Download machine tools - Shop Metalworking Technology

Ò
FABRICATING
Lights out
fabricating p42
VOLUME 1 | NUMBER 3 | MAY 2012
Î
M
ACHINING
& CUTTING
Multi-tasking
cutting demo
p72
Ô
QUALITY
Multisensor
benefits p52
Publications Mail Agreement
g
No. 42327015. Shopp Metalworkingg Technology
gy PO Box 93171 RPO Headon,, Burlington,
g , ON L7M 4A3
Overcoming
HEADWINDS
Î
W
ELDING
Welding special
metals p48
Challenges hamper strong
growth prospects for aerospace
Ò
C
UTTING
TOOLS
Small part
grooving p58
COVER
STORY
p16
SOFTWARE
4 Steps to better
machining
p66
MACHINE TOOLS
Cutting
cycle times
p30
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1-800-4A FAGOR
www.fagorautomation.com
Canada Head Office: Mississauga 905-670-7448
Montreal Office: 450-227-0588 | Email: canada@fagor-automation.com
ÒContact us...
EDITOR
Mary Scianna | 647.932.4477
marys@shopmetaltech.com
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johns@shopmetaltech.com
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Brian Gillett | info@shopmetaltech.com
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Canadian Publications Mail Sales Agreement
42327015
ISSN 1927-7962
V O LU ME 1 | NUMBER 3 | MAY 2012
ÒThis
issue...
MANAGEMENT
REPORT
16 | OVERCOMING
HEADWINDS
Strong growth prospects
for aerospace hampered
by tough challenges.
MACHINE TOOLS
20 | MIGHTY MILLING
Gas turbine parts maker
stays competitive with
full service support and
technology investments.
30 | CUTTING
CYCLE TIMES
Motion control
software enables
Ontario manufacturer
to reduce machining
cycle times on
three-axis work.
54 | AUTOMOTIVE
MACHINING DRIVES
Changes at automotive
OEM level impacts
machine shop suppliers.
SOFTWARE
66 | 4 STEPS TO
BETER MACHINING
&$0VRIWZDUHEHQHÀWV
for your shop.
CUTTING TOOLS
34 | SPINDLE
CONNECTIONS
A strong spindle
connection for
improved cutting.
58 | SMALL PART
GROOVING
Attention to detail
in tooling a must for
small parts.
16
72 | CUTTING DEMO
Prooving the cost
effectivenss of hard
machining on a multitasking machine with
different cutting tools.
QUALITY
52 | MULTIPLY
YOUR BENEFITS
Multisensor technology
cuts measurement costs.
20
FABRICATING
42 | FABRICATING
WHILE SLEEPING
Lights out automation
means Alberta shop
doesn’t have to turn
business away.
58
70 | AUTOMATING
YOUR PRESS BRAKE
Advice on when to
automate and why.
63 | PUNCH TOOLING:
SPECIAL SHAPES
Improve nesting strategies
with special shape tooling.
WELDING
48 | GTWA ON
TITANIUM
Tips for welding a
challenging metal.
72
ÒEvery issue...
7 | SHOP VIEW
8 | INDUSTRY UPDATE
68 | YOUR BUSINESS
MAY 2012 www.shopmetaltech.com
5
NEED FINANCING? LET’S TALK!
ELLIOTT-MATSUURA CANADA INC. IS PLEASED TO OFFER YOU
0% INTEREST FOR 24 MONTHS WITH AN ADDITIONAL 24 MONTHS AT 1.99%
ON MATSUURA, NAKAMURA-TOME, INCLUDING SELECTIVE MODELS OF
AGIECHARMILLES, HURCO, AND ZEISS MACHINES
0% FOR 0-24 MONTHS
1.99% FOR 25-48 MONTHS
10% DEPOSIT WITH PURCHASE ORDER
„ 48 EQUAL MONTHLY PAYMENTS WITH ABOVE TERMS
„ OPTIONAL RESIDUAL BALANCE AVAILABLE
„ OFFER EXPIRES JUNE 30TH 2012
„ ALL RELEVANT FINANCE DOCUMENTS TO BE SIGNED
„ SUBJECT TO CREDIT APPROVAL BY ELLIOTT'S FINANCIAL INSTITUTION
„ 3 YEAR WARRANTY AVAILABLE FOR MATSUURA RANGE
„
SEE US AT MMTS
(MONTREAL SHOW)
BOOTHS 633,
533, 647, 547
CONTACT US FOR MORE DETAILS:
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ELLIOTT-MATSUURA CANADA INC.
TEL: 905-829-2211
E-MAIL: FRANK.HAYDAR@ELLIOTTMACHINERY.COM
WWW.ELLIOTTMACHINERY.COM
Shop View
Canada’s Carrots
G
“
There is no path to
profitability for the
plant, not even with
significant government
subsidies coupled with
wage concessions from
the union—the gap is
simply far too large.
”
ROWTH IN THE manufacturing industry in Canada occurs
in two ways—through domestic companies and foreign direct
investments.
Both avenues of growth require the right economic conditions.
Companies are more willing to invest when they know they will get a return on
their investments. During poor economic periods, investments slow down.
One way countries spur manufacturing growth is with Foreign Direct
Investment (FDI) incentives. In 2003, the Organization for Economic Cooperation and Development (OECD)— Canada is a member—published a
checklist for foreign direct investment policies. The document lists the tools and
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incentives, infrastructure and job training subsidies, temporary wage subsidies,
relocation support and administrative assistance. It also outlines the challenges
and pitfalls countries face when implementing such incentives.
Looking at Mexico, one might say these incentives are working. The Mexican
government has set up an aerospace supplier park to accommodate the growing
LQÁX[RIVXSSOLHUVZKRZDQWWRPRYHFORVHUWRWKH2(0VWKDWKDYHVHWXS
manufacturing operations in the country (Canadian aerospace manufacturer
Bombardier announced in 2005 it would invest US $200 million over seven years
to set up in the park). It offers free multi-year land leases and pays the infrastructure
cost for roads, lighting, sewer, natural gas, telecommunications and electric power.
Look at Canada though, and you start to wonder: are incentives the way to
go to secure foreign investments and the future of the manufacturing industry?
In March, Spanish appliance manufacturer Mabe announced the closure of its
PDQXIDFWXULQJSODQWLQ0RQWUHDO´7KHUHLVQRSDWKWRSURÀWDELOLW\IRUWKHSODQW
QRWHYHQZLWKVLJQLÀFDQWJRYHUQPHQWVXEVLGLHVFRXSOHGZLWKZDJHFRQFHVVLRQV
from the union—the gap is simply far too large,” said Michael McCrea, VP of
operations for Mabe Canada.
Mexico, even without incentives, attracts foreign companies because it’s a
fast-growing market with a low-cost labour force and with better geographic
access to the even faster growing economy of Brazil. So how does Canada
compete against this growing competitive tide that continues to push
manufacturing out of the country?
Striking the right balance with incentives is important; Canada needs to
choose and implement policies that encourage manufacturers to invest here, but
those policies can’t be the sole reason businesses invest here. Canada needs to
rethink its policies to ensure that incentives encourage sustainable growth in the
manufacturing sector.
MARY SCIANNA, EDITOR | marys@shopmetaltech.com
MAY 2012 www.shopmetaltech.com
7
Industry Update
Close to 60% of
Canadian businesses
expect sales to
increase in 2012.
PEOPLE
Sandvik Coromant has
reorganized its business
structure to better focus on
growth, it announced recently.
JOHN ISRAELSSON will lead the
new regional organization (as
announced earlier in the year)
as president of Market Area
Americas. Management reporting to him include ROSS CARPINO
and CARLOS VELAZQUEZ who will
continue in their current roles
overseeing operations for
Canada and Mexico respectively. JAMIE PRICE is president of
Sandvik Coromant USA, while
CLAUDIO CAMACHO is president of
the sub-market area of South
and Central America.
LARRY SCHWARTZ, chief strategy
officer and former president of
Okuma America Corp.,
Charlotte, NC, has
retired. The 40plus year veteran of
the manufacturing
industry spent 17
years with Okuma
and served as president
from 2005 to 2011. He will
continue to serve in an advisory
capacity to Okuma for a
minimum of 18 months.
8 www.shopmetaltech.com MAY 2012
SPRING GROWTH:
Firms looking at
expansion, investments
CANADIAN BUSINESSES ARE ready to expand,
hire more people and invest in machinery
and equipment, according to the Bank of
Canada’s Spring 2012 Business
Outlook Survey.
The survey “was
considerably more upbeat
on the outlook for sales but
didn’t register a big shift
in the inflation backdrop,”
notes Douglas Porter,
CFA and deputy chief
economics for BMO,
commenting about the
survey online at BMO’s
web site. “A snap-back
in future sales growth
expectations—from a negative
territory in Q4, to a two-year
high in Q1—was the most
notable aspect of the survey.”
Leslie Preston, an economist
with TD Economics, says the
survey “showed that Canadian businesses have a significantly
sunnier outlook on their sales prospects over the next 12
months than back in December: 35 per cent more businesses
expect their sales to be better than last year, the highest level
of optimism since early on in the economic recovery.”
Of the 100 businesses surveyed, close to 60 per cent said
they expect future sales volumes to increase at a greater rate
than sales in 2011. Close to 50 per cent said they expect
their investment spending in machinery and equipment to
be higher in the next 12 months than over the previous 12
months. And firms are also planning to hire more people;
55 per cent said the level of employment over the next 12
months will increase.
And while businesses are still dealing with labour
shortages that may restrict their ability to meet growing
demand, many reported that credit conditions are easing;
26 per cent noted that in the past three months, terms and
conditions for obtaining financing have eased.
Visit Bank of Canada online at www.bankofcanada.ca for
the full report.
EVENTS
SEPTEMBER 10-15
IMTS 2012
Chicago, IL
www.imts.com
SEPTEMBER 11
IMTS Canadian Luncheon
Organized by Shop
Metalworking Technology
Chicago, IL
www.shopmetaltech.com
SEPTEMBER 25
Insights 2012 Conference
Organized by Shop Metalworking
Technology
Toronto International Centre
www.shopmetaltech.com
With great power
comes great
reliability.
Your unique skills
and our premium
products — destined
for heroic deeds.
Pat and the
Axcess® 450 —
joining forces to
reign supreme
[ ]
Together, this
tremendous team
tackles the most
troublesome
welding tasks!
Visit our website to nominate
your own welder hero.
The Power of Blue®
MillerWelds.com/hero
MMTS FLOOR PLAN
(Montreal Manufacturing Technology Show)
BOOTH 16
BOOTH 703
BOOTH 815
BOOTH 725
BOOTH 726
BOOTH 533, 547, 633, 647
BOOTH 149
BOOTH 457
BOOTH 363
www.mmts.ca
TRADE
SHOW
UPDATE
Industry Update
MMTS: Bigger event reflects rising optimisim
The issues facing Quebec manufacturers are
no different than those facing manufacturers
across the country: improving productivity,
cutting costs and retaining a
skilled workforce.
What is different is
that manufacturers in
the province will have the
opportunity to tackle some of
these issues at the Montreal
Manufacturing Technology
Show, being held May 14-16
at Place Bonaventure in
downtown Montreal.
“Manufacturers need
up-to-date technology,
equipment and services to
remain competitive and it’s
our job to present those
solutions in a format that
makes it easy for them to
find the answers,” says Nick Samain,
group show manager with the Society
of Manufacturing Engineers (SME),
MMTS organizer.
Quebec business leader Larry Smith will
kick-start the event in a keynote address
to attendees. A former
football player, president
of the Montreal Alouettes
Canadian Football League
franchise, and former
president and publisher of
the Montreal Gazette, he
will give delegates pointers
on achieving success in
manufacturing.
For the first time at
MMTS, the educational
component will be held on
the show floor, a growing
trend among trade shows,
says Samain. It’s a good
way for attendees to
take in the educational
events and not miss the opportunity to see
the technologies at the show. Called the
“interactive practical education component,”
the event is designed to deliver open, informal
hands-on technical information.
A new key initiative is a special night
dedicated to job shops.
“It’s an opportunity to celebrate the
independent job shops in the province
and the work they do to support the
manufacturing industry. We’re holding this
event on the night of May 15,” notes Samain.
The rising optimism about the
manufacturing industry’s rebound is
reflected in the larger show for 2012, a 15
per cent increase from the previous MMTS
event. Many of the major machine tool
builders and distributors have committed to
the event, including DMG, Elliott Matsuura,
Ellison Technologies (Mori Seiki distributor),
EMEC Machine Tools (Okuma, Hardinge),
Huron Canada, Mazak, Megatel, Prima Power
and TRUMPF.
Samain says more than 5,000 attendees
are expected to attend this year’s event. For
details on exhibitors, educational events and
registration, visit MMTS online at www.mmts.ca.
MAY 2012 www.shopmetaltech.com
11
Industry Update
MANUFACTURING BUSINESS
MANUFACTURING SUCCESS SECRET: Boost services, says report
If the mantra in real estate is location, location, location, in the
the survey conducted with Quebec-based manufacturing SMEs, 45
manufacturing industry, it’s service, service, service. The notion is
per cent said one of the biggest challenges in offering a service is
supported by a recent report from the Conference Board of Canada
finding qualified personnel—the ongoing issue of the shortage of
in conjunction with McGill University entitled “SME Manufacturers
skilled workers. Another 12 per cent said “identifying what specific
in Quebec: Adding Services to Boost
services to provide” as a challenge and a
Revenue Attributed to Sale of Service
Competitiveness and the Bottom Line,”
surprisingly small number, only 1 per cent
(percentage of firms; n=86)
by Samuel Suss, Michelle Thomson,
of survey participants, identified “accessing
Vincent Thomson, and Michael Bloom.
significant capital to fund the development of
24
Value-added services is not a
new service offerings” as a challenge.
„ 0%
new concept; it’s one key to how
The report also looks at how some
manufacturers can remain competitive.
manufacturers have overcome these
„ 1-20%
4
The report identifies the reasons why
challenges. Some have consulted their OEM
„ 21-60%
manufacturers should offer services
customers to ensure they have the services
5
with their core product offers. It states
they need, others have partnered with
„ 61-100%
67
“services have higher profit margins than
distributors, while still others have developed
products…and provide a more stable
specialized personnel and expertise.
NOTE: Respondents were asked “Approximately
source of revenue because they are more
“The key factors that helped SMEs
what percentage of revenue do you attribute to the
resistant to economic cycles that affect
deliver services to their clients were in-house
sale of services?” Source: McGill University
investment and equipment purchases.”
expertise, knowledge of their products,
It also notes that services are “more difficult to imitate than
knowledge of foreign languages and regulations, knowledge of
products and as such are a source of competitive advantage.”
clients’ needs, and the ability to provide solutions."
And while providing services is important, the report identifies
For the full report, visit the Conference Board of Canada’s online
the challenges manufacturers face in trying to implement them. In
library at www.e-library.ca.
LVD Strippit undertakes new manufacturing initiative
LVD Strippit, part of the LVD Group of companies, has begun
implementation of a World Class Manufacturing initiative to improve
throughput, reduce waste and assure product quality. The initiative is
being carried out at LVD Strippit in the US and at LVD Company
in Belgium.
The undertaking will be overseen by Peter Maes, the company’s newly
appointed director of world class manufacturing.
World Class Manufacturing is a process-driven approach primarily
focused on continual improvement in quality, cost, lead time, flexibility
and customer service. As part of its World Class Manufacturing initiative,
production assembly departments are participating in an extensive
program of process improvements following the principles of the “house
of lean,” 7 mudas, continuous improvements, 5S and many more aimed
at optimizing each step of the assembly operation to increase throughput,
reduce waste and assure the high finished product quality.
“We’ve embarked on this continual process improvement to create
an even leaner organization and to remain flexible and responsive to our
customers,” explains Maes.
12 www.shopmetaltech.com MAY 2012
Industry Update
FABTECH Canada debut a success
BY MOST ACCOUNTS,
FABTECH CANADA
2012, Canada’s
newest trade show for the
metal fabricating industry, was
a big success.
The three-day event held at
the Toronto Congress Centre
March 20-22, drew more than
5000 attendees to see the latest
fabricating technologies and
services from 225-plus exhibitors.
Many of the attendees that
dropped by Shop Metalworking
Technology’s booth were from
Western Canada, a region that has
been undergoing a manufacturing
boom because of the oil and gas industry.
Admittedly, there was some skepticism in the industry when the show was first
announced, in part because it was being held just five months after FABTECH 2011
in Chicago, the largest fabrication show in North America. That show’s attendance hit
record numbers.
Despite the early skepticism, exhibitors committed to the event and many said they were
so pleased with leads from the first day, they committed to FABTECH Canada 2014.
Mark Lobit, marketing manager for Mazak Optonics, said he was impressed with
the quality of attendees that stopped by the company’s booth during the first
day of the show. Others who were pleased with the turnout included Stefan
Schreiber, managing director of TRUMPF Canada, and Bob Watson,
president of Fabricating Machinery Solutions (FMS).
In today’s economy it’s not often that you hear of a new equipment
builder, particularly one that is manufacturing its product in Canada.
But that is the case with Rhino Cutting Systems, a new manufacturer
of oxy and plasma cutting machines being manufactured in the
company’s Stoney Creek, ON, plant. Paul Bhogal, managing
director, says the company’s machines were developed by former
Westinghouse engineers who now work with Rhino. Look out for our
upcoming story on Rhino.
“The first FABTECH Canada surpassed expectations as the one-stop
venue for welding, fabricating and metal forming solutions. Exhibitors
were enthusiastic about the activity level on the show floor and quality of
leads,” says Janine Saperson, FABTECH Canada event manager.
The positive signs were not exclusive to exhibitors. For Cornelius Dueck, vice
president, Hi-Tec Indutries, the trip from Portage La Prarie, MB, was worthwhile.
“I was looking to check out machinery for our shop in Manitoba and found a good
selection to choose from. This is a good event.”
FABTECH Canada 2014 will be held March 18-20 at the Toronto Congress Centre.
14 www.shopmetaltech.com MAY 2012
More than 5,000
people from across
the country
attended the new
event for the metal
fabricating industry.
Shop Thought
Industry Update
What advice would you give the federal government to help save and grow the Canadian manufacturing industry?
I recently spoke to several college mechanical engineering
technicians. The level of training for the programs was good but the
operating budgets are creating limitations to how much they can
do. We must not let manufacturing slip further and government help
(funding) is required at the high school, college and apprenticeship
levels. We can produce competitively, but we need the training and
increased technology to compete on a global scale. I see an
ever-increasing shortage in available skilled help in Ontario
that is hampering our immediate growth needs. IP. China's repeated use of cyber espionage only reinforces the fact
they do not have any ethics in this regard.
I believe we should threaten to eject Mexico from NAFTA as
they still have yet to come close to US and Canadian standards in
these areas.
—Peter Pubben, president, Tapmaster Inc., Calgary, AB
—Gerry Vandersanden, president, Sciens Industries, Peterborough, ON
THE CUTTING EDGE
We find the federal government to be very aggressive in
connecting Canadian businesses abroad.
We use Premium Micro grain solid
carbide for longer tool life and
increased feeds and speeds.
