metalworking news

2 Editor’s Comment 4 Viewpoint 8 Industry News New machines from Haas Automation; Badger; Denel; Western Cape metals and engineering; What online presence really means; MicroStep; Rugby World Cup 2015 and EMO 2015 in Milano, Italy; Traceability Solutions; Talmac Machine Tools; Amada Johannesburg; Wind tower factory; JIMS; Airbus A400M; Toolquip & Allied; Boeing and Paramount Group; New AFM 3D CNC; Jetstream Cutting Solutions; AHRLAC; AIS guidelines 42 Shopfront Focus S&D Precision Toolmakers; Scientific Engineering; Not just a service centre; Steelbank unwinding the way forward 70 Better Production Current trends in the machine tool industry 74 International News Global robotics industry; CIMdata; EuroBLECH 2014; Autonomous living; Amazon launches 3-D printing store; Iscar Ltd. partners with Machining Cloud GmbH 84 Product Review Sandvik Coromant; DMG Mori DMU 70 ecoline; HyPrecision Waterjet; Victor Vcenter-AX350; TaeguTec’s ApexMills; A-Tap; SMTCL Brio Miller; Edgecam 2014 R2 released; Renishaw; Hurco; Iscar’s latest developments; New high-end DX200; Yaskawa; Feeler FT-Series; Mastercam’s Dynamic Motion technology; Tongtai; 3M; Okuma’s LB4000 EX-II; Doosan; Kitagawa RK200

METALWORKING NEWS v 13. 4 September 2014 1 editor’s comment

Automation, automation, automation!!!

ith a large shift towards automation Volume 13 Number 4 in industrial manufacturing making September 2014 production more efficient and smarter, W Editor an integrated industry approach is not far off. To remain competitive, companies need to make Bruce Crawford their manufacturing processes more efficient, Online Editor and that means greater investment in Damon Crawford state-of-the-art automation technology. Internationally, companies and executives are Editorial Board Professor Dimitri Dimitrov, taking the steps and the decisions required to Global Competitiveness Centre develop a smart-factory vision into a real-life in Engineering, Department of Industrial solution. There are challenges along the road Engineering, University of Stellenbosch to achieving this reality as it requires Dr Willie Du Preez, Senior Researcher, Faculty information sharing, investment, and of Engineering and Information Technology coordination. Their competitiveness also of the Central University of Technology hinges on access to a reliable, sustainable energy supply. It is therefore sad to see that in the face of this reality, Unions and their Production Manager Wendy Crawford members choose to strike. Or should I say they intimidated, threatened and assaulted people who tried to work and shamelessly damaged and vandalised Reproduction company properties. This is an all too common occurrence in South Africa Jericho Graphic Design these days, as is the phenomenon of as one strike ends, another one begins Advertising in a different sector of industry. It is commonly referred to as ‘strike season’. Bruce Crawford / Wendy Crawford The pressure that manufacturers and business in general have been put Tel: + 27 11 463 0489 under over the last decade by these countless strikes resulting in lost Cell: + 27 83 628 7654 production is starting to create anger and forcing companies to relook at their E-mail: [email protected] circumstances, which could have far reaching repercussions for the labour Website: www.metalworkingnews.co.za force in South Africa. Printed By This is evident in the three Viewpoints that have been published in this Paarl Media issue. The writers have put in black and white what the reality of the situation is. Not many people are prepared to put their views in writing but I believe, METALWORKING NEWS is published by: like many others, that they have become ‘gatvol’ (fed up). BA Crawford Specialised Publications (Pty) Ltd In the International News section, the IFR President Arturo Baroncelli PO Box 69299, Bryanston, South Africa, 2021 reports that in 2013, about 179,000 industrial robots were sold worldwide - again an all-time high, and 12 percent more than in 2012. More than 700 41 Arklow Road, Bryanston, South Africa, 2021 Tel: + 27 11 463 0489 industrial robots were sold in Africa, 87% more than in 2012. The metal and E-mail: [email protected] machinery industry had an average annual growth rate of 22% in the same Website: www.crawfordpublications.co.za period. Does this not say something to the employees? In Industry News I report on new developments in the marking and Subscriptions Annual – Local: R140.00 (incl VAT) authentication industry which includes barcodes that can be identified from International: on application any iOS or Android smartphone, and new technology to be introduced that will ISSN 1682-8909 provide a variety of security solutions for preventing counterfeiting, brand protection, fraud and diversion – copper cable theft could be thwarted. Copyright Radio Frequency Identification (RFID) and barcode technologies are two All rights reserved. No editorial matter published in Metalworking News may be tools that manufacturers can leverage to establish an effective traceability reproduced in any form or language without programme. That’s because they provide direct visibility into the manufacturing written permission of the publishers. While process while streamlining data collection and communication. every effort is made to ensure accurate These three stories all point to the shift towards automation, which is reproduction the editor, authors, publishers and their employees or agents shall not be happening worldwide. So why should it not happen in South Africa? We are responsible or in any way liable for any errors, part of the world stage now and time and again we prove that we are equal to, omissions or inaccuracies in the publication if not better, than many first world countries. Look at the recent test launch of whether arising from negligence or otherwise the Advanced High-Performance Reconnaissance or for any consequences arising therefrom. The inclusion or exclusion of any product Light Aircraft (AHRLAC), a story also included in does not mean that the publisher or editorial this issue. If only the Unions and their board advocates or rejects its use either members would realise this. generally or in any particular field or fields.

2 METALWORKING NEWS v 13. 4 September 2014

VIEW POINT

The affects of the strike in the metals industry

he impact of the strike in the metals industry in South Africa Tcould have far reaching implications and unions must accept that actions always have consequences. I have heard countless stories of wanton vandalism, assaults, intimidation and many other horrific stories relating to the strike. I personally came close to being caught up in an incident that involved ‘strikers’ and all I can say is that I was grateful that I was in a car of their normal workforce, and have managed to manufacture and could speed away from the incident. at least 80 percent of their normal monthly production. I say ‘strikers’ as I am sure that 95% of the ‘strikers’ were As a result, the monthly profit has risen dramatically because hired hands because in most instances I have heard that the of not having to pay the extra wages. intimidation was just too organised. According to employers I Many companies have now just decided to close their have spoken to none of the ‘strikers’ were recognised by the doors – more unemployed – and others have serious cash employers, and the nature of the aggression of the ‘strikers’ flow problems and cannot afford to pay their employees, does not fit the profile of their employees. In other words they so are only working a four day week until they recover. (the ‘strikers’) were bussed in. Not an unusual tactic in This is going to put employees under even more pressure South Africa. to pay their debts because even though they approach the The threats on the lives of office employees is inexcusable employer for a loan the employer simply does not have the and should be dealt with but then we live in a country where money to lend. our law enforcement is in complete disarray in most eyes. All through this the Union bosses collect hundreds of Then I hear the stories of where companies have worked thousands of Rands from their members every month and ‘night shift’ to avoid the ‘strikers’ with maybe 10 to 20 percent continue to “Live a life of Reily”. Have the employees really analysed what they get for their monthly contributions? A month off work with no pay that will take them years to recover from! A funeral policy! Whoopee!! This strike has really annoyed many and you have got to ask whether Numsa has pushed some unwanted buttons? You only have to look at the international headlines in July, in particular those related to the automotive OEMS, where numerous million-dollar projects are being awarded and none are directed South Africa’s way. So are foreign automotive investors at the point of losing patience with strike-prone South Africa? Or will militant trade unionists be proven right in their gamble that multinational motor companies are too deeply embedded in South Africa to walk away? These are the questions asked by David Furlonger for his cover story in a recent issue of Financial Mail. Furlonger continues: “Though there appears to be no question at this stage of disinvestment by any of SA’s seven full-scale vehicle manufacturers — BMW, Ford, General Motors, Mercedes-Benz, Nissan, Toyota and Volkswagen — there is a sense that they may reconsider the scope of their presence here. BMW and Datsun, Nissan’s reinvented entry-level brand, admit that plans to build new cars in SA were put on hold because of the uncertain labour environment.” “The cars would have been mainly for export but the companies say they can’t risk an unreliable workforce. Last month, Datsun’s global head, Vincent Cobee, expressed regret at having to bypass SA for the Go car, which is designed for emerging markets and will go on sale in SA in a few weeks. The first generation of the car will be imported from India.” The South African and sub-Saharan Africa markets may have good long-term prospects but they are not that important to the OEMs, in world terms, that the usual rules of economics don’t apply.

