June 2011

Transcription

June 2011

jun11
AUSTRALIAN
MANUFACTURING
TECHNOLOGY
Motorsport
– the great
Australian
passion
Story p34
Australian Manufacturing Technology June 2011
Forming & Fabrication > Welding > EDM/Toolmaking > CAD CAM
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CONTENTS
Volume 11 Number 5 June 2011
ISSN 1832-6080
Motorsport
INDUSTRY NEWS
Vale William Henry Sutton 10
Walter Australia’s official open house 12
Autodesk unveils manufacturing
software portfolio 14
AquaGen harnesses waves’ power 17
New centre strengthens manufacturing
innovation 19
Bid for advanced radio telescope for
Australia and NZ 20
Local motor racing manufacturers
help push the pedal to the metal
23
CSIRO helps clinch global car component deal 24
ONE ON ONE
Bruce Griffiths – Federal Government’s
Rail Supplier Advocate 32
MOTORSPORT
Quality goes a long way 36
The Bullet Project land speed record challenger 38
Noonan employs Camplex knowhow
3D printing: Aston Martin Racing 41
From concept to reality 42
34
Australia has had a proud history of
race manufacturing. PWR Performance
Products is just one Australian company
supplying state-of-the-art components
around the world, creating hundreds of
jobs and generating millions of dollars in
turnover and exports. MoTeC electronics,
Albins Gears, Walkinshaw Racing, Kelly
Racing and Borland Racing are other
Australian manufacturers carving out a
name in international racing circles while
contributing to Australia’s manufacturing
skills base.
Australian government’s record $3bn for CSIRO 20
Carbon tax – offshore options considered Lead Story
Welding
64
CAD/CAM
66
Estimating total welding costs
Keeping your welding costs low goes far
beyond buying the lowest priced wire
available. You must analyse how welding
processes that increase deposition rate
and increase productivity will reduce the
largest component of welding costs –
your labour and overhead.
Software proves to be key to success
Speed: the one thing that matters 46
Toro Ross F1 and Geomagic Qualify 48
FORMING & FABRICATION
m3Plasma system for weld preparation 52
Heavy plate bender – upstroke & downstroke 54
Entry level sophistication: sheetmetal fabrication 56
Optimal tool path = reduced production times 58
Hypertherm’s new fibre laser 59
Knowledge-based CAM goes from
strength to strength
Increasingly, developers of CAM
software are moving towards
knowledge-based machining,
especially for simpler parts that can
be produced by prismatic machining,
KBM can be incorporated into
CAM systems at various levels. By
comparing the three different styles
of programming - operations-based,
process-based and feature-based
programming, the different approaches
to KBM can be compared.
WELDING
Revolution in steel-beam fabrication 60
Weldmatic brand to survive 62
CAD/CAM
Intercad debuts SolidWorks 2011 68
iMachining: a CAM revolution 70
From hours to seconds – Miller CNC 72
Mastercam X5 for SolidWorks 74
COVER DETAILS
AMTIL FORUM
Training – Behavioural profiling 82
OHS – Worker responsibility under OHS law 83
76
Strategies – Innovation & opportunity capture 84
Efficient machining of micro EDM electrodes 78
Pressing ahead with software automation 80
Law – Protecting the appearance of your
new products 85
EDM & TOOLMAKING
Automated EDM – the way forward? 4
The Kelly Bros of Kelly Racing.
The Kelly family
established their
own team in
the V8 Supercar
Championship
Need finance to lift
your exports?
If financial barriers are holding back your export business,
talk to EFIC. Our finance solutions, including performance
bonds and advance payment bonds, can help free up your
working capital for your export activities.* We work with
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Overcoming financial barriers for exporters
5
EDITOR in Chief
Martin Oakham
[email protected]
Ph: +61 3 9800 3666
Fax: +61 3 9800 3436
CONTRIBUTING Nina Hendy
EDITORS
[email protected]
Ph: +61 3 5333 4939
ADVERTISING SALES
MANAGER
Anne Samuelsson
[email protected]
Ph: +61 3 9800 3666
Fax: +61 3 9800 3436
PUBLICATIONS co-ordinator
Gabriele Richter
[email protected]
Ph: +61 3 9800 3666
Fax: +61 3 9800 3436
PUBLISHER
Shane Infanti
[email protected]
Ph: +61 3 9800 3666
Fax: +61 3 9800 3436
DESIGN: Graphic Heart Pty Ltd
COVER DESIGN: Typographics
PRINTER:
Printgraphics - Australia
Post all correspondence to:
Australian Manufacturing Technology
Suite 1, 673 Boronia Road,
Wantirna, Victoria 3152, Australia
Copyright Australian Manufacturing Technology
(AMT). All rights reserved. Magazine or part
thereof may not be copied or reproduced without
written permission by the publisher. Contained
specifications and claims are those of the
manufacturer.
Disclaimer: The opinions expressed by AMT
contributors or editorial staff are not necessarily
those of AMTIL.
AMT is dedicated to Australia’s machining,
tooling and sheetmetalworking industries and is
published monthly (10 issues). Subscription to
AMT (and other benefits) is available through
AMTIL associate membership at $120pa.
Suite 1, 673 Boronia Road,
Wantirna, Victoria 3152.
Ph: 61 3 9800 3666
Fax: 61 3 9800 3436
www.amtil.com.au
6
Martin Oakham
Editor in Chief
Editorial
What’s in it for manufacturers?
he strong Aussie dollar and GFC have, of course, had a significant
impact on manufacturing here in Australia, but for the ‘glass half full’
amongst us, the budget offers us hope. It addresses many of the key issues
we’ve been facing including education, training and contract procurement.
It appears that Wayne Swan, Deputy Prime Minister and Treasurer,
has acknowledged that the manufacturing sector is vital to this nation,
by making it one of the key beneficiaries of the skills package focus on
apprentices and training. The chief aim here is to counter the skills shortage currently faced by the manufacturing industry. In addition, there is a
$34.4m ‘buy Australian at home and abroad’ program that will make its
aim to secure a higher level of Australian manufacturing involvement in
big resources projects, especially for SMEs. This much welcomed program
will help link local suppliers and manufacturers to project opportunities
and enable Australian companies to benefit from the booming sectors.
This new initiative will no doubt help Australian suppliers identify the
opportunities and how to get on board. The Government will help buyers
understand the strength of the local manufacturing and service sectors.
Through the Industry Capability Network (ICN), specialist advisers will
work with the procurement teams of major projects like the Woodside
Browse LNG development in Western Australia, the INPEX Ichthys project
in the Northern Territory and LNG projects in Queensland. Increased
funding of $1m per annum will facilitate an expanded ICN. To coordinate
these activities, the Federal Government will establish a Resources Sector
Supplier Advisory Forum and appoint a Resources Sector Supplier Envoy
in consultation with the Minister for Resources and Energy.
Another ‘newbie’ is the $21m ‘Inspiring Australia’ program which
will help bring science to every Australian. The aim is to put more young
people on the path to science careers, celebrate Australia’s great strengths
in science and help people understand what science can do to improve
their lives. It will co-ordinate the efforts of Australia’s research agencies,
media outlets, universities, academies, professional bodies, the business
sector, state-based science centres and museums and community-based
organisations. This will be funded with $2.4m over three years.
On the downside, nothing has been done to re-visit the green car innovation fund or address the high cost of energy. $220m has been cut from
its ‘Solar Flagships’ program, which helped fund feasibility studies into
large-scale solar power plants. Further, the carbon capture and storage
programs are to lose more than $400m in funding.
So, whilst the 2011 budget certainly contains some positive measures,
especially in relation to skills and training, Australian manufacturers will
continue to struggle with high labour costs on a global scale, which is unlikely to alleviate the rising costs of production. International competition is
a major hurdle and Australian businesses are very much up against it. That
said, ‘new technologies’ outside the reach of developing economies, offer
great opportunities and it’s here that the government seems to be focused.
SIX NEW ANGLES ON
SQUARE SHOULDER MILLING.
c-#2/..#(!!-*,#(-,.
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The locking screw is placed in the same
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c.",# ,(.#(-,.!)'.,#ME09 for stainless steel; M13 for steel and cast iron;
MD15 for harder materials and higher cutting speeds.
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',,#!) )()'3(*, ),'(
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E-Mail [email protected]
7
$17m to boost jobs growth in
SA’s south-east
From the Minister
Senator Kim Carr,
Minister for Innovation, Industry,
Science and Research
ederal Innovation Minister Senator Kim Carr and South
Australian Industry Minister Tom Koutsantonis are
encouraging South Australian businesses to help boost jobs
and innovation in the state's south-east. The push marks the
opening of the $12m South-East South Australia Innovation
and Investment Fund (SE SAIIF) to applications. The Fund
is a joint initiative between the Australian and the South
Australian governments and it is expected the investment
will create new long-term jobs in high-value manufacturing.
The Fund was announced by the Ministers earlier this year
following an announcement by Kimberly-Clark that more
than 200 jobs would be lost at its Millicent site. The $12m
SESAIIF program is part of a $17m package which includes
up $5m for a labour adjustment program for KimberlyClark displaced workers that involves skill assessment and
re-skilling workers.
Carr said both governments have worked hard to put the
assistance package in place quickly to offset any hardship
the local communities may endure. “Around 170 permanent
and 35 temporary jobs have been lost from Kimberly-Clark's
Millicent Mill following the international company restructure,” Carr said. “And a further 65 Australian jobs could
be lost if there is no buyer for the Tantanoola pulp mill.
“The Government cannot and will not stand by and watch
families and communities struggle through circumstances
such as this. Through SE SAIIF grants, we will invest in
projects that will lead to the creation of high-value, highskill jobs in the south-east region. This will strengthen the
region’s manufacturing and service capacity and minimise
unemployment.” Koutsantonis said the funding provides a
timely opportunity to achieve just that while diversifying
the region’s economy.
“The south-east is home to a major regional city –
Mount Gambier – as well as several other commercial and
service centres with access to infrastructure and transport
networks, making it a great place to value-add and grow
emerging industries,” Koutsantonis said. Federal Senator Anne McEwen visited Millicent in South Australia's
south-east on 17 May to speak with the local community
and officials about the Fund. Businesses looking to apply
for funding can also attend information sessions in the
State. More information on these sessions will be provided
through the local media. The Fund will be available over
the 2011-12 to 2012-13 financial years. Applications close
5.30pm AEST 12 August 2011.
www.ausindustry.gov.au
[email protected]
Federal Budget hits
and misses
From the CEO
Shane Infanti
CEO AMTIL
his year’s Federal Budget provided some good news for
manufacturers in relation to building skills and infrastructure. The bad news was that key issues such as export development and investment in technology were again passed by.
The establishment of a National Workforce and Participation Agency will further enhance the national perspective on
skills and training. In addition, the $558m National Workforce Development Fund will continue to address critical
skill shortages and provide tangible incentives for small to
medium manufacturers looking to upskill their workforce.
This fund will include the $200m Critical Skills Investment Fund, through which AMTIL has applied for $5.6m
to service our industry sector over the next three years.
We are also pleased to see additional funding for apprenticeships included in the budget. The $100m over four
years will aid industry and support accelerated apprenticeships which will enable competency based progression of
much needed skills in manufacturing. AMTIL has strongly
supported this notion for many years. Apprenticeship men-
8
toring has also been noticed with $101.4m being allocated
to support services to apprenticeship. Some of you may
remember AMTIL’s Youthlink mentoring program from
many years ago. It is pleasing that the role mentoring places
in apprenticeship completion rates and “fast tracking” has
been recognised by this Government.
Whilst the focus on skills and returning the budget to
surplus was high, it was disappointing to see that not enough
has been done to assist our manufacturing sector in relation to exports and investment in innovation. These are key
elements of a strong and healthy manufacturing sector and
have largely gone unrecognised. The forecast strong growth
of our economy has overshadowed current weaknesses and
uncertainty with our major manufacturing sectors. The high
Australian dollar, coupled with changes to the Export Market
Development Grant making it harder for companies to access, are contributing to a slowing of our export potential.
AMTIL will continue to work with Governments at all
levels to seek out strategies that will address these issues.
Of particular importance will be the creation of a significant national program focused on export development and
an investment program focused on incentives to invest in
technology and innovation. Without these two fundamental
measures, industry will continue to be critical of Government’s lack of focus on our manufacturing future.
Securing a competitive and
sustainable manufacturing industry
From the Industry
Heather Ridout –
Chief Executive Australian Industry Group
he Federal Budget had a strong focus on the fundamentals of fiscal restraint, skills and training and increased
infrastructure investment. However, it was disappointing that
more wasn't done to support businesses on the wrong side
of the minerals boom under pressure from the high dollar.
The big training reforms were based on an Ai Group
proposal to establish a National Workforce Development
Agency. Under the new arrangement, industry will have a
major voice in the training system while also shouldering
its share of the responsibility. This new platform will better match economic needs to skills development in order to
maximise return on investment in terms of skills enhancement, productivity and jobs.
Increased investment in workforce skills, literacy and
apprenticeships including the delivery of an additional 13,190
places in the Workforce English Language and Literacy program, additional funding of $19.7m for the Apprenticeship
Access Program, $100m over four years to assist industry
in developing strategies to support competency-based progression and $101.4m over four years to provide mentoring
support services to apprentices, were very welcome initiatives and long advocated by Ai Group.
Still on skills, we had sought an increase in the skilled
immigration program to pre GFC levels and the Government
went part of the way, lifting the program from 168,000 to
185,000. The 16,000 permanent migration places for regional
areas and fast track temporary visas for major resource
projects are also positives.
This immigration boost will certainly help in the delivery
of some of the new investments in transport infrastructure
outlined in the Budget. These projects will also be assisted
by the improved resourcing and additional responsibilities
for Infrastructure Australia.
Despite these investments, more needs to be done to
offset the risks to the economy due to the impact of the
strong dollar on sectors such as manufacturing. It is disappointing, despite the frequent acknowledgement of the
problem, that little has been done by way of programs to
address the lopsided nature of the economy with the Budget
very light on investments in innovation, business capability development and exports – which is where the future
of manufacturing lies.
One of the biggest issues facing the Australian economy
is how we secure a competitive and sustainable manufacturing industry in this country. To help develop strategies
to address this, Ai Group is conducting a Manufacturing
Industry Study involving more than 400 businesses across
the many sub-sectors of the sector. The study includes a
survey which will analyse the performance of the manufacturing industry and identify areas of priority for policy
reform. It will also highlight key successes within the
industry, which will provide valuable insights and lessons
for achieving growth. Furthermore, it will provide an upto-date reference guide on the state of the overall industry
and its importance to the broader economy.
We have also been calling for some time for more discussion about what can be done about the high dollar. Our
surveys show only 7% of exporting manufacturers can be
competitive with dollar at parity or above. This pain is
further reflected in our manufacturing index which has been
in negative territory for seven out of the past eight months.
We will be using the manufacturing study to have a
fresh look at strategies to deal with the unbalanced nature
of the economy and to support businesses under pressure.
While the Budget did not make sufficient investments in
areas such as innovation, R&D and exports which would
help manufacturers, our study will be an opportunity to put
new proposals to the Government for action that will help
preserve a balanced and diversified economy.
Stay connected with the Boge iPhone APP
Boge has recently launched a new iPhone APP designed
to provide compressed air users with a remote monitoring solution. The Boge APP allows the compressed air
user to remotely view important site information such
as temperature, pressure, operating and idling times.
As a mobile application the user can log in anywhere
and at anytime to monitor their compressed air system.
Crucially, the APP alerts the user with any fault messages or warnings. The APP complements Boge’s range
of compressed air monitoring tools and ensures that a
Distributor and / or End User can continuously monitor
their compressed air system.
The APP receives data from the Boge airstatus remote
auditing system which is installed inside the compressor. This machine data retrieval tool ensures that even
the most remote or difficult to reach compressors can
easily be monitored enhancing production reliability.
BOGE Compressors (Australia) Pty Ltd is the Australian Daughter Company of BOGE International GmbH
based in Bielefeld, Germany. BOGE manufactures a
comprehensive range of oil lubricated and oil free screw
and piston compressors used by all sectors of industry to
supply compressed air for a wide range of manufacturing processes. It also supplies a complementary range of
filters, dryers and condensate management equipment.
The product is sold and serviced through a growing
network of dedicated distributors throughout Australia.
The BOGE iPhone APP is available for download
from the Apple Store.
BOGE Compressors (Australia) - 08 9528 2157
[email protected]
www.boge.net.au
9
Industry News
Vale – William (Bill) Henry Sutton
20 July 1934 – 27 April 2011
Director of Sutton Tools
Bill Sutton started his working career as an Engineering
Cadet with General Motors Holden at Fishermans Bend after
leaving secondary School in 1952. During his cadetship Bill
attended RMIT to study for an Engineering Diploma. After
completing his engineering studies Bill joined the family
business Sutton Tool & Gauge Mfg. Co. which at this time
was located at Northcote, Victoria. However, Bill’s interest
in Sutton Tools didn’t start then, his father, Henry George
Sutton, had made sure that Bill worked at the factory during
school holidays and sometimes at weekends.
As a young boy, Bill would have to clean machines
from top to bottom - this is where his great knowledge of
engineering and cutting tools all began. Bills knowledge of
manufacturing taps, milling cutters, reamers, hobs, thread
rolling dies and special tools grew as he worked within the
engineering departments. Sutton Tools was the Australian
leader, but the learning process didn’t stop there. In 1958
Bill was sent to England to work at several iconic British
tool manufacturers, which at that time were considered to
be the leading cutting tools manufacturers in Europe. Bill
also pursued an in-depth study of the local English pubs,
which earned him a reputation that stayed with him for
many years. He was notorious in Sheffield, which he visited
on many occasions.
Bill returned to Australia in 1960 and was given the
assignment to start twist drill production at a new factory,
located at Settlement Road Thomastown, Melbourne. This
assignment again required Bill to travel overseas to Europe
and the USA in order to investigate the best methods of
manufacturing drills in high volume. Whilst in the USA
Bill discovered a new range of machines for grinding drills
from solid. Up until then, all Australian-made drills were
produced using the roll forging method by Patience &
Nicholson, a competitor located in Maryborough Victoria.
Bill determined that grinding the f lutes from solid made
a better drill and proceeded with purchasing the Hertlein
machines from the USA. This decision has proved to be
smart, as today the best drill manufacturers in the world
use this method for making drills. Under Bill’s management the Thomastown plant continued to grow and in 1964
the Northcote factory, along with the head office were
relocated to Thomastown.
The 1970s proved to be a decade of economic difficulty
for Australian manufacturing. It was also during this period
that Bill’s father, Henry George Sutton died. Bill and his
brother Jim (the third generation of Suttons) took up the
reins as joint Managing Directors and steered the business
through these challenging times. They did this by remaining
dedicated to employing the best new technology, developing
highly qualified staff and manufacturing precision cutting
tools to the highest global standard. Under the dedicated
10
leadership of Bill and Jim Sutton, the business continued
growing, expanding the product and acquiring other like
businesses. These included a small business manufacturing holesaws which Sutton acquired in the 1980’s. Further,
Surface Technology Coatings was established as a wholly
owned subsidiary of Sutton Tools and provided the only
PVD hard film coatings in Australia.
The acquisition of Patience & Nicholson, the major
competitor in Australia, was perhaps Sutton’s greatest
achievement. After the purchase Bill said “I always wanted
to own a factory at Sutton Road, Maryborough”. Today Sutton Tools boasts four modern manufacturing plants, three
distribution centres including New Zealand, Singapore and
Europe and employs some 450 staff.
In recognition of a lifelong contribution to Australian
manufacturing, Bill Sutton in 2010 was nominated and listed
on the honour roll of the Victorian Manufacturing Hall of
Fame - a prestigious award and an honour given to very few.
Bill Sutton retired in 1995 but remained actively involved
as a Director in the business; unfortunately Bill suffered
an illness and died on 27 April 2011. We mourn the loss
of a leader and a friend who always maintained high business ethics, and offered wise counsel to many of us. It goes
without saying that Bill’s life achievements and contribution
to the greater community gives rise to a true Australian, it
has been an honour to have known him. Our thoughts are
with Bill’s family.
www.kraas-lachmann.com
Tiger·tec® Silver is the new highperformance miracle tool for steel
and cast-iron milling from Walter.
Extremely tough, extremely hard and
extremely long-wearing, it improves
performance by up to 100%.
The machining age is over.
It’s time to Tiger.
Competitor
Tiger·tec®
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Tiger·tec®Silver
Walter Australia Pty. Ltd.
Hallam, Victoria
+61-3-8793 1000
[email protected]
www.walter-tools.com
11
Industry News
Walter Australia's official open house
As opportunities continue to expand
for its global parent operations based
in Western Europe, Walter Australia
has officially opened new premises in
Hallam, Melbourne, after a decade of
operation across Australia, shifting
from Noble Park in order to better serve
its staff, its distributors and end users.
The official opening was marked by
a visit from Walter AG Vice President
Pawel Duzniak, who divides his time
between Vienna, and Walter Headquarters in Tübingen, Germany.
"Only 15 years ago, Walter was
doing 75% of its business only in Germany," Duzniak said. "Today, we are
distributed all over the world."
Above: Walter AG
Vice President
Pawel Duzniak
Far left: Pawel
Duzniak with
Walter Australia
Managing
Director
Neil Hyde
Walter Australia Managing Director Neil Hyde addressed
attendees, which included key industry figures from Australia, New Zealand, and the German-Australian Chamber
of Industry and Commerce, before introducing Duzniak,
who gave a presentation situating Walter Australia within
expanding Walter global operations.
"We are very successful," Duzniak said, "and we are
growing above the market average."
"We develop not only tools, as such, but the strategies
and methodology of the implementation of our tools,"
Duzniak said. "We have global service, where we can support our customers on their sites, wherever they have their
manufacturing."
12
In an age of highly competitive precision manufacturing, Walter has been innovating in highly engineered tool
coatings. While other toolmakers seek to solve overheating problems with coolant, Walter—with its three-century
industry pedigree—develops coatings that do not heat
excessively in the first place.
"Our aim is to be seen as a competence leader in manufacturing technology," Duzniak said. "Not only as a provider of good-quality cutting tools, but a provider of the
metallurgy of how to cut materials—we can cover almost
95% of all applications in turning, milling drilling and
threading."
Boasting a large multipurpose room suitable for meetings, training, and large events, as well as a boardroom,
the new Hallam premises is soon to be equipped with a
DMG machine, for onsite product testing, demonstrations
and training.
With in-house design engineering at its new Hallam
premises, Walter will be providing a nationwide customtooling service, for when the perfect solution is not already
available from the 56,000-item product line currently available in Australia.
Walter Australia Pty Ltd - 03 8793 1000
55-61 Nissan Drive, Dandenong, Victoria 3175
Tel: (03) 9706 8066 Fax: (03) 9706 8067
[email protected]
www.appliedmachinery.com.au
13
Industry News
Autodesk unveils 2012 manufacturing
software portfolio
Autodesk, Inc. has recently introduced its
new 3D design and engineering software
portfolio for manufacturers, including the
new Autodesk product design suite that
makes design, visualisation and simulation software easier to adopt, use and
maintain. The complete Autodesk digital prototyping software portfolio helps
manufacturers to design and build better,
more sustainable products, reduce development costs and get to market faster.
‘No product design and development
challenge is too complex to overcome
when you combine the powerful 3D mechanical design capabilities of Autodesk Inventor together
with world-leading Autodesk visualisation and simulation
software,’ said Robert Buzz Kross, senior vice president,
Manufacturing Industry Group at Autodesk. ‘Our customers need to create remarkable products more efficiently.
The new Autodesk Product Design Suite makes it easier
for manufacturers to adopt digital prototyping workflows
to achieve this goal.’
Autodesk Product Design Suite is a new, comprehensive
and cost-effective design solution for creating compelling
products. The new suite provides flexibility to innovate and
more easily respond to changing business requirements from
early concepts to detailed engineering and simulation. According to its developers, the Suite also provides significant
cost savings and is easier to deploy, maintain and manage
than stand-alone products.
Autodesk offers three editions of the Product Design
Suite, namely Standard, Premium and Ultimate. The Standard suite offers foundational conceptual design and drafting
tools for product design, featuring AutoCAD Mechanical,
Autodesk Showcase, Autodesk SketchBook Designer, Autodesk Vault and Autodesk Mudbox software.
The Premium suite optimises digital Prototyping and
visualisation tools for maximum performance that features
standard edition tools along with Autodesk Inventor and
Autodesk 3ds Max Design software. The Ultimate suite
features advanced surfacing, simulation and tooling and has
the same tools as the Premium edition along with Autodesk
Inventor Professional and Autodesk Alias Design software.
Combining Inventor Professional products with the software powering Hollywood-quality imagery, movies and interactive presentations has enabled Autodesk to create visually
impressive and dynamic engineering solutions for our design
and engineering teams,‖ said Carl Maas, CAD/engineering
services manager with L-3 Communications, Power Paragon,
Inc. ―With the new Autodesk Product Design Suite we can
create, validate and communicate our digital designs with
even greater confidence and shortened development time.
Autodesk Factory Design Suite 2012 is a factory layout
and optimisation solution that helps manufacturers make
better layout decisions through the creation of a digital
factory model. It offers unique factory specific functionality in both AutoCAD Architecture and Autodesk Inventor,
14
combined with Autodesk Navisworks’
powerful visualisation and analysis
and Autodesk Vault to improve collaboration. New additions to the suite
in 2012 include AutoCAD Mechanical
for automating mechanical CAD tasks
and 3ds Max Design and Showcase for
enhancing communication and bids.
Autodesk Inventor Fusion brings
3D direct modelling to range of Autodesk products
Autodesk Inventor Fusion makes its
commercial debut and is now included
at no extra cost as a companion application to Autodesk Alias Design and Alias Automotive,
Autodesk Inventor, Autodesk Moldflow, Autodesk Simulation
and AutoCAD products. Inventor Fusion provides robust 3D
modeling ease-of-use and direct modeling for rapid design
changes. It also unites direct and parametric workflows
within a single digital model created in Autodesk Inventor.
Each product in the ‘Manufacturing portfolio’ offers
powerful new capabilities, spanning conceptual design,
engineering, manufacturing and technical documentation.
AutoCAD Mechanical 2012 enables editing 3D models from
any source with Inventor Fusion and intelligent drawing
view creation with a new model documentation feature.
Also new is mobile and web viewing and editing through
AutoCAD WS, so mechanical engineers can spend more
time innovating.
Autodesk 3ds Max Design 2012 visualisation software
enables you to demonstrate the operation of designs in
real-world settings, providing seamless aggregation of
CAD data and transforming digital prototypes into highquality visuals with ―push-button‖ rendering and cinematic
quality animation. Alias Design, Alias Surface and Alias
Automotive software ― make it easier to create accurate
3D models with Class-A surfaces and feature improvements
to the technical surfacing process with modelling tools that
are dramatically easier to use.
Autodesk Inventor 2012 provides easier ways to interact
with 3D mechanical design data; new opportunities for sharing, accepting and updating CAD data regardless of source
and complexity; and high-impact performance and productivity improvements for both users and IT departments.
Autodesk Moldf low 2012 introduces new real-time
injection-moulding simulation functionality, enabling dynamic evaluation of a range of plastic part design alternatives in a fraction of the time it takes to perform a standard
simulation, helping to pinpoint the best design more quickly.
Autodesk Vault 2012 product data management software
gives workgroups across multiple locations more control
over engineering data and documents from design through
manufacturing, expanding its integration to additional
Autodesk applications, including Navisworks, Inventor
Publisher and Autodesk Simulation.
Autodesk
www.autodesk.com.au
CO-LOCATED WITH
21-23 JUNE 2011
SuPPORTED BY
BRISBANE CONVENTION
& EXHIBITION CENTRE
REGISTER TO VISIT QLDSAFETYSHOW.COM.Au
15
Are you benefitting from a major Government
initiative that supports manufacturing/you?
The initiative is Enterprise Connect
A $50 million per annum Australian Government initiative
aimed at delivering practical support to Australian
manufacturing firms.
Enterprise Connect delivers two main services:
AMTIL is one of 15 partner organisations that support
this Initiative and is keen for both AMTIL members and
non-members to benefit from this.
– Tailored Advisory Services funding up to $20,000 to
help the firm implement improvements arising from the
Business Review.
– a Business Review, delivered by a Business Adviser
at no charge to the firm; and
To qualify
• you possess an Australian Company Number (ACN)
• you are a manufacturer
• if located in Melbourne, Sydney, Adelaide, Perth or Brisbane - have revenue or expenditure of more than $2 million and
revenue or expenditure under $100 million in the current financial year or one of the two preceding financial years
• if located in a regional area, that is, outside the above cities - have revenue or expenditure of more than $1.5 million and
revenue or expenditure under $100 million in the current financial year or one of the two preceding financial years
16
If based in Melbourne:
Call the AMTIL business adviser,
Bruno Bello on 0409-123-701
Email [email protected]
Or go to www.enterpriseconnect.gov.au
Industry News
AquaGen harnesses waves' power
on price with the more traditional forms of
AquaGen Technologies has prototyped their
renewable energy."
key technology, SurgeDrive, a ground breakBoyd says that without a working protoing wave energy system which harnesses the
type it is difficult to gain investment in an
energy of ocean waves to produce electricity
idea. A proven concept has put AquaGen
or desalinated water.
ahead of competitors and helped refine its
A technology company specialising in solubusiness strategy into a commercially realtions to deliver clean, renewable ocean energy,
istic plan. "Many investors will only invest
AquaGen installed an open water working
once they see a working prototype in its
prototype at Lorne Pier in Victoria - successnatural environment. Commonly known
fully demonstrating its potential to withstand
as 'the valley of death' this is where you
powerful ocean storms and compete on price
need to prove that you have something of
with traditional forms of renewable energy.
real value but you don't have the cash flow
Managing Director Nick Boyd says Aquato demonstrate it.
