MACHINING - Shop Metalworking Technology

Transcription

VOLUME 2 | NUMBER 3 | MAY 2013
Ò
WELDING
Laser welding p45
Î QUALITY
Multisensor
technology p36
Ô YOUR BUSINESS
WWW.SHOPMETALTECH.COM
COVER
STORY
p16
Job estimating p70
Î CUTTIN
CUTTING
TOOLS
Publications Mail Agreement No. 42327015. Shop Metalworking Technology PO Box 93171 RPO Headon, Burlington, ON L7M 4A3
Wiper
inserts p30
SQUEEZE
PLAY
Aerospace OEMs tightening
manufacturing supply chain
Cover_May.indd 1
MACHINING
5 axis milling
p22
FABRICATING
Punch laser
automation
p41
13-04-17 6:49 AM
“Leading-edge
technology, combined
with unmatched
service and support
are the reasons we
chose Amada.”
— Stéphane Côté
General Manager
Groupe Côté Inox
“It’s The World’s Fastest, Most
Productive Fiber Laser.”
Groupe Côté Inox, with its two divisions, Côté Équipements and Côté Métal, is the most versatile
company of its kind in the Québec metal processing industry. Since 1977, this family-owned business has
provided full service sheet metal fabrication as well as design, manufacturing and installation of finished and
ready-to-use food processing equipment parts. Faced with equipment that could no longer keep pace with
ever-increasing demands for speed and precision, the company turned to Amada for the optimal solution.
Gaston Côté, Director of Sales & Marketing
Nancy Côté, Administrative Manager
and Stéphane Côté, General Manager
Stéphane Côté, General Manager, reflects on their recent purchase, “Our decision to buy Amada’s Fiber Laser
allowed us to regain our competitive edge and to once again provide our thin metal industry customers the superior
quality they have come to expect. Furthermore, with the addition of automation on the FOL3015AJ, the entire
system is now autonomous, it loads raw material and unloads finished parts.” With all three axes driven by linear drives, Amada’s FOL-AJ delivers rapid traverse speeds of 13,380 ipm and a 5G acceleration speed for
the entire work envelope — the system’s maximum cutting speed of 9,449 ipm cuts processing time in half!
The FOL-AJ Fiber Laser and ASUL Automation Provide:
• Non-Stop Productivity (Cutting 3 to 4 times faster than a comparable 4000 W CO2 laser, the
FOL-AJ is ideally suited to meet the demands of high volume contracts. The ASUL automated material
storage load/unload system ensures that speed and productivity are mathematically predictable —
delivering around-the-clock production).
• Uncompromising Accuracy (Amada’s 3-axis linear drive system ensures absolute accuracy even
at the highest cutting speeds).
• Expanded Capabilities (The system’s resonator generates a laser beam with a wavelength that is
approximately a tenth of that produced by a conventional gas laser — expanding processing capabilities
to include materials that were previously difficult or impossible to cut with CO2 lasers).
An 8-station changer automatically changes,
cleans and calibrates the nozzle based on
material processing requirements.
Gaston Côté, Director of Sales and Marketing, adds, “We are very satisfied with the results we’ve
obtained. Amada’s Fiber Laser and automation have greatly improved our productivity and increased profits
while reducing lead-time and cutting costs.”
Amada Canada, Ltd.
885 Avenue Georges Cros, Granby • Quebec, Canada J2J 1E8 • 800-363-1220
2345 Argentia Road Unit #101 • Mississauga, ON L5N 8K4 • 800-561-4578
www.amada.ca
2-5_Content May.indd 2
13-04-17 6:36 AM
IBAQUS, the first full package technical
application of its kind for tablet/smartphone
devices combines useful applications such as:
ITA (Iscar Tool Advisor)
CMS E-Catalog, etc.
Nonstop Continuous Cutting with
ISCAR
Products
Minimum Machining Downtime!
w w w. i s c a r. c a
13-04-17 6:36 AM
/ŶĞƌŽƐƉĂĐĞ͕ƚŚĞƋƵĞƐƟŽŶƐ
are always the same...
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It’s a
FAGOR
&ĂŐŽƌ͛ƐƵŶŝƋƵĞŝŶƚĞŐƌĂƚĞĚƉůĂƞŽƌŵďƌŝŶŐƐ
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ƚŽǁŽƌŬŝŶƉĞƌĨĞĐƚŚĂƌŵŽŶǇĂŶĚŝŶƚĞůůŝŐĞŶƚůǇƐĞůĞĐƟŶŐĂŶĚĞǆĞĐƵƟŶŐ
ƚŚĞĂůŐŽƌŝƚŚŵƐƚŽĞǆĐĞĞĚǇŽƵƌĞǆƉĞĐƚĂƟŽŶƐͶ EVERYTIME!
1-800-4A FAGOR
www.fagorautomation.com
Canada Head Office: Mississauga 905-670-7448
Montreal Office: 450-227-0588 | Email: [email protected]
13-04-17 6:36 AM
ÒContact us...
EDITOR
Mary Scianna | 905.430.9990
[email protected]
CONTRIBUTING EDITORS
Jim Barnes | Kip Hanson | Tim Wilson
[email protected]
PUBLISHER
Larry Bonikowsky | 289.337.0728
[email protected]
SENIOR ACCOUNT MANAGER
Sherry Theien | 815.282.6000
[email protected]
CIRCULATION MANAGER
Brian Gillett | [email protected]
ADMINISTRATION
Catherine Scianna | [email protected]
GRAPHIC DESIGNER
Jill Nelson | [email protected]
SUBSCRIBER SERVICES
To subscribe, renew or change your
subscription information, visit us online
at www.shopmetaltech.com.
SUBSCRIPTION RATES
$70 per year in Canada.
$115 per year for US. $12 per single issue.
Shop Metalworking Technology Magazine is
published 8 times a year by Zedcom Media Inc.,
PO Box 93171 RPO Headon, Burlington, ON L7M 4A3
[email protected] | Tel: 289.337.0728
President, Larry Bonikowsky
Vice-President, Mary Scianna
All rights reserved. Printed in Canada. The contents
of the publication may not be reproduced or
transmitted in any form, either in part or in full,
including photocopying and recording, without the
written consent of the copyright owner. Nor may any
part of this publication be stored in a retrieval system
of any nature without prior written consent.
Content copyright 2013 by Zedcom Media Inc., may
not be reprinted without permission.
Shop Metalworking Technology receives unsolicited
materials (including letters to the editor, press releases,
promotional items and images) from time to time. Shop
Metalworking Technology, its affiliates and assignees
may use, reproduce, publish, re-publish, distribute,
store and archive such unsolicited submissions in whole
or in part in any form or medium whatsoever, without
compensation of any sort.
Shop Metalworking Technology accepts no responsibility
or liability for claims made for any product or service
reported or advertised in this issue.
DISCLAIMER: This publication is for informational
purposes only. The content and “expert” advice
presented are not intended as a substitute for informed
professional engineering advice. You should not act on
information contained in this publication without seeking
specific advice from qualitied professionals.
PRIVACY NOTICE: From time to time we make our
subscription list available to select companies and
organizations whose product or service may interest
you. If you do not want your contact information
made available, please contact us via one of the
following methods: Phone: 289-337-0728.
Email: [email protected]
Mail to: PO Box 93171 RPO Headon,
Burlington, ON, L7M 4A3 Canada
Canadian Publications Mail Sales Agreement
42327015
ISSN 1927-7962
V OL UME 2 | NUMBER 3 | MAY 2013
ÒThis
issue...
COVER STORY
AEROSPACE
16 SQUEEZE PLAY
Aerospace OEMs
tighten manufacturing
supply chain.
only a fraction of total
machining costs, so how
do you gain real cost
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MACHINING
MULTISENSOR
TECHNOLOGY
MILLING
36 A QUALITY EDGE
Quebec mouldmaker
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technology in a big way.
Blow mould
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in technology for
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MICRO MACHINING
WELDING
66 GAME-CHANGING
TECHNOLOGY
LASER WELDING
R&D in
micromachining
FRXOGJLYHSUHFLVLRQ
machining
manufacturers a
leading edge.
Keyhole welding
processes offer higher
power densities and
faster welding speeds
than conduction
welding technologies.
22 THE FIVE AXIS LEAP
CUTTING TOOLS
TURNING
30 WIPE OUT
Unleashing the wiper
insert’s potential.
AUTOMOTIVE
CUTTING TOOLS
16
QUALITY
22
45 WHY LASER WELD
58
FABRICATING
PUNCHING
41 2 FOR 1 DEAL
Punch laser
combination machine
opens doors to
new business for
Ontario fabricator.
73
50 CUTTING IT CLOSER
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parts is a game of inches
and speeds, with no
time or room for errors.
PERSPECTIVES
56 RETHINKING
TOOLING COSTS
Cutting tools represent
ÒEvery
NESTING
58 NOT JUST
FOR THE BIRDS
issue...
7 | SHOP VIEW
Nesting software can
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gains, but how do you
NQRZLI\RXKDYH
the right software
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10 | INDUSTRY UPDATE
68 | SHOP TOOLS
70 | YOUR BUSINESS
73 | EXIT
MAY 2013 www.shopmetaltech.com
5
13-04-18 10:42 AM
See leading edge technology
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Your business is unique and you seek a tailored
soluƟon to your metalworkinŐ needs!
ome and ǀisit anada͛s leadinŐ istributor
to ǀiew the latest teĐhnoloŐy Ĩrom EllioƩ͛s
Ɖremier maĐhine suƉƉliers!
Take adǀantaŐe oĨ this oƉƉortunity to meet
with our teĐhniĐal staī to reǀiew and
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>et͛s disĐuss the beneĮts oĨ EllioƩ͛s sƉeĐial
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Shop View May.indd 6
13-04-17 6:37 AM
Skills Training:
Government funding isn’t enough
T
HE FEDERAL GOVERNMENT spends nearly $2.5 billion
for skills training in Canada via training transfers to provincial
governments and territories. Close to $2 billion is allocated for
training those who qualify for Employment Insurance (EI) and
another $500 million to train those not eligible for EI.
Despite this, the quality and availability of skills training in Canada has
EHHQZHDN7KH)HGHUDOJRYHUQPHQWLVZHOODZDUHRIWKHVNLOOVGHÀFLWDV
evidenced in the 2013 Federal Budget released in March.
“Jobs, Growth and Long-Term Prosperity, Economic Action Plan 2013” offers up a
three-point plan for the manufacturing sector to address the skills training
shortage, job growth and productivity. Of note is the improvement of the
apprenticeship training program to make it easier to get the experience
individuals require to achieve journeyperson status.
The Federal government plans to reallocate $4 million of the funding it
provides to provinces and territories for skills training over three years to
increase opportunities for apprentices. Perhaps of utmost importance, it plans
to reduce barriers to apprenticeship accreditation, including examining the use
of practical tests as a method of assessment for apprentices.
These are good measures, but the government must go further to improve
the execution of programs for apprentices.
An example is the approximate $2 billion allocated for skills training for
those who qualify for Employment Insurance (EI). Employers and employees
pay into the program to take advantage of training programs such as Red Seal,
typically a four to six week block of time for a level. As many know, employees
leave their employment to train off site for this period and receive pay via EI,
but often the federal government arm that runs the program is slow to send
cheques to employees and some don’t receive pay until they’re back at work.
One reader cited it as such a big issue it has become a deterrant for some
employees who can’t survive without pay for such a long period of time.
Since manufacturers already pay EI premiums, the government could
consider allocating money directly to manufacturers who in turn would
commit to paying employees on time during training and also implement
more apprenticeship programs in their shops to help train future machinists,
welders and manufacturing engineers.
A well executed apprenticeship program would go a long way in ensuring
highly skilled workers to sustain and help grow manufacturing in this country. SMT
Mary Scianna, Editor, Shop Metalworking Technolog y Magazine
Shop
View
“
The government must
go further to improve
the execution of skills
training programs
for apprentices.
”
Please send me your comments
at [email protected].
Shop View May.indd 7
7
13-04-17 6:37 AM
SMTCL is the
largest machine
tool builder in
the world
W
ith over 60 years of
experience, SMTCL has
become the largest
machine tool builder in the world,
both in terms of units produced
and their aggregate dollar
value. SMTCL has thousands of
earlier machines still operating
in the field, and with every new
machine we build, our reputation
as a high quality, high value
machine tool builder continues to
be acknowledged. From simple
manual machines to 5-axis,
high speed, and multi-function
milling/turning CNC machines,
we can make your next machine
tool investment more .affordable
without any sacrifice of quality.
SMTCL is ISO certified.
Canadian HQ:
2783 Portland Dr.
Oakville ON L6H 6M6
Ph:905-829-1579
www.smtcl.ca
www.smtcl.com
SMTCL_May.indd 8
Quality machine tools t
HTC2050
Horizontal Turning Centre
AH130
Automatic Horizontal
Boring Milling Machine
Advanced structural design
guarantees ideal machining
characteristics
The AH series horizontal boring
milling machine can be operated
very easily, owing to advanced
electronics and user interface.
It can do many operations such
as drilling, boring, face-milling,
and tapping. It is ideal for large
box-shaped or frame-style workpieces.
This automatic horizontal boring
milling machine is a newlydesigned machine having the
following characteristics:
tOne button axis selection which
releases the axis desired and
clamps all others.
tDrilling cycle with fast
approach, drilling feed to preset depth, and rapid retraction
of tool.
tPeck drilling cycle for deep
hole drilling, with interruptions
for breaking chip, and pre-set
depths for each insertion.
tFloating tapping cycle with
automatic calculation of
threading feed based on
spindle RPM and thread pitch
to pre-set depth, and rapid
reverse of threading for tool
removal.
tAutomatic face milling cycle.
The structure has been designed
using finite element analysis
software, producing a machine of
high accuracy and repeatability,
with consistent results.
The work area of this CNC lathe
has been increased in volume by
nearly 50% despite little change
in the overall dimensions of the
machine, and this means that the
lathe will be much more efficient
for the user. The patented oilwater separation unit can improve
environmental conformity, and
reduce production costs to the user.
This is a world class slant bed CNC
lathe that is competitive with any
other machine in the marketplace.
Features
High speed, rapid speed and
high accelerations produces high
efficiency.
tThe general power of the
machine, under the same
condition of cutting, can save
2.5kW.
tThe tailstock is integrally driven
by hydraulic device, saving time
and labor.
tInner protection of the machine
adopts wing-type support
structure, which is safe and
environmentally responsible.
t High-rigidity integral slant bed
of 45° with stable performance
ensures the machining accuracy
and service life of the machine.
13-04-17 6:56 AM
that will exceed your expectations
VMC1000B
Vertical Machining Center
Innovative frame structure with
high rigidity
Main components such as bed, columns,
etc., incorporate high quality cast iron
with excellent vibration dampening and
thermal characteristics for excellent
rigidity and accuracy of machining.
Rapid speed
The rapid speeds for X/Y/Z are 32/32/30
meters/minute. This is due to the
incorporation of linear guideways,
which minimizes non-cutting time, thus
improving machining efficiency.
Easy-to-use control panel
Fanuc 0i-MD CNC system is easy to
use, and the conveniently located
control panel which swings 90 degrees
makes the operation of the machine as
effortless and intuitive as possible for
the operator.
High accuracy, high quality spindle
Standard spindle is BT or CAT40,
10000 RPM. Optionally, BT or CAT50
8000 RPM spindle can be supplied
with VMC1100B for heavier machining
requirements.
Large Machining Envelope
The Z axis travel of 650 mm. makes the
work-piece envelope much larger than
other machines of the same table-size
can provide.
SMTCL_May.indd 9
VMC1600B
Vertical Machining Center
VMC 2100B
Vertical Machining centre
tFrame structure with heavy load bearing capability and high rigidity;
tReliable box-style structure – both X and Y axes have linear guide-ways, Z-axis
box-style guide-ways are of cast iron. Design ensures stability during feed,
and reduces vibration during heavy cutting for high accuracy;
tProcess parts of greater weight and size than comparable machines
in the same class;
tMaximum load up to 2000 kg. X-axis travel of VMC 2100 B over 2100 mm –
larger than many other machines in the same range of table size;
tCAT-50 spindle has high precision and great torque, with coolant through.
Belt-driven and of high quality and accuracy, meeting requirements of
machining with high power and heavy torque;
t ZF gearbox for even higher torque in lower range of speed.
t6 linear bearing blocks for X-axis and for the Y-axis 4 linear
guideways for heavy cutting, minimizing deformation
caused by worktable overhang and ensuring accuracy;
tHigh efficiency chip removal system.
MODEL
Worktable
UNITS VMC1000B VMC1600B VMC2100B
Worktable
dimensions
mm
1200 x 500
1700×800
2200×800
Operating range X-axis travel
mm
1000
1600
2100
Y-axis travel
mm
610
800
800
Z-axis travel
mm
650
800
800
10000
8000
8000
FANUC
FANUC
FANUC
Spindle speed rpm
Control system
13-04-18 9:07 AM
INDUSTRY UPDATE
Canadian manufacturer lands contracts worth $130 M
Î
CAE, A CANADIAN MANUFACTURER of civil
aviation and military flight simulation
equipment, has been awarded a series
of military contracts valued at approximately $130
million, including options.
They include contracts to provide an MH-60R
avionics maintenance trainer and weapons load
trainer for the Royal Australian Navy, a C-130J
weapon systems trainer for the US Air Force (USAF),
construction of a training facility for the Kuwait Air
Force, and additional training support services as
part of the KC-135 aircrew training system program
for the USAF.
CAE, formed in 1974 and based in St.
Laurent, QC, is considered a global leader
in modelling, simulation and training for
civil aviation and defence. The company’s
primary manufacturing facility is based in
Montreal and employs more than 3,500
people. The 1 million-plus sq ft facility
manufactures almost all of the flight
simulators.
“Our position on key platforms such
as the C-130J and MH-60 helicopters
continues to provide a range of
opportunities globally, including foreign
military sale contracts through the US
government,” says Gene Colabatistto, group
president, Military Products, Training and
Services, CAE. The contract to develop an MH-60R avionics
maintenance trainer and weapons load trainer (AMT/
WLT) is for the Royal Australian Navy (RAN) under
the US foreign military sale (FMS) program. CAE USA
will be the prime contractor responsible for the design
and manufacture of the MH-60R AMT/WLT that will
be delivered in 2015 to HMAS Albatross, located near
Nowra in New South Wales. CAE is also currently
under contract to develop two MH-60R tactical
operational flight trainers (TOFTs) for the RAN.
Lockheed Martin has exercised a contract option
for CAE to design and manufacture an additional
C-130J weapon systems trainer for the US Air Force
as part of the C-130J Maintenance and Aircrew
Training System Phase II program. The simulator will
be delivered in 2016 to Little Rock Air Force Base.
The US Army Corps of Engineers has awarded CAE
USA a foreign military sales contract to construct
a training facility for the Kuwait Air Force at Al
Mubarak Air Base in Kuwait. The two-bay training
facility will house a KC-130J full-mission simulator
that CAE is currently under contract to design and
manufacture for the Kuwait Air Force.
The US Air Force awarded CAE USA a contract,
including options, to perform operations and
maintenance support for KC-135 Boom Operator
Weapon Systems Trainers (BOWST) as part of
the KC-135 aircrew training system program. This
initial contract for the first year of operations
and maintenance is valued at more than $5
million. Annual maintenance support contract options
for the remaining seven years of the program are
valued at approximately $50 million.
10 www.shopmetaltech.com MAY 2013
News May.indd 10
13-04-17 6:38 AM
INDUSTRY UPDATE
ONLINE
REVIEW
Shop Metalworking
Technology Online brings you
the latest in technological
advances, new product
developments and
industry updates.