—Jim Jantzi, president New-Form Tools, Stratford, ON
As long as companies are allowed to source products
overseas, manufacturing in Canada and the United States is
in trouble. I think there should be some sort of levy/tax on
product produced in countries where the rate of pay for
workers is ridiculously low and where there is little regard for
health and safety, with regards to the public and the employees.
Funding through programs like SR&ED, Yves Landry
Foundation, CME-Smart, are definitely a positive thing.
—Nigel Burbridge, vice president, operation,
Footage Tools, Vaughan, ON
I would tell our politicians this: Do not enter into free trade
agreements with countries that do not have, or at the very
least aspire to, our level of intellectual property protection,
labour standards and environmental protection. Given a level
playing field, Canadian manufacturers can compete with
anybody in the world. Countries like China have corrupt trade
practices with their habit of subsidizing raw materials,
artificially keeping their currency low and total disregard for
ONLINE REVIEW
Shop Metalworking Technology Online brings you the latest in
technological advances, new product developments and industry
updates. Here’s a sneak peek at what’s online:
Tools are stocked uncoated
and ALTiN coated.
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...
MACHINING: Medical machining: a healthy business
Low profile screw keeps
chips flowing
FABRICATING: Advancing science with waterjet cutting
CUTTING TOOLS: Milling techniques that make the cutt
WELDING: Controlling MIG welding costs
QUALITY: ISO certification
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SCIENTIFIC CUTTING TOOLS, INC.
110 W. Easy Street / Simi Valley, CA 93065 / 800-383-2244 / 805-584-9629 [fax] info@sct-usa.com / www.sct-usa.com
MAY 2012 www.shopmetaltech.com
15
Â
COVER STORY |
AEROSPACE
Overcoming
HEADWINDS
The Challenger 300.
Image courtesy
of Bombardier.
BY JIM BARNES
Funding Issues
The aerospace industry has made
significant investments in R&D and
in property, plant, and equipment
over the years. In 2009, it invested
some $1.9 billion, of which R&D
comprised 72.7per cent, according to
the Aerospace Industries Association of
Canada (AIAC) report.
Before the last federal budget,
Canada offered some of the more
positive R&D tax incentives globally.
That may have changed. The
government has de-emphasized
entitlement programs like the
Scientific Research and Experimental
Development (SR&ED) tax credit and
turned towards direct funding.
In its response to the budget, AIAC
hailed overall levels of support—
while raising some concerns. “The
proposed changes to SR&ED have the
potential to counteract some of the
other positive changes the government
has proposed in the budget,” notes
David Schellenberg, chair of AIAC.
“…Reducing the SR&ED tax
credit rate from 20 to 15
per cent and the decrease
of the eligibility rate for
subcontractors from
100 to 80 per cent,
in particular, may
well have the
opposite effect.”
In the AIAC research conducted
in 2009, most respondents did not
believe the Canadian government
provided enough funding to the
industry. Nearly two-thirds said
governmental funding is not adequate
when compared to other countries.
16 www.shopmetaltech.com MAY 2012
Strong growth prospects affected
by globalization, new technology,
changes to R&D incentives
HE GLOBAL
AL economic
downturn inn 2009 hit the
Canadian aerospace
erospace industry
hard and the totall of just over 400
aircraft ordered was painfully
i f ll low.
l Si
Since
then, the recovery in the industry has
pretty well kept pace with the general
economic recovery, but there are a
few clouds in the sky.
In 2009, makers of aircraft and
aircraft parts in Canada generated
about $11.0 billion in revenue,
according to The Strategic and
Economic Impact of the Canadian
Aerospace Industry. Deloitte & Touche
published that research in October
2010 for the Aerospace Industries
Association of Canada (AIAC).
Respondents to the research at the
T
time were optimistic.
Some 80 per cent said
that business conditions
VKRXOGLPSURYHVLJQLÀFDQWO\
over the
h following
f ll i three
h years.
The industry does not seem to be
breaking out the champagne, though.
“The recovery is not strong, yet,” says
Haley Dunne, senior spokesperson,
Bombardier Aerospace. “We have been
hoping for a year now that it would pick
up faster than it has on the commercial
aircraft side.”
More than 77 per cent of the
industry’s revenues come from exports.
The US is the biggest customer,
accounting for about 57 per cent of
revenues, according to the AIAC
research. That may not last.
The CS100
series aircraft.
Image courtesy
of Bombardier.
““A
A shift in the
thh industry is
underway towards
toward low-cost,
high-GDP
high-GD
G P areas including
i
Asia
3DFLÀFDQG/DWLQ$PHULFDµQRWHV
3DFLÀFDQG/DWLQ$
$
the document
document. “No
“Nor
“North America is
installed base, and
still our largest installe
will be for a very long ttime,” says
Dunne. However,
o
export markets have
grown dramatically in the past decade.
She notes that about ten yyears ago, the
split of North American sales
s versus
sales to the rest of the wo
world would have
broken down at approxim
approximately 70/30.
´1RZWKDWKDVDOPRVWÁL
´1RZWKDWKDVDOPRVWÁLSSHGµ
A company like
lik B
Bombardier
b
must
embrace globalization. “We have to
have more manufacturing capacity
close to the emerging customer base,”
says Dunne. Beyond maintaining
service levels by producing parts
locally, “it’s a question of having
local roots, making investments in
those markets. That gives us a better
understanding of those markets.”
Nearlyy 94 per cent
of respondents
pondents to the
AIAC survey said they felt
“substantial” pressure to become
more environmentally responsible over
the next three years.
composites, technologies related to
The workforce is another core issue
improving engines in terms of fuel
for this industry, which employed
consumption and emissions are keys
nearly 79,000 people in 2009.
to the success of the industry,” notes
Production staff accounted for the
Martin Vézina, leader–Aerospace &
lion’s share, at over 47 per cent of
Defense, Deloitte & Touche LLP.
the total.
The rising price of fuel is driving
Staff shortages are causing concern.
LQWHUHVWLQQHZPRUHHIÀFLHQWDLUFUDIW
Many respondents to the AIAC survey
“Greener” aircraft—producing fewer
indicated that the greying of the
emissions and less noise—are also
Canadian workforce and the boom in
drawing attention.
retirements would become problems,
“The environment has to be a
KDPSHULQJDFFHVVWRDTXDOLÀHG
very important component in
workforce. The need for
the design, manufacture
Innovation at work:
training is acute.
and maintainability of our
a Makino machining
The other challenge
aircraft,” notes Dunne.
cell at Chicopee
Manufacturing's
Kitchener, ON, plant.
Image: Makino
Innovation
Another cause for optimism in
the industry is the arrival of a new
generation of aircraft. “Besides
MAY 2012 www.shopmetaltech.com
17
Â
COVER STORY |
AEROSPACE
is the cost of labour, notes Vézina.
“Countries like Mexico and some parts
of the US have much lower labour
costs. We need to improve productivity
by acquiring equipment to automate
processes and remove
some of the pressure
resulting from the cost of
labour.”
Like many
manufacturers,
productivity growth
has been under the
spotlight at Bombardier
Aerospace. “We have
undergone quite a
transformation in our manufacturing
IDFLOLWLHVRYHUWKHSDVWÀYHRU
six years,” says Dunne. “We are
involved in lean manufacturing, as
well as the 'Achieving Excellence'
system, which impacts every aspect
of the corporation, from plants to
administration.”
As demand for aircraft grows
and as its new programs come in,
Bombardier will have to address
capacity issues. “We are expanding our
manufacturing footprint accordingly.
:HKDYHWRUHÀQHRXUSURFHVVHV
more and expand our manufacturing
capabilities,” says Dunne.
New spending
The Canadian defense aviation market
is different from many other countries,
says Vézina. The current government
has not shied away from defense
expenditures, while other nations are
18 www.shopmetaltech.com MAY 2012
Top: Interior of Bombardier's
Learjet 60 XR Signature series
aircraft. Courtesy of Bombardier.
Left: Machined aerospace part
from Heroux Devtek.
looking for ways to cut their military
budgets. While the multi-billion
dollar F-35 program recently became
a political football, the government
announced an investment of $5.2
ELOOLRQLQWKH&RDVW*XDUGÁHHWLQWKH
recent budget. The expenditure will
include both ships and helicopters.
“We hope that these programs will
help attract investments. We also hope
that the smaller players in the industry
ZLOOEHDEOHWREHQHÀWIURPWKHVH
investments. The IRBs (industrial
UHJLRQDOEHQHÀWVZLOOKHOSPDLQWDLQ
or increase investment in Canada for
those industries,” says Vézina.
From a global perspective, the
commercial aircraft sector is likely
to enter a prolonged up-cycle in
production in 2012, according to
the 2012 Global aerospace and defense
industry outlook: A tale of two industries.
Deloitte Touche Tohmatsu Ltd.’s
Global Manufacturing Industry group
published the research.
Over the last few years, the
global industry has delivered about
a thousand large aircraft per year.
“Studies show that the demand for
aircraft over the next 20 years will be
roughly 30,000 aircraft, which means
an average of 1,500 per year. There
is huge pressure on the supply chain,
and we hope that Canada will get its
sshare. Other countries like China,
Brazil, Russia and India are investing
B
massively,” says Vézina.
m
The opportunities lie in the supply
cchains of the major aircraft OEMs.
““The large OEMs don’t want to deal
with thousands of suppliers. They want
w
tto deal with as few as possible, and
ttransfer some of the risk to Tier One,
Tier Two and Tier Three suppliers,”
says Vézina. “We should see more
consolidation in the industry as well as
the appearance of Tier One integrators
that deal directly with the smaller
suppliers and integrate parts which
could be sold to larger OEMs.”
The bottom line? The business is
there to be had, but Canadian suppliers
ZLOOKDYHWRÀQHWXQHWKHLUZRUNIRUFHV
and productivity, make savvy
investments in R&D and gravitate
toward top-tier status if they want to
compete.SMT
Jim Barnes is a Toronto-based journalist
with more than 30 years of experience in
writing about manufacturing technology.
simply more success
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MACHINE TOOLS | Milling Case Study
THE SOLUTIONÒ
THE PROBLEMÔ
Mighty
Improve machining
productivity for large
complex parts
MILLING
Gas turbine
maker stays
competitive
with full service
support and
technology
investments
HEN RIVER Associates
Investments was looking
at acquisitions in Canada,
it turned its eye on KK Precision, a
privately held custom manufacturer
in Toronto.
The Chattanooga, TN, company
knew a good investment when it saw
it. KK Precision specializes in a niche
market—precision manufacturing of
W
Full five axis machining
with new $1.2
million universal
milling machine
BY MARY SCIANNA
complex components for gas turbines
used in the aerospace, defense, energy,
marine and general industrial markets.
Last fall, River Associates acquired
KK Precision.
Machining gas turbine components
is a challenging business that requires
engineering and manufacturing
expertise. It’s a niche market that has
helped set KK Precision apart from
MILLING MACHINES METALTECH REPORT
ÒGF AGIECHARMILLES
1G acceleration
Designed for the production of
tools, moulds and high quality
parts, the GF AgieCharmilles
Mikron HPM 800U HD five axis
high performance machining
centre features High Dynamics
(HD) technology that delivers 1G
machine acceleration rates for
fast precision part processing
and significantly reduces noncut time.
A Step-Tec 20,000 rpm
HSK-A63 in-line spindle
generates 84 Nm (63.7 ft-lb)
of torque at 4,450 rpm for high
metal removal rates, while also
providing the fast spindle speeds
necessary for producing superior
part surface finishes.
The spindle is also fitted
with oil-lubricated ceramic
hybrid bearings and is vector-
controlled, enabling thread
cutting without the use of a
compensating chuck. A fast
30-tool automatic tool changer
keeps the spindle supplied with
tools and further reduces noncut times. GF AgieCharmilles
offers tool changer capacities up
120 positions.
As a gantry portal-type
design machine, it incorporates
direct drives in the rotating and
swiveling axes of its table, which
20 www.shopmetaltech.com MAY 2012
securely clamps for precise
workpiece positioning. The
machine’s design also provides
a large work envelope and
unrestricted workpiece access,
even with the fully automated
pallet version of the machine
that can be equipped with a
2,7,9, or 12-pallet changer.
For maximum manoeuvrability
around various part sizes and
shapes, the machine provides
800 mm (31.5 in.) of travel in
the X and Y axes, as well as
550 mm (21.6 in.) of clearance
between its table surface and
spindle nose in the Z axis.
The machine’s table
surface measures 800 mm x
599 mm (31.5 in. x 23.6 in.)
and accommodates five axis
workpieces weighing as much as
500 kg (1,250 lb).
www.gfac.com/us
ÒDMG
B axis swivel range between
-5° and +110°
DMG’s universal milling machine
DMU 50 Ecoline is capable of
five-side machining and features
a NC swivel-mounted rotary
table with digital drives, a direct
measuring system and an optional
air sealing design.
With a swivel range of the B
axis between -5° and +110° and
the integrated NC round table,
this creates the high precision
basis for the machining of
complex workpieces.
A close up of
a blade ring in
production at K&K
Precision's shop.
PRODUCT: MATSUURA MX520
End User: Camatech Inc.
The DMU
160 P
duoBlock
machine.
continued on page 24 Î Î Î Î
A 8,000 rpm milling spindle with 83 Nm torque
or (optional) a fast spindle with 10,000 min-1
ensures efficient machining in all workpiece
positions. In the standard version, the spindle is
fed from a pick-up tool magazine with 16 places;
flexibility and productivity can be optimized with
the optional 30-pocket tool magazine.
For the first time, Progressline is integrated
into the machine housing. The display allows the
operator to see the remaining running time of the
workpiece and the quantities of the machining
job, while a green illuminated Lightline in the
shape of a corporate identity bracket emphasizes
the brand character of the new generation.
Larger safety panes ensure a clear view of the
operations in the work area.
New to the entry-level machine is the
incorporation of the Siemens 840D solutionline.
The user interface includes full functionality
of the ShopMill programming system. Users
can choose to adapt high-tech controls of
Heidenhain including Slimline Panel (TNC
620) or the Mapps IV from Mori Seiki.
http://ca-en.dmg.com
Milling
Machines
Metaltech
Report
From the start, Camatech Inc., a supp
lier to the alternative fuel, general
industrial and aerospace markets form
ed in 2000, knew it would have to
invest in top notch machining technolo
gy to meet the tight tolerances of part
s
demanded by its customers.
A steady increase in complex machinin
g work lead to the purchase of two
Matsuura five axis machines acquired
from Elliott Matsuura in 2010 and in
2011.
The Acton, ON, manufacturing busi
ness operates out of a 13,000 sq ft
facility which houses a Zeiss CMM
and 15 CNC machines, including lath
es from
Colchester Storm, turning centres from
Mazak, a tapping centre from Brother,
a multi-axis machining centre from
Nakamura-Tome, machining centres
from
Matsuura and Romi, and the most rece
nt addition, the two MX520 Matsuur
a five
axis machining centres.
“We’re machining more complex part
s that need
a done-in-one type of machining to redu
ce set-ups
and that’s why we went with the five
axis machining
process,” says Paul Culumovic, vice
president. “We
have other machines, including othe
r Matsuura’s and
they’re reliable machines with little dow
ntime.”
Culumovic adds the machinists in his
shop are
comfortable with the Matsuura machine
s because
they’ve worked on them for several year
s. “The
controls are the same and although
the software
program is a little different—it’s mor
e user friendly—at the end of the day
it’s a
Matsuura and our employees know how
to work with this machine.
The machine is also better ergonom
ically designed, says Culumovic.
“It’s easy to load and unload the part
s; you can step into the machine and
load
the parts, so during setup you don’t
need to be a contortionist.”
While Camatech likes the design of
the machines, it’s the productivity
gains of five axis machining that cinc
hed the decision to purchase them.
Five
axis gives the company the ability to
machine a variety of parts from simp
le to
complex faster and in one set-up.
The two 12,000 rpm Matsuura mac
hines are five axis vertical machining
centres that can hold workpieces up
to 520 mm in diameter by 350 mm
in height.
Machine load is made easier because
of the 385 mm distance from the mac
hine
door to the table centre and a front
door opening width of 805 mm.
X, Y and Z axis travels are 630 mm,
650 mm and 510 mm respectively.
The
rapid traverse rate in X, Y and Z axes
is 30m/min. In the A axis it's 10 min
-1
and
in the C axis it's 25 min-1.
New to these machines is several supp
ort functions that are now standard,
but
were optional in the past. Among them
is a collision avoidance system, Intellige
nt
Protection System (IPS), and the new
generation operation system, the Mat
suur
a
Intelligent Meister System (MIMS).
www.elliottmachinery.com
MAY 2012 www.shopmetaltech.com
21
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machining productivity at the
Photo: DMG Canada
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technologies. In addition to
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The conference is co-located
with AMEXPO 2012, Canada’s
exclusive manufacturing event
for Advanced Manufacturing,
sponsored by SME Canada. And
with the AMCON Design and
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More details to come within the
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MACHINE TOOLS |
THE EQUIPMENT
Milling Case Study
Î Î Î Î continued from page 21
standard custom job shops in Canada,
says George Koulakian, vice president.
“It’s what differentiates us from
others in the market. Because of the
type of precision work we do, we work
directly with our OEM customers to
manufacture parts. So even before the
drawings are generated, our engineers
will meet with our customers’
engineers to discuss how the part
will be made. It’s a good partnership
because our customers are good in
designing a part and we are good in
knowing how best to manufacture it.”
At the heart of KK Precision’s
business is its manufacturing shop, a
28, 000 sq ft facility in North Toronto
that houses 22 CNC machines—
vertical lathes, horizontal boring mills
DQGÀYHDQGVL[D[LVPLOOLQJPDFKLQHV
grinding machines, and machining
centres. The latest member of the
IDPLO\LVDIXOOÀYHD[LVXQLYHUVDO
milling machine from DMG, the
DMG Canada, Mississauga, ON, installed the DMU 160 P duoBlock universal milling
machine in KK Precision’s shop in 2010. What sets the machine apart from other five
axis machines in the company’s shop is the full, simultaneous five axis machining
capability that has reduced set up times and improved machining cycle times on some
parts by 20 per cent, estimates George Koulakian, KK Precision’s vice president.
“We used to buy Japanese machines and this is the first German-made machine we
have purchased. It has made a good impact. Our other machines are good, but they are
older models and the DMG machine has the latest technologies, so we expected it to
perform better. It’s a high speed machine and it’s very accurate,” notes Koulakian.
“This milling machine has provided us with the opportunity to be more competitive
because we’ve been challenged with costs. We are more productive with it because of
its full five axis capability, which allows us to machine on all sides of the part, even
far reaching areas that we can’t machine on our other CNC
machines. Set up is also faster because we onlyy
have to set up once to do an entire part whereas
as
with our other machines we may have to do more
ore
than one setup and that means idle time on thee
machine, which costs us money.”
And when you’re dealing with a $1.2 million
n
machine tool investment, you want to minimizee
machine down as much as possible. Koulakian
says he expects a five-year ROI in the investment.
ent.