Gen has been supported by the Department of
"We have ref ined our message, reInnovation's Commercialisation Australia and
searched our markets, honed in on potential
R&D Tax Concession programs.
partners and innovated the next step in our
"We needed assistance in proving the conAquaGen's prototype at Lorne
product development. Our growth at this
cept of our wave power device in an open water
Pier, Victoria
environment which would then allow a flow
stage is fuelled 100% by our innovation".
of development capital into the company. We also needed
By permission from AusIndustry
assistance in expanding our skills and knowledge in order
to enhance our chances of commercialising the product."
AMT magazine would like to apologise for the incor"The support enabled us to complete the build and instalrect contact details given last month following the
lation of our first open water SurgeDrive demonstration unit
article “Fanuc – The latest generation of CNC controlon Lorne Pier in Victoria. The unit demonstrates that our
lers” printed on pages 96-97. This should have been:
technology is able to convert the power of the ocean’s waves
Fanuc Oceania - 02 8822 4600
into electricity in a world-first configuration which has the
potential
to
allow
wave
power
to
compete
for
the
first
time
AMTM_AU_3406143_EMO Hannover 2011 02.05.11 14:48 Seite 1
The world of metalworking
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INFO:
VDW – Generalkommissariat EMO Hannover 2011
Verein Deutscher Werkzeugmaschinenfabriken e.V.
Corneliusstrasse 4, 60325 Frankfurt am Main, GERMANY
Tel. +49 69 756081- 0, Fax +49 69 756081-74
[email protected] · www.emo-hannover.de
17
Tech News
Germany: Perfect welds for car bodies
Surface welding instead of penetration welding, allows a
laser to produce a weld that is only visible on one side. But
how do you control the laser power to prevent it burning
a hole through the sheets of metal? A new camera system
analyses thermal images in real time - and ensures a perfect
weld. Expensive work to hide the weld seam, such as folding
the sheet metal or covering with trim would no longer be
necessary. This is termed “controlled partial penetration
welding”, in contrast to full penetration welding, where a
hole briefly forms in the melt pool. .Up to now it was not
possible to precisely control this type of welding and produce
a seam that meets strength requirements. An innovative
camera us used that generates temperature images. This
enables the system to recognise how deep the laser has
penetrated into the sheets. Zinc does not vaporize on the
bottom side of the weld; consequently corrosion problems
encountered on galvanized car bodies are a thing of the past.
Fraunhofer IPM
Japan: Laser sparks : internal combustion
engines
Car manufacturers are closer to replacing spark plugs with
laser igniters. Previously, lasers strong enough to ignite
an engine’s air-fuel mixtures were too large to fit under a
car's hood. This multibeam laser system is small enough
to screw into an engine’s cylinder head and is made from
ceramics, therefore could be produced inexpensively in
large volumes, according to Japan's National Institutes of
Natural Sciences. Spark plugs can erode electrodes so fast,
the solution is not economical. By contrast, lasers have no
electrodes and are not affected. Additionally, lasers inject
their energy within nanoseconds, compared with milliseconds for spark plugs, provide better performance and fuel
economy, and reduce emissions. The work is supported by
the Japan Science and Technical Agency.
Optical Society of America
USA: Strong and now cheap - new way to
process metallic glass
Stronger than steel or titanium - and just as tough - metallic glass is an ideal material for many applications. A new
technique has been developed that allows the production
of metallic-glass parts utilising the same inexpensive processes used to produce plastic parts. With this new method,
a piece of metallic glass can be heated at a rate of a million
degrees per second and then moulded into any shape in just
a few milliseconds. It is made of a metal that's 20 times
stronger and stiffer than plastic. The glass is heated at least
a thousand times faster than anyone has before.
California Institute of Technology
Germany: Lasers cut fibre-reinforced plastics
To reduce weight, manufacturers are increasingly turning to
the use of fibre-reinforced plastics for cars. The disadvantage
is that these new materials are difficult to process.. However
lasers can cut fibre-reinforced plastics without wear and can
18
join them too. They can even be joined to metals with laser
welding. The laser roughens the metal surface, while the
plastic, briefly-heated, penetrates the pores of the metal
and hardens. At Laser 2011, Fraunhofer presented, for the
first time, a new welding head capable not only of focusing with extreme precision but of moving back and forth
across the seam with high frequency to mix the molten
materials. When they harden, they create a stable bond.
Fraunhofer
Switzerland: Curtains that quench noise
Researchers have developed lightweight, translucent
curtain materials which quench five times more sound
than conventional translucent curtains. The combination of light weight and translucence has been lacking
until now. Yarns were chosen that gave materials the
necessary characteristics in terms of flammability and
translucence and the weave structure was then determined. The sophisticated manufacturing process was
then adjusted so that the curtains displayed the required
acoustic characteristics
Swiss Federal Laboratories for Materials Science and
Technology (EMPA)
Germany: Sensors that can stretch
Researchers have now developed sensors capable of expanding, in extreme cases, to twice their original length
and so supple as to go virtually unnoticed when sewn
into clothing. The sensor films can measure stretch, as
well as pressure and are made of a highly stretchable
elastomeric film, coated on both sides with flexible
electrodes.. These sensors have a wide range of applications - eg measuring the pressure of gases. To do this,
the elastomer film is stretched. If gas exerts pressure
on the sensor membrane, it deforms – which is detected
by the sensor. Pressure sensors are also useful in safety
technology: eg: if someone enters an area too close to a
hazardous machine, sensors embedded in the floor can
detect this and set off a warning.
Fraunhofer Institute for Silicate Research
Sweden: Third of tested plastic products leach
toxic substances
Many plastic products contain toxic residual chemicals,
additives and degradation products that can leach, as
they are not bound to the plastic polymer. Global annual production of plastics has doubled over the past 15
years, to 245 million tonnes in 2008. At the University
of Gothenburg, the toxicity of 83 randomly selected
plastic products and synthetic textiles was undertaken.
The products were leached in pure (deionised) water for
1-3 days. The acute toxicity of the water was then tested
using water fleas. Five out of 13 products for children
were toxic, despite the leaching being mild. Examples of
plastic polymers made from the most hazardous chemicals are certain polyurethanes, polyacrylonitriles, PVC,
epoxy and certain styrene copolymers.
University of Gothenburg
Industry News
New centre
strengthens
manufacturing
innovation
A new multi-million dollar Victorian Centre for
Advanced Materials Manufacturing (VCAMM)
facility has been opened in Knoxfield, Melbourne to
spur new opportunities in innovation and research.
Officially opening the centre, Minister for
Manufacturing, Exports and Trade Richard DallaRiva said the facility will draw international
projects and focus to Victoria, promoting local
industry capabilities and reinforcing the state’s position
as the manufacturing hub of Australia.
“Since its formation in 2002, VCAMM has assisted a
large number of Victorian companies build their innovation
potential and helped orchestrate the resources needed to
develop and commercialise globally-relevant new technologies,” Mr Dalla-Riva said.
“The centre’s support of new technology development
and assistance for high technology businesses, including
small start-ups and SMEs, will create valuable, high tech
jobs inVictoria.”
VCAMM Chief Executive Officer Brad Dunstan said
the Innovation Centre will accommodate around 50 staff
members from a mix of small start-up companies and
larger, established organisations that will work in a flexible
environment to undertake advanced engineering projects.
“This new centre represents the next step in the evolution
of the VCAMM mission. It will provide a focal point for
industry and research collaboration, assisting VCAMM in
its role to coordinate interaction in the advanced materials
and advanced manufacturing arena, allowing enterprises to
develop technologies in a unique incubative environment,”
Mr Dunstan said.
Minister Dalla-Riva said the Victorian Coalition Government is committed to ensuring manufacturing businesses
have greater access to new research and technologies,
expanded markets and future opportunities through en-
hanced relationships with tertiary and R&D institutions
and industry-focused government assistance.
“Victoria’s science and engineering capabilities continue
to see our state excel globally, and many major international
companies have chosen to invest in Victoria by establishing
worldclass R&D facilities here,” Dalla-Riva said.
“Victoria has considerable skills in advanced materials
and advanced manufacturing technologies. VCAMM’s role
is to provide businesses of all sizes with managed access
to this expertise and the Victorian Government is pleased
to support this work.
“Innovation is a key driver of our economy and the
new centre will further enhance the ability for our local
manufacturing businesses to innovate,” Dalla-Riva said.
After officially opening the new VCAMM Innovation
Centre Dalla-Riva toured the facility and learnt about some
of the outcomes from VCAMM’s most recent collaborations,
including the use of advanced materials to develop bushfire
protective solutions, green technology for the production
of high-value chemicals and innovative surface treatments
for the auto and aerospace industries.
VCAMM Ltd is a not-for-profit company representing
a consortium of public research and development organisations. VCAMM facilitates technology development and
commercialisation for Australian manufacturing businesses.
It identifies technology projects, partners, capabilities and
commercial opportunities, and also assembles resources
and manages program delivery.
Japan’s tragic earthquake impacts on
Toyota’s Australian operations
The continued repercussions of the earthquake in Japan
have hit manufacturers around the world, including
Toyota’s Australian operations. Vehicle production at its
Altona manufacturing plant will be reduced to about 50%
in May and June. Innovation Minister Senator Kim Carr
said the Government is pleased that the 3300 workers at
the Toyota Australia plant will remain in work.
“The company, workers and their unions have worked
together to ensure that jobs will be kept, and it is my
understanding that the jobs of Toyota workers are not
at risk,” Carr said. “They will work half-day shifts to
continue to produce vehicles and, when possible, undertake training.This situation has been brought about
by the after-effects of the recent Japanese earthquake
and tsunami. The problem is not unique to Australia.
Globally, integrated supply chains have been a feature
of modern manufacturing for some time.I look forward
to a speedy recovery of the Japanese suppliers and will
be encouraging Australian component manufacturers to
redouble their efforts to fill the gap.”
19
Government News
Bid for advanced radio telescope for
Australia and New Zealand
The Gillard Government will provide
$40.2m over four years to support Australia’s bid to host the Square Kilometre
Array (SKA), in partnership with New
Zealand.
The SKA will be the largest and
most advanced radio telescope ever
constructed. It will consist of thousands
of antennas, spread out across a continent and connected by a fibre-optic
network, with the data it generates
processed by a powerful supercomputer. Australia is an ideal candidate
to host the SKA, thanks to the data
and speed capabilities of the National
Broadband Network, our large tracts
of radio-quiet land and our research
strengths in astronomy, the physical
sciences and ICT. Our joint bid with
New Zealand is one of two shortlisted
to host the SKA, with a decision on the
final site expected early in 2012.
This funding will assist Australia's
bid and support pre-construction design
and development work if the bid is successful. Attracting global investment in
The Square
Kilometre
Array
dishes by
night
this massive technologically advanced
project to Australia will generate spinoff returns for business. Researchers
and engineers from the world’s leading
institutions will work together on the
SKA, developing the next generation
technologies the project will demand.
In turn, Australia’s research community will build their skills and expand
their networks. They can use those
same capabilities to create cutting-edge
products for consumers in computing,
in renewable energy and in communications. By the end of 2011 the SKA program will be ready to transition to the
detailed design and pre-construction
engineering phase.
Finding room for this funding in a
responsible Budget shows the strength
of theGovernment’s support for Australia’s involvement in this important
international project.
Australian government’s record $3bn
support for the CSIRO
The Gillard Government will invest a record $3bn in the
nation’s premier scientific research agency, the CSIRO,
through a new Quadrennial Funding Agreement to operate
over the four years from 2011. The Agreement will allow
the CSIRO to continue to work with industry, government and the research community to build a stronger
economy, a healthier society and a cleaner environment.
Finding room for this funding in a responsible Budget
has been difficult, but it demonstrates the value the Government places on this important institution.
The CSIRO is a highly successful national asset,
delivering returns by taking research discoveries to the
market, increasing Australian industry competitiveness,
and improving the evidence base for policy development
and government investment.
The CSIRO’s expertise is invaluable across Government, with commissions worth well over $100m every
year to assist the work of many Australian Government
departments.
These government contracts are on top of the new
$3bn in operational funding over four years.
20
As part of this support, the Government is investing
$20m over five years to extend the Tasmanian ICT Centre. The CSIRO is matching that funding with a further
$20m. The Tasmanian Government is committing $5m,
with another $5m to be raised from industry. The CSIRO
has a particularly strong track record in priority areas,
including wireless networks, disease resistant crops, sustainable fisheries, smart materials and alternative energy
solutions. This type of work helps Australia to identify
and deal with the risks and opportunities facing our nation. Its technology breakthroughs provide a competitive
advantage for more than 150 Australian companies that
have been directly founded on CSIRO work.
With the launch of a new Strategic Plan scheduled for
July this year, the focus of the CSIRO’s work will include
building an integrated national picture of carbon, water
and land use; maintaining Australia’s bio-security; enhancing national productivity and supporting the growth
of the digital economy; and addressing the key national
and global challenges of food security, clean energy,
climate change and preventative health.
Take in ALFEX CNC ad
21
Take in Alfex CNC ad
22
Industry News
Carbon tax forces local manufacturing
to consider offshore options
One of Australia’s leading manufacturing groups has warned
that the impost of a unilateral carbon tax on Australian business
will cost jobs and severely erode the nation’s manufacturing
base, with a number of its members already considering alternative locations in the region.
The South East Melbourne Manufacturers Association
(SEMMA) has heard from a small cohort of its members
that they have already started to explore the possibility of
relocating to South East Asia, such is their concern over the
impact of a carbon tax. A number of countries, particularly
Thailand and Malaysia, are promoting themselves as alternative manufacturing locations, offering tax breaks and other
incentives, apparently keen to exploit the growing concern
among Australian manufacturers regarding the Federal Government’s proposed carbon tax.
According to Paul Dowling, SEMMA Executive Officer,
while SEMMA members recognise and advocate the need for
enhanced environmental responsibility, they remain concerned
that a carbon tax applied unilaterally will leave them at a competitive disadvantage. “This will cost jobs, it is already leading
to investment decisions being stalled, and comes at a time when
manufacturers are also battling a relatively fragile economy and
a historically high dollar,” said Dowling.
“One of our members has calculated that a carbon tax of
$20 per tonne would equate to an annual cost of 6-10% of his
sales; a tax of $30 a tonne even more. Meanwhile his major
competitors are based in South East Asia, and won’t have to
deal with the double whammy of a carbon tax and high dollar.
“Even the nation’s largest manufacturers, such as Orica
are expecting a carbon tax to have a double digit impact on
earnings,” said Dowling. “We are starting to see seasoned
investors move away from companies like BlueScope and
OneSteel because of the uncertainty over the carbon tax. For
smaller manufacturers this will be devastating.
”SEMMA members strongly support environmentally
sustainable manufacturing – but the proposal in its current
form won’t deliver that. Instead it will lead to local manufacturing becoming completely unsustainable and needs an
urgent rethink.”
SEMMA considers the current carbon tax proposal deeply
flawed as it provides no incentive to reduce emissions. By
offering compensation to both emitters and end users the
Government has failed to draw the nexus between the cost of
carbon and the need to reduce carbon emissions.
Dowling said that SEMMA members did not believe that the
proposed regime had been structured to help or even encourage
manufacturers to reduce their carbon footprint or transition to
non fossil fuel energy sources. Instead it would prove a cost
burden that would be passed onto consumers, while making
Australian manufacturing less competitive internationally.
“We have 180 member companies which currently employ
more than 9200 people. The Government has to understand
that if this regime is introduced as it is currently proposed
it will cut jobs and damage Australia’s ability to compete as
a manufacturing nation, possibly forever,” warned Dowling.
“The Treasurer’s comments that this will have only a negligible
effect on local companies are just plain wrong.
“The Government needs to stop grandstanding on this
issue. Yes, climate change is a concern, and yes, we need to
take steps toward more environmentally sustainable manufacturing – on that we agree wholeheartedly. But the Government’s current proposal will do more damage than good and
will seriously jeopardise the nation’s manufacturers’ ability
to compete internationally.”
The road ahead
years, spoke at the Smart Conference on why
sales and marketing must take a leadership
role in demand planning and forecasting.
The presentation shared BlueScope’s pracA leading Australian and New Zealand steel comtical experience on the continuing journey
pany, Bluescope Steel exhibited at this year’s Smart
to execute best practice Demand Planning
Conference and Expo in Sydney last month. The
theory, and outlined the importance of having
organisation highlighted the work they have been
a professional demand management review
doing with business improvement specialists, Olprocess that manages key activities and drives
iver Wight, to improve its demand planning and
towards the company strategy and vision.
forecasting.
The Smart Conference and Expo is AusLike many businesses, BlueScope Steel is expetralia’s leading supply chain event. The
riencing increasing levels of volatility in its supply
Oliver Wight partner,
biennial conference and exhibition provides
chains as markets become more dynamic, global
Mike Reed.
an opportunity for supply chain and logistics
competition increases along the value chain, and cusprofessionals
to
find out what’s new in the industry. The
tomer lead times are becoming shorter. But the organisation
theme for this year’s event, which was held in the Sydney
has greatly improved its forecasting and demand planning
Convention and Exhibition centre on 25 and 26 May, was
processes, since working with Oliver Wight to implement
‘The Road Ahead: Supply Chain Models for the Future.’
an Integrated Business Planning (IBP; advanced S&OP)
Oliver Wight was present at the event, along with partner,
programme. "Since implementing IBP we have been unMike Reed. Reed spoke on ‘Integrating Product Manageable to find a benchmark source that shows anyone with a
ment in to the Business Planning Process’, referring to case
better forecast accuracy," says national demand manager,
studies from leading companies to demonstrate his points.
Brett Shemmell.
A white paper on the subject will be published after the
Shemmell, who has been with BlueScope Steel, Ausconference.
tralia’s largest manufacturing company, for more than 20
23
Industry News
CSIRO technology helps clinch global
car component deal
Access to a portfolio of cost-competitive CSIRO casting
technologies was crucial to Nissan Casting Australia’s
(NCAP’s) recent successful bid to manufacture components
for the Nissan Motor Company’s new LEAF electric car in
Dandenong, Victoria. “NCAP’s access to CSIRO’s advanced
casting technology, which offers significant potential future
savings, was instrumental to our winning the contract,”
said NCAP’s business development and corporate planning
manager, Brian Cooper. “Nissan Motor Company’s R&D
engineers in Japan were highly impressed by the level of
CSIRO R&D innovation, as well as the extent of state and
Australian Government support available to the Australian
die casting industry.”
Technologies jointly developed by CSIRO and NCAP
through the CAST CRC will be implemented as part of
the Australian Government’s recently announced $21m
investment in sustainable, zero-emission technologies.
These include the CASTvac technology, a low-maintenance
vacuum valve which eliminates machine stoppages due
to valve blockages by molten aluminium, which has been
estimated to save about $100,000 a year in the production
of a single component. In addition, NCAP has evaluated a
suite of casting technologies developed by CSIRO’s Light
Metals Flagship.
The prospect of future access to this suite of cost and
process-efficient high-pressure die casting technologies
was one of the major selling points which convinced Nissan to invest locally.
“Australia showed it can compete with some of the
world’s leading low-cost countries by combining cost
control and technological manufacturing solutions,” said
The CASTvac™ chill vent vacuum valve, developed by CSIRO
researchers and Nissan working together through the CAST CRC
Nissan’s Senior Vice President of Global Manufacturing, Toshiharu Sakai. The Group Executive of CSIRO’s
Manufacturing, Materials and Minerals Group, Dr Calum
Drummond, said the outcome was an example of how
CSIRO research enhances Australia’s ability to compete
successfully in international markets. “CSIRO aims to
support Australian industry and maintain and grow Australian jobs with technologies that are sustainable and
globally competitive,” Drummond said. “Support for 145
Victorian manufacturing jobs in the highly competitive
international automotive industry is a great outcome, and
CSIRO is delighted to have contributed to it.”
Additive Capability
David Creighton
03 9800 3666
[email protected]
Don’t be left behind...
Additive Manufacturing technology offers significant
potential as a next-generation fabrication process.
AMTIL AND RMIT HELP GET YOU TO THE FRONT OF THE PACK
24
Industry News
Moving forward with new sales structure
With the aim of strengthening its presence
“We are one company,” Weiwadel emin Australia DMG/Mori Seiki Australia is
phasises. “As such, we are working as a
now restructuring its service and dealer
team, and our three dealer companies are
organisation.
part of this team. Customers can choose
German machine tool builder GILDwhich sales channel they prefer, direct or
EMEISTER AG commenced joint sales
indirect through our dealer network. We
and services with the Japanese machine
are currently conducting extensive training
tool manufacturer Mori Seiki Co Ltd in
for all sales and service staff on DMG and
Australia on 1 March 2010. The joint
Mori Seiki products.”
company DMG/Mori Seiki Australia
DMG/Mori Seiki currently trains all sales
is a now market leader in Australia,
and service staff, including all dealers, on the
and plans to increase its market share
new DMG ECOLINE. While the company
to 50%.
offers high-end, quality CNC lathes, 5-axis
The decision to form a new sales
milling machines, mill/turns and ultrasonic
“We are one company,”
structure in Australia facilitates further
laser machines, not all machines come with
Stefan Weiwadel comments
strengthened customer relations and servthe high price tag, Weiwadel says.
on the joint company DMG/
ice. With the combined strength of two
“With a simple recipe, DMG is setting
Mori Seiki Australia.
leading global machine tool builders,
new standards for entry-level machines:
DMG/Mori Seiki offers solutions for 95% of all metalcutThe best price is offered in addition to the usual high DMG
ting applications.
quality, reliable construction and modern 3D control technolDMG/Mori Seiki Australia President Stefan Weiwadel
ogy,” he explains. “Our ECOLINE machines are available at
said, “Combined with our new sales structure, we are now
very reasonable cost-/performance effective selling prices
creating the conditions to further strengthen positions in
and we plan to expand our market share in this segment
Australia and the entire region, maintaining the highest
tremendously as well.”
service level and product support for our customers.”
The design of the economy version of the DMG turning
As part of this strategy, DMG/Mori Seiki is implementand milling machines is based on the idea of delivering
ing the following restructuring:
proven DMG quality at the best possible price by combining
l The three (formerly Mori Seiki) independent dealers
consistent standardisation, simple and reliable construction
Qumac Engineering Services , QLD, HS CNC Machines,
methods and state-of-the-art 3D control technology. While
VIC, and Harris Machine Tools in WA are fully integrated
the universal turning machines in the CTX eco series have
into the DMG/Mori Seiki Australia sales team, and will
already become the international top sellers at DMG, the
offer both companies’ products, machines and service
latest winning model in the ECOLINE world is the new
l The existing (formerly DMG) direct sales structure with
CNC universal milling machine DMU 50 eco, which makes
its current seven Area Sales Managers have responsibilentry into 5-axis machining possible.
ity in the area of sales, technical support and service for
DMG Mori Seiki Australia Pty Ltd - 03 8545 0900
DMG and Mori Seiki products
[email protected]
25
Product News
On your marks
Sydney-based 600 Machine
Tools has been appointed the
sole outlet in Australia for
Electrox Raptor laser marking
systems. The UK-based company
is an acknowledged global leader
in the design, development, and
manufacture of laser marking
systems. Many industries that
have not traditionally used laser
marking are now recognising
the benefits of laser technology
as opposed to more traditional
techniques such as stamping, pin, and dot-peen marking.
The Raptor is a compact system for high or low volume
applications and is the first to be powered by EF technology. It
has a very small laser head, incorporating an optical unit, fully
sealed to IP52, to ensure extremely low maintenance even
in hostile environments. EF Technology provides very short
energy pulses – 25 nanoseconds (ns) compared to anything
from 70ns to 200ns in other systems – which enables high
peak powers (up to 10kW) combined with low pulse energies.
This allows high-contrast, low-damage marking on metals and
plastics. Near perfect beam quality and exceptional energy
stability over the entire operational range means that the
technology delivers very small spots – typically 70µm from a
254mm lens. Smaller spots are possible – down to 25µm.
The air-cooled, single-phase units can be supplied with a
safety workstation as a turnkey system or for integration into
a production line. The 5U, 19-inch rack electronics enclosure is
about the same size as a tower PC.
Serdar Cevik of Arçelik A.Ş. Dishwasher Plant, says “When it
comes to marking control panels and other parts of machines, the
use of laser marking represents the most advanced technology
in the industry, and it enables us to achieve the most precise,
clean, and permanent markings. The Electrox laser systems have
been integrated into our dishwasher production plant and the
results are helping us to maintain our market-leading position and
worldwide reputation in the domestic appliances industry,”
Managing director 600 Machine Tools, Cliff Purser,
commented: “This application clearly demonstrates the
suitability of Electrox lasers for high quality and permanent
marking of plastic products and it can be seen that Arçelik
A.Ş. and other global customers derive important costbenefits, along with other advantages in terms of quality and
performance, by their decision to utilise laser-marking in this
way.” Such is its faith in this new system that Electrox is able to
give EF Technology a four-year warranty – the longest warranty
available anywhere in the laser marking industry.
600 Machine Tools - 02 9674 4738
www.600machinery.com.au
26
Flex element designed into
Zero-Max CD couplings
Motion system designers have a new option to arrest
electrical current. Zero-Max CD® couplings are designed
with composite flex elements that are non-conductive in
addition to their primary function.
According to Robert Mainz, Zero-Max Sales Manager,
“We have had several engineers specify the CD couplings
in systems that required the high performance CD coupling
design because it did not pass electrical current through
the coupling.”
In addition to protecting from stray electrical
current, CD couplings protect generators in a system
from transferring lower reaction loads to the generator
bearings. The couplings composite discs withstand all
types of environmental elements, including temperature
extremes from -40 to +70°C, and also moisture and
chemicals. Additional operating features include: zero
backlash, excellent for reversing loads, smooth operation
at high speeds, and compact size with a clamping system
that fits most applications. CD couplings have very long life
cycles and require less replacement over time.
They provide exceptional cost-effectiveness and
reduced waste. CD couplings are available in many
models and sizes, including custom designs for unusually
large and challenging applications such as wind turbines.
Standard models and sizes include single and double flex
models with clamp style hubs with or without keyways.
The torque capacities range from 40Nm to 1436Nm and
beyond with speed ratings from 4400 RPM to 17,000revs/
min. All CD couplings are environmentally friendly and are
manufactured of RoHS compliant materials.
Zero-Max, Inc.
Naismith Engineering & Mfg Co. - 03 9489 9811
www.zero-max.com
[email protected]
MTIQualos_Jun2011:Layout 1
19/5/11
11:04 AM
Page 1
Product News
End mills for ultra-hard cases
Walter, has introduced a new range of Proto•max Ultra ball-nose
end mills for machining ISO-H materials. Users have two variants
for two diameter ranges: These are standard versions with
3-12mm and mini versions for small to extremely small contours
with 0.1-2.5mm. When it comes to small diameters, a reduced
neck and a reach of up to 10xd are beneficial for machining
deep cavities. The tolerance of the shank diameter is h4 for
the mini tools and h5 for tools with standard dimensions. This
results in excellent concentricity properties, which are absolutely
essential at the high speeds required when using tools with small
diameters. The primary applications are hardened materials of up
to 70 HRC in mould and die making, but also similar operations in
general machine and plant construction.
Key features include a new TiAlSiN-based coating and
optimised microgeometry for stabilising the cutting edges. All
diameters, even those in the mini versions, have two cutting
edges and a helix angle of 30 degrees. The milling cutters are
therefore well-suited to simultaneous machining of freeform
surfaces with both Z-constant and 5-axes. When combined,
these features allow you to use the tools both for semiroughing and roughing, as well as for semi-finishing
and fine finishing.
Walter Australia - 03 8793 1000
[email protected]
Weldable strain gauge
Bestech Australia has launched a range of high
temperature weldable strain gauges. The ‘AW’ series
of strain gauges are fully encapsulated in a corrosion
resistant metal tube for use in a variety of environments
including gas filled atmospheres and under water.
Installation of the weldable gauges is routine with the
dedicated spot welder, W-50R. Gauges for both static
and/or dynamic applications, and matched with high pass
filters to eliminate spurious signals are available.
The gauge length is either 5 or 8mm. Temperature
compensated ranges are from -196°C minimum to +800°C
maximum. The backing material options include Inconel
600, SUS321 and 304. Further options include grounded
tube, narrow gauge width, bent backing and tube for a
nominated curved surface and fitted cables or terminals.
Quarter to full bridge configuration is available.
Bestech Australia Pty Ltd - 03 9540 5100
www.bestech.com.au
After introducing the World-Renowned Absolute System
to Digimatic Calipers, Mitutoyo now announces a further
major breakthrough in electronic Caliper Design.
The New COOLANT PROOF Caliper achieves an Ultimate
Dust/Water/Coolant protection level.
The COOLANT PROOF Caliper can be used in tough workshop conditions
where at present only a mechanical Vernier Caliper can be used.
M.T.I. QUALOS PTY. LTD.
MELBOURNE
55 Northern Road, West Heidelberg, Vic. 3081.
Phone (03) 9450 1900 Fax (03) 9458 3217
SYDNEY
5 Hallstrom Place, Wetherill Park, N.S.W. 2164.
Phone (02) 9756 5577 Fax (02) 9756 5666
Web: www.mtiqualos.com.au
e-mail: [email protected]
27
Product News
TaeguTec extends Chase
Mill line
As part of its new product drive, TaeguTec has now extended its
exceptional Chase2Mill range of milling cutters. The 90 degree
cutter line and corresponding four cutting edged inserts have
been expanded with three new cutter bodies and four new
insert designations to offer the end user improved productivity
benefits.
