMC Posted An Operating Income Of JPY16.0 Billion

Tokyo, Japan: Mitsubishi Motors Corporation (MMC) has posted an operating income of JPY16.0 billion (US$162 million), a seven percent or JPY1.1 billion increase over the same period in the last fiscal year. The increase came despite a two percent or JPY9.9 billion decrease in consolidated net sales over the first quarter of fiscal 2012.

The reason for the growth in operating income was due mainly to favourable exchange rates as well as reductions in material and other costs which together overcame such negative factors like decreases in wholesale volume and increases in sales expenses including advertising costs.

Along with the increased non-operating income from factors including foreign exchange gains, MMC posted an ordinary income of JPY22.3 billion, a 57 percent or JPY8.1 billion increase year-on-year. Net income for the term amounted to JPY16.4 billion, an 18 percent or JPY3.6 billion decrease year-on-year. This is without the benefit of a JPY11.4 billion in extraordinary income from the sale of stock in affiliates like what was recorded in the first quarter of last fiscal year. Global retail sales volume for the first quarter of fiscal year 2013 totalled 249,000 units, a four percent or 10,000-unit increase over the same period last fiscal year.

Indonesia: Daihatsu Motor ( Da ihatsu) w i l l ex tend its production line for passenger c a r e n g i n e s a t i t s A s t r a Da i hat su Motor (A DM ), a subsidiary in Indonesia, also a ke y o v e r s e a s b u s i n e s s

Daihatsu To Strengthen Engine Manufacturing Capability In Indonesia

location. The production line will have an annual production capacity of 200,000 engines. The extended line is scheduled to run from the summer of 2015.

F o r t h e p u r p o s e s o f i n c r e a s i n g t h e c o s t

competitiveness of the engines and continuously improving their quality, engine production will be shifted in stages from the existing line to the new line. The total production capacity w i l l not c ha n ge f rom t he current level. By means of this extension, the company will further step up its operations in Indonesia.


Businessnews

TaeguTec Ltd. World Headquarters1040, Gachang-ro, Gachang-myeon, Dalseong-gun, Daegu 711-865, KOREATel: +82-53-760-7640 Fax: +82-53-768-8055 www.taegutec.com

Argentina _ Australia _ Belarus Rep. _ Belgium _ Brazil _ Chile _ China _ Croatia _ Czech Rep. _ Denmark _ Finland France _ Germany _ Greece _ Hungary _ India _ Indonesia _ Ireland _ Italy _ Japan _ Malaysia _ The Netherlands _ New ZealandPakistan _ Philippines _ Poland _ Portugal _ Romania _ Russia _ Serbia _ Singapore _ Slovakia _ SloveniaSouth Africa _ Spain _ Sweden _ Taiwan _ Thailand _ Turkey _ Ukraine _ United Arab Emirates _ United Kingdom _ U.S.A. _ Vietnam ENQ

UIR

Y N

O

16

7

Tüv Süd PSB Appoints Richard Hong As CEO Singapore: Tüv Süd PSB has appointed Richard Hong as CEO for the ASEAN region. Mr Hong has over 18 years of experience in product certif ication and international compliance management for information technology equipment, home appliances, wireless products and audio-visual products.

APPOinTMenTs

Richard Hong

NUM Increases Asian Presence With South Korean Office

Seoul, South Korea: NUM has opened a subsidiary for applications support, sales and after-sales service in Seoul, South Korea, to serve the country’s growing market for CNC machine tools. This is the fourth Asian office for the CNC vendor, and results directly from the company's core business strategy of placing skilled applications engineering resources at the disposal of customers to help them develop machine solutions.

South Korea is the third largest economy in Asia, and is highly export-driven. The country has a diverse manufacturing base of indigenous, local and international companies, with a particularly strong presence in the electronics, semiconductor, automotive, shipbuilding, machine tools and luxury products markets, as well as a flourishing financial services sector.

Fluke Awarded The 2013 IDEA For Product DesignEverett, US: For the second year in a row, the Industrial Designers Society of America (IDSA) has honoured the industrial design team at F luke Corporat ion with an International Design Excellence Award (IDEA).

I t i s a n i n t e r n a t i o n a l competition honouring design e x c e l l e n c e i n p r o d u c t s , ecodesign, interaction design, packaging, strategy, research, and concepts. The Fluke team won a Bronze Award in the

The high number of machine builders and machine tool OEMs in South Korea — the country is close to becoming the fourth largest producer, and user, of machine tools in the world — demonstrates the long term stability and sustainability of the CNC market in this part of Asia.

As Robert von Arx, the company’s director of business development, explains, “South Korea's amazing manufacturing success is continually creating opportunities for its machine builders, ma ny of which a re sma l l to medium size companies with limited engineering resources. However, bigger sized enterprises often face similar issues. Our new subsidiary can support such companies, enabling them to seize their chances. We wil l help them to ta i lor CNC systems to suit their particular applications, to create unique machinery solutions, and get to market further.”

Commercia l and Industr ia l Products category for its work on the Fluke 805 Vibration Meter.

The meter is a tool for t e c h n i c i a n s p e r f o r m i n g p r e v e n t a t i v e b e a r i n g inspections. It teaches the user how to get an accurate reading by calculating how hard it is being pressed against a motor. When the user applies the correct force, a ring around the handle lights up: green for "ready to measure” and red for “try again.”

“Precision vibration analysis is a science requiring complex equipment and know-how, so the challenge in designing the 805 was to create a handheld tool that simplifies the measurement process,” said Matthew Marzynski, industrial design manager for Fluke Corp. “By designing an interface that makes measurement taking and interpreting the results easy, we created a product that anyone on the maintenance crew can use successfully.”


Businessnews

Tungaloy Singapore Pte. Ltd.31 Kaki Bukit Road 3#05-19 TechlinkSingapore 417818Tel: (65) 6391 1833 • Fax: (65) 6299 4557www.tungaloy.co.jp/tspl/ ENQUIRY NO 165

Toyota’s Indonesia Engine Plant To Go Online In 2016

Zeiss Industrial Metrology Shares Expertise In Northern Thailand

Singapore: In collaboration with Thai Ministry of Labour, Department of Skill Development and Skill Development Centre Division 10 Lamphang, Zeiss Industrial Metrology was invited to Lamphun, a northern province in Thailand to promote and share knowledge in industrial measuring technology with manufacturers.

This is in l ine with the goal of the ASEAN Economic Community (AEC) in developing human resources and building capacity. The Thai government is looking increasingly into raising labour skills and developing manufacturing skills. A metrology centre will also be established at Siam Tool Engineering, acting both as a demonstration and knowledge facilitation centre in the area.

Toyota City, Japan: PT Toyota Motor Manufacturing Indonesia (TMMIN) will start producing engines for vehicles other than the IMV series at an engine plant due to go online in the first half of 2016. The site for the plant, near TMMIN's Karawang plants, was acquired last year.

The engine plant will have an annual production capacity of 216,000 engines. Approximately JPY23 billion (US$233 million) is to be invested in the plant, for which approximately 400 new employees are to be hired.

The company currently produces engines for IMV series vehicles at its Plant One Sunter for export to other ASEAN countries, as well as to Latin America and Africa. Engines for standard passenger cars produced at the new plant will also be exported, thereby furthering Indonesia's position as a key engine production and supply base.

Schuler On Track Göppingen, Germany: The latest figures of Schuler confirm expectations for a stable fiscal year 2012/13. With consolidated sales of €851.6 million (US$1.1 billion) after nine months, the press manufacturer a lmost reached its high prior-year figure of €877.8 million.

Growth in Germany and the Americas compensated for shortfalls in other regions. The

company was able to make up lost ground in new orders during the third quarter — especially in its North American business.

Orders received during the first nine months however fell by 20.1 percent to €836.5 million. The engineering company had already forecast a fall in mid-December 2012, as orders returned to normal levels following two exceptional years with new orders worth €1.3 billion in each year.

In the f irst nine months

of its current fiscal year, the company achieved an operating result before interest, taxes, depreciation and amortisation (Ebitda) of €83.1 million (prior year: € 84.1 million). The Ebitda margin rose once again from 9.6 to 9.8 percent. With a consolidated profit of €34.6 million (prior year: € 34.5 million), equity rose by 13.2 percent to €276.9 million while the equity ratio improved from 27.1 percent at the beginning of the fiscal year to 28.1 percent.


Businessnews

Hexagon Metrology Nurtures Talent For The Industry

India: In order to promote skill enhancement in using Coordinate Measuring Machines (CMMs), Hexagon Metrology has stationed its ‘Explorer 575’ CMM at IMTMA Technology Centre and at the International Exhibition Centre, Bangalore.

The company, in collaboration with Indian Machine Tool Manufacturers' Association (IMTMA), has been organising training courses and workshops to promote exchanges between manufacturers, users and experts in the field of metrology.

This collaboration is a step towards the company’s commitment to providing a range of products to the industry that can help customers improve quality and production efficiency in their plants around the world. To stay ahead of competition, the company understands the need to adapt to the changing needs of specialised metrology industry and continuously engage and reinvent its skilled professionals.

Recently, the company and IMTMA organised a course with hands-on training in effective use of CMM at the IMTMA Technology Centre. The purpose of this training course was to deliver training to metrology professionals and help them hone and expand their practical dimensional metrology skills, resulting in increased productivity and improved competitiveness. The course covered all the aspects a practicing CMM engineer requires to know for effective use of CMM for reliable measurement results. EN

QU

IRY

NO

1

58

23rd InternationalS

heet M

eta

l Work

ing T

echnolo

gy E

xhib

ition

Sheet metal, Tube, Section Joining, WeldingFinished products, Parts, Assemblies Handling Forming Separation, Cutting Surface treatmentFlexible sheet metal working Machine elements Tube / Section working Composites Tools, DiesData capture / processing CAD/CAM systemsControlling, Regulating, Measuring, InspectionSafety at work Environment protection, RecyclingFactory and warehouse equipment R&D

Your finest products for a

forward-thinking trade audience

EuroBLECH 2014 – innovation, quality and business on a global scale

www.euroblech.com

21- 25 October 2014Hanover, Germany

EB_Advert_AsiaPacificMetalWorking_80x240_en.indd 1 04/07/2013 14:56September 2013 asia pacific metalworking equipment news www.equipment-news.com 15

Businessnews

PwC: Global Light Vehicle Assembly To Reach 81 Million Units In 2013

Detroit, US: Global light vehicle assembly is expected to reach 81 million units in 2013, an increase of 2.3 percent compared to 2012, according to Autofacts, PwC’s automotive analyst group. While the global market is expected to see positive growth overall, there are a number of mixed signals at the regional level.

North America and developing Asia-Pacific markets are driving most of the growth, while developed Asia-Pacific is expected to see continued declines as assembly is localised abroad. The European Union, meanwhile, is not expected to see volume recovery until 2014.

“Economic performance is anticipated to remain mixed through the remainder of 2013,” said Rick Hanna, PwC’s global automotive leader. “However, we do see light at the end of the tunnel and are forecasting a global compound annual growth rate of approximately five percent, double the 2013 rate, through 2017.”

Strong growth in developing Asia-Pacific, improving stability in the EU and investment in new technologies will drive the industry forward. The group forecasts that the annual global light vehicle assembly to reach 101 million by 2017.

Global Automotive Industry TrendsEuropean Union: While assembly was expected to recover in 2013, Autofacts is forecasting a ye a r- over-ye a r drop o f fou r p ercent to approximately 15.3 million units in EU assembly.

New vehicle demand fell by 4.7 percent in June, and 8.1 percent year-to-date, while the light commercial vehicle sector continues to decline, with registrations down 7.3 percent in May and 6.2 percent for the first five months of the year.

North America: While the world is waiting for the recovery of the EU, North American sales and assembly increased through the first half of 2013, contributing 13.4 percent to global growth. The region is forecasted to contribute approximately 770 thousand units to the global top-line growth in 2013.

Developing Asia-Pacific: Light vehicle sales showed strong growth in 2013 compared to 2012, with developing Asia-Pacific delivering an increase of 2.24 million units. Particularly notable are SUVs and MPVs, up 45.1 percent and 26.8 percent, respectively, compared to last year. Although 2013 has started off well for vehicle assembly, Autofacts is forecasting a modest 9.7 percent growth in assembly for the full-year, and jumping to 13.2 percent in 2014, despite global economic climate constraints.

R&D Growth: R&D continues to grow as the industry approaches a new era of innovation and collaboration. The analyst group forecasts a steady release of new technologies into vehicles over the coming years, while others are not expected to reach mass production for some time. Hybrid, electric and fuel cell vehicle production accounted for roughly 2.8 percent of global light vehicle assembly in 2012.

This is expected to increase to approximately five percent by 2017, as industry collaboration drives costs down and performance metrics are simultaneously improved. The development and integration of new technology into vehicles to improve safety, fuel efficiency, communications and infotainment continues to accelerate and proves to be an increasing trend in the auto industry.

Mitsubishi Electric Acquires FA Tech In ThailandTokyo, Japan: Mitsubishi Electric Corporation has acquired FA Tech, a Factory Automation (FA) product distributor and long-time partner in Thailand, to expand the company's FA business there, which is already

experiencing growth. Through the acquisit ion, Mitsubishi Electric expects to raise FA sales in Thailand to JPY20 billion (US$210 million) by the fiscal year ending in March 2018.

The acquisition will strengthen

the group's FA solution, sales and technical capabilities. Growth is forecast in Thailand's factory automation market, particularly in the automotive industry, which is attracting increasing foreign investment.

Light vehicle sales showed strong growth in 2013 with developing Asia-Pacific delivering an increase particularly in the SUVs and MPVs segments.

Daniel Oines, USA


Businessnews

ENQUIRY NO 174

Optical Gaging (S) Pte Ltd21 Tannery Road, Singapore 347733Tel: 65 6741 8880 • Fax: 65 6741 8998E-mail: [email protected]: www.smartscope.com.sg

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

Do you need to measure accurately the medical devices

you make? You need to look closer at SmartScopes®

from OGP.® Look closer at the number of measurements

you can get in a single setup. Precise dimensional

measurements with vision, laser, touch probe, and

micro-probe technologies – all calibrated to a common

XYZ reference frame. Look for powerful 3D metrology

software for graphic visualization and numeric analysis

data. If accurate measurements are important to you, look

closer at OGP SmartScope metrology systems.

Optical Gaging (S) Pte LtdA Quality Vision International Company

JMTBA: Machine Tool Orders Dipped Slightly In June

Japan: According to JMTBA, total monthly machine tool orders exceeded JPY 95 billion (US$972 million) for two consecutive months, and domestic demand increased as well. The association also reported that the investment environment in Japan and overseas is heading toward steady improvement.

Domestic orders rose by 9.9 percent over May, amounting to JPY 32.05 billion. This marked the second consecutive month of increase. Despite the upward trend, the figure was a decrease of 7.9 percent from the same month of the previous year and marked 13 consecutive months of year-on-year decline.

However, in the grand scale of things, the total value of machine tool orders in June was a decrease of 2.0 percent compared to May and marked the first month of decline in two months. This figure also represented a decrease of 12.4 percent compared to the same month of the previous year, with June posting the 14th consecutive month of year-on-year decline.

Looking at major industries, orders compared to May fell by 4.5 percent in industrial machinery, rose by 24.5 percent in motor vehicles, fell by 3.3 percent in electrical and precision machinery, and rose by 89.5 percent in aircraft, shipbuilding and transport equipment.

Foreign orders fell by 7.1 percent from May to JPY 63.13 billion. This marked the first month-on-month decline in two months. Foreign orders showed a decrease of 14.5 percent from the same month of the previous year, with June posting the ninth consecutive year-on-year decline.

By region, orders from Asia fell by 16.9 percent from the previous month to JPY 25.0 billion. This was also a decrease of 40.9 percent from the same month of the previous year. Orders from Europe rose by 8.0 percent over May to JPY 12.76 billion. This was also an increase of 24.7 percent over the same month of the previous year. Orders from North America fell by 3.7 percent from May, amounting to JPY 23.77 billion. However, this was an increase of 20.1 percent over the same month of the previous year.

Total orders for the first half year of 2013 (Jan-Jun) totalled JPY 517.26 billion, which was a decline of 18.7 percent from the previous year. Total domestic orders fell by 13.1 percent from the previous year to JPY 173.41 billion. Total foreign orders fell by 21.3 percent from the previous year to JPY 343.84 billion.

BASF To Invest In Resin Plant In Shanghai To Support Automotive Coatings

Shanghai, China: BASF is investing around €90 million (US$119 million) to set up a production plant at the Shanghai Chemical Industry Park in Shanghai, China. The plant will produce resins and electrocoat (e-coat). The start-up of the production line is planned for the second half of 2015. It will help to address the increasing demand for high quality coatings solutions in growing industries, notably the automotive industry, in Asia Pacific.

“The continued investment in our infrastructure and capacity de mo n st ra te s ou r s t ro n g commitment to supporting our customers’ growing business in the automotive market in Asia Pacific, particularly in China,” said Peter Fischer, senior VP, Coatings Solutions Asia Pacific. “With the new plant in place, we will respond to customers even quicker and further enhance our efficiency of logistics and supply of advanced coatings products.”

This resin and e-coat plant will be located adjacent to another BASF automotive coatings plant which broke ground in early 2013. The close proximity of these two plants will allow for more synergies and efficiency.

Resin is a key intermediate used in the production of various types of coatings. The facility will supply resins to support the company’s expanding coatings production and growth plans.

Sebastien Batardy, Luxembourg

Despite a slight dip, total monthly orders still exceeded JPY 95 billion for two consecutive months. On the other hand, domestic demand also increased.

Visit us at these shows!


MITF 2013October 9-12

Metalex Vietnam October 10-12

Metalex Thailand November 20-23

Intermach Myanmar 2013October 24-26

Manufacturing Indonesia

December 4-7


Businessnews

Singapore’s Manufacturing Sector On The Up

Daewoo International Starts Production From Myanmar Gas Field Kyauk Phyu, Myanmar: Daewoo International has started gas production from its Myanmar gas field. The three gas fields of Shwe, Shwe Phyu, and Mya, which were discovered by the company since 2004, contain over 4.5 trillion cubic feet of buried gas available for exploitation, and together represent the largest oil and gas field in scale discovered by a South Korean company abroad in the past 30 years.