The DMG milling machine’s performance
is partly attributed to its design and
construction, which features the machine tool
builder’s patented duoBlock construction on a solid threepoint support machine bed for higher machining precision and accuracies. The 12,000
rpm machine is designed with X, Y and Z work areas measuring 60.0 in. x 49.2 in. x
43. 3 in. (1.5 m x 1.2 m x 1.1 m) respectively. The machine can handle table loads
up to 8, 818.5 lb (4,000 kg).
Part of KK Precision’s success in the gas turbine manufacturing market is its focus
on technology.
“As we move into new technologies [with gas turbine component machining] we
are looking at milling machines with turning capabilities. This is something that we
are looking at for the future and I know that DMG and others have mill turn machining
centres that could meet future needs. While cutting tools are important in the machining
process, for us, it is the machine tool that makes the difference in our ability to precision
machine the parts we make.”
MILLING MACHINES METALTECH REPORT
ÒDOOSAN
Tight tolerances for
hard-to-cut materials
The NHM5000 is a new
horizontal machining centre
designed to achieve tight
tolerances in hard-to-cut
materials, while machining parts
as large as 33.5 in. x 43.3 in.
(850.9 mm x 1,100 mm).
The one-piece casting
provides a rigid base for the table
and column. The bed consists of
fine-grain Meehanite to dampen
vibration and dissipate heat.
Ribs are strategically located to
improve rigidity. The integral box
ways are induction hardened,
precision ground, and coated
with a low-friction fluoroplastic
resin for longer life, maximum
rigidity, and greater precision.
24 www.shopmetaltech.com MAY 2012
Powering the spindle is a
25 Hp, two-geared motor that
generates speeds up to 6,000
rpm, and produces 704 ft-lbs of
low-end torque. A refrigerated
spindle cooling system maintains
a constant spindle temperature
for high accuracy, regardless of
ambient temperature or cutting
conditions. Coolant circulates
through jackets in the spindle
head as well as through the
gearbox.
Feeding the spindle is a servodriven ATC that accommodates
60 tools (up to 376 optional)
50-taper, with maximum
diameters of 12.6 in. (320 mm)
and lengths of 20.9 in. (531
mm). The Big Plus dual contact
system allows contact between
the machine spindle face and the
toolholder flange face, and at the
same time, between the machine
spindle taper and the tool holder
taper shank. Tool-to-tool time is a
quick 2.0 seconds.
The machine has a rotarytype, high speed servo motor
with reducing gear, for faster, 9.6
Drill/Tap machines can tap quickly, but only make sense
Haas Automation
in a mass-production environment.
Haas is Different.
The DT-1 taps at 5000 rpm, but still offers generous travels, sufficient milling
capabilities, and the industry-leading Haas control. A quick, rugged, simple
solution for a wide range of parts where speed is at a premium.
Find your local Canadian Haas Factory Outlet:
Vancouver: 604-276-2131 s%DMONTON: 780-435-3928 s#ALGARY: 403-720-3201 s7INNIPEG: 204-925-9300
Montreal: 514-337-3101 sToronto: 416-255-3503 s7INDSOR: 519-966-4880sWWW(AAS#.#COM
Â
MACHINE TOOLS | Milling Case Study
DMU 160 P duoBlock installed in 2010. The new high speed
machine has helped the company improve productivity by
reducing set up times and machining cycle times.
The shop can accommodate a variety of large sizes. Tables
for all of the machines range in diameter and include 1 m, 1.6
m, 2 m, 3 m and 4 m tables.
The custom manufacturing business is a competitive one,
even when you’re working in a niche market such as gas turbine
component manufacturing. KK Precision has positioned
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and by providing component assembly of precision modules.
The latter service means having a supply chain management
program overseen by a supply chain manager.
MILLING MACHINES METALTECH REPORT
second pallet changes. The table
measures 19.7 in. x 19.7 in.
(500 mm x 500 mm), supports
a load of 1,764 lb (800 kg), and
indexes to 4° x 90°.
www.doosaninfracore/
machinetools.com
ÒFEELER
1.9 second tool change time
The Feeler line of vertical
machining centres, available in
North America from Methods
Machines Tools Inc., includes
the HV-Series, VB-Series and
VMP-Series.
The HV-Series VMCs, including
HV-800 and HV-1000 models,
offer high performance machining
featuring 1G X axis acceleration
and 1.9 second tool change time
in 800 mm or 1,000 mm X axis
travels. Roller guideways are
on the X and Y axes. A 15,000
rpm, 30 hp direct drive, 40 taper
spindle, Fanuc 18i-MB Control
with fourth axis prep. and 30tool automatic tool changer are
standard.
The VB-Series VMCs are heavy
duty boxway machines featuring
a high torque two stage gearbox
and spindles from 15 hp to 30
hp, available in 40 or 50 taper.
Models include VB-900, VB1100, VB-1300, VB-1400, VB1650, VB-1900 and VB-2200. X
axis travels range from 900 mm
- 2,200 mm (35 in. – 87 in.), Y
axis travels range from 610 mm –
1,000 mm (24 in. – 39 in.) and
Z axis travels are from 600 mm
– 800 mm (24 in. – 31.5 in.). A
30-tool automatic tool changer
and Fanuc 0i-MD control are
standard.
KK Precision's
shop is equipped
to handle large
parts used for
turbine engines.
guideways on X and Y axes and
boxways on the Z axis. X axis
travels range from 580 mm –
1,100 mm (23 in. – 43 in.), Y
axis travels range from 420 mm
– 610 mm (16.5 in. – 24 in.) and
Z axis travels are from 510 mm
– 600 mm (20 in. – 23.6 in.).
The VMP-580 features a 24-tool
automatic tool changer and the
VMP-800 and VMP-1100 use a
30-tool automatic tool changer. A
Fanuc 0i-MD control is standard
on the VMP-Series machines.
The rigid machines range in
weight from 3,000 kg (6,600
lb) – 22,000 kg (48,400 lb) and
include a two year warranty.
FEELER machines are
manufactured by Fair Friend
Group (FFG).
www.methodsmachine.com
ÒFIRST
The VMP-Series includes the
VMP-580, VMP-800 and VMP1100 models with 10,000 rpm
spindles ranging from 15 hp – 25
hp. The VMP-580 machine is
available in an APC pallet changer
version. Machines feature linear
26 www.shopmetaltech.com MAY 2012
High speed machining
The First V700 high speed
machining centre, available in
Canada from Heinman Machinery,
is a robust machine designed with
three axis high rigidity precision
roller guideways and a direct drive
rigid 10,000 rpm spindle for low
noise/low vibration machining.
It features a rapid traverse
speed of X, Y and Z of 48 m/
min. A wide door opening makes
it easy for operators to access
workpieces.
The machine is constructed
using Meehanite cast iron. A
box type headstock construction
contributes to the machine's high
cutting capability. The ball screws
are directly driven with servo
motors, and all axes are designed
with C3 grade ball screws.
The machine is equipped with
a 24 tool magazine and automatic
tool change with a tool-to-tool
time of 2.0 seconds and a chipto-chip time of 4.8 seconds.
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High-speed
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Coolant Proof
protection for
digimatic gauges
In-line CMM with
Pre/Post machining
feedback
Patented high speed
micrometer
U-Wave Wireless
measuring system
Solar powered
digimatic gauges
Electromagnetic
Linear Scales with
patented ABSOLUTE
encoder
Non-contact
line-laser probe for
CMM
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MACHINE TOOLS | Milling Case Study
“In the past a customer would go to a
number of different suppliers to machine and
assemble different components for a part. We
approached our customers and said to them
‘let us handle the assembly of the parts we’re
machining for you.' So now we purchase
the components that we don’t machine and
assemble them onto the parts we do machine
WRSURYLGHEHWWHUYDOXHDGGHGVHUYLFHWRRXU
customers.”
$QH[DPSOHRIWKLVLVDIXHOVKXWRIIYDOXH
It has more than 25 components that need to
be assembled. KK Precision machines only
three to four of these components, purchases
the remaining ones, and assembles them into a
part for its customer.
..3UHFLVLRQLVZHOOSRVLWLRQHGWRH[SDQG
in its niche market. It employs 40 machinists
Above: Gas turbine components are machined from high
temperature alloys, such as Cobalt, Hastelloy, Inconel,
Titanium and Waspaloy.
Top right: The machine shop houses 22 CNC machines.
Bottom right: The latest machine in the shop, the DMG
DMU 160 P duoBlock universal milling machine wilth
full five axis capability.
MILLING MACHINES METALTECH REPORT
For chip removal, a standard
spiral type chip conveyor in the
middle of the machine removes
chips easily. As well, two
independent pumps ensure there
is strong chip flushing during
machining and efficient cooling
on workpieces too.
www.heinmanmachinery.com
travels of 762 mm x 508 mm x
520 mm (30 in. x 20 in. x 20.5
in.) and a 24-tool ATC. As with
all Hurco machine tools, the true
advantage of the VMX30U resides
within the control technology.
Not only does the integrated
Hurco control have both NC
ÒHURCO
Conversational programming
at the control
The benefits of a five axis vertical
machining centre go beyond
simultaneous five axis work
that requires a CAM system.
More shops are realizing greater
profit margins on existing parts
by converting to a five-sided
machining process using a five
axis machine instead of using a
conventional three axis VMC.
Hruco’s VMX30U five axis
machining centre features X/Y/Z
Management, and an intuitive
graphical user interface are just
a few of the control features
that increase productivity and
usability.
The VM10U, with X/Y/Z
travels of 533 mm x 406 mm x
483 mm (21 in. x 16 in. x 19
in.), is a smaller version of the
VMX30U, but just as powerful,
claims Hurco. Its small footprint
and large work cube make it
especially popular when space is
at a premium.
www.hurco.com
ÒMAKINO
and conversational, with full NC
support, you can program five
sided parts at the control with
conversational programming—no
CAM system needed. Features,
such as Universal Rotary,
Transform Plane, Tool Path
Linearization, Tool Centre Point
28 www.shopmetaltech.com MAY 2012
14% larger work envelope
Makino’s a51nx and a61nx
horizontal machining centres
extend the capabilities of the
highly successful a-series with
technologies for next-generation
productivity, accuracy and
reliability. It's designed with
larger work envelopes, improved
casting designs and spindle and
axis guide enhancements, the
nx machines offer rigidity, speed
and precision far beyond that of
typical 40-taper machines.
The machines boast expanded
axis travels to accommodate larger
parts or more parts per fixture.
The a51nx features a 560 mm
(22.0 in.) X axis and extended
Y and Z axes of 640 mm (25.2
in.) for a total axis volume of
8.1 cubic feet. Its additional Y
stroke yields a 14 per cent larger
MACHINING GAS TURBINES
Î
GAS TURBINE ENGINES ARE LARGE, heavy parts that
power large commercial aircraft, nuclear power plants,
ships, trains, and even military tanks. The turbines can
weigh hundreds of pounds and are typically made from super alloys
such as Cobalt, Hastelloy, Inconel, Titanium and Waspaloy. Some of
the gas turbines can cost upwards of $35 million and take up to 300
hours to machine. No surprise then that machining components for
such parts requires problem-free precision machining.
“We specialize in this area and it’s not something that any machine
shop can make because these types of parts require knowledge of the
machining process, knowledge of the materials being machined and
knowledgeable engineers that can provide the support to ensure the
machining is done correctly,” explains Koulakian.
KK Precision manufactures gas turbine components for many
of the major OEMs in the aerospace and energy markets including
Rolls-Royce, Siemens, Atomic Energy of Canada, GE, Pratt & Whitney
Canada and Husky. Components in a gas turbine vary depending on
the OEM and the end market, but all are complex parts that require
precision machining and assembly.
For instance, for some of the gas turbine engines for Siemens and
Rolls-Royce, KK Precision manufactures many components, such as
casings (inlet, intermediate pressure compressor and high pressure
compressor), inlet and outlet variable guide vane assemblies, bearing
housings and lands, 2.5 m and 3 m blade rings and blade ring
housings, turbine shafts and turbine discs.
working envelope.
The standard a61nx features
a 730 mm (28.7 in.) X axis, 650
mm (25.6 in.) Y axis and extended
Z axis of 800 mm (31.5 in.). An
optional tall column on the a61nx
expands the Y axis to 730 mm
(28.7 in.), making it beneficial
for large die-cast or near-netshape applications. Thanks to the
expanded Z axis stroke, maximum
tool length on the a51nx and
a61nx models is increased to 430
mm (16.9 in.) and 510 mm (20.1
in.), respectively.
The machines offer new, more
powerful standard and optional
spindles. The standard spindle is
a 14,000 rpm design with 240
Nm of duty-rated torque and
22 kW of continuous output, a
19 per cent increase over the
previous model. An optional 300Nm spindle designed for high
metal-removal rates in ferrous
applications is also available.
Along with the two new spindles,
the current 20,000 rpm corecooled spindle remains available
as an option on both machines.
The nx machines are designed
with a 1G axis acceleration
supplemented by high power servo
motors and enhanced casting
rigidity for faster acceleration.
Additionally, nx models have a
standard Direct Drive (DD) motor
B axis table for faster indexing
time over the previous worm-geardriven NC rotary table (NCRT).
www.makino.com
ÒMAZAK
50-taper spindle
Mazak’s Vertical Centre Nexus
700D-II is equipped with the
unique combination of a 50-taper
spindle together with a 10,000
rpm maximum speed capability.
The 40 hp (30 kW) spindle
generates a maximum torque of
and 25 support staff all
involved in what Koulakian
describes as the company’s
“complete solution” for gas
turbine OEMs.
“We’ve developed
expertise in machining for
this niche market and it’s
not something that everyone
can do. We’ve differentiated
ourselves from others
by providing a complete
solution for a specialized
market—purchasing
component materials,
machining high temperature
alloys, providing engineering
knowledge and component
assembly.” SMT
223 ft-lb (302 Nm). Additionally,
the machine’s spindle and motor
housing, as well as its ballscrew
cores, are temperature controlled
to ensure stable machining
accuracy over extended periods of
high speed operation.
A large table measures 1,740
mm x 700 mm (68.5 in. x 27.6
in.) with a maximum part weight
capacity of 2,000 kg. (4,409 lb).
The table, in conjunction with X,
Y and Z axis strokes of 1,530 mm
(60.2 in.), 700 mm (27.6 in.)
and 650 mm (25.6 in.), expands
the machining envelope for
larger workpieces. For reducing
For more information on
machining technologies,
visit Shop Metalworking
Technology’s MACHINING
ZONE online at
www.shopmetaltech.com.
non-cut times, the machine
rapid traverses at a rate of 30
m/min (1,181 ipm), features a
quick tool-to-tool change time of
just 2.0 seconds with a 24-tool
standard magazine (40-tool
magazine optional).
For vibration control, the
machine is equipped with the
Active Vibration Control, which
reduces vibration for high
accuracy motions in all axes while
reducing machining time.
Table access is a short 330.2
mm (13 in.) reach from the
front cover and the front door
is 1,798.3 mm (70.8 in.) wide
for easy set up and loading.
The overhead cover retracts for
convenient loading of heavier
parts by use of a crane. All
lubrication inlets, air valves and
other maintenance items are
located on a single panel for
operator convenience.
www.mazakcanada.com
MAY 2012 www.shopmetaltech.com
29
Â
MACHINE TOOLS | PRODUCTION MACHINING
Cutting
CYCLE TIMES
Software enables Select Tool to reduce cycle times on three axis work
Hurco's motion control
software reduces
machining cycle times
for Ontario shop by
25% to 33%.
BY JIM BARNES
The Technology
Hurco claims a number of quantifiable
benefits for the UltiMotion technology:
9
CORNERING VELOCITY: Speed
increases of 250 per cent over
conventional motion techniques.
Cycle times decrease even further on
complex part geometries.
9
IMPROVED SURFACE FINISH:
Machine jerk may be reduced during
direction changes by 50 per cent.
The smoother motion results in fewer
chatter marks, less vibration and
consequently better surface finish.
9
FASTER DRILLING AND TAPPING:
Cycle times for repetitive tasks such
as drilling or tapping may be reduced
because the machine takes the
shortest path from hole to hole and
features high speed tap retract.
9
EXTENDED MACHINE LIFE:
Reductions in jerking and vibration
extend the life and accuracy of the
machine tool.
30 www.shopmetaltech.com MAY 2012
IMES ARE TIGHT in Canadian
job shops, and most owners are
looking for effective ways to
improve productivity without excessive
cost or effort. Enhancements to
machine tool programming may be one
method of achieving this. What if you
could improve cycle rates and quality
with a simple control upgrade?
That was an opportunity acted
upon by Select Tool Inc., a busy shop
LQ2OGFDVWOH217KHÀUPLVDVDYY\
operation when it comes to automation
and CNC.
The company makes gauges,
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T
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production lines. It designs and
manufactures everything from the
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complex attribute and automated data
FROOHFWLRQÀ[WXUHV0RVWRIWKHSURGXFWV
are unique.
While productivity is an imperative
IRUWKHÀUPLWLVQRWWKHRQO\RQH
Since customers use Select’s products
for quality control, they have to be
produced to the highest standards for
accuracy.
The company describes itself as
having an “aggressively proactive
approach to cost management, quality
assurance, on-time delivery and
extensive after-sales service.” It puts
HPSKDVLVRQHIÀFLHQWPDQXIDFWXULQJ
initiatives, capital investment and
FRQWLQXDOWUDLQLQJ
Enhanced control
Select Tool built its current facility in
,WLQFOXGHVD&00URRPDORQJ
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and future expansion were keys to the
EXLOGLQJ·VGHVLJQ
All computer-controlled equipment is
QHWZRUNHGZLWKWKHÀUP·VHQJLQHHULQJ
systems. As a result, the company can
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work is done in-house in a 3D solids
environment.
As you would expect, Select has
an extensive array of CNC machine
WRROVLQFOXGLQJÀYHIURP+XUFR1RUWK
K
$PHULFD³WZRÀYHD[LVPDFKLQHVDQG
three, three axis machines. The three
axis machines are two VMX24s and a
VMX42.
7KH+XUFRFRQWUROVJDYH6HOHFW7RROO
WKHRSWLRQWRXSJUDGHLWVRSHUDWLRQV
with UltiMotion, a software product.
“UltiMotion is basically a patented
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explains Poulin.
“On a normal machine, you have
the X-Y-Z axis drive. The drive follows
parameters that control the path the
machine has to follow.” Once installed
LQWKHFRQWURO´8OWL0RWLRQPDQDJHV
Select Tool uses several Hurco
machines, including three axis
models equipped with Hurco’s
UltiMotion software.
Select Tool has “drastically
increased feeds and speeds,”
says owner Paul Hollister.
the machine movement. You are not
limited by the hard parameters that are
set in the drives,” he says.
´6D\\RXDUHJRLQJIURPKROHWRKROH
RQDW\SLFDOPDFKLQH2QFHLWÀQLVKHV
WKHÀUVWKROHLWLVJRLQJWRUHWUDFNDQG
hop from hole to hole instead of the
W\SLFDOUHWUDFWDQGPRYH\RXZRXOGÀQG
on a standard motion,” says Poulin.
“With UltiMotion, it looks ahead at
ZKDW·VLQWKHSURJUDPDQGZKHUHLWKDV
WRJR³DQGLWÀQGVWKHVKRUWHVWSDWK
WRJHWWKHUHXVLQJDG\QDPLFYDULDEOH
look-ahead.