The new inserts are available in the ANMX designation for
economical, high performance cutting with extremely long tool
life whilst the MR series offers strong cutting edges and has
been perfectly adapted to rough and interrupted cutting. The
ANHX 16 ML inserts have a high rake angle to ensure excellent
surface finishes and the AL line has been specifically developed
to meet all the customers aluminium machining demands.
The four new insert designations are currently available in
existing TaeguTec grades that will soon be replaced with the
new and far superior TT6080, TT6800, TT7080 and TT8080
insert grades. The new additions will enable the extended
Chase2Mill Series to machine an expansive range of materials
that includes low and high carbon steel, alloyed, tool and
stainless steels, inconel and titanium alloys, grey and nodular
cast iron and aluminium. With the combination of innovative
insert geometries and TaeguTec’s impressive new grade
compositions, the Chase2Mill can machine these materials at
depths of cut beyond 7mm at speeds up to 350m/min and feed
rates of 0.25mm per tooth.
To correspond with the inserts, TaeguTec has three new
cutters that add to the already existing face mills in the
Chase2Mill range. The smallest of the cutters, the modular
cutter body is available with the option of two or three insert
pockets on a 32 or 40mm diameter body. The long edged
shouldering cutter is available in 50, 63, 80 and 100mm
diameters with two to five insert pockets on the PCD with a
total of 6 to 25 insert pockets on the cutter body. The extended
flute end mill cutter body is available as either a 40 or 50mm
diameter cutter. Available with either two or three inserts on
the PCD, the cutter has the option of 6, 8 or 12 insert pockets
New Makino PS65 VMC
Equipped with the standard 12,000revs/min spindle,
the Makino PS series caters for the majority of parts
machining applications, e.g. face milling, slotting,
circular interpolation and rigid tapping. In line with
Makino’s commitment to build machines that are reliable
and competitive, several key features that improve
productivity and accuracy include: core cooling of axis ball
screws, large spindle bearings, efficient chip management
system and 2 spindle range options – 12,000 and
20,000revs/min.
This high-power, high-torque spindle works hand in
hand with the rigid machine structure. Both spindles are
equipped with spindle jacket cooling technology to ensure
thermal stability.
Headland - 1300 592 061
www.headland.com.au
28
depending upon customer specifications. All cutter body
types have a through coolant facility to ensure an optimum
temperature is maintained under heavy cutting and guarantee
the efficient removal of swarf from the work envelope.
The smaller modular type cutter body has already proven
a resounding success in general engineering and mould &
die applications. Whereas the extended flute end mill with
its ability to machine at depths beyond 70mm has delivered
staggering productivity benefits in medium to heavy machining
applications such as the power generation, wind turbine,
automotive and rail industries. The larger shouldering cutter,
with up to 25 insert pockets and a maximum diameter of
100mm has delivered cycle time reductions and productivity
benefits far beyond competitor products. However, a rigid and
robust machine tool is advised to optimise cutter performance
when conducting heavy machining applications with the
shoulder and extended flute cutters.
TaeguTec Australia - 02-9894-8077
www.taegutec.com
Product News
Performance
Unequalled...
with chatter-free milling
Stop the stink!
Melbourne based, CC Technologies has been actively
researching and developing an electrolytic mineral ion process
that it claims has been proven to be effective in the treatment
of synthetic, semi synthetic and soluble coolants. As such it
controls the level of bacteria, mould and fungi, giving rise to
smelly coolant, dermatitis, respiratory irritation and asthma,
although some cases of dermatitis can occur for other reasons
in susceptible people.
This process is known as Silver Ion Technology or Silver
Antibacterial Technology. CCT has revisited and improved
this process, by using the bactericidal properties of silver and
introducing microscopic silver ions into water at precisely
calculated amounts. This is held in suspension by a ‘tiny’
positive electric charge, which is applied to each atom. The
viruses and bacteria’s possess a negative charge, this causes
a mutual attraction between the organisms and silver ions,
which in turn interferes with the organisms DNA production,
preventing reproduction and accelerating its death.
Further, although silver ions are lethal to bacteria and fungus,
they are completely safe to humans, animals and plant life. The
amount of silver ions in the disinfected water is well below the
limits recommended by the World Health Organization (WHO)
and complies with the Australian Drinking standards.
According to CCT, all that is required is one of their
Antibacterial Units (ABU). This is connected in line with the
feed used to top up or fill the coolant tanks. They claim this is
all you need to rid yourself of smelly coolant and itchy hands.
Some of the general benefits of silver ion treated water are:
• Increased duration between coolant changes.
• Reduces the storage of the waste.
• Reduces the cost to dispose of water / oil waste.
• Helps the environment.
• There is no need to use a machine cleaner between
changeovers.
• Improved working conditions.
• Reduced downtime due to mould and fungus blocking
pumps, lines and filters.
CC Technologies - 03 97017089
[email protected]
• Longer Tool Life
• Improved Surface Finish
• Increased Productivity
• Reduced Production Costs
ENDMILLS
for an on-site demonstration
contact Sutton Tools on
1800 335 350
100% Australian Owned
www.sutton.com.au
29
Product News
Noshok mini valve with
10,000 psi pressure rating
Noshok 100 & 150 Series Mini Valves are small in size, but
deliver serious strength and durability. Available in zinc
nickel plated steel, electro-polished stainless steel and 360
brass, these Mini Valves were designed with your toughest
applications in mind. These valves are equipped with both a
Viton O-Ring seal and a Teflon back-up ring below the stem
threads to protect them from corrosion and galling. The stem
threads are rolled for strength and ease of operation. Their
patented design incorporates an improved internal bodyto-bonnet, metal-to-metal seal. The body seal incorporates
a novel dovetail feature that improves the metal-to-metal
contact forces as pressures increase.
With a maximum hard seat pressure rating of 10,000 psi for
the stainless steel and steel models and a 6,000 psi rating for
the brass models, Noshok’s 100 Series Hard Seat Mini Valves
have much to offer for such a small valve. They feature a 316
stainless steel stem, and the stem tip on the stainless steel Mini
Valve is hard chrome-plated to prevent galling.
Noshok’s 150 Series Soft Tip Mini Valves feature a patented
non-rotating soft tip stem. Unlike metal-to-metal seals, the
soft tip-to-metal seal helps extend the service life of the valve
by easily conforming to the metal sealing surfaces that may
become damaged by corrosion, cavitation or chemical attack.
This valve has a pressure rating of 6,000 psi for stainless steel
and steel, and 3000 psi for brass models.
With a variety of options to choose from, these Mini Valves
will fit perfectly into any application.
Noshok Mini Valves are 100% helium leak tested to 1 x 10-4
ml/s for guaranteed performance and reliability, and conform
to the MSS SP-1999 (R 2005) Instrument Valve Standards. Also,
valves supplied with packings conform to MSS SP-132-2004
Compression Packing Systems for Instrument Valves.
AMS Instrumentation & Calibration - 03-9017 8225
[email protected]
www.ams-ic.com.au
FARO launches innovative measurement arm, the FARO Edge
Faro Technologie’s, ‘Edge’ is a portable
measurement arm that allows manufacturers to
easily verify their product quality by performing
inspections, tool certifications, CAD-to-part
analysis, and reverse engineering. According to
its manufacturers, the Edge improves production,
quality, and reverse engineering processes by
rapidly verifying or scanning parts with confidence
and accuracy. The new Arm also simplifies the user
experience with improved performance, portability
and reliability.
“The FARO Edge was designed with our
customers’ input and built with our experience,”
stated Jay Freeland, FARO’s President & Chief
Executive Officer. “It offers unparalleled simplicity
for the user while maintaining all the existing
benefits of a FaroArm.”
A laptop is no longer needed to perform quick
and simple dimensional checks, or to optimise system
performance with its on board diagnostic routines. It has
an integrated personal measurement assistant, including a
built-in touchscreen and on-board operating system.
“Everything about the Edge was designed from the
ground up to boost productivity and deliver the best
30
performance from any portable arm CMM,” said Orlando
Perez, Product Manager - FaroArm. “The FARO Edge changes
absolutely everything.”
Faro
www.faroasia.com/Edge.
TURNING
HOLDING TOOLS
TAPPING
ROTARY TOOLS
END MILLING
THREADING
MILLING
www.seicarbide.com
Your Cutting
Tool Specialists
NSW Toll Free 1300 307 099
VIC 03 9548 8516
31
SA 0418 826 155
QLD 0418
732 729
Q
A
OneonOne
Bruce Griffiths is the Federal Government’s Rail Supplier Advocate – a role in which he has helped
to set the country’s rail industry on the path to long-term sustainability. Griffiths, who was inducted
to the Victorian Manufacturing Hall of Fame for services to the manufacturing industry, in 2003, is a
well-respected figure among rail manufacturers. He spoke to Nina Hendy
AMT: Tell us a bit about yourself, including your professional background and how you came to be in your current role
BG: I have extensive experience from 35 years in the automotive industry. I established and expanded a successful
Australian manufacturing company that had to deal with
significant cost pressures and globalisation. The lessons I
learnt during this time were powerful in terms
of business performance improvement.
I would have found a mentor with this
experience very useful during my career, so when I was offered the role of
Rail Supplier Advocate, I thought my
knowledge would be helpful to others who are facing similar challenges.
As board member of the Automotive
CRC, Industry Capability Network
Limited, Enterprise Connect and the
Automotive Industry Innovation
Council, I also have a broad understanding of government business
support mechanisms.
I am very passionate about
Australian manufacturing, which is
under enormous pressure. At this
stage in my career, I am keen to give
back to the manufacturing industry,
and impact lessons learnt from my experience and insights from the automotive sector, which has faced significant
international competition for a number of
decades, similar to those now being faced
in rail. The challenge for rail suppliers is raising their competitiveness to succeed in bidding for contracts.
AMT: What are some of the most important
projects you’re working on right now and
when will they come to fruition?
BG: : In consultation with industry, I have developed a robust agenda of key initiatives that
address the challenges faced by the sector,
drive competitiveness and maximise opportunities. There is no silver bullet, it’s a
matric of activities that are interdependent and need to be driven concurrently
to ensure a more sustainable industry.
These include:
l I championed the need for Enterprise
Connect to implement the Supplier
Continuous Improvement Program, which
accelerates the competitiveness of individual
businesses as well as the performance of the
wider supply chain. Thirty companies have
been nominated by rail primes to participate in
32
this pilot over a three year period. The program uses diagnostics tools to identify areas for improvement to achieve:
modernised supply chain relationships, improved business
communications, increased efficiency and simplification,
and increased innovation.
l I am passionate about innovation and the need to develop a Rail Manufacturing Technology Roadmap to
map industry’s technology and manufacturing
capabilities and future opportunities. The
importance of this project is demonstrated
by the financial contributions provided
by the Commonwealth Department of
Innovation, the Victorian, New South
Wales and Queensland state governments and the Australasian Railway
Association on behalf of the industry. The
project commences mid-2011 and will involve extensive industry engagement.
l Forecasting the demand for passenger rolling stock nationally for suppliers
to better plan for production schedules
has the potential to reduce costs for
suppliers and buyers. This important
project coordinates state bodies and
major suppliers by providing demand
for passenger rolling stock. We have
commenced gathering data to allow
for analysis that will provide a national
picture of the states’ demand for passenger rolling stock. It is anticipated that
project outcomes will be available in late
2011.
l Harmonise targeted rolling stock specifications that impose a resource and cost burden
on suppliers and buyers. The project will coordinate
state bodies and major suppliers for a trial process
to identify 5-10 key specifications in passenger trains
for modelling of cost savings and benefits if harmonised. The project is a progression that will follow the
outcomes of the demand forecasting project, with
the intention of promotion performance specifications rather than method process specifications. In
turn this will bring about innovation.
l I undertook a rail and maintenance survey in 2010
to quantify the contribution of rail manufacturing to
the economy. It will provide information to underpin
industry and government activities. The statistics report will be publically released mid-2011.
l I am working with the Industry Capability
Network (ICN) to market Australian rail capabilities through the Rail Directory (www.rail.icn.org.au)
launched in 2010. It is a free web portal that lists
suppliers’ capabilities to assist in linking Australian
companies to opportunities both domestically
and internationally.
OneonOne
l I lead international rail missions focused on exposing key
Australian rail suppliers to best practice manufacturing and insight
in to integrating into international supply chains, building firms’ understanding of international competitiveness and benchmarking,
learning new competitive practices, and developing international
partnerships and technological innovations.
AMT: What size is the country’s rail manufacturing sector and is there any
room for growth in this sector?
BG: : There are significant opportunities for rail manufacturers with increased demand, not only in Australia but worldwide, due to increased passenger usage, planned rail extensions, ageing fleets and
emerging new fleet as a result of the mining boom. Australian rail
suppliers have opportunities to seize future sales if they succeed in
meeting international competiveness. Rail is considered an important part of the transport solution on both the Australian Government
and Opposition’s agenda and is also seen as clean and green.
Until now, there has been incomplete published data on the overall
size and value of the Australia rail manufacturing sector. That is
why, at the industry’s request, I instigated the collection of industry data in 2010 to identify a complete list of suppliers in the rail
equipment manufacturing and maintenance sector and to gain an
accurate picture of the scale of manufacturing for the rail industry.
The results of the survey will be published in the coming weeks.
AMT: What are the biggest challenges in your role and why?
BG: The rail industry battles with the legacy of federation. Cultural
shifts and acknowledgment of, and embracing the benefits of
reform take time, but this is beginning to occur and filter down
through the industry. There also needs to be greater recognition
by industry of the reality of globalism, and a greater preparedness
to meet aggressive competition and participate in future growth
opportunities through innovation, efficiencies and international
partnerships.
AMT: What sectors of the country’s manufacturing industry has the most
potential for growth over the next one to two years, and what is
driving that growth?
BG: : Increased passenger demand and ageing fleets continues to
lead to huge opportunities for suppliers. These include the recent Victorian Government tram contract, South Australian rail
link contract, the South Australian contract for new carriages for
Adelaide’s metropolitan rail network, the current Queensland next
generation rolling stock tender, the recent New Zealand tender for
electric multiple units and locomotives for the Auckland rail network and the staged Gold Coast light rail project.
Australia has a strong and diverse manufacturing base.
Bombardier is utilising Australian capabilities for a large amount
of work on recent contracts in which they were successful.
The mining boom is generating significant growth in freight, particularly in Western Australia. This is a difficult market for manufacturers where volume is being driven heavily by price.
The beneficiaries of these opportunities are primes who bid and
succeed and system orientated Tier 1 and 2 suppliers. These have
flow on effects down the rest of the supply chain.
AMT: What issues make it difficult for rail suppliers to compete on a global scale and what is being done about this at a government level?
Also, what have manufacturers got to look forward to in terms of
government policy that will help the sector thrive?
BG: The major challenges that Australian rail manufacturers face are
boom and bust state government procurement cycles, the pro-
liferation of specifications in state procurement contracts and
aggressive global competition. The activities I am championing,
which were developed by industry, are practical initiatives that are
focused on addressing these difficulties.
The Supplier Advocate program and my appointment by the
Commonwealth Minister for Innovation, Industry, Science and
Research, Senator Kim Carr, is recognition of the importance
of Government places on the Australian rail manufacturing industry and testament to its supplier for the industry’s long term
success. The practical activities I am championing to build on
Commonwealth and state government programs and industry association initiatives.
The participation by state governments demonstrates a level of
cooperation that has not been seen before. A dedicated resource
in Austrade, the Industry Capability Network appointed rail specialist to work at a national level, and support by the Department
of Infrastructure and Transport also indicates the widespread commitment to the industry at a national level. Collaboration by these
organisations with the peak industry associations has been invaluable in instigating and progressing the key initiatives that will increase competitiveness and maximise opportunities for Australian
rail suppliers.
AMT: What technological advancements do you predict will be made in
the rail manufacturing sector in the coming few years?
BG: The rail manufacturing technology roadmap will assist in identifying the cost competitive medium and long term strategic opportunities for the Australian rail industry. The technology roadmap has
two objectives:
l Ten year capability map to highlight gaps and opportunities to
help identify export and import replacement opportunities, particularly for tier 1 and 2 suppliers, and to inform investment attraction activities, and a
l thirty year innovation map with a shared industry vision of future direction and what technologies will be required.
This process will identify Australia’s competitive niche to carve out
in the domestic and international market.
AMT: What can rail manufacturers do to remain competitive both locally
and internationally?
BG: l Be innovative and proactive. Build collaborative relationships
with customers and network with industry colleagues
l Have a heightened awareness of international competition.
Those who participate internationally will learn and hone their expertise as a result of international exposure.
l Benchmark against what is best practice in the international
market
l Small to medium enterprises should take advantage of
Enterprise Connect’s free business reviews to assist firms discover
new ways of transforming their operations and future results. For
more visit www.enterpriseconnect.gov.au
l Be aware of the international missions that Austrade coordinates for the benefit of industry. Talk to your industry colleagues
that participated on the recent European and Hong Kong missions
to learn first-hand their experience and identify target markets for
your own company. I am leading an industry development mission
to China in the second half of 2011. To register your interest email
[email protected]
For more information on the activities the Rail Supplier Advocate is championing, visit www.innovation.gov.au/supplieradvocates or email [email protected]
33
Motorsport
Cover Story
Local motor racing manufacturers
help push the pedal to the metal
When Australian Formula One driver Mark Webber manoeuvres his Red Bull Racing car on to
the grid for a grand prix, he puts his faith in some Australian technology. Bolted just a few
centimetres to the left and right of his body, in the bulging side pods of his 370km/h car, are
two Australian-made aluminium radiators – one for cooling the water-based coolant circulating
through the Renault engine, and another for cooling engine oil. Ron Hammerton reports.
t is a tough gig for any radiator, helping an engine that revs
to 18,000 revs/min – three times as fast as a family car
engine – to keep its cool while withstanding extreme forces
in an often harsh environment. Like other top F1 teams, Red
Bull Racing sources its radiators from PWR Performance
Products, which is just one of several Australian companies
supplying state-of-the-art components around the world, creating hundreds of jobs and generating millions of dollars in
turnover and exports. MoTeC electronics, Albins Gears and
Borland Racing are just some of the other Australian manufacturers carving out a name in international racing circles
while contributing to Australia’s manufacturing skills base.
In the case of Queensland-based PWR, its radiators are
not only the dominant cooling technology in F1, but also in
America’s biggest racing category, NASCAR, the world’s
fastest race category – Le Mans sports cars – and Australia’s
most popular form of motorsport, V8 Supercars. The radiators are made to order completely in-house at the PWR factory near the Gold Coast where the 30-year-old operation is
overseen by founder Kees Weel and his son Paul, a former
V8 Supercar driver.
Australia has had a proud history of race manufacturing, most notably with the Repco Brabham V8 engine that
propelled Sir Jack Brabham and Denny Hulme to F1 world
championships in the 1960s. Like PWR, most of Australia’s
successful motorsport manufacturing operations started out
as family businesses, often created by individual enthusiasts
in their home garage. Frequently, they simply started by
making a part for their own weekend race car, often with an
ingenious twist that helped their car go faster or last longer
than the next guy’s. One such racer was Victoria’s Ivan Albin,
who had a passion for off-road racing in Volkswagen-based
buggies. He started making his own bits for his buggies 30
years ago, and that grew into an international supply chain
specialising in gears and gearboxes.
Now, the business he founded has a staff of 34, designing
and manufacturing entire race car gearboxes from scratch at
its Albins Offroad Gear factory at Ballarat, using sophisticated
but expensive milling machines, lathes and gear-cutters – one
of which is the only machine of its type in Australia. So far,
Albins has sold about 700 of its gearboxes around the world,
and even supplies other industries, such as the military. In its
biggest coup to date, the company has just been named the
official gearbox supplier for V8 Supercar’s new, standardised
race car – dubbed the Car of the Future – which is scheduled
to make its debut on race tracks around Australia in 2013,
replacing the current formula that has done service since 1994.
34
Triple F1 world champion Sir Jack Brabham being shown some
Australian-made carbon fibre race components during a visit to
Triple 8's Team Vodafone V8 Supercar workshop in Queensland.
According to Albins executive and former Holden Racing
Team engineer Steve Macdonald, Albins originally tendered
for a smaller component of the new-generation V8 Supercar
which has been under development by a team appointed by
V8 Supercars Australia and led by five-time V8 Supercar
champion Mark Skaife since 2008. But when V8 Supercars
officials visited the factory for due-diligence checks, they
spotted the sophisticated and rugged Albins transaxle gearbox
produced for offroad racing, and realised the potential for such
technology in the V8 category.
Skaife said the gearbox – mounted on the rear axle instead
of behind the engine like the current Holinger gearbox – will
help to achieve two of the primary goals of the new Supercar
design: make it better and cheaper.
At $25,000 each and about $20,000 a pop cheaper than
the current gearbox-and-differential arrangement used in
V8 Supercars, the Albins transmission is expected to make a
significant contribution to the goal of chopping about $100,000
out of the price of each and every V8 Supercar, which currently cost between about $350,000.
Says Skaife: “With more races each year and rising expense
for the teams, costs have been getting out of hand. “We were
asked to come up with a template that would cut that cost of
building a car by a third, and also make it easier and cheaper
to repair. We are looking to standardise the design of the platform under the car, as well mandate a basket of standardised
parts – gearboxes, ECUs, seats and so on – to help keep the
costs in check, as well as improve safety.”
Motorsport
“With a increasing number of ‘fly-away’ rounds
(events such as the Abu Dhabi and New Zealand
rounds to which the 28 V8 Supercars and team equipment have to be air-freighted), each two-car team
really needs four cars – two spares back at the workshop being refitted while the others are away at the
race meeting. A more affordable Car of the Future
design will make it more viable for teams to do that.”
The former Holden star said that while the list
of standardised components identified so far had all been put
to competitive tender, many of the contracts had gone to local
manufacturers who were competitive on both technical and
price levels. He said that where possible, V8 Supercars liked to
support Australian industry. “Apart from anything else, there
is a logistics advantage in having local suppliers,” he said.
Currently, six V8 Supercar operations build racecars at
their own factories, with several of those supplying other teams
with new cars – for those who can afford them – or hand-medown cars that have reached what the premier teams regard
as their use-by date after two or three seasons. Operations
such as Walkinshaw Racing, Triple 8 Racing, Ford Performance Racing and Kelly Racing all have their own fabrication workshops to build the cars from the ground up, with a
dedicated staff of welders, metal workers, spray painters and
technicians, not only turning out a couple of new cars each
year but refurbishing damaged and worn cars.
According to Walkinshaw Racing, it takes 720 hours to
build a car, and while engines are imported from the United
States at $120,000 each, all of the major teams spend many
more hours in eking out power gains from the five-litre V8s.
Starting later this year, the major teams will be hard at work
on the new Car of the Future vehicles that become compulsory
in the first round of the 2013 season.
In the case of Kelly Racing, the team expects to start the
first of at least four new race cars in about October. Over
the course of the following 18 months, it will build cars for
its four drivers – brothers Todd and Rick Kelly, Kiwi Greg
Murphy and Albury youngster David Reynolds – and then
start on spare cars. In all, a minimum of 28 of the new cars
collectively worth more than $7m will be built by all teams
over the next two years, with dozens of suppliers benefitting
from the project. As before, current race cars will be sold down
to the second-tier ‘development series’ – the Fujitsu Series –
where the stars of tomorrow give the older cars a second life.
While the high-profile V8 Supercars series is the biggest
and highest budget racing category in Australia, dozens of
Top left clockwise:
HRT engineers at data desk
Albins Gear grinding a shaft
HRT Garth Tander's V8 Supercar
Commodore
other categories make a major contribution to Australian
manufacturing. The traditional nursery for most of Australian’s best circuit racers, including Webber, Craig Lowndes,
Jamie Whincup and Garth Tander, is Formula Ford, where the
dominant constructor is Melbourne-based Borland Racing
Developments with its Spectrum brand of race cars.
Founded by Michael Borland in 1984 as a team running in
the Australian Formula Two series, the organisation started
making the smaller and lighter Formula Ford cars in the 1990s,
while also adding Formula Vee cars – under the Sabre brand
– to its repertoire. Last year, Borland built 17 cars to order for
teams in Australia, New Zealand and the UK. In the latter,
six Aussie-made Spectrum cars are running in the British
championship against European-made cars. The company
is now turning its eyes towards the US market, although the
high Australian dollar might put that ambition on ice for now.
Of all the Australian motor racing manufacturers, none
is more successful than MoTeC – the Melbourne-based electronics firm founded in a home workshop in the late 1980s.
Its success with its electronic control units in local touring
cars and other categories has stretched across the world, with
a network of more than 200 dealers now supplying gold-cased
engine management computers, data loggers, digital dash
displays and power supply systems to thousands of competitors in all sorts of race categories, from Dakar Rally to jet
boat racing, and from IndyCars to MotoGP motorcycles. Its
engineering continues to be done in Melbourne, in a purpose
built facility where the most critical function of MoTeC systems – the software programs – are written.
Like component assemblies from Albins and PWR, MoTeC’s ECUs, digital displays and power-supply systems have
locked up the contract to exclusively supply electronics to all
V8 Supercar teams under the new V8 Supercar of the Future
project. It’s a far cry from the backyard operation that started
with a good idea that just grew. In the end, hundreds of Australia suppliers benefit from Australia’s passion for fast cars
and burning rubber.
35
Motorsport
Quality goes a long long way
obbie O’Brien has an undeniable passion
for machining, and the success of his
Dandenong-based CNC machining business
FlexiCut Engineering is a true testament to
how hard work and being good at your trade
can pay off. After completing a fitting and
turning apprenticeship in one of Australia’s
leading V8 Supercar race teams, O’Brien
worked for John Hart specialising in CNC
machining and training before taking the
gamble and investing in his own business.
O’Brien is quick to give credit where credit
is due and says he has a great deal of respect
for the professional training and valuable
experienced gained during his time at John
Hart. “John Hart not only taught me the insand-outs of the latest in CNC machinery and
associated technologies, but also instilled their
motto of how experience and technology can
equal success which has been the foundation
on which we’ve built FlexiCut
Engineering.”
Showcasing the latest in CNC
machinery with an impressive
Mazak machine workshop and
many years of experience of CNC
machine tooling and CAD/CAM
programming, FlexiCut Engineering caters to all CNC machining
requirements. O’Brien states the
success of his business is, “as
simple as, offering our customers
an efficient service of superior
quality at a competitive price”
– all critical qualities within motorsport.
As a direct result of working within the motorsport industry for many years, O’Brien quickly learnt the importance of
his workshop delivering exceptional quality work on time –
every time. Understanding what clients expect of them and
that there is no such thing as 'near enough is good enough',
O’Brien is quick to communicate the responsibility CNC
machinists have and why he instils the importance of each
part meeting its technical specifications before it leaves the
front door. “Through years of working within motorsport I
have learnt how critical it is to deliver quality parts by focusing on cost-effective, technically superior manufacturing
techniques, vigilant quality control and short manufacturing
lead times,” says O’Brien.
O’Brien has built FlexiCut Engineering with that attitude
and always follows three important rules in order to maintain
his success explaining, when producing parts, “it’s got to be
done fast, the quality has got to be there, and it must be cost
effective for everyone involved. “Race teams can’t afford to
waste money on poorly manufactured parts that aren’t delivered
on time - there’s no room for error in this sport.”
In motorsport in particular, if the required part is not manufactured to the highest quality and on time, the race car is
loaded onto the truck incomplete and that can cost the team
36
time and money. O’Brien goes on to
state how there is a direct correlation
between how well you achieve in the
workshop to how well you perform on
the track. “Having good race results at
the end of the day make up the most
memorable moments of working within
a race team, and even knowing how
FlexiCut is contributing to a team’s
success today makes all the hard work
worthwhile.”
Speaking to Robbie about his company, it’s easy to see why he’s been
so successful. His passion for engineering and motorsport is infectious,
although he’s quick to point out how hard work has been the
biggest factor in growing his business, putting in long hours,
working all night in order to complete parts, “CNC machining
is an amazing trade that can provide great satisfaction at the
end of the day when you see how your components are being
used to achieve great things,” says O’Brien.
O’Brien describes how the Australian motorsport industry
is cut-throat, and if you want to be running up the front of the
pack you need to have ‘current equipment’ in the workshop
and in-house design facilities, “It’s a competitive industry
and time and money are critical components in running a
successful race team.” Traditionally teams would buy race
components off mainstream suppliers resulting in over 30
cars on the track running identical parts. Whereas today’s
advanced CNC technology allows teams to precisely manufacture individual components to perform with perfection.
CNC machining is an essential component in any successful
team’s setup. Their ability to convert raw material to a finished
component in a single machine set-up, multi-tasking machines
provides 21st century innovation to the industry.
John Hart - 03 9542-6262
www.johnhart.com.au
There are no shortcuts in evolution
INTEGREX i-Series
Evolved from almost 30 years of
Multi-Tasking experience
• Unsurpassed ease of programming
• Designed for optimum utilisation
• Maximum return on
your investment
www.machines4U.com.au/
directory/John-Hart-Pty-Ltd/443/
www.youtube.com/
user/JohnHartPtyLtd
C N C M AC H I N E TO O L S
www.johnhart.com.au
37
VIC-Tel: 03 9542 6262 | NSW-Tel: 02 9725 4962 | QLD-Tel:
07 3399
6033 | SA-Tel:
08 8346 9068
Australian
Manufacturing
Technology
June| WA-Tel:
2011 08 9277 6100
Motorsport
The quest to create history
The Bullet Project presents - the Silver Bullet
RV1 world land speed record challenger
The ambitious goal of the Bullet Project team is to design and build the Silver Bullet RV-1, a 30Ft (9.144m)
four-wheel steerable liquid oxygen and kerosene rocket propelled land vehicle with a top speed in excess of
1,000 mph (1609.34 km/h). The RV-1 will incorporate the latest knowledge in vehicle aerodynamics and chassis
design, as well as break new ground in wheel design and driver safety. New ground being broken by The Bullet
Project team includes a wheel with an internal suspension system where only the outer rim rotates, and a
fireproof blast-resistant ejectable driver capsule that maintains the driver in a breathable atmosphere.