Here’s what’s online:
MACHINING: Big part
machining
FABRICATING: Heavy range
plasma cutting
WELDING: Welding automation
QUALITY: Testing aerospace
parts
CUTTING TOOLS: Deburring
holes in aluminum
www.shopmetaltech.com
MSC Industrial enters Canadian market
MSC Industrial Direct Co.,
Melville, NY, is entering
the Canadian market with
its acquisition of Barnes
Distribution North America.
The acquisition doubles
MSC’s sales force and expands
its portfolio of inventory
management solutions and
other metalworking and MRO
products and services.
Barnes Distribution is
based in Cleveland, OH, and
distributes fasteners and
other high margin, low cost
consumables with a broad
distribution footprint in Canada
and the US. The company
operates three distribution
centres in Canada in Alberta,
Ontario and New Brunswick.
EVENTS
“MSC’s acquisition of
BDNA reflects our continued
commitment to provide our
customers with the best, most
accessible metalworking and
MRO solutions” says Eric
Gershwind, president and CEO
of MSC. “Now, customers
across both the United States
and Canada will benefit
from unparalleled inventory
management solutions, an
expanded product portfolio
and an enhanced ability to
help their businesses succeed.
From a business perspective,
this transaction, along with our
expected long-term organic
growth, will help us to achieve
our goal of $4 billion in
revenues by 2016.”
MAY 7
Iscar Tools Canadian IQ
product launch at The Living
Arts Centre, Mississauga, ON.
www.iscar.ca
MAY 27-JUNE 7
Canadian Welding Bureau
(CWB) Welding Inspector Level
1 in Dartmouth, NS. More
courses and dates online.
ww.cwbgroup.org
JUNE 4-6
Western Manufacturing
Technology Show (WMTS) at
the Edmonton EXPO Centre,
Edmonton, AB.
http://wmts.ca
Your Production Matters To Us
PLASMA MACHINE
PRESS BRAKES
SHEARS
WE OFFER
INNOVATIVE
SOLUTIONS TO
INCREASE YOUR
PRODUCTIVITY
ONTARIO - EASTERN CANADA
3980 Chadburn Crescent
Mississauga, ON L5L 3X4
Tel: 905-820-3232
Fax: 905-820-3234
WESTERN CANADA
Westside Service Ltd
4406-58 St. South
Lethbridge, AB T1K7E2
Tel: 403-380-5047
Fax: 403-380-5048
FIBER LASER
PLATE ROLLS
PROFILE ROLLS
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Q U A L I T Y | S E R V I C E | VA L U E | W W W . F E R R I C M A C H I N E R Y. C O M
News May.indd 11
13-04-17 6:38 AM
INDUSTRY UPDATE
Robot arms come to Canada
An innovative user friendly six axis robot arm is now available in Canada through
Ontario distributor Advanced Motion Controls Ltd., Barrie, ON.
Manufactured by Denmark‘s Universal Robots, the robots made their debut at
IMTS in Chicago last fall and since then, the company has established distributors
throughout North America.
“Nobody else has a collaborative robot that’s easy to program, can be easily moved
from spot to spot throughout a factor, and is relatively low in cost,” says Ed Mullen,
national sales manager for Universal Robots, handling the North American expansion.
The robots, which weigh as little as 40 lb (18 kg), are
available in two models with payloads of up to 11.3 lb (5.1
kg) and 22.6 lb (10 kg) respectively, with reach capabilities
of up to 51 in. (1, 295 mm). They’re in compliance with the
ISO standard for collaborative robots; when an employee
comes into contact with the robot arm, it will automatically
stop operating. It features repeatability of +/- .004 in. (0.10
mm) and can handle even microscopic sized parts.
Universal Robots’ Thomas Visti, chief commercial officer,
expects to see rapid growth for the robots.
“We’ve created an incredibly strong line-up of distributors
that are well positioned within our target markets, so we’re
off to a very promising start.”
The more HAIMER, the safer.
PEOPLE
:
Same cutting edge,
more innovative shank.
SCOTT ELLIS is the new national sales
director with YG-1 Canada Inc.,
Burlington, ON. He has 25 years of
business development experience in
the manufacturing sector including
technical sales and management positions. He will
be responsible for managing sales and building
relationships with the company’s distributors.
:
The safety belt for your tools
BRIAN BOLLERT has joined Spark &
Co. Canada, Montreal, QC, as the
company’s waterjet field technician
for Canada. He has training with all
the major waterjet machine builders
and has specialized in waterjet cutting since 1991.
GREG VAN DYKE has joined Centerline
Productivity
Tool life
Process reliability
Runout accuracy (Heavy Duty Chuck)
More
Haimer USA, LLC | 134 E. Hill Street | Villa Park, IL 60181 | USA
Phone +1-630-833-1500 | [email protected] | www.haimer-usa.com
News May.indd 12
(Windsor) Ltd., Windsor, ON, as an
account manager specializing in
resistance welding consumables and
automation component products. He
has more than 10 years of resistance welding
experience in sales and service.
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Tool Holders
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Balancing Machines
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13-04-17 6:38 AM
INDUSTRY UPDATE
SHOW
Canadian distributor to sell Swiss, bar fed lathes
UPDATES
The Canadian Division of Dynamic Machine of Detroit, Burlington, ON, has
been appointed exclusive distributor for Ontario and Quebec for the Citizen and
Miyano line of Swiss and bar fed lathes.
“We are very pleased to add these world leading products to our current
Canadian line up, says Gary Richardson, manager for the Canadian Division of
Dynamic Machine. “Quality parts, high uptime and efficiencies are essential to
the profitability of customers today and both these products offer this.”
Manufacturing in the West: WMTS
Edmonton, AB, will play host once again to
the largest manufacturing show in the region,
the Western Manufacturing Technology Show
(WMTS), which runs June 4-6 at the Edmonton
Expo Centre.
More than 2000
people are expected
to attend the biennial
event organized by the Society of Manufacturing
Engineers (SME). New to the event is a Job Shop
Night on June 4, 4-6 pm, and an education
program with presentations on the show floor,
which is free with admission to the event.
“For manufacturers, WMTS is the place to
learn, evaluate and compare technologies and
solutions on a one-on-one basis, all under one
roof, over three days, says Janine Saperson,
event manager. Visit WMTS online for details and
registration at http://wmts.ca.
Manufacturing in the East: CMTS
Canada’s biggest event for manufacturers, the
Canadian Manufacturing Technology Show
(CMTS), returns to the International Centre in
Mississauga, ON, September 30 to October 3.
One of the flagship events for the Society of
Manufacturing Engineers (SME) Canada, the event
will draw thousands of manufacturers from across
Canada to see hundreds of industry suppliers to
the metal product manufacturing industry.
In addition to the educational program and
conference presentations, the event will include
a Job Shop Night, which means SME will extend
the hours for busy shop owners on October
2 from 4 to 8 pm. New to the event is the
Medical Manufacturing Innovation Series, which
will encompass a conference and the Medical
Manufacturing Innovations Centre with learning lab
presentations.
Visit CMTS online for
more details about new
events and to register.
http://cmts.ca.
Visit www.shopmetaltech.com for more events
News May.indd 13
EmjYlYEYl]jaYd@Yf\daf_Kgdmlagfk
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13-04-17 6:38 AM
INDUSTRY UPDATE
POSTSCRIPT
53
$
The amount the Federal government
plans to allocate to support local and
economic infrastructure projects over
TEN YE ARS.
$1.4
BILLION KPMG “Competitive Alternatives 2012”
CA N A DA’S POPUL ATION
Statistics Canada, January 2013
Engineers Canada
35,056,064 95,000
PROFESSIONAL ENGINEERS
WILL
RETIRE
BY
2020
in TAX RELIEF for Canada’s
manufacturing and processing
sector through a TWO-YEAR
extension on the accelerated
capital cost allowance for
NEW INVESTMENT in
machinery and equipment.
Federal Budget 2013 proposal
JUNE 14 - 11 A.M. TO 2 P.M. ET
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Manufacturing in Florence, Kentucky since 1974
News May.indd 14
13-04-17 6:38 AM
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13-04-17 6:38 AM
Â
SHOP REPORT |
Aerospace
BY TIM WILSON
EMC’s Purchasing
Co-op Takes Flight
Canada’s Excellence in Manufacturing
ng
Consortium (EMC) has a Purchasing
Co-op that is gaining traction with
manufacturers–including those in thee
aerospace sector.
“The EMC Purchasing Co-op
is the first of its kind for Canadian
manufacturers,” says Jason Bates,field
eld
ship
service advisor-team leader membership
development at EMC. “It is a 100 per
er
cent member owned organization, a true
co-op in that members work togetherr on
rough
purchases to achieve cost savings through
rebates and improved supply chains.””
Bates says aerospace manufacturers
can take advantage of most of the
program, with specific opportunity in
the areas of maintenance, repair, and
operations (MRO).
“Areas such as welding, industrial
gases and supplies, freight, and courier
would apply to aerospace,” says Bates.
“And perhaps even some industry-specific
materials, such as high-end adhesives.”
Of specific interest to aerospace job
shops is EMC’s intention to expand the
program to include steel and packaging.
The organization also has an energy
purchasing group that has been popular
with some aerospace companies.
“I know of a large aerospace
manufacturer that is participating in the
program and saving significant dollars,”
says Al Diggins, EMC’s president and
general manager. “A company can have
a study done and hedge for heavy usage
periods; it is a very friendly, manufacturercentric contract.”
Diggins says the program–available in
Ontario and Alberta where the markets are
deregulated–has grown substantially and
is still generating significant interest.
“We could now be considered a small
utility in Ontario,” he says.
SQUEEZE
PLAY
Aerospace OEMs tightening
manufacturing supply chain
HANGES ARE AFOOT
in the aerospace sector, and
many metalworking shops
in Canada are in a good position to
EHQHÀW7KHUHFHQWSUREOHPVZLWKWKH
Boeing 787 Dreamliner have resulted
in an industry-wide push to shorten
the supply chain, and technological
advances are supporting Canadian
shops delivering to precise design
VSHFLÀFDWLRQV
“British Columbia is part of the
Northwest hub, and Boeing wants
its supply chain in proximity,” says
Steve Archer, director of business
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other parts of Asia are now compelled
to look at collaboration with local
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C
which is providing opportunities for
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There is room for growth in the
BC lower mainland for companies
like Avcorp that serve the nearby
Boeing assembly plants in the Puget
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designs and builds airframe structures
for Bombardier and Cessna, sees the
trend as creating overall opportunity
for aerospace manufacturers in the
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“If you look at Bombardier in the
east, it is also tightening its supply
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Heavy Industries moved its
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It is an automated, lean plant for
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Cover story.indd 16
13-04-17 6:54 AM
AV&R Vision &
Robotics’ automated
blade leading and trailing
edge profiling system
has caught the attention
of the aerospace
manufacturing
industry.
Pushing the envelope
This is happening in the context
of combined total demand nearly
outstripping the capacity of the
larger Boeing and Airbus global
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industry and its ability to build
parts with increasingly rigorous
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“The more precise the jet
engine parts can be, the better
the engines are,” says Eric
Beauregard, CEO of AV&R
Vision & Robotics in Montreal,
which is setting a new standard
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“When we asked around to
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Precisely Canadian
the precision looked for was ± 50
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something interesting happened
when we presented our solution:
the required precision was
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In effect, the designers who
impose production precision
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“Moreover, these days we are
starting to hear the designers talk
about precision levels of as low as
PLFURQVµVD\V%HDXUHJDUG
The ongoing pressure to make
parts as precise as possible should
continued on page 19 Î Î Î
Montreal-headquartered AV&R Vision & Robotics
has developed an automated blade leading and
trailing edge profiling system specifically for
aerospace manufacturing–and it has caught the
attention of those in the industry. It won SME’s
Innovations That Could Change the Way You
Manufacture 2012 Award, and was chosen as a
finalist of Aviation Week’s Innovation Challenge in
the Power & Propulsion category.
“AV&R had already developed robotic finishing
systems for aerospace, but when we really niched
our activities we looked for a common and
recurrent need from our customers, a need which
existing technologies couldn’t answer,” says
Eric Beauregard, AV&R’s CEO. “That is how we
started the development of our automated blade
profiling system.”
AV&R says the system includes all the
required technologies to create high precision
elliptical profiles on leading and trailing edges of
compressor blades’ airfoils. These are used on
blades in jet engines–mostly nickel based,
in titanium and aluminium–at a tolerance of
± 37.5 microns.
“This beats the precision obtained manually,”
says Beauregard. “It enhances ergonomics and
safety while increasing repeatability and quality
of production. At the end of the day, jet engines
including blades with precise profiles, make
less noise and have lower fuel consumption and
higher performance.”
AV&R’s software provides adaptability to the
robotic system, allowing for repeatable results even
if the parts coming in are not identical. Inspection
results are as precise as other systems currently in
use, but much faster. The platform also includes
an auto-teaching capability, which allows for new
products to be quickly added into the system.
“Typical customers of these systems are
OEMs and their supply chain,” says Beauregard.
“However, the MRO Industry will start to need
these systems too since retrofit programs are
being elaborated to increase repaired engines’
performance, leading to new precision tolerances.”
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Cover story.indd 17
13-04-17 6:54 AM
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Cover story.indd 18
13-04-17 6:54 AM
Â
SHOP REPORT | Aerospace
Î Î Î continued from page 17
provide a solid boost to Canadian job
shops feeding the aerospace sector,
given that the drive to increased
SUHFLVLRQHQKDQFHV&DQDGD·VORQJWHUP
competitiveness, something that is
now backstopped by a market-driven
incentive to keep the supply chain
FORVHWRKRPH
Support for Aerospace Manufacturing
Canada boasts the world’s
fifth largest aerospace
industry and the sector
generates more than $22
billion, exporting 80 per
cent of its output. With
investments of more than
$2 billion, the aerospace
industry is the second
largest R&D investor in
the country, according to
figures from the Aerospace
Industires Association of
Canada (AIAC).
The Federal government
recognizes the sector’s
contributions to the
economy and in the recent
Federal Budget 2013,
committed more than $1
billion dollars to support it.
At the ready
“Our aerospace manufacturers
are good at what they do,” says
Al Diggins, president and general
manager, Excellence in Manufacturing
Consortium (EMC), and co-CEO
of the Canadian Manufacturing
continued on page 21 Î Î Î
It has committed close to
$1 billion over five years
for the permanent Strategic
Aerospace and Defence
Initiative (SADI). There is
also the new Aerospace
Technology Demonstration
Program, which will be
funded to the tune of $110
million over four years,
beginning in 2014–15 and
another $55 million per
year on an ongoing basis.
SADI has played a
significant role in aerospace
manufacturing since it was
established in 2007. Project
highlights include:
t$7.7 million to ASCO
Aerospace Canada,
Delta, BC, to support
innovative manufacturing
technologies to produce
aircraft bulkheads
and specialized metal
components.
t$43.4 million to Bristol
Aerospace Ltd., Winnipeg,
MB, to support new
processes for composite
manufacturing and
complex assemblies that
incorporate both composite
and metallic components.
t$300 million to Pratt
and Whitney Canada,
Longueuil, QC, to support
research leading to
lighter aircraft engines
with more power, better
fuel consumption and
improved durability.
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Cover story.indd 19
19
13-04-17 6:54 AM
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Cover story.indd 20
13-04-17 6:54 AM
Î Î Î Î continued from page 19
Network. “They can hold their own with the high tech
requirements.”
Diggins says that 17 per cent of EMC’s
membership is in the aerospace sector,
and they are among the consortium’s
most active members, with aerospace being a bright spot
on Canada’s manufacturing landscape in part because it
is backed by strong global demand. Boeing, for example,
now has a record sold backlog of more than 4,000 airplanes
worth nearly US $310 billion.
“The demand for these airplanes is driven by sustained
HFRQRPLFJURZWKLQ&KLQDWKH$VLD3DFLÀF5HJLRQDQGWKH
Middle East, coupled with the replacement of a large number
of aging aircraft in North America and Europe,” says Archer
from Avcorp. “At the same time, Airbus is experiencing an
increase in demand for new aircraft.”
And though the use of composites is on the rise, the
LQFUHDVLQJSULFHRISHWUROHXPPHDQVUHVLQVDQGÀEHUVDUH
Â
SHOP REPORT | Aerospace
more expensive, too, which argues for the
continued use and relevance of precision-tested
lightweight and high strength metal alloys. There will
be special demand for long bed aluminum and hard
metal complex machining in multi-axis environments,
with those machine shops that can deliver to advanced
specs likely in good shape for years to come.
“With airplane production rates set to increase 40 per cent
over the next three years, Boeing will spend more than US $30
billion per year globally with its suppliers,” says Archer.
To produce those airplanes Boeing and Airbus depend
heavily on thousands of suppliers from all over the world.
However, a more streamlined supply chain is a necessity for
OEMs to reduce production risk and meet demand. That
puts Canada in a sweet spot, with strong incentives to build
competitiveness in the sector. SMT
Tim Wilson is a contributing editor. [email protected]
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13-04-17 11:19 AM
Â
MACHINING | Milling
The Problem
Meeting increased customer
demands for aggressive
delivery times
The Solution
Increase machining
capacity with investment in
three, five axis universal
milling machines
BY KIP HANSON
Quebec mouldmaker
embraces five axis
technology in a big way
www.rocand.com
www.dmg.com
The 5 Axis Leap
HEN ANDRÉ ROCHETTE
decides to do something, he
does it in a big way. As president
of Rocand Inc., Sainte-Foy, QC, he was
faced with a substantial increase in sales
and development activity. He wasn’t
about to let his customers down. “Client
relations are very important to us, and
as a Tier 1 automotive supplier, we have
to meet aggressive delivery times. Our
existing equipment was unable to keep up
with demand, so it was a simple decision.
We increased capacity to meet our
customers’ needs.”
Most manufacturers would respond by
purchasing an additional machine to meet
that need. Rocand ordered three. “Small,
medium, and large,” laughs Rochette,
GHVFULELQJKLVQHZÀYHD[LV&1&XQLYHUVDO
milling machines from DMG. “Our goal
is to continually produce high quality
products to the automotive industry, with
the best lead time and a competitive price.
Choosing that equipment was a way for us
to achieve those goals.”
Mouldmakers need a number of
W
The 340p in Rocand's shop, the largest of the three
DMG machines the company purchased to meet
growing customer needs.
capabilities to do their work. Chief among
WKHVHLVDQHIÀFLHQWPHWKRGRIUHPRYLQJ
large amounts of material quickly. DMG
delivered that with its U-series machines.
The largest of Rocand’s new machines,
the DMU 340 P, has a 3400 mm work
envelope and table load capacity of 16
tons. Its 52 kW, 12,000 rpm spindle
boasts 430 Nm of torque. And since
Rocand purchased the optional 24000
rpm pickup spindle, it can rough and
ÀQLVKÀYHVLGHVRIWKHZRUNSLHFHLQRQH
handling. Says Rochette, “now we can do
more machining in a single operation and
produce tools for our customers in the
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Machine1_Rocand.indd 22
powered by CME
13-04-17 7:01 AM
Presetting for Uptime
Assembly of
an extrusion
blow mould
cavity.
shortest possible time.”
Those tools include sophisticated
injection moulds for motor covers.
“That one has an integrated lead-frame,
with two overmoulded components
inside,” says Rochette. “We had to
develop that expertise to manage a
variety of global programs for all the
major car manufacturers, including
Porsche, Mercedes, BMW, Peugeot,
Renault, GM, Ford, Nissan and
Hyundai.”
Why did Rocand choose DMG?
An inside look at the DMU 210p, the medium
size machine in the trio of DMG machines
Rocand purchased.
´:H·YHEHHQGRLQJÀYHD[LVPDFKLQLQJ
since 2004 and already had a good
idea of what we needed,” explains
Rochette. “But we wanted to look at
different approaches to high speed
machining, so we visited the 2011
EMO show in Hanover, Germany.