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QRUPDOO\XVHVWKHSURJUDPSDUDPHWHUV
to decelerate, turn the corner and
accelerate back to the feed rate,” he
VD\V7KHPRWLRQFRQWUROWHFKQRORJ\
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down and how much it needs to speed
back
b up.”
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EHLPSUHVVLYH´(DFKLQGLYLGXDOVDYLQJ
E
PLJKWQRWDGGXSWRPXFKLQGLVWDQFH
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E
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make
m any difference in this application.
UltiMotion
works the same way. “If
U
they
t use G-code, it will still do the same
process,”
says Poulin.
p
Real world
SSelect Tool quickly came to see the
EEHQHÀWVRIWKHWHFKQRORJ\RQLWVWKUHH
DD[LVPDFKLQHV´,W·VRQDOORIRXUWKUHH
DD[LV+XUFRFRQWUROVQRZµVD\V3DXO
+ROOLVWHURZQHU´,WHQDEOHVXVWR
drastically increase our feeds and speeds
RQÀQLVKLQJ«:H·UHJHWWLQJRXUEHVW
IHHGVDQGVSHHGVRXWRIWKH+XUFRVZLWK
UltiMotion, compared to any of our
other machines.”
Select Tool has two basic types of
DSSOLFDWLRQSULVPDWLFPDFKLQLQJDQG
FRQWRXULQJ7KHFRQWRXULQJRSHUDWLRQV
ZHUHWKHIRFXVWREHJLQZLWK
MAY 2012 www.shopmetaltech.com
31
Â
MACHINE TOOLS | PRODUCTION MACHINING
The new Hurco software
has helped cut down on
machining cycle times.
Ultimotion is used on
Select Tools’ three
axis Hurco machines.
“We haven’t really played with it
a whole lot on prismatic—drilling,
tapping and hole punching. We
haven’t noticed much change, but
then we have not pushed the limits
and the programs are rather short,
W\SLFDOO\µH[SODLQV+ROOLVWHU´:H
KDYHQ·WSOD\HGZLWKWHVWLQJLWRXW«
EXWWKDW·VQH[WRQRXUOLVWµ
“UltiMotion makes the big difference
on our contour machining, primarily
ZLWKDOXPLQXPPDWHULDOµKHVD\V´2XU
contouring programs are longer and
ZH·YHQRWLFHGDQ\ZKHUHIURPDWR
per cent reduction in machining time,
DQGFXWWHUOLIHLVH[WHQGHGµ
Hollister supports Hurco’s claims
RILPSURYHGVXUIDFHÀQLVK´:H·UH
ÀQGLQJLPSURYHPHQWVLQVXUIDFHÀQLVK
LQWKHWUDQVLWLRQDODUHDVµKHVD\V´,I
ZH·UHUXQQLQJDORQJDUHODWLYHO\ÁDWRU
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about the same as what we were getting
before, but it’s faster. However when
it goes to transition—say, into a steep
XSULVHLQWKHFRUQHUV³WKHVXUIDFHÀQLVK
looks a lot better. They seem to be able
WRVPRRWKLWRXWWUHPHQGRXVO\µ
The new technology did not
require too many changes to the way
the shop was operating. As far as the
32 www.shopmetaltech.com MAY 2012
“
We’ve noticed anywhere
from 25 to 33 per cent
reduction in machining
time, and cutter life
is extended.
”
operators were concerned, nothing
changed except that jobs were getting
done faster.
Part programming changed slightly
in response to UltiMotion. “It is
allowing us to use higher rates of speed
on our programming, because the
PDFKLQHVFDQKDQGOHLWµVD\V+ROOLVWHU
As well, some internal changes
were made in the shop, modifying the
logistics of transporting materials. “We
actually moved some machines around
that were doing one type of job before,
and dedicated two Hurcos to doing a lot
PRUHÀQLVKLQJDQGFRQWRXULQJEHFDXVH
RIWKHVSHHGGLIIHUHQFHµVD\V+ROOLVWHU
UltiMotion will soon be available
IRUÀYHD[LVPDFKLQHVWRR´:HKDYH
WZR+XUFRÀYHD[LVPDFKLQHV³RQH
capable of running UltiMotion,
DQGDQROGHUPDFKLQHWKDWLVQRWµ
says Hollister. “Our next three axis
machine will be another Hurco with
8OWL0RWLRQIRUVXUHµ
Hollister says that Select Tool has
not tried to push the technology to
its limits yet. “It does more than I
expected, and I haven’t even stepped
LQWRZKDWHOVHLWFDQGRµKHVD\V´,
wish I knew more about the product.
Give me a few more months, and I’ll
KDYHDORWPRUHWRVD\DERXWLWµ SMT
Jim Barnes is a Toronto-based journalist
with more than 30 years of experience in
writing about manufacturing technology.
For more information on machining technologies, visit Shop Metalworking
Technology’s MACHINING ZONE online at www.shopmetaltech.com.
“That Canadian Guy” live at the
SHOP IMTS Canadian Luncheon
Presented by:
See Glen Foster ( “That Canadian Guy”) live on
September 11 at the SHOP IMTS Canadian
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at the SHOP IMTS Canadian Luncheon before being
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Sandvik Coromant Canada, and Schunk Intec.
Presented by Shop Metalworking Technolog y Magazine.
Stay tuned for details.
September 11, 2012 | McCormick Place | Chicago
:
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CUTTING TOOLS | Turning
SPINDLE
UILDING TODAY’S
modern aircraft, many
engineers are switching
to high strength lighter alloys
like titanium for component
materials to increase fuel
HIÀFLHQFLHV0DFKLQLVWVDUH
challenged to maximize metal
removal rates to achieve
SURGXFWLRQHIÀFLHQFLHV\HW
face low cutting speeds and
considerably higher cutting
IRUFHV0DFKLQHWRROEXLOGHUV
must also provide greater
stiffness and damping in their
spindles to minimize undesirable
vibrations that deteriorate tool
OLIHDQGSDUWTXDOLW\
B
BIG Kaiser's
HSK-A125
tooling
system.
BY
KEITH
WIGGINS
When machining tough
materials like titanium, cutting
speeds are relatively low due
to thermal effects on cutting
WRROV,QUHVSRQVHPDFKLQHWRRO
builders have improved stiffness
and damping on spindles and
machine structures over the
\HDUV6SLQGOHVKDYHEHHQ
designed with high torque at low
URWDWLRQDOVSHHGV
Although all these advances
add to greater productivity, the
spindle connection often remains
WKHZHDNOLQNLQWKHV\VWHP
Spindle connections
The tool-spindle interface must
TURNING TOOLS METALTECH REPORT
ÒISCAR
Deeper face grooving and turning
Iscar has expanded its Minicut line of inserts
and cutting tools for deeper and wider face
grooving and turning.
cutting edge. The new products can be used for
grooving in deep holes. They offer uninterrupted
chip flow on the insert rake and can also be
used for rotating applications. Standard inserts
are available in 2.0 to 3.0 mm widths made
from IC908 grade, and special widths can be
ordered on request within this range.
www.iscar.ca
energy required to remove the chip. In most
applications, the answer means slower speeds
and feeds, since a carbide cutting tool’s
strength decreases as temperatures increase.
ÒKENNAMETAL
Better performance in OD and ID turning
The expanded diameter range is 10 to
34 mm, for up to 9 mm grooving depth. The
MIFR 10 inserts are screw-clamped into a long
pocket of the MIFHR bars with rigid clamping,
resulting in prolonged tool life and enabling
high machining parameters.
An internal coolant hole is directed to the
34 www.shopmetaltech.com MAY 2012
Because of their high performance strength
and relatively light weight, high temperature
alloys are growing in applications across many
manufacturing industries, notably aerospace
and defense, automotive, heavy equipment,
and energy.
Higher temperature strength materials,
however, also mean high cutting forces when
machining. Titanium, for example, exhibits
high work hardening and a large strain rate,
which also raises temperatures and the
New Beyond grades from Kennametal
are delivering higher productivity for turning
tough alloys, in higher speeds and feeds
(faster turnaround time) and longer tool life
(more parts per tool). KCU10 is specifically
engineered for increased performance in
OD and ID turning, grooving, plunging,
undercutting, and threading. KCU25 covers
threading, grooving, cutoff, and selected
CONNECTIONS
withstand high loads and
\HWPDLQWDLQLWVULJLGLW\,Q
most cases it will determine
how much material can
be removed on a given
operation until the tool
GHÁHFWLRQLVWRRKLJKRUWKH
RQVHWRIFKDWWHULVUHDFKHG
High performance
machining is commonly
characterized by the use of
high feeds and aggressive
GHSWKVRIFXW:LWKRQJRLQJ
advances in cutting tools,
there is a need for a spindle
connection that makes the
best utilization of available
SRZHUSRVVLEOH
Several different types
of spindle connection
have been developed or
optimized over the last few
GHFDGHV'XHWRDJRRG
FRVWEHQHÀWSRVLWLRQWKH
7/24 ISO taper became
one of the most popular
V\VWHPVLQWKHPDUNHW
Used successfully in many
applications, limitations
in its accuracy and speed
prevent it from growing
IXUWKHU*HQHUDOO\WKH
taper starts to open up
around 20,000 rpm, and if
a system doesn’t have any
LQWHUIHUHQFHÀWVWKLVLVWKH
additional turning applications.
Both take advantage of new PVD (physical
vapour deposition) coating technology, including
special surface treatments that improve
machining performance in high temperature
materials. In many cases, speeds, feeds, or
depth-of-cut, can be increased, while related
wear issues like depth-of-cut notching, are
reduced.
KCU10 has a dual-layer coating application,
a top layer of AlSiTiN atop a second layer of
AlTiN. The boundary between the two serves to
help deflect micro-cracks
www.kennametal.com
A strong spindle connection
is key to machining titanium
point that the taper starts
to lose contact on taper face
contact tools and standard
9ÁDQJHWRROLQJPRYLQJ
ZLWKLQWKHVSLQGOH
The advent of face
contact represented a
major step forward over
WKHVWDQGDUGWDSHU
The combination of face
contact with 7/24
the BN2000 provides high wear resistance and
robust toughness. It boasts a newly developed
CBN substrate consisting of a ceramic
binder with exceptional purity. While impure
binders contribute to premature chipping and
cutting edge wear, the purity of the BN2000
significantly reduces tool failure.
Sumitomo Electric Carbide Inc.’s most recent
hardened steel turning advancement is the
uncoated CBN grade BN2000.
Designed for turning die steels and bearing
steels with hardnesses of 50 HRc and above,
Kennametal's
KM4X, the next
generation of its
quick change
system.
improved edge sharpness offers customers
consistent parts with the capability of attaining
surface finishes as low as 3.2 Ra.
www.sumicarbide.com
ÒSANDVIK COROMANT
Inserts for small batch production
ÒSUMITOMO
Turning hard steels
solid taper provides higher
accuracy in the Z axis,
but also presents some
disadvantages, namely the
loss in stiffness at higher
VSHHGVRUKLJKVLGHORDGV
Most of these tools in the
market are solid, and the
spindles have relatively low
FODPSLQJIRUFH&RQQHFWLRQ
stiffness is limited, as
The tool excels in both continuous to
medium interrupted hardened steel finishing
applications. This wide application range makes
it suitable for even small bores that may require
lower SFMs–speeds conventional CBN cannot
match. Along with its exceptional tool life, the
Sandvik Coromant has launched a new range of
turning inserts for 2012.
Spectrum turning is a minimum program
that provides a simplified choice of inserts
designed to efficiently machine different
materials at various cutting conditions.
Excellent for different small batch
production, Spectrum turning grades and
geometries take away the complication of
having many different tools for different jobs.
So whether external or internal machining,
rough turning or finishing, machining
continuously or with interrupted cuts, these
inserts have been designed to be as versatile as
possible, yet deliver high performance output
MAY 2012 www.shopmetaltech.com
35
Â
CUTTING TOOLS | Turning
TURNING TOOLS METALTECH REPORT
Kennametal's KMX4: High clamping force and
interference level lead to a robust connection,
and high stiffness and bending capacity.
radial interference
needs to be kept to a
PLQLPXP5HTXLUHG
tolerances to achieve
consistent face
contact are thus very
tight, leading to high
PDQXIDFWXULQJFRVWV
Why restricting
bending capacity
is important
As mentioned earlier,
when machining
tough materials
like titanium,
cutting speeds are
relatively low due
to thermal effects
RQFXWWLQJWRROV,Q
response, machine
tool builders have
improved stiffness
and damping on
spindles and machine
structures over
WKH\HDUV6SLQGOHV
are designed with
abundant torque
Above and below:
Sandvik Coromant's
Coromant Capto: the
tapered polygon shape
gives the connection
a positive drive.
at low rotational
VSHHGV
The spindle
connection must
provide torque and
restrained bending
capacity compatible
with machine tool
VSHFLÀFDWLRQVDQG
the requirements for
KLJKHUSURGXFWLYLW\
It becomes obvious
in end milling
applications, where
projection lengths
are typically greater,
the limiting factor is
the spindle interface’s
EHQGLQJFDSDFLW\
As an example, an
indexable helical
cutter with 250 mm
LQSURMHFWLRQ
from spindle face,
PPLQLQ
diameter generates
1P
IWOERIEHQGLQJ
moment and less
WKDQ1P
IWOERIWRUTXHSMT
Keith Wiggins is
leader, Tooling
Systems Team, Global
Product Management
for Kennametal Inc.
continued on page 40 Î Î Î Î
36 www.shopmetaltech.com MAY 2012
in terms of
reliability, tool life
and chip control.
The grades
can be used for
turning in steels,
stainless steels,
HRSA, cast irons,
titanium and
nonferrous materials.
Two grades are being launched: GC15, which
combines high strength micro-grain cemented
carbide with a thin, PVD coating that adds edge
strength and wear resistance, and GC30 which
has high bulk toughness with a gradient cemented
carbide substrate and a highly wear and heat
resistant CVD coating.
www.sandvik.coromant.com
ÒWALTER
75% productivity boost in steel turning
Walter’s Valenite Tiger-tec Silver for turning is a
combination of three new insert grades and four new
geometries developed in parallel that can boost the
productivity of steel turning applications by up to 75
per cent, claims the company.
The Tiger-tec Silver inserts also feature a new
micro-edge technology that makes it possible, in
some cases, to increase tool life by over 30 per
cent, and a new silver flank face for easier wear
detection. In addition, the insert seating surface is
ground after coating to ensure optimum seating in
the toolholder.
The new grades are designated WPP10S,
WPP20S, and WPP30S. WPP10S offers the
highest temperature resistance and hardness.
It has excellent wear resistance and is suitable
for processes ranging from continuous cutting to
minor interrupted cuts at very high cutting speeds.
WPP20S, the medium-grade, is suitable for use as
a universal cutting material for processes ranging
from roughing to finishing, and brings exceptional
reliability to automated production. WPP30S, the
toughest of the three, brings maximum reliability to
the most difficult applications, such as interrupted
cuts and unstable conditions.
In addition to the three grades, Tiger-tec Silver
for turning includes four new geometries developed
in parallel and matched to one another to ensure
that the complete range of steel turning applications
is supported, reducing the number of insert types a
user needs.
For facing and light cuts, the FP5’s double V
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Pneumatic clamping
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Table 74.5”x17.5”
Metric ball screws
Spindle head feed
2-Axis feed
Milling Machine
CS-G450B
Vertical & Horizontal
Table 51”x12”
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At Heinman Machinery we ensure that you receive a machine manufactured in Taiwan that will not only be accurate
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Â
CUTTING TOOLS | Turning
Î Î Î Î continued from page 36
WHAT’S RIGHT FOR YOU?
MANUFACTURERS HAVE several
toolholding options to choose from,
such as Kennametal’s KM (ISO
standard) quick change system, and Sandvik
Coromant’s Coromant Capto (ISO standard), BIG
Kaiser’s BIG Plus (patented dual contact between
spindle face and flange face), HSK (hollow
taper shank) and CAT (steep taper shank) style
adapters.
The machining application has an impact on
the type of quick change tooling system
y
you choose, say suppliers. “Selecting
ng
the proper toolholder for the
application is key, says Alan
Miller, engineering manager
with BIG Kaiser, Hoffman
Estates, IL. The company’s
latest product is the HSK-A125
tooling system for machines such
ed in the
as Makino’s T2 and T4 models used
aerospace industry.
“Our HSK-A125 tooling system provides
ave the right
the variety that ensures that you have
ity and
toolholder for the job, and the rigidity
precision to get the job done right. HSK-A125 is
he aerospace
quickly becoming very popular in the
industry,” says Miller.
Kennametal has introduced its next
generation KM quick change system,
m, the
KM4X. “Some systems may be ablee to
transmit considerable amount of torque,
orque,
but cutting forces also generate bending
nding
moments that will exceed the interface’s
face’s
limits before torque limits are exceeded,”
explains Wiggins. “The combination of the KM4X
system’s high clamping force and interference
level lead to a robust connection, and extremely
high stiffness and bending capacity for greatly
improved performance in titanium machining.”
What distinguishes Sandvik Coromant’s
Coromant Capto is the shape of the connection,
says Dave Andrews, product application specialist
for turning products at Sandvik Coromant
Canada, Mississauga, ON.
“The shape of the connection gives it the
function. It’s a tapered polygon so the connection
provides a positive drive. This, and the way the
connection locks in three separate ways, on the
polygon, the taper and with shoulder contact,
makes it a very strong quick change tooling
system.”
Like Kennametal’s KM system, Sandvik
Coromant’s Coromant Capto is now an ISO
standard toolholder (accredited in 2008),
which means that “others who manufacture the
Capto have to do so according to ISO standard
tolerances,” explains Andrews.
He adds that other units on the market,
such as the HSK, are round connections, “so
it’s possible to have some movement in those
connections.”
Kennametal’s
early quick change
Ke
model
mo was the KV system, which
was
w a shortened version of
C
CV tooling with a three-ball
mechanism
acting on a conical
m
surface
of a bore. Later versions
s
were designed and sold with face
w
contact.
Kennametal and Krupp
co
Widia
Wid initiated a joint program in
1985 to develop a universal quickchange system, now known as KM and
recently sstandardized as ISO 26622. The
polygonal taper-face
connection known as
ta
PSC, now also standardized as ISO 26623,
and the early 9
90’s HSK system, later became
DIN 69893, the
then ISO 121.
Kennametal’s Wiggins adds “the most critical
parameters of a ta
taper-face spindle connection are
the clamping force and radial interference.
Maximizing cclamping force and selecting
appropriate vvalues of interference can
further improve
impro connection rigidity.”
Manufacturers have several spindle interface
choices when making a machine tool investment,
says Wiggins.
Sandvik Coromant’s Coromant Capto interface
offers a single coupling solution for turning and
rotating applications and the self locking tapered
polygon with face contact gives additional rigidity
during high speed machining or in hard metal
cutting applications.
Ultimately, manufacturers must choose the
system that’s right for their application to improve
cutting performance, say suppliers.