As the facilities required for gas production and sales including the offshore production platform, undersea pipeline, ground gas terminal, and ground pipeline have been completed over the past four years, the company can now produce 120 million cubic feet of natural gas daily for export to China and utilisation in Myanmar.

Once gas production is fully on line, starting in the second half of 2014, 500 million cubic feet of gas will be produced daily and sold to CNUOC for the coming 25 to 30 years. This amount of natural gas converts to 860,000 barrels of oil, which is the daily usage of 670,000 homes. The company expects the Myanmar gas fields to generate KRW 300 to 400 billion (US$269 to 358 million) of profit yearly.

Manufacturers in Singapore expect business conditions to improve

Singapore: In the manufacturing sector, a weighted 13 percent of manufacturers expect business conditions to improve while a weighted five percent foresee deterioration in the second half of 2013. Overall, a net weighted balance of eight percent of manufacturers anticipate a more favourable business situation in the next six months ending December 2013 compared to the second quarter of 2013.

Despite the positive sentiment, the manufacturing sector continues to be concerned about the global macro-economic environment, in particular the US, EU and China.

Within the manufacturing sector, the general manufacturing industries cluster is the most optimistic. A net weighted balance of 17 percent of firms expect business situation to improve in the second half of 2013 compared to a quarter ago. The miscellaneous industries segment expects continued support from domestic construction activities.

The precision engineering and electronic clusters also anticipate better business conditions in the six months ahead ending December 2013. In the precision engineering cluster, a net weighted balance of 11 percent of firms expect more orders ahead.

This positive sentiment is noted in the semiconductor related equipment and machine tools industries within the machinery & systems segment. In the electronics cluster, a net weighted eight percent of firms expect better business prospects in the second half of 2013. Within the cluster, the semiconductor segment is the most upbeat, as it expects a seasonal uptick in orders over the next six months compared to the second quarter of 2013.

Output Forecast Compared to the second quarter of 2013, a net weighted balance of five percent of manufacturers expect output to increase in the third quarter of 2013. All except the biomedical manufacturing cluster foresee higher production in the next three months.

The general manufacturing industries cluster is the most bullish with a net weighted balance of 17 percent of firms expecting a higher output level in the third quarter of 2013 compared to a quarter ago.

In the transport engineering cluster, a net weighted eight percent of firms project a higher level of activity in the third quarter of 2013 compared to the preceding quarter. This optimism is led by the marine & offshore engineering and land segments. The former expects to record a higher percentage of work done in the yards and the latter foresees more orders for land transport equipment.

jjcb

Your Intellectual

Property

September 2013 asia pacific metalworking equipment news www.equipment-news.com 19

Businessnews


In the manufacturing arena, the tried and tested model of high volume, low mix continuous production

has been facing some headwinds over the past few years. With end products that are more varied, manufacturers have to adopt a new strategy in production and embrace the model of low volume, high mix.

While this paradigm shift may not be particularly welcomed by some, it is necessary to be flexible and sensitive to the prevailing market trends in order to stay relevant. Unfortunately, implementing a low volume, high mix production model is not just a matter of adopting a new doctrine. There are many challenges (both human and technical) to overcome in order to make this crossover.

ChallengesThe transition from a high volume, low mix model to a low volume, high mix model

m a y s o u n d simple on paper but on the shop floor, this migration requires much commitment from the management and also heavy investments.

In Yishun, located at the northern part of Singapore, Disk Precision is a contract manufacturer that supplies

Facing increasing complexity and more varied products, a contract manufacturer in Singapore has turned to machines that add versatility and flexibility to their production capability. By Joson Ng

Feature Story:

‘Mill/Turning’Into High Mix Production

From left: Adrian Lim, FL Leong & Vincent Leo

various industries like oil & gas, automotive and aerospace. With history in supplying the disk drive industry, the company understands the importance of producing quality parts and for many years, has invested in various systems and machines to ensure that they ride existing trends and are ready for the current market requirements.

CuttingEdgE


Their transition took place some seven years ago when they started diverting from the hard disk drive market. F L Leong, group executive director said: “Because of some price erosion, we shifted (hard disk drive production) to our Malaysia plant. Over here (Singapore), we started to invest in some high-end machine.”

Referring the change in manufacturing philosophy as “a different ball game altogether,” Adrian Lim, the group’s MD, went on to illustrate the problems that came with a high mix manufacturing environment.

According to him, the number of setups invariantly went up because of the high mix nature of production and that gave rise to the need to use a different management system to monitor the situation, which is more complex in nature compared to the past.

He added: “Initially, the challenge was putting a new management system in place. As our manufacturing management system in the past was based on continuous production, a lot of focus was on efficiency and output, ie: hitting the target for every shift.

Coming into high mix low volume, the technical skill of our workers started to take a higher level of importance. We have to train our machinist to achieve a higher skill level. Setup time, machine downtime and efficiency are the main areas we have to focus on.”

Vincent Leo, executive director, also weighed in on this issue. He said: “In terms of challenges, besides the utilisation of machines, we also faced difficulties in terms of planning. Planning for such production is different. Instead of using a normal Excel spreadsheet, we had to move on to using Microsoft Project and we are currently implementing an ERP system to help us.”

Overcoming Difficulties With VersatilityThe natural progression towards

a high mix environment culminated in the

purchase of machines that offer versatility. Painting an example with a DMG CTX Alpha 300, a universal turning machine with integrated spindle motors for fast acceleration and deceleration, Mr Leo said some parts were manufactured previously using a split process, ie: turning followed by milling. That process required one setup on the turning machine and one or two setups on the milling machine. The output is between 10 to 20 pieces.

“Together, we used up to six to eight hours to setup two or three machines. Setting up one machine took four hours,” he said. In terms of machining time, Asia Pacific Metalworking Equipment News (APMEN) understands that it varies depending on part complexity but by and large, the company experienced a 30 percent reduction in machining

The natural progression towards a high mix environment culminated in the purchase of machines that offer versatility.

Disk Precision

Established: 1986

Locations: Singapore, Malaysia, Thailand

Total number of employees: 600

Yishun plant: 40,000 sq ft 70 employees Three shifts, eight hours each

Fact File

The company experienced a 30 percent reduction in machining time after they adopted one machine for all processes.

CuttingEdgE


t i m e a f t e r t h e y

adopted one machine for all processes. Along with a reduction in time, better quality and accuracy can be achieved.

Using a particular part that goes into a pump in the oil and gas industry as an example, Mr Leo said: “Using a multitasking machine makes it easier to control the positioning of holes.” He added multitasking machines not only improve consistency and reduce scrap; the task is easier compared to using separate machines.

The ability to manufacture parts in one setting also helps push down fixturing costs, which in turn, brings down the total cost of manufacturing the part. Fixturing and other reductions result in “easily 20 to 30 percent

lower costs,” said Mr Leo.

The story of Disk Precision is a familiar one that many contract manufacturers in the country have experienced or are going through now. The days of high volume production of low value parts are coming to an end in Singapore. This is the age of delivering not just good quality parts but good value. In order to stay ahead or survive, versatility is crucial and contract manufacturers have to invest in their employees as well as machines to do just that.

Gradual Transition & ProgressionThe pursuit of quality comes at a price — investments in capital equipment.

F L Leong, group executive director of Disk

Precision told Asia Pacific Metalworking

Equipment News (APMEN) that they were

established in 1986 in a small factory

unit in Toa Payoh and were very active in

supporting the hard disk drive industry.

“We started with a very simple

Japanese machine. In 1992, we moved to

Yishun and that was the time we started

looking for better machines with higher

output,” he said. He revealed that their

initial investments were 10 units of Mori

Seiki turning machines.

With an estimated floor area of 40,000

sq ft, the Yishun plant houses some 70

staff today. Altogether, the group employs

some 600 workers in three countries

(Singapore, Malaysia and Thailand). The

company is not stopping there however,

as Adrian Lim, group MD, shared with

APMEN that the company is also looking

at Vietnam.

The growth in business also went

hand-in-hand with capital investments in

machine tool. Although the company is

used to working with Mori Seiki machines,

they bought their first DMG machine four

years ago. After a series of test cuts on an

aluminium part for the automotive industry

and a three-month trial period, they bought

the CTX 310 Ecoline. They shared that the

main draw of the machine is its ability to

reduce cost.

The part in question is made of titanium

for the aerospace industry. Using a five-axis milling machine (DMU 65 monoblock), 20 pieces of the

part can be manufactured

from one block in

about 5.5 hours.

Enquiry No. 6002Turn to page 80a or log on to www.equipment-news.com to enquire


Dr Christian Braun, MD of DMG/Mori Seiki (SEA) joined the folks from Disk Precision to study the parts made with the DMU 65 monoblock.

From raw materials to finished parts (right), that is what contract manufacturers do.

CuttingEdgE

InnovatIve band saw blades for your requIrements of today and tomorrow

Customised band saw blades and support for higher efficiency

Made in Spangenberg, made in Germany. www.wikus.com

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

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

WIKUS-SägenfabrikWilhelm H. Kullmann GmbH & Co. KGmelsunger str. 3034286 spangenbergGermany tel.: + 49 5663 500 – 0eMail: [email protected]

ENQUIRY NO 130


Turn-milling is a process w h e r e b y a m i l l i n g c u t t e r m a c h i n e s a rotating workpiece. This

method combines milling and turning techniques and has many advantages, but only the introduction of multitasking machine tools have allowed turn-milling to display its benefits.

For years, even with the mass adoption of CNC technology, development of metal cutting machine tools was deemed traditional. It is therefore not surprising to see the progress of specific machines like turning, milling or drilling moving in separate directions.

In a bid to explore new ways of making manufacturing process more ef f icient ( by reducing settings of a machined part and its transfer from one machine to another), a tool head with rotary drive was

Improve ProcessesWith Turn-Milling & Less ChatterAndrei Petrilin, technical manager (Indexable Milling) of Iscar dissects the world of milling, starting with turn-mill, and looks at how chatter can be reduced by conducting milling intelligently.

added to typical CNC turning machines a nd a l lowed the realisation of turn-milling.

Today’s modern multitasking m a c h i n e t o o l s f e a t u r e additional axes of the head movement, advanced control systems and upgraded software

that provide the opportunity to perform the majority of machining operations with only one setting per workpiece.

Noticing The DifferenceIn turn-milling, there are two principal methods of machining:

CuttingEdgE


Shhhh…Cut The Chatter

The chatter — vibration in metal cutting — poses an eternal headache for

manufacturers. In machining, harmless vibration brings about poor surface

finish, loss of accuracy, reduced tool life and intensive wear of critical machine

tool parts. While trying to prevent these negative effects, the manufacturer is

obliged to use expensive vibration-resistant tooling devices and reduce cutting

data that lead to an increase in production costs and lower productivity.

Indexable milling inserts with an asymmetric shape offer an interesting

solution. They open new opportunities for the reduction of vibrations in metal

cutting and lead to a rather different approach for the design of vibration-

proof inserts.

In metal cutting, every possible mean of reducing vibration is an important

factor for improving performance. There are various technological methods

intended for this objective: changes in workholding principles, using more

rigid clamping fixtures, and adopting toolholders with vibration damping

properties, etc.

Exploring Other Designs

The field of special interest is in specific principles that allow the creation of

a robust vibration-proof cutting tool. As for these principles, there are a few

possibilities. An unequal tooth pitch (angle pitch) gives good results. In the

case of solid carbide endmills, a variable helix angle significantly improves

chatter stability.

Also, a cutting edge with chip splitting action has definite advantages and

effectively helps in reducing vibrations. In addition, a combination of the above

can be very successful.

Attempts to apply these principles to indexable milling cutters (with inserts)

are often met with difficulties. Making a chip splitting cutting edge has led to

considerable success. However, making indexable milling tools with a variable

positive axial rake is associated with a lot of design constraints. Varying axial

rake angle by changing the inclination of an insert pocket is actually very

limited: a correct design has to ensure proper tool back clearance. Evidently,

a step forward here requires another solution.

A Different Approach

A typical laydown indexable milling insert features rotational symmetry of its

peripheral, when axes of a workpiece and a cutter are parallel; and face, for which these axes cross. Peripheral turn-milling is similar to milling by helical interpolation and may apply both to external and internal surfaces of the revolut ion, whi le with the use of face turn-milling, only the external surfaces can be machined.

Although turn-milling may appear very similar to turning (turning by rotating mill), there is a substant ia l di f ference between these two machining processes. The cutting speed in turn-milling is defined by the peripheral speed of the milling cutter and not by the rotary velocity of the workpiece like in turning. The workpiece rotation relates to feed.

Advantages Of Turn-Milling & Its Application • First of a l l , machining of

non-continuous surfaces may cause interrupted cutting (eg: various grooves, undercuts). In c lassica l turning, this operation results in unwanted impact load, poor surface finish and early tool wear. In turn-milling, the tool is a milling cutter that is intended exactly for interrupted cuts with cyclic load.

• Machining mater ia ls that produce long chips. In turning, chip disposal is difficult; and finding a proper chipbreaking geometry on a cutting tool is not a simple task. The milling cutter used in turn-milling generates a short chip that considerably improves swarf handling.

• Take for example, machining eccentric areas of rotating c o m p o n e n t s s u c h a s crankshafts or camshafts: In turning, off-centre masses

CuttingEdgE



of these components (eg: crank journal, eccentric cam) cause unbalanced forces that adversely affect performance. Turn -mil l ing with its low rotary velocity of a workpiece g i ve s t he p o s s ib i l i t y to prevent this negative effect.

• A lso, consider machining heavy-weight parts: Their ro t a t io n , w h ic h d e f i n e s cutting speed in turning, is connected with the limitations of the main drive of a machine tool. If the drive does not allow rotation of large masses with the required velocity, cutting speed is far from the optimal range, and turning per formance wil l be low. Tu r n - m i l l i n g prov ide s a way to overcome the above difficulties effectively.

Indexable face milling cutters are good tools for turn-milling. However, productive machining with the use of the turn-milling method demands right cutter positioning with respect to the workpiece, correct choice of insert geometry and tool path.

Cu t te r p o s i t io n i n g , fo r in sta nce , in f lue nce s for m errors, and insert geometry. The f ina l shape is usua l ly produced by a wiper insert, which is mounted on the cutter. The quest ions of apply ing turn-milling, tool choice and defining cutting data deserve fuller consideration and should be examined specifically.

Introducing turn -mil l ing into the manufacturing process can solve serious problems and substantially improve your output. Productivity using this relatively new and promising machining method is possible when you have a suitable modern machine and correctly chosen cutting tools.


cutting edges about an axis perpendicular to the insert base. As a rule, it is the

axis of a mounting hole.

There is a one-sided insert that uses a different approach. The insert has two

helical cutting edges, but their inclination to the base is different. Consequently,

when the insert is clamped into a tool, its cutting edges produce various axial

rakes. As a result, the achieved result is basically similar to the variable helix

angle of the solid endmills, which has been so effective in the reduction of

vibrations during machining.

It is important to note that the asymmetric insert is suitable for existing milling

cutters. This feature results in an improvement in the cutters’ performance in

shoulder milling when the rigidity of a technological system is low (eg: high cutter

overhang, thin-walled workpiece, problematic workholding, etc). Consequently,

the tool life of the insert increases by 15 to 20 percent and power consumption

is reduced by 10 percent or even more in some cases.

More Options

According to tool manufacturer Iscar, the new approach for designing

indexable inserts is promising. Development of powder metallurgy and pressing

technology will bring further increase in the height difference between corners

of an insert and therefore expand possibilities of changing the axial rake.

Chatter has a complex nature. Simulating vibrations is difficult — it depends

on many factors. In the design stage, simulation does not always help to find

the geometry of a vibration-proof indexable milling cutter for broad-spectrum

applications. Therefore, the ability of simple ‘cutter tuning’ for a vibration-free

mode by changing the order of insert clamping looks promising.

Turn-milling method demands right cutter positioning with respect to the workpiece and correct choice of insert geometry and tool path.

CuttingEdgE

Nothing compares to Equator™

- one gauge, many applications

To see Equator in action call +65 6897 5466 or scan the code

The unique new Equator™ is a versatile alternative to

traditional gauging, offering inspection of an unprecedented

variety of manufactured parts. It has been developed and

proven on the shop-floor with industry-leading gauging users

in multiple industries and applications.

Nothing compares like Equator™

Benefits which can be gained by using Equator™ include:

• Reduced gauging costs

• Robust shop floor measurement process

• Reduced production bottlenecks

Singapore T +65 6897 5466 F +65 6897 5467 E [email protected]

Thailand T +66 2 746 9811 F +66 2 746 9816 E [email protected]

Malaysia T +60 3 5631 4420 F +60 3 5631 5407 E [email protected]

Indonesia T +62 21 2550 2467 F +62 21 2550 2555 E [email protected]

ENQUIRY NO 108


material into a thin sheet with variable thickness is not energy efficient. Therefore, there is a need now to develop that process. At PE COI, we are developing a hybrid process to produce components of different thicknesses.”

While machining processes are well-entrenched in many of the job shops in Singapore, he highlighted the need for companies to get the best out of the five-axis machines. To Dr Yong, it is about understanding the capabilities of the machine and utilising it to secure some of the higher value and more complex jobs. Therefore, it is important for machinists to realise the full potential of their machines.

As far as technology trends go in the machining field, Dr Yong sees a greater need to machine exotic materials like Inconel and titanium, mainly due to the rising demand in the aerospace and oil & gas sectors. According to him, it is important for PE companies to equip themselves with relevant competency for the emerging markets because certain capabilities are required to serve those industries.

“We are working with companies that are interested to venture into those growing sectors. As such, we have initiated and will be launching several collaborative industrial projects on the machining of exotic materials as well as the welding of exotic materials. These experiences are important; without it, the MNCs

won’t consider you (the contract manufacturer). We are preparing our companies, to enable them to secure projects on those fronts,” he said.

Finally, APMEN asked Dr Yong about the happenings on gun drilling for the oil & gas drill column. In his response, he divided his answer into two parts. “In this industry, oil exploration will go deeper and tools to carry out the work will be subjected to harsher environments.