By Franklin Ratliff
( Te a m Me m b e r, t h e B u l l e t P r o j e c t)
the target speed. RV-1 will have a capacity for approximately
4200lbs (19050Kg) combined weight of liquid oxygen (LOX)
and kerosene. This will be sufficient to support a continuous
thrust of 35,000lbs (15876Kg) for a minimum of 30 seconds or
50,000lbs (22679Kg) for a minimum of 17 seconds. The thrust
will be variable so that it can be tailored to match the planned
trajectory for each run. Trajectories will be plotted based on drag
curves calculated through detailed computational fluid dynamics
(CFD) analysis. To avoid the mechanical complexity of a pump-fed system,
a blowdown system will be used with
nitrogen pressurising the LOX and
kerosene tanks. The explosion hazard is minimised by placement of the
LOX and kerosene tanks in separate
compartments, divided by bulkheads
and further separated with the cockpit
and the nitrogen tanks.
he Bullet Project, in comparison
to Australian, British, and American teams which all have vehicles
now in the build or testing phase 44
feet (13.4112m) in length or longer and
weighing six tons or more, is taking
a radically different approach to the
problem of building a supersonic car.
The target dry weight of RV-1 is three
tons with a rocket propellant capacity
of approximately two tons. Bloodhound SSC, a British project lead by
Richard Noble, is a combination jet
and rocket vehicle 44 feet long with a
fully fueled weight of approximately
seven tons. Aussie Invader 5R, a pure
rocket vehicle under construction by Australian land speed record
holder Rosco McGlashan, is 50 feet (15.24m) long with a dry
weight in excess of seven tons. The North American Eagle, a jet
vehicle converted from an F-104 Starfighter, is 56 feet long and
weighs 6.5 tons. The other American project, the Sonic Wind
LSRV rocket car now under construction by Waldo Stakes, is
47 feet long with a dry weight of 3.5 tons.
A design was originally contemplated for a vehicle 60 feet
long (18.288 m), however, the current design was arrived at by
examining various iterations of much lighter vehicles, beginning with the smallest possible, and then working up until the
minimum size still capable of holding enough rocket propellant
for 1000 mph (1609.34 km/h) had been achieved.
A conventional four-wheel layout was
chosen to avoid stability problems that
have been demonstrated in the dynamics of ultra-narrow front track/ultrawide rear track configurations, such as
the Budweiser rocket car (1979) and Craig Breedlove's third jet car
(1996). The primary structural element for the RV-1 chassis will be
a large diameter tube that houses the main LOX tank, the nitrogen
tanks, the cockpit, the kerosene tank, and the rocket motors. The tube
will also provide the attachment points for the forward LOX tanks,
the wheels, the braking ballutes, and the body shell. It is currently
planned for the tube to be of carbon fiber composite construction,
although consideration is also being given to fabricating it using
rolled and welded magnesium. Magnesium has the same density
as carbon fiber, but is not as stiff and so would have to be thicker,
as well as protected against corrosion from salt. The cockpit will
be a sealed and self-contained capsule that drops in a compartment
located near the mid-point of the vehicle.
Power plant
Driver safety
Rocket engines were selected due to their inherent compactness
and light weight as well as eliminating the need for a large and
destabilising air inlet duct. The drawback to rocket engines is the
large mass of fuel and oxidiser they require, and the potential for
explosion. The amount of rocket propellant needed for RV-1 is
minimised by keeping the size and weight of the vehicle as small
as possible, while still storing enough energy onboard to achieve
38
Chassis design
Once it was determined that the cockpit would be a sealed fireproof and blast-resistant capsule, inspired by the example of the
Scott Crossfield incident in the X-15 rocket plane, consideration
was then given to making the capsule ejectable. After studying
examples from both aviation and 250 mph (402.33Km/hour) drag
boat racing of ejectable or separable capsules, it was decided to
pattern the capsule separation for RV-1 largely after the drag
Motorsport
Driver cage (left) with ejectable driver escape capsule
boat model, in which the capsule separates only after a crash has
already initiated. However, due to the much higher speeds and
different motions expected in comparison to a drag boat if RV-1
were to crash, it was decided to incorporate both a mechanism
for actively ejecting the capsule and an aerodynamic decelerator.
Banks of compressed air rams on each side of the capsule will
serve as the ejection mechanism, with tilt switches mounted
in the horizontal and vertical planes acting to initiate ejection
without driver intervention. In the ejection sequence currently
envisioned, if the RV-1 pitches or rolls beyond preset limits, a
tilt switch will open a solenoid valve that releases compressed
nitrogen into the banks of rams. As the capsule is launched outward, the tension from a steel cable lanyard attached between
the capsule and the chassis will pull a mechanism in the capsule
that releases a ballute to decelerate and stabilise the capsule.
Wheels and suspension
At 1,000 mph, a 30 inch (762mm) diameter wheel will be turning
over 10,000 rpm, generating a centrifugal force of 50,000g at the
rim. When it was found that even with a hollow all carbon fibre
wheel, based on a rim sandwiched between two disks, the lightest
that could be expected for a 30 inch diameter 8 inch (203.2mm)
wide wheel was still 230lbs (104.3Kg), the decision was made
to explore reducing rotating mass by going to a design where
only the outer rim rotates. This had the ripple effect of making
an internal suspension system practical, which in turn freed up
the volume that would otherwise be occupied by a conventional
suspension system. To generate a stable and consistent steering
response, tireless wheels must plane on the surface of the track
instead of plowing ruts. The wheel width of 8 inches for RV-1
was determined by reviewing the experience of other teams
to run vehicles with tireless wheels on a salt flat. Based on the
experiences of these other teams, it was felt 8 inches should be
wide enough to support a five tons gross weight vehicle running
on dry salt without cutting ruts. The wheel rim will rotate on air
bearings placed around the perimeter of a bearing block that also
houses the slide which serves as the suspension system. Rubber
cushions on the top and bottom of the slide permit an up and
down movement of +/- 1 inch (25.4mm). The sides of the slide
will serve as adjustable friction dampeners to control bounce.
case the tunnel on top of the vehicle housing the rocket propellant
feed lines, against two vertical aerodynamic surfaces.
Downforce is further enhanced through the two canard
wings located beside the cockpit. The canard wings for the
RV-1 are based on studies of disk wings. The shape permits a
large amount of surface area while maintaining a short span. So
that the wing angle of attack can be adjusted while the vehicle
is in motion, the wings pivot from the front moved hydraulic
actuators attached at the rear. This combination of a short span
and two-point attachment provides a very rigid system which
reduces the potential for flutter, a destructive aerodynamic
phenomenon that results in rapid uncontrolled motion which
can lead to structural failure.
Conclusion
Setting the World Land Speed Record requires two runs in opposite directions within one hour through a mile speed trap
located in the middle of the course. There is no minimum course
length. We believe that minimising the size of the vehicle also
minimises other problems, such as building the vehicle, transport of the vehicle to the Lake Gairdner salt flats, and the length
of the course needed. A smaller vehicle can accelerate quicker
and stop in a shorter distance. Minimising the stopping distance
maximises the margin for error, and means the team doesn’t
have to search all over the world for a track that allows a twelve
or fourteen mile (19 or 22Km) course, because it can do it in
nine miles (14.5Km) on Lake Gairdner.
WLSR Challenge - 0437 467 780
www.thebulletproject.com
Aerodynamics
To assure yaw stability, the centre of pressure must be behind
the centre of gravity. The RV-1 design accomplishes this through
two large tail fins and moving the center of gravity as far forward
as possible through placement of the heaviest components in
the front half of the vehicle. To counteract any lift that might
be generated as shockwaves form at transonic and supersonic
speeds, various methods of generating downforce are being
incorporated, principally the shape of the nose and the use of
canard wings. However, the use of ground effects tunnels on the
underside of the nose is also being considered.
The channel formed between the tail fins is intended to augment vehicle downforce at speeds in excess of Mach 1 by taking
advantage of a phenomenon called compression lift. To generate
compression lift, air is forced outwards by a centre body, in this
39
Motorsport
Noonan employs Camplex knowhow
n amongst the CNC machines, the
cylinder head computerised flow
bench, Spintron testing machine,
engine dynos and other specialised
equipment at Noonan Race Engineering
(NRE) in Queensland, is a very important computer that alongside its 5-axis
machining centres, enables NRE to be
at the forefront of race car engineering
both in Australia and overseas.
Usually the spotlight falls on the
dynos or some of the other more obvious high performance aspects of the
business but without this computer
it would be so much more difficult to
produce the sort of race spec engines
and specialised components that NRE is
developing. “To NRE, CNC machining
is not just a form of engineering, it is
pure art,” said Jamie Noonan, founding
partner of NRE. “Our customers look
at our products and are amazed at how
the toolpaths flow and add character to
the product.”
That’s no accident as the company
uses the inbuilt versatility of Delcam’s
PowerMill to ‘tweak’ things and add
extra dimensions to their machining.
Time is a luxury when you’re developing race engines and associated products; there’s always another race just
around the corner and teams demand
more power and reliability.
Just recently the company received
approval from the NHRA – the premier
US governing body for championship drag racing in North America
– for competitors to use the NRE X1
aluminium billet hemi top alcohol
40
cylinder head, based on a big-block
Chrysler engine in the ‘blown alcohol’
classes.
Overseas companies supplying
major engine compo¬nents such as
these do not normally receive the stamp
of approval from the NHRA. In fact
NRE is the only overseas supplier. In
Australia NRE has supplied engines
and engineering expertise to many V8
Supercar teams, perhaps the most wellknown being Brad Jones Racing and
Paul Morris Motorsports. To achieve
this, NRE relies on its software. “PowerMILL puts the power in our hands,”
said Noonan. “We have the ability to
control the toolpath outcomes to a very
high degree. The porting strategies
have also enabled us to bring another
key area of our products in-house, again
putting the power to take the end results
back in our hands.”
According to NRE, PowerMILL sits
perfectly with their needs in the performance industry as it gives them the
ability to control the toolpath outcomes,
creating not only a proven performance
product – but also a stunning worldclass finished result. “The ability to
work with very simple 2D toolpaths
all the way through to very complex
5-axis surface machining while maintaining simple to use forms is also of
great benefit,” said Andrew Collins,
joint business partner and head of the
machining area at NRE.
Collins is also very impressed with
the integration of PowerMILL with
FeatureCAM and PowerSHAPE. “In a
lot of cases suppliers of CAD packages
don’t complement the CAM package.
With PowerMILL and PowerSHAPE,
you are getting two genuine heavy
hitters in their own rights, which are
really made for each other,” said Collins. Collins and Noonan both agree
that any product is only as good as
the support behind it. “It was obvious
from the outset that our local agent
Camplex, was very passionate about
the product,” said Noonan. “For me it
made the whole relationship click from
training through to ongoing problem
solving and support.”
“Knowing that the support was in
place to back us up when we needed it
is worth its weight in gold. The outcome
of this is simple, after trialling others
that claim to do the same – this software
has improved our overall productivity
in excess of 20% - which is a huge
gain,” he said.
“The real issue is the ability for the
whole workshop to all work together
on one common interfaced system with
FeatureCAM, PowerMILL and PowerSHAPE allowing the company to
streamline the processes, said John
Noonan, marketing & sales at NRE.
“We can all work in the same system
as one, something not many other software manufacturers can do with as
much power and flexibility.”
Camplex Pty Ltd - 03) 9532-4566
www.camplex.com.au
Motorsport
3D Printing enabled Aston Martin Racing to
develop LMP1 race car in under six months
ston Martin Racing (AMR) was able to meet an aggressive development schedule for their AMR-One race car
by using 3D printing. The company's ‘Dimension’ 3D Printer
was used to mock up the chassis, driver controls and engine
of the race-car. The 3D printer produced prototypes for concept and testing of Aston Martin's new AMR-One, (LMP1
class). Developed in under six months, the car will be driven
by the Aston Martin Racing works team drivers in the 2011
Intercontinental Le Mans Cup (ILMC).
AMR selected the ‘Dimension’ machine for its rapid prototyping capabilities
after seeing the speed and quality of the
parts produced for the Prodrive run rally
team in a previous project. Having the
machine on site helped the race team to
design, test and build a complete car to
meet the tight deadline for entry into
this year's ILMC.
Built from the ground up, AMR-One
features a new custom carbon fibre chassis, an open cockpit and a significantly
down-sized engine, all of which required testing during the
building process. The Dimension machine was used primarily
for designing and testing the engine parts as well as mocking up the chassis and driver controls. This ensured ultimate
efficiency and that the new design met the 2011 regulations
from the Le Mans governing body - the ACO. The car was
developed from start to finish between autumn 2010 and the
end of February 2011.
Aston Martin Racing is also exploring the idea of using
the 3D printer to make finished parts for end-use on the car.
One item being considered is the front wing splitters used for
aerodynamic flow.
"When we received final sign-off to build the car for this
year's ILMC, using rapid prototyping was a no-brainer for us,
The finished LeMans car. Left: The engine,
which had a great many parts 3D printed.
as we had a tight deadline to meet. Most of
the engine was prototyped on the Dimension
machine, which also proved very useful for
the early stages of determining the driver fit
for the car," says George Howard-Chappell,
Technical Director at Aston Martin Racing. "Without the 3D
printer, we would not be testing the car today. Following the
success with the AMR-One, we hope to utilise the capabilities
of another Stratasys machine to help build and deliver end-use
parts for future cars."
"The AMR-One has achieved a balance of aesthetics and
aerodynamics, and FDM technology has helped make this
possible," says Tim Heller, European Managing Director for
Stratasys. "We wish the Aston Martin Racing team the best
of luck with the upcoming season." The FDM 3D Printing
process is patented by Stratasys, Inc.
Tasman Machinery Pty Ltd. 03 9584 8355
www.tasmanmachinery.com.au
“Being backed by STAR’s
longest serving agent of 23
years, Realtek offer
outstanding support and
product knowledge. It gives
us the edge.”
Warren, Yann Engineering
41
Motorsport
From concept to reality
By Russell Gallagher,
FR-1 Chief Engineer
or the past nine years, the charitable foundation ‘Autohorizon,’ has been designing, simulating, building
and testing the FR-1 (Fund Raiser 1) concept vehicle. FR-1
is a one-off, hand crafted, high performance vehicle, built
to demonstrate, locally and internationally, the design and
manufacturing expertise available in Australia. FR-1 is also
being used to develop design related study programs for
secondary, TAFE and tertiary students, to encourage students to consider design and manufacturing related careers.
FR-1 will be auctioned, with all proceeds being donated to
four children’s charities. The project has over 90 sponsors,
including the Victorian State Government, VCAMM, Holden
and Boeing, and is being built at the Automotive Centre of
Excellence (ACE) in Docklands, Melbourne.
FR-1 is powered by a Holden 6.0Lt V8, mated to a Ferrari 355 transmission. Chromoly front and rear sub-frames
are mounted to Australia’s first carbon fibre monocoque
passenger car chassis. Unequal length, double wishbone
rear suspension and a unique hydraulically actuated front
in-wheel hub suspension, ensure the lightweight chassis
stays on the road. A hand crafted aluminium skin is being
coach-built using a wooden buck and traditional coach
building techniques.
The VCAMM (Victorian Centre for Advanced Materials and Manufacturing) designed and built carbon fibre
composite chassis weighs around 80 kg, and showcases
several new composite technologies developed locally.
Project supporter: GMS Composites in Dandenong South
Melbourne, supplied a low temperature, out-of-autoclave
curable carbon fibre prepreg, suitable for high strength applications. This newly formulated material cures at 70°C
under vacuum pressure and provides comparable strength
to autoclave cured materials, without the costs associated
with running an autoclave. Significant cost savings were also
achieved by using cheap fibreglass mould tooling, developed
by VCAMM and Bellmont Nominees in Kilsyth Melbourne.
The fibreglass tooling was finished to class A standards, and
designed to have minimal temperature distortion at 70°C.
Curing was conducted at Boeing in Port Melbourne. The
chassis was laid-up in two moulds, and bonded together
using aerospace-grade, high strength adhesives.
Despite having a longer wheelbase and track than the
current Holden Commodore, the two-seater roadsters’ styl-
42
ing presented several design issues to overcome. Achieving
the targeted chassis torsional rigidity for example, required
careful optimisation of the quantity, placement and orientation of the carbon fibre plies. To support this task, material
strength testing was conducted at Deakin University Geelong, and later correlated and analysed using Nastran and
Patran FEA software, supplied by MSC Software Australia.
Designing the rear suspension, transmission, cooling and
exhaust systems was also challenging, due to the minimal
distance between the seats and rear-wheel centreline. CAD
modelling, 3D scanning and FEA thermal modelling was
used to ensure under bonnet temperatures and sufficient
clearances were designed to ensure a reliable vehicle.
Similar packaging and component performance design
challenges were also faced in the front. Targeted suspension
performance could not be achieved within the front space
constraints. A unique in-wheel suspension system, supplied
by Diver Consolidated Industries (Reservoir, Melbourne)
allowed both styling and performance targets to be met. A
hydraulic piston mounted in the front hub, transfers road
loads to a remotely mounted spring and damper unit, providing packaging freedom. The in-wheel hubs are mounted
to a custom engineered and styled, aluminium cross beam,
5-axis machined from a single piece of billet by Marand
Precision Engineering, in Moorabbin, Melbourne.
FR-1 project
www.conceptfr1.com.
43
Motorsport
Software proves to be key to success
ith Edgecam being the winning
CAM Solution for six years
since January 2005 Triple Eight Race
Engineering (also known as TeamVodafone since 2007) has had to perform
with tight racing schedules and time
constraints to develop and manufacture components for their V8 race cars
as well as supplying components for
other teams. Components ranging from
simple aluminium brackets to complex
manifolds, Edgecam has been the only
product to handle these tasks within
the short time frames given.
“Constant design and development
changes was the biggest drawback,
when new ideas and improvements
were made, the process of getting the
final machined product had to be just
as fast, hence Edgecam was selected,” says Commercial Manager Peter
Jamieson.
“Chasing hundredths of a second
around the track can be costly both in
terms of development time and money.
Only the teams with the best equipment
are able to compete at this level, “adds
Jamieson. “TeamVodafone is proving it has the resources, with recent
success in both the Teams (2010) and
Driver (2008, 2009) Championships,
as well Bathurst endurance Champions
in 2006, 2007, 2008 and 2010.”
In 2009 Triple Eight’s Design centre
turned to SolidWorks as its CAD Solution. As expected, the Machine shop
saw no change or experience delays in
trying to cater for the new CAD models. Edgecam performed as expected
with direct CAD link and Integration
to SolidWorks.
The power of shuffling the CAD
Software upstairs had no effect on what
took place in the machining centre,
giving confidence to make the design
move and without having to train machinists in new software whilst keeping
to schedules.
Senior Machinist Craig Johnston
explains. “In the Design office all
the ideas are formulated, here in the
Machine shop is where it all happens,
this is where the pressure is and this
is where we make those ideas come to
life. In my life the equation ½ time =
2 x pressure comes to mind. Without
time, we would not have pressure.”
“Edgecam is our saving grace
here. We utilise it for everything from
maintaining Job records in ‘Edgecam
Job Manager’ dating way back, to
the programming of our SolidWorks
models for our Haas machines for the
SL20 lathe VF3 4-axis and Haas VF5
5-axis machining centre. We do it all
in Edgecam and if the designers make
changes, Edgecam picks up on these
and will automatically update the tool
path, remaining fully associative to
the SolidWorks model. This saves us
a lot of time in development as small
changes can easily be accepted with
the minimum amount of reworking
taking place,” said Johnston. With the
Team currently leading the Championship, i.e. Jamie Whincup 1st and Craig
Lowndes in 2nd place, a very competitive season appears ahead.
“We are as always pushing the innovation boundaries whether it’s on
the track or in the workshop, so being
aligned with Stillam AU and Edgecam
is a logical decision” concludes Jamieson.
Stillam AU
03 9584 9733
44
Motorsport
Aussie Racing Cars – utilising SLS
to meet deadlines
ussie Racing Cars was only a
week away from the deadline
of completing their new scaled-down
Toyota Aurion racing car when they
contacted Formero for assistance. The
new car was to be launched live on
Channel Ten's RPM show, and raced
for the first time at the Gold Coast Indy
street-circuit. With time running short,
thinking outside the box was the only
way to meet their deadline.
Formero's innovative SLS production process would allow them to manufacture the grille and side mirrors in
nylon material directly from the 3D
CAD, avoiding the time-consuming
process of tooling and moulding.
In just three days the CAD data
was transformed into parts with impeccable detail.
Aussie Racing Cars was able to
paint the parts and finish assembling
the car just in time for the long anticipated public launch. According to Aussie Racing Car’s Phil Ward: “Formero’s
SLS will play a significant role in the
future production of our scaled-down
racing cars as we strive to reduce lead
times further and guarantee the best
possible level of production response
time.”
Formero - 03- 98156010
www.formero.com.au
Machining Solutions
Intelligent Design
• Micro Precision CNC milling
and Cylindrical grinding
• High speed CNC machining
• 3 axis EDM CNC machining
• CNC wire cutting
• 3 axis CNC turning
•
•
•
•
Measurement
World acclaimed CAD, CAM software
In house product and development
In house mould design
Specializing in the manufacture of high
speed Liquid Silicone Rubber moulds
and Plastic Injection moulds
• Turnkey Solutions including Robotic de
moulding.
• Precision machining of all materials
• CMM metrology with virtual
3D CAD model comparison
• Non Contact Optical measuring
10 Binney Road, Kings Park,
NSW 2148 Australia
Bennett Precision Tooling Pty Ltd
Tel: +61 2 9621 5900
www.bptooling.com.au
F +61 2 9621 5966
45
Motorsport
Speed: the one thing that matters
n the world of motorsport, there is
only one thing that matters: speed.
Making its debut to the Australian
V8 Supercar Championship Series in
2009, the Kelly Racing team truly understood the value of a well-designed
car. Without the technology to design
better cars, the team wouldn’t be in
a position to be fighting for podiums
and titles.
The challenge is to squeeze the
most horsepower and torque possible
out of a Holden Commodore or Ford
Falcon engine whilst staying within the
series’ regulations. At time of print,
Rick Kelly sits just 81 points behind
the V8 Supercars Championship series
leader, with the entire team going from
strength to strength since its debut at
the Clipsal 500 in Adelaide on 19-22
March, 2009.
After breaking ties with Walkinshaw Racing in 2009, the Kelly family
took the plunge to establish their own
team in the V8 Supercar Championship
Series. Based in Melbourne, Kelly Racing is now in its third season and, as
the team looks to continue its climb up
the championship ladder, it is the only
four-car operation in the V8 Supercars
pit lane in 2011.
As an integral part of growing the
success of Kelly Racing, the engineering team entered a long-term relationship with Autodesk, a leading developer
of 3D design software. “This is literally
a fast-paced industry. If we can’t keep
up in terms of creativity and design,
we can’t keep up on the podiums”, says
Nick Ryan, Kelly Racing Commercial
Manager.
Kelly Racing will be using Autodesk
Inventor, Autodesk Vault Workgroup
and Autodesk Algor. Combined, this solution will be used to increase the cars’
aerodynamics, weight and ultimately,
speed. Using Autodesk Inventor, Kelly
Racing is able to transcend 3D design
to Digital Prototyping by enabling the
production of accurate 3D models that
assist engineers design, visualise, and
simulate mechanical alterations before
they are built. This enables the team to
design faster cars while simultaneously
reducing development costs in a faster
time frame.
“Engineering is such a huge part of
what we do because so many compo-
46
Rick taking Kelly Racing’s first V8 Supercars Championship win
(Hamilton, NZL 16 April 2011)
nents in these cars are custom-made,”
says driver, Todd Kelly. “It’s forever
evolving, all the suspension, anti-roll
bars, uprights and diff-housings. The
amount of change that’s been happening in all those areas in the last five
years has been massive, so we needed
to work with a design system that could
keep up with these changes, to ensure
that we stay competitive and continue
to chase podiums and titles”.
“The teams that are really good at
designing those elements of their cars
and have the engineering capacity to
keep updating and improving – drawing those things and getting them made
on the car as fast as possible – are the
teams that win races and ultimately win
championships. We saw this opportunity in Autodesk’s software,” continues
Todd Kelly.
By using the Autodesk Vault Workgroup, Kelly Racing is able to keep
track of designs, reduce errors and
promote design reuse by consolidating
product information in a single location. In this way, engineers are able to
track design data and manage work-inprogress designs without the need for
manual, paper-based processes.
The program makes data management more efficient by organising design data and protecting it from inad-
vertent changes. This data-management
tool makes work-in-progress data more
accessible and reusable while avoiding
the versioning problems inherent in
sharing files among workgroups.
Autodesk’s solution for Digital Prototyping enables engineers to create a
single digital model that can be used
in every stage of production, bridging
the gaps that usually exist between
conceptual design, engineering, and
manufacturing teams. “The Autodesk
solution is exactly what we were after. Its provision of a seamless range
of tools allows us to produce more
integrated designs faster and more
efficiently,” says James Small, Kelly
Racing’s Race Engineer.
Rod Hunt, Autodesk’s Simulation
Executive Manufacturing industry
Group in ANZ Australia and New
Zealand explains, “Our digital prototyping solution allows Kelly Racing’s
engineers to explore ‘what-if’ scenarios
in a risk free, virtual environment,
which allows them to reduce the cost
and increase the speed of project development while also giving them the
ability to manage their data throughout
the entire process”.
Autodesk offers the most straightforward path for auto suppliers to create, share, and maintain a single digital
Motorsport
Todd and Rick Kelly and right, Kelly Racing HQ in Braeside, Melbourne
this. Furthermore, with authoritive
model – enabling greater collaboration
restrictions placed on mechanical creaand innovation by bringing together detivity, such components have become
sign data from all phases of the product
even more important, to the point that
development process.
the smallest of changes will have the
In an industry such as motorsports,
biggest impact. Air pressure in tyres
it is possible to have an average driver
and the weight of the car are two such
win in a great car, but no matter how
variables in a limitless list.
fantastic the driver is, an average car
With the right technology, though,
will never qualify. The industry has
these variables can be eliminated in a
come to a point where engineering
QMTHalfpage2011:Layout
1 18/3/11
PM Page
1 environment. Engicontrolled
testing
and
technology advances have
ensured 12:29
neers can determine, ahead of time,
the impact that elements such as weight,
shape or size will have on a prototype,
and examine it in a virtual environment
until the results have been maximised
to achieve the most efficient component
possible.
Autodesk Australia Pty Ltd
02 9844-8072
www.autodesk.com.au
Turn Mill Centre with Y axis
KEY FEATURES:
• Turn Mill Centre
• Optionally available Sub Spindle
• Modular Construction
• 30 Degree slant bed construction
• Axes with hardened & ground guide ways with turcite liners
• Large turning diameter 400 mm & swing of 640mm
• 12 station radial single motor driven servo turret
• Main spindle with C axis capability
Vantage series is equipped with state of the art control
technology from Fanuc. Vantage multi axis Turn Mill center
offers complete solution to your complex machining
requirement with modular design at a affordable price.
QUALITY MACHINE TOOLS PTY LTD
Engineering Machines & Accessories
Tel: +61 3 9587 8788 Fax: +61 3 9587 5788
91-93 Malcolm Rd, Braeside Vic 3195
www.qualitymachinetools.com.au
[email protected]
• Huron 5 Axis Machining Centres
• CNC Lathes & Mills
• Vertical Machining Centres
• CNC Wirecut EDM
• Digital Readouts
47
Motorsport
Toro Rosso F1 racing team boosts success
with the aid of Geomagic Qualify
Advanced 3D inspection software from Geomagic coupled with optical scanning technology is
helping Italy-based Scuderia Toro Rosso improve the performance and reliability of its
Formula 1 racing cars.
f ever there was an industry in which time compression is the name of the game, it’s Formula 1 Grand Prix
motor racing. Among the teams competing in Formula 1
is Scuderia Toro Rosso, which is owned by the Red Bull
Company. And like all other Formula 1 teams, Scuderia
Toro Rosso is always looking for new and better ways to
compress development and production times and to increase
the reliability of its racing cars.
One advantage that the team has over the competition though is the use it makes of Geomagic Qualify 3D
inspection software at its headquarters in Faenza, Italy.
This has reduced the time required to inspect new parts
by an average of 30%. It has also given Scuderia Toro
Rosso the ability to inspect parts that previously could
not adequately be inspected within the demanding time
frames of Formula 1. Geomagic Qualify is advanced
computer-aided inspection software that enables fast, easyto-understand graphical comparisons between 3D CAD
models and as-built parts, or between parts from different
production runs. It saves time and increases accuracy for
first-article and in-process inspection and enables trend
analysis, 2D and 3D dimensioning, geometric dimensioning and tolerancing (GD&T) and automated reporting in a
variety of formats, including Microsoft Word, Microsoft
Excel, PDF and VRML/HTML.
Pierluca Magaldi, Quality Manager at Sduderia Toro
Rosso believes that in addition to the reduction in the time
needed to inspect new parts, Geomagic Qualify has played
a part in enabling the team to achieve the best result in its
history last year. During the 2008 Grand Prix season the
team earned its most points ever, its first pole position and
its first win, fittingly at the Italian Grand Prix in Monza.