“With more materials that are tougher to
machine and require considerably higher cutting
forces, choosing wisely to achieve and maximize
cutting-edge performance is a must,”
says Wiggins.
www.bigkaiser.com | www.kennametal.com | www.cormant.sandvik.com/ca
40 www.shopmetaltech.com MAY 2012
TURNING TOOLS
METALTECH REPORT
chip breaker provides reliable
chip control during turning
operations from 0.008-in.
depth of cut. It has a positive,
curved cutting edge to reduce
the tendency to oscillate, thus
allowing excellent surface
finishes. Its undulating chip
formers prevent chip packing in
turning and facing operations.
The MP3 geometry excels
at medium machining. Its
cutting edge is ideal for
machining forged parts such
as gearwheels, ball joints,
transmission shafts or cold
pressed sheet components
such as cover plugs or converter
housings. The spherical design
of the surface—the so-called
“bullet design”—gives the chip
greater rigidity for optimum chip
breaking.
From smooth cuts to bar
stock and interrupted cuts,
the MP5 geometry can handle
them all with its versatile and
stable “basket arch” design
cutting edge. In addition, its
reinforced chip breaker blades
ensure better chip breaking and
reduced tool wear.
The RP5 geometry is
designed for roughing. The
strong, positive 3° chamfer
reduces power requirements
and its open, deep and wide
chip breaker groove generates
a low cutting temperature,
reducing wear.
www.walter-tools.com
Learn how to
improve your
fabricating
productivity at the
INSIGHTS 2012 Conference
Bending Technology Sponsor
Laser Cutting
Technology Sponsor
Photo courtesy of TRUMPF Canada, Inc.
P r e s e n t e d b y : S h o p M e t al w o r k in g Te c h n o l o g y
SEE AND HEAR
Mark your calendar for the Shop
Metalworking Technology
INSIGHTS 2012 Conference.
To be held September 25, 2012
at the International Centre west of
Toronto, you’ll hear industry
thought leaders explain what
you need to know to stay on
top of the latest in fabricating
technologies and manufacturing
best practices. There’s also a
stream of presentations on
machining technologies. In
addition to networking with
your peers, you’ll also have the
opportunity to see potential
suppliers in person with a large
table-top display area.
The conference is co-located
with AMEXPO 2012, Canada’s
exclusive manufacturing event
for Advanced Manufacturing,
sponsored by SME Canada. And
with the AMCON Design and
Contract Manufacturers Expo.
More details to come within
the magazine and within
the Shop INSIGHTS
Fabricating Technology
eNewsletter. You can sign up
for the free eNewsletter at
www.shopmetaltech.com
NETWORK | GROW | SEPTEMBER 25, 2012
Â
FABRICATING | PUNCH LASER CASE STUDY
FABRICATING
Preparing for the equipment
Precision had to overhaul its warehouse to accommodate the new EML
line. It relied on Amada’s expertise during the six-month renovation, which
started with a visit in February 2011, and ended up with a dozen semi
trucks delivering the machines by end of summer.
“Amada told us what we needed to install the EML and we renovated the
building as per their instructions,” says Horinek. It was a huge undertaking
that meant moving offices and part of the manufacturing warehouse into the
truck accessory and water distillery store. It also meant gutting the building,
at a cost of $275,000.
The company poured a new floor, with various thicknesses to support
the machine, and moved the heating, insulation and electrical components
to accommodate the set up of the EML. “There were five or six guys from
Amada there during the process,” says Horinek. “It was a big deal, not a
small undertaking.”
BY PATTY JESSOME
A
PHOTOS
BY
PATTY
JESSOM
E
PRODUCT: EXP PUNCH TECHNOLOGY | User: Fileco
The switch to Wilson Tool’s new EXP punching technology was a simple decision
for Oakville, ON-based Fileco Inc., a division of Teknion Ltd., says Megan Walker,
manufacturing engineering coodinator.
“The new EXP punches are completely interchangeable with our existing toolholders.
The punch holder is also interchangeable with other punch tips in the EXP tooling line.”
Fileco manufactures office furniture, such as filing cabinets and lockers. Most of the
products are fabricated from mild steel between 18 and 22 Ga. Fileco uses four Amada
turret punch presses: Amada Vipros–358 King, Amada Vipros–368 King, and two Amada
Vipros–255. All of its turret tooling is from Wilson, series 90
and HP products.
Walker says the main difference between the existing
tooling and the new EXP tooling is the punch.
“The EXP punch has two pieces—the punch holder and the
punch tip. The traditional punches were one piece. Punches
and dies require regular sharpening. Eventually a punch can no
longer be sharpened and must be replaced. With the traditional
tooling, the entire punch needed to be replaced. With the new
EXP tooling, only the punch tip needs to be replaced. The EXP punch tip is less expensive
than the traditional Series 90/HP punch so, in the future, replacements will be cheaper
and we will save money on our tooling.”
The punches offer four times faster setup, which means less downtime, claims Wilson
Tool. Ultima tool steel makes EXP punches last two times longer. Standard holders
with universal punches make it practical to replace only the punch. Smaller
punches mean you can stock more shapes in less space. The punches also
Punching
require less material to produce, resulting in less waste.
Machines
Fileco purchased its first EXP tools about three months ago.
& Punch
“So far, we have not needed to sharpen any of the EXP Punch tips, so the
Tooling
punches do seem to be lasting longer. We will not only be saving money on
replacement punches, but also on labour required for sharpening punches.
Metaltech
www.wilsontool.com
Repo
rt
42 www.shopmetaltech.com MAY 2012
LBERTA’S PRECISION
DESIGN and Manufacturing
owner Ehreth Horinek is taking
his Westlock, AB, business to a new
level with the combination of laser and
punch technology, allowing him to
produce and grow even as he sleeps.
With the recent purchase of the
Amada
EML, with fully automated
A
capabilities, he’s giving his company
the upper edge in technology, one
that allows him to run lights out.
“The EML runs 24/7, even while I’m
at home sleeping,” says Horinek. “It
ÀQDOO\JLYHVXVWKHDELOLW\WRPHHWRXU
customer’s demands.”
The timing of the machine
purchase couldn’t have been
better. This year Horinek says the
business will grow between 10 and
20 per cent and he’s already seen a
PUNCHING MACHINES & PUNCH TOOL
ÒAMADA
Eco-friendly technology
Designed as a lower-cost alternative to
Amada’s flagship EM-series twin servo
drive turrets, the AE-series has been
designated as an “Eco Product” by the Japan
Forming Machinery Association because
of the machine’s reduced requirements
for petroleum product and electrical
consumption.
The AE-series is equipped with a servo
ram drive that has no hydraulic system or oil
chiller. This design not only eliminates the
need for ongoing hydraulic oil changes and
related maintenance and service, but the
servo drive consumes an average of less than
WHILE SLEEPING
THE PROBLEMÔ
Increasing production
and flexibility
Lights out automation means Alberta
fabricator doesn’t have to turn business away
VLJQLÀFDQWLQFUHDVHLQGHPDQGVLQFH
the installation. “If we hadn’t
Ehreth Horinek and
purchased the machine when
sons Dan and Rob
discuss the next run
we did, we would have worked
on the Amada punch
around the clock keeping up with
laser combination
machine.
demand and we would have had to
turn business away.”
Horinek has been running his own
manufacturing business for almost
\HDUVÀUVWVWDUWLQJRXWLQZDWHU
distillers and then moving into truck
accessories. Today, he runs the OEM
manufacturing business with the help
of his two sons, Dan and Rob, who
play important roles to support the
EMLZ3610NT. The unique
business—both programming the
combination of the high speed punch
machines and sharing duties between
and hybrid laser has the capacity to
day and night shifts.
Together they chose and oversaw the form and cut at the same time, speeding
installation of Amada’s laser and punch XSSURGXFWLRQVLJQLÀFDQWO\DQGJLYLQJ
SURGXFWVDQXOWUDVPRRWKÀQLVK
combination machine, the 4 kW
THE SOLUTIONÒ
Investing in automated lights
out punch/laser technology
Flexibility
One of the big advantages of the EML
is the ability to mix long and short runs.
“Now we are able to nest our products,”
Horinek says. Together the EML and
the automated material storage rack
LING METALTECH REPORT
half the oil of a typical hydraulic punching
machine, amounting to savings of several
thousand dollars per year.
The machines are available standard with
Amada’s exclusive “Triple-Track” high capacity
45 or 51-station turrets, each featuring four
auto-index stations. Used in conjunction
with the AMNC/PC controls’ scheduling
functions, the Triple-Track configuration allows
fabricators to load the turret with enough tools
(up to 4 ½ in. in diameter) to run multiple
jobs without tool changes, and without the
need for using multi-tools to make up for a
lack of overall capacity.
The machines are offered in 50 in. x 100
in. (1.3 m x 2.5 m) and 50 in. x 50 in. (1.3
m x 1.3 m) sheet capacities (larger sheets can
be processed with a reposition) and feature
brush tables to help reduce scratching and
punching noise. In addition, air blow and
power vacuum die capabilities help to increase
tooling life while virtually eliminating slug
pull—even when operating at high speeds.
www.amada.com
ÒLVD STRIPPIT
51% larger turret
LVD Strippit’s M-Series of mid-range 20 metric
tonne CNC turret punch presses feature a 51
per cent larger turret capacity than previous
models. The 47-station turret provides high
flexibility and reduces set-up time, increasing
machine productivity. Equipped with LVD
MAY 2012 www.shopmetaltech.com
43
Â
FABRICATING | PUNCH LASER CASE STUDY
An overview of
the shop and
the lights out
operation.
with 35 shelves, MARS7510-5EX,
also newly added, picks the material,
ÀQLVKHVWKHSDUWSXWVWKHPDWHULDODZD\
and then starts all over again.
The laser’s precise cuts and quality
ÀQLVKJLYHV3UHFLVLRQÁH[LELOLW\ZLWK
its current products, and gives the
shop a lot of capability in terms of new
product and special designs.
Precision recently introduced two
new lines of truck grilles they weren’t
able to manufacture before and the
company will continue to expand due
to the laser capabilities. “You can only
do so much with a punch, but with
the laser you can do almost anything:
circles, arches, and various sizes of
letters for logos. It’s simple to use, you
draw the part, program it, lay it out on
the sheet and you’re running within an
hour,” Horinek says.
This also works well with
the company’s truck accessory
manufacturing line, which constantly
changes as the automotive industry
evolves. “New vehicles require new
PXGÁDSVQHZJULOOHVOLJKWEDUV
exhaust systems and running boards,”
The combination of laser and punch technology
speeds up production significantly.
he says. “That will remain a constant
in our business and now with our new
technology we will be able to produce
more.”
Hands off
Horinek says the automation is another
plus, as it allows zero handling of
materials. The MARS picks, dumps and
racks without anyone touching it, which
frees up time for employees to focus on
other tasks. “The machine runs itself,
there’s nothing you have to do.” Well,
almost nothing. For peace of mind,
Horinek installed an app on his iPhone,
which lets him view the shop via web
continued on page 46 Î Î Î Î
44 www.shopmetaltech.com MAY 2012
PUNCHING MACHINES & PUNCH
TOOLING METALTECH REPORT
Strippit’s Energy Reduction System
(ERS), the punch presses consume up
to 30 per cent less electrical power than
comparable machines and are less costly
to operate and maintain.
Designed to minimize the time spent
changing tooling, the punch presses
have a mix of turret stations, including
three 3.5 in. (88.9 mm) auto-index
stations and four 2 in. (50.8 mm)
stations. Every station accepts shaped
punches and dies and can be enhanced
with the addition of indexable multitools to further expand turret capacity
and flexibility while reducing set-up
time. Quick-change die holders also
minimize tool changeover time.
Hardened steel guide bushings
and hardened shot pins provide
precise alignment of punch and die
for exceptional hole quality and long
tool life. Bi-directional turret rotation
automatically selects the shortest
possible route to the next punching
station for fast station-to-station
positioning resulting in
higher productivity.
The machines are equipped with a
servo-driven hydraulic press drive
optimized for high performance
operation. Axis speeds of up to 380 hits
per minute on 1 in. (25 mm) centres
and up to 900 hits per minute on 0.04
in. (1 mm) centres are achieved.
The machine handle workpieces up
to 49.21 in. x 98.4 in. (1250 x 2500
mm) with larger sheets processed
using clamp repositioning. Workpiece
thicknesses up to 0.250 in. (6.35 mm)
are accommodated.
www.lvdgroup.com
ÒMATE TOOLING
Adjustable thick turret canisters
Mate Tooling’s new Rapidset adjustable
thick turret canisters are designed to be
used with Mate Original Style and AMX
punch press tooling. The canisters are
also compatible with Amada Standard,
Amada ABS and Wilson Standard
tooling styles.
The product is designed to provide
quick tool changes and make punch
Mate Special Applications
tooling rises to new heights.
Finding the best process to emboss large stainless-steel exterior wall panels for a high profile residence was a challenge for
Todrin Laser Industries. A unique architectural design called for symmetrical rows of diamond shapes across the entire sheet
surface with optimal surface quality, along with keeping a protective film intact during processing. Todrin turned to the solutions
experts at Mate Precision Tooling.
Our custom engineering team developed Special Applications tooling
to produce the magnificent looking panels on this very unique
building. With Mate’s combined 170 years of fabricating expertise,
you wouldn’t expect anything else.
If you have a fabrication challenge, contact Mate for an
expert solution. You will get fully-vetted tooling right out
of the box…fast. In fact, we accelerated our delivery by
20% over the past two years, and many common
applications are available for same-day shipment.
Mate…the Special Applications experts.
To learn more visit mate.com or call 800.328.4492.
Â
FABRICATING | PUNCH LASER CASE STUDY
PUNCHING MACHINES & PUNCH TOOL
Î Î Î Î continued from page 44
ENVIRONMENTAL
ADVANTAGES
The MARS7510-5EX is an automated machine that
picks, dumps and racks with the help of a computer.
cameras and alerts him if the machine stops.
He is considering the Amada equivalent for the
future, a machine monitoring software called
v-Factory. It gives the customer the ability to see
the parts produced and send messages should
something go wrong.
The Amada lights out automation is allowing
the business to grow while keeping up with
demand as it continues to ship worldwide from
North America to Europe, South America and
Asia. While Precision is in good shape, with
annual earnings between $5 and $10 million,
Horinek is keeping his eyes on new products
that will continue to keep his business in
an upward swing. “There’s always someone
looking to buy; always lots to sell.” SMT
Patty Jessome is a freelance writer based in
Edmonton, AB.
Deciding on the right technology
Horinek says the hardest part of the process wasn’t
the six-week set up of the machine or the additional
training required to run it. It wasn’t even the
complete gutting of the warehouse in preparation
for the EML. The most difficult part for him was
choosing the technology. While he always knew he’d
go with Amada due to the company’s long history
of quality and service, it was choosing the machine
that he says was the most difficult. He found it hard
to settle on a single technology. In the end he went
with the best of both worlds; punching and laser
cutting. “It was the right choice for us, it meant
growth and more product options.”
46 www.shopmetaltech.com MAY 2012
The EML offers environmentally
friendly products that more
manufacturers are looking for.
They include:
tPower consumption is cut by
two thirds.
tThe laser has a long life
turbo blower with the most
energy efficient CO2 resonator
available—lasting for the
lifetime of the machine.
tThe punching machines do
not use hydraulic oils; they’re
servo-driven.
tEML series twin servo ram drive
is assembled from only 64
parts, reducing maintenance
costs.
tRegenerative braking on
the EML stores energy in a
capacitor bank for additional
energy savings, just like a
hybrid car.
EML’s laser offers independent movement
of the laser head from the Y Axis.
length adjustment faster with existing
tooling inventories.
Available in A and B station canisters,
Rapidset works with keyed or non-keyed
punches and has these features.
tA non-rotating clamping head with
an easily adjustable clamping screw
for setting punch length. It has a
textured Gription canister feature for
ease of handling.
tA pre-loaded, self-contained spring pack
provides consistent stripping pressure,
consistent die penetration, and reduced
slug-pulling.
tGreater grind life than the Original Style:
0.315 in. (8.00 mm) in 0.039 in. (1.00
mm) material with 0.118 in. (3.00 mm)
die penetration.
tFast punch length adjustment without
removal from guide.
tCan be easily used with existing guides
with or without pins.
tPunches material thickness up to
0.250 in. (6.35 mm). (Competitive
canisters restricted to 0.150 in. (3.81
mm) material).
www.mate.com
ÒPRIMA POWER
Servo electric punching
The new Prima Power E6x features a
new, easy way of operation, a high
degree of productivity and accuracy,
as well as low energy and maintenance
cost. All the benefits of versatile, servo
electric punching technology are now
within easy reach.
The E6x comes with the Lite version
LING METALTECH REPORT
of Tulus, a member of a software suite
developed by Prima Power. It makes the
machine easy to use even for operators
without prior experience of Prima
Power technology. Convenient downloading
of programs, instructive task lists and
set-up screens giving clear indication of
material and tooling requirements, are just
some of the standard features adding to
ease of operation.
Product: TruPunch 5000
Punching
Machines
& Punch
Tooling
Metaltech
Report
User: CGC Inc.
The E6x is an efficient machine
tool for standard punching tasks, but
the machine capabilities also allow
uncomplicated and accurate utilization
of all the latest tooling technologies. For
example, the number of rotating tools can
be increased by using indexable MultiTools. Thus programming is simplified
and set-up times are shortened. New
quick-change toolholders can be used for
even shorter set-up.
A major contribution to operating
efficiency is made by an easy load
mechanism and automatic clamp
positioning and closing function,
as well as a large 500 mm x 500 mm
work chute for components. A lifting
brush table mechanism provides
extra protection for materials with a
sensitive surface.
A three–stage system makes the
machine safe to operate and minimizes
downtime in case of failure. The
machine is equipped with sensors
that automatically stop the machine
if the sheet comes loose or the tool
jams. As an option, a sensor with
similar function for sheet distortion
can be added. Instantaneous machine
stop prevents further damage to
the machine and makes re-start of
operation fast and simple.
www.primapower.com
Canadian Gypsum Co. (CGC), Oakville
, ON, is recognized the world-over for
its
gypsum wallboards, but its other prod
uct lines, namely suspended acoustica
l
ceilings, are also popular items in Can
ada.
CGC is a public company formed in 190
2 and owned by parent company USG
Corp. The T-bars for the grid of the ceili
ngs are fabricated primarily from stee
l and
panels are typically fabricated from alum
inum. CGC perforates the panels usin
g four
TRUMPF punching machines, the lates
t being the TruPunch 5000, purchase
d last
year to help produce larger ceiling pane
ls. The company manufactures the ceili
ngs
at its 100,000 sq ft plant in Oakville
, ON.
Jay McBurney, specialty production man
ager, says the newest TRUMPF
punching machine has helped increase
production capabilities and efficiencies.
“The machine has twice the punchin
g speed and travel speed of our next
fastest
machine. Our other machines are olde
r TRUMPF models and they work well
, but
because this is a new generation of mac
hines, its much faster. So far it’s work
ed
really well. We have had minimal
downtime, accuracy is top notch and
flexibility for large and small parts is
very good. We don’t have to reposition
for long or larger parts, which saves
time and improves quality “
CGC constantly looks for ways to
include automation and continuously
improve material handling capabilities
during its manufacturing processes, says
McBurney. “TRUMPF offers a wide array
of automated accessories, we are cont
inuously researching and trying to work
these
into our operations and innovative offer
ings.”