To minimise the number of joints in the drill column, the tube that is used to bore the hole will be longer and the aspect ratio of the drill will be higher. Secondly, material development will lead to higher usage of exotic materials that can withstand higher temperatures and wear,” he said.

Asia Pacific Metalworking Equipment News (APMEN) sat down with Dr John Yong, director of the Precision Engineering Centre of Innovation (PE COI) to find out more on Precision Engineering (PE) and its importance in Singapore. By Joson Ng

The

PE Venture

Precision Engineering is a key enabler for most manufacturing industries in Singapore, be it in

tooling or processes,” said Dr Yong. This statement aptly applies to metalworking and also Singapore’s manufacturing scene. According to him, the reason for saying so is, unlike other countries where PE is usually a capability embedded within a particular sector such as marine or medtech, it is far more important in Singapore.

“In the Singapore context, PE is a sector itself,” he said. “This is quite a significant sector in Singapore, contributing to 11.1 percent of the overall manufacturing output in 2012, according to MTI’s economic survey.” With manufacturing endeavours in the country dependent on PE, it is important to keep up with the developments in this sector.

Technology Trends In PE In sheet metalworking, he felt that the area of combined stamping and forging would garner more popularity in the next five years.

He said: “At this moment, sheet forming is geared towards producing parts with constant thicknesses. The industries however, are increasingly demanding parts with different thicknesses. This can be achieved by machining but it is not cost effective. This is similar for forging; pressing a thick bulk

Picking Out The ‘PE’ At PE COI

• Liquid Forging Of High Aspect Ratio Parts Nearshapeformingofhighaspectratio

partsfeaturingaluminium,magnesiumandcopper

• Milling Vibration Solver Prevents machining chattering by

predictingoptimalparameters

• Spin Forming Of Metal Components Near net shape cold forming of

cylindricalhollowcomponents

Dr John Yong

TechTalk




Actively ExploreThe PE landscape in Singapore is such that most companies involved in this sector are most likely contract manufacturers. Being proactive, receptive to challenges, and having the zeal to explore new opportunities are the advice Dr Yong would give PE job shop owners in the country.

“Many of the PE companies will look at the sectors and assess the capabilities that they have. They usually come to us with drawings and ask us for the best ways to make a part. Through these industrial collaborative projects, we help them understand some of the new processes. This exposure serves to educate them as well. From there, they can identify the areas closest to their current business and try to get business in that field,” he said.

From Traders To ManufacturersBeing the director of PE COI, Dr Yong has many success stories that highlight the importance of

PE. He shared three examples with APMEN.

“Component Technology embarked on an R&D project with us. Through this, the company developed the world’s first 3D optical wire bond measurement system. That system can help reduce inspection time from 10 seconds to 0.3 seconds,” he said.

This equipment distributor turned OEM story is by no means the only one he has seen; another company is Stamford Tyres. They transformed from a distributor and retailer for tyres and rims to wheel manufacturing.

Nine years ago, Dr Yong and his team worked with them on a project on casting aluminium wheels. Together, they managed to develop

manufacturing plant capabilities to produce high performance and quality alloy wheels. In addition to the casting processes, heat treatment and simulation know-how were imparted as well.

Tru-Marine is the final example listed by Dr Yong. He said the company, which specialises in the maintenance, repair and overhaul of turbochargers in marine, offshore, power plant and locomotive applications, collaborated with PE COI in a project that involved the development of reclamation procedures. Laser Aided Additive Manufacturing (LAAM) was used to achieve quality and productivity gains.

PECOIissitedattheSingaporeInstituteofManufacturingTechnology(SIMTech),a

researchinstituteoftheAgencyforScience,TechnologyandResearch(A*STAR).The

centreshowcasesandpromotesPEthroughknowledge&technologytransferandindustry

development.Inordertodoso,thecentreidentifieshighgrowthareas(typicallythosewith

CAGRofmorethaneightpercent)andseekstoestablishavaluechaininSingaporetoserve

thosesectors.

WorkingalongsideothergovernmentagenciesandMNCs,theconsortiumworkson

understandingtheecosystemanddiscussestheirfindingsaswellasmakesproposals

duringindustryroundtablesessions.Forinstance,whenagapinthevaluechainisidentified,

strategiesareestablishedtocompletethechain.

AccordingtoDrYong,thetypicalprocesstakesaboutsixmonthsandthedatacollected

isupdatedeveryyear.Thisexerciseisimportantbecauseifgapsinvaluechainsarenot

addressed,highvalueprojectsmaygoelsewhere.Forexample,surfacefinishingandheat

treatmentsimulationsaresomeoftheareasthatarelacking(intermsofexpertise)toserve

thegrowingsectorsinSingapore.Theidentificationandthesubsequentcorrectiveactions

areessentialtohelpSMEsinSingaporemoveintherightdirection,inparticular,towards

highvalueproduction.

“Inthepast,PEcompaniesgoforbuilt-to-printprojects.Lookingforward,theyaregetting

intomorevalue-addedprojectsorintoproductspace.Withinproductspace,theybuildto

specificationandincorporatedesignelements.Thekeythingisthattheybuildmodulesinstead

ofcomponents.Thisiswherewewanttohelpmoveourcompaniesinto,”saidDrYong.

PE COI

The centre developed many technical know-how together with private companies.

TechTalk


APMEN: In your opinion, how do you define Precision Engineering (PE)? A big part of PE is the repeatability and stability of the process. Do you agree? What are the technical trends in PE?Michael Grimm (MG): PE is a wide term. It starts with the tolerance definition in the design phase of the components. We see that for example in engines, tolerances are getting tighter to achieve the latest pollution standards and to get the same power out of engines with half the size than those from 10 years ago.

This is only possible if those tighter tolerances can be held under mass production conditions. For critical dimensions, statistical capabilities of Cpk 1.67 or even 2.0 have to be achieved, which basically reduces the tolerance band to half.

On one hand, this requires machines which can guarantee this process stability, for example, by means of machine beds made of mineral concrete with internal thermal stabilisation. On the other hand, the ‘human factor’ needs to be minimised. Automated manufacturing cells or lines with in-process measurement and ‘self-adjusting’ tools are recommended for this.

APMEN: What are the latest technologies Kennametal can offer in this field?MG: When developing tools for precision machining, we have put specific focus on reducing the human influence on the performance of the tool.

This starts with ‘fool proof’ design to avoid assembly of wrong cutting inserts. For solid or brazed round tools, we offer a reconditioning service which assures the same tolerances as with a new tool.

For adjustable tools like our

RIQ reamers, Romicron fine boring tools and Expandable Reaming System, we have made tool setting as simple as possible.

- RIQ reamers for example, do not require the time-consuming back taper adjustment.

- The Romicron system allows repeatable diameter adjustment in ‘feelable’ steps of 2 µm inside the machine. This can even be automated if the machine spindle has CLB (Closed Loop Boring) capability. The Romicron

Asia Pacific Metalworking Equipment News (APMEN) caught up with Michael Grimm, director of Sales, (Key Accounts, Asia Pacific) Kennametal Singapore and spoke with him on the issues surrounding PE. By Joson Ng

Opinion:

Michael Grimm On

Precision Engineering

Tool settings are made as simple as possible for adjustable tools.

Michael Grimm

TechTalk



AVS also provides automatic balancing capability to make the system more stable in high speed machining condition.

- Expandable reaming system will achieve three times IT6 (up to 300 percent tool life) with its wear compensation expandable capability. The accuracy can reach 2 µm in diameter by adjusting the screw.

APMEN: What is the advice you would give to job shop owners in Asia who are trying to improve their level of precision in various metal cutting processes?MG: We would suggest investing in equipment, which reliably keeps process stability at zero or requires minimum operator influence over a long time. Operators change, have different skillsets, or need to be trained. This calls for automated systems, where the operator just loads the parts into a magazine and/or concentrates on the optimisation of the overall manufacturing process.

This might look more expensive upfront, but will definitely pay off in mid-term. Also, this gives a good chance to machine shops to specialise in the operations where they can add the most value, ie: to buy pre-machined parts and concentrate on precision machining only.

APMEN: Do you have any interesting anecdote(s) from your customers on how they managed to achieve a good level of precision and consistency in their metalworking processes?MG: Sure, there are many of those. Here, I like to highlight an example from a Tier 2 supplier in Asia that makes brake components and connecting rods in medium lot sizes for different OEMs on flexible equipment.

He makes conrods on four-spindle machining centres and had an issue in holding the tolerance

of the pin bore (40 µm tolerance band, surface finish window between Rz 7 and 13), resulting in high rejection rates (up to 100 pc per day), short tool life (only 100 pc), and complicated tool setting (two hours per set-up, unreliable setting, differences in gauge diameter and actual component diameter different, breakage of setting elements and therefore high repair costs) — although he used an expensive reamer of a famous global company. All in all, it resulted in inconsistent daily output and high costs.

By changing to the Romicron system, tool life more than doubled, rejection rate reduced below 0.5 percent, tool set-up time reduced to 15 minutes, and tool repair cost went to zero.

The customer’s output is now consistent, and downtimes and cost per part went down tremendously. In addition, by using more advanced cutting parameters, we could even save four seconds in the cycle time per part.

To achieve precision machining, there is a specific focus on investing in equipment, which reliably keeps process stability at zero or requires minimum operator influence.

Expansion always reversible: Rotate the Allen wrench to contract the reamer.

TechTalk


Al t h o u g h t a c t i l e measurement is a highly competent technology, its basic principle of

operation requires a physical connection or ‘touch’ in order for measurements to take place. In a rapidly moving world, the limitation of this technology is being exposed with more regularity, giving rise for the need of a new measuring technology, ie: optical measurement.

Optical measurement is a technique that relies on the use of optical sensors to collect measurements. The main trigger for its usage and the key technological enabler is explained

by Dr Carsten Reich, GOM’s product manager (Automation).

According to him, the growing demand for good design and

product quality made full -field component inspection necessary. That, in addition to the advancement of computers at the start of the 90s, led to the rise of optical metrology in industrial applications because by using computers, image information could be digitised and analysed.

Tactile Vs Optical MeasurementThere are plenty of opinions on whether tactile or optical measurement is better, but it is unlikely to ever have a clear winner. As such, it is better to focus on the pros and cons of each technology and decide which technology is better suited for a particular process.

According to Dr Reich, there are instances when optical techniques have an edge over traditional tactile methods. Speed is namely the issue here.

He said: “The measurement data can be analysed immediately and compared directly with the CAD data or a 2D drawing. D e v i a t i o n s f ro m C A D a re highlighted in colour and easy to recognise as problematic areas, enabling specific improvements to be made to the manufacturing process. This largely eliminates unnecessary iteration loops, thereby saving valuable time as well as money.”

Another pertinent point is the role that optical measurement

GOM’s Dr Carsten Reich gives his take on optical measuring techniques. By Joson Ng

Showing Good Measuring Touch

OpticalTechnology

Dr Carsten Reich

Optical measurement is a technique that relies on the use of optical sensors to collect measurements.

Software &MeaSureMent

ENQUIRY NO 163




p l a y s i n a u t o m a t e d 3 D measurement, which is touted by him to be on the rise.

“The vision of manufacturing in the future sees each component p ro d u c e d a n d m e a s u re d completely in 3D. Component faults will automatically be corrected dur ing the manufactur ing process. We still have a long way to go but it is a fact that full 3D component measurement can only be achieved with optical measurement processes.

Optical inline metrology is therefore set to gain ground in the future. One pioneering example is the production of doors and closures for the latest VW Golf in Wolfsburg (Germany). Atos systems (3D digitiser) already monitor the quality of engine hoods, tailgates and doors on the individual production lines,” he said.

H e a d d e d t h a t o p t i c a l metrology helps companies cut product development and production start-up times, making them competitive. Moreover, users of optical measurement systems can make the transition from idea to product faster, optimising their manufacturing workflows and minimising scrap produced during manufacturing at the same time.

Although optical measurement

may have a slight edge over tactile measurement, Dr Reich said there are areas where tactile processes may still come out on top.

He said: “As things stand today, tactile measuring technology may offer advantages for features with minimal manufacturing tolerances and to areas that are not easy to access for optical measurement.” Places like cooling ducts or

deep cylinder bores that need closer inspection were listed as examples.

Optical Measurement In AsiaDr Reich shared with Asia Pacific Metalworking Equipment News (APMEN) that he sees Asia as a strong production environment as his company’s solutions are increasingly implemented in all fields, especially in automotive, aerospace, consumer goods as well as casting and forging industries.

In terms of presence in Asia, he revealed that the company has representations in “more than a dozen countries” and will continue to strengthen its presence in the region, which he thinks is “growing and exciting.” The region is also important in a financial sense. He said Asia amounts to a “significant percentage” of global sales annually.

The Atos ScanBox from GOM is the first standardised solution for automated measurement

and inspection processes. The mobile optical 3D measurement machine was developed

for automated quality control in production environments.

Unlike conventional, tactile coordinate measurement devices, the machine can be

moved from site to site. It can be set up in one day and integrated into production processes.

All that is required is a power source.

At the heart of the measurement cell is a robot-guided Atos Triple Scan 3D digitiser. This

technology achieves fast, non-contact, and full surface measurement of components. The

measurement and inspection processes in the machine are fully automated, meaning even

regular production personnel can control the processes via the simplified user interface.

GOM: Mobile 3D Measuring Machine

Manufacturing in the future sees each component produced and measured completely in 3D.

Software&MeaSureMent

ENQUIRY NO 169


Ea c h y e a r, S c a n i a , a Volkswagen company based in Söder täl je , Sweden, manufactures

more than 80,000 truck, bus, marine and industrial engines. Engine blocks are built using a u t o m a t e d m u l t i - s t a t i o n machining and assembly cells, whereby each machining centre forms one node of a lean flow line. Cells are linked via automated conveyers and a robotised material handling system.

Inspecting machined engine blocks is a key element of the company’s quality control process, and dimensional quality checks are conducted to measure 33 unique part features against an inspection plan. The engine block is

transferred to a pneumatic lift table from a conveyer transfer system for inspection; however, the system is not capable of exact positioning, and the lift table is not rigid.

The operator is free to reposition the lift table to optimise working height and ergonomics. They also need to consider the range and alignment of the metrology instruments.

The company’s previous metrology instrument had a limited measurement volume and could not accurately compensate for movement and subtle vibrations in the lift table. Dust from the manufacturing environment would also degrade the instrument’s scales and encoders, making it prone to breakdowns.

In-Process Inspection CellWith the objective of increasing measurement system availability, T h e c o m p a n y ’s i n t e r n a l production quality control department initiated a process improvement project.

Specifically, the team would implement a fixed metrology station dedicated to rapid in-process inspection. This station would be equipped with an optical tracker and tactile probing system to provide 360 degree part inspection, complying with the following major requirements:

1. Total measurement uncertainty no greater than +/- 50 µm within the inspection volume

2. Ability to compensate for vibrations and/or contaminants

3. Ability to move the part freely during the inspection process

4. Equipment durability and reliability on the shop floor

NDI’s Pro CMM Optical Tracking solution was deployed as the foundation for its fixed metrology station. One optical tracker is mounted to a ceiling structure 4 m above the inspection cell. This configuration provides the optical tracker with an unobstructed line of sight to the part, which sits inside the measurement volume. The ceiling mount minimises the

An in-process inspection system has allowed more accuracy and operational reliability. By Jarrad Morden, director (Industrial Division), NDI

Case Study:

In-Line Quality Inspection For

Engine Manufacturing

Difficulty: Metrology instrument had limited measurement volume and accuracy. In addition, it was prone to breakdowns.

Solution: Implementing a fixed metrology station dedicated to rapid in-process inspection.

Conclusion: Total volumetric uncertainty of +/- 35 µm was achieved, better than the initial target of +/- 50 µm




solution’s footprint to no greater than the dimensions of the pneumatic lift table, while meeting Scania’s condition of maintaining a ‘clean floor’.

Compensation for movement and vibration is achieved with the solution’s Dynamic Part Referencing (DPR) functionality, in which part coordinates are automatically referenced and re-referenced, subtracting movement from the measurement observations.

To facilitate proper alignment, the operator places four magnetic infra-red targets (IRED markers) on the engine block to create a virtual reference frame that transforms the part’s coordinate system through all six degrees of freedom in near real-time. The part can be moved at any time, and proper measurement alignment is automatically maintained. For the Scania application, measurement data is captured at a speed of 21 Hz.

Once the DPR targets have been applied, the operator uses a Multi-Sided Probe (MSP) to perform the alignment and manually inspect all points and features on the engine block. The MSP uses a standard Renishaw M6 85 mm stylus with 4

mm ruby and wireless trigger, and can be tracked from any orientation relative to the optical tracker.

Customised measurement scripts were developed in Polyworks v12 Inspector and guide operators through a controlled inspection plan. Automated Process Capability Index (Cpk) analysis is performed using Scania’s Statistical Process Control (SPC) package and predefined UCL/LCL control limits.

The Results: 35µm Measurement AccuracyInspection of over 1,000 engine blocks using the NDI optical tracking and tactile probing solution were conducted with no reported downtime. This is attributed to the system’s solid state design, which is unaffected by dust and contaminates, thereby meeting the company’s requirement for shop-floor durability and reliability.

The number of inspections also established a measurement benchmark. The results surpassed t h e q u o t e d m e a s u re m e n t specification by ~70 percent, achieving a total volumetric uncertainty of +/- 35 µm. Table 1 shows the quoted volumetric

accuracy of the solution, where 35 µm was the maximum measurement of total realised results.

A subset of measurements was taken during onsite testing; the accuracy rate is both consistent and repeatable, as shown in table 2. All inspections are 100 percent verified by correlating data against traceable third-party CMM measurements.

The engine block was measured by the NDI optical tracker on the shop floor and in a controlled CMM lab by a Granite Bridge CMM. The ‘Actual Achieved Performance’ column represents the delta/correlation between the NDI system and the Bridge style CMM.

SummaryScania achieved its objective of increasing measurement system availability and lowering total cost of ownership for performing dimensional quality checks. Measurement accuracy for engine blocks exceeded expectations, with the fixed metrology inspection cell consistently measuring below 0.050 mm.