We looked at a number of machine
tools, but the deciding factor for us
was DMG’s approach on the design
of the equipment, the size and the
FRQÀJXUDWLRQIRURXUDSSOLFDWLRQ
Aside from the quality of the machines
overall, many of them have a cubic
work envelope, which is very good for
mouldmaking.”
The machines have been in
production since September 2012.
“This investment allows us to serve
our different customers as quickly as
possible, with quality products at a
competitive price. The DMG equipment
helps us to achieve that objective.”
Rocand has been on a steady
growth path since its doors opened in
EVEN THE BEST MACHINE
tool is useless if it’s not
making parts. When Rocand
purchased its DMG machines, founder
André Rochette recognized this fact
and made one additional investment: a
DMG Microset V10 20-70 linear MV IV
presetter. “What we like to do in the new
DMG machines is cut materials,” says
Rochette. “Of course, each machine has
the capability to measure a tool’s length
and diameter, but while you’re doing that,
it’s obvious that you’re not cutting.”
The VIO linear presetting system
from DMG increases machine uptime by
allowing a technician to configure the
tool length and diameter offline while
the machine is producing parts. Fully
automated offsets can be sent directly
to the machine control, avoiding manual
input and the possibility of mistakes. And
the VIO’s linear scales assure measuring
accuracy to +1 μm, and measuring
cycles up to 25 per cent faster than its
competitors, claims DMG. Says Rochette,
“by presetting tools offline, we are
ready to start cutting when we arrive
at the machine.”
Reducing setup time is
only part of the story. “It’s
not just the time we save,
but also the precision we
can achieve over manual
tool setting methods,”
explains Rochette. “If you
i lless
measure outside, you’re relying
on a human and more on technology.
The VIO measures the tool the same way,
every time.”
When you’ve made an investment as
large as Rocand’s, it only makes sense to
optimize that investment by measuring
cutting tools accurately, consistently,
and offline.
23
13-04-17 7:01 AM
Â
MACHINING | Milling
,WDFKLHYHG,62FHUWLÀFDWLRQLQGRXEOHGWKHVL]HRILWV
SURGXFWLRQÁRRUD\HDUODWHUDQGLVDGGLQJVSDFHWRWKHIDFLOLW\DJDLQ
this year. With technical centre facilities in Mexico, Brazil, France and
Germany, Rocand is now a leader in complex injection and extrusion
blow moulding, and prides itself on fair and ethical relationships with its
FOLHQWV7KHWULRRI'0*PDFKLQHVQRZVLWWLQJRQ5RFDQG·VVKRSÁRRU
can only serve to strengthen those relationships. SMT
Kip Hanson is a contributing editor. [email protected]
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5 Axis Champions
JEAN-PIERRE BOYER is the DMG North
American regional sales manager for
Quebec. “We presented Rocand with a
variety of options, but the company settled on the
DMU 100 mB, DMU 210 P and DMU 340 P. They are
very satisfied with the equipment.”
They should be. DMG designs its machines with
mouldmakers in mind, explains Boyer. “They have a
high speed machining strategy built directly into the
controller. With the DMU’s gantry-style design, DMG
can control the thermal expansion of the machine
extremely well. And the machine itself is very fast and
very flexible.”
The DMU series offers capabilities to satisfy
even the most demanding of industries. The largest
machine (DMU 600) offers a 30-ton table load option,
tool magazines
up to 313 tools,
and an optional
geared spindle drive
with 2500 Nm
of torque. Many
of the machines
can be configured
with linear drive
motors, pallet
changers, integrated
measuring systems,
and a number
of milling heads
and rotary table options. With pickup
The DMU 100
spindles available to 24000 rpm, HSK,
machine.
and B axis machining angles to -20°,
the DMU can tackle most anything that
comes its way.
Perhaps the most unique option on the
larger machines is an interchangeable head. On
HSK-equipped spindles, an electronic connector built
into the milling head opens the door to high tech
possibilities such as laser structuring of workpiece
surfaces and ultrasonic oscillation of the Z axis to aid
in hard milling of advanced materials.
Rocand is part of an elite club. While there are
upwards of 500 DMG machines operating in Canada
today, you can count the number of manufacturers
who own a 340P on one hand. That fact should put a
smile on the face of André Rochette as he steps onto
the shop floor each morning.
For more information on machining
technologies, visit Shop Metalworking
Technology’s MACHINING ZONE online
at www.shopmetaltech.com.
Visit www.komet.com/promotions
for all the details or scan this QR code.
www.komet.com
905-954-0466
THE EQUIPMENT
TOOLS PLUS IDEAS
13-04-17 7:01 AM
Milling Machines MetalTech Report ÒDMG
Milling and turning
DMC 65 FD monoBlock
with FD capability (milling
and turning) features an
automatic pallet changer
consisting of three integrated
diameter of 100 mm (3.937
in.) equipped with a CAT 50
spindle taper.
www.tosamerica.com
ÒFORTWORTH
Vertical/horizontal
milling
pallets each with a loading
capacity of 500 kg able to
accommodate workpieces
measuring 630 mm in
diameter and 500 mm
in height. It offers good
accessibility to the work
area, setup area and tool
loading station. It has a small
footprint of just 16.5 m2
that includes the machining
centre and the pallet
changer.
ca.en.dmg.com
ÒFERMAT
Boring mill
The Fermat WFC 10
CNC horizontal boring
mill available from TOS
America is suitable for four
axis machining of small to
mid-sized workpieces up
to 5.5 ton (11,000 lb). The
one-piece bed construction
provides accuracy and
rigidity. It features a boring
diameter of 100 mm (4 in.),
a boring spindle with travel
of 730 mm (29 in.) up to
3000 rpm, and a spindle
The CSG450B
vertical and
horizontal
milling
machine is
Taiwanesebuilt by
Chung
Sing Machinery. It features
a three-axis power feed,
rapid traverse rates (vertical
59. 8 in/m or 1520 m/min
and longitudinal and cross
rates of 116.5 in/min or
2950 mm/min), a automatic
lubrication system, and a
hand wheel on the saddle for
table travel. It is equipped
with a turret type milling head
and a variable speed vertical
spindle.
www.heinmanmachinery.com
table surface allows for maneuverability
around workpieces.
www.gfac.com/us
ÒHAAS
(500 mm), 17.7 in. (450 mm) and 15.7
in. (400 mm), respectively, while a
distance of 5.9 in. (150 mm) between
the machine spindle nose and rotary
5 axis, 40 taper VMC
The UMC-750 40 taper VMC offers
five-sided (3+2) and simultaneous five
axis machining.
3YNERGYIN
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4ECHNOLOGIES
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AGIECHARMILLES
5 axis milling
The five axis HEM 500U
features a 12,000 rpm
spindle and 30-tool
magazine with a two-second
chip-to-chip time for high
speed continuous milling
operations and increased
spindle uptime.
The trunnion table
is 19.7 in. (500 mm) in
diameter and accommodates
workpiece weights up to 440
lb. (200 kg). It tilts +50
mm/-110 mm in the B axis
and rotates 360° in C for 3
+ 2 machining and five-side
positioning. Axis travels in
X, Y and Z measure 19.7 in.
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13-04-17 9:00 AM
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MACHINING | Milling Machines MetalTech Report
ÒHARDINGE
Rigid C frame
The Bridgeport GX-250 5AX five
axis vertical machining centre
is a rigid C-frame machine in a
compact footprint, equipped with
a five axis rotary table and Fanuc
31i control with 10.4 in. LCD. The
Travels are 30 x 20 x 20 in.
(762 x 508 x 508 mm) travels.
The base machine is equipped
with an 8100 rpm inline directdrive spindle, powered by a 30 hp
vector drive system (12,000-rpm
optional), and comes standard
with a 40+1 tool side-mount tool
changer. The dual-axis trunnion
table can position parts to nearly
any angle for contouring and
complex machining. The trunnion
provides +110 and -35°of tilt and
360° of rotation for excellent tool
clearance and large part capacity.
www.haascnc.com
machine, ideally suited for the
demanding requirements of the
die/mould, aerospace, medical
and automotive industries, is
designed to handle small, complex
workpieces that require closely
held tolerances and fine surface
finishes. Axis travels are: 11.8 in.
www.bigkaiser.com
(300 mm) X, 15.7 in. (400 mm)
Y, and 16.9 in. (430 mm) Z.
www.hardinge.com
ÒHYUNDAI WIA
30-tool tool changer
F500VM is a new VMC in the
Value Master range with X, Y and
Z axis travels of X-axis, 43, 22 and
20 in. (1100, 559 and 508 mm)
respectively. Standard features
include a 30-tool swing arm tool
changer, Thru Spindle Coolant,
Big Plus Tooling, and Rigid
Tapping, as well as a large Y axis
(1100 mm x 550 mm).
The machine can be configured
with an 8,000 rpm spindle
for taking deep cuts, or with a
12,000 rpm spindle for high
speed precision applications. The
standard Big Plus spindle system
(BBT #40) provides dual contact
between the spindle face and the
flange face of the tool holder. Thruspindle coolant is standard, and
the machine is equipped with a
30-tool, side mount swing arm tool
changer with 1.3 sec tool-to-tool
change times.
www.hyundai-wiamachine.com
ÒMAKINO
New machining platform
The N2 and N2-5XA (five axis)
horizontal machining centres for
medical and small aluminum parts
manufacturing feature the new N2
platform that consumes less than
26 sq ft of floor space. The overall
Boring Tools · Tool Holders · Cutting Tools · Presetting · Workholding · Accessories
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Visit www.bigkaiser.com/boring or scan the QR code to watch the video.
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13-04-17 11:02 AM
footprint is 45.3
in. wide by 83.7
in. long by 84.6 in.
high (1,150 mm by
2,125 mm by 2,150
mm).
The four axis
N2 offers a 400
mm high, 400 mm diameter
cylindrical work envelope with X,
Y and Z axis travels of 300 mm
by 300 mm by 230 mm, and a
300 mm diameter direct-drive
rotary table. The 5 axis N2-5XA
shares the same linear axes and
includes twin, trunnion-style
direct-drive A and B rotary axes
for the production of complex,
contoured parts.
www.makino.com
ÒMAZAK
Improved machining
accuracy
The Variaxis i-800 features a
Y axis travel of 33.46 in. (850
mm), an X axis travel of 28.74 in.
Need to program
parts that require
extremely precise
tolerances?
(730 mm) and can accommodate
workpieces up to 39.37 in. (1,000
mm) in diameter and 19.69 in.
(500 mm) high. A roller gear
cam-driven rotary/tilt table with
360° of rotation in the C axis and
+30°-120° of tilt in the Ax axis, is
supported at both ends. It comes
standard with a 10,000 rpm,
40 hp, 50 taper spindle with a
compact nose design to increase
the machine’s Z axis stroke to
22.05 in. (560 mm). The machine
is available with the standard
30 tools up to 120 tools. Rapid
traverse rate of the X, Y and Z
axes is 1.654 ipm (42 m/min).
www.mazakcanada.com
ÒMC MACHINERY
New milling line
The Diamond Cut general milling
line is comprised of five series of
vertical machining centres and
drilling and tapping machines. The
MCV Series is a general purpose
machining centre with two spindle/
tooling system types. The DV
Series features a 15,000 rpm
direct drive spindle and CAT 40
tooling. It can accommodate
rigidity and stability in large parts
and has a10,000 rpm spindle,
CAT 50 tooling, and hand-scraped
box way guides.
www.mitsubishi-world.com
ÒMILLTRONICS
Linear roller ways
The VM3224 VMC features a
38 x 24 in. (965 x 610 mm)
table and travels of 32, 24 x
26 in. (813 x 965 x 660 mm).
It has removable side doors,
linear roller ways and a dual arm
24-pocked tool changer. It offers
smaller cutting tools. The DM
Series features a 20,000 rpm
HSK-A63 spindle. A 32-position
automatic tool changer, the
M720 Mitsubishi controller, linear
scales, and roller guideways are
standard features.
The SV Series is built with a
heavy-duty box way construction
in the X, Y, and Z axes, ideal for
cutting feedrates of 500 ipm
(12.5 mpm) and rapid feedrates
of 1600 ipm (40 mpm).
www.milltronics.net
Next Intent (San Luis Obispo, CA) designs and builds
precise tolerance components and sub assemblies for aerospace, aircraft, defense & national laboratories. Looking for
proven performance in their CAM software solution, the
company chose GibbsCAM.
GibbsCAM integrates cutting-edge CAD/CAM technology with industry-leading ease-of-use features — critical
qualities needed when programming parts like the rotary
housing for NASA’s Mars Science Laboratory. The housing
is designed with thin walls and multiple pockets (with some
features requiring a tolerance of ±.001"). JPL’s STEP-format
CAD model opened directly in GibbsCAM, where its 5-axis
functions were used to program the part. If failure is not an
option and you need to program parts that require extremely
precise tolerances... Gibbs Can!
Curiosity
imagery courtesy
NASA/JPL-Caltech
The rotor housing for Curiosity was machined
from 6AL-4V titanium on a 3-axis machining
center equipped with
fourth-axis rotary table.
Powerfully Simple. Simply Powerful
See GibbsCAM
at Booth #1032
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Bill Gibbs
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800-654-9399
M
13-04-17 7:01 AM
Â
MACHINING | Milling Machines MetalTech Report
ÒTOSHIBA
FIELD NOTES
Face, end milling
The BTD-200QH is an easy-to-use machine best
suited for face and end milling operations. New
features support advanced machining opeations.
It features a CNC system Tosnuc 999, an optional
spindle with 5000 min speed and an optional NC
rotary milling function which allows for four axis
control in lieu of the current three axis control.
www.toshiba-machine.com
Y
DELIVER
Y
A
D
T
X
NE
GO TO
GT
FOR YOUR TAPPING NEEDS
HIGH - PERFORMANCE
TAP S
YG - 1 Canada | [email protected]
PRODUCT: Fanuc RoboDrill
END USER: Camcor Industries
When you’re machining precision parts at high speed and
feed rates, holding tight tolerances of +/-.001 in. (.025 mm)
is critical. That’s why Camcor Industries, Carp, ON, invested
in the Fanuc T21i-Fla RoboDrill for its milling operations.
The 16,000 sq ft machine shop offers three, four
and five axis precision machining of 2D and 3D complex
geometries. It specializes in the high tech manufacturing
sector (e.g. avionics, telecommunications, medical and
scientific devices) and while it’s a niche market, it’s still a
competitive one. So when Camcor installed the RoboDrill
in February 2011, the company was looking to also reduce
cycle times and improve machining productivity.
“We’ve cut cycle times in half compared to a 10,000
rpm machine we were using. We also have a low scrap rate
through the 4th axis and no backlash [no loose movement
on each axis of the table due to the servo motors and the
Fanuc control]” says Robert Brinker, operations manager.
Camcor selected the RoboDrill
because the price point was right,
but more importantly, Brinker
says he likes the reliability of
the machine. The machine was
purchased from Legere Industrial
Supplies Ltd., Ottawa, ON, a
Canadian distributor for Methods
Machine Tools Inc., the exclusive
North American sales, service
and training source for Fanuc.
“We haven’t had a service call yet; it’s a reliable machine.
It has a fast tool changer, and fast table speed, and a
simply designed coolant supply. The Fanuc 31i-A5 control is
perfectly integrated and tuned with the machine.”
Method’s now offers the new generation RoboDrill, the
Fanuc D21. It features a new 31iB control for high speed
processing, as well as troubleshooting and maintenance
capabilities. It allows users to receive notifications if any of
the drives or electronics requires adjustments. The machine
is available in three sizes (small, medium and large) with a
14 or optional 21-tool tool changer. It features accelerations
in X, Y and Z axes to 1.5 g, rapid traverse rates of 2,125
ipm and feed rates to 1181 ipm (2,362 ipm optional).
Camcor is an ISO 9001:2008 certified manufacturing
business formed in 1992 by brothers Roberto and Orlando
Campagna. In addition to machining, it offers secondary
services--welding, electron beam welding and assembly.
www.camcorindustries.com
www.legereindustrial.com
www.methodsmachine.com
3 3 7 5 Nor th S er v ice Road, Unit A 8 Bur lington, ON L7N 3G2
Phone: 9 05-3 35-250 0
Fax: 9 05-3 35-4 0 0 3
13-04-17 7:01 AM
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Â
CUTTING TOOLS | Turning
BY JIM BARNES
What You Don’t Know
About Wipers
“The overwhelming reason that people
don’t use wipers is lack of education,
lack of knowledge. They just don’t know
what a wiper is intended to do. They are
not comfortable with it,” says Seco Tools'
Don Graham. What kind of questions do
customers often come to him with? ‘What is
a wiper?’” he says with a laugh.
The main misconception about
wipers is largely the industry’s fault, says
Kennametal's Jan Andersson. When they
were introduced, “we talked high and low
about finishing. Wipers have so many more
application areas than just finishing.”
Semi-finishing and even roughing
operations can be improved with wipers.
In roughing, it can give you better chip
control. “If you’re increasing your feed rate,
you’re increasing your chip area, which gives
you better chip control,” says Andersson.
In medium roughing applications where you
have interruptions, you can utilize the edge
strength of the wiper, he adds.
That wipers are hard to set up is another
misunderstanding. “You do have to think
about your setup, you have to think about
what materials and components to use them
on. That’s all true, but I think we [tooling
industry] went slightly overboard. People
think the wiper is more complicated to
apply than it actually is,” adds Andersson.
Some wipers are designed to be more
forgiving in setups. In some Seco products,
a very large radius is built into the geometry.
“That radius is there to compensate for any
of the toolholders being out by a degree or
two. So even if the insert is off by a degree
or two, you’re still going to get the wiper
effect,” says Seco Tools' Chad Miller.
Sandvik Coromant's Dave Andrews
says the company's "wiper flat is typically
a series of five radii blended together.
With a larger radius, you don’t have the
requirement to have the tool absolutely
perpendicular to the workpiece, it’s less
critical, you get a little more flexibility with
the blended radii.”
Wipe Out
Unleashing the wiper insert's potential in turning
IPER INSERTS ARE
well-established in turning
operations, but some of their
capabilities are not well-recognized.
The experts interviewed for this
article emphasize that these tools have
wide potential applications that could
HQKDQFHSURGXFWLYLW\DQGSURÀWDELOLW\
but that many shops seem to be
unaware of them.
The wiper insert concept is based on
a series of radii that make up the cutting
edge. Instead of just one nose radius, a
wiper edge consists of a main radius and
several smaller radii. The multiple nose
radii smooth out the peaks and valleys
caused by conventional inserts with a
“wiping” action.
“In essence, what you’re doing is
W
extending the effective radius. By
doing that, you’re producing a better
ÀQLVKµH[SODLQV-DQ$QGHUVVRQ
senior global product manager,
Kennametal Inc., Latrobe, PA.
:LSHUVÀUVWDSSHDUHGDERXW\HDUV
ago in milling applications and over
10 years ago in turning. There were
reasons for the lag.
“In milling, the concept of the wiper
is a little more obvious. In turning,
there were concerns about what the
wiper would do to the nose radius and
whether or not that would be accepted
by the market,” says Don Graham,
manager of Education and Technical
Services, Seco Tools Inc., Troy, MI.
“Conceptually, it just is not as easy to
grasp in turning as it is in milling.”
CONSIDERATIONS
THE LIST OF WIPER
limitations is
moderate.
Make sure your machine
can supply the necessary
rigidity. Since between five
and 10 per cent more cutting
force is involved, your machine
tool has to have the capacity.
“You need more stability in
the machine tool because you
do have more contact between
the insert itself and the
workpiece,” says Andrews.