One example of its innovative products
is “Pixels," that provides customers with
the option of placing their design onto
a wall or ceiling.
The TruPunch 5000 operates 10 per
cent faster than its predecessor, with
1,400 strokes/min for medium format
(2500 mm x 1250 mm) or 1,200 strok
es/
min for large format (3050 mm x 155
0 mm), which means 200 more strok
es
without using more energy. It is designed
with a simultaneous increase of the
rotational speed and acceleration in the
C axis. On the medium format the
maximum number of tools with three
clamps is 18 pieces, while on the large
format
model with four clamps, its 21 pieces.
It takes 2.8 seconds to change tools
and 0.3
seconds to change the tools within the
MultiTool.
Another member in the TruPunch fam
ily is the new TruPunch 3000, which
offers skeleton-free punching with its
5 ft by 8 ft (1.4 m x 2.4 m) format (5
ft
x 10 ft/1.4 m x 3.0 m with repositioning
). An electric punching head results in
average electrical consumption of abou
t 5 kW. By contrast to the hydraulic vers
ion,
this machine uses little power in stan
dby mode. A high rotation speed mak
es
the
electric punching head fast when rotat
ing tools or forming threads. The skel
eton
free processing allows for an average
of 10 per cent higher material utilizatio
n.
www.us.trumpf.com
MAY 2012 www.shopmetaltech.com
47
Â
WELDING | SPECIAL METALS
GTAW on Titanium:
Tips to Succeed
BY BRENT WILLIAMS
ECAUSE OF ITS exceptional
corrosion resistance, titanium is
frequently chosen by companies
to help increase the service life of parts
and reduce life cycle costs. This material
also offers an excellent strength-toweight ratio: it is 45 per cent lighter,
yet more than three times stronger
than mild steel. It is also relatively
maintenance free. Following are some
recommended tips to help successfully
GTA weld titanium (ASTM Grade 5
titanium: Ti-6A1-4V).
Similar to the trailing
shield, purge dams
shield the underside
of the weld from
contamination by
supplying it with a
constant stream of
shielding gas.
B
Cleanliness is key
It is critical to keep titanium clean prior
to and during welding. Because it is a
highly reactive metal, titanium responds
quickly (and negatively) to contaminants
such as oils from the forming and
drawing process; shop dust; paint; dirt;
ERG\RLOVIURPKDQGVFXWWLQJÁXLGV
and more. Encountering any or all
of these contaminants can easily lead
to localized corrosion or cause weld
embrittlement and failure. To prevent
such issues, always keep the welding
environment as clean as possible and
PLQLPL]HDLUÁRZWRDYRLGGLVUXSWLQJ
48 www.shopmetaltech.com MAY 2012
the shielding gas coverage that protects
the weld pool.
Due to its reactivity, titanium easily
forms a very hard oxide layer on its
surface (similar to aluminum). This layer
provides titanium with its corrosion
resistance, but it also melts at a higher
temperature than pure titanium. For
that reason, it must be removed from
the area to be welded. Use a die grinder
with a carbide deburring tool or carbide
ÀOH³VHWWRDORZJULQGLQJVSHHG³WR
remove the layer of titanium oxide
without overheating the base metal,
which can also lead to embrittlement.
After removing the oxide layer, once
again, wipe the area to be welded using
MEK, acetone or other non-chlorinated
solvents, and allow it to dry completely
before welding.
Two important words of caution:
one, be certain to use the grinder
exclusively for the task so as to avoid
introducing contaminants from other
jobs. Two, never use steel wool or other
abrasives to remove the titanium oxide
layer as it can contaminate the metal
and lead to weld defects.
Proper preparation techniques
3DUWÀWXSZKHQZHOGLQJWLWDQLXPLV
important since gaps between parts
can lead to contamination from the
underside of the weld. Prior to striking
an arc, use a clamp or tooling to hold
parts together and prevent movement
during GTA welding. Typically, it is not
necessary to pre-heat titanium under
1/8-in. thick, but some applications
may require a pre and post-heat to
ensure weld integrity. Always follow the
prescribed welding procedures. Also, to
reduce the chance of contamination and
to minimize the heat and the amount of
ÀOOHUURGQHHGHGWRÀOOWKHZHOGDYRLG
beveling the edges of titanium parts.
Shield the weld pool
The American Welding Society (AWS)
recommends measuring shielding gas
purity to ensure quality when GTA
welding titanium. Most titanium
applications call for a 100 per cent
Argon shielding gas that is at least
99.995 per cent pure. In addition, the
shielding gas should have no more than
20 parts-per-million (ppm) of oxygen
and a dew point greater than –50 to
–76ºF. Some applications demand
even higher purity levels (up to 99.999
percent purity), so always consult the
ZHOGLQJSURFHGXUH:KHQVSHFLÀFDWLRQV
allow, a 75 per cent Argon/25 per cent
Helium mixed gas may be used to
improve arc stability and increase weld
penetration. The gas should be set at
20 cubic feet/hour (cfh) to obtain ideal
weld protection. Use a plastic hose to
transport the shielding gas, as a rubber
hose can allow oxygen to mix with the
shielding gas and contaminate the weld.
There are additional considerations
for shielding gas when GTA welding
titanium, including back purging
and the use of a GTAW torch with a
trailing shield.
Back purging the underside of
the weld prevents oxygen from
contaminating welds from below. It is
important to allow enough shielding
gas to replace the air environment
ten times over to ensure complete
weld protection. Similarly, adding a
trailing shield to the GTAW torch
keeps the shielding gas over the weld
longer, decreasing the potential for
weld contamination while the material
is above the 500 to 900º threshold.
Below that threshold, oxygen can no
longer react with the titanium. Trailing
shields are available through welding
distributors; however, some companies
also fabricate their own trailing shield to
PDWFKWKHLUVSHFLÀFDSSOLFDWLRQ
Also, for complex geometries
or large weldments that cannot be
adequately shielded, an argon enclosure
PD\EHXVHG7KLVHQFORVXUHLVÀOOHG
with argon as the air is vented to
provide an inert atmosphere. Special
gloves and viewing ports give welders
access to the parts in the box while the
enclosure protects the titanium parts
during the weld and cooling process.
Adding a trailing shield to the GTAW torch (as
shown with this fabricated one) keeps the shielding
gas over the weld longer. It also decreases the
potential for weld contamination while the material
is above the 800º threshold.
Filler metal and tungsten electrode
Use a pointed, two per cent ceriated
or lanthanated tungsten electrode.
Follow this sizing for applications:
when welding below 90 amps, use
a 1/16-in. tungsten electrode; use
a 3/32-in. tungsten electrode for
applications between 90 and 200 amps;
and use a 1/8-in. tungsten electrode for
applications over 200 amps.
For most applications, match
WKHÀOOHUURGVWUHQJWKH[DFWO\WRWKH
titanium base metal. Some applications
PD\FDOOIRUDGLIIHUHQWÀOOHUPHWDOEDVHG
on the desired mechanical properties of
the weld or the service conditions. An
example would be to use lower strength
ÀOOHUPHWDOWRLPSURYHGXFWLOLW\7KLQ
sections of titanium can be welded
DXWRJHQRXVO\RUZLWKRXWÀOOHU:HOGLQJ
consumables, techniques and quality
requirements for titanium should be
based on welding codes and procedures
that apply to the industry or application.
Equipment selection
For the best results when GTA
welding titanium, use an inverterbased power source that provides
high frequency arc starting and at
least a 250-amp output. Ideally, this
power source should also provide
remote amperage control capabilities
DQGDSRVWÁRZWLPHU
Direct current electrode negative
(DCEN) is used to weld titanium.
Alternating current (AC) can also be
used if additional oxide cleaning is
required. AC welding has become more
common as GTAW inverters offer
extended AC balance control; so the
cleaning or electrode positive (EP) cycle
can be set to minimal levels.
Depending on the application,
air-cooled and water-cooled torches
may both be used to weld titanium.
Air-cooled torches work well for
portable applications, short welds
and/or applications under 150 amps.
Water-cooled torches are best for
high-amperage applications. They
are also preferred for production
or continuous welds since they
are lighter and typically easier to
manoeuvre than air-cooled torches.
Because they are typically smaller
MAY 2012 www.shopmetaltech.com
49
Â
WELDING | SPECIAL METALS
www.millerwelds.com | www.weldcraft.com
than air-cooled torches, water-cooled
models also offer more accessibility
to the weld joint. The decision to use a
water-cooled torch should be considered
when purchasing a power source.
The addition of a gas lens to either
torch helps ensure smoother and more
consistent shielding gas coverage of the
weld, and it can help reduce instances
of contamination. Gas lenses are
commonly used for short welds on
titanium, as they provide a less turbulent
DQGPRUHFRQVLVWHQWÁRZRIVKLHOGLQJ
gas. As welds increase in length, other
methods, like a trailing shield or inert
gas enclosure must be used.
Executing successful techniques
After completing all preparations
properly and selecting the right
equipment, begin welding with a
freshly cut, ground and contaminantfree tungsten. Allow the shielding gas
to surround the weld area for a few
seconds before striking an arc using the
inverter’s high frequency start feature.
The titanium weld pool forms
easily and tends to be sluggish, similar
to that produced when GTA welding
stainless steel. For that reason, using
VLPLODUWRUFKDQGÀOOHUPHWDODQJOHV
and torch speed is appropriate. Use
a “dab” technique, keeping the
ÀOOHUPHWDOZLWKLQWKHVKLHOGLQJJDV
envelope. Because excessive heat
can cause the weld to crack, it is
important to minimize input as much
as possible, too.
Upon completing the weld, allow
the shielding gas to continue covering
50 www.shopmetaltech.com MAY 2012
the weld for 25-50 seconds to prevent
the atmosphere from contaminating
the weld.
Some codes require shielding gas
SRVWÁRZWLPHVHYHQORQJHUGHSHQGLQJ
on the welding amperage and material
WKLFNQHVV3RVWÁRZRIVKLHOGLQJJDVLV
important because the titanium is high
reactive until the weld cools below 500º
F. Always check the welding procedures
IRUSRVWÁRZUHTXLUHPHQWV
Finally, know the proper colour of a
titanium weld. The colour of a cooled
weld indicates the thickness of the
resulting oxide layer and whether the
VKLHOGLQJJDVKDVVXIÀFLHQWO\SURWHFWHG
the weld from contaminants. Figure
1 (top right) provides a guide for
determining the quality of the weld
based on its colour. Typically, bright
silver and sometimes a slight gold or
straw colour are ideal. Any further
discolouration indicates excessive
heat input or poor shielding that
could result in weld embrittlement.
Regardless of colour, additional tests,
including dye penetrant inspection,
hardness testing, x-rays, ultrasonic
and destructive tests, should also be
used to fully evaluate the soundness
of the weld or to qualify a procedure.
In addition, refer to the appropriate
welding code, procedure or standard
IRUHDFKVSHFLÀFDSSOLFDWLRQIRUZHOG
quality and colour requirements.
Figure 1: Specific welding codes will determine
whether a given titanium weld colour is acceptable
for the application.
Remember, titanium may be
FKDOOHQJLQJWRZHOGEXWWKHGLIÀFXOW\
lies just as much in preparing and
cleaning the material properly, and
selecting the right welding equipment,
as in the actual welding process
Always take the proper precautions
before ever striking an arc. Doing so
will save the cost of scrapping this
expensive material, and can help ensure
companies gain the corrosion resistance
and long-term service life desired from
using titanium. SMT
Brent Williams is marketing manager,
TIG solutions, Miller Electric Mfg. Co.
and technical contributor, Weldcraft.
For more information on welding technologies, visit Shop Metalworking
Technology’s WELDING ZONE online at www.shopmetaltech.com.
Â
QUALITY | Multisensors
S COMPANIES LOOK to
improve productivity and
become more competitive,
every aspect of the manufacturing
process is scrutinized. One critical
aspect is quality. If you can’t ensure
the quality of your part, no matter
what high end technologies you
employ in your machine shop, you
will not succeed. And, as many
know, this is especially important if
you service the high precision, tight
tolerance-oriented aerospace, energy
and automotive markets.
Yet, as companies try to better
position themselves competitively,
they want to do it cost effectively.
When it comes to quality though,
it can be a challenge because a
single sensor can’t measure every
part feature and provide every
measurement function you may
need. Hence the need for multiple
sensors that can measure different
part aspects.
One way that manufacturers
are trying to cut costs without
compromising on quality
measurement is by investing in
multisensor devices. The concept
is relatively new and only a few
suppliers, such as Carl Zeiss
Industrial Metrology, Optical
Gaging Products and Starrett offer
the technology.
Shop Metalworking Technolog y
discusses the merits of multisensor
technology with John Pearson,
technical sales engineer with
Carl Zeiss Industrial Metrology,
Brighton, MI.
A
52 www.shopmetaltech.com MAY 2012
Multiply Your
BENEFITS
Multisensor technology cuts
measurement costs
Q
A
SHOP MT: What is the definition
of a multisensor device used for
quality control?
JOHN PEARSON: A multisensor
device in quality control may be
defined as a measurement system
with two or more sensor options for
data acquisition. For example, you may
have a device that includes a tactile probe
with laser scanning capability.
Top: Zeiss's Accura CMM.
Q
A
Below: The 0-Inspect, optical and contact
measuring technology for true 3D measurements.
SHOP MT: What is the benefit
of it versus other stand-alone
measuring devices?
JOHN PEARSON: A multisensor
device allows for the integrated
measurement of many complex
workpieces on a single gauge
in a single setup with a single
software. The benefits derive from sensor
integration into 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
a measurement plan.
Our metrology software, Calypso, treats
all data the same regardless of sensor
type. Another benefit is that all of the data
acquired through the various sensors is
in the same coordinate system, meaning
that accurate evaluations can be made
regardless of the source sensor.
Q
A
SHOP MT: What is the cost of a
multisensor device and how does it
compare to having multiple standalone devices?
The Accura CMM with the ViScan optical sensor
on an articulating head.
JOHN PEARSON: Many of our
CMMs, including MASS (MultiApplication Sensor System) CMMs, as
well as others in our product line, are
pre-wired and ready to accept various sensors.
These systems all start with a tactile scanning
sensor as standard.
The cost varies between the available sensor
options which include active and passive tactile
scanning and single-point sensors, as well as
optical sensors, such as visible light cameras,
laser probes, and white light sensors.
Overall cost is of course always a factor,
but the key metric here is the attractive cost to
Q
SHOP MT: Multisensor technology
A
JOHN PEARSON: Integration is the
for quality control is relatively new.
What have been the key technology
improvements that make these
devices more accessible to small and
medium sized manufacturers?
key development. Our sensors have
remained relatively stable.
What does change and where
improvements are being made continually
is with the software and in the functions
available for users.
We upgrade and enhance software twice
a year. We try to include as many of the
enhancement requests from our customers
as possible.
An example is sheet metal measurement
Integration is key. What does
change, and where improvements
are being made, is with the
software and in the functions
available for users. —John Pearson
The Accura CMM with the company's VAST
scanning sensor.
benefit ratio. Our systems offer an economical
solution for the customer who needs, for
example, both optical and tactile measurement
capability but doesn’t want the expense of
purchasing two systems.
Additional benefits accrue as the customer
realizes that he will have only one software to
learn and maintain, and that he will be able to
produce a single report. For many workpieces,
a single setup will be required, further reducing
the time needed to evaluate components.
Zeiss's O-Inspect scanning sensor rack.
The VAST XXT sensor on an articulating head
measuring a part.
for car bodies. Specs for this area have
tightened and customers, over the years,
have requested that we enhance this
functionality, so we have. In the aerospace
industry, there’s been a big push for
surface profiles, so we long ago added this
functionality to our software.
Two areas of development in the
multisensor technology are in non-contact
measurement and in reverse engineering. I
think we’ll see significant developments and
improvements in multisensory technologies
for these two areas in the future. SMT
www.zeiss.com
MAY 2012 www.shopmetaltech.com
53
Â
MACHINE TOOLS | Automotive
Automotive Machining Drives
Changes at the automotive OEM level impact machine shop suppliers
BY MARY SCIANNA
HE AUTOMOTIVE industry
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54 www.shopmetaltech.com MAY 2012
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Those that supply the automotive
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the trends emerging in automotive
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with some tooling programs
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MACHINE TOOLS | Automotive
welding and had to deal with deformed
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56 www.shopmetaltech.com MAY 2012
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Â
CUTTING TOOLS | Grooving
HOW SMALL
Is Small?
Î
WHEN DISCUSSING GROOVING applications,
industry players can have differing views as to
what constitutes small part machining.
“I would say anything under an inch and a half
in diameter,” says Scott Etling from Kennametal.
“The segment is very broad; you can get down to ten
thousandths to twenty thousandths of an inch
in diameter. This definition can change for many
different manufactures that fall under the small part
machining umbrella.”
Alex Livingston from Tungaloy puts the cut off a little
lower.
“I would say a small groove has a width of under two
millimetres (mm), or 80 thousandths of an inch,” he says.
In fact, Tungaloy has both three corner and two corner
inserts that can go well below two millimetres —all the
way to a .3 mm groove.
“These are usually steels and stainless steels,”
says Livingston. “You also see titanium for medical
components like dental implants.”
In fact, Tungaloy has just launched its Tiny-Turn
product line for small components in boring, threading,
and grooving.
“With Tiny-Turn, widths will focus on 2 mm down to .5
mm,” says Livingston. “A big percentage of this market
will be in production environments.”
Dave Andrews of Sandvik and Steve Geisel at Iscar
both say that small would be defined as under 1 mm, or
about 40 thousandths of an inch.
“For us twenty thou is pretty standard, and we can go
smaller upon request,” says Geisel.
For Horn USA, anything under 10 mm in diameter is a
small part.
“When you get to under 2 mm you’re getting into
micro machining,” says John Kollenbroich, a technical
manager with Horn USA. “We can do that as well.”
Kollenbroich says when it comes to micro machining,
accuracy is a must.
“The centre line plays a critical role with small parts,”
says Kollenbroich. “Being off centre by even a thousandth
can break a tool; there is much less room for clearance.”
To cut a .2 mm hole, for example, if you are off by
even .05 mm, that is too much depth of cut; you’ll break
the tool right away. As a result, knowledge, experience,
and a high quality tool are required to ensure that it goes
back into the pocket at the same place where it was first
set up.
58 www.shopmetaltech.com MAY 2012
The
BIG WORLD
of Small Part
GROOVING
Attention to detail in tooling a
must for small part grooving
BY TIM WILSON
ROOVING
applications for small
parts is broad-based,
with demand being seen in
medical, aerospace, turbines,
the electrical and hydraulic
industry, job shops supporting
the automotive sector, and even
watches. Applications include
face grooving and small internal
and external grooves–O rings,
seals, snap rings–that are often
machined off of Swiss-style
lathes. These machines can
groove down to just a few
microns, the equivalent of
thousandths of an inch.