Table 1

Table 2: NDI Pro CMM Optical Tracking Solution vs Granite Bridge CMM

Inspection Cell

Volumetric Specification (µm)

= 90+ 2.5L/100 Length (in mm), 95 percent Confidence Interval using ISO 10360

Volumetric Spec. (Scania Application)

= 90 + 2.5 (1037)/100= 115.9 µm

Largest distance between inspection features was 1,037 mm

Realised Performance (Scania Application) = 35 µm

Measurement Feature

NominalVolumetric

SpecSpec For Given Length

Actual Achieved Performance

Distance 804.00 90+2.5L/10090+2.5(804)/100

=110.1 µm21 µm

Diameter 12.00 90+2.5L/100 90+2.5(12)/100

=90.3 µm12 µm

Diameter 12.00 90+2.5L/10090+2.5(12)/100

=90.3 µm8 µm

Distance 18.00 90+2.5L/10090+2.5(18)/100

=90.45 µm12 µm

Distance 1037.00 90+2.5L/10090+2.5(1037)/100

=115.93 µm35 µm

Cylinder 82.00 90+2.5L/10090+2.5(82)/100

=92.05 µm22 µm

Distance 371.00 90+2.5L/10090+2.5(371)/100

=99.275 µm15 µm

Cylinder 82.00 90+2.5L/10090+2.5(82)/100

=92.05 µm25 µm

Optical Tracker(Fixed Mounted)

Conveyor System

Workstation

Pneumatic Lift Table

Machining Centre

Dynamic Part Referencing (DPR)

Targets(Used to ‘Subtract’

part movement from measurements)



Ch a n g e s i n d e s i g n philosophy and product trends in the industry can often leave the

manufacturing sector unprepared to manufacture new designs. These changes are usually slow and subtle but occasionally, they are dramatic and obvious. Recently, this has been the case for industrial laser material processing (Photos 1 & 2).

In the aerospace industry for instance, programs for processing workpieces and the laser processes themselves are developed cooperatively by the end user and laser system manufacturer, to ensure that the relevant machine capabilities are both fully understood and fully utilised.

The capabilities of the latest laser systems are increasing rapidly, and relying on experience from previous generations of laser systems can lead to significant missed opportunities.

Over the past two decades, the capability of laser systems has grown rapidly, through multiple iterations of both aerospace component design and laser system capabilities, to produce components efficiently and with high quality results.

One area of focus in the growth of laser systems and laser processing technology is the production of effusion cooling holes in advanced turbine designs.

Effusion cooling holes are small (typically 0.5 to 0.75 mm diameter) and positioned at increasingly acute (as small as 10 degrees) compound angles to the surface of the engine component. New cooling holes continue to challenge laser processing for both the drilling process and expanded laser system capability. Similarly, component designs have called for increasing levels of precision (Photos 3 & 4).

In the aerospace industry, smaller components with a higher accuracy requirement will facilitate the usage of more laser cutting systems that have the ability to move into the realm of multi-axis processing. By Mark W Barry, VP, sales & marketing, Prima Power Laserdyne

Expected In Aerospace

Multi-Axis Processing

More

Photos 1 & 2: Environmental friendliness has been a driver in aerospace engine design and the laser system used to process components for them.

FORMJOinCut


Photos 3 & 4: Cooling hole design and manufacture hold the key to aerospace engine efficiency. Next generation engines call for denser cooling hole patterns and more complex holes. Only next generation laser systems can efficiently and economically produce these hole patterns.

Lasers To Achieve More Advanced ComponentsThroughout the early use of laser systems in aerospace manufacturing, the number of applications was quite varied. Often, manufacturers invested in laser systems based on speculation about their ability to extend the processing benefits achieved on one or more test components, to more difficult to process components.

That drove laser system design flexibility, in other words, the ability of the system to handle a wide range of workpiece sizes, shapes, material thicknesses and lot sizes. The large work envelope of systems were developed to fill this need. These laser systems allowed processing 3D workpieces while remaining stationary. This permitted multiple setups, reducing changeover time between small lot sizes (Photo 5). However, when it comes to smaller components, other systems might be more suitable.

Smaller Laser Systems For Smaller PartsLaser processing in the aerospace industry today is a key part of a strategy to realising efficiency increments and emissions reductions. For laser processing to be viable for the volume production of these new engines, it must be capable of cost effectively laser processing the smaller components

that will make up the next generation of engines.

Taking into account the growing number of holes, the new designs, and the projected volumes of new engines coupled with replacement parts required for regular engine maintenance, the highly flexible, large work envelope laser processing systems that have so long dominated this market are no longer the best solution for every situation.

One key to increasing the fuel efficiency for aircraft engines is to

use only enough of the air passing through the engine for cooling as required — the rest is used for combustion and thrust. This has created an ever increasing need for precision in both the airflow through laser drilled cooling holes, and in the position of laser cut and drilled features. The result of this is seen throughout the designs of the newest laser systems — from the volumetric precision of the motion axes to the control loop that ensures dynamic precision and smooth motion.

More Axis For More DimensionsIn response to these emerging needs, Prima Power Laserdyne has introduced the Laserdyne 430 BeamDirector, a six-axis system for processing 2D and 3D components. This system incorporates the BeamDirector rotary tilt laser processing head for producing precise effusion cooling holes at shallow and complex angles, into a smaller, more floor space efficient system platform (Photo 6).

A modern 3D laser system must include controls that are

Photo 5: One example of a large work envelope system is the Laserdyne 795, a five-axis laser machining system, designed to drill, cut and weld medium to large 3D parts with a moving beam motion system.

FORMJOinCut


faster (higher bandwidth), more intelligent, and able to support the faster processing rates and more intricate holes and feature patterns. The structure of these systems ensures component rigidity to maintain precision throughout complex contours as the individual machine axes accelerate/decelerate throughout a higher speed range.

The precision of this system is also seen in its process control capability, including that of process control sensors. This is ensured because the laser process is robust and repeatable, in contrast to being one for which quality of the finished workpiece is operator dependent. This is accomplished with the following features found in the Laserdyne S94P laser process control that is the heart of the laser system:

1. Automatic Focus Control (AFC) for capacitive workpiece sensing, to ensure that the laser beam focus position is maintained at the proper location relative to the surface on metallic components.

2. Optical Focus Control (OFC) for sensing and maintaining the correct laser beam focal position relative to thermal barrier coated surfaces.

3. Breakthrough Detection (BTD) for drilling clean, consistent holes with the minimal number of pulses.

4. Feature Finding automatically finds the approximate location of certain workpiece features, including protrusions and holes.

S ince the part program (sometime generically referred to as the NC program) that drives the laser system is also a factor influencing precision, producers of laser sheet metal fabrication s y s t e m s h a v e d e v e l o p e d programming utilities.

These ut i l i t ies produce integrated laser and motion control that is optimised for the specific laser system. They help in programming shaped holes and the automatic programming of patterns of holes on cylindrical workpieces by trepanning, percussion drilling, and drilling on the fly.

The user of the laser system need only provide information about the particular workpiece to be drilled, because the details of the laser system required to optimise throughput, quality, and repeatability of the process are embodied in these routines. As indicated previously, a key design

objective for the 430 BeamDirector was to make performance independent of the operator's (and programmer's) skill and knowledge of the system design.

Elsewhere, process control and verification are important re q u i re m e n t s f o r t o d a y ’s manufacturing environment. SPC (Statistical Process Control) Data Acquisition provides a tool for system control to monitor and record, as a part program is executing, the key process and system information.

The part program contains codes that specify data to be collected by the SPC Data Acquisition feature. The system monitors key parameters (ie: time, date, temperature, position commanded and/or actual laser power, pulse conditions, etc.) and stores the data as a text file. Data from the text is easily retrieved for further analysis and/or archived to provide a permanent process record.

The FutureAs previously mentioned, process development must not be overlooked in order to realise the highest performance and quality from the system. With the new aerospace component designs, there are new challenges in motion, feature type and positioning.

In the future, the use of laser processing will continue to grow. The older, large scale laser processing systems that are appropriate for small batch manufacturing of medium to large size components will continue to be bought and used.

Newer system designs will take a larger portion of the system installations in the future. It is the natural evolution of equipment design to favour more efficient use of floor space while producing to higher tolerances. This is the real definition and meaning of value.


Photo 6: The system incorporates a rotary tilt laser processing head for the automated production of effusion cooling holes.

FORMJOinCut

ENQUIRY NO 173


With today’s advanced water jet cutt ing systems, shops are able to cut taper-free

parts, bevels, weld preparations, hole chamfers, blisks, intricate hub and blade assemblies, tubes, and a variety of other sophisticated parts. These advanced capabilities enable shops to gain an edge over their competition and take on many new types of projects. With an advanced waterjet cutting system, shops are also able to produce increasingly more parts exclusively with waterjet, saving time and money, and freeing up other equipment and skilled labour for additional projects.

Using a waterjet to produce these sophisticated parts rather than a traditional cutting tool brings the benefits of waterjet cutting to a whole new range of parts. With the technology, shops can cut parts from virtually any material and thickness without creating a Heat-Affected Zone (HAZ). There is no

case hardening or recast, and no molecular change of the material.

Covering All AnglesNaturally, five-axis waterjet cutting systems require a higher level of programming and additional operational considerations.

Before purchasing an advanced waterjet cutting system, shops should check the manufacturer’s specifications for angle limits of the cutting head to ensure the system meets their needs, advised machinist Brian Wallace, who runs the test cutting lab for waterjet manufacturer Jet Edge. Shops should also ensure that the system has software safety limits and safety shields to prevent cutting outside of the tank walls, to prevent injuries and to avoid cutting holes in the tank.

“The programming is more challenging and the cut sequence should be carefully evaluated,” Mr Wallace noted. “For instance, if a surface is to be cut more than once,

it may need to be tabbed to prevent part movement, and parts requiring extensive external angle cuts may require a larger portion of material when nesting parts together.”

Angle cutting also involves important fixturing and safety considerations, he added.

“Cutting at extreme angles causes more tank turbulence and could move the cut material if not clamped,” he said. “These cut angles could also be a safety concern, requiring the use of guards or Lexan shielding.”

When cutting at extreme angles, he suggested using a smaller orifice. “I have found that cutting with a smaller orifice results in less tank turbulence, meaning less material disturbance and possibly resulting in a better cut, of course, at the expense of cut time,” he said.

When cutting at an angle, it is essential to make sure that the material is flat and level, he emphasised.

Five-Axis Waterjet Technology:

Precision waterjet cutting shops around the world are taking their business to the next dimension with advanced five-axis waterjet technology. By Nancy Lauseng, marketing manager, Jet Edge

A New Dimension

FormJoinCut



“This is critical when cutting angles, or for taper control,” he added. “Material mapping or active height control can help correct for warped or out of level material conditions, but they do not completely remove the inaccuracies of cutting material that is not perpendicular to the cutting tool.”

Keeping The Right DistanceMaintaining correct nozzle standoff is also critical, added Jeff Schibley, the company's regional manager for the Great Lakes region.

“As an example, a 0.125” movement of the plate, when cutting a 0.5” diameter hole with taper compensation applied, will result in a 0.020” change in hole diameter,” he said. “Plate warpage during the cut does not affect a 2D cut like it does for a bevel or taper compensation cut.”

He noted that water je t software such as IGEMS makes it

relatively easy to cut bevels into flat plate, but added that anytime you begin to angle the nozzle and cutting head away from 0,0, the focal point becomes critical. Any variance in height can affect total part accuracy.

Nozzle changes are more time consuming with an advanced system, because of the need to recheck focal point and make adjustments. “You might utilise a 0.010”/0.030” by 4” nozzle when cutting thin material and a 0.015”/0.045” by 4” nozzle when cutting thick material,” he suggested.

Special CareShops should be aware that there is some additional maintenance with a five-axis system. These systems typically have more moving parts related to the cutting head motion components that require precision assembly and alignment. Tank slats will also need to be replaced more

frequently when cutting at an angle, and some work surface grates may not be suitable for five-axis cutting.

When considering such systems, shops should look for a single-source manufacturer that also offers free five-axis operational training. “With advanced waterjet systems in particular, it is very important to source your system from a company that engineers and manufactures the complete system, including the pump, the controller and the motion system,” advised David Anderson, international sales manager at the company. “That way if you have any problems or need warranty work or service, you only have to contact one company for support.”

Waterjet shops should also carefully evaluate their pump choice when upgrading to a five-axis system. When cutting thicker material, it may be beneficial to upgrade to a 90,000 psi pump, rather than using a traditional 55,000 psi pump, but not all manufacturers offer this higher pressure pump.

A higher pressure pump would enable shops to process parts as much as 40 to 50 percent faster, and lower operating costs as much as 40 percent by reducing garnet consumption.

With a taper compensating cutting head, operators can cut parts at a lower quality setting while still maintaining straight edge parts. This gives the higher pressure pump an edge, such that you can increase cutting speed, maintain edge quality and cut taper free with a taper removal system.

With a five-axis system, waterjet shops can gain a new edge over their competition and open additional revenue sources. These systems do require additional considerations, but with proper training and maintenance, they are a tremendous asset that will take your business to a new dimension.

Example of bevels and chamfers that can be cut with five-axis waterjet machines

Brian Wallace

FormJoinCut


As healthcare improves i n t h e d e v e l o p e d countries, demands for medical devices and

pharmaceutical products inevitably increase. Take Johnson & Johnson for example, the manufacturer of medical devices, pharmaceutical and consumer packaged goods posted an increase of 8.5 percent in sales in the second quarter of 2013, as compared to the same quarter a year before.

The company also reported a worldwide pharmaceutical sales of US$7 billion in the same quarter and sales of US$7.2 billion in worldwide medical devices and diagnostics. These two sectors both grew 11.7 and 9.6 percent respectively compared to the same period in 2012.

The performance of Fresenius Medical Care in the First Quarter of 2013 also mirrored this upward trend. The provider of dialysis products and services reported an increase of seven percent in net revenue in Q1 of 2013, compared to the first quarter of 2012.


Organic revenue growth worldwide was four percent. Dialysis services revenue grew by eight percent and dialysis product revenue increased by two percent.

Home Medical EquipmentOver at the home medical equipment arena, similar trends were reported by the Freedonia Group in a study, titled World Home Medical Equipment. In the report, it is said that world demand for home medical equipment is projected to increase 7.0 percent annually to US$28 billion in 2016.

Asia is expected to dominate the fastest growing markets with China and India named alongside Brazil and Russia. Together, these four nations are experiencing increasing economic prosperity, culminating in the boosts of the level of third-party and direct consumer payments applied to health care. In these countries, home health care activity will expand rapidly due to cost saving advantages and ongoing shortages in professional medical providers.

In the grand scale of things however, the US is still expected to remain the largest market globally, said the report. This claim is based on the country’s extensive network of home health care providers, high health care spending intensity, widespread insurance coverage, and shifting patient care strategies toward home settings.

Spillover EffectsThe amount of activities in the medical industry will no doubt bring opportunities to supporting industries like contract manufacturing. After all, they have expertise, particularly in making parts like screws.

As simple as they might sound, these screws have big applications in the medical segment. For instance, Medtronic has introduced the CD Horizon Solera Spinal System Sagittal Adjusting Screw (SAS), which may be used in the surgical correction of complex spinal pathologies.

The medical industry is in focus in this issue of Asia Pacific Metalworking Equipment News. In this section, we will bring you the trends in the medical industry as well as how these trends affect the manufacturing process of certain medical devices.

Medical Industry:

In The Pink Of HealthThe medical industry is trending upwards at the moment and this can have a positive impact to even those involved in its supporting industries.

Iwan Beijes, Utrecht, Netherlands

IndustryFocus

MedIcal Focus

ENQUIRY NO 160


The f ield of medicine has often been aided through the use of tools. History has recorded

t h a t m e d i e v a l s u r g e o n s w o u l d a l re a d y u s e s h a r p metal instruments to perform surgery, at a time when the use of anesthetics was unheard of.

Today, wi th the advent of modern technology and manufacturing, medical devices are a lot more sophisticated, not to mention integral to the wel lbeing of pat ients . The Federal Food, Drug and Cosmetic Act defines a medical device as ‘a product intended for the diagnosis, cure, mitigation, treatment or prevention of disease that does not achieve its primary intended purpose through chemical reaction, and is not dependent upon being metabolised’.

Anything from the humble t h e r m o m e t e r t o a c o s t l y dig i ta l imaging equipment can be considered a medical d e v i c e . To d a y, t h e Wo r l d Health Organisation (WHO) e s t i m a t e s t h a t t h e re a re 1.5 million medical devices wor ldwide . Unfor tunate ly, many of these devices are used exclusively in developed countries. Nevertheless, with rising affluence in developing countries, it would not be long before medical devices gain popularity there as well.

F u r t h e r m o r e , w i t h a n

increasing global population, and ageing citizens in many parts of the world, it is predicted that the demand for medical services, and the devices associated with such services, will continue to grow. These trends, in both the developed and developing world, are expected to result i n s t r o n g g r o w t h i n t h e metalworking industry related to the medical field.

Medical Devices & MetalworkingB u t j u s t w h a t d o e s metalworking have to do with medical devices? In a nutshell, any device with metal parts or fixtures will require some form of metalworking in its production.

As a material, metal has many characteristics which makes it suitable for use in the medical field. It can be finished to provide a smooth surface, which can then be easily cleaned and made sterile. This is especially important in a medical setting, where bacterial infections from the use of equipment can be fatal.

The electrical conductivity of metal is another characteristic that makes it useful, particularly when used in a device which requires electricity to function, such as a pacemaker. A pacemaker is a device attached to the walls of a person’s heart to assist in stabilising his or her heartbeat.

It does this by using electrodes which deliver electrical impulses to the heart muscles.

The electrodes in the pacemaker are made from a platinum-iridium alloy. Such alloys of platinum are selected for their biocompatibility. This means that they can be used in human bodies without any allergic reactions. Besides pacemakers, platinum alloys are also used in implantable defibrillators, catheters and stents.

M e t a l s , u n l i k e o t h e r materials, are unique in that they can be fabricated into tiny, complex shapes through the use of micromachining. This involves the use of highly special ised equipment and techniques, such as CNC Swiss screw machines and EDM. The Swiss screw machines are tasked with fabricating the main components while EDM is used to achieve the fine details needed on the parts.