4 METALWORKING NEWS v 13. 4 September 2014 The following are three viewpoints by concerned business owners in the metals industry. Names have been withheld for obvious reasons.

Who are the real victors of the strike? staff who will eventually own 47.5 % of the company. These are Numsa’s extended strike had little to do with workers’ rights the same staff that were threatened and intimidated into and more to do with a thinly disguised intention of developing a staying away for a month. higher political profile for the organisation. It is common The loss of production for the entire month of July has knowledge that Numsa intends on forming a political party. completely wiped out the profits made from March to end June. However, if big Jim continues to lead the country down this path The monthly fixed costs, rent, machinery installment to poverty, he may find as he “toyi-toyis” his way into the agreements, electricity, rates, insurances etc., are high, and palatial homestead, that the fire pool has turned green, the margins in a competitive industry are small. Our company is tuck shop is empty, the presidential jet that has been grounded very dependent on production volumes in order to be profitable. with flat tyres and no fuel, parked in a rusty hanger mostly Numsa’s denial of people’s right to work, has therefore ensured stripped bare and being used for shelters in the newly built that the same people whose best interest that they pretend to squatter camp, by residents who found the instant lawn on the represent, will lose dividends as well as the ability to “pay off’’ artificial soccer pitch quite appealing. shares through company profits. The company now faces a Who are the real victors of the strike? Certainly not our serious cash flow problem and has had to look for ways to cut company which has had the year’s profits wiped out. Certainly costs. Once again it is individuals that have to pay the price. not our workers who have lost a great deal of money and now The company has unfortunately embarked on a four day week have to work a four day week. Certainly not government who programme, not because of a lack of orders, but rather in an faces negative growth, recession and who is viewed as attempt to save the company and generate a positive cash flow powerless in the face of the unions. Perhaps the only position in as short a period as possible. organisation seen to be benefiting is the Numsa body itself. The owner of our company was one of the first to pioneer Their claims of victory may be believed by the ignorant, real empowerment of his workforce by implementing the uneducated or dim witted, which may increase their opportunity for workers to own 47.5% of his company. This membership and thereby the monthly contribution received in progressive and proactive programme specifically developed for the short term. However, the damage done to individuals and the company at no cost to any staff member, is being severely the personal hardship that they have had to endure may begin hampered by narrow minded organisations like Numsa, who to influence the vast majority of their membership to rethink. falsely accuse this business of racist colonialist policies. They may find their members becoming disillusioned. They may Honest hardworking business owners who have started in fact begin to lose membership. I know it has already begun businesses from scratch, have exposed themselves to huge to happen in our company. personal financial risk, and have dedicated their lives to building up successful operations, now find their businesses A concerned business owner under threat. Government is doing little or nothing to protect Profits for the financial year to date wiped out, staff lose businesses from unions and business owners will in the interest thousands in pay, annual dividends destroyed, consumer of self-preservation make firm decisions. Many business confidence eroded, relationships between business owners owners will sell up, while others will relocate, possibly even into and staff severely damaged, a depreciating currency, a country African countries north of our borders, where business conditions on the verge of a negative growth rate, are just a few of the are becoming more attractive. Many more business owners disastrous consequences of the recent month-long strike in the however will take the decision to automate their plants and one metal industry. can expect large cutbacks in the labour force in favour of Government once again proved that they are powerless to automation. Numsa has left business owners very little option. prevent unions dictating who does, and who does not, have the A study of figures also reveals just how much individual right to work in South Africa in 2014. Numsa successfully workers lost throughout the course of the strike. The losses are intimidated, threatened and assaulted people who tried to quite staggering. Analysis of the percentage increases received work. Numsa shamelessly damaged and vandalised company at our company show that the company gave an average of properties whilst government and the police force looked on. 12.31% per employee in 2013. The highest increase received With its 200 000 members, Numsa was able to bully was an astonishing 46% by one individual who upskilled industry into shutting down, affecting millions, from the local himself, whilst the lowest was 7.8% (still higher than the food vendor on the street corner, who had no lunch customers, industry 7%) by a high earner who performed poorly. Our shop taxi drivers who had no fares to transport, to suppliers to the steward happily chanted his way out into the street with a cool industry and related services, to banks, retailers, medical aid 22.22% 2013 increase in his back pocket! The new average funds, etc., who did not receive money for bonds, accounts, or increase per worker following the strike in 2014 is 9.6%, 2.7% monthly subscriptions. Workers who were forced against their lower than our 2013 average. Numsa claims this to have been will to endure a no work no pay situation. Industries across the victory! Our records show that our company has consistently board were negatively affected by this strike. paid staff more than the prescribed annual increase since Numsa declared the strike a victory, yet an analysis of the company inception. We believe that this will be the first year figures shows a very different picture. In a financial year which that this will not happen. This is a direct result of the strike. runs from March through to February, our company had Our figures show that a Grade H worker on minimum wage operated profitably during the months of March through to the who was on strike for 20 days, lost R5 520.00. We have end of June. The professionally and successfully managed alculated that it would take that worker 4.2 years to recoup his business’s financial records show that the company was on losses. Similarly our spread sheet illustrates that a Grade D target for a good year, with healthy growth and sound financial worker lost R7 393.00 and will take 7.89 years to recoup the management policies in place. The company could have loss, a Grade B worker lost R7 919.00 will take 14.1 years, and expected to make sizable profits as well as being able to a Grade A worker who lost R10 479.00 and only received an declare solid dividends for the company shareholders. Our 8% increase, will never recoup his losses. Yet Numsa claim a companies’ shareholders are made up of the majority of the victory for the workers! 

METALWORKING NEWS v 13. 4 September 2014 5 “Who are the real victors of the strike? Certainly not our company which has had the year’s profits wiped out. Certainly not our workers who have lost a great deal of money and now have to work a four day week. Certainly not government who faces negative growth, recession and who is viewed as powerless in the face of the unions.”