Wide-ranging inspection needs
Apart from the engines, which are supplied by Ferrari,
around 35% of the components of Scuderia Toro Rosso’s F1
cars - including the chassis, rear crash structure, body shell
and bonded aerofoil wings - are produced in-house. The
remaining 65% - including light metal castings, machined
parts and carbon fibre laminates – are produced by external
specialists. Final assembly is done completely in-house.
“Production runs for our components range from one
to maybe 30-40 for a complete season,” says Magaldi. “So
we are definitely a prototype company, even though the
prototypes we produce are used for racing.” Before implementing Geomagic Qualify, Scuderia Toro Rosso used
an outside company to inspect parts with complex shapes.
Parts with less complex shapes were inspected in-house in
the traditional way, using micrometers, vernier calipers and
co-ordinate measuring machines (CMMs).
48
New Formula 1 racing car parts like this gear box case are
inspected for quality at Scuderia Toro Rosso by using a Faro Laser
ScanArm and Geomagic Qualify software.
Geomagic Qualify enables fast, easy-to-understand graphical
comparisons between 3D CAD models and as-built parts, or
between parts from different production runs. Geomagic Qualify
automatically assigns colors to the 3D model that represent
different degrees of deviation.
This traditional method required collecting individual
measurements at specific points on the part. Those points
would then be analysed for any deviation from the nominal
as defined on the corresponding 2D part drawings. Inspection was therefore a long and laborious process and only a
selection of points on the part could be inspected. Today,
the wide range of inspections carried out at Scuderia Toro
Rosso start with a Faro Laser ScanArm scanner and a Laser
Line Probe to capture the shape of an object, be it a cast or
moulded component, an aerofoil wing, or a casting pattern.
The resulting ‘point cloud’ represents the bounding surface
of the object to an accuracy of 35 microns. This point cloud is
read into Geomagic Qualify to begin the inspection process.
“We still use CMMs for geometric dimensioning & tolerancing (GD&T) checks on machined parts where tolerances
are set to a few microns,” explains Magaldi. “But in general,
we use the scanner and Geomagic Qualify because the process
is much quicker and allows the whole part to be inspected
in detail, rather than just a few selected measurements.”
Simple, fast process
The inspection process relies on two inputs to Geomagic
Qualify: the 3D scan data of the part to be inspected and
the original 3D CAD model of the part from Scuderia Toro
Rosso’s Unigraphics CAD/CAM system.
The first step is to create a single, unified 3D scan data
model of the part by aligning and merging the individual
Motorsport
scans taken from different viewpoints. The scans are aligned
using automated methods provided by Geomagic Qualify.
When the single 3D scan data model has been produced,
datums and features upon which the inspection is going
to be based are created on the CAD model. The scan data
model is then aligned with the nominal 3D CAD model using
both manual and automatic alignment facilities provided by
Geomagic Qualify. The whole process, from reading in the
scan data and the CAD model to arriving at the point where
the two models are aligned correctly and inspection analysis
can start, takes no more than an hour or so to complete.
With the models aligned, the 3D scan data model is automatically analysed against the 3D CAD model to identify
and measure any deviations between the physical part and its
counterpart 3D CAD model, as well as for GD&T purposes.
Geomagic Qualify automatically assigns colours to the 3D
model, with the colours representing different degrees of
deviation. Actual deviation values are also shown, along
with GD&T call-outs.
Generally speaking, surface form errors at Scuderia
Toro Rosso are 0.2 mm maximum for complex shapes. If
appropriate, whisker plots of cross-sections and wall thickness analysis results can also be calculated and displayed
by Geomagic Qualify.
Inspection reports are then output as PDFs automatically
and sent to the research & development (R&D) department
and the design office for any remedial action. If any big
non-conformities are discovered, the reports are sent to the
FMTool_April2011:Layout
4 19/5/11
original
part manufacturer for
action. 10:42 AM Page 1
Front brake duct detail after initial scanning with a Faro Laser
ScanArm.
“There’s no doubt that the use of Geomagic Qualify has
brought us a number of very real benefits,” says Magaldi.
“For a start, we are now more confident that parts conform
correctly to what was designed. We are also able to inspect
parts that previously we couldn’t inspect fully, either because we didn’t have the technology or because of time
constraints – or a combination of both of these. This gives
us a better understanding of what we are going to assemble
on a race car which will help towards better performance
and reliability.”
WYSIWYG - 02 9153 9974
www.wysiwyg3d.com.au
49
Motorsport
Siemens helps make Formula One
in Milton Keynes, England – making
Red Bull Racing a pioneer in the racing world.
There is no industry where products
have to be developed and manufactured
as fast as they are at Formula One
factories. And nowhere else where
minimal changes in configuration can
RN.8925/1
ed Bull Racing and Sebastian
Vettel became double World
Champions in 2010 winning the Constructors and Drivers championships.
Red Bull Racing develops and manufactures its championship winning car
using Siemens’ software for Product
Lifecycle Management (PLM). The
software forms the highly efficient
digital backbone of the manufacturing
process and enables new components to
be designed at high speed on the computer, sent into production seconds later
by a mouse click and then built into the
vehicle. This speeds up development
and improves lap times. “Siemens PLM
software plays an important role within
the company feeding data from our
design engineers to our manufacturing facilities. This contribution should
not be underestimated,” said Christian
Horner, Team Principal of the Red Bull
Racing team. In addition, Siemens is
now reducing the energy consumption
and CO2 emissions of the team’s factory buildings and production systems
One magazine
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50
affect the entire performance of the
car the way they can in Formula One.
Victory and defeat are often only fractions of a second apart. During the
brief periods between races, around
100 engineers at Red Bull Racing work
under tremendous pressure every day,
using Siemens’ software to make the
Motorsport
factory more energy-efficient
rial waste. Additionally, designers and
manufacturing regained up to 75% of
their time by eliminating tedious and
repetitive portions of the design and
manufacturing process.
To make the vehicle suitable for the
various race tracks with their particular
characteristics, many configurations
are available. The engineers design and
simulate the interplay of the parts on
the computer to find the ideal combination. All the developers and engineers
across the entire production facility can
access all the data they need, whether
in the factory or on the racetrack, at
Siemens AG
[email protected]
www.siemens.com
RN.8925/2
cars driven by Sebastian Vettel and
Mark Webber just that bit faster. The
engineers virtually develop the entire
vehicle, constantly design new components, assemble all 4000 individual
parts and put the vehicle through its
paces – all while sitting at the computer. A mouse click is all it takes for
the developers to have the new parts
milled and moulded immediately – it
is not necessary to enter any data by
hand into the machine tools or other IT
systems. By using the software, Red
Bull Racing has significantly reduced
physical prototyping and limited mate-
any time, and always know what was
altered on the car.
Siemens is also optimising Red Bull
Racing’s factory with products from
its environmental portfolio. The object
is to significantly reduce the plant’s
energy costs, resource consumption
and CO2 emissions and also make the
production processes more efficient.
“An industrial company like Siemens
is an ideal partner for optimising production – with expertise accumulated
from over 160 years of manufacturing,
with 300 plants and the largest environmental portfolio in the world,” said
Horner. Siemens is currently inspecting the entire production process, including all the existing machines and
work processes. It is also carrying out
an energy check on the building technology, heating and air-conditioning
systems.
53,600 readers
98% of our readership surveyed values
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AMT magazine provides industry-leading value
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For advertising rates call Anne Samuelsson
AMTIL on 03 9800 3666
or email [email protected]
www.amtil.com.au
51
Forming & Fabrication
m3Plasma system tested for
weld preparation
astCAM Pty Ltd has produced a new digital bevel
head, designed specifically for the creation of true 3D
‘weld ready’ shapes from steel. The most useful common
application for FastCAM’s new technology is precise weld
preparation for flat and formed plate although pipe cutting
with bevels is also supported. Testing commenced in early
2009, in Canada.
The object of the first test was a tolerance in every dimension of +/-1mm required for weld preparation, even on a
very small part.This was achieved with the precision of the
m3Plasma torch. Having established accuracy, the second
challenge was the preparation of a rolling weld face K bevel
for formed plate (VBA or Varying Bevel Angle). The key
distance to observe is the depth of the top and bottom of
the root face or land. This must be constant regardless of
the angle of the weld face.The access grooves are cut at 30
degrees relative to the weld face. Again it was totally successful with the precision of the m3Plasma torch. The land
is particularly sensitive to the slightest error in position,
kerf, feedrate, or torch height.
The quality of the cut from the m3Plasma means minimum cleaning or grinding is required for perfect results.
Using the latest in high precision torches with the rapid
switch between cutting and marking means the parts can be
marked for forming and labeled, further reducing forming
and assembly times.
A separate challenge was to ensure that the weld specifications could be originated from the drawing office in a
way that translated seamlessly to the NC cutting machine.
Shows the simulation of the NC code in the FastCAM® 3D
Programming System. Note the complex vectored corners and
stationary points for the machine. Red is an undercut and blue is
top cut.
52
The goal was to achieve the level of automation that the machining industry has enjoyed for
years, where they send 3D files through to 5-axis
machining centers, knowing that the end result
will be perfect.
In the new FastCAM 3D approach,
the breakthrough concept for plate
cutting was to adapt the 2D format
to include 3D weld information in a
parameterised form, so that the file
can be transmitted, edited, nested and
cut in the usual production manner.
To ensure absolute control over
accuracy, all welding specifications
can be independently defined by the
A test part with
original designer, based on complete a symmetrical K
drawings, design and welding standards bevel cut in three
passes on 25.4mm
and workshop practices.
The new format allows for a non- plate, 10, 5.4, 10
vertical weld face, non-orthogonal tan- at 30 degrees.
gent vectors and continuously varying weld faces. Using
the annotated 2D file provided by the drawing office, the
programmer only has to load this same file into the FastCAM 3D processing system. All the elements are in 2D to
allow for machine independence. The file can be used by
triple torch oxy, single torch plasma, water jet, laser or any
Variable dihedral K preparations generated by FastCAM.
Plate forming
other process. Details of offsets, multiple passes, corners,
notches and the rest are all handled in the usual way by the
nesting software. Weld prepared parts can be freely mixed
with standard cut parts for material optimisation. The end
result is a true 3D object from a 2D machine.
These CAM files are also generated by complementary
software programs such as FastSHAPES so as to completely
automate the development and forming of transitions for
all the different segments in the heavy engineering market,
from simple Cones and Mining Buckets to complete HydroElectric Pen Stock type developments.
This new approach to fabrication will totally eliminate
grinding from almost all weld preparation, limited only by
the maximum angle of the m3Plasma torch at 55 degrees.
This means not just an increase in productivity, but the
complete elimination of an entire process in fabrication and
all the double handling. It also means contract cutters and
service centers can be certain of their results, mixing square
cut parts and beveled parts with ease. Dr. Matthew Fagan
of FastCAM, was thrilled with the results, saying “After 20
years, we have finally made a breakthrough on accuracy,
simplicity and cost, making automated weld preparation of
heavy engineered parts a viable reality.”
FastCAM Pty Ltd - 03 9699 9899
www.fastcam.com
About FastCAM
Established in 1978, FastCAM Inc. is a software company
specialising in NC plate processing with over 36,000 NC
programming systems throughout the world.
FastCAM is located in three locations: FastCAM Inc. in
Chicago, USA, FastCAM Pty. Ltd. (Research & Development)
in Melbourne, Australia and FastCAM Shanghai, in China.
Dr. Matthew J. Fagan, Ph., invented interactive graphic
nesting in 1983, even before the creation of the PC. His
vision was to make programming simple and affordable.
For the last decade he has focused on simplifying and automating weld preparation.
Plasma weld preparation in industry
Most plate has to be weld prepared, however automated weld
preparation not been widely accepted for fabrication. Traditionally, only a small percentage of NC plate cutting machines
are beveling machines. Even those are used mainly in single
pass chamfering for shipbuilding.
However primary industries such as mining, transport, road
works and agriculture, are moving to harder Q&T steels with
more strength, more impact resistance, more wear resistance
and other special properties. These materials are much
harder to grind so weld prepared parts straight off a cutting
machine has the potential to offer a dramatic savings for a
much larger market segment.
For a weld prepared part to be acceptable, there must be an
overall accuracy of +/- 1mm. However machines, torches and
programming systems are still tested by this type of application which is machining, not rough flame cutting. For many
reasons, it just has not worked or has been too expensive or
too complex. Where accuracy is required, there are varied
inherent problems such as torch height control, special logic
for loops, corners, adjustment to kerf, feedrate and more.
A small error in the head position, horizontally or vertically
means a big shift in the position of the small land formed in
a ‘K bevels’.
To complicate matters further, there are multiple ways in
which a drawing can be defined. Thus a simple rectangle is not
enough. When bevelled you have to know if you are looking at
the top, the bottom, half way through or even the top on one
edge and the bottom on another, with the biggest or smallest
rectangle approach. In many cases, the NC programmer has
had to tackle problems best left to a welding engineer. If not
calculated correctly, you may have a beautiful bevel but on a
part which is too big or too small and does not fit.
Steel service centres have been reluctant to take responsibility for accurate weld preparation for customers. It is a
specialist job and they usually do not have the full set of drawings, the 3D systems or the ability to read the complex weld
diagrams or to perform the offset calculations. For a variety
of reasons, the old approach of manual or semi-automatic
weld preparation is still the standard, despite the huge labour
and time penalties.
53
Heavy plate bender now works in
upstroke and downstroke movements
axitec has made available a bi-directional bending
machine to provide a lengthy list of time and quality
advantages when used in place of the much simpler ‘press brake’
technology. Schröder MAK 4 EVO UD has a bi-directional
folding beam ensuring a part will never need flipping again.
A bi-directional (up and down) folding beam facilitates
faster setup, more precise dimensional part accuracy (folders gauge the part, not the flange), outstanding angular part
accuracy (material variation does not affect the bend angle),
superior ergonomics, single man operation requiring less
skill , better safety, part repeatability, it eliminates whip-up,
and provides mar free forming.
Whether work requires one station or two stations, operators will never again widely varying set up times and never
again will you have a 10 minute run with a 30 minute set up.
The unit’s performance is based around The POS3000
Sheet Metal Designer operator control. This is a production
management system through which the operator directly
interfaces with the bender. This sophisticated control system
automatically calculates the most efficient method of part
manipulation, axis positioning and tool setup. No matter
who created the program, or whether it originated in the
office or at the machine control, the part is always run with
the same level of efficiency.
A bi-directional bending process allows operators with
a standard workaround of 180 mm on the MAK4, arguably
the largest forming area available for this type of process.
A ‘U’ shaped back gauge is a must for the MAK 4 to
achieve the level of flexibility and ergonomics it does.
54
Achieving perfection in precision and complex geometric
shapes would be impossible without the most sophisticated
gauging in the world.
Schröder MAK 4 Evo UD has with twin ball-screw drives,
steel or nylon ball transfers, solid gauging fingers, and popup stops which simplify handling of even the largest parts.
Back gauge fingers are pneumatically ‘popped’ up, in
rows 850 mm (33.46”) apart.
Programmable fingers drop below the gauge deck for
easy part manipulation.
Sheet support surface is outfitted with brushes, steel or
nylon ball transfers.
Pneumatic pop-up squaring arms are optionally available
at multiple locations across the width of the gauging table.
Gauge pans are removable to accommodate parts with
negative geometries. The control system displays part placement relative to gauge fingers, squaring arms and ‘U’ shape.
Finger height is relative to the maximum gauge thickness
to reach over larger bend radii.
Grip gauging systems are available for sheet metal or
plate up to 12 mm thick. Used in conjunction with the autosequence function of the POS3000, parts are held in place by
grippers and effortlessly fed through the forming sequence.
Tool positioning is automatically optimised by the
POS3000 control. Nothing is left to chance, and tool change
times can be relied upon time after time.
Maxitec Pty Ltd - 02 8536 5800
[email protected]
55
Entry level sophistication in
sheetmetal fabrication
axitec Pty Ltd has made available t he new E5x Compact
Express - a compact, highperformance servo electric
t ur ret punch press. This
unit provides fully automated material handling capabilities that arm small/medium
sheemtetal fabricators with
a multi-purpose machine for
bending, forming, tapping
and marking.
Manufactured by FinnPowe r, t he E5x Compa ct
Express eliminates the bulky,
vibrating issue of hydraulics by
using servo-electric punching technology together with programmable
punch modes, stepless adjustment
of speed and position and accurate
forming. It also returns low energy
consumption and low maintenance
costs – both which are quantifiable by
Maxitec’s user-specific ROI analysis
and can be supplied with Finn-Power’s
‘compact express’ load/unload system
for automated production.
Unloading is integrated in the machine table, which saves space. The unloading cycle and simultaneous loading
mean a minimum interruption of productive processing. Providing a compact 1250mm x 2500mm working area
that requires no repositioning of the
job piece – the E5x provides high accuracy and productivity while operat-
56
ing in a tight workspace
footprint. The unit’s single water-cooled servo
motor operates on a ball
screw for its linear movement and a pneumatic
RAM return movement.
A pull movement provides strokeless wearing
for the mechanics.
With fast punching
speed, fully adjustable in both directions, the Finn Power E5x has a position above the sheet that is fully adjustable (S value) and a position under the
sheet that is fully adjustable (P value).
A one-sided wedge system, with high
static force in forming, facilitates low
tonnage load for mechanics and has
17 or 23 ton punching force available.
Closed-circuit water cooling means
it is prepared for high ambient temperatures. Pneumatic clamps with central
locking and sheet security monitoring
centres provide a safe production and
fast setup with optional PCS and 3rd
clamp with ‘move’.
With brush tables, the system handles a maximum sheet weight of 200kg
and maximum sheet thickness of 8
mm, therefore a silent, scratch-free
sheet motion with best sheet support
is gained. Optional lifting brushes
provide an extra safety for sensitive
materials.
Optional vertically moving sheet
supports make it easy to move heavy
sheets on the table surface during loading. Overall, it combines best features
of ball and brush tables.
A metal sheet support at table edge
facilitates loading of heavy or large
sheets. Plastic brush table segments
are provided around the turret. Sheet
loading is assisted by a 5-position moving table; therefore simplified loading
for all sheet sizes, affording higher
productivity through fast operations.
The E5x has a turret with a total of 20
stations offering customisation. Fixed
or indexed, as well as Multi-Tools®,
can be chosen. The total number of
tools can be increased to more than
100 by adding Multi-Tool stations. Indexable Multi-Tools are available as
an option. Further, easy touch screen
operations, standard Windows functions, USB port and 100Mbs ethernet
for data transfer are standard.
Maxitec Pty Ltd - 02 8536 5800
www.maxitec.com.au
MACS Engineering adopts Dye pressbrake
technology for Lean manufacturing
MACS Engineering’s Mackay operation has taken delivery of their eagerly
awaited Dye NGX 110 tonne x 3.6m
5-axis synchronised pressbrake. MACS
Engineering specialises in purposebuilt bodies, equipment and accessories for light vehicles (up to 4.495
tonne GVM), medium trucks up to 32
tonne GVM and specialised innovative
engineered safety solutions such as
egress towers, pumps/pontoons, elevated work platforms, stairs, handrails
& walkways, solar lighting plants and
repeater towers.
After careful consideration, the
company’s board decided on the Dye
product for its design and rigidity reputation and its ability to integrate with
the company’s current processes. “A
mutual client, Swift Engineering purchased their Dye 325 tonne machine
last year and is extremely happy, making our decision a little easier from
the backup and serviceability point
of view,” states Ross Frederickson,
Founding Director.
With the company’s focus on Lean
manufacturing, which is aimed at the
elimination of waste in every area of
production, MACS’ goal is to incorporate less human effort, less inventory,
less time to develop products, and less
space. This is in order to become highly
responsive to customer demand while
producing top quality products in the
most efficient and economical manner
possible.
“We offer a genuine ‘one stop solution’ adds Frederickson. We design,
engineer, manufacture, supply and install all our products ensuring our clients benefit from low risk, value for
money and safe solutions. We see our
new purchase as being the key to assist
with our production bottlenecks in our
folding ability and accuracy”, concludes Frederickson.
www.macs.net.au
TruEdge
The New Standard in High Definition Plasma Cutting
Plasma Cutting Moves Closer to Laser Cutting
FARLEY
LASERLAB
Only on a TruEdge plasma machine by Farley Laserlab
can you get laser cut quality parts at a fraction of the cost.
To view a machine demo please ring us to arrange a time.
Go to our TruEdge site to view a TruEdge machine in action.
www.truedge.com.au
47-51 Export Drive Brooklyn, Victoria 3012 Australia | Ph 61 3 9931 9300 | Fax 61 3 9931 9301
57
Optimum tool path strategies
reduce production times
here are many components to an
effective CNC machining process
for fabrication shops. While a highquality CNC machine is an important
factor for the efficient machining of
quality products, a good automatic
toolpath generating software package
is equally as important and sets you
apart from the competition by improving your product quality and value.
No matter how sophisticated a CNC
machine is, it can’t do anything without
a tool and a tool path.
Australia’s premier manufacturer
of CNC routers and plasma cutters,
Advanced Robotic Technology (ART),
believes that sometimes full productivity gains have not been made by
the latest CNC machine technology
because of the inherent shortcomings
in the off-line generation of tool paths.
Increased productivity
“The tool path has always been the
weak link in the chain,” says David
White, Director and co-founder of ART,
Brisbane. “A high-quality cutting tool,
driven by innovative tool path programs
can increase productivity by as much
as three times.”
ART works with different software
companies to match the correct tool
path software to the production needs
of each customer. Among these is the
in-house developed multi-purpose
ART ToolShop software, CAMduct/
PM2000 for plasma cutters and large
format routers in aluminium (including
automatic patterns for ducting applications as an option), as well as ProNest
for plasma cutters and EnRoute for
advanced 2D and 3D CNC routing
applications.
EnRoute software for CNC
routers
EnRoute is able to take most CAD files
and rapidly process them into NC files
suitable for use on ART CNC machines.
Specialised modules are available for
3D modelling, cabinetmaking, engraving, advanced nesting and most types
of machining processes.
“Generating an optimum tool path,
optimum speed and feeds ensure a
58
customer a heightened return on investment,” White continues. “With
the use of EnRoute Software for router
applications, we discovered that it not
only streamlines the CAD/CAM production cycle, it also takes on a whole
new aspect of affordability, accuracy
and uncompromising technical support
allowing for maximum productivity.”
Automatic tool pathing
By utilising EnRoute Smart Tool Path
technology, users can create a toolpath
strategy that best fits their needs. This
refers to the different types of toolpath
creation methods. Users can set parameters for routing offset, hatch fill, island
fill, drills, slots, pyramid and engraving.
Powerful tool path techniques can be
easily applied to any text or vector art.
Text can have a bevelled "pyramid" effect
that also includes a rough pass option
to clear out extra material and an offset
pass to cut out letters when completed.
EnRoute software is designed to
save time and make production processes more efficient. Automatic tool
pathing (ATP) brings together many
of the disciplines required into a fully
automated environment. The software
package is able to make many decisions
on behalf of the operator by following
predefined strategies – which means operators spend less time preparing design
files for output to the CNC machines.
EnRoute's ATP engine connects
seamlessly with any CAD software to
process layered DXF files and batched
files into nested sheets, complete with
drill holes, dados and layers ready for
output to the machine.
Minimising material waste
How parts are positioned on the material plate is another important factor for
increased efficiency in CNC machining. Parts positioning impacts both
the amount of material that the job
will consume and the machining time
required to cut the parts. A shop’s profit
margin is directly connected to part
nesting.That's why it is important for
CAD/CAM software to have a complete
set of nesting algorithms that can find
the optimum geometrical arrangement
to simultaneously minimise material
waste and maximise cutting times.
Behind EnRoute's easy-to-use interface is a powerful CAD tool with a
complete nesting suite that automatically finds the optimum geometry that
minimises material waste and maximises machine efficiency. EnRoute will
nest parts efficiently even on nonrectangular workspaces and automatically compensate for tooling fixtures
or material flaws. With EnRoute, you
can prioritise parts before nesting for
an efficient workflow.
Advanced Robotic Technology (ART)
07 3393 6555
[email protected]
www.advancedrobotic.com
Hypertherm introduces new fibre laser
ypertherm designs and manufactures advanced cutting
systems for use in a variety of
industries such as shipbuilding,
manufacturing, and automotive
repair. Its product line includes
handheld and mechanised plasma
and laser systems, consumables,
as well as CNC motion and height
controls and cutting software.
Hypertherm’s new HFL015
HyIntensity Fibre Laser system
is unique in that all of the components are engineered and designed
to work together as one complete
cutting system. Its system includes
the power source, cutting head,
gas supply, operator interface
consoles, motion controls, and
software. Hypertherm believes
this solution based approach will
make it much easier for partners
and their customers to use laser
cutting for their fine feature cutting requirements. Additionally,
the system operates on familiar
Hypertherm control platforms, with
pre-developed cutting processes, for
significantly simplified table integration and operation as well as higher
levels of efficiency, when compared to
other laser cutting solutions.
Two new Powermax systems made
their debut at EuroBLECH. Hypertherm’s Powermax65 and Powermax85
come with more torch options, techno-
logical innovations, and a more rugged
torch design for greater durability in
difficult cutting environments. Available torch options are an ergonomic 75
degree hand torch, a 15 degree hand
torch for gouging and cutting in tight
locations, a 38cm full-length machine
torch, and a 15 cm short barreled machine torch for robotic and pipe-cutting
applications, enabling operators to use
plasma in more applications than
ever before. In addition, the torches, which are part of Hypertherm’s
new Duramax series, are claimed
to be up to five times more rugged
and durable than before.
Hypertherm’s new HyPerformance HPR800XD, 800 amp system
delivers a wide process range and
cut ti ng capacit y. It feat u res
HyDefinition cutting performance
for mild steel up to 80mm, and
can production pierce 75mm and
sever 160mm thick stainless steel
and aluminium. The thick piercing
capability is attributed to PowerPierce, the patent-pending technology that minimises damage to
the torch using a liquid cooled
shield to repel molten metal during piercing and cutting. In testing, there was no damage to the
consumables or lessening of cut
quality, even after piercing 75mm
stainless steel over 400 times. The
HPR800XD can just as easily cut
thin metal—including gauge—without
the need to switch torches. Until now,
fabricators needing to cut a wide range
of metals and thicknesses had to use
two or more systems to complete the
job.
Hypertherm in Australia and NZ
07 3103 1695
www.hypertherm.com
59
Welding
Revolution in steel-beam fabrication
A ‘game changing’ SIN Beam welding machine from Austrian company Zeman Bauelemente, Austria, is now
being distributed in Australia by Perth based, Specialist Machinery Sales. The fully automated, highly versatile,
steel beam production line only requires one operator, offering welding speeds up to 1m/min. reinforced
profile widths of between 333 to 1500mm, and beam lengths of 400-16000mm (tapered: 400-12000mm) can
be fabricated. The individual components arrive on a conveyor at one end, and emerge a short time later at
the other end as a perfectly assembled steel beam that then only needs to be given a protective coating and
loaded onto a truck. According to Specialist Machinery Sales, the main advantages of the SIN Beam is that it
is one-third lighter than traditional ‘H’ beam sections yet stronger because of the corrugated web. This allows
greater spans, and in many cases, the reduction of supporting columns.
ntil recently, the only way fabricators could put their steel beams
together, anywhere in the world, was
by hand. This means that traditionally,
structural-steel elements are assembled
by manually welding on the headplates,
baseplates, connection plates and whatever ‘stiffeners’ may be needed to meet
structural-design requirements. However, in ‘Western’ countries, this is no
longer economically viable. More and
more firms have relocated their production to low-wage economies, only to find
that problems with technical fulfilment,
deadline-keeping and quality control
often eat up much of the cost advantage. As a result, many structural steel
fabricators have lost ground to eastern
competition. The Steel Beam Assembler
(SBA) performs all the steps involved
in fabricating a steel member, without
anyone needing to lift a finger. Instead,
computer-controlled robots execute the
CAD engineering drawings 1:1 – with
no errors, and in a fraction of the time.
The first step is that a conveyor system feeds all the add-on parts into the
production line past a high-powered
scanner. This detects the position of
each of the parts, which will have been
placed on the conveyor table at random,
and captures the actual dimensions for
comparison with the target values stated
in the CAD drawings. This ensures that
the specified tolerances are complied
with. The scanner relays all these data to
the positioning robot, in real-time. This
robot now has the job of picking up the
parts one by one, and positioning them
correctly on the steel beam. It has several
different magnetic grippers with which
it can safely pick up the various add-on
parts, which are of differing sizes and
weights. If any parts come in from the
infeed table facing the wrong way, the
positioning robot can briefly set them
down on a holding device on the robot
60
table, and then pick them up again the
right way round. There is no longer any
need for laborious measuring up, or for
the comparatively ‘fiddly’ job of manually attaching the add-on parts such as
angles, tappets and frame corners.
In the case of thick add-on parts and
large weld-seams, it is important to preheat the parts to be joined. Otherwise
the metal may be distorted, or stress
cracking may occur. This pre-heating
is also carried out by the positioning
robot, using a heat torch.
Once the plates are correctly placed
on the steel beam, one of the two welding
robots comes into action, tack-welding
the plates to the main member in the
order dictated by the positioning robot.
If higher capacity and output are needed,
the production line can be designed with
two parallel lines. In this dual-line configuration, while the two welding robots
finish welding the workpiece on one
line the positioning robot can carry on
working on the other.
The welding robots are also equipped
with all the necessary tools: welding torch,
plasma cutting device and laser measur-
ing system. Changeover to whichever
tool is needed is also performed fully
automatically. The two welding robots are
mounted on a shared longitudinal trackway, but can be separately controlled.
For the transverse and vertical strokes,
there are two further traverse-axes for
each robot. The vertical axis also has a
telescoping unit which enables the line to
be installed in production buildings of the
usual height. Each of the welding robots
is also equipped with laser measuring
heads. This enables them to recognise
the actual fit-up situation and compensate
for any weldment tolerances.