Producing a metal part which will form the finalised medical device does not end at the

Metalworking:

Helping the Medical Industry

Save Lives

Surgical instruments are just some of the medical devices utilised by today’s medical professionals.

The use of metals in the medical industry has greatly expanded the usage of medical devices, many of which are crucial in saving the lives of patients. By Shahnawaz Abdul Hamid

Phil Beard, Leicester, United Kingdom

IndustryFocus MedIcal Focus




fabrication stage. Fabricated metal parts need to exhibit a high surface finish for them to be used as medical devices. This will greatly determine the product’s biocompatibility and lubricity, traits which allow such devices to be used inside a patient’s body or bloodstream.

To i l l u s t r a t e , t h e u s e of sta in less steel surgical equipment requires extensive deburring — the removal of burrs from a part ’s edges. This allows a certain level of sharpness to be attained in the surgical equipment, an important trait given the nature of their usage.

Drawbacks Of Using MetalsThere are several disadvantages t o t h e u s e o f m e t a l s i n manufacturing medical devices, unfortunately. For one, metals can be costly, especially when rarer metals such as platinum are used. The use of micromachining a n d o t h e r s p e c i a l i s e d metalworking techniques to produce the metal parts needed are another addition to cost.

W h i l e m e t a l s c a n b e m a c h i n e d i n t o m i n i a t u re

parts, as mentioned earlier in the article, caring for these extra small bits can be time-consuming and costly, in terms of accounting, logistics and maintenance. It is no wonder why many medical procedures, which require the use of such tiny devices can cost the patient tens of thousands of dollars.

Furthermore, some of the ailments which require medical devices with metal parts are uncommon. This requires a

certain level of customisation, and translates to a smaller volume during production. As such, profit-driven factories often feel less inclined to plan and execute such production cycles, resulting in longer lead times.

The FutureWhi le the manufacture o f medical devices can be lucrative business, the challenges stated cannot be overlooked. As the medical device industry pushes forward to create better, more effective equipment, suppliers of metal parts will have to improve their capabilities, or face the prospect of losing out.

F o r i n s t a n c e , a s p a r t s become more complex, so too will inspection equipment (eg: CMMs, RAM optical systems and laser marking tools). Capital expenditure in purchasing such equipment is likely.

N e v e r t h e l e s s , w i t h a growing global population and older people needing help to live longer, it seems the demand for the industry will continue to swell, making such expenditures and investments well worth it.

The Swiss screw machine is named as such because it traces its origins to

Switzerland, home of precision watch components. It is an automatic lathe which

machines turned parts. The workpiece rotates rapidly on the lathe and is shaped

till the desired design is achieved.

There are two types of Swiss screw machines: the CNC and the automatic.

The former uses a computer to direct the machine, allowing for several machining

processes to be carried out concurrently. This shortens the machining time needed,

and this is one of the reasons why CNC Swiss screw machines are preferred to

automatic ones.

In addition, the CNC Swiss screw machine is more precise compared to the

automatic version. They can rotate parts at speeds of 10,000 rpm at an accuracy

level of 0.0002 to 0.0005 inches. It is for this reason that such machines are finding

themselves popular among suppliers of medical devices, where there is growing

demand for tiny parts.

Swiss Screw Machining Technology

Typ

o_q

ueen

, Uni

ted

Sta

tes

Imaging technology allows a quick diagnosis of a patient’s ailments

IndustryFocusMedIcal Focus


APMEN: In your opinion, what is productivity?Moh Chong Tau (MCT): Doing more with less. In order to do that, you have to do it in an innovative way so as to achieve the maximum using the least resources.

APMEN: Do you envisage workers in Singapore matching workers in countries like Germany or Switzerland in terms of productivity?MCT: Well, that will take a while. WDA can facilitate it, but the employers and employees have to play their part. One issue is on employers, whether they want to spend the time and effort.

In addition, employers tend to view things in short term. As such, they are not willing to spend one week or one month in order to improve productivity, which will bring them long term benefits. That’s a very myopic view.

On the other hand, the employees must be willing to learn. Some employees see learning more as working more.

DoMore

With LessAsia Pacific Metalworking Equipment News (APMEN) sat down with Dr Moh Chong Tau, chairman of the Singapore Workforce Development Agency (WDA) Precision Engineering Industry Skills & Training Council (PE ISTC) and the president & CEO of Makino Asia to talk about productivity, an issue close to his heart. By Joson Ng

APMEN: On this note, how serious are Singapore job shop owners taking the issue of productivity?MCT: The business model in Singapore is such that these job shops are sub-contractors, mainly to multi-nationals (companies). When cost goes up, these multi-nationals may move away. As such, they (job shop owners) cannot see the long term (picture) and worry about their customers moving away. They are not willing to spend the money sometimes because once the multi-nationals move away, the money spent on training and development goes to waste. The skills acquired no longer have a meaning.

APMEN: What advice would you give job shop owners on how to increase productivity?MCT: The important thing is how to enhance the scope of work. They should not just be a sub-contractor. They should add in design, value and assembly work so that the customers feel that they need them. Job shops must

create values for customers and take away work that the customer is doing (on their own), in order for the customer to be dependent on them. For example, Foxconn is a contract manufacturer but can Apple go without them?

Be partners because any other company can be a sub-contractor. We must go into (local manufacturers partnering multi-nationals that produce specialised products) specialised products, those that require special licensing. The entry barrier is high but the barrier to exit is even higher. That is how you put yourself in a secure position.

APMEN: Apart from automation, are there any other ways to improve productivity?MCT: Besides automation, Lean Manufacturing and Six Sigma can improve process work flow. This alone can help you improve productivity by 20 to 30 percent without having to invest very much.

APMEN: What are the programmes available in

Dr Moh Chong Tau

ExEcutivEZonE


Precision Engineering Workforce Skills Qualifications (PE WSQ)The Precision Engineering Singapore Workforce Skills

Qualifications (PE WSQ) framework is a national skills

credent ia l ing system for the PE industr y. I t t ra ins,

develops, assesses and recognises individuals for the

key competencies that PE companies look for in potential

employees.

The framework is based on national skills standards

developed by WDA in collaboration with the PE industry,

comprising of employers, industry associations, trade

unions and training providers. It serves to:

• Professionalise the industry, particularly where recognition

of continuing education and training qualifications are

lacking; and

• Enhance workers’ employability by allowing companies

in the PE industry to recruit workers with the necessary

skills whilst improving opportunities for workers to enter

the industry.

Operations Management Innovation (OMNI) Programme



This WSQ Operations Management Innovation

(OMNI) Programme is a joint initiative by

the Singapore Institute of Manufacturing

Technology (SIMTech) and the WDA.

The objective is to train key personnel

— engineers, managers and senior staff of

companies — to be technology innovators, in

order to achieve manufacturing excellence.

This is accomplished by promoting the use

of operations management techniques and

technologies that support a company’s strategy,

ensuring that operations improvement are both

effective (aligned to the company’s strategy) and efficient (achieve productivity gains).

The programme offers an Operations Management Innovation methodology

based on R&D, proven through successful applications in various sectors of the

manufacturing industry.

It consists two parts: classroom training and mentorship. The classroom training

focuses on transferring knowledge in operations management and the use of this

methodology. The mentorship reinforces the classroom learning by applying the

said methodology in the student’s company. During on-site training, the participant

will identify operations improvement areas, generate suitable initiatives and develop

implementation action plans that are based on productivity improvements, mentored

by SIMTech’s trainers.

ENQ

UIR

Y N

O

16

8

Neoboss GmbH – in former times Jakob Boss Söhne GmbH & Co. KG – more than 100 years high precision tools made in Germany.

The company Neoboss GmbH, which is certi-fi ed according to DIN ISO 9001, is belonging since 01.01.08 to the French group Poisier Finance et Industrie S.A.

Neoboss is producing over 2 Mio. precision tapping tools at the site in Germany and Hungary and distributes worldwide and with its own sales in Germany, Hungary and Poland. The product portfolio includes taps, hand taps, nut taps, roll taps, special customized taps according drawing, thread millers, dies, thread plug gauge, thread gauges and synchro chucks. To achieve best per-formance for nearly every application we supply our tools added by suitable high-quality coatings and surface treatment. It will be also possible to use individual marking and labeling (OEM).

Our way: with selected materials from in-ternationally renowned suppliers, our own heat treatment technology, various cutting edge prepa-rations, and our 100 years of experience in prod-uct engineering, we are producing tools which are successfully used all over the world. Together with our partners, we offer state-of-the-art coating technologies to provide a reproducible manufac-turing process for top level quality.

Our philosophy is simple and convincing: we constantly work on improving the quality of your goods and help to increase the profi tability of your production.

Our sales team and our application engineers are looking forward to your inquiries!

Neoboss GmbH – a reliable and strong partner in global business!

Phone: +65 6562 7670Fax: +65 6562 7671Mobile phone +65 9758 3729Mobile overseas: +49 172 7601732Email: [email protected]

25 International Business Park#05-109c German Centre Singapore 609916, Singapore

www.ehnland.com

Singapore to help boost productivity? Can you tell us a little more about the PE WSQ Operations Management Innovation (OMNI) and the WSQ Precision Engineering Master Craftsman programmes?MCT: These WSQ programmes are just what the industry needs to train their workers to be more productive and effective. They help employees to be more versatile and multi-skilled so as to handle jobs in a more holistic manner. We need to make our employees understand the whole process in order to achieve the maximum with the least effort.

People have to be multi-skilled. In Europe, one person can run three to four machines. They can also make machines run unmanned. We have to move into that. The main purpose of the WSQ Master Craftsman programme is to train people to help them manage both hard and soft skills, as well as manage the system in order to be productive.

ExEcutivEZonE


Did You Know?

APMEN: I understand some employees from Makino Asia attended the courses. How are the results?MCT: The WSQ programmes are not only on machining but also on how to manage the system. Participants gain an understanding from preparing the machine, to machining and to measuring. So they understand the process in a holistic manner and see the process through without any hindrance or only understanding part of the process.

APMEN: In terms of metalworking, machining in particular, are there interesting stories or tips on increasing productivity?MCT: Machining of titanium or exotic materials require different skills. Aluminium materials for instance, require high-speed machining whereas the slow process of machining is used for titanium. In addition, you have to have a good understanding of the coolant system and the characteristics of the machine, like the torque.

For us (Makino Asia), we used to have 150 workers producing only 40 odd machines in the past. Today, we have 130 producing over 100 machines. It is all about laying out (the production floor, being organised) and using supporting industries to do the non-core chores so we can concentrate on doing the high value tasks.

“I think it is enriching and rewarding to see the government providing continuing education and training for the adult workforce. Hopefully, (the WSQ programmes) will make them more employable and extend their working life. This will help them increase their income as well.

- Dr Moh



The programmes aim to raise productivity by deepening employees’ skills and

knowledge in precision engineering. This is a collaborative effort by EDB, WDA,

SPRING Singapore and NYP to help employees stay relevant by sharpening their

technical capability and training them to become technical specialists and assume

supervisory and leadership positions.

The 900-hour, two-year part-time WSQ Diploma and Specialist Diploma

programmes cover various areas of specialisation including CAD/CAM, precision

mould making, precision plastic components, tools and tooling systems, machine

and automation solutions and technology innovation. Participants undergo rigorous

training via lectures, tutorials, lab work, case studies, and project work before they

undergo an assessment to be certified competent.

The WSQ Diploma and Specialist Diploma in Precision Engineering (Master Craftsman Skills) Programmes

Dr Moh has been the chairman of the WDA PE ISTC since 2006 and with WDA since its inception in 2003. Before that, he was involved in a similar capacity with the Ministry of Labour. For his contribution to the manpower development of Singapore, he was awarded the Public Service Medal in 2010.

ExEcutivEZonE

ENQUIRY NO 138

Diploma Course • Nanyang Polytechnic (NYP)WSQ Diploma In Precision Engineering (Master Craftsman Skills)

Description Launched by NYP with support from EDB, SPRING Singapore and WDA, the programme helps employees stay relevant by enhancing their technical capabilities and training them to be higher achievers. The course is designed to deepen and upgrade the skills and knowledge of participants in relevant precision engineering areas. Participants will complete 6 common core and sector core modules that will provide them with a strong foundation in applying productivity tools and topics covered include managing productivity, engineering science and engineering mathematics, Computer-Aided Design (CAD) and project management.

Participants will then complete another 5 specialised elective modules that will enhance their expertise in the technology areas of precision machining and advanced Computer-Aided manufacturing techniques, complex equipment building, and mould design and moulding processes.

Course Modules Common Core1. Manage Manufacturing Productivity Improvement2. Apply Productivity Improvement Tools3. Apply Mathematical Concepts in Engineering Solutions4. Apply Mechanics in Design Solutions

Sector Core5. Apply Computer-Aided Design (CAD) Techniques6. Apply Mechanical Fixtures Design

Participants will select one of the following Electives:Elective 1 [Advanced Mould Design & Process]7. Apply Advanced Mould Design8. Apply Advanced Mould Flow Simulation9. Apply Plastics Injection Moulding10. Apply Plastics Material Technology11. Manage Engineering Project (Mould Design & Process)

Elective 2 [Advanced CAM & CNC Machining]12. Apply Computer-Aided Manufacturing (CAM) Techniques13. Apply Advanced CNC Machining14. Apply Advanced Toolroom Machining15. Apply Process Optimisation & Cutting Technologies16. Manage Engineering Project (CAM & CNC Machining)

Elective 3 [Equipment Building and Automation]17. Apply Solid Modelling & Drafting for Machine Parts18. Apply Mechanical Components & Peripherals in Automated Equipment19. Apply Automatic Control for Machines20. Apply Project Management in Equipment Building21. Manage Engineering Project (Equipment Building & Automation)

Qualification Awarded

WSQ Diploma in Precision Engineering (Master Craftsman Skills)

Course Duration 600 hours, 1 full day (8 hours) and 1 evening (3 hours) session per week

Enquiries & Applications

Course EnquiriesMr Desmond TanTel: 6550 0674E-mail: [email protected]

Mr Mike KwekTel: 6550 0677E-mail: [email protected]

Application EnquiresProfessional Development CentreTel: 6550 0555E-mail: [email protected]

Online Course Applicationwww.nyp.edu.sg/nyppdc/Course-List.aspx

Precision Engineering

Precision Engineering forms the backbone of Singapore’s complex manufacturing sectors, enabling core industries such as aerospace, electronics, medical technology and oil and gas. With Precision Engineering WSQ courses, you can upgrade your skills to be primed for success in this dynamic industry.

AdvertoriAl


Specialist Diploma Course • Nanyang Polytechnic (NYP)WSQ Specialist Diploma In Precision Engineering (Master Craftsman Skills)

Description The course is designed as an advancement pathway for graduates of the WSQ Diploma in Precision Engineering (Master Craftsman Skills) to further deepen and broaden their technical skills. Apart from technical knowledge, participants will also acquire pedagogical skills to be able to lead, train and manage junior craftsman.

Course Modules 1. Apply Advanced Metrology & QA2. Apply Advanced Materials Technology3. Apply Advanced Manufacturing Technology & Process4. Apply Pedagogy Methodology for the Workplace Part 15. Apply Pedagogy Methodology for the Workplace Part 26. Manage Shopfloor Monitoring & Process

Qualification Awarded WSQ Specialist Diploma in Precision Engineering (Master Craftsman Skills)

Course Duration 300 hours, 1 full day (8 hours) and 1 evening (3 hours) session per week


Course EnquiriesMr Desmond TanTel: 6550 0674E-mail: [email protected]

Mr Wong Looi KianTel: 6550 0934E-mail: [email protected]

Application EnquiresProfessional Development CentreTel: 6550 0555E-mail: [email protected]

Online Course Applicationwww.nyp.edu.sg/nyppdc/Course-List.aspx

Graduate Diploma CourseSingapore Institute of Manufacturing Technology (SIMTech)WSQ Operations Management Innovation (OMNI) Programme

Description The programme’s objective is to train key personnel of companies to be technology innovators to achieve manufacturing excellence. This is accomplished by promoting the use of operations management techniques and technologies that support a company’s strategy. This will ensure that operations improvement are both effective (aligned to the company’s strategy) and efficient (achieve productivity gains).

The programme offers a proven Operations Management Innovation methodology (OmniMethodologyTM) based on R&D, proven through highly successful applications in various sectors of the manufacturing industry. It consists of two parts: classroom training and mentorship. The classroom training focuses on transferring knowledge in operations management and use of this methodology. The mentorship reinforces the classroom learning by applying the said methodology in the participant’s company. At this on-site training, the participant will identify operations improvement areas, generate suitable initiatives and develop implementation action plans that are based on productivity improvements, mentored by SIMTech’s trainers.

Course Modules 1. Understand Operations Improvement Fundamentals2. Improve Operations Action Plan using OmniMethodology3. Implement Action Plan using OmniMethodology

Qualification Awarded

Statement of Attainment (SOA) will be awarded for each successfully completed module.

Participants may top up with 2 other modules from the WSQ Graduate Diploma in Manufacturing Operations Management (MOM) to be awarded a full qualification in MOM.

Course Duration • 3-month part-time• Classroom training consists of 10 half-day sessions, conducted over a 4 to 5-week period• 3.5 months mentorship consisting of both scheduled and ad-hoc supervised sessions at

company and SIMTech• All sessions are held during working hours


Course EnquiriesMr Ma BinTel: 6793 8441Email: [email protected]

Course Applicationhttp://kto.SIMTech.a-star.edu.sg

For more information, please visit www.wda.gov.sg or call 6883 5885

AdvertoriAl



In the true sense of the word ‘congress’, the event, organised by the Singapore Welding Society and the

International Institute of Welding saw many come together and discuss one topic that is close to everyone’s heart — welding.

On the f i rst day of the congress, Ho Siong Hin, divisional director of the Occupational Safety & Health (OSH) Division of the Ministry of Manpower, Singapore, highlighted the importance of OSH in the welding industry, along with the quality of welders in Singapore.

He said: “It is imperative that we upgrade our welders’ skill set and we must nurture our workforce in welding.” In

addition to the management side of the equation, he also called for continuous advancement in welding technologies.