SEIFSA wage negotiations were a farce Were the negotiations about wage increases this year or Actual Wages CPIX wages were Numsa adamant that they wanted a strike to gain 1996 R8.69 R8.69 prominence in the race with Julius Malema, Joseph Mathunjwa (Amcu) and Numsa general secretary, Irvin Jim? 2014/5 R35.40 R24.30 Long before negotiations were deadlocked Numsa declared Increase 307% 180% their intention to go on strike. Ironically, I think this is the longest strike the metals These increases are only base rate increases and do not sector has had in the last 20 years and SEIFSA, on behalf include some of the less tangible costs incurred over this of the employers, has been more than generous in its period, namely: offerings to the unions. In fact the offering of wage increases a) Three days family responsibility leave has not changed by more than 0.5% over the 2nd July offer b) An extra weeks leave taken a year earlier yet the strike dragged on for four weeks because of section c) Increase in overtime rates from 1.3x to 1.5x normal rate 37 – none of our employees even know what this section d) Reduction in working hours from 45 hours to is all about. 40 hours/week So Irvin Jim won the war with a 34% increase for his e) Payment of overtime after 40 hours/week and not troops (that remain employed) over the next three years. 45 hours/week The economy is in recession, we have an abundance of f) Increase in afternoon shift rate from 7.5% to 8% unemployment, we have an industry that cannot access the minimum 2. Closing of the “wage gap” youth subsidy as its wages are too high It could be argued that the lower and yet we still give a 10% per annum income population has had a much increase. This will undoubtedly greater access to our government’s continue the decline of employees free housing programme. Assigning a in the metal industry. The General Rand value to this is difficult but we Secretary of the Bargaining Council came up with the following numbers: (MEIBC) said recently on national • R30 000.00 RDP government television that the industry lost house paid over 20 years at 11.5% 700 000 employees. is equivalent to R320.00 per month Employers need to assess their • 6 000 litres of water at R8.00 per allegiance to SEIFSA who again have kilolitre is equivalent to R48.00 per rolled over and given unreasonable month and unaffordable wage increases in • 150kW of electricity at R0.60/kW an industry that is battling to survive. is equivalent to R90.00 per month Neasa appears to be the Association • Most employees will have one child (that SEIFSA loves to hate) who are grant of R240.00 per month each willing to support small and medium Total: R698.00 per month given enterprises. Neasa have locked out by Government their employees as they have only offered 8% increases. The minister The question then begs – Do we may still decide to enforce a bylaw that still need differential wage increases in: SEIFSA and the Minister of Labour a) Grade H to A? negotiated for a package across the board. b) KwaZulu Natal to Gauteng where salaries are 20% higher and cost of living is higher (properties, toll roads, We undertook a simple exercise to see: insurance etc.) a) How successful our industry has been in negotiating wage increases each year The average wage increase for grade G over the next three b) The impact of this on employability versus years is 10% per annum. The average wage increase for grade automation and came up with the following A (artisans) over the next three years is 7.5% per annum. numbers: If this wage increase differential continues for the next 23 years then the operators will earn the same as artisans! A. Wage Increases Makes sense doesn’t it when you have a shortage of artisans 1. Base Rate increases and a surplus of operators. The actual and CPIX increases over the period (The above is based on scheduled rates. In the real world 1997to 2014, using April CPIX rates and more recently the artisans are paid higher than the minimum rates due to CPI as the benchmark, are as follows for a Grade G supply and demand. The operators are not paid less than the employee: scheduled wages in spite of the excess supply of operators!)

6 METALWORKING NEWS v 13. 4 September 2014 B. What impact does this have on employability and automation? In 1996/7 the Grade G wage rate was R8.69 per hour. Working a 50 hour week (45 hours normal time and five hours overtime) and adding 31.55% cost to company (UIF, 13th cheque, leave, sick leave, compassionate leave, NIC levies) resulted in a cost to company of R29 687.00 per annum. Remember you don’t recover 52 weeks work back for this, only about 47 weeks which pushes the actual cost per hour to approximately R16.00 per hour! Purchasing a piece of capital equipment in 1997 for R110 000.00 at 19.25% interest and using a five year payback gave an annual repayment of R29 000.00 which made it costly to automate. In 2014/5 the Grade G wage rate is R35.40. Times have changed and the standard number of hours of work per week is 40 hours, overtime rates have increased to 1.5x and levies have increased. This has resulted in the cost to company (for a 50 hour week) increasing to R141 741.00 per annum (using 52 weeks per year and 40% cost to basic). Our government has introduced some capital incentives, one of which is the MCEP (The Manufacturing Competitiveness Enhancement Programme), which pays 30% of the capital back. Taking this into account, with current interest rates of 9%, and the cost to company for employees allows us to buy a piece of capital equipment for around R785 000.00 to replace one operator with a five year payback.

This of course only assumes: a) your new piece of equipment only replaces one person and works a single shift five days a week! b) labour rates do not increase over the next five years!

We are finding it incredibly easy to automate a cell for around R500 000.00 and reduce employment by three employees!

C. What does the future look like? 1) Our government is discussing the possibility of all employed people joining a new low cost medical aid to be subsidised by employers. Let’s assume the total cost is R300.00 per month and we have to pay half of this. 2) SEIFSA has informed us that the employer will increase contributions to the Metal Industries Provident Fund from 6.5% to 15% over the next 22 years.

The costs continue going up with no give and take in terms of productivity.

Summary Is there any incentive for business to employ more people? Is this what our country needs – automation? SEIFSA needs to be complemented on taking the non-confrontational approach over the last 20 years and invariably giving into the Unions demands and passing these costs onto industry. Employment numbers continue to decrease, companies invest less in their operations and businesses close. The only real winners are the people, that are in the serious minority, that are still employed whose wages are now 45% greater than inflationary increases over the last 20 years. A country that has a strategic advantage of an abundance of labour is not using this resource due to it being out priced by the capitalist Union leaders! The losers are the unemployed, balance of payments, crime and a good quality of life for all South Africans!

METALWORKING NEWS v 13. 4 September 2014 7 industry news

cover story New machines from Haas Automation

aas has launched Large through-bore the new UMC-750SS turning center handles big Huniversal jobs machining center and the Big parts are big large through-bore business. And today’s ST-55 turning center that shops need large-capacity handles big jobs at the machines to handle the IMTS 2014 exhibition. big jobs commonly found in The company has also such industries as announced that it has oil & gas exploration, partnered with alternative energy, mining, Scuderia Ferrari, the and aerospace. most successful team The ST-55 turning in the history of center from Haas Formula One. Automation features twin-chuck capabilities, a HSM enables five-axis high-torque spindle and simultaneous operations a 318 mm diameter Five-axis machining is an through-bore. The turning effective means to reduce center is well-suited for setups and increase machining heavy pipes accuracy for multi-sided and and fittings, large couplers complex parts. Machining and long rollers, the those parts quickly further increases throughput and company says. improves the bottom line. The turning center has a maximum cutting capacity of Haas Automation’s UMC-750SS universal machining 648 x 2 032 mm, with swings of 876 mm over the front apron center enables high-speed five-sided (3+2) and and 648 mm over the cross-slide. A servo-driven tailstock simultaneous five-axis operations. The 40-taper machine (MT5 taper) is standard, and a rest provision is available for features 762 x 508 x 508 mm XYZ travels, 30,5 mpm rapid supporting long shafts. traverse rates and an integrated, dual-axis trunnion table. A 41kW vector dual-drive unit powers the spindle through The high-speed, roller-cam trunnion table offers feed rates a two-speed gearbox to provide 2 847 Nm of torque in low of 150 degrees/sec. to position parts at nearly any angle for gear. High gear supports a spindle speed of 1 000 rpm. 3+2 machining or simultaneous, five-axis contouring of Both front and rear A1-20 spindle noses accept a variety of complex parts. The table provides +110 and -35 degrees of aftermarket large-diameter manual and pneumatic chucks, tilt and 360 degrees of rotation for effective tool clearance and a heavy sheet metal enclosure provides protection from and large part capacity, the company says. It measures chips and coolant during machining. 630 x 500 mm and has standard T-slots and a precision pilot The machine is equipped with a hydraulically clamped, bore for fixturing versatility. 12-station, bolt-on-style tool turret that accepts 184 mm split The machine features a 15,000-rpm, inline direct-drive boring bar holders, as well as BOT toolholders. An optional spindle and a high-speed 40+1 tool side-mounted tool changer. According to the company, the inline system couples the spindle directly to the motor for reduced heat, increased power transmission and improved surface finishes. The spindle is powered by a 23kW vector drive system yielding 90 foot-pounds of torque. To simplify job setup, the machine features dynamic work offsets and tool center point control. The machine also comes standard with the company's high-speed machining software and Wireless Intuitive Probing system. Additional options include a belt-type chip conveyor, high-pressure, through-spindle coolant system, and expanded program memory.