“There is a lot of small
grooving going on out there,”
says Todd White, sales director
DW6FLHQWLÀF&XWWLQJ7RROVLQ/RV
G
$QJHOHV&$´2QHWRRO,DP
looking at now goes into a 1/8th
bore, but is ten thousandth
RIDQLQFKZLGHDQGRQO\ÀYH
thousandth of an inch deep.”
7KLVLVDYHU\ÀQHJURRYH
made out of 303 grade stainless
steel for a Swiss part. In such a
situation, White will offer a tool
quote that serves the customer’s
VSHFLÀFUHTXLUHPHQWV
“In this example they’ve
sent me a tool drawing with
width and a description of their
needs,” he says. “We see that
quite often.”
With such detailed
applications, it is crucial that
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VXUIDFHÀQLVK\RXGRQ·WZDQW
chips sticking because of grind
marks. As well, at such small widths a
tool has to be made correctly so that
there is clearance and the chips don’t
pack into the bore.
“You can grind the shank to give it
more strength, and instead of having a
round shank you can have one that is
more elliptical,” says White. “This way
you can get into a small bore, but with
more strength.”
To get the right tool for a small
grooving application, it makes
sense to shop around with vendors.
Kennametal, for example, launched
an expansion of its small reinforced
toolholders last year. The toolholder
works well in Swiss machines utilizing
the company’s A4TM double sided
grooving and cutoff inserts.
“We launched an A4TM club
KHDGWRROKROGHUVSHFLÀFDOO\
GHVLJQHGWRÀWLQWRVPDOOHU
type, Swiss machines,”
says Scott Etling, recently
Kennametal’s global manager
for grooving and cutoff, and
now the company’s manager,
global product management,
for indexable milling.
“The new toolholders
RIIHUVKDQNVL]HVWKDWÀWWKH
Swiss style machines’ tool
blocks. The design offers
extra material under the insert
to maximize stiffness. This
will directly affect the surface
ÀQLVKRQWKHZRUNSLHFHDQG
increase tool life.”
For operations that
require small groove
widths on small diameter
workpieces, selecting the
correct geometry is important
to keep cutting forces at a
minimum and to optimize
chip control. As in many machining
applications, the right combination
means understanding the trade-offs.
“Depending on the applications—
and this includes the workpiece
material type, the type of machine,
overhang of the toolholder, and size of
work piece to name a few—it is very
important to choose the best tool for
the operation,” says Etling.
Kennametal’s A4 –GUP geometry
is designed to lower cutting forces as
well as offering excellent chip control.
By minimizing the cutting forces, the
WRROSUHVVXUHZLOOQRWGHÁHFWWKHZRUN
pieces, and will keep the heat at the
cutting edge to a minimum, directly
improving tool life.
Etling also has some advice if the
tool wears prematurely.
GROOVING METALTECH REPORT
ÒHORN
Sintered chip
breaking geometries
Horn’s mini system is
improved with sintered
chip breaking geometries
for grooving and boring
in internal diameters
from 8 mm (0.315 in.).
Additionally, the Mini System range is
extended to include the 18P inserts
allowing for groove depths of as much as
8 mm (0.315 in.) in bores from 20 mm
(0.787 in.). Together with the existing
ground carbide inserts, the mini tool
system now offers two insert versions to
satisfy a wider range of applications.
The mini system inserts are available
with different widths and groove depths
for machining all materials. If required,
intermediate dimensions or corner radii
of the sintered inserts can be adjusted
for special tasks while preserving the
sintered chip shape geometries.
The mini inserts provide
manufacturers with positive, free cutting
geometries, improved chip control,
shorter cycle times through higher feed
rates, and increased machine utilization
through improved chip control.
Horn says the sintered mini inserts
provide an ongoing benefit for existing
users of the mini system as they are fully
compatible with existing mini holders
from the company. The positive fit
connection between the insert and holder
ensures maximum torque transmission
combined with precise concentricity.
www.hornusa.com
ÒSANDVIK COROMANT
Deep grooving
Sandvik Coromant’s CoroTurn SL70 deep
grooving solution handles deep grooving
applications in aerospace engine
machining.
Designed as a flexible system,
utilizing Coromant Capto adapters and
replaceable blades, this system offers
customers a wide choice of insert
styles as well as different adapter and
blade angles to handle complex shapes
typically used aerospace engines.
The coupling design features Sandvik
Coromant’s serration lock (SL) interface
MAY 2012 www.shopmetaltech.com
59
Â
CUTTING TOOLS | Grooving
www.hornusa.com | www.coromant.sandvik.com/ca | www.kennametal.com | www.iscar.ca | www.sct-isa.com | www.tungaloyamercia.com
“If the insert failure mechanism is
tool wear, apply a harder grade to reduce
the time the insert wears. If the cutting
edge is chipping, then apply a tougher
grade,” he says. “Always remember to
change one variable at a time to zero in
on the best cutting tool combination for
your particular application.”
When grooving small parts in
Swiss-style machines, having the latest
and greatest coating is also plus. From
Kennametal’s perceptive, that would be
WKH.&839'FRDWLQJ
´7KHUHFHQWO\ODXQFKHG.&8
Beyond grade is a tougher grade
with an advanced PVD coating that
maximizes performance in those harsh
applications. In fact, this grade should
DOZD\VEHRXUFXVWRPHU·VÀUVWFKRLFH
when grooving and cutting off. A more
ZHDUUHVLVWDQWJUDGHZRXOGEH.&8µ
says Etling.
“
H[WUDÀQHVXEPLFURQFDUELGHJUDLQV
that have extra sharp cutting edges,”
VD\V$OH[/LYLQJVWRQDSURGXFW
manager for Tungaloy America,
Brantford, ON. “With this technology
Because the grooves are so small, having micrograin
carbides has become the norm to provide thermal
protection and prevent chipping.
The whole picture
As people look to reduce costs in small
grooving applications, they have their
sights set on new products with more
wear resistant grades, longer tool life,
and better overall performance.
“In our newer products there are
”
you reduce the risk of having cutting
forces that move the part as you
machine it.”
Because the grooves are so small
—whether for inside, outside, or
face grooving—having micrograin
carbides has become the norm in
GROOVING METALTECH REPORT
combined with an oval shaped
coupling for superior strength
and stability, as well as good
accessability into complex shapes.
The blades for carbide inserts
also offer high pressure coolant
capability for excellent chip control
and optimized tool life.
www.coromant.sandvik.com/ca
ÒSECO
Grooving micro parts
Seco has released the MDT 2MM
for grooving, parting and profiling
of small and micro parts. An
extension of the successful MDT
family of tools, the MDT 2MM
offers a cutting edge width of just
2 mm (0.078 in.).
The MDT 2MM is available
in two sizes of inserts and
toolholders. Designed primarily
for Swiss machining applications,
MDT19 inserts feature a compact
size and are shaped to provide
insert indexing accessibility
even when space is restricted.
With a longer reach, larger
toolholders and broader
product range, the MDT28
size offers solutions for general
machining applications. It allows
parting off of bars up to 2 in. in
diameter. Both sizes of inserts
feature a thinner width than the 3
mm and 4 mm tools in the MDT
family, resulting in costs savings
on materials when parting.
To maximize stability and
accuracy, the MDT 2MM
incorporates the Secoloc insert
60 www.shopmetaltech.com MAY 2012
clamping system. A combination
of V-top clamping and serrated
contact surfaces between the
insert and toolholder ensures the
highest possible process security.
MDT 2MM inserts are
available in multiple geometries.
The FT-geometry provides strong
performance for grooving and
parting off FTR6 and FTL6
geometries reduce burring and
centre pip when parting off in
more demanding applications.
For profiling, the round MPgeometry is optimal.
Inserts are available in CP500
and CP600 grades. CP500 offers
high speed capability and applies
to general grades with high wear
resistance, while CP600 provides
additional toughness for more
difficult applications, such as
interrupted cuts.
www.secotools.com
ÒSUMITOMO
More stable insert life
Sumitomo’s new SumiNotch
grooving insert products feature
a new specially formulated grade
EH510V with a new “V” coating,
designed for superior wear and
notch resistance.
Compared to conventional
grades, SumiNotch Grade
EH510V exhibits more stable tool
life. It is capable of performing
continuous cuts, as well as
finishing light to medium light
interrupted cuts.
The insert can machine exotic
materials, including heat resistant
steels, titanium alloys, N, Fe and
Co-based alloys.
order to provide thermal protection,
and also to give a tough edge line to
prevent chipping. All of this has to
happen in a stable environment to
ensure optimal speeds.
“Grooving small parts is
generally about tool stability and
selecting the right cutting speed,”
says Dave Andrews, product and
application specialist with Sandvik in
Mississauga, ON.
6DQGYLN&RURPDQW
VWRROVVSHFLÀF
to grooving small parts, both internal
DQGH[WHUQDOLQFOXGHWKH&RUR&XW;6
which helps with external parting,
grooving, turning, backturning, and
WKUHDGLQJ,WKDVWKH&RUR7XUQ;6IRU
small internal applications.
“Grooving is a very demanding
application,” says Andrews. “You have
a lot of insert engaged in the cut. A
Sumitomo’s “V” coating
contributes to continuous
cutting capability and tool wear
resistance. Flank wear is also
reduced, for increased cutting
up-times and decreased tool
indexing, downtime.
three millimetre wide cut has a lot of
engagement, and can present problems
with tool pressure on the component.”
When grooving small parts, a tool
has to be as rigid as possible for best
performance. But stiffness and rigidity
don’t go well together.
“The harder it is, the more fragile,”
says Steve Geisel, senior product
manager for Iscar Tools Inc., Oakville,
ON. “We’re making cutting tools out
of very tough pieces of carbide, which
gives us strength but increases fragility.
Some of the biggest challenges when
talking about grooving parts this small is
spindle speed, and also chip evacuation
Tim Wilson is a freelance writer based in
Peterborough, ON.
For more information on cutting tool technologies, visit Shop Metalworking
Technology’s CUTTING TOOL ZONE online at www.shopmetaltech.com.
industry-standard competitive
toolholders and boring bars.
All SumiNotch toolholders
feature a simple pocket design,
which is CNC manufactured.
These turning toolholders (SS
Series) and boring bars (A-SE
Series) consist of a single clamp
and screw design, making them
highly cost effective.
www.sumicarbide.com
ÒWALTER TOOLS
Shallow depth grooving
SumiNotch inserts offer the
industry’s most accurate indexing
repeatability, claims the company.
They boast a rigid groove locking
design, for maximum stability and
minimum movement.
Additionally, featuring standard
design in 16 grooving widths,
they can be accommodated by
so that the tool doesn’t snap.”
Surface feet per minute (sfm) can
be very low when grooving small
parts because bore diameters are so
small. As a result, an operator may
ÀQGWKDWKHLVUXQQLQJDWUSPVZHOOLQ
excess of what is required.
“People often overlook this,” says
Geisel. “They know they should be
UXQQLQJDWWRUSPEXWLID
bore diameter is at 100 thousandths of
DQLQFKWKH\FRXOGÀQGWKHPVHOYHVDW
20,000 RPM, which is way too fast.” SMT
Walter USA LLC has expanded
its line of Walter Cut tools for
parting, grooving and turning with
three new models optimized for
shallow depth grooving of up to a
maximum of 0.236 in. (6 mm).
These three new tools—
designated G1511, G1521, and
G1551—each have different
approach angles. The G1511
is straight at 0°, the G1521 is
angled at 90° and the G1551 is
angled at 45°. The straight and
the 90° versions are suitable for
radial and axial face grooving,
as well as for turning. The 45°
G1551 is intended primarily for
recesses, undercutting and copy
turning applications.
Though optimized for shallow
grooving, all three models can be
used for a variety of applications
including parting off small and
thin-walled workpieces, or for
making sealing ring and snap ring
grooves.
Enhancing this versatility is
the fact that inserts in widths
ranging from 0.079-0.236 in.
(2-6 mm) can be used in the
same Walter Cut toolholder. This
reduces the number of tools
required and leads to a reduction
in tool and inventory costs.
These double-edged inserts
are formed from the latest
Tiger·tec cutting tool materials
with geometries and coatings
specifically for grooving.
As with previous tools in
the Walter Cut G1011 range,
the three new models boast a
key feature that both simplifies
handling and increases safety:
The clamping screw can be
accessed from both sides.
This means that inserts can be
changed quickly and easily, even
with inverted use.
In addition, the low tool height
typical of Walter Cut toolholders
facilitates chip removal,
enhancing process reliability.
www.walter-tools.com
MAY 2012 www.shopmetaltech.com
61
FABRICATING | Punch Tooling
Increasing
Productivity
WITH
Special Shapes
BY PETER
VISSER
Improve nesting strategies;
reduce hit counts
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HERE SEEMS TO be a disconnect between how
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WKHLUWXUUHWGHSDUWPHQWV$ORQJP\WUDYHOVWRVKHHW
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IDWLJXHGVSULQJV0RVWVKRSVDUHRQO\UXQQLQJDW
WZRGHSDUWPHQWVWRGHWHUPLQHZKDWWKHLU´UHDOµ
Mate's Nova tooling system
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designed for Prima Power's high WRSHUFHQWRIWKHLUSRWHQWLDOFDSDFLW\QRW
6KRSVFDQGRDVLPSOHDQDO\VLVRIWKHFRVWRI speed hydraulic punch press. WRPHQWLRQWKDWWKHQH[WPDFKLQHGRZQWKHOLQHLV
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T
0$< www.shopmetaltech.com
63
Â
FABRICATING | Punch Tooling
Examples of special
shapes from Mate
Precision Tooling,
across and below.
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KLWFRXQWV,I,ZHUHWR´QLEEOHµDLQFLUFOHZLWK
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WHQKLWV7KHDYHUDJHPDFKLQHKDVDKLWUDWHGHSHQGLQJ
RQPDWHULDOWKLFNQHVVRIDERXWKLWVSHUPLQXWH%\
“
”
Imagine saving hundreds, even thousands of hours a year in production.
This can translate into five or six figure savings each year.
SXUFKDVLQJDVSHFLDOVKDSHLWZRXOGUHGXFHDOPRVWWZR
PLQXWHVSHUSDUWZKLFKPHDQVWKDWLWLVSRVVLEOHWRUHGXFH
DZKROHGD\·VZRUNRYHUWKHFRXUVHRISXQFKLQJDIHZ
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PRUHGD\VFRXOGEHWDNHQEDFNHDFK\HDUMXVWE\VSHQGLQJ
XQGHULQWRROLQJ
7KHDYHUDJHWXUUHWFRVWVDFRPSDQ\DERXWDQKRXU
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KRXUVD\HDULQSURGXFWLRQWKLVFDQWUDQVODWHHDVLO\LQWR
ÀYHRUHYHQVL[ÀJXUHVDYLQJVHDFK\HDU5()2$VZHOO
FRPSDQLHVQRZKDYHWKHDELOLW\WRSURGXFHPRUHSDUWV
SHU\HDUZKLFKFRXOGPHDQWKHDYHUDJHVKHHWPHWDOVKRS
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DQGLQYHVWLWLQRWKHUHTXLSPHQWDQGWRROLQJIRUHYHQPRUH
LQFUHDVHGSURÀWVDQGUHGXFHGPDQXIDFWXULQJFRVWVSMT
5HPHPEHUWLPHLVPRQH\
Peter Visser is a sales engineer with Mate Precision Tooling.
www.mate.com
64 www.shopmetaltech.com 0$<
For more information on fabricating
technologies, visit Shop Metalworking
Technology’s FABRICATING ZONE
online at www.shopmetaltech.com
“We chose the Prima Platino
because after researching
the industry, we found that it
had just as many, if not more,
machine features than the
competitors at a better
price. Bang for the buck,
it was the best machine on
the market. I liked the
construction of the machine
because it had the cantilever
arm construction with the
single frame so the
resonator sits on top of the
machine. And it was also one
of the only lasers that
offered the rotary axis
option for tube cutting.”
Alfredo Darolfi
VP Manufacturing
D & R Electronics Co. LTD
Bolton, ON
Prima Power is a leading
supplier of 2D and 3D
laser sheet metal
processing systems. We
provide the option of either
CO2 or fiber laser power
sources. A single-source provider,
Prima Power manufactures the CO2 laser
source, machine tool, control, software, and
material handling. For more than 40 years, the Prima laser
manufacturing division has been producing high-quality industrial CO2
laser resonators, providing DC excited, fast axial flow 3000, 4000, and
5000-watt resonators.
Compact design saves floor space, facilitating efficient material flow,
and requires no special foundation.
Efficient resonator design reduces power consumption by as much
as 33%... and uses fewer optics, further reducing operating expense
and maintenance costs.
Cantilever design provides tremendous flexibility in terms of
operator access and material handling options.
SEE US AT MMTS
BOOTH 703
Prima Power Canada
1040 Martin Grove Road / Unit 11 Toronto, Ontario / M9W 4W4
Tel. 416 242 4431 • www.primapower.com
Â
SOFTWARE | CAM
œ
STEPS to Better Machining
CAM software enhancements offer machining benefits
BY JOHN WELCH | IMAGES: OPEN MIND TECHNOLOGIES
“IN THE ONTARIO market we
have seen a high surge of CNC multiaxis machinery being shipped out to
YDULRXVW\SHVRIPDQXIDFWXULQJRXWÀWVµ
says Marty Cornacchi, vice president,
operations, CAM Focus Consultants,
Richmond Hill, ON, a supplier of CAM
software for manufacturers.
Complicated tire moulds can be programmed efficiently.
“This high demand for equipment
has pushed the Canadian manufacturing
sector to reach into new areas of
production and allow for growth.
Along with complex CNC machinery,
the demand for sophisticated CAM
software has also risen due the need
of programming state-of-art CNC
PDFKLQHVIDVWHUVPDUWHUDQGHDVLHUµ
Five axis machining strategies are
particularly important for mould and
die manufacturing, as they enable
66 www.shopmetaltech.com MAY 2012
FRQWLQXRXVPDFKLQLQJRIVLJQLÀFDQWO\
larger areas with shorter tool lengths
on vertical or steep walls, improving
process parameters and surface quality.
Now further developments in CAM
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These developments include: automatic
tool-axis adjustments to avoid
collisions, automated rest machining,
automatic indexing, and shape offset
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,QÀYHD[LVPDFKLQLQJWRPDNH
generating an NC program as easy
as possible, you need a CAM system
that exploits the performance range
of each machine tool and takes
machine kinematics into account.
Compared to three axis milling, in
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movements of the tool reference point
and the movements of the machine’s
linear axes (pivot point path) are
different. This is because movements of
the rotary and tilting axes result
in compensation movements in the
linear axes.
Successful milling projects strike a
balance between programming effort,
cutting time, machine movement,
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upon the shop in question.
™
COLLISION
AVOIDANCE
Automated collision avoidance
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axis strategy. For complex
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sometimes even impossible,
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for tool orientation. Five axis
simultaneous movement with
fully automated calculation of
tool angles solves this problem.
Traditional programming
solutions require a programmer
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rotary axis movement, then
simulate the resulting milling
operation to check collision.
This process must be repeated
until the programmer correctly
guesses proper tool inclination.