I n a c o n g re s s s u c h a s th is , technica l exchanges are expected to dominate proceed ings , but the one pertinent point brought away from the opening round of speeches was surprisingly not of a technical nature.

The leaders of the welding community in Singapore were united in recognising the need to raise the status of a welder. For too long, welders were seen as blue collar workers and the hope is to change the general perception and reinvent them as craftsmen instead.

Aw a y f ro m t h e s e r i o u s discussions, participants at the congress were also treated to the sight of welding experts trying their hand in a light-hearted welding competition, albeit in a virtual setting made possible by the Vrtex 360, a virtual reality arc welding trainer by Lincoln Electric.

Introducing Human Intelligence Into Welding MachineIn the plenary session, four papers were discussed. After which, the event was split into three break out tracks. The topics discussed were mainly in the areas of microstructure & mechanical properties, arc welding, friction stir welding

Asia Pacific IIW International Congress

Special Report:

Asia Pacific Metalworking Equipment News (APMEN) was amongst welding experts from all over the world, to look at recent developments in welding and joining technologies. By Joson Ng

Features


Welding, virtual reality style.


and weld design & fabrication.One of the papers discussed

in the plenary session talked a b o u t b u i l d i n g a h u m a n response model to control a weld ing process . In h is presentation, Dr Yu Ming Zhang, professor from the department of electrical and computer engineering and institute for sustainable manufacturing of the University of Kentucky, talked about the pros and cons of the human welder.

The paper investigates the possibility in harnessing the positive points of a human welder, like the ability to react to a situation and make good decisions and adjustments b a s e d o n t h e e x i s t i n g conditions. According to him, the motivation for the project i s t o i n c o r p o r a t e h u m a n in te l l i gence w i th we ld in g machines.

The underlying basis of the project lies in the weld pool. It is thought that the human welder uses the weld pool to judge if full penetration is produced. Therefore, a human response model is developed to help machines ‘think’ like a human. In order to do that, a vision system is used to acquire the 3D weld pool geometry that the human welder may sense.

A 3D vision based weld pool sensing system uses a 20 mW

illumination laser generator at a wavelength of 685 nm. It is used to project a 19-by-19 dot matrix structured light pattern on the weld pool region.

The acquired information is used to build a model with an acceptable accuracy. Using this model for machines, it is concluded that it is possible to use the weld pool surface to determine and control the weld joint penetration and emulate the intelligence of a skilled welder.

Welding Dissimilar MetalsC h o w N g a i M u n o f S h e l l Chemicals Seraya shared his exper ience in jo in ing two dissimilar base metals (titanium and stainless steel/carbon steel) by Gas Tungsten Arc Welding (GTAW) via V-butt joint with and without the root gap. He also revealed the two intermediate metals, vanadium and aluminium bronze, were introduced as bi-filler rods between the two dissimilar base metals.

First, he explained the reason behind formulating such a welding procedure. He said in a chemical plant, titanium

cladding materials are sometimes damaged during maintenance and he wanted to devise a way to repair the damage.

During the course of the project, he learned that the challenge of welding titanium is to formulate a way to isolate it and prevent reaction with gases like oxygen. In order to do so, the welder must take special effort in the cleaning procedure.

He later explained why welding of dissimilar metals is done in the industries. According to him, welding dissimilar metals can “reduce high cost of single homogenous material used.” As such, it is advantageous both technically and economically to join titanium with other metals, such as stainless steel, so as to lower cost.

Titanium cladding on a stainless steel substrate construction offers not only a significant cost reduction, but also durability in comparison to pure titanium equipment. In conclusion, he told the crowd that a sound weld can be produced by GTAW.

Chow Ngai MunMr Ho feels it is important to upgrade the skill set of welders.

Features


Electronic current limiting is not always a 100 percent effective way to prevent torque overloads in a

mechanical system. On a servo motor, it is relatively easy to set torque limits in the parameter programming of the machine. When doing so, one must remember that the electronic torque limit is at the motor only. This means that the motor’s electronics do not account for the masses of gears, couplings, and shafts, further along down the drive line.

Oftentimes, a manufacturing process is many mechanical power transmission components away from the motor. In addition, the servo drive and/or PLC monitoring the torque of the motor may not pick up an over torque condition quickly enough to prevent damage from occurring.

E l s e w h e re , i n ro t a t i n g equipment, there are often gearboxes and shafts which have a lot of rotating inertia not accounted for by electronic means. Additionally, linear applications impart their inertia into the rotating components driving them when they stop or crash.

Machine Crash InvestigationWhen we examine what happens in a machine crash, it is often useful to look at an impact force equation:

F = (0.5m x v2)/s

Where: F = force in Newtons m = mass in kilogramsv = velocity in metres per seconds = stopping distance in metres

Examining this equation tells us that the force imparted by an impact is directly proportional to the mass and/or velocity, while being inversely proportional to the stopping distance. That being said, the more massive any component is, and the faster it is moving, the more impact force is exerted during a crash.

For many mechanical designers, this is quite obvious, although many electronic programmers do not account for this principle while limiting currents and/or torque values. Because the stopping distance is inversely proportional to the impact force, the smaller it gets, the more force is imparted by the crash. This can be very

difficult to predict and plan for by system designers. It can be fairly straightforward to find the mass of mechanical power transmission components and know how fast they will be moving. What is difficult to gauge is how likely the machine will crash and what will cause this to happen.

Further examining the force equation from a mechanical design stand point, one can see that the effects of a machine crash can be mitigated by keeping the mass of the moving parts to a minimum. One way to do this would be to use lighter materials such as aluminium instead of steel if possible. There are companies which produce hollow carbon fibre and aluminium line shafts for this reason.

Slowing down the speed of moving parts also cuts down on the forces associated with a machine system crash. While decreasing speeds are not often a good option in the world of manufacturing machine building, designers can be creative. For example, in certain metal forming operations, making multiple parts in a slower fashion can be preferred over making single parts very quickly.

Cushioning The BlowSince mass and velocity are directly proportional to inertia, decreasing either obviously cuts down on impact forces in a machine crash. Preventing a crash and/or cutting down the distance at which it occurs however, is difficult.

One obvious method of protect ing operators and preventing externally initiated jams would be to ensure proper guarding is always in place. This is an OSHA requirement around many processes and prevents operators from dropping tools, clothing and even themselves onto moving parts.

Limit switches at the ends of actuation paths in conjunction with soft bumper stops can also be very helpful. Linear motion applications

Limiting Factors To Prevent

Machine CrashThe combination of mechanical torque limiters and electronic torque limiting can go a long way in preventing machine crashes. By Niilo Nykanen, application engineer, R+W Antriebselemente

Features



such as moving a machine centre’s cutting table with ball screws can benefit from this.

One example would be a table moving past its limit switch with enough inertia from the work piece that it shuts down the process by moving past the limit switch, but still hits the soft bumper at the mechanical stop. This is a case where the stopping distance would be significantly increased, which would decrease the impact force of the crash.

Building A Protective CoverDue to the number of people from different backgrounds involved in machine design, how the machine operates on the grand scale of things can sometimes be overlooked as people tend to focus on their area of specialty.

For instance, mechanical drive engineers may concentrate on the process and drive components without thinking about the full capabilities of the motor and electronics. Conversely, electrical programmers and designers do not always consider how the total mechanical inertia of drive systems can impact their overload settings.

Electrical designers are generally trained to implement multiple levels of overload protection into circuits. Most industrial control boxes normally have main breakers and/or fuses and protection on each branch circuit. Many individual devices also have their own overload protection.

This concept can also be seen, arguably in a lesser degree, in the mechanical design side of machine building. Oftentimes, drive components such as belts, chains, and couplings are designed to be mechanical fuses. Many systems are built with a series of shear pins to protect the drive line.

Mechanical Circuit Breaker A newer technology on the market is mechanical torque limiters.

These can be used to limit torque as well as linear chain or belt pull. A torque limiter is essentially a mechanical circuit breaker. Rather than having a component that breaks and needs to be replaced, a torque limiter can trip and be reset many times during its life.

An advantage of using mechanical torque limiters over shear pins and/or relying on a belt or coupling to break apart in an over torque condition is that they are available in maintenance free designs. The best advantage of using them in conjunction with electronic torque limiting is that they can usually be installed very closely to the device where a crash could occur, as well as multiple points in the system.

Mechanical torque limiters are designed to instantaneously detect an over-torque condition and disengage very quickly. Often times, mechanical torque limiters are capable of disengaging an over-torque drive line before an electronic device such as a servo motor even begins to pick up the condition.

In the developing study and career field of mechatronics, a mechanical torque limiter allows for an integration of mechanical and e lectr ica l des ign . An electronic proximity switch can be positioned near an actuation mechanism which moves in the event of an overload.

This system works well because the overload is detected

and disengaged, followed by an electronic signal to a PLC or process controller to shut down the part of the system with the over-torque condition. Because torque limiters can be placed in multiple parts of a machine, the source of the jam can be detected very quickly using proximity sensors.

To summarise, the peak process torque value must be known. This value must be calculated through the driveline back to the servomotor and be programmed into the servo drive parameters. Bear in mind that this will only truly protect the motor from the over-torque condition.

The best backlash free option to limit torque at the process is to install a mechanical torque limiter that is as practically close to the area which jams (both for maintenance of the process and possibly resetting the limiter). Essentially, machine builders should be aware to not put all of their eggs in one basket when mitigating machine crashes.

Circuit breakers, fuses, and electronic limiting should be used at multiple levels on the electrical design. Torque limiters, guarding, and bumpers should be employed on the mechanical design. As always, consult the manufacturers of each component if there are any questions or concerns.

Machine builders should be careful when mitigating machine crashes.

Features


The message from Nguyen Quan, minister, Ministry for Science and Technology was a simple one: Use MTA

Vietnam as a platform to bridge local enterprises and foreign business partners, to further establish Vietnam as an attractive investment destination in the eyes of the global industrial community.

Judging from the numbers released by the organiser, it looks as though people have responded to his rally call. This year’s show saw a record number of more than 12,000 attendees comprising trade visitors, exhibiting staff, seminar speakers and delegates, competition participants, and members of the press.

Trade visitor count was up by 23 percent compared to last year. In addition, the show saw some 163 group delegates arriving from provinces such as Ho Chi Minh City, Dong Nai, Long An and Tra Vinh. The next edition of the show will be held from July 8 – 11, 2014.

Slow Start But Strong Finish?A common obstacle for machine tool manufacturers selling into Vietnam is the difficulties faced by their customers in getting loans for capital expenditures. However, things are expected to pick up in the second half of 2013.

Price is very much a factor in Vietnam. Using an automobile as an analogy, Jack Pham, general director of DMG/Mori Seiki (Vietnam) told APMEN that some customers told him instead of buying a ‘Mercedes Benz’ (a DMG/Mori Seiki machine in this context), they just need a normal car to get them from point A to B. They, however, run into difficulties once they start getting larger orders. The present may be challenging but the future is brighter according to him. He said: “In three to four years, Vietnam will turn to high end machines.”

Dr Christian Braun, MD, DMG/Mori Seiki (SEA) also weighed in on the intriguing Vietnamese

market. “Knowledge is important in Vietnam and we provide competent solutions like technical service and applications. We want to be a strong local supplier of machine tool,” he said.

Event Review:

MTA Vietnam 2013

Press ConferenceOver at the press conference, Te e B o o n Te o n g , d e p u t y chief representative of the SES representative office in Ho Chi Minh City told members of the media that the show has grown in size. In this year’s edition, there are 341 exhibiting companies whereby 80 percent are from outside Vietnam. All in all, they come from over 21 different countries or regions. The internationality of the show is something he is happy to report.

“This year has a big participation f rom the group pavi l ions. I ’m happy the governments of Asia are supporting the show by coming out in force. For year 2013, we have 11 pavilions, some countries have more than one pavilion,” he said.

EvEnts&Exhibitions



When asked about the second quarter of 2013, Dr Braun was bullish about his company’s chances of doing well in Vietnam. He said the economy in 2012 was weighed down by a high interest rate but things will soon change.

“The second half (of 2013) will be better. The Vietnamese are more confident. This is my third time at MTA Vietnam and discussions are more optimistic,” he said. He told APMEN that they had some 200 company meetings on the first day of the show alone. With that, he said the second half of the year may see a 30 to 40 percent increase (in sales) compared to the first half of the year.

This sentiment is echoed by Philip BC Loh, MD of Bystronic. He said the Vietnamese business people are more cautious in the beginning of the year but they will catch up in the second half. He predicted a 30 to 40 percent increase in sales in the second half of the year compared to the first.

This ‘feel good’ factor is not exclusive to European m a n u f a c t u re r s . J a p a n e s e companies Sodick and Okamoto both registered a similar positive take on the second half of 2013.

Naoki Mori, director, sales division, Sodick (Thailand), said although the situation in Vietnam is “complicated,” the economy “should be ok.” He also told the show organiser that he has had a “good show.” He estimated a 20 to 30 percent increase of visitors to his booth. He also managed to sell two machines and establ ished contact with a few new local potential customers.

Yu i c h i ro K i m u r a , s a l e s manager of Okamoto (Singapore) revealed that the year 2012 was not ideal because of the economy in Vietnam and also in Japan, because their customers in Vietnam are from Japan. Like many of his counterparts, he

has high hopes for the second half of the year. “This year, I have some information that Japanese customers are slowly picking up. They are preparing to purchase machines. They are going to buy machines in the third quarter,” he said.

Away from the machine tool manufacturers, others are optimistic as well. Hisashi Takaki,

Southeast Asia regional manager of NT Tool (Thailand) said that for his company, Vietnam is a new market as they only started selling a year ago. He felt that the sales in 2012 is “little bit down,” but he told APMEN that it is possible to double sales in the second half of 2013 compared to the first.

Exhibitors are predicting a better second half of the year.

EvEnts&Exhibitions


What’s New At MTA Vietnam?Here is a quick look at what caught the eye in this year’s show.

Another Japanese manufacturer,

Okamoto, b rought the i r

internal grinding machine to

the show. The Max-15N-ID-2

has two spindles available.

According to Yuichiro Kimura,

sales manager of Okamoto

(Singapore), the machine

can help in providing more

productivity.

The Japanese chuck manufacturer NT Tool

rolled out their slim hydro chuck at the show.

The hydraulic clamping system is said to be

capable of runout accuracy of 3 µm. Although

the price of the hydro chuck is higher compared

to a shrink fit chuck, Hisashi Takaki, Southeast

Asia regional manager of NT Tool (Thailand), told

APMEN they focus on the running cost more than initial cost

because in the long run, it is going to be higher and therefore

a more important consideration when choosing the chuck. He

added that his product can reduce vibration, resulting in lower

stress for the cutting tool and ultimately, longer tool life, which has

cost implications.

Over at Singapore Oriental Motor, Chok

Yun Min, the company’s sales manager,

believes the World K Series of induction

motors are suitable for the Vietnamese

market. He claimed that the motors are

not only “price competitive,” but they have

improved on the quality as well.




Over at the German pavi l ion, Bi lz

showcased the ISG 3400 ThermoGrip

shrink machines. Andy Hooper, general

sales manager of the company told

APMEN his company’s big focus is on the

shrink product.

“From the precision point of view, when

you are looking at really accurate tool life

or close runout quality, shrink product is

the way forward,” he said. The machine is

said to be capable of a runout accuracy of

3 µm, according to Mr Hooper.


Sodick brought the AD30L, a linear motor

drive high-speed Die Sinker EDM to the

show. Naoki Mori, director of the sales

division of Sodick (Thailand) said the

machine features a linear drive system. The

linear drive motor has many advantages

compared to a ball screw, like better

accuracy and longer life. According to

the company, the direct-drive system

is said to generate high speeds,

dynamic responsiveness and good

positioning accuracy.


EvEnts&Exhibitions

www.metalexvietnam.com

Reserve your exhibit space now and enjoy extensive branding opportunities!For more info, please contact Tel: +66 2686 7299 E-mail: [email protected]

Vietnam’s International Exhibition on Machine Tools & Metalworking Solutions for Production Upgrade

10-12 October 2013Saigon Exhibition & Convention Center (SECC)

Ho Chi Minh City, Vietnam

Spirit • Innovation • Technology • Knowledge • Network

Vietnam’s manufacturing sectors is upgrading their production ef ciency for the expansion of ASEAN market. Meeting the increasing standards of foreign manufacturers is the key, and you can help them raise the bar of ef ciency by offering them your quality machine tools and metalworking solutions at METALEX Vietnam 2013. This is the place they will come discover exactly what they want including new knowledge and a wider network in the supporting industries. This is the place for you to answer to their needs while expanding your market share in Vietnam.

500 Global Brands, 25 Countries

10,000 Quality Buyers

HI-TECH Zone with “Robot Demonstration”

Conferences & Technology Presentations

Part of “METALEX,” the Largest Event in ASEAN

Organized by:Local Partner:Co-located with:

ENQUIRY NO 143


The 6th edition of JEC Asia was held at the Suntec Convention Centre in Singapore from June 25

– 27, 2013. According to the organiser, over 300 companies f r o m 4 9 c o u n t r i e s w e r e represented at the event. The total visitor number is 5,200.

“JEC Asia is an event for the Asia-Pacific region. The content and the setting of the event are adapted to the local needs with a global organisation. The Asian market is a strategic market for the composites industry. In 2012, out of an estimated €83 billion (US$106.7 billion) global composites market, €29 billion is generated in Asia Pacific, ie: 36 percent of the market against 34 percent in America and 23 percent in Europe,” said Frédérique Mutel, JEC’s president and CEO.

“In (terms of) volume, 41 percent of the global composites production is done in Asia-Pacific versus 32 percent in Americas

and 20 percent in Europe. This reflects the major place the region holds in the worldwide market and the growing interest from local participants as well as visitors and exhibitors from western countries,” she added.

Innovative Composites Summit This year’s Innovative Composites Summit (ICS) topics mainly

dealt with issues, developments and innovations that directly concern the Asian markets. At the ICS, participants were able to attend lectures related to aeronautics, thermoplastics and transportation, among others.