8 METALWORKING NEWS v 13. 4 September 2014 hybrid BOT/VDI turret is available. Standard equipment Scuderia Ferrari took its first Formula One victory in includes rigid tapping, a color remote jog handle, a 1951 at Silverstone and currently has 221 race victories, 15" color LCD monitor and built-in USB connectivity. with 16 constructors titles and 15 driver championships. High-productivity options include a belt-type chip conveyor, Two-time F1 World Champion Alonso and 2007 F1 World high-torque live tooling with C axis and high-pressure Champion Räikkönen comprise Scuderia Ferrari’s driver coolant systems. lineup, with the duo combining for 52 F1 victories The rear chuck area is also fully enclosed during (32 for Alonso and 20 for Räikkönen). machining, but a wide sliding door and swinging end panel “We are pleased to welcome Haas Automation as our provide complete access from the front and top, simplifying newest official supplier,” said Scuderia Ferrari Team chuck installation and adjustment, and making it easy to Principal Marco Mattiacci. load pipe using an overhead crane. Unlike some competing “This agreement strengthens our existing connections machines, it’s not necessary to remove sheet metal panels or with the USA, an important market not only for our modify the enclosure to handle drill pipe. company, but also for Scuderia Ferrari, as it is one where The turning center is designed for jobs common in the team already benefits from several important oilfield work. Haas’s Intuitive Programming System features partnerships. built-in threading and rethreading cycles for both straight and “Over the past few months, we have been exploring tapered threads. with Haas a number of potential areas of collaboration, and this agreement is an immediate opportunity that Partners with Scuderia Ferrari we are pursuing, which proves Haas’ interest in Haas Automation, the largest CNC machine tool builder Formula One. This collaboration will enable Haas Automation in North America, has partnered with Scuderia Ferrari, to reinforce its brand awareness and promote its the most successful team in the history of Formula One. products and services around the world, thanks to the Beginning with the 65th British Grand Prix held recently appeal of Scuderia Ferrari and the global reach of at Silverstone, UK Haas Automation was featured on the Formula One. We are therefore delighted to make this lower sidepods of the Ferrari F14 T piloted by championship- announcement, which sees another premium brand join winning drivers Fernando Alonso and Kimi Räikkönen. our portfolio of partners. In parallel, but as a separate Haas Automation branding will be seen on the cars for the project, Haas is committed to entering Formula One with remainder of the 2014 Formula One season and throughout its own team, a testimony to the growing appeal of our the 2015 season. sport in the USA and on this front, technical discussions “Haas Automation is a premium brand, and there’s no are ongoing between us.” better way to drive that point home than to connect it with Haas Automation’s partnership with Scuderia Ferrari Scuderia Ferrari on motor racing’s biggest stage,” said Gene also allows the company to become engaged in the business Haas, founder of Haas Automation. of Formula One before becoming a primary sponsor of Gene “Scuderia Ferrari is F1’s most prestigious and Haas’ planned Formula One team. Haas’ team will debut in decorated team with a large, loyal and passionate fan 2016, where it will become the first American-based F1 team base. Exposing Scuderia Ferrari fans and Ferrari since 1986. customers to the quality of Haas Automation CNC machine For more information about Haas Automation and tools is an important first step to expanding our global Haas products contact the local agent Haas Factory Outlet reach.” on TEL: 011 974 2301, or visit www.haassa.com

METALWORKING NEWS v 13. 4 September 2014 9 Local manufacture of Badger to start within 24 months

The first local Badger is expected to be completed in late 2016, with the entire fleet of 238 vehicles to be delivered over a ten-year period, rejuvenating the country’s landward defence capabilities.

perational testing and evaluation of Denel’s Badger South Africa. During this second stage 70% of the vehicle will infantry combat vehicle are continuing apace with be produced in South Africa using local skills, manufacturing Oserial local manufacturing expected to start within capacity, defence technology and subcontractors. the next 24 months. Prototypes were currently being tested “The contract will create and retain at least 2 000 jobs at various testing grounds in the Northern Cape such as at in the downstream South African defence industry among Armscor’s Alkantpan facility and the South African Army’s local subcontractors as well as 200 direct jobs at Denel Land combat training centre at Lohatla. Systems. These jobs cover a wide spectrum from graduate “The evaluation of the prototype vehicles is in process and engineers, system designers and artisans to skilled and we have received very positive feedback from the joint teams semi-skilled workers,” said Burger. responsible for the testing,” says Stephan Burger, the CEO of “The programme makes a decisive contribution to meet the Denel Land Systems. country’s industrial objectives with regards to skills development, Preparation for manufacturing has been ramped up advanced manufacturing and job creation,” says Burger. after the Armscor and the SANDF placed an order for 238 The Programme Manager, Avishkar Govender says Denel 8X8 armoured wheeled vehicles in November 2013. The full Land System has developed the modular infantry system in five fleet will be delivered over a ten year period and will rejuvenate variants, namely Command, Section, Mortar, Missile and Fire the country’s landward defence capabilities. Support derivatives. The common turret structure, fitted with Burger says the locally-designed and produced Badger different weapon modules as well as a common platform, with is the culmination of decades of research, testing and varying specific fits will simplify the logistic support and reduce development that produced a mature vehicle which will provide the cost of through-life support. South African soldiers with unrivalled firepower and mobility The Badger variants are equipped with various weapon and maximum armoured protection. systems. The main weapon system, used on the Section and The various prototypes are being put through their paces Fire Support Variants, is the 30mm externally-driven at various testing grounds in the Northern Cape such as cam-operated cannon. This was developed by DLS, along with Armscor’s Alkantpan facility and the SA Army’s combat the 30mm ammunition produced by PMP, another Denel training centre at Lohatla. The SA Army – as the end-user division. This complements PMP's existing range of world-class – and Armscor are involved with the process every step of the small-and medium calibre ammunition. way to ensure the final design meets their requirements. For the Mortar Variant, a 60mm breech-loading The first fully-completed local Badger is expected to roll off long-range mortar was developed by DLS, along with Denel’s production facilities in Lyttelton in late 2016. 60mm long-range NATO ammunition while the Ingwe anti-tank The vehicle’s platform is based on a design from the missile system, developed by Denel Dynamics, is used on Finnish company, Patria, which was modified by DLS to meet the Missile Variant. local user requirements including landmine protection, Mr Burger says the Badger confirms Denel’s position as maneuverability and firepower. South Africa’s premier producer of world-class defence products A South African team will soon spend a few months in and systems and a strategic partner of the SANDF. It is a Finland to participate in the manufacturing of the initial “best-of-breed” infantry combat vehicle able to compete with vehicles after which the entire production will be migrated to any other vehicle in its class.