Modern CAM software
should calculate a collision-free
toolpath from the beginning,
taking into account the tool,
toolholder, spindle geometry,
and machine kinematics.
The rotary axis should be
automatically adjusted to
minimize machine movement
while completing the
necessary toolpath.
š
REST MACHINING
Traditional rest machining is a labourintensive process that has typically
involved mentally dividing a job into
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orientations for each. Today, rest
machining strategies are available that
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required 3+2 machining orientations
and the resulting toolpath for all separate
project areas in a single operation.
This reduces programming
time for complex geometries. If a
collision is detected in one of the
rest machining areas during toolpath
calculation, minimal simultaneous
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the tool axis adjusted to avoid the
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This optimizes machining time
by maximizing the use of 3+2 and
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motion.
In one example, a metal injection
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more than 370 steep rest material areas
with different angles was machined in
a single operation. All the user had to
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This cut the required programming time
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Automatic indexing enables another
machining strategy that moves only
once around the C axis in small steps
in a single 360° rotation. Compared to
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can always maintain the programmed
feedrate even when using a slow
worm drive. And because unnecessary
movements are avoided, this process
is also easy on the machine, saving
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AUTOMATIC INDEXING
It is now possible to automatically
control both rotation axes
independently so only one of the
two rotation axes is used to achieve
continuous, collision-free machining.
This 4+1 machining style is particularly
advantageous because rotation axes
are typically different in terms of
technical capabilities and precision due
to different masses to be moved or
different drive power. Some of today’s
CAM solutions go one step further and
provide automatically indexed axes. Tool
angle is calculated so tool orientation
within a milling area on the surface is
not changed. If necessary, the milling
area can be automatically subdivided
further, or local simultaneous
movements can be generated.
Rest machining strategies can result in significantly
less programming time for complex geometries.
œ
SHAPE OFFSET
ROUGHING, FINISHING
Modern high performance roughing
algorithms have proven ideal for hard
milling applications. These volumetric
roughing processes prevent the cutter
from cutting deeply in corner areas or
having a sudden change in direction.
They also provide ideally distributed
milling paths, climb-only milling
strategies, and dynamically adjusted
feedrates. They have been proven to
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of large volumes of material, plus the
constant cutter load extends both tool
and machine life. Today, this approach
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conditions using shape offset strategies.
Z-level roughing and Z-level
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programming approaches that have
been used successfully for years. In
some applications, such as tire mould
programming, the toolpath projected on
the geometry by Z-level has proven to
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condition resulting in multiple retracts.
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named due to the toolpaths offset from
a shaped surface rather than projected at
Z-level, overcomes this issue and allows
for the inclusion of bull-nose tools and
end mills.
A programmer need only select the
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toolpath accounts for the shape of the
surface, bull-nose and end mills may
be employed and the tool is constantly
engaged in material.
Modern CAM software can do
much to shorten the learning curve
for programmers with less experience
while providing a competitive edge
for the veterans. SMT
John Welch is account manager for Open
Mind Technologies USA Inc.
www.openmind-tech.com
MAY 2012 www.shopmetaltech.com
67
Â
YOUR BUSINESS | Job Shops
Growth Strategies
Quebec job shop expands with US acquisition
T’S NOT OFTEN that you hear
of a Canadian company acquiring
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BY MARY SCIANNA
I
68 www.shopmetaltech.com 0$<
Yves Proteau, left, with brother Jean, in APN's Quebec City machine shop. The brothers' father
Claude founded the business in 1970.
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“S&S had too many jobs for the
US military; it was after 9/11, so many
shops in the US serving the defense
industry were busy. S&S couldn’t do
the job but the people at the company
spoke to us and gave us advice about
how to machine this die. We were
interested in expanding into the US
military market so partly joking, I
asked the owners if the company was
for sale, which it was not at that time.”
In 2008, S&S Carbide was one of
many US job shops affected by the
ecomomic downturn. So the
owners contacted Yves and his
brother Jean to discuss the possibility
of an acquisition.
´:HZHUHMXVWÀQLVKLQJD
million investment, we had no money
left in our bank account and we were
in the middle of an economic crisis,
but we decided to go to California
anyway. We had a good feeling about
the company—the people that worked
there and the owners had good
knowledge of the defense industry
and machining.”
It took close to 20 months of
negotiations, but on January 4,
2011, APN purchased S&S Carbide,
IXOÀOOLQJDGUHDPIRUERWKEURWKHUV
to expand their business into the US
military component manufacturing
market.
Proteau and his brother Jean knew
they were taking on more than they
could handle in terms of managing
two growing businesses in two
countries, so they negotiated to keep
on the employees, including the two
owners who continue to run the
California job shop.
While the former owners of S&S
Carbide Tool run the shop, Yves, who
5 Tips on Expanding in the US (4 to succeed in Canada too)
{
Understand American
patriotism
APN decided to keep the S&S Carbide
Tool name because it understood the
patriotism Americans feel about products
manufactured in their country. “When you
arrive as a Canadian business and you
have just purchased a US company, you’re
better not to do too much flag waving.
We are driving growth, improving it and
implementing management strategies,
but we didn’t want to disturb it too much
because of US customers who want to have
products made in the US," says Proteau.
|
Meet customers' needs
Be innovative
Be innovative in how you manage your
business and in how you manufacture
your products. “Everyone can purchase
a high-end machine, but it’s how you
implement all the things that go with the
machine that will set you apart. It’s about
having the right tooling, right toolholder,
properly designed workholding for your
product, and you have to integrate all of it.
As a company, our job is to integrate these
systems and be innovative in our approach
to implementation. And if you don’t do this,
then some other company, either in Canada,
China or the US, will beat us.”
“
Invest in your employees
Stay close to your customers and
understand their needs. If there is one thing
that the Proteau brothers have learned well,
it is to establish strong relationships with
customers to better understand their needs.
“Everything in this type of business is about
serving the customers and if you don’t do it
right, and many companies don’t, it will get
a business into trouble,” advises Proteau.
}
~
Invest in the right technology
The right technology is not just about
CNC machines. “Of course machining
is important, but you have to look at
manufacturing as a system and invest in all
the right technologies for CAD, programming,
ERP, quality and other systems to help run
your manufacturing business.”
has the title of president for the
US company, oversees the business.
He and his brother are now
implementing the management
practices that have made their Quebec
operation so successful.
“Last year in total between the two
For APN, employees are part of its secret
to success. It invests in benefits and
training and offers incentives to keep
people satisfied with their work and the
company. For instance, APN gives back 5
per cent of its profits to its employees. “We
are transparent with our profits and it is a
strategy that is working well for us.”

TIPS
companies we experienced cloAPN
increased 39 per cent and S&S
Carbide increased 34 per cent.
"We’ll be sending one of our
employees down for a one to
two-year period to help manage
the machine shop.” SMT
MAY 2012 www.shopmetaltech.com
69
Â
FABRICATING | Press Brakes
Automating Your
Press Brake
S
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Shop Metalworking Technology: What
fabricating shop conditions would justify
the automation of press brakes?
SHANE SIMPSON: Customers who
have high runs in their production
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it can come down to 10 parts per day
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70 www.shopmetaltech.com MAY 2012
SMT: What’s involved in automating a
press brake? Does it entail acquiring new
technologies to replace old press brakes
or can automation be added to existing
press brakes?
SHANE SIMPSON: You can apply third
party robotics to press brakes and
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SUHVVEUDNHV7KHTXHVWLRQLVWKDWZKHQ
\RXKDYHWKLUGSDUW\LQGXVWULDOURERWV
how is programming and integration
handled? The reason TRUMPF came
out with its own automation—we used
to use third party robotics—was that it
was cumbersome to program parts with
the teaching pendant. This only lent
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which is becoming an industry-wide
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because they can see collisions in a 3D
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www.us.trumpf.com
have already been programmed or the
current part you are trying to program
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programming each part.
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IDEULFDWRUFDQSURJUDPSDUWVZKLOHWKH
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Although we make our own robotic
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Shop MT: Press brakes are offered in hydraulic, electric and hybrid models. Does
this have an impact on automation?
SHANE SIMPSON: From a speed
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Shop MT: How does the cost of automated press brakes compare to manual
press brakes?
SHANE SIMPSON:$JHQHUDOUXOHRI
WKXPELVWKDWWKHFRVWRIDXWRPDWHG
press brakes is about twice the price
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JHQHUDOFRVWGLIIHUHQFHIRU75803)
but this cost really depends on the
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run very large parts. TRUMPF has
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are also there even with just one
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that does not have automation.
Shop MT: What new technologies are
now available with automation and press
brakes that would benefit a fabricator?
SHANE SIMPSON: There are new techQRORJLHVIRUPDNLQJEHQGLQJIDVWHU,W·V
not just TRUMPF; all our competitors
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basis.
QA
&
Shop MT: Is press brake automation
technology modular and flexible to allow
fabricators to slowly build up automation
when required?
SHANE SIMPSON: TRUMPF
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that it is possible to purchase a
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our experience is that most customers
who are going to automate a press
brake will do it all at one time.
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automation system with storage and
retrieval. This means material can be
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WKDWFDQEHFXWVRUWHGDQGGHOLYHUHG
WRWKHEHQGLQJFHOOWREHIRUPHG
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the laser and punch cells are standDORQHIRUFXWWLQJRUWKH\DUHSRVVLEO\
FRQQHFWHGWRDPDWHULDOVWRUDJHWRZHU
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using an automatic controlled bending
system that automatically validates
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tower. The parts are retrieved and
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which knows where the part is on the
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to the cutting machines. CCD
cameras capture the parts orientation
and adjust the gripper to the proper
location. The part is bent—without
anyone ever touching it.
How will press brake automation change
in the coming years–what improvements or technology gaps need to be
addressed?
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V\VWHPVIRUYHU\VPDOOSDUWVDQGIRU
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customers still need automation to be
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with more automation in tool changers
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For more information on fabricating technologies, visit Shop Metalworking
Technology’s FABRICATING ZONE online at www.shopmetaltech.com.
MAY 2012 www.shopmetaltech.com
71
Â
MACHINING & CUTTING | WHITE PAPER
Cutting Demo
Hard machining is cost effective on a multi-tasking
machine equipped with the right cutting tools
HIS CUTTING demonstration white paper proves that a cost effective
multi-tasking machine equipped with a compact milling spindle and turning
spindle, provides the rigidity and maximum performance for hard milling
and hard turning operations when equipped with the proper cutting tools.
T
HARD MACHINING SUMMARY
7KHGHPRQVWUDWLRQFRQÀUPVWKDW
the Mazak multi-tasking machine,
together with proper tooling, is
both rigid and powerful enough
for hard machining. Additionally,
the demonstration illustrates the
capability of the multi-tasking
machine’s Y axis and compact
milling spindle for machining
above and below workpiece
centrelines. Complete actual
bearing race processing time was
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part processing time as compared
to other manufacturing methods.
ÎWorkpiece Material: Raw cylindrical bar of 52100 bearing steel 6
EQUIPMENT AND TOOLING
The demo used a Mazak Integrex
j-200 multi-tasking machine with
20-position front-load tool magazine
and an 8 in. chuck mounted in the
machine’s 15 hp, 5,000 rpm integralmotor main turning spindle with a
torque output of 119 ft-lb (20-hp, 5,000
rpm turning spindle with 172 ft-lb of
torque optional).
The machine’s milling spindle is 10
hp (7.5 kW), 12,000 rpm and indexes
in 5º (or optional 1º) increments
from –30º to 190º (B axis control).
Axis strokes measure 17.7 in. (450
mm) in X and 7.87 in. (200 mm) in
Y. The machine is equipped with
Mazak’s MX Hybrid Roller Guide
System for vibration dampening, high
load capacities and fast acceleration/
deceleration.
in. long, 5 in. in diameter, and at a
hardness of 50-55 Rc. Four separate 0.750 in. thick bearing races
are produced from the bar.
ÎRequired Processes: Turning,
Maazak's Integrex j-200 multi-tasking machine
used in the cutting demo.
SECO CUTTING TOOLS
TH 1500 carbide
turning inserts with
Duratomic coating
technology.
CNMG
432-MF2:TH1500
Hi-Feed indexable milling cutter, 1 in.
diameter with three MH 1000 inserts.
R217.21-1.0012RE-R100.3A – 1 in.
cutter body
218.19-100T-MD08:MH1000 - inserts
72 www.shopmetaltech.com MAY 2012
Four separate
0.750 in. thick
bearing races,
such as this one,
were produced
from a raw
cylindrical bar.
Jabro hard milling
solid carbide endmill,
0.472 in. in diameter,
3 in. long.
141V120R300Z4MEGA-64
milling, boring, threading,
chamfering, engraving, grooving
and cut off.
Jabro Hi-Feed
0.393 in. diameter
roughing mill.
180100R200Z5MEGA-64
Jabro HK
450-025
solid carbide
chamfer.
HK450-025
HARD MACHINING OPERATIONS
™
Operation 1:
Hard turn part face and part O.D. with TH 1500
inserts feeding at 500 sfm for facing and 450 sfm
for O.D. turning. Both operations ran dry taking
a 0.040 in. maximum depth of cut at a removal
rate of 0.006 ipr during facing and 0.007 ipr during
O.D. turning.
g
Hard turn part face and
part O.D. machining
with TH 1500 inserts.
š
Operation 2:
5RXJKLQJLQVLGHSRFNHW,'SURÀOHZLWKLQ
diameter Hi-Feed Mill using helical ramping and no
coolant. The helical cutting technique involved more
passes, higher speeds and feeds and lighter depthsof-cut. The technique is somewhat uncommon for
this type of operation, but it eliminated the cutter
loads typically associated with taking heavier depthsof-cut and actually reduced operation cycle time.
The j-200’s milling spindle ran the cutter at
1,910 rpm and feeding at 183 ipm, taking 0.020 in.
depths-of-cut. The workpiece remained stationary
(no turning spindle C axis movement) as only the
machine’s Y axis was used to rough the pocket to
a depth of 1 in. (deeper than the part thickness for
cut-off purposes).
Solid carbide,
coolant through
thread mill.
Jabro Mini solid
carbide mill (for
engraving).
TM-MF12X1.
5ISO-12R5
116ML010TNMEGA-64-T.
Roughing the inside pocket/I.D. profile with a 0.472 in. diameter
Hi-Feed mill using helical ramping and no coolant.
›
CBN 200 grooving/
part off tool
LCGN 1604040400S-LF:CBN200
Operation 3:
Finish cut pocket inside walls with Jabro endmill
using the milling spindle and Y axis and high
feed capabilities of the j-200. The machine ran
the cutter dry at 3,657 rpm, feeding it at 70 ipm
for a 0.020 in. depth-of-cut. This operation
HOLPLQDWHGWKHQHHGIRUJULQGLQJWKH,'SURÀOH
of the workpiece.
Seco Jetstream
high pressure
coolant system.
C6-CFML45080-04JET
MAY 2012 www.shopmetaltech.com
73
Â
MACHINING & CUTTING | WHITE PAPER
Left: Using Seco's end mills, the machine ran
the cutter dry at 3.657 rpm, feeding it at 70
ipm for a 0.020 in. in depth-of-cut.
Right: The cutting demo included
machining four holes in the bearing race.
œ
AD INDEX

ž
Operation 4:
Helical bore four holes in part O.D. using (10
mm diameter) Jabro Hi-Feed mill. Using machine
power and rigidity, the cutter, rotating at 2,312
rpm, constantly ramped downward in a circular
path feeding at 37 ipm and taking a 0.020 in.
depth-of-cut.
Operation 5:
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Jabro carbide chamfer. Cutter speed was 1,472 rpm
for 0.015 in. depths-of-cut removing 0.002 ipr.
Operation 6:
Thread mill four holes using machine C axis
positioning and milling spindle with solid carbide,
through-coolant thread mill cutter. Running at
2,596 rpm and feeding at 1.56 ipm for a depth-ofcut of 0.030 in., the cutter completed each hole in
one revolution around the I.D.
Ÿ
¡
Operation 7:
Engrave part number on face using Jabro-Mini
running 10,000 rpm, feeding at 7 ipm for a 0.015 in.
depth-of-cut.
Operation 8:
I.D. grooving with CBN 200 tool at bottom of
inside pocket to avoid interrupted cut condition at
part cut-off. Jetstream high pressure coolant used.
Machine rotated part in C axis at 395 rpm with tool
removing at 0.005 ipr.
Operation 9:
Part cut-off at 395 rpm part rotation speed with
CBN 200 removing 0.005 ipr and using Jetstream
high pressure coolant.
Testing the cost
effectiveness of hard
machining using
a multi-tasking
machine. Cutting
processes tested:
turning, milling,
boring, threading,
chamfering,
engraving, grooving
and cut-off.
www.mazakcanada.com | www.secotools.com
DMG Canada .......................................... 19
Lincoln Electric ...................................... 51
Shop Insights Conference 2012 ......... 22, 41
Elliott Matsuura Canada ............................ 6
Mate Precision Tooling ............................ 45
Shop IMTS Canadian Luncheon ............... 33
Fagor Automation ..................................... 4
Miller Electric ........................................... 9
Sirco Machinery ..................................... 25
Ferro Technique ...................................... 55
Mitutoyo Canada ..................................... 27
Thomas Skinner ..................................... 25
Haas Factory Outlet ................................ 25
PRIMA Power ......................................... 65
TRUMPF ................................................ 62
Heidenhain ............................................ 37
Sandvik Coromant Canada ....................... 76
Tungaloy ................................................ 13
Heinman Machinery .....................23, 38-39
Scientific Cutting Tools ........................... 15
Wilson Tool ........................................... IBC
Henkel ................................................... 57
Scotchman Industries ............................. 11
Iscar Tools ............................................... 3
Seco Tools ............................................ IFC
74 www.shopmetaltech.com MAY 2012
Now, more than ever, Canadian tooling
manufacturers Exacta Precision and Exacta
Fabtool offer the most comprehensive
selection of tooling solutions for the metal
stamping and fabricating industries. Whether
you need to punch it, bend it, or stamp it,
Exacta’s standard, precision, or custom tooling is
manufactured with the latest
technology to ensure high quality results.
For all your tooling needs, trust the experts
at Exacta. Call Exacta Fabtool at
800.268.4180 for press brake tooling or
Exacta Precision at 800.268.5573 for all types
of punches, dies or specialty tooling solutions.
EXACTA
PRECISION
EXACTA
FABTOOL
Smart tools - pocket sized
Our apps don’t play music or entertain you with games, they
All our apps can show you how small changes in the way you
don’t give anything away, and they won’t even make you
use your tools can make a big impact on your results.
laugh,
but they are smart and can come in very handy when you
With these essential, quick question and answer tools, you
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always have an answer wherever you are.
What they will do is help you get the most out of your
Check out our smart tools from our pocket sized range at
machining. The Start Values App recommends speed, feed
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and depth of cut. The Machining Calculator App optimizes
performance in turning, milling and drilling by calculating
(And as they are free that should make you appy) ;-)
optimal cut settings based on your job parameters.
Call your local Sandvik Coromant Productivity Engineer at 1-800-268-0703 today or visit us at
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Scan the code and download all the smart apps for metalcutting.