The robots can trim the edges ready
for large-volume welding seams using
the plasma cutter, and make any openings needed in the web, or cut-outs on
the members. When the steel beam is
finished, it emerges from the line via the
unloading device. The line is designed
in such a way that not even a power outage has any damaging consequences:
Once power has been restored, work
can resume unhindered.
It took nearly five years of research
and development, and 4.5 million euros,
Welding
larger production runs. However, Zeman
has a big head-start in terms of sectorspecific know-how. And secondly, this
Austrian company has already proved
many times over that it can tackle even
the most challenging assignments.
The benefits at a glance
to get the SBA to the point where it was
able to revolutionise the market.
The Austrian Research Promotion
Agency (FFG) also provided financial
support for the development work. The
devil was not just in the detail, but in
an endless number of different details.
Which is why on several sub-projects,
time after time, the verdict was: “Back
to the drawing-board and start all over
again”. This was particularly true of the
control software.
Now fully proven and perfected, the
control program – called pro-FIT – is the
centrepiece of the machine. It consists of
several overlapping modules. The first of
these is the clerical processing module,
which prepares the production operation.
This module defines the position of each of
the parts for attachment, and specifies the
welds etc. – in short: everything needed in
connection with the production operation.
Module Two is the control station. This is
where the work is divided up efficiently
between the plant control system and the
robots. This module continually gathers
data and passes it on to the appropriate
locations, and regulates how the robots
interoperate. The third module is an extensive databank. It contains a huge library of
‘collected works’ about assembling steel
members, and all the parameters used in
production. These are the cornerstones
needed for producing many very different
workpieces: machine parameters, welding
parameters, approach strategies for the
various robots, and so on.
When it came to the hardware, the
amount of development work involved
was equally large. It began with the
infeed tables. When the plant has two
production lines, both of them use the
same scanner. If the positioning robot
used by both lines is to be able to pick
up the necessary parts from both tables
correctly, and then place them correctly
(and within the tolerance limits) on the
steel beam, the two infeed tables must
be running absolutely in parallel. Over a
length of 30 metres, the maximum tolerance allowed here is just plus/minus half
a millimetre. The scanner itself comes
from Plasmo Industrietechnik and was
specially developed for the SBA with
assistance from Arsenal Research.
Over very many series of tests, Plasmo
and Arsenal Research finally found a
system that met all the demands made
of it. The principal hardware developer,
however, was ABB Robotics. As its name
implies, this firm was responsible for the
robots used. “ABB has worked with us
previously on a number of successful
joint developments, with us covering
all the development costs”, says Ersoy
Asil, Technical Manager for Mechanical
Engineering at Zeman. For the welding
technology, his company turned to Fronius, and the linear guideway system is
from Güdel.
It is quite possible to conceive of Zeman’s technology finding uses in other
fields as well. One example of this would
be for joining and welding truck frames.
A lot of work is still needed before this
will be feasible, though, as the systems
available at present could only handle a
limited spectrum of parts, and only in
The main way in which clients can save
money and at the same time increase
capacity, is because of the much shorter
production times. Zeman promises reductions of up to 85% here. Instead of at least
eight hours for a tonne of steel, it now
takes just under two hours for the beam
to be completely finished. This also cuts
the energy costs. And as long as the SBA
is given the correct data, the result is not
only of the very highest accuracy but also
always of consistently high quality. This
is taken care of by the control software,
which was specially developed for the
SBA and can import all the production
data directly from any standard CAD
program. In principle, the SBA can handle all common beam formats: rolled
sections, welded plate girders, tapered
beams or special formats such as Zeman
SIN beams. Member heights range from
200 to 1560 mm, and the lengths from
3000 to 16,000mm.
Specialist Machinery Sales
04 14151 900
www.smsales.com.au
TEN GOOD REASONS TO INVEST IN ROBOTICS
1. Reduce operating costs -
Reduce overheads and direct costs mproved competitiveness
2. Improve product quality and consistency -
Avoid tiredness and distraction. High quality for ever product produced
Improve
quality of work for employees
3.
Robotics are ideal for work in dusty, hot or hazardous environments.
Employees can learn valuable robotic programming skills
4. Increase production output rates
Use robots to achieve continuous production
Increase
product manufacturing flexibility
5.
One robot can handle a variety of tasks
6. Reduce material waste and increase yield
Reduce breakages, scrap and wastage
Comply
with safety rules and improve workplace health and safety
7.
Robots can take unpleasant or health threatening tasks
8. Reduce labour turnover and difficulty of recruiting workers
Ensure the highest precision, skill and training. Greater flexibility with robots
Reduce
capital cost
9.
Save energy, reduce waste and the cost of consumables used
Ensure a fast, efficient order turn around
10. Save space in high value manufacturing areas
Variable mounting options saves space. Robotics are ideal for confined space
61
Welding
Weldmatic brand to survive
WIA
(Welding Industries of Australia), one of Australia’s leading welding supply companies, has announced
major changes to the production of
its highly respected Weldmatic range
of MIG welding machines. “For the
Weldmatic brand to survive in an increasingly competitive industry, we
have made the difficult decision to
outsource the manufacturing of our
MIG equipment range,” says Alan
Hamilton, WIA’s General Manager.
“This decision was not taken lightly
and we are proud to have retained our
Australian manufacturing operations
for as long as we could.
“We haven’t opted for an off-theshelf option. Instead, we have engineered every aspect of the product with
our partner company, and selected the
highest quality components to retain
the exceptional quality, performance
and reliability that the Weldmatic
brand is renowned for. By outsourcing manufacturing, we have achieved
very competitive price points for a high
quality product, enabling us to reposition Weldmatic, making it even better
value for money,” continues Hamilton.
Brett Blackwell, WIA’s Equipment
Product Manager, says “WIA takes
product quality very seriously. Our
machines are still built to exacting
specifications and we guarantee there
will be no reduction in product quality.
The Weldmatic range will continue to
produce a superior arc for continuous,
high quality welds. We’ve taken this
opportunity to fine-tune the performance across our range, and we think
our customers will be very impressed
with the result.”
“To show we’re confident in the
quality of our products, the warranty
on Weldmatic machines can be extended for an additional 12 months,
giving a total of four years. However,
62
this offer is only available for a limited
time. Over many decades, WIA has
built a reputation for consistently delivering high quality, high performing
welding products that customers can
trust to get the job right the first time,
without the costly hassles of downtime
and rework. This is the result of a great
deal of effort by a highly skilled team
of engineers, selection of the best quality components and stringent product
testing,” said Blackwell.
The Weldmatic range comprises of
both single and three phase options to
suit a wide range of applications.
There are two options in the singlephase range: the new Weldmatic 190
and the high performing Weldmatic
270. Both machines have been pur-
posely designed for rural workshops,
light industrial fabrication, hire fleets
and serious DIY work.
The Weldmatic 190 offers the highest output in its class, and a new spool
holder design to make spool changing
quicker and easier. The heavy-duty
three phase machines include the Weldmatic 356, 396 and Fabricator, designed
for medium to heavy fabrication. The
Fabricator has been engineered to handle the toughest fabrication and industrial applications, from rail manufacturing, ship construction and mining
maintenance.
Welding Industries of Australia
1300 300 884
www.welding.com.au.
Welding
WTIA national technology forum
he Welding Technology Institute of
Australia (WTIA) is running a series of national technology forums which
aim to clarify current best practice &
introduction of Australia’s first national
Model Work Health and Safety (WHS)
Act & Code of Practice for Welding and
Allied Processes. As such it will:
l Clarify Federal and State Government approaches to Welding and Allied Processes OH&S and timetable
for introduction through Acts and
Regulations;
lIntroduce the related draft Code of
Practice and stimulate discussion on
its format and content;
lClarify industry viewpoints on the
documents
lIntroduce the latest revisions to
WTIA’s Technical Note 7 Health and
Safety in Welding;
lD escribe latest technical developments and welding management best
practice in Australia and overseas.
lI llustrate industry best practice
through the presentation of state of
the art equipment and technology
available in Australia through WTIA
OzWeld Technology Support Centres.
lPromote the role of WTIA OHS Welding Coordinator within an OHS Welding Management System
These will be held on the following
dates:
Newcastle, NSW Mon 6 June
Sydney, NSW Tue 7 June
Melbourne, Vic Wed 8 June
Adelaide, SA Thur 9 June
Perth, WA Mon 13 June
Bunbury, WA Tue 14 June
Darwin, NT Thur 16 June
Brisbane, Qld Mon 20 June
Mackay, Qld Tue 21 June
Gladstone, Qld Thur 23 June
strategies within its business plan cover
the ‘total life cycle of welded products/
structures’.
Formed in 1989 by the amalgamation of the Australian Welding Institute
(AWI) and the Australian Welding Research Association (AWRA), WTIA has
currently over 325 member companies
and 1050 personal members.
WTIA plays a significant role in the
different industry sectors in Australia,
through gover nment and industr y
projects, industry groups such as the
WTIA SMART Industry Groups and
Technical Panels, ongoing industry
events, involvement with Standards
development and the Secretariat role
with AICIP.
The WTIA is the recognised national
Australian Body representing the overall
interests of the Australian “welding”
industry, with its primary goal to: “lead
and assist in making Australian Industry locally and globally competitive in
welding-related activities”. The goal and
To register contact: Welding Health and
Safety Forums Events Administrator,
WTIA Federal Office
PO Box 6165, Silverwater, NSW, 2811
Phone: (02) 9748 4443
Fax: (02) 9748 2858
Email: [email protected]
The standard in intelligent CAD/CAM solutions
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Working in conjunction with SNC Solutions
63
Welding
Estimating total welding costs
Keeping your welding costs low goes far beyond buying the lowest priced wire available. You must
analyse how welding processes that increase deposition rate and increase productivity will reduce
the largest component of welding costs – your labour and overhead. Regis Geisler III tells how.
In order to keep welding costs as low as possible,
shouldn’t I just select the lowest price wire available?
There are several factors that need to be considered
when determining the overall cost of welding. Of
course, the most obvious factor is the cost for the consumables (electrode and shielding gas or flux). The less
obvious (and frequently overlooked) cost is the labour and
overhead expenditure that can be allocated to the actual
process of welding.
However, as will be shown in our example, the labour and
overhead portion of the actual cost of welding is generally
between 60% to 70% of the total cost. So selecting an electrode that improves productivity (by increasing deposition
rates) is far more important that selecting an electrode with
a lower cost. A process to determine the total costs of welding will be outlined below.
Using an arbitrary $50 labour and overhead rate and the
“market list price” for a wide range of welding consumables,
an estimation of the cost for one pound of deposited weld
metal is listed in Table 1. Five different operating factors
were used (the lowest being 20% and the highest 60%),
Table 1. Total cost in $ per pound of weld metal at $50 per hour
labour rate
where operating factor is defined as the percentage of a
welder’s time that he is actually welding. For the GMAW,
FCAW-G and MCAW processes, a rate of $0.20 per cubic
foot was used for shielding gas costs.
In addition to labour, electrode, and shielding gas costs,
the charge for the electricity needed to power the welding
machines was incorporated into the total welding costs.
Although in our example the cost of electricity per pound
of weld metal never exceeded $0.40, this value is not insignificant and therefore was included in the calculations. On
average, the cost for electricity was determined to be about
2% of the total welding costs when a $0.20 per kilowatt-hour
rate was utilised. No “demand charge” pricing structures
were used.
Complicating the selection of the most economical welding process (FCAW, GMAW, SMAW, etc.) and the right
welding electrode (wire or stick) is the available equipment
within the fabrication shop. If the highest output power
sources presented to the welder happen to be 450 amp, 60%
duty cycle machines, then the answer to electrode selection
may not be as simple as “let’s use the largest wire diameter
available to get the highest deposition rates.”
DARDS
SETTING THE STAN
IVE SAFE STORAGE
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Welding
For example, in Table 1, the costs per pound for UltraCore
70C are shown and indicate that it is more economical to use
5/64 in diameter than it is to use 3/32 in diameter (at 60%
operating factor the cost per pound of weld metal is $7.14,
versus $8.67). This is because at 450 amps, the deposition
rate for 5/64 in diameter UltraCore 70C is greater than that
of the 3/32 in diameter, due to its higher current density.
However, had we been able to fully exploit the full amperage range of the 3/32 in wire (with the maximum output
amperage being around 700 amps), we would have seen the
3/32 in diameter wire provide a cost advantage.
So for our calculations, the welding current used was
either the highest amperage value in the range provided
for the electrode, or the maximum output for the welding
machine (450 amps). From this amperage a deposition rate
in pounds per hour is determined, and then the total welding time for one pound of deposited weld metal can be
calculated. This time to deposit one pound of weld metal
is listed in Table 2. At this point, the labour and overhead
cost required to deposit that pound of weld metal can be
determined by multiplying this time value by the stated
labour and overhead rate of $50 per hour.
Table 2. Minutes needed to deposit one pound of weld metal
In addition to using a 450 amp multi-process power source
for the potential “open arc” welding processes being considered, we also have an additional resource in the form of a 1000
amp AC/DC submerged arc welding power source. Although
operating factors approaching 80 % or more are possible with
submerged arc welding, we will limit the operating factor at
60 % for the basis of comparison to the open arc processes.
However, we will make full use of the maximum 1000 amps
available on the machine, as this aligns nicely with the maximum recommended current for 5/32 in submerged arc wire.
Based on the constraints that we have set, the components
of the total welding costs (at an operating factor of 60%) have
been separated out for the potential welding consumables
under consideration in Table 3. For an E7018 stick electrode,
the labour and overhead portion of the total welding cost comprises anywhere between 69 % to 85 % of the total welding
cost. On the opposite end of the spectrum, the labour component makes up only 32% of the total welding cost for the
Table 3. Components of the total welding cost at 60% operating
factor
submerged arc welding process at 1000 amps. And finally, for
the wire-fed processes, the labour component of the total cost
falls squarely between 60% and 70%. It is interesting to note
that in this example even though the costs for the submerged
arc welding consumables are higher than those for the gasshielded processes, the overall total cost for depositing one
pound of weld metal is lower for submerged arc.
The message is that for the open arc processes, a 10%
reduction in labour costs will be greater than a 10% reduction in consumable costs. Once again, using 3/32 in
UltraCore 70C as an example, a 10 % reduction in labour
and overhead will result in a transfer of almost $0.60 per
pound of deposited weld metal to the bottom line. On the
other hand, a push for a 10 % decrease in consumable cost
will only save $0.25 per pound of deposited weld metal.
Ultimately, moving towards a higher deposition rate
process will provide the biggest bang for the buck by reducing the amount of time spent welding. And as we know,
time is money.
It should be reiterated that these calculated costs listed
in the accompanying tables are based on a $50 per hour
labour and overhead rate and market list price for the consumables. In the real welding world, very few customers
pay list price, so in few cases will these be the actual dollar
values of the welding costs in any given welding fabrication
shop. However, the trends observed here will nevertheless
hold true. Welding processes that increase deposition rate
and increase productivity will reduce the largest component
of welding costs – labour and overhead.
This article was first published in the March 2011 issue of
Fabricating & Metalworking. www.fabricatingandmetalworking.com
Regis Geisler III is an AWS Certified Welding Inspector
who has been an Application Engineer for ten years at
The Lincoln Electric Company, 22800 Saint Clair Avenue,
Cleveland, OH 44117-8542, 216-481-8100, Fax: 216-4861751,
www.lincolnelectric.com. For questions or comments on this
column, contact Regis at [email protected].
65
Cad/Cam
Knowledge-based CAM goes
Knowledge-based machining can be incorporated into CAM systems at various levels. By
comparing the three different styles of programming - operations-based, process-based and
feature-based programming, the different approaches to KBM can be compared.
ore and more developers of CAM software are moving in
the direction of knowledge-based machining, especially
for simpler parts that can be produced by prismatic machining. With today’s demands to make parts faster and cheaper,
these CAM systems offer “push-button” programming while
retaining control over the machining process. With machining intelligence built right into the program, these systems
increase efficiency by requiring less time to program prismatic
parts and by enabling new users to produce more consistent
NC code with minimal training.
Operations-based
Operations-based CAM systems require the user to go through
multiple steps to machine each part. The user must select
which type of operation to use and then select the machining
boundary, the type of toolpath to use and then manually select
tools, feeds and speeds, and multiple machining options such
as step-over and step-down distances. These multiple steps
must be repeated one at a time for every operation on a part,
making it a time-consuming process that is prone to error unless
undertaken by a skilled user. Operations-based CAM is mainly
used for more complex operations, like continuous five-axis
machining. It can have benefits for prismatic machining since
the skilled user can often reduce machining times to the extent
that the savings over a long production run may compensate
for the extra programming time.
Process-based
Process-based CAM systems attempt to reduce these steps by
grouping operations in standard processes. This approach is
most effective when the same processes are used repeatedly
for similar parts in the same grade of material. Processbased systems often start life as a step-by-step operations
based process, where the experience and skilled users finds
common elements in a job and creates their own macro’s to
suit. However, when this technique is applied continuously
to different types of parts, made of different materials, the
CNC programmer must still spend considerable time altering
macro’s to ensure that the correct operations were used in
each case and that the correct tools, step-overs, and speeds
and feeds were selected by the automated process.
Feature-based
Feature-based CAM systems use a set of interrelated features, such as pockets, bosses, slots and holes, to describe a
complete part. The big advantage of features is that they not
only describe shape, they also include one or more associative
operations that describe the preferred method for cutting that
shape at the NC machine. A predefined set of machining rules
and user preferences are applied to each feature within a part.
KBM in these systems streamlines the manufacturing process
by building the highest level of machining intelligence right
66
- Feature-based CAM systems automatically recognise features
within a CAD file and assign the appropriate machining strategy
into the CAM system. Features contain information and rules
describing how and where material removal should occur,
cutting depths, whether to use climb cutting, whether to spot
drill or centre drill, and preferred machining strategies for
roughing and finishing. The CAM system evaluates the part
geometry and part material, then automatically selects the
most appropriate tools and operations, recommends machining strategies, calculates feeds and speeds, then automatically
generates the NC code. With more advanced systems, the
automation does not only consider individual features. Automation of machining processes is also occurring between
all of the features that make up a part, resulting in toolpath
optimisation. Operations are ordered based on a system
analysis to reduce tool changes, air cutting, and the number
of tools used.
Since every company operates a different range of equipment, an essential component of KBM is the ability of users
to define their own set of machining preferences. The system
will be supplied with a set of predefined machining rules but
users will inevitably need to enhance these rules with their
own customisations to optimise the program for their own
machines. This modified set of rules – based on workpiece
material, feature parameters, and user preferences – can then
be used to create toolpaths automatically, that will operate
successfully on each machine in the particular company.
Setting up specific machining preferences and rules in the
CAM system not only reduces the time it takes to generate
programs; it also helps to maintain quality standards because
the approach to machining every part is predictable and consistent. Machine operators can rely on the fact that each job
will be machined in a predictable manner regardless of who
did the programming.
One important factor to consider when choosing a knowledge-based CAM system is the ability to machine a part
Cad/Cam
from strength to strength
run components. It will allow complex parts to be produced
more easily in cases where the range of hole sizes is larger
than the number of positions in the crib. In addition, the
number of different tools that need to be stocked can be
reduced and it will be much simpler to move jobs between
different machine tools.
Companies that do not have automatic tool changing on their
machines can also benefit. In some cases, it will be possible to
use a combination of drilling and milling with a single cutter
to generate all the holes in the part. This could then allow the
complete sequence to be run without the machine needing to
be manned and without interruptions to change the tooling.
No loss of flexibility
Above: Mill-turn equipment can produce parts with many
prismatic features in a single operation
Left: FeatureCAM’s
drill-mill
combination
strategy allows
parts with many
different sizes
of holes to be
machined with
fewer cutters.
directly from any CAD model. To this end, users must look
for a system with the ability to examine an imported CAD
model and identify its features automatically and correctly.
Once these features are recognised, the CAM system can
automatically create matching machinable features that contain the process for machining the entire part so that it can
automatically generate the NC code.
When those machinable features are associative with the
solid model, it is only a matter of importing the new CAD
model after changes are made in order to automatically update
the CAM features and generate new toolpaths. There should
be no need to reprogram the part unless really major changes
are made to the design.
There is a common belief that feature-based systems are
only suitable for the simplest parts but this is not the case
for the most established programs. For example, Delcam’s
FeatureCAM was the world’s first feature-based programming system when it was introduced in 1995 and has been
developed continuously for the last 15 years. One of many
innovative programming options is combined drilling and
milling functionality that will allow more efficient hole creation on machines fitted with automatic tool changing. This
option generates roughing and finishing toolpaths to produce
any holes for which the appropriate drill is not loaded, using
the existing tooling within the machine’s crib.
This approach is much faster than having to change the
tooling available to match the set of hole sizes in each job,
especially for companies manufacturing prototypes or short-
The main problem with many knowledge-based systems is
their lack of flexibility if the user is unhappy with the toolpaths proposed by the software. This can be a real frustration
with longer runs of parts, when the user can see that a few
minor changes to the generated toolpaths could reduce cycle
time and save significant amounts of time over the complete
production cycle.
With toolpath editing in FeatureCAM, users can make
changes to part toolpaths after they have been generated,
without needing to retrace their programming steps back
to the initial feature description. Instead, once the affected
toolpaths have been selected, users simply click on the section of the toolpath they want to edit and indicate the desired
change. Examples of edits include changing a rapid move to a
linear feed move, changing a linear move to an arc, setting or
changing the feed rate, deleting a move, inserting a toolpath
from another operation, reversing the path, combining two
moves into a single move, as well as several other options.
While there are still areas, especially continuous fiveaxis machining, where the knowledge-based approach has
seen limited success, it is clear that KBM many advantages
for prismatic machining. This is especially true for modern
mill-turn equipment, which is capable of producing complete
parts by undertaking a long series of prismatic operations in
a single set-up.
Whatever type of machine is being used, the largest benefits come either when inexperienced programmers have to
produce small numbers of very different parts. Having machining knowledge built into the software means that casual
users can become successful programmers with very little
training. The faster programming times mean that machining
can be started more quickly, giving significant savings when
producing one-off parts or short runs of components. These
savings can be particularly beneficial when producing replacement items in cases where the cost of having equipment out
of action is far higher than the cost of the new part. It might
still be true that an expert user with an operations-based
system, with enough time, and without a customer demanding
an immediate result, can generate more efficient toolpaths.
However, the gap between this traditional approach and
feature-based machining is rapidly closing.
Camplex Australia - 03 9532 4566
www.camplex.com.au
67
Cad/Cam
Intercad débuts SolidWorks 2011
New features enhance collaboration, performance and ensure ease-of-use
ntercad, Australia’s specialist 3D
computer-aided design and manufacturing (CAD/CAM) company, has
worked with vendor partner SolidWorks
on the inclusion of Australian-specific
improvements targeting sustainable design in the latest version of 3D CAD/
CAM software, SolidWorks 2011.
The built-in SolidWorks SustainabilityXpress module within SolidWorks
2011 now includes data from Australia
on materials, transport and manufacturing processes. Australian designers can
use this functionality to not only ensure
their products are eco-friendly but also
evaluate the environmental impact on parts that are produced
in other regions, off shore manufacturing and distribution
around the world. In addition to usual parts and materials,
customised materials can also be added to the database.
SolidWorks 2011 also includes hundreds of other refinements, many based on feedback from the global SolidWorks
community. Headline improvements include a boost to drawing functionality, new technology for thermal simulations,
an enhanced user experience through memory and interface
improvements, and new tools for greater collaboration with
suppliers, partners and manufacturers.
“We worked closely with SolidWorks on including
Australian information in the SustainabilityXpress module
for this release,” says Max Piper, Chief Executive Officer,
Intercad. “Our account management and services teams
work directly with our customers to help solve their business
issues so we know green design is one topic on their minds.
We provided that feedback to the SolidWorks engineers for
this module within SolidWorks 2011.”
68
“Our services team has also been hard at work actioning
some of the requests received in our recent customer survey,”
continues Piper. “Coinciding with the launch of SolidWorks
2011, we have re-organised our sales and support teams so
that customers with multiple licences have a single point
of contact with Intercad so we are closer to each client. It’s
about getting under the skin of their businesses and being
able to make recommendations on improving efficiency,
optimising use of the software and answering any niggling
technical issues on the spot.”
While working with suppliers, partners and manufacturers
on designs is essential to product development, protection
of intellectual property is one of the key concerns in this
region. The new Defeature tool allows designers to strip
details out of a design or model and control how much
intellectual property is exposed to vendors, partners and
customers.
“Australia is renowned for its innovation and unique designs,” says Piper. “But having to submit electronic designs
Cad/Cam
to suppliers, partners, customers and vendors is a fact of
working in today’s digital environment. Being able to send
a model that includes only the details that are essential for
approval or manufacture means you can preserve your design intent and your products can’t be replicated as easily.”
new feature, SolidWorks Design Checker, has been
integrated into SolidWorks Enterprise PDM Software to
automatically check designs against company standards
to ensure they are correct. It also streamlines the release
of designs to manufacturing, and integration with 3DVIA
Composer ensures design documentation is also correct.
Drawing details have also been enhanced to ensure
models are clear and accurate, and designers no longer
need to waste time manually dimensioning their products.
SolidWorks 2011 automatically aligns, staggers, or centres
dimensions without any overlap. Designers can also select
several dimensions for linear, radial, collinear, or staggered
alignment, or top/bottom/left/right justification.
Other key features in SolidWorks 2011
include:
lPlanar simplification – faster analysis of parts with
consistent sections by focussing on the geometry of the
parts rather than the entire structure.
l Dedicated HVAC thermal simulation – simulate air
and heat flows through electronic and HVAC systems and
show heating and cooling performance on a building, room,
or subsection.
lFaster structural analysis – analyse 2D parts by selecting intersecting planes and applying loads and constraints.
Results are calculated and displayed instantly on the full
3D model.
lEnhanced beam analysis – vary loads along the length
of a beam to analyse the real- world stresses more accurately.
lRouting improvements – use existing designs to create
faster pipe, tube, electrical cable and conduit courses.
lWelded structure improvements – the new Smart Weld
Selection Tool improves accuracy by automatically adding
weld beads and completing documentation and appearance
of welded structures.
l3DVIA Composer interactive storyboarding – drag
and drop models, drawings and views to communicate more
effectively with employees and customers by showing
product details in a logical way.
Intercad Pty Ltd - 02 9454 4444
www.intercad.com.au
GibbsCAM 2011 supports 5-axis machining
ibbsCA M 2011 includes
many new Multi Task Machining (MTM) and 5-axis CNC
programming features. These
include a new routine for 5-axis
hole-making operations, aided by
enhancements to GibbsCAM’s automatic feature recognition, hole
manager and hole wizard, makes
programming 5-axis drill cycles
much easier and much more efficient. Programming drill cycles at
off-axis orientations will be very
easy and will take a fraction of the
time taken by previous methods.
A new ‘operation modifier’
allows converting 2.5- and 3-axis
toolpaths for machining in 5-axis,
which enables use of shorter tools
Valve body programmed with GibbsCAM for 5-axis machining, as displayed with
to achieve smoother toolpaths at
Cut Part Rendering, the GibbsCAM toolpath verification module.
certain surface intersections and
other geometric conditions.
Additional swarf cutting capabilities have been
multiple axes (typically running with 5-axis simultaneadded, as well as a new 5-axis trimming (wireframe)
ous motion). Thread whirling attachments provide the
strategy. Support for B-axis (tilting live tooling) enables
rigidity and rotary tools to make screws of high lengthprogramming of 5-axis milling with Y-axis offsets on
to-diameter ratio, such as ball screws, worm shafts,
lathes and multi-task machines equipped with a livefeedscrews and acme screws.
tooling B-axis.
Further, GibbsCAM support of thread whirling atCNC Works Pty Ltd - 0400 079 020
tachments is a key addition for multi-task machines with
www.GibbsCAM.com
69
Cad/Cam
iMachining - a revolution in CAM
technology and high productivity milling
olidCAM has launched its revolutionary iMachining™ CAM
software, a major part of its latest
SolidCAM2011 release. According to
its developers, iMachining is a giant
leap forward in Tool-Path technology
reducing cutting times by up to 70%.
It achieves this by optimising tool
engagement and cutting feed through
the entire tool-path therefore allowing much deeper and more efficient
cutting.
The sof t ware is d riven by a
knowledge-based ‘technology wizard’, which considers the machine
being used, the material being cut
and the entire geometry and material
of the cutting tool. This ensures the
tool load is constant which in turn
increases tool-life and makes it possible to machine with the
full length of the cutter. Most conventional CAM software
will cut deep features in small steps to ensure the tool is not
overloaded and to minimise the impact of over-engagement.
With iMachining, programmers can confidently cut to the
full depth of the tool in a single pass, as cutter engagement is completely controlled by the technology wizard
generating smooth morphing tool-paths.
Furthermore, the software automatically
avoids sudden direction changes and sharp
corners, eliminating shock loading on the
tool, and enabling the maximum volume
of material to be removed in a single pass.
Toolpath calculations are based on the
theory that a spiral toolpath and constant
tool engagement are by far the most effective method of removing material. However, an efficient spiral toolpath is not
always achievable, so the toolpath will
automatically adjust to produce a morphing troichoidal to
separate areas of the part so that the most efficient spiral
toolpath is then achievable.
The software optimises the feeds and speeds through
the technology wizard for each individual component and
setup taking into account all the machine specifics (Spindle power, max feed / speed etc.), all the cutting tool data
(number of teeth, helix angle, cutting
length, tool material etc.) and all the
material properties By combining all
this information and then selecting the
level of aggressiveness for machining - matching it to the rigidity of the
setup – the software produces a safe and
smooth tool-path which will routinely
halve machining times.