10 METALWORKING NEWS v 13. 4 September 2014

Western Cape metals and engineering cluster well-positioned

New opportunities for business growth revealed.

he Western Cape metals and engineering cluster is According to the June 2013 business plan of the Western well-positioned as a hub to fuel growth and attract foreign Cape metals and engineering cluster (recently formed by the Tdirect investment into South Africa and across the African Western Cape provincial government), the exact number of continent. The Western Cape has the capacity to increase its firms operating in the manufacturing sector is unknown, but current exports and supply a wide range of metals and officially at least 337 firms employ more than 25 000 people, engineering solutions to Europe, the US, as well as the although it is likely that more than 600 firms are active. relatively untapped African market. Last year, two world-class technology manufacturers These are some of the findings of a recent publication invested in new manufacturing plants in Atlantis, namely entitled ‘Made in Africa: Western Cape Metals and Engineering’ South African technology company, Tellumat which opened a compiled jointly by PwC, Wesgro and the City of Cape Town. 15 000 m² television manufacturing plant, and Chinese The publication focuses in particular on the metals and consumer electronics company Hisense, which opened a engineering cluster within the manufacturing sector. R350 million electronics factory. This cluster is characterised by a high level of innovation, However, several other sectors, including renewable specialised knowledge and niche manufacturing capabilities energy and the green economy, oil and gas, development of that supply most industries and sectors with machines, medical devices and aerospace manufacturing have also been production systems, components and associated services. identified as high-growth opportunities for investment in the Tertius van Dijk, PwC Deals Partner, says: “The Western Western Cape metals and engineering cluster. Cape is broad and diversified in terms of manufacturing The study provides a detailed account of the many activity. The metals and engineering cluster is poised for further initiatives and incentives that are currently in place and that sustained growth are expected to and the enhance the development of competiveness of both the regional the metals and and national engineering economy of South cluster. These Africa. In particular, include, amongst the manufacturing others, tax sector acts as a incentives, generator of special economic important zones, competitive employment enhancement opportunities.” programmes and “The energy incentives. manufacturing “Initiatives industry plays a such as the DTI’s significant role Industrial Policy towards the growth Action Plan and of the economy. finance providers It is one of underpin the the largest future growth of contributors to the the innovative Western Cape’s gross domestic product (GDP), as well as manufacturing sector. They provide the regulatory framework, providing much needed jobs for thousands of residents in incentives and capital for future growth and expansion in the City and throughout the Province,” said Patricia de Lille, South Africa and abroad,” adds van Dijk. Executive Mayor of the City of Cape Town. More recently, the DTI published a directive that gives the The Western Cape’s manufacturing sector contributed International Trade Administration Commission the power to R45 billion, or 15%, to the South African manufacturing regulate the exportation of scrap metal by barring exports if sector output of R300 billion in 2012. Manufacturing is the the metal has not first been offered for local beneficiation at a second-biggest sector in the Western Cape after the financial price discount of 20% below the international spot price. The services industry. directive is expected to benefit the foundry industry. “We are making substantial investments in infrastructure “A strong foundry industry is important for key industries to ensure we have the required capacity to create a conducive such as the automotive, capital equipment and aerospace,” environment for the private sector to thrive in. The City of said Christelle Rassou, PwC Deals Associate Director. Cape Town is also working closely with potential domestic and The study also provides a focus on South Africa’s export international investors to further unlock development not only environment and macro-economic environment, Africa’s in the manufacturing sector but in other key sectors as well,” potential for growth, as well as the many associations in the added de Lille. Western Cape that support companies to grow.

12 METALWORKING NEWS v 13. 4 September 2014 Denel agrees to proposed acquisition of BAE Systems Land Systems South Africa business

AE Systems has announced it has reached an tactical-wheeled vehicles, agreement for the sale of its BAE Systems Land Systems mechanical driveline BSouth Africa Proprietary Limited (LSSA) business to products, precision-machined Denel (SOC) Limited (Denel), a South African government- components and gears, fire owned defence manufacturer in the air and land domains. directing systems, and remote The transaction includes sale by BAE Systems of its 75 percent weapon launching platforms, interest in LSSA, as well as sale by DGD Technologies (2001) subsystems and products. Proprietary Limited of its 25 percent stake in LSSA. Riaz Saloojee, BAE Systems Land Systems “This proposed sale will further shape our portfolio around Chief Executive Officer of South Africa had recently secured our core capabilities in tracked, combat and amphibious Denel added, “This proposed a contract from Denel Land Systems under the 8x8 armoured wheeled vehicles and weapon systems, which represent markets where acquisition is in line with vehicle programme, to provide we possess strong franchise positions and discriminating our company’s strategy to commander and gunner sights capabilities,” stated Erwin Bieber, president of BAE Systems, broaden our leading land Inc.’s Platforms & Services sector. system solutions through the addition of resources and assets, “We also recognise that the LSSA employees have made a such as those of LSSA, which complement our capabilities in significant contribution to BAE Systems over the last 10 years, the design and integration of combat turrets, artillery and and we believe that transitioning ownership to Denel will better infantry systems and armoured vehicles.” position the LSSA business to achieve its full potential working The proposed sale of the LSSA business is conditional upon with a strong South African company.”The LSSA business, a receiving certain regulatory and other approvals. Thus, we antici- joint venture between BAE Systems Land Systems (Investments pate the proposed sale to close during the fourth quarter of 2014. South Africa) Limited (75 percent) and DGD Technologies (2001) BAE Systems Land Systems South Africa had recently Proprietary Limited (25 percent) has comprised three business secured a contract from Denel Land Systems under the 8x8 segments employing approximately 500 people. The LSSA armoured wheeled vehicle programme, to provide commander business specialises in the design and manufacture of military and gunner sights.

METALWORKING NEWS v 13. 4 September 2014 13 What online presence really means

As clichéd as it is, it seems like just the other day that Crawford Publications decided to take its first plunge into the vast sea of the world wide web that is the internet. It was something that we had been toying with for a few years, but at the beginning of 2014, we finally leapt off the diving board, and haven’t looked back since.