Make sure your CAM
system is up to speed. The
complex geometry may make
programming toolpaths,
including interpolated moves,
more complex. As an example,
Pathtrace software has
Sandvik wiper geometries built
in. An insert can be chosen
by catalogue number and the
program will generate the
appropriate toolpaths.
The application matters,
too. For example, profiling
can be a problem. “If you
are doing straight turning or
a facing operation, you get
an excellent surface finish.
If you’re doing profiling, you
don’t get the wiper effect,”
notes Graham.
“Basically, you would
use a wiper in a cylindrical
operation, not a tapered
operation of any sort. Ideally,
it’s on a straight shaft of
some kind. Typically, you
would not use it where you
had to come into some kind
of controlled radius in a
corner,” notes Andersson
Another application that
could be a problem is long,
thin workpieces. The heavy
feed means you might get
vibration. You should also
be careful with thin-walled
CT Wiper.indd 30
13-04-17 6:48 AM
“The problem with adapting it to turning is that a
straight, parallel land doesn’t work as well," adds Dave
Andrews, former product and applications specialist,
turning products for Sandvik Coromant, and now
regional business manager for Western Canada for
WKHFRPSDQ\,W·VDOLWWOHPRUHGLIÀFXOWWRPDNHVXUH
the toolholder is always 100 per cent parallel to the
ZRUNSLHFH7KHQZKHQLWFRPHVWRSURÀOLQJDQGVR
on, there are other issues with a straight, parallel land.
Some engineering needed to be done.”
Capabilities
“When wipers were introduced to the metalworking
industry, they were presented as a product to increase
WKHIHHGUDWHZKLOHPDLQWDLQLQJWKHÀQLVK7KDWLV
still valid, absolutely the case,” says Andersson. Shop
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FRQYHQWLRQDOLQVHUWVRUEHWWHUÀQLVKHVDWWKHVDPHIHHG
,QIDFWWKHVHVXSHULRUÀQLVKHVPLJKWHYHQ
PDNHVHFRQGDU\ÀQLVKLQJRSHUDWLRQVOLNHJULQGLQJ
unneccessary.
You also get good chip control at low feeds and
consistent chip breaking at high feeds. “If you
increase your feed rate, the chip is thicker. On
the springier steels, using a wiper insert aids chip
control,” explains Graham.
Negative and positive variations are available in
the technology.
workpieces.
Some materials, such as
heat-resistant superalloys,
might exhibit work-hardening
if wipers are used, though
some wiper inserts have been
designed specifically for these
applications. Solutions are
available for aluminum, too.
Stainless steel is also
getting attention, according to
Chad Miller, product manager,
advanced materials. Seco
Tools Inc., Troy, MI. “We’re
working on what we’re calling
a ‘short wiper.’ The wiper
radius is reduced. That results
CT Wiper.indd 31
in a reduced cutting force...
with stainless steel, you cause
built-up edge on the cutting
edge. It really affects the
surface finish. If we can get
rid of that with a freer cutting
geometry, a wiper geometry
that’s tailored for stainless, we
do better.”
Generally speaking, wipers
don’t need special handling.
They use the same toolholders
and cutting fluids and
machines you are using now.
They are graded similarly to
conventional inserts.
“[Shop owners] should
Spotting for Taps
Seco's wiper insert.
Kennametal's turning
wiper insert.
Now &
the future!
2 in 1
Sandvik Coromant's WMX
wiper insert.
continued on page 33 Î
be taking advantage of the
productivity gains, now more
than ever, with the push in
the industry to reduce costs,”
says Andrews. “You can make
good gains in cycle time with
very little effort involved in
programming or changing
toolholders. It’s no more
than popping in an insert,
and increasing the feed rate
accordingly.”
The technology has
progressed dramatically in
the past decade. It may be
time for a second look at this
powerful solution.
Spot drilling for high
performance drills and
90° chamfering all in one.
Inserts fit standard holders.
Imported exclusively into Canada by
Caliber Industrial supply
Contact us for your local distributor
1-800-465-5743
[email protected]
13-04-17 6:48 AM
CT Wiper.indd 32
13-04-17 6:48 AM
Î continued from page 31
Â
CUTTING TOOLS | Turning
A positive wiper design involves less tool
SUHVVXUHEULQJLQJWKHEHQHÀWVRIZLSHUV
to applications that can’t handle the extra
pressure caused by the wider radius that
could result in vibration and other problems.
Negative wipers support increased tool
pressures, increasing cutting power on highly
rigid machines. The negative angle grind
pushes crater wear away from the edge,
increasing tool life. SMT
Jim Barnes is a contributing editor.
[email protected]
DX
SIMTEK Turning Tools TypeDX (Delta-Line)
www.kennametal.com
sandvik.coromant.com
www.secotools.com
For more information on
cutting tool technologies,
visit Shop Metalworking
Technology’s CUTTING
TOOL ZONE online at
www.shopmetaltech.com.
Turning Tools MetalTech Report Grooving
ÒHORN USA
CVD coated diamond tools
CVD thick-film tools are harder than PCD
and twice as wear-resistant. The extremely
long tool life of diamond tools combined with
an optimized
chip breaker
on the CVD
diamond cutter
can increase
machining
productivity by
up to 35 per cent
and reduce processing costs by up to 80 per
cent. Various inserts with wiper geometries
have been developed for high performance
machining and continuous turning.
www.hornusa.com
ÒISCAR
Innovative clamping
Iscar’s new Dove IQ Turn features a dovetail
pocket combined with a lever clamping
mechanism that provides firm and rigid insert
clamping, eliminating the need for a top clamp,
which interrupts chip flow. The clamping
mechanism can firmly hold double-sided
inserts featuring double negative prism flanks.
The dovetail pocket and insert prismatic flanks
CT Wiper.indd 33
prevent the insert from
being lifted by the
cutting forces.
Available are three
insert geometries
with prismatic flanks:
WOMG-R3P-IQ, COMGR3P-IQ and SOMGR3P-IQ, designed with a new R3P chipformer
for rough turning of steel.
www.iscar.ca
ÒSANDVIK COROMANT
New insert geometries
New insert
geometries for
steel, stainless
steel and HRSA
material and
customized
toolholders have
been added
to the company’s range of options to apply
coolant in the machining process. When
using low pressure (7-10 bar/100-150 psi)
the CoroTurn HP holders with high precision
continued on page 35 Î Î Î Î
Boring
Threading
Face
Grooving
Available from 0.280”
minimum bore
1-800-465-5743
[email protected]
13-04-17 6:48 AM
PROPELLING
PRODUCTIVITY FORWARD IN AEROSPACE
INTEGREX e-670H
INTEGREX i-630V
VORTEX 1060V/8S
Full 5-Axis Multi-Tasking
for Long Shaft Work
Full 5-Axis Machining With
Turning and a Pallet Changer
Full 5-Axis Machining With a
39.37" Square Single Table
MEGATURN NEXUS 900M
VERSATECH V-140N
MAZAK PALLETECH SYSTEM
MEGA 8800
Vertical Turning Center With
a Milling Turret
5-Axis Machining With Up
to a 393.7" Work Table
Pre-Engineered, Easily Expandable
Automation System
Highly Rigid Horizontal Machining
Center With a High-Torque Spindle
COMPREHENSIVE MANUFACTURING SOLUTIONS FOR ACHIEVING
SOARING LEVELS OF PRODUCTIVITY, PRECISION AND PROFITABILITY
WHETHER YOU’RE MACHINING landing gear, jet engine parts, large airframe structures
or system controls, our expansive technology portfolio and unsurpassed industry expertise
provide everything you need to optimize your aerospace manufacturing operations.
To learn more about Mazak’s solutions for the aerospace industry, visit one of
Mazak’s eight North American Technology Centers or WWW.MAZAKUSA.COM.
MAZAK CORPORATION
8025 Production Drive, Florence, KY 41042
(859) 342-1700
WWW.MAZAKUSA.COM Facebook Twitter YouTube
ONTARIO
Mazak Canada Technology Centre
50 Commerce Court
Cambridge, Ontario
Canada N3C 4P7
1-800-668-5449
CT Wiper.indd 34
WEST CANADA
Machine Toolworks, Inc.
4803 74th Avenue
Edmonton, AB T6B 2H5
(800) 426-2052
QUEBEC & MARITIMES
A.W. Miller
2685 Boul. Pitfield
St. Laurent, Quebec H4S 1T2
(514) 333-9174
Committed to productivity-enhancing connectivity, Mazak supports the MTConnect open
communications protocol to simplify the monitoring and management of its production
systems. Currently, 36 Mazak customers are using or implementing the protocol to
improve the utilization of their manufacturing equipment.
13-04-17 6:48 AM
continued from page 33
Turning Tools MetalTech Report nozzles outperform regular
toolholders that have an
tendency to flood coolant,
claims the company. The new
-SMC, -MMC, -PMC insert
geometries in combination
with the CoroTurn HP nozzle
technology, provide greater
productivity for demanding
materials such as duplex
stainless steel and HSRA
material, which require higher
coolant pressures of 70-80
bar (1000-1200 psi).
www.sandvik.coromant.com
ÒTECHNIKS
ÒWALTER
Nexus Tools is a new line
of turning and boring tools
with negative and positive
toolholders and boring
bars. The new tooling
provides greater rigidity
and reduces vibration, and
leads to reduced insert wear
and increased tool life.
Also offered is the Captocompatible internal and
external turning tools available
Tiger∙tec Silver Turning for
steel turning applications,
consisting of three new grades
and four new geometries, can
bring longer tool life, faster
cycle times and process
reliability to a wide array
of applications.
Increased rigidity
Steel turning
Fine Engraving
ÒSECO
Turning cast iron
The Duratomic-coated
TK1001 and TK2001 insert
grades achieve versatility,
reliability and exceptional
wear resistance in cast iron
machining. They also allow
for faster cutting speeds
and reduce the number of
grades needed in cast iron
applications.
TK1001 is a hard, finegrained tungsten carbide
turning grade with low binder
phase content. Designed
primarily for tackling gray
cast iron up to semi-stable
conditions and nodular cast
iron under stable conditions, it
also works on hardened steels
in the 40 – 45 Rc range.
TK2001 is a fine-grained
tungsten carbide turning
grade with high toughness. It
offers strong performance in
interrupted finishing operations
due to its tough substrate and
extra edge toughness.
www.secotools.com/us
CT Wiper.indd 35
in C6 internal and external
models for turning, boring,
threading and grooving.
www.techniksusa.com
ÒTUNGALOY
AMERICA
Longer tool life
The new NS9530 incorporates
Tungaloy’s “PremiumTec”
special surface technology
that reduces micro roughness
on the surface to support
improved tool life. The smooth
layer on the NS9530 grade
insert has cut flank wear in
comparison to rival products.
The GT9530 offers
enhanced adhesion between
the substrate and the coating
layer to stabilize wear
resistance and tool life while
delivering a consistently high
quality surface finish whereby
sudden peeling or fracture are
avoided.
www.tungaloyamerica.com
The cutting tools can
handle a variety of materials
including unalloyed and alloy
steel, cast steel, stainless
ferritic and martensitic steel,
as well as ductile cast iron.
www.walter-tools.com/us
ÒWIDIA
Improved wear
resistance
Widia Victory turning grades
include 10 different grades
and 14 different geometries,
including five new chipbreaker
designs. The inserts employ
coating technologies to
improve wear resistance and
allow for higher speed and
feed capabilities. Additional
post-coat treatment provides
increased cutting edge
toughness to reduce the
depth of cut notching and
extend tool life.
www.widia.com
Ø6
Corner
Rounding
and Back
Chamfering
1-800-465-5743
[email protected]
13-04-17 6:48 AM
Â
QUALITY | Multisensors
A Quality Edge
BY
MARY
SCIANNA
Multisensor technology gives Ontario blow mouldmaker a competitive edge
ISTAKES ARE COSTLY in
manufacturing, and in today’s
competitive environment,
your mistake may mean a new
customer for your competitor.
It’s why quality’s role in
manufacturing continues to grow and
why manufacturers like Garrtech Inc.,
a blow mould manufacturer in Stoney,
&UHHN21KDYHPDGHVLJQLÀFDQW
investments in quality control.
For Garrtech, the investment
was an approximate $175,000 Zeiss
CMM, the Contura G2, equipped with
multisensor technology. The automated
measuring system, purchased and
installed in February 2012, replaced
an older CMM from another supplier
that could not keep up with changing
demands from customers for tighter
tolerances and faster quality reporting.
The CMM was purchased from Zeiss’
M
Canadian distributor, Elliott Matsuura
Canada Inc., Oakville, ON.
“Our machines, several of which
have probes on them, are quick, and
our machinists are skilled at their
work, but I [quality department] was
the bottleneck, “says Tina Brogaard,
quality assurance manager at Garrtech,
referring to the situation before the
new CMM was installed. “It was
imperative for me to have four days to
GRP\FRPSOHWHÀQDOLQVSHFWLRQEXW
now with the new CMM, I’ve cut that
time to a day or a day and a half.”
The CMM is equipped with
three probes loaded on Zeiss’ MSR
mini MultiSensor rack (the CMM
can be equipped with a second rack
and additional probes). The RDS
articulating probe allows the probe
to move, scan and measure in all
angular positions. A camera, the
ViScan, for visual inspection, has the
ability to view at 5, 10 and 20 times
PDJQLÀFDWLRQ*DUUWHFKLVXVLQJWLPHV
PDJQLÀFDWLRQ:KHQHTXLSSHGZLWK
the RDS, it allows for measurements
in all spatial directions without having
WRUHFKXFNDSDUW:KLOHWKH&00
is automated, Garrtech can change
SUREHV´RQWKHÁ\µYLDWKHWRROUDFN
or manually if required, adds Brogaard.
The CMM also comes with Zeiss’
Calypso software, which Brogaard
describes as “absolutely fantastic”
because of its user friendliness. The
:LQGRZVEDVHGVRIWZDUHGHYHORSV
WKHPHDVXULQJWDVNVDQGWKHIHDWXUH
oriented interface makes it easy to use.
Calypso offers a common interface for
measuring 3D parts when different
sensors are being used.
Brogaard estimates the new CMM
KDVFXWÀQDOLQVSHFWLRQWLPHE\WR
often forced to buy multiple stand-alone devices.
Metrology equipment advances means
multisensor devices now have the ability
to offer more data generated quickly and
automatically, which in turn cuts the time
and cost associated with such tasks in a
quality department.
“The benefits derive from sensor integration
with the CMM hardware and software platform,
the ability to seamlessly switch from one
sensor to another within a measurement plan,
and the ability to evaluate data from multiple
sources within that measurement plan,” notes
John Pearson, technical sales engineer with
Carl Zeiss Industrial Metrology, Brighton, MI,
who spoke with Shop Metalworking Technology
for an article on multisensor technology in our
May 2012 issue.
Why Multisensor Technology?
Multisensor technology is defined
as a measurement system with
two or more sensor options for
data acquisition.
Multisensor technology makes sense in
today’s competitive market. A single sensor
can’t measure every part feature and provide
every measurement function and parameter
a customer may require, so a manufacturer is
Quality.indd 36
13-04-17 6:50 AM
50 per cent, and she’s now
able to produce faster and
better customer reports with
key quality data.
“Our customers are
adamant about reports and
the quicker I can provide
them with the information,
the quicker we can start
machining the part. Our
customers have never
the time I used to spend on
data input.”
:LWKWKHROGHU&00
there was no automated
visual scan; Brogaard
performed manual scans
with an eye loop equipped
with a scale. For every
measurement, Brogaard
would have to shine a light
on the part being measured,
Best In Class!
The Zeiss
multisensor CMM has
cut final inspection time
by 40 to 50 per cent,
says Tina Brogaard,
quality assurance
manager.
Achieve record times in your production by full cost
control, transparency and maximum efficiency in
production processes.
Our three compatible software packages with
TMS Tool Management Solutions guarantee a smooth workflow
and are key to a cost-effective manufacturing.
doubted what we produce
in terms of quality, but
now we have another fully
automated, precise tool
that backs up what our
machinists are doing.”
The other aspect of
having a CMM with
multisensor technology is
customer delivery, adds
Brogaard.
´:KHQRXUFXVWRPHUV
come in for inspection we
have reliable data with all
the critical dimensions they
require, all in one report and
I can generate that report
quickly, which has cut down
do the manual scan with
the eye loop and then write
down the measurement.
“I would have to do
this on different parts and
when I had 19 moulds, for
example, times two, I’d
be looking at hundreds of
measurements by eye and
that was time consuming
and it hurt my eyes.”
The CMM has been in
operation for more than a
year and has run smoothly
ever since, but Brogaard
says she’d like to add more
capability.
“Zeiss offers so many
Learn more at one of our upcoming Lunch & Learn Workshops visit our website for a complete list of events and registration!
www.zoller-usa.com
ZOLLER Inc. - PH: (734) 332-4851 - Email: [email protected]
Quality.indd 37
37
13-04-17 6:50 AM
Heinman Machinery Ltd.
6105 Kestrel Road, Mississauga, ON | Tel: 905.564.9479 |
CNC HORIZONTAL
BORING & MILLING
MACHINES
HB-110-20T
79”x59”x55” XYZ travel
35HP
2500rpm
Fanuc OiMD
60 tool ATC
Bed Type Mills
CS-VBM-5VHL Vertical & Horizontal
CS-VBM-5VL Vertical
86.6”x20” table
CS-VBM-4V
75”x18” table
Metric ball screws
Pneumatic clamping
Milling Machine
CS-G450B
Vertical & Horizontal
Table 51”x12”
ISA40, 5HP & 7.5HP
3-Axis power feed
Rapid traverse
CNC VERTICAL
MACHINING
CENTRES
MCV-300
10HP
8000rpm
Fanuc Oi-Mate MD
16 tool ATC
V-700
27.5”x15.7”x21.6” XYZ travel
10HP
10000rpm
Fanuc Oi-Mate D
24 tool ATC
MCV-1000
20HP
8000rpm
Fanuc Oi-MD
24 tool ATC
CNC VERTICAL MACHINING CENTRES
Double Column X-Axis
KMC-3000SV(B) 127”
KMC-4000SV(E) 166”
KMC-5000SV
206”
CNC Lathes
FCL-820
FCL-1028
Slant bed
Fanuc Oi-Mate
or Oi-TC
Hydraulic
10-station ATC
8”/10” chuck
Heinman_MayDPS.indd 38
13-04-17 6:57 AM
At Heinman Machinery we ensure that you receive a machine manufactured in Taiwan that will not only
be accurate today, but one that will maintain its value long after. We supply a full range of CNC and
conventional metalworking equipment for a diverse customer base and we look forward to serving you.
Visit our showroom, machines are on display and under power for demonstrations. OVER 250 machines in stock.
| [email protected] | www.heinmanmachinery.com
CNC VERTICAL MACHINING CENTRES
MCV-1020BA
40”x21.6”x22” XYZ travel
15HP
10000rpm
Fanuc OiMD
24 tool ATC
MCV-1100
43”x23”x22”XYZ travel
25HP
10000rpm
Fanuc 21iMB
24 tool ATC
Cylindrical Grinders
CGP-816
CGP-1224
CGP-1240
Heinman_MayDPS.indd 39
MCV-1200
47”x23.6”x19.7”XYZ travel
15HP
10000rpm direct drive
Fanuc 0iMD with high speed
machining
MCV-1450
57”x29.5”x29.5” XYZ travel
25HP
6000rpm
Fanuc OiMD
32 tool ATC
V-43MD
43.3”x23.6”x20” XYZ travel
20HP
15000rpm
Fanuc 18iMB
24 tool ATC
Automatic Surface Grinders
FSG-2040ADII
FSG-2060ADII
FSG-2460ADII
MCV-1700 67”x33.5”x29.5” XYZ travel
MCV-2100 82”x33.5”x30” XYZ travel
MCV-2600 102”x33.5”x30” XYZ travel
25HP / 30HP / 30HP
6000rpm
Fanuc control
32 tool ATC
V-2000
Double Column
80.7”x45.3”x27.6”XYZ travel
30HP
15000rpm
Fanuc 18iMB
30 tool ATC
Automatic Surface Grinders
FSG-1224ADIII
FSG-3A818
FSG-1632ADIII
FSG-3A1020
FSG-1640ADIII
FSG-3A1224
Handfeed Surface Grinders
Grinders that will last for years
ACCU-618SP Super Precision
FSG-618M
Includes: 6”x18” Walker Neo
Micro magnetic chuck
13-04-17 6:57 AM
Â
QUALITY | Multisensors Î Î Î Î continued from page 37
tools and I’ve looked into the laser
scanner. It would give us the ability
to better scan 3D contours and would
also be good for reverse engineering.