Algorithms within iMachining also
eliminate air cutting, thus concentrating on areas where excess material is
located, keeping the tool in contact
with the work-piece at the maximum. iMachining has the
ability to subdivide pockets into areas that can be cut with
iMachining’s morphing tool-paths.
The intelligent separation routines use iMachining’s
unique channelling tool-paths to divide the pockets up into
areas that can be efficiently machined using the standard
imachining morphing tool-paths which smoothly remove
the remaining material.
iMachining also includes ‘rest’ and ‘finish’ operations
to remove uncut areas left by the larger roughing tool, both
strategies utilise the intelligent morphing technology which
completely controls the cut at every position.
SolidCAM ANZ - 07 3102 9697
www.solidcam.com
[email protected]
70
Cad/Cam
Mackay’s PPD department plays crucial
role in providing solutions
nvestment by Mackay Consolidated Industries in virtual
engineering tools and infrastructure has resulted in a
product and Process Development Department (PPD) that
is truly multi-faceted. Mackay Consolidated Industries is a
100% Australian owned private company and a major supplier of a diverse range of engineered rubber and bonded
metal/rubber composite products for the automotive, defence,
transport, construction and industrial markets.
The PPD department has a number of functions. The first
involves the design and development of new rubber products
and the second, refining and modernising existing products.
The department is also responsible for the tooling design
for the multitude of moulds that are required for Mackay’s
extensive product range.
“In simplistic terms our role is to take a customer’s concept
or problem, work out the technical solution and design an
end product that can be manufactured cost effectively,” said
Mackay’s Product Development Manager, Ian Simmonds.
Rubber is a notoriously difficult material to model and to
aid in the design function, Mackay has invested in the latest
proprietary tools including licenses for the powerful Adams
Kinematic Modeller, and the ANSYS non-linear Finite Element
Modeller. These virtual engineering tools enable Mackay to
understand the system and review how rubber components
will perform across a wide range of real life conditions.
The ANSYS tool enables Mackay to examine areas
such as stress/strain levels, modal analysis and importantly,
calculate the rubber volume required and cure temperature/
time parameters before the part is manufactured. The Adams
modeller enables Mackay to build a virtual vehicle to test
its theoretical dynamic behaviour.
“The crucial thing about these software tools is that
they allow us to bypass or reduce the expensive and time
consuming steps of producing pre-production models - we
can proceed confidently and expediently to full scale production,” Mr Simmonds went on to say.
The PPD department is also involved with Capability
Technology Demonstrator (CTD) projects which in some
cases can literally take years to complete – especially with
hi-tech items such as defence products.
The third function that the PPD department has responsibility for relates to specific problem solving – bringing
the department’s extensive facilities, skills and knowledge
bank to focus on and solve a particular problem or issue
that a customer has encountered – often when a product is
already in use and a fix is required quickly.
A typical example would be a vibration issue on the
engine or transmission of a car or boat. Given that rubber
is the best vibration dampener available, Mackay’s experience would be applied to this and a suitable remedy developed and applied to the offending area. This often necessitates the design of a unique component that can be retro
fitted to the existing assembly.
Mackay Consolidated - 03 9276 4633
www.mackayrubber.com.au
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71
Cad/Cam
From hours to seconds
Born in racing, Miller CNC’s high-tech equipment and programming tools drive growth in
medical and aerospace parts
ormer race driver, Todd Cuffaro now specialises in
high precision manufacturing at his California based
workshop, Miller CNC. “My uncle, a lifelong hobby machinist (and the Miller of Miller CNC), left his job to launch
his own shop,” says Cuffaro. “We partnered up, bought
some equipment (lathe, mill, and other necessary tools),
and started learning the machining business.” However,
just at the time Cuffaro was getting experience on some
pretty tricky race car parts, such as brake hub assemblies
and other steel and aluminium parts, his uncle injured his
back and had to return to his former job.
“Through racing, we were able to store a little money
away,” says Cuffaro. “We were getting busier as a shop and
made the decision to sell off our racing equipment and go
full-bore as a machine shop. Part of that decision was to go
CNC and high quality from the start, which for us meant
5-axis machining. That’s where we dedicated the majority
of our attention.”
The young company began casting its nets for more
business, billing itself as a quick-turn, high-tech job shop
for competitive service on complicated parts. “Our philosophy is really simple,” says Cuffaro. “Give 110% no matter
what. We’re a young business and we simply transferred
our competitive spirit from racing into the machine shop.
We’re eager to take on difficult parts and challenge ourselves. With our 5-axis capabilities and the software we’re
running, we can be very competitive with most types of
milled parts, not just true 5-axis parts. If the part has more
than two ops on a vertical, we throw it on a dovetail fixture
in the 5-axis mill and handle it in a single setup. Accuracy
is much better, part handling is reduced, and we maintain
short lead times, which we’ve found is a huge advantage in
a slow overall economy.”
CAM Just As Critical As Equipment
As Cuffaro and his team were investigating 5-axis equipment in earnest, it became apparent to them that the CAM
system running the machine was as important as the machine itself. “If the two can’t work in unison, you’ve got a
huge mess on your hands, spending too much time working
around problems to be competitive,” explains Cuffaro. “We
needed to be able to create fixtures and toolpaths without
too much wasted motion. We also wanted flawless machining simulation with the goal of eliminating setup time and
running 100% on the first part.”
After kicking the tires on a number of popular CAM
systems, Miller CNC purchased a Hermle C30U five-axis
CNC machining centre with a working area of 650 X 600 Y,
and 500mm in Z, an NC-controlled swivelling rotary table,
and a 32-tool magazine and a seat of hyperMILL from Open
Mind. “We were counting on the personal service we were
promised after the sale,” Cuffaro relates. “We were taking
some really big steps in a really short amount of time, and I
72
Automated five-axis drilling in hyperMILL uses feature
recognition to reference drilling operations with differing
inclinations and find the best possible path.
wanted to avoid any disruptions that would result in moving
backward as opposed to the huge leap forward we wanted.”
Training on hyperMILL involved a week of one-on-one
at Miller CNC, after which the company was confident in
making parts on its own. “hyperMILL turned out to have
everything we knew we needed plus several features we
didn’t appreciate prior to implementation, like stock regeneration and feature recognition,” Cuffaro says. “We’re
able to import a 3D model, design a fixture, create efficient
toolpaths, simulate the machining process, and post the code
to the machine, all in the same program. Any rev change,
we just regenerate the solid model and the toolpaths adjust
themselves”
Feature recognition played a role in helping Miller
CNC tackle an amplifier box aerospace part with 600-plus
holes. Where the shop had to pick every hole and program
for centre drilling, drilling, tapping, hole depth, and inclination, machining specialists at Open Mind were able
to show Miller’s programmers how to build a macro that
would communicate the entire job to the machine tool in a
fraction of the time. With feature recognition, existing CAD
geometry information is used for CAM programming, and
typical and repeating geometries are defined as features.
Along with the assigned geometries, features contain all
information relevant to production, such as top, bottom,
and start point. These are defined once and can then be
assigned to the machining strategy.
“From a single programmed coordinate system, the
software automatically defines the hole type, depth, and
inclination using feature recognition and applies machining
Cad/Cam
parameters with macros based upon the customer‘s shop
standards,“ says Open Mind Account Manager, Kevin Lewis.
The movement between positions, including jumping over
bosses, is 5-axis movement collision-checked against the
model. “Collision-checked removal of safe position movements save time, “Lewis adds. “The result is production
machining without the hassle.“
More importantly, programming the job and communicating all the information to the machine tool is now a matter
of 20 seconds versus the three hours it previously took.
Throughout the process of implementing hyperMILL,
Cuffaro says he’s learned how valuable the right tools can
actually be. “We make several different aluminium housings
with intricate pockets and up to a few hundred tapped holes,
“he says. “Previously, we were forced to constantly create
our own geometry to make sure we weren’t slamming end
mills into corners, and we had to pick hole locations one by
one. Now we can use feature recognition and tell hyperMILL
to use a half-inch end mill for roughing these pockets, a
quarter-inch end mill for finishing, and then drill/tap all
the 2-56 holes on X level. With macros, every time we’re
doing a common feature, we use the same tools, and feeds
and speeds are already proven. Programming is faster by a
significant amount, we aren’t breaking tools during setup,
which would force us back into editing the program, and
our cycle time is quicker. The burden rate is slightly more,
but hyperMILL is so much faster that it instantly creates a
return. Jobs are more profitable and we have more machine
time available.”
Todd Cuffaro (right) and Brian Toth in front of Miller CNC’s 5-axis
Hermle C30U.
Cuffaro says the cutting edge capabilities of Miller CNC
(the company recently completed ISO 9001 and AS-9100
certifications) have him predicting sales will double in each
of the next three years. He also believes his process advantages can help him exploit such situations as machining from
a solid faster than waiting for castings. Automation and pallet systems are another area he’s investigating. “We want to
put out what customers want to see in a shop: quality, process efficiency, quick turnaround, and competitive pricing.
We always have to be doing something different.”
73
Cad/Cam
Mastercam X5 for SolidWorks
astercam for SolidWorks provides a full suite of cutting
strategies, including Feature Based
Machining (FBM) and 3D High Speed
Machining (HSM) toolpaths. Mastercam for SolidWorks delivers powerful automated cleanup toolpaths that
complete parts faster, with little or no
handwork.
Benefitting both the Mastercam and
SolidWorks communities, Mastercam
for SolidWorks provides familiar, shoptested parameter screens and processes,
including a machining tree for quick
access to any point in the machining
process.
Besides conventional 2D programming, such as pocketing and contouring, the software offers a range
of high-power machining functions.
These include: ‘dynamic milling’ which
creates an active toolpath with more
consistent cutting conditions and use
trations, and then gives you a clear,
step-by-step process for defining how
you’ll cut the part. Mastercam’s multiaxis machining also includes a new
highly specialized interface for smooth,
gouge-free engine head porting.
Fast, aggressive, intelligent
roughing
of the entire tool flute length, High
Speed Machining (HSM), and peel
milling which assures efficient constant
climb milling between two selected
contours or along a single contour.
When cutting hardened material, the
peel mill toolpath uses the entire flute
length and avoids many shallow cuts.
Dynamic milling techniques
Dynamic milling constantly adjusts the
toolpath to ensure the most efficient cut
possible and allows use of the entire
tool f lute length, often eliminating
the need for multiple depth cuts. New
dynamic milling techniques include
Dynamic Rest Mill and Dynamic Con-
74
tour. Dynamic Rest Mill behaves in a
manner similar to the current toolpath,
only it uses dynamic milling motion
instead of core mill or area mill motion for the rest operations. Dynamic
Contour uses an intelligent, efficient
high speed contouring strategy to remove material along walls. It supports
multi-passes and can optionally include
finishing passes.
Multiaxis machining
Mastercam’s multiaxis suite has new
machining techniques and a new, easy,
workflow-oriented interface. Mastercam lets you choose the basic type of
work you’re doing using clear illus-
Mastercam’s new 3D surface high
speed OptiRough toolpath is a new
technique designed to remove large
amounts of material quickly using its
successful dynamic milling motion.
Large, aggressive cuts are followed by
fast, smaller up-cuts, safely delivering
a fully roughed part faster than ever.
Smart hybrid finishing
Hybrid finishing intelligently blends
two efficient cutting techniques in a
single toolpath. This new toolpath
evaluates the model shape and smoothly switches between Constant Z cutting
and Constant Scallop machining. The
result is a dramatically finer finish with
less work.
Technology Sales and Support
- 02 4455 3904
www.mastercam.com.au
www.mastercamforsolidworks.com
75
EDM & Toolmaking
Automated EDM – the way forward?
Automation has clearly taken centre stage of late, with companies realising that it is necessary to
compete with today’s demands for short lead times and product lives etc. Everyone talks about
China’s low labour costs but the labour-cost content in a typical tool or mould tool is probably less
than 20%. If you can make your skilled people more productive and reduce waste by eliminating
mistakes, you can easily overcome that 20%. Automation is about making people more productive
and not about putting production responsibilities in the hands of low-wage novices.
By Martin Oakham
n most cases, the automation process can be broken down
into basic steps and doesn’t require you to put all your
eggs in one basket and invest in a full-blown automated
workshop first off. It’s a bit like the ‘better to learn how to
walk before you can run’ type scenario. Most of the systems
currently in the market are independent of application and
can be implemented step-wise depending on budget and
organisation culture.
In step 1, automation, jobs are prepared off-line on the
pre-setting/measuring station, while the machine tool is
eroding another job. This level of automation utilises an
off-line CMM and can function with or without a handling
system. Measurement data is downloaded to the EDM control
via diskette or DNC connection. A pallet/electrode holder
system is used to ensure precise positioning. The objective
here is to maximise effective EDMing hours.
In Step 2, work handling is also automated with an electrode rack and automatic clamping chucks on the worktable.
For example, a Agie/Charmilles die-sinking system can
be integrated with a CMM and a robot from either Fanuc,
System 3R or Erowa, to name but a few on the market today.
In such a set-up, electrode and workpiece handling would
be handled with the robot, while the erosion program would
be generated using Agievision or compatible CAD/CAM
software such as MasterCAM or ESPRIT by DP Technology. Mastercam Wire, for example, supports Agie EDM
with Agievision controls. This Agievision support includes
a new interface and a complete set of machine definition/
control definition/post processor files. The user simply
chooses an Agievision AWF Wire Machine Definition and
the parameter pages will be displayed.
Working along these lines, automation and tooling
specialists, System 3R launched ‘WorkPal Compact’ robot pallet-changer, a spin-off from the highly successful
‘WorkPal’ programme. The new ‘WorkPal Compact’ is a
very easy-to-use pallet changer for all the machines used
in a typical toolmakers/mould and die shop, transforming
any machine into a fully automated production cell.
In step 3, off-line job set-up and programming, with
automated workhandling are joined by an identification
system that further enhances scheduling flexibility and
productivity. ID chips are permanently affixed to the pallets
and electrodes, and an ID reading device identifies the palletised workpieces and electrodes before the initial measuring step. This allows all data to follow the workpiece and
76
WorkPal Compact Servo is a pallet changer that requires minimal
floor space. It is designed for automatic changing of pallets in
chucks on machine tables and is ideal for die-sinking and wireEDM machines.
electrodes throughout the manufacturing process. Because
all electrodes and workpieces carry a unique identity, they
can be loaded into the robot handling system chaotically,
that is, any pallet can occupy any location; any electrode
can be put in any station. Every time the door is opened and
closed, the robot scans and reads everything.
When scanning is complete, the cell computer lists all the
parts in the magazine and creates a priority list. Typically,
priorities are assigned based on the jobs’ deadlines. But if
priorities change - as when a customer calls to request an
earlier delivery date than initially planned - the on-going
process can be interrupted. Communicating dynamically
with e.g. the Agievision feature, piece insert, the robot
removes the work in progress at the end of the erosion step
that’s underway at the time, replaces it with the new work
EDM & Toolmaking
System 3R
Twistlock
automated
workholding
PS-Electrode supports the design and manufacture of all types
of electrode
and starts eroding. When the emergency job is completed,
the system automatically reloads the interrupted job and
finishes it. Thus, communication between the Agievision
control, the Agietron Innovation die-sinking system and
the robot is a constant process.
Another example of this flexibility occurs if, say, three
out of six electrodes have yet to be fabricated when a job
is begun. When the fourth electrode is called for, and the
robot says, ‘Not here,’ Agievision says ‘go to the next job
on the list’ and starts implementation. Then, when the final
three electrodes have been fabricated, they can be inserted
into the magazine in any position, at any time. When the
door is opened and closed the robot rescans, finds the
missing electrodes, and goes back to finish the previously
interrupted job.
Software electrode production
Having a highly automated Di-sinking process is likely to
open up a new problem, that is being able to produce the
electrodes fast enough to keep up. Software such as Delcam’s PS-Electrode automates the design and production
of electrodes for EDM systems. This opens the process to
more widespread use.
Electrode designs can be transferred directly to Delcam’s
PowerMill CAM program for generating programs for machining electrodes from blanks. PS-Electrode will rotate the
blank into the most efficient orientation to minimise mate-
rial waste and cutting time. The software also incorporates
recommended spark gaps for both roughing and finishing
electrodes, based on the material and required surface finish, which are applied automatically to the geometry from
the model.
Wire EDM
Almost without exception, the most significant innovation
in automating wire EDM processes has been increasingly
reliable and efficient automatic wire threading systems.
Automatic workpiece loading has further increased untended operation, allowing days of work to be staged at the
machine. However, with or without automatic loading, the
effectiveness of untended machining is limited if the work
piece contains slugs. Stamping dies are a prime example.
Whilst the majority of the job can be cut successfully under
lights out conditions, the final point, where the wire cuts
the centre out often presents the problems. Typically, the
slug tips over, as it is breaking free, putting a bias force on
the wire, which in turn either distorts the intended profile
or breaks the wire or both. The practical way around this
is to leave the slug attached by a tab/s; these are removed
in a second operation, involving rethreading and rough/
finish machining the tab area, thus tying up the operator,
the machine and any loading equipment involved.
In contrast, a slug eject system automatically leaves the
minimal tab, safely knocks off the slug and disposes of it,
then rough and finish machines the tab area to leave the
opening complete, before the machine proceeds to the next
job. For example, if 15 jobs containing slugs are loaded in
the tank for lights out cutting, a slug eject system will save
around two hours of operator and machine time the next
morning. At $80 per hour this becomes significant over a
year, and more than justifies the investment. Like a die-sink
system, an automated wire EDM system will make use of
a robot arm to pick and place jobs.
In conclusion
Automation doesn’t have to happen all at once. It is achieved
in degrees, one step at a time. In fact, the move to automation
is never truly complete - every shop has to have a starting
point though. To ignore the need to automate is to ignore
progress, and everybody knows what that means.
77
EDM & Toolmaking
Efficient machining of micro
EDM electrodes
To achieve efficiency and quality in machining micro EDM electrodes, consider a machine
dedicated to this process. Much has been written about the technology and process required to
achieve efficiency and quality in machining small EDM electrodes. Yet, the proven methodology is
not always employed by mould manufacturers due to the perceived cost of a graphite machining
centre designed to withstand this abrasive process and also produce intricate micro electrodes.
By Steve Carter
ndeed, the upfront cost of a machining centre
featuring dust protection is significantly more
than a conventional metal-cutting CNC. That is why
many mould manufacturers would rather make an
inexpensive milling machine do double-duty: machining metal and producing graphite electrodes in
rotation. There are a couple of flaws in this approach.
First, this type of machine may take a beating
machining graphite if it lacks the appropriate dust
protection and it may not have the tight tolerance
required for repositioning and redressing electrodes.
The bottom line is that achieving efficiency in machining micro EDM electrodes calls for a machine
dedicated to this process and designed for it.
Machine criteria
A suitable machine should provide dust protection
Verifying the quality of the finish product is a key part of evaluating your
milling process.
and the high-spindle speed required for intricate
machining with micro tools. For dust protection,
Typical mill speeds with micro-tools are 50, 100 or 150
look for a machine that employs covered linear guides and
ipm. Therefore, standard industrial PC controls are acceptball screws with positive air flow to ensure that no abrasive
able for most applications, and controls based in a Windows
or harmful materials can get into the motion mechanics of
environment offer more flexibility and ease of use due to the
the machine. Also consider an automatic greasing system
familiar format. Aside from the machine itself, the micro
that forces any debris out of the machine’s working parts.
tooling used should feature diamond or specialty coatings
In addition, a sealed housing for all motion control
designed specifically for abrasive materials.
electronics and motors that will protect against contaminaConsider a light-weight machine: While both convention of the machine control system. The spindle should be
tional VMCs and specialty high-speed mills excel at milling
pressurised to prevent any dust from entering the bearings.
graphite moulds, consider the overall ROI and benefits of
Plus the machine should have dust extraction.
smaller machines to mill intricate electrodes.
For example, a graphite vortex unit surrounding the
Many graphite parts used in the mould industry are small
spindle and workpiece that features an industrial brush
and intricate. Fuel cells that use graphite components have
head and a spiral air flow extraction chamber—limiting
detailed features milled into them. Compact and light-weight
the travel of airborne dust and working in concert with an
machines are ideal for these micro-milling applications.
external dust collection system to remove debris from the
Plus, there are many benefits that occur as a by-product of
machining environment—is an option. Many manufacturers
the machine being light-weight.
ponder the importance of the CNC control and its processThe first benefit is the most obvious, as manufacturing
ing power. It is true that a high-end CNC control will yield
floor space is becoming a premium, a smaller footprint means
optimum results on large complex moulds. But, when millthat two or even three machines can fit in the space of one
ing smaller electrodes with micro-tools, the advantage of
larger VMC. As a result, the manufacturer can double or triple
a high-performance control, while still apparent, is not as
throughput without incurring the cost of additional space.
substantial.
78
EDM & Toolmaking
Perhaps more importantly, is the long-term savings that
can be achieved as a result of the low-power requirement
of some light-weight machines. Smaller motors and drives
require fewer amps—drawing e.g. 5 to 6 amps with single
phase power—saving money on electricity.
Also, light-weight machines use light-weight components,
so the replacement cost is less. Often these small replacement parts can be shipped inexpensively and installed by
maintenance staff rather than requiring an onsite visit from
a service engineer. In many cases the turnaround for the
replacement is quicker and this maximises uptime.
Finally, if a machine needs to be moved, smaller machines
are easier to handle and usually a fork lift or even a pallet
cart will do—eliminating the need for and cost of riggers
and factory service personnel.
Keep in mind; light-weight should not sacrifice rigidity
and durability. Some light-weight machines are available
with cast steel construction and solid granite or concrete
polymer machining tables. This stiff mechanical construction is of paramount importance for machining intricate
graphite EDM electrodes with superior surface finishes.
Also, make sure to examine the machine’s travel capabilities as ample Z-travel is required to accommodate typical
graphite fixturing systems.
High RPMs
The wonderful thing about graphite is that it cuts easily and
unlike metals such as steel it won’t anneal or get heat treated
at high RPMs—so, high feeds and speeds can be employed to
reduce cycle times. High-RPM spindles assist in proper evacuation of debris from the cutting tool and are the most effective
means of using the fragile micro tooling required to machine
thin walls and intricate detail on small EDM electrodes.
The spindle should be kept at a constant temperature
with a chiller. This will help in the overall accuracy of the
machine. A low-vibration spindle that uses specially-balanced
toolholders is also desirable when using small tools. This
will aid in achieving the best surface finish possible.
Close up of the part
being machined.
and protecting the capital investment by prolonging the
lifecycle of the milling machine.
So, achieving real efficiency means selecting a machine
designed for this process. Dust protection, light-weight
construction, high-spindle speed, rigidity and low power
consumption are the key ingredients to success or true efficiency in this application.
Reprinted by permission of MoldMaking Technology
magazine, copyright 2011, Gardner Publications, Inc, USA.
www.moldmakingtechnology.com
Summary
In machining intricate graphite EDM electrodes, the word
efficiency means many things—getting a good quality
part, reducing cycle times, minimising operational costs
Learn more about the power
of Verisurf by registering
for free webinars on
19 May 2011 - 11am or
6 June 2011 - 11am
visit our website or
call for an onsite demo.
Illustrates the small size of some electrodes.
www.memko.com.au
or 03 9013 5787
79
EDM & Toolmaking
Pressing ahead with software automation
he noticeable tendency of the decreasing scale of tool
making in local manufacturing had reached its peak.
“As we can see from our Australian customer base and tool
making industry overseas the interest in the latest CAD/
CAM developments are on the rise. VISI 19, the Vero flagship CADCAM suite for example, due for a 2011 summer
release, is packed with new features. These include core 3D
CAM development and a continued focus on tool design and
manufacture. The benefits of the newest technology combined with the traditional toolmaking skills of Australian
engineers help offset competition from Asian and Eastern
European markets.
Established in 2005 by brothers Declan and Brendan Ward,
Irish Pressings, based in Gweedore, Co. Donegal, Ireland,
have over 30 years experience in research & development, tool
manufacture and project management in the automotive field,
working with industry giants such as Ford, GM, Toyota and
BMW. “One of our major objectives was to try and improve
the lifecycle time for an entire project without a reduction
in quality. All of our tooling is designed and built in-house
which allows us to maintain a full level of control and react
immediately to customer requirements” states Managing
Director, Declan Ward.
Recent investments to upgrade the toolroom have seen
the commission of a Bridgeport VMC 1000, HAAS (VOFE)
machining centre, Fanuc Alpha EDM machine and an ABB
Damien Boyle at VISI workstation
plasma robot welder. “The toolroom is now very efficient”
claims Ward, “but we also needed to update our design office
– we simply could not keep up with the increasing requirements of the toolroom.”
After using a mixture of traditional CAD and CAM
systems, Irish Pressings decided to search the market for
software more aligned to the tool & die industry and one
which would automate some of their most repetitive tasks.
8952RN
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AMT Magazine, Austech, AMTIL – The Source, regular E-Newsletters,
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with discounts on exhibiting at Austech, AMT Magazine advertising,
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Explore the opportunities today. For more information or
to join AMTIL visit amtil.com.au or call 03 9800 3666.
AMTIL Membership starts from as little as $200.
80
2011
Manufacturing
8952 AMTIL June
FEN Hor
HalfAustralian
Page Ad.indd
1
Technology
17/3/11 11:39:27 AM
EDM & Toolmaking
After extensive research and benchmark tests Irish Pressings selected VISI Progress and VISI Machining from Vero
Software. VISI Progress is a dedicated application for the
design of 3D progressive die tools with different possibilities for the definition of the neutral fibre and the step by step
development of the blank. Once the strip design is complete,
the shearing and bending stages can be simulated to prove the
function of the tool. The 3D tool is constructed using solid
and surface technology combined with intelligent standard
library components which include all clearance holes and
CAM attributes for automatic plate machining.
“Our previous CAD & CAM systems were too generic
and a little too cumbersome for tool design” explains Damien
Boyle, chief design engineer for Irish Pressings. “For a complex
tool build, we were always worried that mistakes could creep
in. If a plate has to be removed from a tool for modification
because of a design fault, this could take as much time as the
plate programming itself.”
The benefits of VISI were highlighted in the very first
tool designed using the software. The die was a 3 stage tool
for an automotive suspension component. “We were able to
construct and visualise the 3D strip in less than 30 minutes”
explains Boyle. “Being able to view the die in 3D is a huge
help and removes the mystery of trying to unravel a 2D drawing in your head. The flexibility of the software allowed us
to simply drag and drop the punches within the strip layout
and view the effect on the die.”
The greatest time saving was found in the toolroom when
using MFR (machining feature recognition) for automatic
plate machining. “Instead of providing detailed drawings, we
simply issue a 3D model and let the CAM system detect the
drilling features. On the first tool, our analysis shows that the
CAM programming time has been reduced by more than 60%.
Machining time for a multi-stage die used to take approximately
6-8 weeks. However, when using VISI, it was less than two
weeks.” explains Brendan Ward, Production Manager.
Six days of basic and advanced VISI training, initially
provided by Irish reseller Elon Designs (Co. Sligo) and later
Bliss 250 ton automatic press
by Vero directly were sufficient for the designers at Irish
pressings. “After their initial training, the designers were
already competent when working with VISI” confirms Ward.
“We are still learning the product and the support has been
fantastic. If we are ever stuck, the engineers at Vero are quick
to use Webex and take control of our system and show us
how to overcome our issues.”
Declan Ward concludes by making a comparison against
a recently produced tool of similar size and complexity for
BMW. “Before the introduction of VISI, a large die, including tool build would take approximately 8-10 weeks. The
first tool designed with VISI was complete and signed off in
less than four weeks. There is no doubt that the software has
given us a competitive edge.”
Since the initial introduction of VISI, Irish Pressings have
already added an extra design seat and employed an extra
tool designer and apprentice toolmaker to keep up with the
increased workload and extra demands.
Camtek Pacific - 03 9588 2390
www.pepsau.com
Advance wire EDM
itsubishi’s new FA-VS Advance Wire EDM combines the top
features of the FA-S and FA-V machines. The series combines
the high speed of the V machine with the FA-S’s high accuracy
and surface finish. In addition, the high-speed V500 power supply
produces the world's fastest machining speed at 47 sq"/hr, greatly
improving machining performance for difficult-to-cut materials
such as titanium alloy or heat-resistant high-nickel alloys.
According to its manufacturers, the FA-VS Advance offers
improved total part processing time by 20% or more through
increased high-speed rough-cut machining and improvements in
the finish machining areas. High-speed high-accuracy machining
with 3μm straightness is possible with a minimum number of finish cuts. Total part processing speed can also be improved by up
to 30% or more even when machining thick workpieces. Machine
travel for the FA-20VS measures 19.7 x 13.8 x 11.8, and FA-10VS
Advance machine travel 13.8 x 9.8 x 8.6.
The Series features the new M700 series Mitsubishi control. This
Windows-based system, with 15-inch touch screen, provides easy
user interface and simple menu configuration for easy navigation.
Courtesy of MoldMaking Technology
81
Training
Forum
Behavioural profiling
for businesses
Ron Pollak explains “behavioural profiling” and how this facilitates people gaining insights to
their own behaviours – essential for improving the effectiveness of the way we communicate
here are two universal truths in
designing a training course for a
business. “All businesses are different”
and “All business is the same”. When you
approach a training episode that targets
the soft-skills of management, sales or
customer service you’ll find that these
‘truths’ are readily apparent.
These ‘truths’ are based on the precept
that business is about people communicating with one another. While we communicate differently, there are commonalities
that are basic to the way people communicate at work. All soft-skills training
then, is about helping people make these
commonalities more common.