or us, professionalism, relevance and the age-old concept course of the last six months. of ‘content is king’ remains of the upmost importance to The recent addition of the Foundries page, which is a Four business, and on the internet, this is no different - it’s comprehensive collection of companies that supply and service about making our site and our content valuable to our readers. the various aspects of the foundry industry, as well as a list If the content is relevant to the user, they will consume it. After by geographical region, opens us up to innumerable browsers all, it is what you have come to expect from our publications. looking for information about suppliers and the like. Browse for You need to know what your readers want to know. You need specific information pertaining to the relevant heading, based to know what they will “Google”, thereby placing yourself, and upon your need, or simply narrow things down to the location your content, at the top of the search results when they hit the you’d like to know more about. ‘enter’ button on their keyboard or mobile browsing device like The Castings SA website has now had visitors from a smartphone. 96 countries across the globe, including a large percentage But it’s not just about search results and being at the top from the US, to the more obscure locations such as Moldova – of the rankings. The internet has levelled the playing field when a tiny country sandwiched between the Ukraine and Romania. it comes to competing with the big boys, and our industry is a Metalworking News has equally as pleasing results on this large playing field. You have one shot at making a good first front, with visits from 112 countries – most interestingly, one impression, and getting that from the Vatican City person to return to our sites. (pope’s browse the internet This is one of the key strategies for their latest metalworking that have remained top of mind news too, it would seem). for us right from the beginning. It goes without saying that Sleek, professional layout with this is highly beneficial for us an uncluttered user experience because we can tell exactly is what makes browsing our what people are searching sites such a pleasure for our for, and how they are ending users and one of the many up reading our content. At the reasons why we have a high end of the day, this doesn’t rate of returning visitors. just mean a brilliant brand One thing that has been extension for us, but also to of crucial importance to us our readers, and of course has been the ability to our clients – some of whom understand our readers, and are already experiencing the for this, the array of software benefits of joining us on this we have installed to monitor online journey. We have also and evaluate what our users created a space for ourselves are doing on our sites has been for opportunity and further nothing short of fantastic. For growth down the line such instance, we can tell that a user as our job listing portfolio – in France, when searching the somewhere that you can tailor search phrase ‘metalworking a listing, and find the right news’, is guaranteed to see the Metalworking News website person, saving time and unnecessary job advertising costs. amongst the top search results across a number of different We now even have users from various parts of the world search engines including Yahoo! and Bing, as well as the most specifically searching for the online versions of our publications widely used Google, thereby ensuring he or she will likely click (digital and PDF copies) – users that have likely never before through to the Metalworking News Online website. Of course read our magazines, but we know that they now want to read this expands across a number of different search phrases too. our publications. This is incredibly fulfilling for us, because our Six months down the line, exploring the numbers reveals brands – and your brands – and now reaching markets that some incredibly satisfying and interesting information. were previously unattainable. Metalworking News Online now has more than 4 500 unique We all know that the internet never sleeps, and essentially, users, averaging around 50 unique readers a day, and more ignoring the power of the internet and this important potential than 10 500 unique pageviews – in other words, the unique marketing platform is similar to saying: "I don't need any new visitors to Metalworking News’s website have viewed more than business." Traditional methods of advertising have not changed 10 500 pages over the last six months. a great deal, but to use an analogy – a skeuomorph – where While the numbers are slightly different for Castings SA, we look at the old through the new – a website that speaks in they too are incredibly satisfying with more than 2 500 a sophisticated manner crosses time zones and cultures. For unique users, averaging around 30 unique readers a day, us, it’s simple: The internet is crowded, and people don’t like to and more than 8 000 unique pageviews during the look very hard to find meaningful content. Research indicates

14 METALWORKING NEWS v 13. 4 September 2014 that 75 percent of users never Metalworking News is part scroll past the first page of search of the Crawford Publications results. So, even if we manage to (www.crawfordpublications.co.za) make it into the first page of the stable, which includes Castings search results, 70 percent of those SA (www.castingssa.co.za), a users don’t trust a website with business-to-business publication poor design. dedicated to the metalcasting Search isn’t everything, and industry. Crawford Publications online privacy is all but a thing of brands are distributed to the past – for example, do you decision makers – owners, read all those terms and management and senior conditions when you download employees that are involved in that latest ‘free’ app for your decision making, buying and smartphone? Chances are you’ve manufacturing – working in allowed the company that metal working and metalcasting manufactures that app access to facilities of all sizes – from your phonebook, email addresses, small job shops to OEMs and photographs – and even your component manufacturers. They camera and microphone. provide suppliers, foundries, So, a holistic approach is a job shops, service centres and necessary one. Nowadays, search industry related companies a engine algorithms are based on the quality of content, and variety of opportunities to advertise. matched to a large degree to a user’s internet profile. These Full details on the Metalworking News publication and to ‘bots’ that decide whether our content is qualified to be of use see how you can reach a wider market via the Metalworking to you also look at website design and layout – that’s why your News website can be found on www.metalworkingnews.co.za user experience flows in the way it does when you visit our or contact the publishers directly on TEL: 011 463 0489 or sites. It’s easy on the eye, and this all benefits us immensely email [email protected]. because we know that our content is going to be related to Onward and upward (in the search rankings), as they say. what our users want to know, thereby increasing our chances that our content will appear on those first pages of search Damon Crawford is the online editor at Crawford Publications and has results. an Honours degree in Journalism from the University of Cape Town.

METALWORKING NEWS v 13. 4 September 2014 15 MicroStep sets up subsidiary in South Africa

Looking to extend footprint into Africa.

icroStep, a European manufacturer of CNC cutting machines for plasma, laser, oxyfuel, waterjet and M3D milling since 1991, has decided to set up a subsidiary in South Africa. The subsidiary, MicroStep South Africa, opened an office in Jet Park, Gauteng in June 2014. Abroad the MicroStep Group has established and consolidated a network of agencies based on dealerships in 51 countries all over the world, and have delivered machines to the markets of Europe, USA, Russia and Middle East, China, India, Brazil and South Korea. MicroStep have been represented in South Africa via a dealer for a number of years. However, the MicroStep Group has decided to become more active in the South African market with a view to extending its reach beyond the borders and into Africa. Ludwig Oellermann, who is already known as a trusted partner by all MicroStep clients in South Africa, will be heading up the newly established company. For many years he has been successfully servicing the Southern African market with its special needs. The MicroStep Group, based in Bratislava, Slovakia is a leading manufacturer of CNC controlled cutting systems, which enable manufacturers to carry out complex processing of sheetmetal, pipes, profiles and domes, including bevel cutting, drilling, countersinking and marking, as well as supplying control systems and software products for the power industry, rubber industry, automobile industry and mechanical engineering. The parent company MicroStep, spol. s r.o. was established in 1991 by 10 members of the Department of Control and Automation, Faculty of Electrical Engineering and Information Technology, Slovak University of Technology in Bratislava, with the aim to develop and deliver microprocessor- based control waterjet, laser and milling technology to technologies. various branches of Rapid growth of MicroStep, industry. spol. s r.o. resulted in the As the company establishment of several founders had long subsidiaries, most important of term experience in which are: Microstep Europa GmbH the area of multi- in Germany, MicroStep HDO s.r.o. axis motion control and MicroStep PA s.r.o. systems, the In 2007 another subsidiary development of joined the group, MicroStep control systems Photonics GmBH, dedicated to the for CNC machine development of applications for tools and cutting laser cutting machines and support machines followed. in the field of laser technology. In 1994 the Additionally the MicroStep company started Group also supplies automation and production of plasma cutting machines. Further cooperation software applications for almost any business in the steel with another Slovak company – IQM Ltd. – who provided a and manufacturing sector. team of highly qualified machine design engineers, resulted in For further details contact MicroStep South Africa on a complete series of machines equipped with plasma, oxyfuel, TEL: 083 463 0999 or visit www.microstep.eu

16 METALWORKING NEWS v 13. 4 September 2014 Watch the Springboks vs. Scotland at Rugby World Cup 2015 and then visit EMO 2015 in Milano, Italy

etalworking News and Trade Fair Travel are working on If you are interested please contact the Editor a package to include attending the Springboks versus – my details are in the front of the magazine – and we will MScotland rugby game in the Rugby World Cup 2015 keep you abreast of developments. Otherwise contact before continuing on to EMO 2015, the world’s largest Peter Stephenson of Trade Fair Travel on international exhibition for metalworking equipment and TEL: 031 916 1414. related accessories, which takes place in Milano, Italy. The 2015 edition of EMO will be held at the exhibition centre Fiera Milano from 5 to 10 October 2015. The game takes place on Saturday 3 October 2015 at St James Park, Newcastle, UK. This is an exciting opportunity for you to combine a bit of pleasure with work. Hotel rooms etc. have already been booked in Milan for the exhibition but we need an indication of numbers for the extra leg. A provisional booking has been made at a hotel in Newcastle and we are investigating purchasing tickets for attending the rugby game. The trip will include flights from South Africa to Newcastle, UK and then on to Milano, Italy and back to South Africa, hotel accommodation, rugby entrance tickets, exhibition entry tickets and travel insurance.