I can do this type of measurement
now, but it would be quicker with a
laser scanner.”
The multisensor technology has
the added advantage of allowing
manufacturers to add new tools when
requirements change.
Longer term, Bogaard says Garrtech
is looking at merging quality processes
LQOLQHDQGRIÁLQH
´:H·OOEHDEOHWRFRPPXQLFDWH
between the machines equipped with
probes in our shop with the quality
GHSDUWPHQW:H·UHQRWWKHUH\HWEXW
we’re working on this.” SMT
Making Blow Moulds
for 22 Years
www.garrtech.com
www.elliottmachinery.com
www.zeiss.com
Garrtech is looking at merging quality processes inline
on the shop floor and offline in the quality department.
In an industry that has seen many
shops driven out of business because
of low cost tooling from India and
China, blow mould manufacturer
Garrtech Inc., Stoney Creek, ON,
has found a recipe for success:
investing in technology, machinery
and engineering services difficult to
replicate by offshore competitors.
The blow mould manufacturing
services include part design, mould
design and construction.
The 35,000 sq ft plant operates
19 CNC multi-axis machining centres
equipped with an automated tool
crib system for increased machine
uptime and productivity. An in-house
engineering department with reverse
engineering and 3D model generation
capabilities supports the shop, as
does a quality department equipped
with the recently purchased CMM with
multisensor technology.
Highest Precision-Tightest Tolerance
ID/OD Grinding
VOUMARD-UNCOMPROMISING QUALITY,
PRACTICAL SOLUTIONS TAILORED TOWARD YOUR NEEDS.
Perfectly suited for production of small to large-sized parts, powered by Fanuc linear motors. Performing multiple internal and external
grinding operations in a single clamp. Parts of almost every geometry are processed.
Multi surface ID / OD grinder for work up to 32” (800 mm) diameter and 59” (1500 mm) in length. Capable of up to 4 grinding spindles
with speeds from 3,000 to 120,000 rpm mounted on a hirth coupling turret. High precision automatic taper axis under the work for
grinding angles and quick taper adjustments. Successful installations found in job shop industries to large aerospace companies.
PETER WOLTERS, a global leader supporting your product in any country.
110 CNC
130 CNC
PETER WOLTERS of America Inc.
509 N. Third Avenue
Des Plaines, IL 60016 - 1196
Phone: (847) 803 - 3200
Fax: (847) 803 - 9875
[email protected]
www.peter-wolters.com
150 CNC
Quality.indd 40
13-04-17 6:50 AM
Â
FABRICATING | Punching
BY
MARY SCIANNA
A 2 FOR 1 DEAL
{
Punch laser
combination
machine
opens doors
to new
business
LIAS CUSTOM METAL
Fabrication Ltd. in Vaughan,
ON, has something all custom
job shops should have to succeed:
owners who consistently invest in
technology to diversify and grow.
The strategy is working for brothers
and owners Fadi and Sam Emeid, who
formed the business in 1994. Last year,
the company doubled in size moving
from a 40,000 sq ft plant into a 80,000
sq ft one and investing approximately
$1.5 million in a lights out sheet metal
cutting centre from TRUMPF.
At the heart of the new technology is
TRUMPF’s Trumatic 7000 large format
punch laser combination machine.
“We have punching and laser
machines but when we saw the
demonstration of the punch laser combo
machine at other facilities, we knew
the technology would be good for our
business,” explains Fadi Emeid. “The
most important component for me was
the automation that allows us to run the
E
The Problem
Improving competitiveness
in job shop market
The Solution
Investing in
flexible automation
THE EQUIPMENT
machine overnight and on the week-end.
It’s enabled us to be more competitive,
diversify, and to offer more reliable
service to customers.”
Elias Custom Metal Fabrication has
FRPHDORQJZD\VLQFHLWÀUVWRSHQHG
its doors in a 4,500 sq ft facility. In
addition to the lights out punch laser
combo machine, the full service
machine shop is equipped with two
TRUMPF laser cutting machines,
punching machines (a Strippit turret
punching centre, a Pierce All punch
machine and a Euromac notcher),
press brakes from TRUMPF, Niagara
and All Steel, and a shear from All
Steel. It also offers welding, rolling,
milling, machining, plating, painting,
and assembly capabilities.
Before investing in the punch laser
combo, Elias had been investigating a
tube laser cutting machine, also with
lights out capability.
“We had an order in place and then
in 2009 the economy went south and
THE TRUMPF TRUMATIC
7000 is a punch laser
combination machine that
offers scratch-free sheet metal punching
and C02 laser cutting. The configuration
in Elias Custom Metal’s facility is a 1.6 m
machine that offers a 1.5 x 3 m (5 by 10
ft) working range. The automated sheet
metal fabricating system is equipped with
a dual cart loading system for loading
raw materials at one end and a dual
cart unloading system for finished part
extraction at the other end. The system
is designed for lights out operation
and includes TRUMPF’s GripMaster for
skeleton removal.
For punching, it has a maximum stroke
rate of 1200 1/min and for laser cutting,
it’s equipped with TRUMPF’s TruFlow 4 kW
C02 laser.
Fab1_Punch.indd 41
41
13-04-17 6:46 AM
Â
FABRICATING | Punching
www.eliasmetal.com
www.us.trumpf.com
Fadi Emeid,
beside the punch
laser combo
machine, says the
technology has
opened the doors
to new business.
we put the brakes on that purchase,”
recalls Fadi Emeid.
“Then a year later we re-evaluated
our investments and decided instead
to go with the punch laser combo
machine because of the diversity it
could offer us by opening new doors
to new customers and also allow us to
do more innovative work.”
The automated punch laser system
has been in place a year now and
while there have been growing pains
because of the transition of going to an
automated environment [programming
and managing more job orders on a
faster processing system), Sam Emeid
says the machine has helped Elias
PDNHVLJQLÀFDQWSURGXFWLYLW\JDLQV
“Before certain parts required work
on three different machines [shearing
blanks, punching and laser cutting)
and now we can make these same parts
on one machine and that is a huge
productivity gain.”
7KHÁH[LELOLW\RIWKHDXWRPDWLRQLV
also a plus. The machine can run lights
out with only punching, only laser or
Growth of Punch Laser
Combo Machines
PUNCH LASER TECHNOLOGY
is picking up steam in Canada,
says Charlie Hardie, sales
manager for Central Ontario for TRUMPF
Canada, Mississuaga, ON. Hardie, who
is the TRUMPF rep for Elias, says punch
laser technology didn’t take off when it
first emerged in the market because the
technology was not reliable.
“There was uncertainty around
vibrations and the stability of the laser, but
technologies and designs have evolved to
today where we have sound technology.
Our resonator floats on an airbag so when
the machine goes into punching mode, the
resonator floats on the airbag to absorb a
lot of the shock and then resides itself for
the laser portion.”
He adds that customers are beginning
to take advantage of the productivity gains
the technology can bring to a shop.
“There is greater interest in the
technology now because there is
confidence in the reliability of it; it offers
flexibility and productivity gains that were
not there before,” adds Hardie.
both, depending on the order.
The punch laser machine has opened
doors to new markets and customers.
While the original tube laser machine
the company was considering would
have also run lights out and created
more business opportunities, Fadi says
he and his brother Sam are happy with
the decision to go with the TRUMPF
machine, attributing part of the decision
to the long-term relationship Elias has
had with the supplier. Elias purchased
LWVÀUVW75803)ODVHU\HDUVDJR
“We have built a good relationship
with TRUMPF and we are loyal
customers because they give us
WKHVXSSRUWZHQHHG:HKDYHÀYH
TRUMPF machines and we’re
looking at another press brake for
new orders.” SMT
For more information on fabricating technologies, visit Shop Metalworking
Technology’s FABRICATING ZONE online at www.shopmetaltech.com.
Fab1_Punch.indd 42
13-04-17 6:46 AM
CAD/CAM SOLUTIONS
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Automatic EdgeStart Nesting
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MULTI-LINGUAL SOFTWARE
Since 1975 SHOPDATA SYSTEMS has been providing
fabrication software tools with one goal...one objective; easy to
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manage your jobs by using ShopData's Production Tracking,
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With SHOPDATA'S INVENTORY TRAC module you can enter
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Fab1_Punch.indd 43
13-04-17 6:46 AM
Â
FABRICATING | Punching MetalTech Report
ÎÎÎÎ
ÎLVD STRIPPIT
ÎSALVAGNINI
1750 strokes/min
Unmanned fabricating
The VX series of CNC turret
punch presses are designed
with a high speed 20
tonne hydraulic ram
with a large
48-station
turret and
table,
capable of handling sheet
weights of up to 330 lb (150
kg). The automation-ready
machines can be equipped with
a Compact Tower (CT-P) for
loading, unloading and storage of
raw material and finished parts.
It delivers fast axis speeds of up
to 530 hits/min on 1 in. (25 mm)
centres and up to 1750 strokes/
min.
www.lvdgroup.com
The Salvagnini S4Xe punching
and shearing centre features a
patented multi-press head that
eliminates the slower, fetch
and carry system employed by
turret presses. The stationary
index speed and 150 m/min
sheet positioning speed. The right
angle shear has a servo electric
actuation system of its own,
which makes shear movement
at the same time fast and fully
controlled. Material thickness
in shearing can be up to 5 mm
(Al), 4 mm (mild steel) and 3
mm (stainless steel). Automatic
loading has been integrated, and
also part removal and sorting are
automatic. The SGe reduces total
manufacturing time by 60 per
cent and saves one blank sheet
out of every 10.
www.primapower.com
ÎMATE TOOLING
Two-piece sheet fastening
Mate’s new
Hybrid
Threadform
forming tool
for punch
presses
provides a new solution for
fastening two pieces of sheet
metal together without tapping or
secondary operations.
Designed for use when the
material thickness is greater
than the screw pitch, Mate’s
Threadform forming tool thins the
material in the centre of the form,
creating a threadform helix so the
material fits between the pitch
of the screw head in just one
operation
www.mate.com
ÎPRIMA POWER
60% cut in fabricating time
The Shear Genius integrated
punch/shear combination
features a servo electric 30 ton
punching machine with 1,000
hpm stroke speed, 250 rpm
punching head, with between
76 and 96 active punches that
can fire independently, provides
manufacturers with short cycle
times and long tool life. The
built-in shear makes the machine
the ideal component in a lean,
unmanned metal fabrication
production system.
www.salvagnini.com
continued from page 42
ÎWILSON TOOL
Thick turret tooling
The HPX guide assembly for
thick turret tooling combines
tool-free punch adjustments with
replaceable punch technology
in an easy-to-use package.
The guide assemblies combine
the EXP punch technology (a
standard holder with universal
punches) with the company’s
HP2 punch adjustment
capabilities.
www.wilsontool.com
FIELD NOTES
PRODUCT: AMADA AE2510NT
END USER: J.I.T. Sheet Metals
J.I.T. Sheet Metals, North York, ON, is a sheet metal fabricator that has
carved a niche in the HVAC (heating ventilation and air conditioning)
business, manufacturing components and ductwork. Owner Fred Dametto recognizes the value of investing
in technology; in the past year and a half he’s made a substantial investment in his 20,000 sq ft shop,
with the recent being the installation last December of an Amada AE2510NT punch machine with Amada’s
Alpha Guide tooling. While Dametto could have purchased the machine from any supplier, he selected
Amada because he says it’s a name he could trust. “I purchased two Amada machines used, one 15 years
ago, and the other one five years ago, and they’re good machines. I trust the name and though they’re not
the cheapest machines on the market, people say they’re the Cadillac of machines.”
The Amada AE2510 NT turret punch press has a punching force of 200 kN with Y and X axis travels
of 1270 and 2500 mm respectively. An AC servo motor drives the ram, eliminating the hydraulic power
supply and the hydraulic fluid chiller. Electrical consumption is less than one half of comparable hydraulic
machines; it requires only a 19 kVA power hookup. The drive system delivers up to 370 hits per minute.
Dametto says the machine is much faster than other punching machines he’s used. “We have a plasma
machine where we would burn materials and now we’re able to do everything on the Amada. It’s a more
advanced machine so we can do many more products such as filter racks for furnaces, which is one of the
main reasons we purchased the machine.”
The Amada punching machine has helped J.I.T. improve productivity, but Dametto is looking to make
further improvements in his shop, and is in the process of retooling the plant. “I’m looking at an automatic
loader for the punching machine because it will eliminate manpower.”
The AE-series machines are available with Amada’s “Triple-Track” high capacity 45 or 51-station turrets
equipped with four auto-index stations. It allows fabricators to load the turret with enough tools (up to 4.5
in./114.3 mm in diameter) to run multiple jobs without tool changes.
www.amada.com
Fab1_Punch.indd 44
13-04-17 6:46 AM
Â
WELDING | Process Technologies
ARTFORM.
Why Laser Weld
Keyhole welding processes offer higher power densities and
faster welding speeds than conduction welding technologies
BY CHRIS PILCHER
HE MAJORITY OF joining
techniques use conduction
welding and typically add excess
heat to a part, creating metallurgical
damage to the substrate. Other welding
techniques use high power densities
on small areas 0.008 in. (0.2 mm), such
as Electron Beam and Laser Beam
Welding (EBW and LBW).
Laser beam welding, the focus
of this article, is a more economical
choice because it doesn’t operate
under a vacuum, as does Electron
Beam welding.
T
The beam is focused with an optical head. The
beam, delivered via a laser resonator, travels
through a focusing lens and converges on the part.
How it works
Laser welding relies on an incredible
amount of power and power density
focused on a small spot. Power
densities are typically more than 1 x
106 Watts/cm2. The laser vaporizes
the material before it’s conducted into
the substrate, forming the keyhole.
The laser moves the keyhole along the
part, melting material in front of the
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Laser_welding.indd 45
around the sides of it, solidifying the
keyhole. The result is a small weld
with little distortion.
The light in the laser beam is
different than normal incandescent
light because it is monochromatic,
collimated (meaning it travels in a
straight line and doesn’t disperse) and is
coherent with all photons travelling in
the same direction.
Six Benefits
FAST WELDING SPEEDS: Compared to
GMAW welding speeds, laser welding
can be five to ten times faster.
LOW THERMAL DISTORTION OF PART: In some
cases, parts are finished machined and
then welded together using the laser,
while maintaining tolerances.
NO FILLER WIRE REQUIRED: Typically, this is
not required and the parent material of
the part becomes the filler wire.
NON-CONTACT WELDING: No electrical
(grounding) or mechanical connections
are required, however, zero gap
conditions are best.
CREATIVE CHALLENGE.
CREATIVE SOLUTION.
From architecture as art, to everything in
between and beyond, Mate Special
Application tooling provides fabricators with
the solutions needed to get the job done.
Mate Precision Tooling. Forming
the future since 1962. Find out more by
calling 1-800-328-4492 or visiting mate.com.
RELIABILITY: Consistency is paramount
with the laser. An increase in speed of
10 per cent can translate into a 10 per
cent reduction in depth penetration.
PROCESS FEEDBACK FOR QUALITY CONTROL:
Inspections systems use through-theoptics techniques to determine, in real
time, if the weld is acceptable.
13-04-17 6:44 AM
Â
WELDING | Process Technologies
The laser beam focus is accomplished with
an optical head. The laser resonator delivers
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The beam gets collimated, travels through a
focusing lens, and converges on the part.
The fiber laser
Fiber laser technology emerged in the late
1990s and has been making inroads into the
industry because it is considered more energy
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50 kW and with prices down almost a third of
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technology more accessible to manufacturers.
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Aluminum Extrusion Maker Increases
Friction Stir Weld Capacity
Sapa Extrusions North America able to perform
largest, two-sided panel welds in the continent
ALUMINUM EXTRUSION MANUFACTURER
Sapa Extrusions North America, based in Rosemont, IL, with production
facilities in Mississauga, ON, and Montreal, QC, can now offer customers
two-sided welds up to 55 ft (15 m) long with expansion capability to 75 ft (23 m) long
in aluminum material up to 30 mm thick.
Sapa is able to offer this service because of a recent joint development project with
H.F. Webster, which specializes in manufacturing friction stir welded products and
equipment.
Until now, friction stir weld capacity in North America was generally limited to onesided welds, according to Sapa.
“Friction stir welding is a tremendously valuable tool for our customers,” says Kevin
Stuban, director of fabrication for Sapa Extrusions North America. “Our relationship
with H.F. Webster will now provide Sapa with long-term dedicated capacity to perform
some of the largest two-side panel welds in North America.”
Applications for large scale friction stir welded panels include passenger train floors,
sides and roofs, marine panels and bridge decks.
www.sapagroup.com/na
13-04-17 6:45 AM
13-04-17 6:45 AM
Â
WELDING | Process Technologies Î Î Î Î continued from page 46
materials such as Erbium, which will produce light in the 1.5 micron
wavelength. Changing the doping material to Thulium will produce a
wavelength of light that is 2 microns. Why do this? Each wavelength
of light will absorb into each material at a different rate. Two microns,
for example, has an advantage for welding clear plastics. On the other
hand, 1 micron will absorb into metal better than CO2. It is important to
understand that not one wavelength of light will take over the market.
Designing lasers for welding
Welding geometries must be designed for lasers. Trying to use a joint
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gap between the components being joined as a result of the addition
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Subsequently, lasers rely on little to no gap between the parts. Typical
joint geometries found in laser welding include butt, overlap, T and
Fillet joints. SMT
Chris Pilcher is regional sales manager-Canada, for IPG Photonics Corp.
www.ipgphotonics.com
Welding Processes
MetalTech Report ÎESAB
Multi-process power source, feeder
Warrior is a multi-process power source and feeder
for GMAW (MIG), FCAW (Flud-Cored), SMAW (Stick)
and GTAW (TIG), as well as ACAG (Arc Gouging) that
delivers up to 500 amps at 60 per cent duty cycle. It
carbon arc gouges with electrodes
up to 3/8 in. (9.5 mm) diameter,
welds .030 – 5/64 in. (0.8 - 2 mm)
flux-cored and solid wires, and
has a full range of SMAW (Stick)
capabilities with excellent 7018
and 6010 performance. Warrior’s
durable external body withstands
the elements. Its’ IP23 rating is designed to endure
harsh outdoor environments, up to 60° driving rain.
Ergonomically designed handles are built to withstand
mechanical hoisting, and double bend 14 gauge steel
side panels protect Warrior against collisions and drops.
www.esabna.com
13-04-17 6:45 AM
ÎGULLCO
Remote control oscillator
The portable design of this
heavy duty remote control
oscillator makes it easy to
handle and setup. This compact
unit increases productivity and
improves weld quality by providing
precise automation of welding
applications. Mounted on a KAT
travel carriage, the oscillator
imparts pendulum, tangential or
step motion to the welding gun
with adjustable stroke widths,
sprayable protective
coating that prevents
spatter adhesion on
MIG/MAG welding
equipment for up
to eight hours with
just one application.