Tan Meng Ho, senior sales manager of Kuka, spoke about using automation solutions in the composite f ie ld. He

Event Review:

JEC Asia

The Innovation Showcase displayed 18 innovative parts

EvEnts&Exhibitions



explained how shelf mounted robots can help reduce floor space and interference with w o r k f l o w i n t h e p l a s t i c industry. He also told the crowd how shorter cycle times can be achieved with their technology. He added that articulated arm robots are advantageous in the areas of control, space requirement, working area and 3D capability. However there are limitations in stiffness and welding depth.

In another presentation, Klaus Drechsler, director, Institute of Carbon Composite (TU Munich), shared with the audience the possibi l i ty of transferr ing technology from the aerospace to the automotive industry.

He started by analysing the importance of composites in the aerospace industry. Using the A380 as an example, he showed the role played by composite materials. In the aircraft, CFRP materials were used to manufacture floor beams for the upper deck, outer flaps, vertical tail plane and wing ribs among others.

In summary, he said technology transfer is possible from the aerospace arena to the automotive industry in the areas of design

& simulation and repair. The aerospace industry can also learn from the automotive industry in the area of automation.

Celebrating Innovation The Innovation Awards Program presented 16 trophies, to advanced innovations, along with a Life Achievement and a Student Award. The ceremony was honoured by the presence of no less than nine ambassadors or high commissioners’ representatives from: Australia, France, Germany, Italy, Japan, South Korea, Spain, Taiwan and Turkey.

Krithika Tyagarajan, senior director at Frost & Sullivan, gave an insightful opening speech about Global Mega Trends and Drivers for Aviation Composites.

C o n c u r r e n t l y , i n t h e technical posters area, 40 posters presenting the breaking innovations and know-how that enable the composites materials industr y to progress dai ly were displayed to the public, while live demos took place on the exhibition floor. The Innovation Showcase displayed 18 innovative parts, from a Yike bike to a helicopter door in blow moulding technology.

Business, Announcements & ContractsThe organiser said some 70 percent of the participants declared themselves to be top managers and decision makers. The Business Meetings program, a service of prearranged meeting between buyers and exhibitors, was at full capacity as more than 230 meetings were organised over the three days.

This year’s Composites Tour brought the JEC delegation to Admiralty, a fibre glass and carbon f ibre sh ipbui ld ing company in Singapore. The event was also the stage where VCAMM (Australia) and MAI Carbon Leading Edge Cluster (Germany) s i g n e d a M e m o r a n d u m o f U n d e r s t a n d i n g ( M o U ) , cementing their collaboration in common researches that will help industry participants and research centres in the field of carbon fibre manufacturing research and development.

Suntec Convention CentreSingaporeJune 25 – 27, 2013

Tan Meng Ho Klaus Drechsler

EvEnts&Exhibitions


Wi r e a n d T u b e Southeast Asia will be held at BITEC in Bangkok, Thailand

from September 17 – 19, 2013. Organised by Messe Düsseldorf Asia, over 300 companies will be exhibiting at both the wire and tube segments of the three-day event. Together, the two trade fairs will showcase innovations and trends on high-performing machinery, processing and automation in the wire, cable, tube and pipe industry in Southeast Asia.


Southeast Asia remains resilient

amidst persistent global economic

u n c e r t a i n t y , p r o j e c t i n g a n

average annual growth rate of 5.5

percent f rom now ti l l 2017. The

region is increasingly becoming a

manufacturing and industrial hub

for many global companies seeking

to locate and keep in touch with

available business opportunities.

According to Global Industry

Analysts, the global market for

s e a m l e s s p i p e s a n d tu b e s i s

projected to reach 113.8 mil l ion

tonnes by 2018. In addition, the

global market for spira l welded

pipes and tubes is projected to

reach 24.6 million tonnes by 2018,

d r i ven by e conomic re cove r y,

increase in activity in the energy

s e c t o r a n d g r o w i n g p i p e l i n e

construction projects.

Industry reports indicate that

the Asia-Pacific region represents

the la rges t marke t wor ldwide,

driven primarily by increased use in

transporting natural gas. Similarly,

business opportunities in the wire

and cable industries are estimated

to contribute approximately three

percent of the world’s production of

wire and cable.

Demands For Pipes & Tubes Increasing In AsiaWire & Tube

Southeast Asia

Event Preview:

Compared to the previous event in 2011, the organiser has reported some growth. This year’s edition will have higher profile exhibitors from big international companies, approximately 15 percent of whom are first-time exhibitors.

Apart from exhibitors from Europe, which covers some 40 percent of international exhibitors, there will also be representation from market leaders from around the region. S e v e n n a t i o n a l p a v i l i o n s

and countr y groups f rom Austria, China, Germany, Italy, Singapore, Taiwan and the US have secured participation to the trade fairs.

What To See?The trade fa i r, suppor ted by industry associations, is Thailand’s trade fair for the wire and cable industry. It is all about machinery and equipment, materials trends and accessories used for making all types of wire and cable, and

EvEnts&Exhibitions


ENQ

UIR

Y N

O

12

4


innovative solutions for the wire and cable sector. Trade visitors can expect to see a range of wire, cable, tube and pipe products for the building, electronic, power, and telecommunications sector as well as data wire and cable, and other insulated wires and cables.

In addition, visitors will also be able to attend a series of seminars and training courses at the show as well as other of ferings which have been organised to provide added value to the exhibition and maintain its position in the industry.

BITECBangkok, ThailandSeptember 17 – 19, 2013

EvEnts&Exhibitions


The Manufactur ing & Industrial Trade Fair or MITF, will be held at the Putra World Trade Centre

(PWTC) in Kuala Lumpur from October 9 – 12, 2013. According to organiser Expoworks, the event is set to be much anticipated by the manufacturing industry this year. Exhibitors have set about in bringing in the latest technology and equipment to cater to the complex needs of the manufacturing sector in this inaugural event.

Industry players from the automotive manufacturing, plastic manufacturing, mould & die, electronics & semiconductor, industrial automation, material handling & storage system should consider visiting the show. According to the organiser, visitor numbers are expected to be in the range of 8,000 to 10,000 and the total show size is about 8,000 sq m (gross).

Playing host to over 300 Malaysian companies and national group pavilions from Singapore and Taiwan, visitors can expect to meet with experts in the industry to discover innovative ideas and understand the new functionalities of today’s latest equipment. Knowledge about the latest tools, machineries and equipment are key factors to increase productivity and reduce cost.

Despite being an inaugural presentation, the show has managed to garner international


recognition from the Singapore Industrial Automation Association (SIAA) and Taiwan Machinery Traders Association (TMTA). Both these esteemed associations will be organising national group participation to the event.

MITF will be held alongside OneBuild, an exhibition on bui lding, architecture and c o n s t r u c t i o n t e c h n o l o g y exhibition. The organisers are banking on the synergy of having both these exhibitions as they believe the events together create a better platform for trade visitors

in their sourcing needs. In a joint statement, they said:

“We understand the effort and planning made by visitors in attending exhibitions; especially those coming from abroad. As such, staging both of our exhibitions on the same date and at the venue increase the value and products on display. Visitors will definitely be able to find more things and meet more key people while attending the event.”

As Malaysia’s Economic Transformation Programme moves into full gear, the show aims to be a one stop platform for all sourcing needs. The exhibition will open its doors from 1000 hrs to 1800 hrs.

PWTCKuala Lumpur, MalaysiaOctober 9 – 12, 2013

Event Preview:

MITF 2013

Visitors from the electronics and semiconductor industries would find the show relevant.

Win

del

l H O

skay

, ww

w.e

vilm

adsc

ient

ist.

com

The show will be helpful for people involved in the automotive sector.

EvEnts&Exhibitions

ENQUIRY NO 159

ADVERTISEMENT Singapore$SIZEFull Page 3,0001/2 Page 2,000

Circulation: 5,000

Publication date:

November 2013

To be distributed at

Metalex Thailand 2013

Manufacturing Indonesia 2013

Randy TeoBusiness Development ManagerTel: (65) 6379 2867HP: (65) 9101 9995Email: [email protected]

Melvin WongSales ManagerTel: (65) 6379 2866HP: (65) 9747 7208Email: [email protected]

CompositeMaterialsSupplementAsia Pacific Metalworking Equipment News is proud

to present the Composite Materials Supplement.

The supplement will delve deep into various issues

in the following areas:

• Reinforced plastics

• Metal composites

• Ceramic composites

• Composite building

materials

• Aerospace

• Medical

• Automotive industries

Advertise today!

For more details, please contact our sales representatives:

B C

lear

y, Ir

elan

d E

ire

Time is Running Out!

Organized by:Of cially Supported by:

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

w w w . m e t a l e x . c o . t h

ASEAN’S Largest International Machine Tools and Metalworking Technologies Trade Exhibition & Conference - 27th Edition

BITEC BANGKOK THAILAND

20-23 NOVEMBER 2013

Secure New Opportunities in ASEAN Metalworking Market in Regional Largest EventIf you look forward to tapping into the metalworking and manufacturing industries in ASEAN, METALEX 2013 is a must-attend event for you and over 70,000 international industrialists to understand the regional movements, network and build new contacts and study possibilities for investment or expansion to ASEAN for the upcoming AEC.

METALEX 2013 will be your regional platform to:• Source the latest technologies from 2,700 brands from 50 countries and 7 National Pavilions• Network with thousands of industrial leaders, power groups and key associations• Acquire in-depth and insightful knowledge at exclusive conferences such as the 3rd METALEX Nano Forum and the 2nd Metallurgy Forum

Plan Your Visit Today!

Get special privileges for a group of 3 overseas visitors! For more information, please email your contact details to [email protected]

MTX_2013_Visitor Ad.indd 1 8/8/13 6:22 PM

ENQUIRY NO 172


Reed Tradex, together with Japan External Trade Organizat ion (JETRO) Ho Chi Minh

Office and the Investment & Trade Promotion Centre of Ho Chi Minh City (ITPC), have announced the co-location of ‘Business Alliance for Supporting Industry in Ho Chi Minh’ together with Metalex Vietnam and Nepcon Vietnam. The show will be held at the Saigon Exhibition & Convention Centre from October 10 – 12, 2013. According to the organiser, more than 12,000 visitors are expected during the three days of the show.

Over 100 Japanese companies, mainly in the automobile , motorcycle and electronics parts manufacturing industries will

be present. Local Vietnamese companies can now find the right machinery and solutions for their production upgrade, especially in mould & die making and electronics part manufacturing. Furthermore, they will be able to source for new subcontractors, and sell their parts to Japanese buyers and manufacturers as well.

All participants will receive an opportunity to check out cost effective technology and machinery that match their requirement, and gather new knowledge in seminars and technology presentations. Moreover, the conference and activities available will also help foster closer cooperation among Vietnamese industrialists and foreign investors.

Japanese InfluxC u r re n t l y, Vi e t n a m i s a n attractive investment destination for international manufacturers in automotive, electronics, and other supporting industries. Japan is the top foreign investor in Vietnam and new Japanese companies in Vietnam are continuously increasing their manufacturing capacity in the country.

Hirotaka Yasuzumi, MD of JETRO (Ho Chi Minh Office) said that Vietnam is a promising country for Japanese companies. By 2020, Vietnam will become an industr ia l i sed countr y with sufficient supplies of raw materials and basic fuels.

Currently, Japan is the biggest foreign investor in the country in terms of investment size, drawn in by the advantages of low labour cost and a larger market.

Japanese companies focus on components (eg: small motors for the automotive industry’s export) and textiles. Vietnam, with its lower labour cost, is suitable for marketing- or sales-based distribution outlets for Japanese products in Vietnam. Accordingly, JETRO would like to urge Vietnamese SMEs to develop higher competitiveness to prepare for the jobs that will follow Japan’s investment expansion.

T o k e e p u p t h e competitiveness as well as to acquire new clients, Vietnamese manufacturers need to expand their production line and improve their productivity. Finding the right business partners would also help Vietnam’s industries to become strong and profitable in the long run.

The technologies involved in the automotive and industrial p a r t s k e e p e v o l v i n g a n d changing, due to demands from the market place for new items with improved quality and functions. As a result,

Metalex Vietnam

Event Preview:

EvEnts&Exhibitions


ENQ

UIR

Y N

O

16

4


Vietnamese manufacturers need to keep themselves updated on these developments at all times, and to look out for new technologies and skills that they need to remain competitive in. The event this year will bring many international pavilions and suppliers from many countries that would encourage business dialogues between new and existing partners.

Generating BusinessVietnam’s electronics industry has grown steadily under the government’s support and the local manufacturers’ efforts. Accordingly, Nepcon Vietnam 2013, Vietnam’s only exhibition on SMT & testing technologies and supporting industries for electronics manufacturing, will offer an effective stage for electronics manufacturers to

acquire technologies to enhance their production.

Moreover, i t wi l l be an effective business-generating tool for industrial ists and manufacturers in this industry. A quality technology showcase from international brands will present cutting-edge innovations for industrialists to heighten product ion ef f ic iency and competitiveness.

The exhibitions will not only provide an answer to their requirements, but also introduce new concepts, trends, and ideas, which will be complemented by new technologies and the experts who can help them move forward, strengthening the Vietnamese supporting industry in the process.

The three exhibitions this October are the effective trading promotion, and they have so

far contributed significantly to Vietnam’s industrial sector by enabling consistent production output, entry to new export locations, and liaison with foreign companies in Vietnam, while also offering service for product suppliers and buyers.

Duangdej Yuaikwamdee, deputy MD of Reed Tradex, said that last year, the event had a total turnout of 13,789, an increase of 30 percent from 2011.

SECCHo Chi Minh City, VietnamOctober 10 – 12, 2013

EvEnts&Exhibitions





Anomet: Composite Clad Metal Wire

Precious metal clad gold wire and silver wire that offer better formability, ductility, solderability,

and design flexibility tha n plated w ire for use in a range of electronic connectors and medical devices is available from Anomet Products.

Less expensive than solid wire, these composite wires are more formable and ductile than plated wire and allow designers to combine properties such as strength and conductivity.

Replacing solid silver, gold, and gold alloy wires, the gold composite wire and silver composite wire typically incorporate two percent or more cladding thickness and their uniform density provides better corrosion resistance than plated wire without cracking or flaking, claims the manufacturer. Permitting smaller connector designs, these wires come in 0.05 mm to 3.175 mm OD sizes.

Altium: Integration With ECAD & MCAD

Altium, a provider of 3D PCB design solutions (Altium Designer) and embedded software development (Tasking), has partnered with Desktop EDA to provide designers with ECAD and MCAD integration. The add-on application, Desktop EDA Solidworks Modeler and the IDF Modelers, is currently available for the design software program.

The extension apps and their companion plug-ins form a bridge between the ECAD and MCAD design worlds. Productivity is increased through the full synchronisation capabilities between the target applications. This goes further than simply eliminating the requirement to recreate MCAD assemblies each time, allowing the modeling of Altium Designer-specific features in the target MCAD system.

Edgecam: Apply Toolpaths Fast

Edgecam has further developed its CAD/CAM software. The 2013 R2 contains a number of items of enhanced functionality, including modern redesign of dialogs, four-turret support, free loading of CAD files into Part Modeler, quicker simulation, and improvements to the Wire EDM Feature Finder.

The most far-reaching enhancement in 2013 R2 is Workflow, enabling CAD/CAM engineers to apply toolpaths within seconds. The tools aid in loading and positioning the component, choosing the manufacturing method and suitable machine tools, adding user defined stock or stock from a database, importing fixtures, selecting a machine and toolkit, and managing strategies to automate manufacture.

Elcometer: Coating Thickness Gauge

The Elcometer 456 coating thickness gauge enables users to automatically compare thickness values to a coating’s specification, display trend graphs, store individually time and date stamped thickness readings into memory. The gauges can also transfer data wirelessly to a mobile cell phone, recording the GPS coordinates precisely where the measurement was taken.

The company’s Ultra/Scan Probes for the coating thickness gauges not only allow inspectors to drag the probe across a coated surface without damaging the probe or the coating, but also increases the reading rate of the coating thickness gauge to in excess of 140 readings per minute — speeding up the measurement of a coated ferrous or non-ferrous metal substrate.


ProductFinder

The 24th International Manufacturing Machinery, EquipmentMaterials & Services Exhibition

4-7 DECEMBER 2013The Jakarta International Expo Kemayoran

w w w . m a n u f a c t u r i n g i n d o n e s i a . c o m

IndonesianMould & DieIndustryAssociation

IndonesianMachine ToolIndustriesAssociation

IndonesianAutomotive Parts& ComponentsIndustriesAssociationIndonesia Precision

Tooling Industry Association

Associationof Metalworkand Machinery

Supported by: Organised by:

Ministry of Industry,Republic of Indonesia

For Further Information Please Contact Your Nearest Sales Off ice:Maysia StephaniePT Pamerindo Indonesia, Jakarta - IndonesiaTel: +62 21 2525 320 | Fax: +62 21 2525 482Email: [email protected] www.pamerindo.com

Andrew ToddOverseas Exhibition Services Ltd, London, UKTel: +44 (0) 20 7840 2134 Fax: +44 (0) 20 7840 2119Email: [email protected]

Carolyn LeeInternational Expo Management Pte Ltd, SingaporeTel: +65 6233 6777 Fax: +65 6233 6768Email: [email protected]

The 24th International Manufacturing Machinery, EquipmentMaterials & Services Exhibition

4-7 DECEMBER 2013The Jakarta International Expo Kemayoran

w w w . m a n u f a c t u r i n g i n d o n e s i a . c o m

IndonesianMould & DieIndustryAssociation

IndonesianMachine ToolIndustriesAssociation

IndonesianAutomotive Parts& ComponentsIndustriesAssociationIndonesia Precision

Tooling Industry Association

Associationof Metalworkand Machinery

Supported by: Organised by:

Ministry of Industry,Republic of Indonesia

For Further Information Please Contact Your Nearest Sales Off ice:Maysia StephaniePT Pamerindo Indonesia, Jakarta - IndonesiaTel: +62 21 2525 320 | Fax: +62 21 2525 482Email: [email protected] www.pamerindo.com

Andrew ToddOverseas Exhibition Services Ltd, London, UKTel: +44 (0) 20 7840 2134 Fax: +44 (0) 20 7840 2119Email: [email protected]

Carolyn LeeInternational Expo Management Pte Ltd, SingaporeTel: +65 6233 6777 Fax: +65 6233 6768Email: [email protected] EN

QU

IRY

NO

1

61





Mastercam X7, the recently developed program has many added capabilities, including Mill-Turn product and Renishaw Probing. The Mill-Turn product makes machining on today’s high-powered turning centres and full-function machining centres simpler and easier.