METALWORKING NEWS v 13. 4 September 2014 17

Automated identification solutions for the metal and steel industries, including service centers, are provided for products such as flat steel, long products, sheet, plate, wire, tube, bar and others Traceability Solutions is leveraging technology for manufacturing traceability

Company is growing with the marking and authentication industry. New developments include barcodes that can be identified from any iOS or Android smartphone, and new technology to be introduced that will provide a variety of security solutions for preventing counterfeiting, brand protection, fraud and diversion – copper cable theft could be thwarted.

“Manufacturing has become more global, government App on your smartphone you can trace the source, regulations and reporting requirements have increased, and assuming that the security marking has been incorporated consumers are more cost and quality conscious than ever. from the beginning,” continued Parker. These are some of the reasons why traceability throughout “We have just signed an agency agreement with a manufacturing processes has become so important, and why leading brand protection and security provider. They have so many manufacturers have established formal traceability launched a new mobile application for product and document programmes,” explains Kyle Parker of Traceability Solutions. authentication that reads the patented covert data layer “Radio Frequency Identification (RFID) and barcode embedded in standard 2D barcodes from any iOS or Android technologies are two tools that manufacturers can leverage to smartphone. The solution can also be used in conjunction with establish an effective traceability programme. That’s because track and trace to enable tracking through production and into they provide direct visibility into the manufacturing process post-production. The new mobile application was developed while streamlining data collection and communication. There to become an integral part of a government agency or brand are tools now available that are having a great impact in terms owner’s authentication or brand protection strategy,” of establishing effective traceability programmes. This includes explained Parker. a variety of security solutions for preventing counterfeiting, “Internationally stringent laws are being implemented to brand protection, fraud and diversion, which will make hold companies and individuals accountable for their products incidences of copper cable theft, for example, very difficult that they manufacture, whether it is in the food industry in the future. Marking the copper cables makes the product or in the automotive industry. The shift in the industry is traceable, and together with the Second-Hand Goods Act which therefore moving away from just marking a component but came into effect, should put a check on copper cable theft. rather towards traceability from cradle to grave.” The technology is already in place to thwart theft whereby a “By this I mean that a product is now being marked at the trader will be accountable for possession of items, products, earliest stage of manufacturing and with computerisation it components, you name it, because with the aid of a simple can be traced throughout its life cycle. This enables a company

20 METALWORKING NEWS v 13. 4 September 2014

Throughout the world, renowned companies in the automotive, beverage and food-processing, cosmetics and pharmaceuticals industries are working with laser, inkjet, hot-stamping or thermal transfer devices made by the company in Veitshöchheim, Germany.” Traceability Solutions – “Coding technology is our passion” “Six years ago when I launched the company I did not envisage the transformation in the marking industry and the rapid growth of the company. From a single person company we have grown to a compliment of 30. We purchased our own 1 200 m² building in Deco Park, North Riding, Gauteng and have now just added another 700 m² of office, manufacturing, technical support and stores space to it,” said Parker proudly. “Additionally, we opened up a branch in Cape Town last year, as well as one in the Eastern Cape in April this year. Shortly, our KwaZulu Natal branch will open and next year we A component that has been marked plan to open up a branch in Kenya so that we can service the rest of the African market, where we have been very to have real time information on the component with automatic successful, more efficiently.” identification and permanent traceability.” “We don’t regard ourselves as a marking equipment sales “Key benefits that can be realised include increased worker organisation. Rather we are solution providers for our clients productivity, streamlined data collection including production and we become involved from ‘cradle to grave’, so to speak. details and flow integrity, improved data accuracy, improved An example of this is where we have developed a system for product quality and compliance with traceability regulations, Eskom whereby we have provided the software and hardware, cost-effectively. And of course, accountability at the different which includes a tool crib, for asset management in their stages of the product life cycle.” training departments. Each individual has to use the system to “Tracking individual components can be a costly release or return the tooling they use on a daily basis. Through proposition when standard product labeling techniques fail to the software and coding the system is monitored, tools are measure up over time. Direct Part Marking (DPM) provides a traceable and each individual is responsible for his tools and permanent marking solution that ensures readability thus becomes accountable. To overcome any fraud issues there throughout the life of your products, even when subjected to is a biometric function that has been built in. The cost savings harsh environments during the manufacturing process.” for Eskom are enormous. We are busy rolling this out “Over recent years the actual marking of a product has not throughout Eskom.” changed much. What has made significant strides though are “Another example is one where we are working on the readers enabling a company to extract all the extra data.” implementing a system where traffic law enforcement officers “We have come a long way from the hand stamping system become fully accountable for their daily actions. With the that was available when I first entered the industry nearly availability and advancement of smartphones, real-time 25 years ago. The ability to mark product, components and monitoring can easily be implemented.” workpieces is an important service that many job shops and “Going forward, we are going to develop our Asset product manufacturers must offer their customers. Marking Management App further and we are busy developing another allows parts to be identified and traced to their origin. Laser App that will allow clients to develop their own Solution Builder marking systems that mark directly onto component or product marking and coding system, and another App that will allow have been especially popular because the computer controlled clients to check and verify that they are using the right settings laser is extremely fast and accurate.” for their marking application.” “However, although laser marking has its place in the “We have also completed the weapons track and trace chain, a company does not necessarily need to go that route. At this stage, there will always be the familiar gummed paper label (with black bars on a white background) but these simply can not withstand the coolant spray, cleaning solutions, heat treating and other harsh processes that metal parts routinely undergo. Depending on the individual circumstance inkjet, hot-stamping, laser and thermal transfer printers and laser markable labelsystems, can be perfectly suitable.”

KBA-Metronic “Another new exciting agency agreement we have just signed is with KBA-Metronic. The company develops, manufactures and distributes comprehensive coding and marking systems for a broad audience.” “KBA-Metronic marking and coding devices are used anywhere in the industries The management team at Traceability Solutions. Top Kyle Parker - General Manager where products and packaging are printed, and Fiona Parker - Operations Manager. Bottom Kelby Parker - Sales Manager, labelled or marked in some form or another. Ludwig Magnus - Manufacturing Manager and Johan Wilkins - Technical Support Manager

22 METALWORKING NEWS v 13. 4 September 2014 system with the UN Mission in South Sudan. These systems and defence, mining, pharmaceuticals, plastics and packaging will assist the United Nations with the weapons census, which as well as government, state owned enterprises and public needs to be done in the war torn country.” entities such as municipalities or town councils.” “This has resulted in us developing six individual websites Industrial labels to cover the various aspects. These include Engineering “On the manufacturing side we will soon be able to offer Marking Solutions, Industrial Marking Solutions, Laser.Inkjet a metal photo service which means a high resolution image coding, Track.Trace, RFID, Rent-A-Marker and Mr Marking.” can be reproduced on metal. This includes graphics, pictures, “On the horizon there are more innovative solutions that we and text imaged onto photosensitive anodised aluminium. The are working on. We are also working on some big government result is a sharp, durable image that is weather, UV, and abrasion projects around vehicle documents and authentication.” resistant. Anything that can be printed on paper can be made a For further details contact Kyle Parker of Traceability lasting image on metal. The image is sealed in the anodic layer Solutions on TEL: 011 704 4744 or visit www.tracesol.co.za of the aluminium plate and is resistant to heat, UV rays, vandalism, as well as most chemicals and solvents.” “The opportunities abound in this area, whether it for your own personal memory or used in a creative marketing /advertising display or in industrial use.”