It’s designed for
use on manual and
automatic MIG/
MAG welding, laser/
plasma cutting and
spot welding equipment. By
delivering physical and thermal
protection, it increases welding
equipment service life by four to
five times, and reduces the cost of
consumables by up to 70 per cent,
says Henkel. The coating sprays on
easily and dries in seconds.
www.henkelna.com
ÎLINCOLN
speeds and dwell times. Also,
a wide range of weld patterns
can be produced. This advanced
oscillation package is designed
to minimize weld defects such
as poor penetration, incomplete
fusion, overlap and undercut. By
combining welding gun oscillation
movement with the precision
controlled travel speed of the KAT
carriage, up to 10 weld programs
can be produced and stored.
www.gullco.com
ÎHENKEL
Ceramic shield
Loctite SF7900 Ceramic Shield
for welding is a silicone-free
GMAW wire for trailer
manufacturing
SuperGlaze 5356 is an engineered
aluminum alloy GMAW wire
designed for applications in the
trailer manufacturing industry.
The alloy system provides optimal
puddle clarity and arc action, as
well as excellent wetting for semiautomatic and high productivity
automatic applications.
The company claims the
GMAW wire provides excellent
performance on high speed
groove welds on formed truck
panel applications, as well as
robotic fillet welds on trailer
tanks, requiring minimal post-weld
clean-up. The wire is available in
feature allows operators to jog
wire or purge gas and preset gas
pressure at the regulator before
welding. The welder retains the
Auto Gun Detect feature. It has a
direct connection for Miller 10-pin
XR-Aluma PRO and XR Pistol Grip
air cooled push-pull guns.
www.millerwelds.com
standard diameters of .035 in. (0.9
mm) and 1/16 in. (1.6 mm) wound
in 1 and 20 lb (.5 and 9 kg)
plastic spools, as well as 16 lb (7.2
kg) steel spools.
www.lincolnelectric.com
ÎMILLER
Aluminum welding
Millermatic 350P Aluminum MIG
welder is a dedicated aluminum
welding power source with a
true torque push-pull design,
electronic wire spool brake, Trigger
Schedule Select and synergic
capabilities in MIG and pulsed
MIG weld settings. It features
six aluminum-dedicated pulse
programs, including new settings
for .040 wire. A jog and purge
ÎVICTOR
TECHNOLOGIES
TIG, stick welding
The Thermal Arc 186 AC/DC
inverter for HF TIG, Lift TIG and
Stick welding features 15 amps
more TIG welding power than
its predecessor and features a
new digital operator interface. It
provides a welding output of 10 to
200 amps with a duty cycle of 20
per cent when TIG welding 200
amps/18 volts. Stick welding duty
cycle is 16 per cent when welding
at 120 amps/26.6 volts and is
suitable for welding with 6011,
6013, 7014, 7018 and other
electrodes up to 5/32 in. (4 mm).
www.victortechnologies.com
See us at WMTS
Booth 1300
49
13-04-17 6:45 AM
Â
CUTTING TOOLS |
Automotive
Cutting it
Sandvik
Coromant's CoroDrill
460-XM, one of several
cutting tools used in
automotive machining
applications.
Machining automotive
parts is a game of
inches and speeds,
with no time or room
for error
BY ANDREW BROOKS
Closer
IGHTER. SMALLER.
STRONGER. HARDER.
FASTER. It might sound like
a mixed-up version of the Olympic
Games motto, but it’s actually just
a (partial) list of the terms and
conditions big car makers
impose on the massive
automotive supply chain
that provides them with
parts. Lighter,
smaller parts
that don’t
compromise
on strength,
new metals and
composites that are harder
to machine, all produced to tighter
deadlines and within faster cycle times.
“There’s never enough time to
do everything you need to do in
automotive in terms of product
development and prototyping–and even
in production,” says Mike Whatling,
plant manager for Niagara Precision
Ltd. “It’s very fast-paced and a lot of
times you only get one shot at it, which
puts a lot of pressure on job shops as
well as the production facilities.”
One of the primary challenges
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automotive parts is the increasing
use of advanced high-strength
L
steels (AHSS) in the automotive
manufacturing industry. These
advanced steels are becoming
increasingly important as auto
manufacturers seek to produce cars
that weigh less, employing parts
and components that are smaller
and lighter, but that continue to
meet the same–or even tougher–
strength requirements.
In addition to favouring the use
of AHSS, the automotive industry's
demands have also driven research and
development into advanced composite
materials, and as these make their
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proven to pose problems from the
point of view of machining. Job shops
are often on their own when learning
how to adapt their processes to cope
with new material characteristics.
“A lot of composites that are coming
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period,” Whatling says. “There’s not
enough information out there, or the
tooling doesn’t exist for machining
these components. So everybody
develops their own procedures for
machining exotics.”
At least there are some ways
Autocutting.indd 50
13-04-17 6:40 AM
Best partner of
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in an ever-changing
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TSS-30/55C
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Autocutting.indd 51
13-04-17 6:40 AM
Â
CUTTING TOOLS | Automotive Î Î Î Î continued from page 50
for industry innovators to recoup some of the costs of
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and Experimental Development (SR&ED) federal tax
incentives and credits. And educational institutions with
automotive and engineering faculties are available to support
research and development. But ultimately, Whatling
says, it comes down to a matter of trialing new
procedures in the plant.
“The more exotic metals create new
issues for machining techs that are
evolving as the components are being
designed and produced,” Whatling says.
“From the prototyping standpoint–which
is a lot of what we do at Niagara Precision––
enges
we’re faced with some pretty serious challenges
as far as being able to machine these exotic materials
and composites.” Hardness is one challenge, material
composition is another, and the continual reduction
in part size while strength characteristics are maintained
means it’s always getting tougher to machine components
without encountering distortions and tolerance problems.
“Many of the composites we’re seeing are all different,”
says Randy McEachern, product and application specialist,
holemaking and tooling systems for Sandvik Coromant
Canada, Mississauga,
ON. “Nowadays many materials are
M
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PDQ
see
se any two materials that are the same, which
means for optimum performance, the tools you
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material.”
Sandvik does have some general purpose
tooling,
McEachern says, but he estimates that
t
when
wh it comes to machining composites, most tools
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KDYHWR
be working on. The composites now offer the strength to
(light) weight ratio so sought after by the auto makers, a big
improvement over the early days when composite materials
arrived. “They’re becoming more reliable,” McEachern says,
Sparking your
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ABB Inc., Robotics
201 Westcreek Blvd.
Brampton, ON,L6T 5S6
905-460-3418
[email protected]
Autocutting.indd 52
13-04-17 6:40 AM
Shaving cycle times is a big challenge in automotive work and when you're
dealing with near-net-shape parts, there's not a lot of material on them to
rough out, says Iscar's Steve Geisel, senior product manager. Image: Iscar
“but users still have to know their stuff.”
For Steve Geisel, senior product manager at Iscar Tools,
Oakville, ON, shaving cycle times is a paramount challenge in
automotive work, thanks in large part to the sheer numbers.
“These are very high volume runs,” he says, “and they’re dealing
with near-net-shape parts–a lot of forgings, castings, parts that
don’t have a lot of material on them to rough out. But it’s worth
saving whatever time you can. When it costs $60 to $180 an hour
to run one of these machines (that's $1-$3/min), this can quickly
add up to a lot of money.”
Reducing cycle times means faster cutting, says Mark Hatch,
product director of taps and thread mills for Emuge Corp., West
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times faster than conventional tools.
“The speed is achieved through unique design
characteristics of the taps in areas such as relief, back-taper,
OHQJWKRIWKUHDGDQGÁXWHJHRPHWU\µ
Hatch estimates if tapping is reduced by ten minutes per hour
at a machine rate of $150, a manufacturer can achieve annual
Next
INNOVATION
Mitutoyo Digital Scale and DRO Systems
M
P
Providing
leading-edge digimatic scale and
DRO system measurement solutions to meet the
D
c
changing global market demands for innovative
design and manufactring techniques.
d
Absolute System Patented by MITUTOYO
Mitutoyo Canada Inc.
Digi
Digimatic
imattic Scale Units z Enc
Enclos
Enclosed
osed
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ales z Absol
Absolute
lutte Linear
LiLinear Scales z OOpenn Type
Type LLinear
inear Scales z DROO Counters
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z DRO Pa
Packages z Accessories
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ccess
essori
oriees
es z Image
Image Correlation
Cor
Encoder
Autocutting.indd 53
www.mitutoyo.ca
Toronto (905) 821-1261
Montréal (514) 337-5994
13-04-17 6:40 AM
Â
CUTTING TOOLS | Automotive
savings of $125,000 and increase capacity by 833 machine hours.
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DXWRPRWLYHSDUWVDUHQ·WF\OLQGULFDOLQSURÀOHVRLW·VQRWDOZD\VSRVVLEOH
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VDYLQJV<RXUXQPXOWLSOHWRROVDWDWLPHRU\RXJHWDKLJKHUGHSWKRIFXW
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*HLVHOVD\V,VFDUIRFXVHVRQRSWLPL]LQJPDFKLQLQJSURFHVVHV
THE CUTTING EDGE
We use Premium Micro grain solid
carbide for longer tool life and
increased feeds and speeds.
Tools are stocked uncoated
and ALTiN coated.
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EDODQFLQJWKHVSHHGIHHGDQGGHSWKRIFXW´,W·V
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DQGDQRWKHUODVWVDQGWKDW·VDOO\RXFDQGRµKH
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thousands, hundreds of thousands and even
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FRVWFDQFUHDWHSLWIDOOVIXUWKHUGRZQWKHURDG
Solid carbide
grooving, boring and
threading tools.
Designs for threading, grooving,
PCD, and CBN-tipped inserts
Threadmills
Port tools
Set includes boring bar, 5 inserts,
5 screws, and a torx plus key
Available in coated AlTiN
or uncoated sub micrograin
carbide
Hardened steel head features
proprietary mechanical attachment...
no annealing from brazing heat
Pocket keeps chips away from
machined surface
Fits into SCI standard QHC coolant
tool holders
Inserts lapped and ground to fine finish
for maximum chip flow
Available in right-hand and
left-hand versions
Bars stocked with or without
locating flat...
Low profile screw keeps
chips flowing
SCIENTIFIC CUTTING TOOLS, INC.
110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] [email protected] / www.sct-usa.com
Emuge’s Mark Hatch estimates if tapping is reduced by ten minutes
per hour at a machine rate of $150, a manufacturer can achieve
annual savings of $125,000 and increase machine capacity by 833
machine hours. Image: Emuge
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LQVLVWVRQDYLDWLRQTXDOLW\VWHHO´,WHOOFXVWRPHUV
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ZLWKRIIVKRUHPDWHULDODQGZDQWWRXVHLWDQ\ZD\
,·OOGRLW%XW,PDNHVXUHWKH\·UHDZDUHRIWKH
Autocutting.indd 54
13-04-17 10:05 AM
potential problems.”
Invariably, Whatling says, the cheaper metals
prove to have inclusions or cold shuts that lead to
failure during post-machining tests. “So the parts
have
hav to be made
w
with something
else, which in
most cases is
a domestically
pproduced steel.
The
T purchase
price
pri may be lower
[for less
l expensive
metals], but
bu in the long
run the high
higher quality
material really is cheaper.”
in
Of course variation
v
material quality also impacts
tools. “Sometimes you get different
material batches coming in and it
has a huge impact on cutting tool performance,”
says Iscar’s Steve Geisel. “Where the material is
made will have a huge impact on how easy it is to
machine, which impacts tool life.” Geisel often
gets calls from customers who’ve seen tool life
drop 10 to 30 per cent. “When we go and have
DORRNZHRIWHQÀQGLW·VDQHZPDWHULDOEDWFKµ
Geisel says that Iscar–and he says this goes for
competitors too–builds so many checks and
balances into its own manufacturing that tool
quality is very high.
With machining centres being asked to take
heavier cuts at higher speeds, the programmability
of machines plays a huge role. “You’re dealing
with rapid feeds of over 1500 ipm now, where ten
to 15 years ago you were lucky if you had a machine
that would do 5 ipm,” Mike Whatling says. “The
technology plays a huge role in being able to
make these parts.” SMT
www.emuge.com
www.iscar.ca
www.niagaraprecision.com
www.sandvik.coromant.com
For more information
on cutting tool
technologies, visit
Shop Metalworking
Technology’s CUTTING
TOOL ZONE online at
www.shopmetaltech.com.
Andrew Brooks is a freelance writer based in Toronto.
[email protected]
Autocutting.indd 55
13-04-17 6:40 AM
Â
CUTTING TOOLS | Perspectives
Rethinking
Tooling Costs
Cutting tools represent only a fraction of total machining
costs, so how can you gain real cost savings?
BY
RONNIE
O’BYRNE
Visit Shop
Metalworking
Technology’s
BLOG ZONE
www.shopmetal
tech.com/blog for
more opinions.
Tooling costs in 95 per cent
effect is that you will reduce your overall cost
of machine shops represent
of manufacturing only by 0.6 per cent (20 per
approximately 3 per cent, on
cent of 3 per cent tooling costs).
average, of the total manufacturing costs.
Any areas where you see improved tool
This leads to two important questions:
life should be redeployed to an improved
1. If tooling and inserts represent only 3
production target. The real cost savings are
per cent of the cost of part manufactured,
achieved when businesses redeploy these
what benefits are there in cutting tool
advantages back into production. Increasing
companies providing 50 per cent improvement
speeds, feeds, DOC and metal removal rates
in tool life?
to improve cycle times is where real bottom
2. What advantage is there for a
line savings can be achieved.
manufacturing business to secure a 20 per
When tool life improvements are achieved
cent price reduction on tooling and inserts
the target should always be linked to reducing
from a cutting tool supplier−what would that
cycle times–to the extent that that the tool life
do to the bottom line?
and tooling costs remain the same and the tool
The answer? Very little.
life advantage is used up through increased
Everyone recognizes it
is important to “test” the
Increasing speeds, feeds, DOC and metal
performance of tooling and inserts
removal rates to improve cycle times is where
to ensure quality and performance.
But the next time you find yourself
real bottom line savings can be achieved.
with a new insert or milling tool
that provides a tool life advantage
speeds and feeds to reduce cycle times.
to your business, your manufacturing team
All cutting tool suppliers understand that
should redeploy the advantage into increased
speeds and feeds to reduce cycle times.
customers need to ensure value in the market
Here’s why: a 50 per cent improvement
and that we all operate in a competitive
in tool life will reduce the overall cost of part
global market. But the next time an engineer
manufacturing by 1.5 per cent (50 per cent of
or operator testing a tool tells you it is a
3 per cent of tooling cost).
“good grade” or has achieved 30 per cent
The same applies to negotiations regarding
improvement in tool life. Ask yourself, what
price of tools and inserts supplied.
can I do with that? SMT
Let’s say tomorrow you negotiated a deal
with all your suppliers to get a 20 per cent
Ronnie O’Byrne is general manager for Iscar
price reduction on every tool and insert
Tools Inc., Oakville, ON
supplied for the next 12 months. The net
www.iscar.ca
CT_Perspective.indd 56
13-04-18 9:41 AM
Heinman Machinery Ltd.
6105 Kestrel Road, Mississauga, ON
Phone 905.564.9479
[email protected]
www.heinmanmachinery.com
Bandsaws
Made in Canada
Verticut
115B
Horizontal
360SAHD Semi Automatic
280M Mitering
280S
Variable Speed
Milling Machines
Made in Taiwan
LC-185VS-B
or LC-185VSX-B
Table 50” X 10”
Travel X/Y/Z 31”/ 16”/ 15”
Taper R8 or ISA40
Motor 3HP or 5HP
Included:
8pc R8 German Collets or
German Collet Chuck Set with
10pc ISA40 Collets
Heidenhain 2-Axis Readout
Rapid up and down
Z-Axis Box Way
LC-1 1/2VS $8,950
Table 42” x 9”
Travel X/Y/Z 30”/12”/16”
Taper R8
Motor 2HP
Included:
Set of 8 R8 German Collets
LC-20VHS Vertical/Horizontal
LC-20VSG Vertical
Table 51” x 10”
Travel X/Y/Z 31”/ 16.5”/ 18”
Taper ISA40
Motor 5HP
Radial Drills
Made in Taiwan
Included:
German Collet Chuck Set 10pc
ISA40 Collets
Rapid up and down
Z & Y-Axis Box way
KMR-700DS
KMR-1100S
KMR-1600DH
Lathes
Made in Taiwan
Complete with:
Coolant System
Full Splash Guard
Steady Rest, Chuck Guard
Klopfer Quick Change Tool Post Set
*Self Centering Steel Chuck
*Heidenhain 2-Axis Readout System
CT_Perspective.indd 57
TY-1630S 30” centre 16” swing
TY-2060 60” centre 20” swing
Heavy Duty Variable Speed
TY-2260VS 60” centre 22” swing”
*excluded
13-04-17 6:51 AM
Â
FABRICATING | Nesting
Nesting software can
generate big productivity
gains, but how do you
know if you have the right
software for your shop?
BY MARY SCIANNA
5
PURCHASING FACTORS
Five factors to consider when
purchasing nesting software.
FLEXIBILITY
Can your nesting software be modified easily
to accommodate changes in production?
Can it accommodate manual intervention
if required? Does it have built-in process
parameters for multiple machines and
different fabricating processes?
CAPABILITIES
Does the software offer robust features to deliver
tight nesting and maximized cutting machine
performance? Can it integrate easily with MRP
systems? How quickly and how easily does the
software transfer nested programs to the CNC
machine-the CAD to CAM process?
USER FRIENDLINESS
Is the software easy to use? It is easy for an
operator to handle the programming for static
or dynamic nesting?
AUTOMATION
Can the nesting software easily accommodate
automation in the shop? If you run lights out,
does the software offer the necessary features
to run unattended for long periods of time?
SERVICE & SUPPORT
TECHNICAL
How does your supplier support the software?
Does it provide adequate training? Are there
charges for upgrades? Is technical support
readily available?
NESTING:
Not Just for the Birds
ESTING SOFTWARE
IS often overlooked in
the productivity equation.
Fabricators focus on the machine,
forgetting the nesting process and
associated software can be a big
contributor to productivity gains.
“Manual nesting can slow
production down to a crawl. By
automating the process, fabricators
FDQDFKLHYHVLJQLÀFDQWDQGVXVWDLQHG
productivity gains and cost savings,”
says James Lindsey, product manager for
SigmaTEK Systems LLC, Cincinnati,
OH. “Improved parts nesting impacts
optimization-this alone can reduce waste
E\ÀYHSHUFHQWRUPRUHµ
Beyond the obvious cost savings
from metal scrap reduction, users can
also achieve better machine utilization,
adds John Del Vecchio, vice president
of sales and marketing for Shop Data
Systems Inc., Garland, TX.
“A user may combine advanced
toolpath techniques with nesting to
achieve better material utilization and
better machine utilization. In some
cases, users can also achieve better
consumable life.”
The biggest productivity gain Kyle
Plass, applications engineer at Prima
Power, Arlington Heights, IL, likes
to highlight to customers is “your
programmer will have additional time
N
to focus on improving other processes
for the factory,” because of reduced
programming time required on the
company’s software.
Nesting software should be easy for an operator
to handle the programming for static or dynamic
nesting. Image: TRUMPF
And for a shop that runs multiple
cutting processes–plasma, laser,
waterjet, oxyfuel–you have a single
programming solution which allows
\RXWR´RXWSXW1&MREÀOHVWRDQRWKHU
machine easily when a breakdown
occurs or maintenance is needed,”
says Derek Weston, marketing product
manager, Hypertherm CAM Solutions,
Hanover, NH.