In order for a training program to help
people communicate better, the program
needs to include a degree of introspection. Whether it’s time management,
leadership, selling, delegation, coaching or whatever, it’s important that the
learner reflect on his/her behaviours in
that particular field of endeavour and the
way they communicate when performing
these roles. Because we’re all different,
we’ll make different observations about
ourselves. The success of the training
program will depend on how well we apply those differing reflections to the focus
of the learning.
DISC behavioural profiling
In order to assist people to understand
how they communicate, many businesses
opt for a behaviour profiling tool. We use
the DISC Behavioural Profiling model. With
DISC, people show tendencies to lean towards one of four quadrants. Active and
task oriented – Dominants. Active and
people-oriented – Influencers. Reflective
and people-oriented – Steadiness. Reflective and task-oriented – Conscientious.
The Dominants will want control, need
the big picture first and are great when it
comes to solving problems. Influencers
are motivating and fun. They prefer to
get everyone feeling good about achieving
success. Those with the Steadiness profile
like loyalty, consistency, process and the
82
team all moving forward cooperatively.
Conscientious people love accuracy, thoroughness and attention to detail.
In our experience it’s important that
people gain insights to their own behaviours. It’s equally important that these
insights are able to be shared with others
and used to discuss different behaviours.
Ideally, the language learnt on the course
becomes so useful, so ingrained, that is
changes the culture of the organisation.
Changing the way people work is, however, difficult. Let’s make this the third
truth in this article.
With DISC, people show
tendencies to lean towards one
of four quadrants.
Active and task oriented –
Dominants.
Active and people-oriented
– Influencers.
Reflective and people-oriented
– Steadiness.
Reflective and task-oriented
– Conscientious.
People like consistency in what they
do. They don’t like change, although they
might like some variety. At the same
time, we like the people we deal with
to be consistent. Imagine dealing with a
staff member whose behaviours changed
from day to day. One day, they’re happy
to try something new. The next they are
aggressive when given a new task. One
day they bite your head off when you say
good morning. The next they tell you off
for not saying hello. (No, you don’t really
know someone like that!)
The question is, “Can someone’s underlying behaviours change from outgoing and vivacious to calm (an Influencer),
analytical and pensive (Conscientious)?
Or from being someone who thrives in
chaos and unpredictability (Dominant) to
someone who enjoys a systematic, well-
defined, stable work environment (Conscientous)?” No - and we don’t want them
to. We just want them to see that while
everyone is different, we can improve the
effectiveness of the way we communicate
by following a straightforward framework.
The insights that we get from behavioural profiling can help us present the
changes we want in a way that is most
readily understood by the person we are
speaking to. Dominants want to know
‘what’, Influencers want to know ‘who’,
Steadiness want to know ‘how’ and Conscientious want to know ‘why’.
The problem is that as we become
more consistent in a set of behaviours,
these become etched into our psyche,
what we’d call ‘habits’, and changing a
habit is difficult. There’s probably no habit
more difficult to change than those we use
when we communicate with others.
Changing habitual behaviour can be
influenced by informing an individual
(through learning) why the change is needed. In fact, there’s a strong argument to
suggest that when a person understands
why change is needed they will try harder
to make that change.
As an adult you expect to receive an explanation. Yet, receiving an explanation does
not in itself create change. Take speeding
drivers and alcohol as an example. There is
so much evidence and so many messages
that driving at speed and under the influence
of any amount of alcohol can be lethal, that
you ask - why do people do it?
Getting people to change what they do
requires their manager to take the position
of counsellor or coach. As manager, you
know this. It’s what you do.
So, while training programs will differ,
the outcome is the same. It’s all about
gaining insights into how you behave under different situations, and then how to
use these insights to achieve improved
results.
Ron Pollak Training P/L
Ph: 02 8354 7777
www.ronpollak.com.au
OHS
Forum
Worker responsibility
under OHS law: When is it not
the employer's fault?
Aaron Anderson of law firm Norton Rose, outlines the implications for employers when the national
model Work Health & Safety Act is adopted. Marian Macdonald reports
t is not common to hold
workers responsible for
workplace injuries but what happens when an employee arrives
to work drunk and is injured
attempting to do his work with
the knowledge of co-workers?
In fact, this was the scenario
in a recent court case. Norton
Rose law firm partner Aaron
Anderson will explain the new
responsibilities faced by everyone in the workplace at the
Queensland Safety Show, which
runs from 21-23 June. We asked
for his analysis of the implications for employers now and
once the new national model Work Health
and Safety Act is adopted by Australian
states at the end of this year.
It is generally accepted under statutory occupational health and safety laws
across Australia that employers and other
obligation-holders cannot escape liability
for failing to put in place a safe system
of work even though a worker may have
been wilful or neglectful in carrying out
their duties.
This was recently highlighted in a decision of the Magistrates Court of South
Australia in Symons v Clean Seas Aquaculture Growout Pty Ltd [2011] SAIRC 17 in
which the employer pleaded guilty of an
offence under the Occupational Health,
Safety and Welfare Act 1986 (SA) in circumstances where an employee affected
by alcohol “blacked out” whilst performing
a diving activity.
Requirements for employer
compliance
While the employee’s actions and behaviour were contrary to the employer’s
policies, the employer acknowledged
that there was a failure on its behalf to
enforce compliance with those policies.
In this case, the employer was let down
by the actions of another employee who
was second-in-charge of operations who
was drinking with the other worker on the
the coming months. Under the
model Work Health and Safety
Act, workers will be required to
take reasonable care for their
own safety and for the safety of
others but those obligations are
concurrent with the obligations
of persons conducting a business
or undertaking (PCBU) who must
also take reasonable practicable
steps to ensure the safety of their
workers.
Accordingly, we are likely to
see similar outcomes in prosecutions under the new law once it
commences.
evening before the incident and dropped
him off at the worksite that morning.
This case is illustrative of the ongoing
requirement for employers and other obligation holders to be vigilant in ensuring
that they develop appropriate systems of
work having regard to the nature of their
activities and enforcing compliance with
those policies. Only then will obligation
holders be able to discharge their statutory OH&S responsibilities.
This position will not change as the
model occupational health and safety
legislation is enacted across Australia over
Specific regulations
means altered compliance
standards
Employers will also find that under the
harmonisation process, many tasks will be
covered by specific regulations and, with
them, compliance standards will change.
Height safety and, coincidentally, diving,
are examples.
Obligation holders under the model
Work Health and Safety Act will need to
consider whether the new regulations will
apply and put in place appropriate procedures to ensure compliance.
Free workplace safety seminars at the
Queensland Safety Show
Aaron Anderson's free seminars addressing the model WHS Act forms part of
a line-up of very practical free manufacturing and workplace safety seminars
at the Queensland Safety Show. Experts from Safe Work Australia, the
Chamber of Commerce and Industry Queensland, Queensland Fire and Rescue
Service and Enterprise Connect are among those who will explain how to
attract funding, what to expect from new WHS laws, how to meet obligations
manageably and within budget.
Sponsored by myosh, the Queensland Safety Show, Materials Handling Show
and co-located Queensland Manufacturing Show run from 21-23 June 2011, at
the Brisbane Convention & Exhibition Centre. For more information, visit
www.qldsafetyshow.com.au, email [email protected] or phone
Australian Exhibitions & Conferences on 03 9654 7773.
83
Stratergies
Forum
Innovation & opportunitycapture - is this just for the
big boys?
Roger La Salle defines innovation and opportunity-capture and how these strategies can positively
determine the fate of companies
n a recent book by an MIT Professor
the startling statistic was revealed
that in the 1920’s the life expectancy of
a US company was 65 years, today it is
less than 10!
Companies that do not embrace
change, innovation and opportunitycapture are destined for the scrap heap; or
to be immersed in the mire of competitive
bidding where the ultimate winner is always the customer as businesses compete
in a downward competitive price spiral.
These are the facts.
But do not despair - the solution is at hand.
It is real, practical, tried and proven and
it’s all about understanding what innovation and opportunity-capture means, and
how you undertake them.
Further, this is not “rocket science” and
the smaller the business the easier it is,
since the political impediments present
in large corporation are virtually nonexistent in smaller ones.
Where to start?
The starting point is to first accept that
there is no product, process or service
in the world that cannot in some way
be innovated. By that I mean, changed
in some way to add value. If you wish to
disagree with that, what you are really
saying is that what you do today will be
the same in 100 or more years, this is
clearly ridiculous.
So accept that change is essential, and
that change is always possible and let
innovations abound. Further this can be
done in a structured way that is virtually
guaranteed to yield results, and perhaps
surprisingly the risks in doing so are almost
non existent.
Understand the biggest risk
To say the risks are almost non existent
may lead to the question, what are the
risks and further, how can we remove
those risks?
84
Without doubt the single biggest risk
in business is market risk. Will my new
product sell, or will it be rejected by
the market?
To largely overcome the problem of
market failure we implement innovation
as our business tactic. In doing so what
we do is improve products and services
that are already selling well and simply
make value added changes. That is what
innovation is all about and is why in
all of my books I define innovation as
“Change that adds value”.
To make real value-added improvements to products that are already big
sellers will almost guarantee the improved version will overtake the market
of the previous product, thus largely
removing market risk.
In fact the product you may choose to
innovate does not even need to be one
of your own. Find a competitor with a
great product, or any product that sells
well and make improvements.
Some small business
examples
Some examples where small companies
have embraced change and scored massive wins:
l A company in Scotland that had just
a single product in a competitive
market: canoe paddles. In a singe
work shop we “innovated ” that
product to add a “New Function”.
The new paddle won international
acclaim and propelled the business
into the multi-million dollar elite.
l A company in Melbourne that sold
just one product in competition with
Chinese imports: Tent poles!
Believe it or not, this was their one
and only product sold through some
239 retail outlets. One workshop
later the company commenced what
we refer to as Channel Enhancement.
They now have some five products,
all new and all sold into the same
channel. Before we started talking
innovation and opportunity they had
no idea of the value of their channel.
l Another company, a Milk Bar (convenience store). The owner implemented the innovation of “Complementary Products”. Believe it or
not within three years the owner
tuned his business into a gold mine
and later sold it for five times what
he had paid for it just a few years
earlier.
l A session in Colombia with a company that sold small diameter, 100mm
long drinking straws commonly used
in that country to stir take away
coffee. (A ridiculous stirrer if ever I
have seen one). Using the innovation
tool of “Frustration” the new stirrer
had several enhancements that left
competitors in its wake.
Examples of innovation and opportunity-capture like this abound and can
be applied to every product, process
and service!
Just accept it and move on with the
task.
Roger La Salle, is the creator of the "Matrix Thinking"™ technique and is widely
sought after as an international speaker
on innovation, opportunity and business
development. He is the author of three
books, Director and former CEO of the
Innovation Centre of Victoria (INNOVIC)
as well as a number of companies both
in Australian and overseas. He has been
responsible for a number of successful
technology start-ups and in 2004 was
a regular panellist on the ABC New
Inventors TV program. In 2005 he was
appointed to the "Chair of Innovation" at
“The Queens University" in Belfast. Matrix Thinking is now used in more than
26 countries. www.matrixthinking.com
LAW
Forum
Protecting the appearance of your
new products
Design registration can be used to stop others copying the appearance of your new product, as
explained by Ben Mott
1.
2.
3.
4.
esign registration is often recommended if:
the appearance of the product is important (eg. many consumer goods);
the appearance of the product is dictated by function;
there is a significant risk of direct copying; and/or
a substantial investment has been
made in the new design (eg. new dies
ordered).
Applying for design registration is cheap
and straightforward. It involves filing ‘representations’ of the design and brief text
with the Designs Office. The ‘representations’ are usually line drawings.
Design registrations cover products
which are ‘substantially similar in overall
[visual] impression’ to what is shown in
their representations.
This leads to a critical question - What
does ‘substantially similar in overall
[visual] impression’ mean? Or put another
way - How much change is required to
avoid infringement? Myths such as ‘10%’
are not helpful. The answer depends on
a range of factors and varies depending
on the type of product.
Assessment by an “informed
user”
The coverage of a design registration
must be assessed from the point of view
of an ‘informed user’ of the product and
particular regard must be given to any
features highlighted in the text of the
design registration. The freedom of the
creator of the design to innovate must
also be considered.
In a Court decision1 concerning truck
tail lights, the registered design shown in
figure 1 was found to cover the product
shown in figure 2. The owner of the registered design stopped its competitor selling
the lights and was awarded substantial
damages.
The design registration of figure 1
included text highlighting the lack of visible screws. The infringing light of figure
2 included screws which were visible but
were small, black and countersunk into
the black surround. The Court reasoned
Figure 1 Registered design
no. 3023603
Figure 2An infringing
product
that the screws, even if given particular
regard, did not change the overall visual
impression of the light enough to avoid
infringement.
In contrast to this decision, Belinda
Wadeson successfully argued before the
Designs Office2 that the design registration of figure 3 did not cover figure 4.
Figures 3 and 4 show plastic extrusions
for covering the edges of electrode plates
for refining copper. The outside profiles of
the extrusions shown in figures 3 and 4 are
identical. The only differences are in the
internal profiles.
It was argued that little weight should
be given to the outside profile of the extrusions because the outside profile is dictated by design considerations (it must fit
within another component) so the creator
has no freedom to innovate in this area.
It was also argued that particular regard
should be given to the internal profile because the ‘informed user’ concentrates on
the internal profile to distinguish between
different extrusions when loading the
electrode plates.
tion is applied when assessing validity or
infringement. Indeed the decision relating
to figures 3 and 4 was in regard to the
validity of a manufacturer’s new design
registration (figure 3) in view of their older
design registration (figure 4).
Due to the requirement to not cover
what was publicly known, a broader interpretation is not always better for the
owner of a design registration. A broadly
interpreted design registration is more
likely to cover something that was publicly
known and so less likely to be valid.
When filing a design application it is
possible to manipulate the breadth of
coverage by carefully selecting the words
in the application and the format of the
representations. This is something to
discuss with your patent attorney.
It is important to keep the design secret
until an initial application for design registration is filed. It is also important to keep
in mind that design registration is about
appearance. Design registration will not
stop competitors copying functional details
if they can do so in a product that looks
different. If functional details are important, patent protection may be appropriate.
Patent protection can be pursued alongside
design registration.
Carefully select the words
and format in the application
For a design registration to be valid it
must not cover anything that was publicly
known before the initial application for
registration was filed. The same test to
determine the coverage of the registra-
Ben Mott - Mechanical engineer & patent
attorneyAssociate, WADESON
[email protected]
www.wadeson.net.au
1. LED Technologies Pty Ltd v Elecspess Pty Ltd
[2008] FCA 1941 (18 Dec 08)
2. Icon Plastics Pty Ltd [2007] ADO 2 (5 July 07)
Figure 3 –
Registered design
no. 303361
Figure 4 –
Registered design
no. 305113
3. Another facet of this case relates to the quality
of the images. As you will see figure 1 is unclear.
Nonetheless the Court found the images to be
acceptable because when viewed online a user
could zoom in to see the details clearly
85
n
ibitio 11
Exh dar 20
en
Cal
INDUSTRY CALENDAR
INTERNATIONAL
InterPlas Thailand
23-26 June 2011
Thailand, Bangkok
Composites International 2011 Show
(co-located); plastics & rubber forum,
Includes: pre-processing/ recycling/
blow moulding machines, extruders,
foam, reactive or reinforced resins,
injection moulding machines,
presses/processing/sheet casting
machines, rubber processing
equipment, rapid prototyping,
bending, folding,edge-trimming
machines etc. auxiliary
components.
www.interplasthailand.com
Blechexpo and Schweisstec
6-9 June 2011
Germany, Stuttgart
International trade fair for sheet
metal processing. Supplemented with
Schweisstec with its focus on joining
technologies, Schweisstec will present
all relevant mechanical and thermal
joining and bonding techniques, as
well as thermal cutting and welding
processes.
www.blechexpo-messe.de/en/
Green manufacturing expo
USA (different dates/venues):
7-9 June 2011 New York
21-23 June 2011 Toronto
20-22 Sept 2011 Rosemont
This expo presents the full spectrum
of sustainable manufacturing
solutions and is part of one of
the largest advanced design and
manufacturing events in the US.
Includes resources for long-term cost
savings, improved process efficiency,
and reduced waste.
www.canontradeshows.com/expo/
gmx11
The Africa Iron Ore Conference 2011
7-8 June 2011
South Africa, Cape Town
With a potential West Africa
production increase from near zero
to more than 300mt pa by 2015.
However there are challenges: from
political and sovereign risks, to lack
of infrastructure, to considerable
shipping distance to the main
customer - China. This strategic
mining forum will bring together the
major players
www.immevents.com/africaironore
86
12th China Exhibition on sheetmetal,
machinery, forging, stamping and setting
equipment
23-25 June 2011
China, Guangzhou
(Pearl river delta - the manufacturing
centre of China) . Includes: Sheetmetal
forging, punching, plate shearing
machines , various kinds of pressing
machines, hydraulic machines, oil press,
cylinder, oil cylinder, precision pressing
machines, etc.forging press machines &
accessories.
www.julang.com.cn
Automotive Manufacturing
23-26 June 2011
Thailand, Bangkok
For auto-parts makers and related
industrialists. ASEAN’s only exhibition
for the automotive parts manufacturing
industry. An effective marketing
vehicle for 350 providers of machinery
and technologies from 22 countries,
serving the emerging demands for new
automotive parts
www.automanexpo.com
InterPlas Thailand
23-26 June 2011
Thailand, Bangkok
Composites International 2011 Show
(co-located); plastics & rubber forum,
Includes: pre-processing/ recycling/
blow moulding machines, foam, reactive
or reinforced resins, rubber processing
equipment, rapid prototyping, bending,
folding,edge-trimming machines etc.
auxiliary components.
www.interplasthailand.com
Eastpo
28 June -1 July 2011
China, Shanghai
Includes machine tools, turning/drilling/
boring/milling/grinding/deburring
machines, machining centres, flexible
manufacturing, gear cutting machines,
,sheet metal cutting machines,
electrochemical machining, micro
machining.
http://en.eastpo.net
MTA Vietnam 2011
5-8 July 2011, Vietnam, Ho Chi Minh City
For the machine tool, precision
engineering and metalworking
industries. Vietnam imports 94%
of its metalworking equipment and
mechanical products and only 6% of
demand is met by local manufacturers.
Industrial production in Vietnam is
growing at over 19% per year and
imports of modern technology continue
to increase at an annual 30%.
www.allworldexhibitions.com/industry.
asp?id=9
PDMAEC
17-20 August 2011
Philippines, Manila
Die & mould machinery and equipment
exhibition. The bi-annual events
incorporates Autocor 2011 (automation,
controls, robotics, accessories & services
exhibition), Machine Tools 2011, Metfin
2011 (metal finishing, equipment, tools,
accessories & services exhibition),
Metrology outsourcing and engineering
2011, Philplas 2011 (plastics, machinery),
Philweld 2011 and Sheetmetal 2011
http://pdmaec.brinkster.net/
COMS 2011 (Commercialization of micronano systems conference)
28-31 August, 2011
USA, North Carolina
Focuses on accelerating commercialization
activity among established and emerging
micro and nano businesses. Key industries
include advanced manufacturing,
aerospace and aviation, automotive,
biopharmaceuticals, defence, energy.
Email: info@ mancef.org
http://mancef.org/COMS2011 Vietnam Manufacturing Expo
15-17 September 2011
Vietnam, Hanoi
Consists of four intl. exhibitions: InterPlas
Vietnam (for plastics and rubber
manufacturing,);InterMold Vietnam (for
mould and die making,); Automotive
Manufacturing Vietnam (for automotive
parts manufacturing) and “Automation
Vietnam”
www.vietnammanufacturingexpo.com
EMO
Germany, Hannover
Trade fair for metalworking technology.
Includes cutting and forming machine
tools, manufacturing systems, precision
tools, automated materials flows,
computer technology, industrial
electronics and accessories.
www.emo-hannover.de
It is recommended to contact exhibitor before attending event
LOCAL
Interplas 2011
UK, Birmingham
Plastics exhibition. Offers several new
initiatives such as the British Centre of
Excellence (a unique exhibit of OEM
parts), the Contract Manufacturing Zone,
and the PDI (Plastic Design Intelligence)
programme
www.britishplasticsshow.com
MM Live
UK, Birmingham
International forum for micro, precision and
nano manufacturing. This year two new
and complementary feature events will be
launched: NANO Live and MEMS Live for
the Nano Manufacturing and Micro Electro
Mechanical Systems (MEMS) sectors.
www.micromanu.com/x/mm-live/mmlive
Smart Automation
4-6 October 2011
Austria, Linz
Industrial automation trade fair, contact
platform and discussion forum and
displays all the most intelligent solutions
for industrial automation in Austria.
www.smart-automation.at
Metalex Vietnam
6-8 October
Vietnam, Saigon
Comprehensive machine tools and
metalworking technology trade exhibition
www.metalexvietnam.com
Canadian Manufacturing Technology
Show 2011
17-20 October 2011
Canada, Toronto
http://cmts.ca
Fakuma
18-22 October 2011
Germany, Friedrichshafen
Plastics processing exhibition. Includes
injection moulding technology, extrusion
and thermoforming technologies,
raw materials, processing machines,
peripherals, automation solutions, C
technology
www.fakuma-messe.de/en/fakuma
Gear Expo
1-3 November 2011
USA, Cincinnati
Dedicated to the complete gear
manufacturing process
www.gearexpo.com
Queensland Safety Show/Materials
Handing
21-23 June 2011
Brisbane Convention & Exhibition Centre
Includes workplace health and safety
solutions and services including new and
innovative ways to improve workplace
performance. Co-locating with Qld
Manufacturing Show. (Debut showcase of
the latest technologies in conventional and
CNC machine tools, sheetmetal working
equipment, CAD/CAM, programming
systems and general industrial engineering
products. Provides the opportunity of
face to face contact with major suppliers
of the latest technologies available, as
well as keeping up to date with WHS
requirements).
Email [email protected]
www.qldsafetyshow.com.au
IAHR Congress
26 June – 1 July 2011
Brisbane Convention Centre
Hydraulics in water engineering.
IAHR is a worldwide independent
organisation of engineers and water
specialists working in fields related to the
hydro-environmental sciences and their
practical application. Activities range
from river and maritime hydraulics to
water resources development and ecohydraulics, through to ice engineering,
hydroinformatics and continuing education
and training
www.iahr2011.org
Mining & Engineering WA
5-7 July 2011
WA, Perth
Biennial mining industry exhibition and
conference that focuses on the unique
needs, challenges and opportunities facing
Western Australia’s mining industry.
www.miningandengineeringwa.com.au
International Conference for Women
Engineers and Scientists
19-22 July 2011
SA, Adelaide
Includes innovative technology across the
engineering, science and technological
professions, and will highlight the
important contributions women make to
society in these fields.
www.icwes15.org
Asia Pacific’s International Mining
Exhibition (AIME)
6-9 September 2011
Sydney
Internationally recognised platform for
Australian and international suppliers
of mining technology, equipment and
services.
www.aimex.com.au
Queensland Gas Conference & Exhibition
16-17 August 2011
Brisbane Convention Centre
Examines Qld-specific Coal Seam Gas LNG issues and how these relate to the
broader domestic & international market.
Focuses on the unique needs, challenges
and opportunities facing Queensland’s coal
seam gas industry.
E: [email protected]
www.queenslandgasconference.com.au
Society for Sustainable & Environmental
Engineering National Conference
24-26 October 2011
Brisbane
Event for sustainability executives and
practitioners, engaging engineering,
science, management and related
disciplines.
www.ssee.org.au
INNOVATION INSIGHTS PLANT TOUR SCHEDULE
Innovation Insights is a program comprising on-site visits to Victorian
manufacturing companies to showcase “Best Practice” in action.
Each visit will be hosted by a company that has successfully implemented,
and achieved real benefits from these practices. Offers a first-hand view of
the improvements and provides the opportunity to speak with managers and
employees about their experiences.
Host Company
Holden Engine Operation
Place
Date
Port Melbourne
21 June 2011
Time
9.00am – 12.30pm
GlaxoSmithKline Aust. P/L Boronia23 June 2011
9.00am – 1.00pm
Brivis Climate Systems Braeside
9.00am - 12.30 pm
28 June 2011 For further information on the listed plant tours contact
Innovation Insights on the toll- free number: 1800 007 730
Register online at: www.i2e.org.au
87
60
years with men and machines
-
Part 15
The bullet-proof casket
We continue our regular series of instalments from the book “60 years with men and
machines” - the autobiography of US machinist and author Fred Herbert Colvin (1867-1965).
His first-hand experiences of those bygone days are sure to give us unique and fascinating
insights into the era which laid the foundations of the industry.
Here, Fred relates his experiences with a “prophet” during the 1890s
By Fred Colvin
The dashing figure of Oberlin Smith
rises before my mind. Not as he
delivered a profound paper on the
subject of drawing presses, but as
he tripped the light fantastic during the gay 90s, with a fair partner
at one of the early A.S.M.E. dances.
For even in his late 70s, Oberlin
loved to dance almost as much as
he loved to tinker with machinery.
My first contact with Oberlin was
through an article I had written,
which caught Oberlin’s eye and he
sent me a very flattering letter of
commendation, raising my ego to
new heights.
Being an official of the Ferracute Machine Company of
New
Jersey, he cordially invited me to
visit his plant, and gave me more
than one personally conducted tour
of the several shops, answering my
endless questions with patience as
well as clarity.
The punch and coining presses
made by the Ferracute Machine
Company, after his designs, were
very well known at the time, not
only for their efficiency but also for
their unusual size, as well as for
the uses they were put to.
On one occasion he invited me
to his plant to see a new type of
drawing press in operation, which
he said was designed for making a
highly essential product that every
member of civilized society would
sooner or later have to buy. Interested at once, I asked him what this
highly essential product was. “Come
down to the plant, Fred,” he replied,
“and see for yourself.” When I arrived, Oberlin pointed with pride to
what was then the largest drawing
press I had ever seen. “Isn’t it a
beauty?” he beamed, while I stared
at the huge machine. “It certainly
is big enough,” I replied. “What is
this indispensable article of consumer goods you intend to turn out
with it?” “Coffins. One-piece steel
coffins. Can you imagine the pos-
88
Oberlin Smith
Image supplied courtesy of:
www.Oberlinsmith.org
sibilities? Seamless-steel, corrosionproof caskets, guaranteed to last a
hundred years even in the worst
type of subsoil. Can you imagine
anybody wanting to be buried in an
old-fashioned wooden casket once
these are on the market?”
I said I couldn’t imagine.
It turned out later that the company which had expected to manufacture these durable items had
considerable difficulty in disposing
of them to prospective purchasers,
who may not have relished being
thus encumbered on resurrection
day, and went on favoring the oldfashioned method of interment.
In any event, a considerable
number of these steel caskets accumulated in their warehouse, and
no one had any idea what to do
with them, until it was discovered
during the First World War that
these caskets were ideal for storing and shipping loaded shells and
other types of ammunition. Thus,
with fitting irony, the caskets were
eventually put to a specialized use
in the field for which they had been
originally designed.
June 2011
2011 Australian
Australian Manufacturing
Manufacturing Technology
Technology
June
Oberlin Smith was a man of
many parts, for besides being the
author of a standard text entitled
“The Press Working of Metals,” he
was also an inventor of considerable talent and possessed keen foresight as to the possibilities of future
mechanical developments. As early
as 1891, in a lecture given before
the Franklin Institute in Philadelphia, he predicted the tremendous
expansion of the automobile industry that was to take place forty
years later, the widespread use of
electricity for light and power, and
prophesied many of the inventions
and technological developments
of our present era,. such as electric refrigeration, air conditioning, long-distance telephony, and
even network radio. For those who
may not realize that these things
were practically unthinkable in the
‘nineties, I should like to point out
that Oberlin turned out to be an exceptionally accurate prophet.
Oberlin Smith’s flair for labor
saving gadgets together with his
sound practical knowledge of what
the machines of his day could be
made to do was demonstrated to
me quite dramatically one day, on
one of my first visits to his home.
He was driving me thither in one of
the latest model horseless carriages
of the day, and as we turned in to
the driveway he stopped, reached
out, and pressed a button in a corner post of the porch. I thought at
first he was ringing a doorbell to
announce our arrival, but instead
I was surprised to see the garage
doors opening by themselves as
Oberlin serenely restarted the buggy and drove it into its stall.
To be continued…
Sixty Years With Men and Machines, The Autobiography of Fred
H Colvin, Master Machinist, original copyright 1947, McGraw-Hill
Publishing, reprinted by Lindsay
Publications Inc, 1988, Bradley IL
60915, USA.
89
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AMTIL Membership .......................... 80
AMTIL Projects...................................24
AMT .............................................50, 51
Applied Machinery.............................13
Australian Exhibition &
Conferences.......................................15
Bennett Precision Tooling...................45
Enterprise Connect.............................16
Export Finance and Insurance
Corporation..........................................5
Farley Laser Lab..................................57
90
Flexicut...............................................39
FM Tool & Gauge................................49
Hare & Forbes . ..................................43
Idronic P/L..........................................73
IMTS................................................OBC
Iscar Australia...................................2, 3
John Hart ...........................................37
LMC Laser Services.............................55
Machinery Forum...............................89
Memko P/L.........................................79
MTI Qualos ........................................27
ONE CNC.............................................75
Performance Waterjet.......................26
Priority Supplies................................ 64
Purgon Engineering............................62
Quality Machine Tools........................47
Realtek.................................... 25, 41, 59
Recruit Australia...................................6
SECO Tooling.........................................7
SEI Carbide.........................................31
Stillam.................................................63
Sutton Tools........................................29
VDW...................................................17
Walter.................................................11
WYSIWYG...........................................71
In back cover
91
Out Back Cover
92

June 2011

Transcription

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