The program also integrates Renishaw’s Productivity+ for in-process gauging. This uses a measuring probe on a machine tool to determine fixture offsets, orientation, and critical dimensions.

Probing eliminates the need for tool presetters, expensive fixtures, and manual settings with dial indicators. It allows for machine offsets to be automatically adjusted, even during the machining process, to further enhance the manufacturing process.

Grieve: Cabinet Oven Mastercam: Added Capabilities

The No.1028 oven by Grieve is used for preheating large dies. Workspace dimensions of the two-compartments on the twin compartment, 399 deg C electric cabinet oven each measure 40” x 42” x 51”. A 7,800 CFM, 5 HP recirculating blower provides horizontal airflow to the workload in each compartment and 100 kW are installed in Incoloy-sheathed tubular elements to heat the oven chamber.

The cabinet oven has 8” insulated walls, removable top-mounted heat chamber, aluminised steel interior and exterior, and two tiers of 300-lb capacity shelves supported by rollers to extend 14” in front of the oven.

Hexagon Metrology: Software With Over 40 Enhancements

Hexagon Metrology has developed the PC-DMIS 2013, a metrology software. The software f o c u s e s o n t h e collection, evaluation, m a n a g e m e n t a n d p r e s e n t a t i o n o f manufacturing data to r e d u c e s c r a p , improve throughput, reduce costs, and build lean manufacturing operations.

It rolls out feature like width construction, which facilitates the construction of width features from two opposing sides of a notch, tab, or other similar surface. This construction is useful for GD&T applications that require the width as a datum in Feature Control Frames.

Other enhancements include a ClearanceCube definition that allows collision-free movement around complex geometries without a CAD model.

OGP: Low Cost Video-Based Inspection

The QVI Starlite 250 benchtop video machine, with its updated livery, continues to provide a low-cost video-based inspection and measurement l ike its predecessor.

The machine has a 6.5:1 zoom lens and manual translation stages for accurate positioning in every axis. It is also designed in a way so that users can configure a system for inspection, interactive measurement, or semi-automatic measurement.

Finally, configuring the MVP (Machine Vision Product) system is said to be easy, according to the manufacturer, with the QVI Controller and Measure-X Metrology Software. The software guides users through measurement routines with pictorial instructions using part model and destination symbols and icons.


ProductFinder



Schaeffler: Plain Bearings For Marine Applications

INA plain bearings with Elgotex WA are resistant to sea water and have been developed for use as rudder and stabiliser bearings in marine applications.

This design is suitable for water lubrication and therefore does not require a complicated seal required by conventional rolling and plain bearings.

An advantage of the bearings is the increased load carrying capacity compared to the products that are available on the market for use in marine applications. While the standard so far has been a maximum contact pressure of 10 N/mm2, the bearings can support loads of up to 25 N/mm2.

Steinbichler Optotechnik: Sensors For 3D Digitalisation

Steinbichler Optotechnik has developed the Comet 6 16M sensor for 3D digitalisation. The concept of the sensor is based on a modular structure with the tried-and-tested single-camera technology so that the measurement field size can be quickly adapted to the measuring task at hand.

The compact sensor design and handling system guarantee maximum user friendliness and ergonomic operation. The sensor can be adjusted easily, precisely and quickly — allowing the user to operate the system intuitively and conveniently.

ENQ

UIR

Y N

O

17

5

…stabilising your process

PERFORMANCE UNEQUALLED…

DUOENDMILLS

Sutton Tools Harmony DUO EndMills are specifically designed for the mould and die

industry and purposely designed to optimise the machining of tool‑grade steels and alloys.

4

MICRO

Optimised Edge Conditioning

4

Dual Stepped Core for optimal chip evacuation and reinforced tool

strength

32

3

2

1

5

Endteeth Gash for Edge Strength

5

End teeth clearance

optimized for ramping

1

www.sutton.com.auWORLD CLASS CUTTING TOOLS

To find out more contactSutton Tools Singapore Pte Ltd+65 6745 [email protected]

r

Corner Radius available

Asia Equipment News Sept 2013 v02.indd 1 15/08/13 4:51 PMSeptember 2013 asia pacific metalworking equipment news www.equipment-news.com 75

ProductFinder





Walter Surface Technologies: Ultra-Thin Cutting Wheel

TaeguTec: Small But Durable Inserts

Walter has expanded the Proto•max milling cutter family with a cutter for stainless steel. According to the manufacturer, the Proto•maxInox offers an average performance increase of 50 percent when machining stainless steel in comparison with conventional, universal solid carbide end mills.

The four-edged maximum cutter has two internal helical coolant channels to keep the operating temperature at a constant level, and also to remove the chips reliably and thereby ensure process stability.

The tool is said to be able to deploy its full capacity on machines where internal cooling is combined with external cooling. The TAA coating with a TiAlN base and an optimised micro geometry counteract the typical wear mechanisms of stainless steels.

Walter Surface Technologies has developed the Zip One Type 27, an extra thin cut-off wheels, designed for optimal cutting in thin gauge metal (under 3 mm thick). The cutting wheel features a raised centre for extra rigidity, durability and thinness. The design of the centre hub allows for a larger cutting surface than standard progressive hubs, while enabling straighter, sharper, more precise and higher speed cuts for flush cutting applications.

Manufactured with an iron-free mix, the cutting wheel cuts cooler and faster and is guaranteed not to contaminate stainless steel, according to the manufacturer. It avoids discolouration of the work piece and cuts burr-free, reducing post-cut finishing.

The RhinoTurn insert by TaeguTec is capable of having a depth of cut in rough turning applications up to the 4 mm range.

But it is not only the size that makes a difference, it is the cost. The CNMG09 and DNMG13/TNMG13 line of inserts are just as strong as their CNMG12, DNMG15 and TNMG16 mm counterparts and more economical.

Besides the series’ small but durable size, the insert has a two directional clamping force that outperforms conventional ISO one directional clamping force tools available on the market.

Rockwell Automation: Integrating Multiple Machines Onto Single Network

The Allen-Bradley Stratix 5700 managed industrial Ethernet switch, which now includes an optional integrated Network Address Translation (NAT) feature, allows for high performance and simplified integration of IP-address mapping from a set of local, machine-level IP addresses to the end user’s broader plant-process network.

This can benefit manufacturers that are integrating identical machines into a production line, especially when multiple equipment builders are being integrated into a common production line. The switch also allows users to have the flexibility to segment or isolate network traffic by determining which devices are exposed to the larger network.

Walter: Maximum Performance For Stainless Steel


ProductFinder

E&E’14 APMEN(205x275mm)p 8/1/13 7:36 PM Page 1

ENQ

UIR

Y N

O

16

6


947,900,000PAX(The International Air Transport Association)

2€1.9%

GDPGrowth

4.9%

in the first six months of 2013*

*Compared to the same period in

2012(General Statistics Office of Vietnam)

Airlines based in the Asia-Pacific region carried the most passengers last year with the grand total of

The total value of machine tool orders in June was

Japanese Machine Tool Industry

95.17 billionJPY

(Japan Machine Tool Builders’ Association)

(Ministry of Manpower)

Singapore’s seasonally adjusted overall

unemployment rate in March 2013

billiona year,

and imports most of them.

India needs machine tools

worth more than

(German Machine Tool Builders’ Association)

Partingshot


2013September17 – 19Wire Southeast AsiaBITECBangkok, ThailandMesse Dü[email protected]

17 – 19Tube Southeast AsiaBITECBangkok, ThailandMesse Dü[email protected]

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

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

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

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

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

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

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

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

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

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

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

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


2013-2014

exhibitiONprOgrammeS

Vis

it Us

Vis

it Us

Vis

it Us

Vis

it Us

Vis

it Us

www.equipment-news.comasia pacific metalworking equipment news Jul-Aug 201380

Advertisingindex

ADVERTISING SALES OFFICES

HEAD OFFICESINGAPORE EASTERN TRADE MEDIA PTE LTD 1100 Lower Delta Road, EPL Building #02-05, Singapore 169206 Tel: 65-6379 2888 Fax: 65-6379 2805/2806 E-mail: [email protected]

FOREIGN REPRESENTATIVES

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]

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions.

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

Manufacturers and advertisers that are featured in this issue will send you free information about their products and services. Fill up the Product Enquiry Form on-line at www.equipment-news.com.

enquiry no.

Page no.Advertiser

BENIGN ENTERPRISE co LTD 35 169

BYSTRoNIc PTE LTD 03 162

DEES hYDRAULIc INDUSTRIES co LTD 65 124

DELcAM PLc 05 017

EhN & LAND ASIA PAcIFIc PTE LTD 49 168

EvERGREEN INTERNATIoNAL coRP / TAITRA (MT DUo 2014) 41 173

EXPoWoRKS SDN BhD (MITF 2013) 51 138

GREENLEAF coRPoRATIoN 33 163

hAAS AUToMATIoN INc 09 157

IScAR LTD Fc / IFc 171

KENNAMETAL INc Bc 068

MAcK BRooKS LTD 15 158

MESSE DUSSELDoRF ASIA (WIRE & TUBE 2013) 45 160

MP oRGANISATIoN PTE LTD (EMTE-EASTPo MAchINE TooL EXhIBITIoN 2014)

77 166

oPTIcAL GAGING (S) PTE LTD 17 174

PT PAMERINDo INDoNESIA (MANUFAcTURING INDoNESIA 2013) 73 161

REED TRADEX coMPANY (METALEX ThAILAND 2013) 69 172

REED TRADEX coMPANY (METALEX vIETNAM 2013) 61 143

RENIShAW (hoNG KoNG) LTD 27 108

SEco TooLS (S.E.A) PTE LTD 01 129

SINGAPoRE WoRKFoRcE DEvELoPMENT AGENcY (WDA) 52/53 176

SUTToN TooLS PTY LTD 75 175

TAEGUTEc co 11 167

TAIWAN TAKISAWA TEchNoLoGY co LTD 71 164

TUNGALoY SINGAPoRE (PTE) LTD 13 165

UBM (ThAILAND) co LTD (INTERMAch MYANMAR 2013) 67 159

WALTER AG SINGAPoRE PTE LTD 07 084

WIKUS SAGENFABRIK WILhELM h KULMANN GMBh & co KG 23 130

YAMAZEN (MALAYSIA) SDN BhD IBc 170

ENTER PRODUCT ENQUIRY NUMBER HEREFOR FAST INFORMATION !

YOUR READERREGISTRATION NO. _________________________ Enquire online @ www.equipment-news.com OR Complete and post to: Eastern Trade Media Pte Ltd, 1100 Lower Delta Road, EPL Building #02-05 Singapore 169206 OR fax to: 65-6379 2806 (Singapore)

To: The Manager, Circulation Department,

From: (Surname) ____________________________________ (Given Name) ________________________________

Job Title: ___________________________________________

Company: __________________________________________

Address: ___________________________________________

__________________________________________________

Country: _________________ Tel: __________________ Fax: _________________ E-mail: __________________

Do you want to receive (continue to receive)Asia Pacific Metalworking Equipment News?❑ YES / ❑ NO (Not valid without signature)

Signature ___________________ Date _________________

SIzE OF COMPANY❑ 001 1 – 10 ❑ 002 11 – 30 ❑ 003 31 – 50 ❑ 004 51 – 100 ❑ 005 101+

TYPE OF BUSINESS (Please ✔ ONE box only)

Do you use METAL in your production/manufacturing process? ❑ Yes ❑ No

Do you use machine tools and related equipment? ❑ Yes ❑ No

Do you use automation systems & equipment? ❑ Yes ❑ No

Note: This form must be duly completed and signed.______________

ENTER ENQUIRY NUMBER (S)

No. 6 2013

YOUR BUSINESS ACTIVITY (Please be specific)

❑ 221 Basic Metal/Foundaries/Mills

❑ 150 Electrical & Electronics production

❑ 222 Telecommunications Equipment Manufacturing

❑ 120 Aircraft maintenance/components mfg.

❑ 223 Dies & Moulds mfg.❑ 122 Motor Vehicles Parts❑ 123 Shipbuilding

❑ 160 Design & Consultancy Services❑ 180 Govt bodies, Trade Assns, Exhibitions Cos.❑ 200 Agent/Distributor/Trader of Machine Tools & Accessories❑ 224 Mechanical, Fabrication and all other metal engineering works

❑ 078 OThERS (Please specify) ____________________________________

❑ 300 CNC Machining

❑ 303 Milling

❑ 306 Gear Cutting

❑ 309 Grinding

❑ 315 Stamping

❑ 318 Shearing

❑ 321 EDM/ECM

❑ 324 Inspection/Measuring/Testing

❑ 301 Design with CAD/CAM

❑ 304 Drilling/Boring

❑ 307 Tapping/Threading

❑ 310 Lapping/honing

❑ 313 Forging

❑ 316 Rolling

❑ 319 Die Casting

❑ 322 Welding

❑ 302 Turning

❑ 305 Coil Forming

❑ 308 Broaching

❑ 311 Plastic Moulding

❑ 314 Pressworking

❑ 317 Automated Assembly

❑ 320 Beading

❑ 323 Electroplating

YOUR METAL PROCESS USED ? (Please be specific)

❑ 350 OThERS (Please specify) ____________________________________________________________________________________________

JOB FUNCTION (Please be specific)

❑ 021 Senior & Middle Management

❑ 023 Maintenance Engineering

❑ 025 Research & Devt

❑ 028 Testing & Inspection

❑ 030 Sales & Marketing

❑ 022 Production Engineering

❑ 024 Quality Control/Assurance❑ 026 Design Engineering

❑ 029 Purchasing/Sourcing

❑ 027 OThERS (Please specify)


(Refer to Advertising Index for Advertisers’ enquiry numbers)

ASIA PACIFIC METALWORKING

The Engineering Journal For Manufacturing, Automation & Quality Control

TYPES OF PRODUCTS TO BE PURCHASED IN THE NEXT 12 MONTHS❍ Cutting Tools ❍ Machine Tools ❍ Software ❍ Metrology ❍ Others_____________


Name: (Surname) ______________________________________ (Given Name) ___________________________

Company: ____________________________________________ Job Title: ________________________________

Address: _________________________________________________________________________________________

Country: _____________________________________________ Telephone No: __________________________

E-mail: _______________________________________________ Fax No: _________________________________

Signature _____________________________________________ Date ___________________________________

SUBSCRIPTION RATESAIRMAIL (1 YEAR – EIGHT ISSUES)

■ *Singapore/Malaysia S$60.00 *(GST applicable) ■ Asia Pacific/America/Europe/ Others S$100.00

YOUR BUSINESS ACTIVITY (Please be specific)

❑ 221 Basic Metal/Foundaries/Mills❑ 150 Electrical & Electronics production❑ 222 Telecommunications Equipment Manufacturing❑ 120 Aircraft maintenance/components mfg.❑ 223 Dies & Moulds mfg.❑ 122 Motor Vehicles Parts

JOB FUNCTION (Please be specific)

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

FAST PERSONAL COPY SUBSCRIPTION FORMINVEST $0.15 PER DAY IN TECHNICAL AND BUSINESS INFORMATION

FOR YOUR CORPORATE STRATEGIES IN SOUTHEAST ASIA

❑ 123 Shipbuilding❑ 160 Design & Consultancy Services❑ 180 Govt bodies, Trade Assns, Exhibitions Cos.❑ 200 Agent/Distributor/Trader of Machine Tools & Accessories❑ 224 Mechanical, Fabrication and all other metal engineering works❑ 078 OThErS (Please specify) ____________________________________

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

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

❑ 022 Production Engineering❑ 024 Quality Control/Assurance

❑ 026 Design Engineering❑ 029 Purchasing/Sourcing

YOUR METAL PROCESS USED ? (Please be specific)

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

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

■ Cheque/Bank draft - made payable to Eastern Trade Media Pte Ltd

■ Amex ■ Visa ■ Mastercard

Send this Fast SUBSCrIPTION FOrM to Circulation Department, Eastern Trade Media Pte Ltd 1100 Lower Delta Road, EPL Building #02-02, Singapore 169206 or Fax: 65-6379 2806

Note: This form must be duly completed and signed.

Account Number

Expiry Date Signature

Cardholder’s name

Commencing from: Year Month

■ Telegraphic Transfer Payment United Overseas Bank, Singapore Bank Code: 7375 Branch Code: 037 Account No.: 921-343-851-0 Company: Eastern Trade Media Pte Ltd

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

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

❑ 350 OThErS (Please specify)

• Receipt will only be issued upon request!

Security ID–

Union Tool co.

Yamazen (malaYsia) sDn. BHDLeveL 1, Wisma samudra, No.1 JaLaN KoNtractor u1/14, sectioN u1,Hicom GLeNmari iNdustriaL ParK, 40150 sHaH aLam, seLaNGor daruL eHsaN, maLaysiaKL tel: 60(3)5569-5099 Fax: 60(3)5569-5011Penang tel: 60(4)399-4021 Fax: 60(4)399-3025Johor tel: 60(7)357-7050 Fax: 60(7)357-7059 ENQUIRY NO 170

uNioN tooL end mill “uNimaX” series is wide coverage of line up for your value-added machining needs. We have every 0.1mm sizes as standard model in less than ϕ6mm end mill.

We, yamaZeN (maLaysia) sdN. BHd., are extending stock now in malaysia. We deliver in time upon your request. For more information, please call us or email to: [email protected]

Carbide Tools for Cemented Carbide!

UNIMAX Sole Agent

We have stock! Sales Promotion is going on

We are UNIMAX Sole Agent

New! Breakthrough diamond coating

UDC CoatingPateNted

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

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

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

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

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

RodekaTM double-sided round inserts:

• Three insert ICs: 10, 12, and 16mm.

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

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

Working harder and smarter. That’s RodekaTM

. That’s Different Thinking.

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

TM

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

To learn more about RodekaTM

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

ENQUIRY NO 068

Documents

APMEN September 2013