Choosing the right nesting software
Whether your nesting software is
PDFKLQHWRROVXSSOLHUVSHFLÀFRUFRPHV
from a nesting software company,
fab2_nest.indd 58
13-04-17 9:28 AM
S
fab2_nest.indd 59
O
F
T
W
A
R
E
®
13-04-17 9:28 AM
Â
FABRICATING | Nesting Î Î Î Î continued from page 58
fabricators should consider several
factors to determine the effectiveness
of a nesting software product.
“It’s important to consider the
machine itself,” advises Steffen Kutz,
software manager for TRUMPF’s
TruTops software. “If you have a
machine with two laser heads, for
example, the cutting heads will be at a
certain distance from each other so to
PDNHHIÀFLHQWXVHRIWKDWPDFKLQH\RX
want to nest in a way that makes sense
IRUWKHVSHFLÀFPDFKLQH\RXDUHXVLQJµ
Another example he gives is for
punching machines. “Consider
the clamp area. Can the clamps be
adjusted to accommodate
odate nesting
The Future
for Nesting
In the not-too-distant future, fabricators
will be able to control shop production
flow offsite, from mobile devices. They’ll
use cloud computing to upgrade software,
access customer CAD drawings and transfer
production data via a mobile device such as
a touchscreen tablet/ipad into a shop floor
production software program.
Advanced nesting software algorithms
will give fabricators the ability to improve
speeds and process accuracies, not just
on one machine, but concurrently on
multiple and varied machines in a shop
with the ability to integrate with software
from different machining technologies
such as laser and press brake systems.
Nesting software will also be more
efficient at handling multiple stacked
sheets and fully automated, lights
out operations.
Information based on interviews with
Hypertherm CAM Solutions, Prima Power,
Salvagnini America, Shop Data Systems,
SigmaTEK and TRUMPF Inc.
www.hyperthermcam.com
www.primapower.com
www.salvagnini.com
www.shopdata.com
www.sigmanest.com
www.us.trumpf.com
needs or do you have to take their
À[HGSRVLWLRQLQWRDFFRXQW"µ
6RIWZDUHÁH[LELOLW\LVDQLPSRUWDQW
factor, says Weston. You want a
software program that “incorporates
built-in process parameters for various
machine technologies–plasma, laser,
waterjet, oxyfuel–and machine brands.”
If your fabricating shop incorporates
automation, you need to consider
how the nesting software will operate
in this environment, advise Steve
Aleshin, applications manager and
application engineer for laser nesting
software, and Phil Patrick, application
engineer for punch/shear nesting
software for Salvagnini America
Inc., Hamilton, OH. “Much of our
machinery is tied in with automation
and there are a lot of features in
nesting that are used for automation,
such as tip and hole avoidance and
taking a skeleton to use for parts where
WKHVRIWZDUHFUHDWHVDGGLWLRQDOÀOHVIRU
this,” explains Aleshin.
Salvagnini’s nesting software,
MetalNest, which is exclusive to
its machines and created in Italy at
the company’s main manufacturing
IDFLOLW\LVD´ÁXLGµVRIWZDUHGHVLJQHG
to minimize operator input by running
multiple part programs from a
production list (PL).
´:KHQWKHQHVWLQJLVÀQLVKHG
in addition to the nest programs, a
production list is created,” explains
3DWULFN´7KLVÀOHKDVLQIRUPDWLRQIRU
the order in which the nested programs
are produced and the number of times
each pattern needs to be run.” The
QHVWHGSURJUDPVDQGWKH3/ÀOHDUH
sent to the machine where the operator
VHOHFWVDQGORDGVWKH3/IRUDVSHFLÀF
order and the machine produces the
QHVWV´$VDUHVXOWWKHÁRZRIZRUN
Nesting software can incorporate built-in process
parameters for various fabricating technologies,
such as plasma, laser, waterjet and oxyfuel.
Top image: Hypertherm nesting software.
Bottom image: SigmaTEK's nesting software.
across the work centre is paced by the
software, not the operator starting
each individual program. The result is
improved uptime.”
One advantage of nesting software
from the machine tool supplier
fab2_nest.indd 60
13-04-17 9:28 AM
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Canadian Manufacturing Technology Show
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Â
FABRICATING | Nesting Î Î Î Î continued from page 60
according to Prima Power’s Kyle Plass
is that fabricators don’t have to ppurchase
additional options, such as ERP
P
connectivity and teach functions.
ns.
“Our software is designed for
our products; functions built
into the software are tailored
to how the machine will
process. Third party softwaree
doesn’t always have this luxury
ry
because such software would run into
dy
u
t
S
e
Cas
g
n
i
t
s
Ne
The problem
No nesting software
standardization for multiple
cutting technologies,
machine brands, and
part sizes
The solution
Flexible nesting software
for all machine brands,
technologies
BY MARY
SCIANNA
An overview of
Metal Bernard’s
fabrication shop.
many different styles of machines.
One ggeneral set with many different
parameters
paramete is what you typically
from a third party.”
get fr
Nesting software
N
providers, however, suggest
pr
otherwise.
ot
“Most software that
comes bundled with a
com
machine is focused mainly on
machine motion; it will run, but not
WKHPRVWHIÀFLHQWO\µVD\V6LJPD7(.·V
James Lindsey. “Machine software
is generally a ‘lit’ nesting package
with basic capabilities. On the other
hand, sophisticated nesting software
has the ability to drive virtually any
or all cutting, punch and bending
machine regardless of type or brand.
Fabricators should research and
FKRRVHVRIWZDUHWKDWÀWVWKHLUVKRUW
and longer-term needs.” SMT
Nesting Harmony
$
Standardizing nesting for multiple cutting
processes leads to big savings
HEN METAL BERNARD,
Saint-Lambert de Lauzon,
QC, adopted Lean principles
for its fabricating operation, owners
Louis Veilleux and Mario Ferland
examined every aspect of the business,
right down to the nesting software for
its sheet metal cutting operations.
The two owners were keen to get
on the right track to become more
FRPSHWLWLYHLQWKHÀHUFHO\FRPSHWLWLYH
job shop business.
“When we purchased Metal Bernard
eight years ago, the family-run business
had already been using SigmaTEK
software,” explains Veilleux. “It was
an older version, but we thought it was
good and when we purchased another
fabricating facility, Normadin, two
W
years ago, we wanted to have the same
nesting software for both facilities,”
and for the different equipment in
each facility–laser cutting, punching,
oxyfuel, plasma and waterjet cutting
processes.
Metal Bernard and Normadin are
the two sheet metal businesses in a
group of companies that operate under
the Mundial Group, an industrial
manufacturing outsourcing business,
of which Veilleux is CEO and Ferland
is president. The other companies
in the group include BCI, a rubber/
silicone/polystyrene moulding
company; CDMB, a machining and
welding facility; and UCB, a machining
and mouldmaking shop.
Metal Bernard’s fabrication shop
fab2_nest.indd 62
13-04-17 9:28 AM
fab2_nest.indd 63
13-04-17 9:28 AM
Â
FABRICATING | Nesting Case Study
includes laser cutting (four machines
from Bystronic and three from
TRUMPF), punching (TRUMPF), as
well as bending (Amada, Bystronic,
Cincinnati, TRUMPF and Warcom
Futura), and rolling (Davi and Akyapak).
The Normadin fabricating shop
KRXVHVÀYH75803)ODVHUFXWWLQJ
machines and one Bystronic machine,
a Messer-Brand HD plasma cutter,
waterjet and oxyfuel cutting, bending
(TRUMPF) and welding equipment.
“The OEMs make good nesting
software, but we wanted the freedom
to choose any company of fabricating
machinery so it made sense for us to
go with software that could be used on
Î Î Î Î continued from page 62
www.metalbernard.com
www.sigmanest.com
all of our machines now and those we
buy in the future,” explains Veilleux.
Metal Bernard wanted to
standardize nesting for its laser and
punching machines “between the
two companies so one programmer
from one plant could help in the
second plant; so standardization of
nesting software was important for us.
Standardization is also a lean principle,
which is something we have adopted.”
THE SOFTWARE
The latest version of SigmaNEST,
Version 10, ships this Spring.
Offering all of the features of Version
9.1 that Metal Bernard uses, Version
10 has a new, advanced CAD/
CAM nesting engine. Nesting is
accelerated by several minutes with
tighter nesting to maximize material
yield. Enhanced cutter path planning
saves time and consumables, such
as torch life and abrasives.
Tutorial videos, documentation,
connection to support, news and
updates, are just a click away with
a customized tool bar and welcome
screen. It includes bolt hole quality
for plasma cutting; parts/BOM;
quoting; inventory management;
solid CAD integration; punching
(tool adaptions, destruct and die
management); and user management.
It offers tigher integration with
MRP and other similar systems
to catalogue remnants for future
job runs. It also offers SolidWorks
Enterprise PDM integration and shop
floor control with Colour Offload and
Load Manager programs.
Metal Bernard has improved productivity with the
nesting software and cut waste by 50 per cent
because it's able to use remnants to make parts.
Metal Bernard and sister company
Normadin use SigmaTEK’s
SigmaNEST Version 9.1. One
feature Veilleux likes is how it works
seamlessly with its ERP system and
KRZZHOOLWÀWVLQWR/HDQSUDFWLFHV
“We purchased the inventory
module, which is great. Because of our
/HDQSUDFWLFHV>WKHFRPSDQ\GRHVQ·W
NHHSDQ\WKLQJRQWKHVKRSÁRRUORQJHU
than two weeks] we need to know the
status of our inventory at any time
of the day. Remnants are part of our
inventory and the SigmaTEK software
enables us to be on top of traceability
and prioritize remnants.”
Veilleux estimates the shop has cut
waste by 50 per cent, “because we’re
reusing remnants to make parts. At
the end of each month we audit our
inventory and we have 100 per cent
score in our audit on traceability of our
materials. Using SigmaTEK software
helped us achieve that.”
-DPHV/LQGVH\SURGXFWPDQDJHU
IRU6LJPD7(.6\VWHPV//&
Cincinnati, OH, says a nesting
program is the best way to track
remnants and catalogue material
because "you can store true scrap
geometry and reuse it in future
programs. “Single source software
can relate remnants from a nesting
program into a shop's inventory
control program. This helps create a
more lean environment.” SMT
For more information on fabricating technologies, visit Shop Metalworking
Technology’s FABRICATING ZONE online at www.shopmetaltech.com.
fab2_nest.indd 64
13-04-17 10:08 AM
When you need dependable tooling solutions designed to solve your toughest fabrication challenges,
turn to Wilson Tool Canada. For 45 years you’ve known us as Exacta Precision and Exacta Fabtool. As
Wilson Tool Canada we’ll continue to offer all the standard and custom tooling solutions you’ve come to
rely on, plus the Wilson Tool line of tooling with shorter lead times and reduced shipping costs.
Whatever your tooling needs, choose Wilson Tool Canada. Call 800.268.5573 for stamping or punch
press tooling. Call 800.268.4180 for press brake tooling. Or visit www.wilsontool.com today.
C A N A D A
fab2_nest.indd 65
13-04-17 9:28 AM
Â
MACHINING | Micromachining
Game-Changing Technology
R&D in micromachining could provide leading edge to precision manufacturers in Canada
BY MARY SCIANNA
ROMISING RESEARCH IN
micromachining may hold one
key to helping Canada’s ultra
precision manufacturing industry
become more competitive.
Researchers at McMaster
Manufacturing Research Institute’s
Micro Manufacturing Laboratory
(MML) and at the National Research
Council’s (NRC) automotive research
division are working on machining
optical and high aspect-ratio micro
structures (e.g. micro-lens, pins and
thin wall pillars) with optical surface
quality below ~20 nm that don't lose
their dimensional form accuracy.
“The trend of miniaturization in
consumer and industrial products
today require microscopic features,”
says Stephen Veldhuis, director of the
McMaster Manufacturing Research
Institute and the Micro Manufacturing
Laboratory, and associate professor the
university’s Mechanical Engineering
department, Hamilton, ON. “Cell
phones, cameras, biomedical devices,
diagnostic devices, micro-sized devices
WKDWJRLQVLGHERG\DQGPLFURÁXLGLF
devices all require fabrication with
good surface quality.”
To date, machining micro features
An example of a
part from MML with
optical surface quality
with no compromise
on dimensional form
accuracy.
P
on complex 3D geometries that
have high aspect-ratio structures
(e.g. researchers at NRC created thin
walled structures with widths of 25
microns, approximately a quarter
width of human hair in diameter, with
a height of 7 mm, translating into a
1:280 aspect ratio) and optical surface
quality below ~20 nm has been limited
by physics. You can achieve the high
optic or mirror-like surface, but you
compromise the accuracy of form
during manual polishing operations.
“Now we can produce very complex
geometries with optical surface quality
XVLQJÀYHD[LVFXWWLQJPRWLRQVµVD\V
Evgueni Bordatchev, senior researcher
with the automotive portfolio at NRC-
Automotive in London, ON. “With
automotive lighting, for example, at
least 40 per cent of the cost of tooling
goes into polishing, which is typically a
manual process. By creating an optical
surface, it eliminates the polishing step
and helps to reduce the tooling cost of
this process.”
Bordatchev and his research
team have created demo parts
with complex 3D geometries to
demonstrate the capabilities of this
micromachining process.
“In my work at NRC of Canada
in micro machining
I’m working with
three processes:
micromilling, laser
machin 2.indd 66
13-04-17 7:09 AM
Researchers can no
w
produce complex 3D
geometries with hig
h
aspect-ratio structur
es
(left image from NR
CAutomotive) with op
tical
surface quality (rig
ht
image from MML
shows
optical surface qu
ality
on a flat part).
PLFURPDFKLQLQJDQGÁ\FXWWLQJZKLFK
is cutting with a single point diamond
WRROW\SLFDOO\XVHGIRUPDFKLQLQJÁDW
surfaces with optical quality.”
7KHVLJQLÀFDQFHDVDUHVHDUFKHU
says Bordatchev, is that it’s an
accomplishment to overcome the
challenge of machining at such micro
sized ranges because you have to
have the knowledge about the cutting
process on micro and nano-scales,
optimization of parameters to avoid
GHÁHFWLRQRIWKHFXWWLQJWRRODQG
thin structures, for example. Second,
“such high aspect-ratio structures (e.g.
1:280) can’t be fabricated by any
other process; only micromilling is
a most suitable and cost effective
technology for such types of tooling
and EDM electrodes.”
Creating parts such as very thin wall
structures or arrays of very slender
pins with an accuracy of one micro
meter range is challenging for EDM
technologies but is “state-of-the-art in
advanced machining technologies,”
adds Bordatchev.
The aim for both Bordatchev
and Veldhuis is to create
knowledge-based advanced
micromachining technologies
WKDWFDQWKHQEHWDNHQLQWRWKHÀHOG
by engineers and designers to create
more innovative products not easy to
replicate by potential competitors, a
very real threat in competitive hightech industries, such as photonics,
www.nrc-cnrc.gc.ca
www.mmri.mcmaster.ca
automotive, aerospace and biomedical.
“Manufacturers are always looking
for new technologies they can take
advantage of to give their products
a unique look,” says Veldhuis, citing
LED technology used on Audi front
headlights as an example. “Each
automotive company would like a
technology their designer can leverage
into a unique feature. With the work
we do, which focuses more on the
physics of cutting in the machining
process, and the work that NRC
does, which is more focused on the
demonstration of unique capabilities
by creating complex geometries and
how they can be used in industry,
it’s a coming together of design,
physics and unique capabilities that
manufacturers could leverage to
create innovative products no one else
can replicate.”
Bordatchev adds that in the
automotive industry, the ability
to create micro structures with
optical quality is called a “gamechanger,” adding “several years ago
LWZDVÀYHD[LVPDFKLQLQJDQGQRZ
micromachining is the technology
that they view as the one that will
distinguish them among global
competition because knoweledgebased micromachining technologies
have the potential to create innovative
YDOXHDGGHGSURGXFWVHIÀFLHQWO\DQG
cost effectively.” SMT
For more information on machining technologies, visit Shop Metalworking
Technology’s MACHINING ZONE online at www.shopmetaltech.com.
machin 2.indd 67
67
13-04-17 7:09 AM
SHOP T
LS
QUALITY & PLANT MANAGEMENT
MACHINING
More products online at www.shopmetaltech.com/shop-tools
CUTTING TOOLS
ÒECLIPSE
ÒZOLLER
ÒKOMET
The Bowers Universal Gauge available
from Eclipse Metrology is a modular
device that can configured quickly
to suit most measuring challenges.
The roboSet is an automated tool
measurement system capable of loading
the presetter and measuring machine that
can run unmanned, 24 hours, seven days a
week. It features a six-axis articulated arm
robot equipped with a sensor with forcemoment strain gauge and two pneumatic
parallel grippers at D 3-12 mm. It can load
shafted tools onh the measuring device with
automatic power clamping and is easy to
operate. Loading
configurations
and parameters
are defined
using a “pallet
management”
functionality
incorporated
into the company’s pilot 3.0 software, and
tools can then be measured without further
user input.
www.zoller-usa.com
The JEL MGF XH Micro threadmilling
cutter allows for milling micro-sized
threads directly into hardened steels
in the range of 45 to 60 HRC, eliminating the need for
complex re-machining operations caused by hardening
distortion. The cutter is equipped with a 45° chamfer,
completing both tasks in one single operation. It’s
available in diameters of M1, M1.4, M1.6, M2, M2.2 and
M2.5, in a 1.5xD length to diameter ratio.
www.komet.com
Universal Gauge
When measuring internal and
external diameters (from 0 to 3000
mm/0 - 118 in.), it has the ability to
“freeze” its display on the reading.
The gauge’s constant pressure devices
ensures users achieve accuracy and
consistency of reading. It is fast and
easy to use, and the clear digital
display makes it suitable for inspecting
large parts positioned within the
machine tool.
www.eclipsemetrology.com
ÒTRUMPF
UV laser marking
TruMark 6350 marking laser features
improved laser parameters for more
cost efficiency and high quality marks
with a broader range of applications.
Increased average power with the
same high beam quality leads to
an increase in repetition rates and
higher processing
speeds. The higher
pulse peak power
and pulse energy
allow the laser to
achieve increased
mark contrast. The
passively cooled
marking laser has
enhanced optical
setup for a 50 per
cent reduction in
the time needed to achieve the ideal
crystal temperature prior to marking.
www.us.trumpf.com
Unmanned tool measurement
ÒSCHUNK
Mobile gripping system
The 5-finger hand is a robotic mobile
gripping system designed with motor
controllers integrated into the wrist of the
hand. Via defined interfaces, the gripper
hand can be connected with the lightweight
arm. For mobile
applications, the
energy supply
of the 5-finger
hand requires a
battery-servable
24 V DC. The
gripper hand
is available as
a left and right
hand version.
By means of nine drives, its five fingers
can carry out various gripping operations.
It is also capable of gestures, and the use
of tactile sensors in the fingers provides
sensitivity in the gripper hand. Elastic
gripping surfaces ensure a reliable hold of
the gripped objects.
www.schunk.com
Threadmilling hardened steels
FABRICATING
ÒMAZAK OPTONICS
2.5 kW laser cutting system
The Super Turbo-X Champion is
a 2.5 kW laser cutting
machine with a new Type
10 resonator. It features
a 1,786 lb (810 kg) workpiece
capacity for sheets up to 0.87 in. (22 mm) thick, high
positioning accuracy, improved travel support and easy
loading access. It’s equipped with the Mazatrol Preview
function control, which automatically determines the
cutting speed and acceleration from each cutting point
to the next. It uses integrated technology tables for a
wide range of materials and thicknesses.
www.mazakoptonics.com
WELDING
ÒLINDE CANADA
Welding helmet
The Linde Gladiator II helmet combines
lightweight comfort and ergonomic fit
with superior protection of the head and
neck. Smart construction and a durable
cover plate design makes it one of the
only products available on the market
which can be used for unlimited overhead welding
applications. Expansive shade range and selectable
grinding mode settings make this helmet suitable for
almost any arc welding or cutting operation. The more economical, Linde Maximus II now comes
in a flip-up and a 4.5 x 5.25 in. (114 x 133 mm) wide
view. Both are lightweight, streamlined and balanced
with telescopic and fully adjustable headgear.
www.linde.com
Shop tools.indd 68
13-04-17 1:03 PM
RETROFIT
UPGRADE
YO U R S YS TEM
Today!
Update your existing manual milling machine with a new, user-friendly MILLPWR Control System.
t 2 or 3 Axes Control, 3 Axes Readout
t Immediate Part-View Graphics
t Menu Prompted, Conversational Programming
t Full 3D Contouring
t Precision Glass Scale Feedback
t Bolthole Calculations
t DXF File Input
t Easily Establish Workpiece Zero with Position-Trac
t Compact Flash Data Storage
TM
Ask About Our Compact Flash Upgrade Offer
1-877-920-2703
heidenhain.us 1-905-670-8900
Canadian Regional Office
11-335 Admiral Boulevard, Unit 11
To lL5T
l F r 2N2,
e e P Canada
hone: 1.800.344.2311
Mississauga, Ontario
Shop tools.indd 69
Complete retrofit kits are available for the
following machines:
Acer
Acra
Alliant
Argo
Atrump
Birmingham
Bridgeport
Chevalier
Clausing
Enco
Jet
Kent
Lagun
Lilian
MSC
Millport
Sharp
Southbend
Supermax
Top One
TurnPro
Vectrax
Victor
Wells
Willis
Wilton
YCI
and MANY MORE...
www.acu-rite.com
13-04-17 1:03 PM
Â
YOUR BUSINESS | Job Estimating
Getting the Order
BY TIM WILSON
The dark art of job estimating brought to light
SK SOMEONE HOW he
estimates a job and you’ll likely
get a wry smile, perhaps a
wink. Estimating is one of the best
kept secrets a metalworking shop can
have. Getting it right often comes
from years of experience and profound
understanding of the market and
human psychology. Today, software
applications are turning the art into a
science, but not for everyone.
“Excel, pen, and paper are
incredibly common, perhaps
ubiquitous for at least some operations
in almost every enterprise,” says
George Goodall, senior consulting
analyst for Info-Tech Research Group,
London, ON. “Part of the issue here
is that many job shops have a large
GHJUHHRIÁXLGLW\LQWKHLURSHUDWLRQV
Things change from day-to-day so
LWEHFRPHVGLIÀFXOWWRKDUGFRGH
business logic into operational
systems.”
Increasingly, job shop software
applications are removing a lot of
estimating’s mystery. Central to getting
it right is having a system that has the
ÁH[LELOLW\WRUHVSRQGWRQHZVLWXDWLRQV
but that also has the ability to reference
past set-ups and quotes. Many software
systems can do this. “JobBOSS [from
Exact Software] allows shops to
copy any element of a job to another
A
similar job or quote, thus streamlining
reamlining
and reducing the data entry time,”
says Dave Lechleitner, a software
tware
engineer who works on pre-sales.
sales.
“This includes examples suchh
as routing, bill of material, and
nd
sub-assemblies.”
Splitting orders is anotherr
challenge to the estimator. It’s
t’s
not impossible to do on Excel
el
or with a calculator, but it can
an
be a headache. And if you get
et an
estimate on a split wrong it can be
a costly mistake. “Splitting orders
or jobs is an everyday occurrence
rence
for our customers,” says
Lechleitner. “With one clickk
of the mouse a user can input
ut
the new split order number and
quantity to split. A split job can then
be created and re-scheduled.””
As with other automated estimating
functions, one of the advantages
ages is it
becomes part of the job, which
ich then
LQFUHDVHVWKHHIÀFLHQF\RIRSHUDWRUV
SHUDWRUV
who no longer have to wait on
approvals. If the software is trusted
and adaptable, then estimating’s
business processes can be better
integrated into production.
Getting beyond guesstimates
“Our primary clients are small to
medium size businesses,” says Kenney
Skonieczny, president of Kentech Inc.,
the publisher of Kipware software.
“I would say from my experience the
majority of clients interested in our
products are still using Excel spread
sheets; not so much paper and pencil,
but there are still some of those. The
one thing we stress to clients is the
need for accurate cycle time estimates.
your business.indd 70
13-04-17 6:52 AM
If your cycle time est
estimates are not
correct then your cos
cost estimates are
still guesstimates.”
Kentech has three main
applications: Kipwar
KipwareQTE for
machine shop job costing
co
and
KipwareCYC for
estimating; KipwareC
machining cycle time estimating,
and KipwareTRK for quotation
tracking/analyzing.
track
“Our software
is often broken
uup into two
processes,” says
Skonieczny.
“Someone
with chip making
experience will use KipwareCYC
K
to
create the cycle time estimate, then
import the estimate
someone else will im
into KipwareQTE and
an create the cost
estimate and quotation.”
quotatio
KipwareCYC
Y uses
uses a database
of machinery specs aand cutting
parameters which, the
th company
VWUHVVHVPXVWEHXVHUFRQÀJXUDEOH
VWUHVVHVPXVWEHXVHU
“This is not based on book
knowledge, which a llot of packages
Skonieczny. “The ability
contain,” says Skonie
speeds and feeds
to estimate cutting sp
actually be achieved
that are going to actu
RQ\RXUVKRSÁRRULVSDUDPRXQWµ
RQ\RXUVKRSÁRRULV
packages
Skonieczny says software
so
are a
that boast feature recognition
rec
troubling example, in that the software
itself decides on the best machining
process. All good, but that process
PXVWEHGXSOLFDWHGRQWKHVKRSÁRRU
“The way the software decides the
machining should take place is not the
process that will happen on your shop
ÁRRUµVD\V6NRQLHF]Q\´.LSZDUH&<&
takes this into account in design and
implementation.”
The best of both worlds
In estimating, having experience and
a personal knowledge base has real
value, but there are risks associated
with an expert’s look-and-see
estimating off of blueprints. And it
can also be counter-productive, costly,
DQGLQHIÀFLHQWWRKDYHLQWHUQDOWHDPV
competing for quotes. In either case,
resistance to change can be strong.
“We spend time from sales through
implementation striving to understand
not only the company needs and
requirements but the people dynamic
as well,” says Lechleitner. “Often,
if a shop is experiencing resistance
from internal staff, we’ll recommend
additional project management and
onsite consulting time.”
Part of the resistance comes from
the software’s own requirements. It
won’t work unless costs are nailed
down by the shop itself. Shops have
to be honest about the cyclical nature
of labour rates–if that key metric is
wrong, estimates can be thrown way
off, particularly if the competition is
offshore. And it also means adjusting
for lead times that, in a crunch, can
boost labour costs.
´6KRSÁRRUVFKHGXOLQJDQGMRE
tracking are the primary reasons that
our shops purchase JobBOSS,” says
Lechleitner. “We have a visual, dragand-drop scheduling board that allows
shop foreman and production planners
to see any labour and capacity issues in
real time. They can try various ‘what
if’ scenarios to maximize throughput
through each work centre.”
Where a bottleneck occurs,
Lechleitner says the scheduler can
drag and drop work, seeing the
UDPLÀFDWLRQVLQUHDOWLPH7KHLGHD
Going Mobile
For some, estimating on the shop floor
can be enough of a challenge, but what if
you could do it with ease from your mobile
device? Now you can, with E2 Shop
System’s mobile dashboard.
“The E2 Shop System can generate
a quote in seconds from parts already in
the system, or on the fly,” says Derrick
Lambdin, marketing communications
coordinator for E2, Glastonbury, CT. “With
the Mobile Dashboard, owners can see
what is happening on their shop from
anywhere.”
E2 allows a user to adjust margins for
different components. For example, an
outside service could be put through at
cost, with margins then built on materials
and/or labour. And all of this can be done
off a mobile device.
“Via an iPad or tablet, users can see
what employees are excelling at, what
customers are bringing the biggest profit
margin, how the sales performances are
going, and what percentage of quotes are
winning business,” says Lambdin.
This is a client-server system that can
serve customers as small as a two-man
shop all the way to a couple hundred
employees.
“Any job shop or make-to-order
manufacturer will be able to benefit from
using E2,” says Lambdin. “We have over
6,000 customers, so there is a wide range
of shops using it.”
A base-line purchase provides
estimating and quoting, job scheduling,
shipping and receiving, routers, and
inventory. Modules can then be added
such as accounting, quality, scheduling,
and data collection.
“The implementation can take as little
as a few days or a few months,” says
Lambdin. “It is up to how committed the
new customer is to getting the system
going in their shop.”
is to increase employee resource
availability and production hours to see
which solution drives the maximum
throughput at the lowest cost. SMT
Tim Wilson is a regular contributor.
[email protected]
71
13-04-17 6:52 AM
Punch + Shear
Invented by Salvagnini
Salvagnini’s patented multi-press punching head
provides owners with a competitive advantage over
old turret technology in terms of cycle times, tool life,
productivity and profitability. No turret necessary. No
fetch-and-carry tools. Just pure, lean efficiency.
Lights-out automation
The exclusive, Salvagnini multi-press head is
complemented by either an integrated shear (S4Xe)
or by an integrated fiber laser (SL4) for complete
punched blank production in a single package.
Automatically. Unmanned. Reliably. With high
quality and low scrap.
Punch + Laser
First to integrate fiber laser cutting
into a punching machine
As the acknowledged leader in fiber laser cutting,
it’s only natural that Salvagnini would incorporate
laser technology into its punching centers to take
advantage of the technology’s many assets – speed,
energy savings, flexibility and low maintenance.
The decision is an easy one
When it comes time to buy a new machine, you
have a choice between old, turret technology or the
most efficient, modern technology on the market.
The past or the future. OK profit or maximum profit.
Satisfactory cycle times or stellar times. Separate
operations or combination punching and cutting.
After considering all the options, the decision
should be a simple one – Salvagnini.
www.salvagnini.com
13-04-17 6:52 AM
Â
EXIT | R&D
Boost Profits & Productivity With R&D
Improvements in production equipment can fall under SR&ED claims
BY ANDREW MILIVOJEVICH
ANY65('6FLHQWLÀF Research and Experimental
Development) claims fall under experimental
development. Discussions with Revenue Canada
65('RIÀFHUVVXJJHVWZKLOHWKHPDMRULW\RI65('
FODLPVIDOOXQGHUH[SHULPHQWDOGHYHORSPHQWWKH\DUHRIWHQ
ZLWKLQWKHQHZ´SURGXFWµFDWHJRU\7HFKQRORJLFDOSURJUHVV
in current production equipment is often overlooked.
6LJQLÀFDQWDGYDQFHPHQWVFDQEHUHDOL]HGWKURXJKV\VWHPDWLF
LQYHVWLJDWLRQVWKDWUHPRYHWHFKQLFDOREVWDFOHVWKDWDIIHFW
SURGXFWLYLW\HOLPLQDWLQJWKHQHHGIRUQHZHTXLSPHQW
M
Systematic Protocol
Investment in new production equipment is not without risk.
$V\VWHPDWLFSURWRFRODGYRFDWHVNQRZOHGJHFUHDWLRQ
WKURXJKH[SHULPHQWDQGDQDO\VLVZLWKDJRDOWR
DGGUHVVWHFKQLFDOREVWDFOHVWKDWLQKLELWSURGXFWLYLW\
,WVKRXOGDGGUHVVWKUHHNH\TXHVWLRQV
1.
How do we articulate operational problems
in quantitative technical terms?
'HVFULELQJRSHUDWLRQDOSUREOHPVLQWHFKQLFDO
WHUPVEULQJVVWUXFWXUHDQGREMHFWLYLW\WRWKH
SUREOHP,WGHÀQHVLQTXDQWLWDWLYHWHUPV
WKHWHFKQRORJLFDOEDVHOHYHODQGLGHQWLÀHVWKH
WHFKQLFDOREMHFWLYHDVDTXDQWLWDWLYHWDUJHW
7KHWHFKQRORJLFDOEDVHOHYHOLVDVWDWHPHQWLQ
TXDQWLWDWLYHWHUPVYHUVXVWKHFXUUHQWFDSDELOLW\RU
SHUIRUPDQFHRIWKHV\VWHPXQGHULQYHVWLJDWLRQ
,WTXDQWLÀHVWKHFHQWUDOWHQGHQF\DQGGHVFULEHVWKH
XQFHUWDLQW\DVVRFLDWHGZLWKVXFKDV\VWHP,WGHÀQHVWKH
OLPLWVRIUDQGRPQHVVDQGWKHGHJUHHRILPSURYHPHQW
UHTXLUHGWRVWDWLVWLFDOO\MXVWLI\DQ\LPSURYHPHQWEH\RQG
UDQGRPFKDQFH7KHWHFKQLFDOREMHFWLYHLVDUHTXLUHPHQWRU
VSHFLÀFDWLRQWKDWGHVFULEHVDGHVLUHGOHYHORISHUIRUPDQFH
2.
How to distinguish between routine and experimental
development projects
5RXWLQHGHYHORSPHQWDVVXPHVDGLUHFWOLQHRIVLJKWVROXWLRQ
WRWKHWHFKQLFDOREMHFWLYH$GLUHFWOLQHRIVLJKWVROXWLRQUHOLHV
RQSULRUNQRZOHGJHWKDWVXJJHVWVDSDWKIUHHRIWHFKQLFDO
REVWDFOHV,QVXFKDFDVHURXWLQHHQJLQHHULQJLVDOOWKDWLV
QHHGHGWRPHHWWKHWHFKQLFDOREMHFWLYHKHQFHWKHSURMHFWLV
FRPPHQVXUDWHZLWKURXWLQHGHYHORSPHQW,QVXFKDFDVHWKHUH
is no SRED.
,QRWKHUFDVHVWKHUHPD\EHFRQVHQVXVWKDWWKHWHFKQLFDO
REMHFWLYHFDQEHDFKLHYHGKRZHYHUWKHSDWKWRDFKLHYH
LWPD\EHQXPHURXV$VVXFKSULRUNQRZOHGJHGRHVQRW
H[LVWWKDWZRXOGVXJJHVWDSDUWLFXODUSDWKWRDFKLHYHWKH
WHFKQLFDOREMHFWLYH7KLVEHLQJ
WKHFDVHLWLVXQFHUWDLQDV
to which path will meet the
WHFKQLFDOREMHFWLYH,QVXFK
FLUFXPVWDQFHVDV\VWHPDWLF
LQYHVWLJDWLRQLVUHTXLUHGWR
HYDOXDWHPXOWLSOHVFHQDULRV
which is consistent with the
GHÀQLWLRQ65('
3.
How do we conduct a
systematic investigation?
:KHQDQLQYHVWLJDWLRQLV
V\VWHPDWLFLWLPSOLHVWKHUH
LVDVWUXFWXUHGSODQRIVWXG\
GHVLJQHGWRDGGUHVVK\SRWKHVHVWKDWZLOOSURYHRUGLVSURYH
FDXVHDQGHIIHFWUHODWLRQVKLSV2IWHQHQJLQHHUVDQGVFLHQWLVWV
XVHDVWKHLUEDVLFDSSURDFKWRUHVHDUFKGHWHUPLQLVWLFPRGHOV
WRH[SODLQUHDOSKHQRPHQD:KHQDQHQJLQHHURUVFLHQWLVW
FRQGXFWVUHVHDUFKDQGWKHREVHUYHGGDWDGRHVQRWFRPSO\
with a deterministic model how does the researcher explain or
Exit.indd 73
73
13-04-17 6:53 AM
Â
EXIT | R&D
predict the physical system? Generally, we learn
through a series of activities in which we make
conjectures about the physical system under
investigation, perform experiments to generate
data and conduct analysis. This information is
then used to establish new conjectures that lead
to new experiments, and so on. When the data
are subject to experimental error, use of statistical
methods is the only objective approach to planning
experiments and conducting analysis.
Benefits
+HUH·VDQH[DPSOHRIKRZRQHFRPSDQ\EHQHÀWHG,WSXWDVLGH
$750,000 to purchase equipment to improve productivity
because its existing operation couldn’t meet the requirements
of a contractual job. Yet the purchase would consume more
resources, increasing manufacturing costs and result in a great
loss since available capacity would be consumed to meeting
The first planet rotating in
a 24-hour cycle
Planet earth, home of all known life forms
The first hydraulic expansion
toolholder which transmits
torques of up to 2000 Nm
TENDO E compact, a toolholder from SCHUNK
Superior Clamping
and Gripping
Where clamping technology and
gripping systems are concerned,
we are the superior provider.
SCHUNK is the No. 1 worldwide
supplier of high craft smanship, all
from a family-owned company.
From the smallest parallel gripper,
to the largest chuck jaw program.
We would be glad to inform you.
www.schunk.com
existing demand.
Through effective technical mentorship, the
FRPSDQ\GHÀQHGWKHSUREOHPLQWHFKQLFDOWHUPV
and realized it was commensurate
with experimental development. A
systematic investigation evaluated
16 potential routes to the technical
objective. By the time the investigation came to
its natural conclusion, the technical system under
investigation realized a net increase of 522 per
cent from current production levels along with an
increase of 75 per cent above customer requirement.
The excess capacity was later sold and the organization,
through its experimental development activities, realized a
KHDOWK\SURÀWDQG65('WD[FUHGLWSMT
Andrew Milivojevich is a contributing author to www.sred-iq.net.
Membership to this R&D community is free.
AD INDEX
ABB Flexible Automation ........... 52
Amada Canada ........................ IFC
BIG Kaiser ............................... 26
Caliber Industrial Supply 31, 33, 35
CME (Canadian Manufacturers &
Exporters) ................................ 22
Colonial Tool ............................ 25
Cosen ...................................... 21
CWB Group .............................. 48
DMG Canada ............................ 18
Eclipse Tools ...................... 19, 21
Elliott Matsuura Canada .............. 6
Fagor Automation ....................... 4
FERRIC Machinery ................... 11
Gibbs and Associates ................ 27
Gullco International .................. 23
Haas Automation ...................... 20
Haimer USA ............................. 12
Heidenhain ............................... 69
Heinman Machinery .......38-39, 57
Hougen ................................... 49
Ingersoll Cutting Tools ............... 32
Iscar Tools ................................. 3
Komet of Canada ...................... 24
Lincoln Electric ........................ 47
Machine Tool Solutions ............. 17
Mate Precision Tooling .............. 45
Mazak Canada .......................... 14
Mazak Corp. ............................. 34
Mitutoyo Canada ....................... 53
Murata Machinery ..................... 13
OSG ........................................ 55
Peter Wolters of America ........... 40
Salvagnini ................................ 72
Sandvik Coromant Canada .......OBC
Schunk .................................... 74
Scientific Cutting Tools ............. 54
Scotchman Industries ............... 46
Seco Tools ............................... 15
Shop Data Systems ................... 43
SigmaTEK ................................ 59
Sirco Machinery ....................... 20
SME (CMTS Show) ................... 61
SME (WMTS Show) .................. 29
SMTCL ...................................8-9
TE-CO ..................................... 19
Thomas Skinner ....................... 20
Toshiba .................................... 51
TRUMPF .................................. 63
Tungaloy America ....................IBC
Wilson Tool .............................. 65
YG-1 Canada ............................ 28
Zoller ....................................... 37
Exit.indd 74
13-04-17 12:16 PM
Exit.indd 75
13-04-17 6:53 AM
Every second counts
The quicker and more effective you are, the better
your result will be. This is especially true in small
part machining where the QS™ holding system
for sliding head machines will save you up to 50%
Exit.indd 76
in production time. Time flies; to make the most
of it go to www.sandvik.coromant.com/industry
solutions/small part machining
13-04-17 6:53 AM

MACHINING - Shop Metalworking Technology

Transcription

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