Websites “Because our passion is coding technology and we regard ourselves as identification and traceability experts, our business has evolved into being able to supply equipment and solutions in pinstamp/dot peen marking, flatbed lasers, manual and press marking, heavy duty industrial marking, wire marking, label printers and accessories, laser consumables, inkjet marking, scanners, galvo laser systems, RFID (Radio Frequency Identification), industrial tags and labels and primary/secondary metals solutions.” “The industries that we have experience in, and currently deal with clients involved in include arms and ammunition, automotive, aviation, awards and recognition, carpentry, construction, crafts and home décor, custom and automation, engineering, farming, food and beverage, fast moving consumer goods, promotion and gifts, heavy/primary metals, industrial equipment and general tools, jewellery, leather and leather products, livestock, medical, military

METALWORKING NEWS v 13. 4 September 2014 23 Talmac Machine Tools makes changes

Company now offers laser and more sheet metal fabrication technologies.

auteng based metal forming and fabricating equipment supplier Talmac Machine Tools has Grecently made a number of changes to its operational and sales activities that will enable the company to enhance its presence in the sheet metal, plate and metal removal market. Established in 1990 by Italian immigrant Guglielmo Tallarico as a general engineering shop, Talmac began selling equipment in 2004. The business started to focus more on equipment sales when Guglielmo’s eldest son Francesco, a Mechanical Engineer, joined the company in 2005. The company still offers an equipment refurbishment and repairs service but has built up its machinery sales division with sole agency agreements to supply Faccin (plate rolls, section benders and dished ends), Gasparini (pressbrakes, plasmas and shears) Omera Francesco Tallarico of Talmac, Roberto Costantino of Prima Power, (presses, ironworkers and trimming machines), Malcolm Moriarty of Talmac and Stephen Goodyear of Bigstone (band saws), Timac (circular shears), Simasv Aquarius Technical Services, who looks after the service side for Talmac (punching, notching and bending), Biko (bending rolls), Danobat Group (cutting and drilling lines and for sales of equipment across all the brands that Talmac 3D plasma's) and Mecome (specialised welding equipment). represents. The equipment division is complimented with Italian In addition Talmac has appointed agents countrywide to company Rolleri Tooling, a manufacturer of pressbrake tooling, represent its interests in the Western Cape, Eastern Cape and fast clamping systems, shear blades and accessories. KwaZulu Natal. The company also has a presence in the metal removal Talmac Machine Tools also has an association with side as well, representing Agma (CNC milling machines), Talmac Engineering, a civil, structural and mechanical Force One (CNC lathes), Jen Lian (universal mills) and engineering consulting, design, fabrication, construction and Myday (heavy duty lathes). project management company run by Francesco’s brother Nico. A recent accolade for Talmac Engineering has been its New sales and administration offices nomination for the 2014 SAISC steel awards for The Hyundai Talmac operates from a facility in Wadeville where it has Parkade in Meadowbrook, Edenvale, a project that the an impressive showroom with the latest equipment on display. company was extensively involved in. This facility has now been enhanced with the addition of new sales and administration offices featuring engineering, sales Prima Industrie Group agreement and administration areas and a training room. “Talmac already represents a number of reputable international brands. However we are strengthening our Countrywide representation position in the forming area, namely turret punch presses, Talmac Machine Tools has also been active in its machinery lasers, punch-shear combination, punch-laser combination, sales department. Malcolm Moriarty, who has been associated press brakes, robotic press brakes, automated bending cells, with the sheetmetal and fabrication industries for the last and material management systems,” said Francesco Tallarico. 20 years, has joined the company. Moriarty will be responsible “We are pleased to announce that we have signed a sole agency agreement with the Prima Industrie Group, a company that has been listed on the Italian Stock Exchange since 1999. The Group develops, manufactures and markets laser systems for industrial applications, sheet metal processing, as well as industrial electronics and laser technologies. The Group has manufacturing sites in Italy (Prima Industrie S.p.A, Prima Electro S.p.A, Finn-Power Italia Srl), Finland (Finn-Power Oy), USA (Prima Electro North America Llc, Prima Power Laserdyne Llc.) and China (Shanghai Unity Prima Ltd.) as well as a direct commercial and after-sales presence in 70 countries around the world.” “The machinery division of the Prima Industrie Group is made visible by the Prima Power brand. Prima Power supply 2D and 3D laser machines for cutting, drilling and welding punch presses, integrated punching – laser cutting and punching – right angle shearing cells, press brakes as well as automatic

24 METALWORKING NEWS v 13. 4 September 2014 bending machines and cells. Flexible automation on all levels up to fully-fledged factory wide FMS’s is a major Prima Power strength.” “The product range is one of the most comprehensive in the field. The names of the products are ThePunch, TheLaser, TheCombi, TheBend, TheSystem and the TheSoftware. Over 10 000 machines have been installed worldwide.” “Prima Industrie’s history in laser technology started with the introduction of the first 3D laser cutting machine in 1979. The Finn-Power Shear Genius®, integrating punching and shearing, was introduced in 1987, and the Group continues to be innovators in this field carbon steels and 20 mm in with the recent introduction of the stainless steels. The laser has Platino® Fiber 2D laser cutting opened up many new markets for machine.” the company, markets in the “When it comes to press cutting space that they were brakes Prima Power’s previously excluded from supplying,” experience goes back to 1987, said Francesco Tallarico. when Finn-Power purchased a Finnish press brake and shear Final word manufacturer. The long tradition “The agreement with the has now been combined with the Prima Industrie Group will significantly know-how of servo-electric drive contribute to our product offering, systems with the introduction of the new and will further enhance our ability to offer eP-Series.” our customers optimal life-time value with best in class brands “Prima Power has a number of installations in and will allow us to penetrate new markets,” said Tallarico in South Africa, both under the Prima and Finn-Power brand closing. names. Most notable was the installation last year of one of For more information contact Francesco Tallarico on the biggest laser machines in South Africa. The laser has a 072 265 1323 or Malcolm Moriarty on 072 834 3164 or bed size of 30 by three metres that cuts up to 25 mm in visit www.talmac.co.za

METALWORKING NEWS v 13. 4 September 2014 25 Amada Johannesburg marks 30 years

his year, the Johannesburg branch of Japanese metal working machinery Tmanufacturer Amada Company Ltd. celebrates its 30th anniversary since establishing a fully-fledged branch in South Africa. The manufacturer entered the South African industry in 1984 and offers the full range of machinery, from horizontal and vertical bandsaws, to corner notchers, press brakes (up and down stroking), mechanical and hydraulic shears, turret punch presses, sheet metal and heavy duty CNC CO2 laser and fiber laser cutters, stamping and blanking presses as well as a full range of blades, tooling, spares, software and services for all machinery. Prior to 1984, Amada had been operating on an agency agreement basis. From an original compliment of five staff, Amada Johannesburg now employs 28 staff and occupies its own 1 350 m² building in Meadowdale, Johannesburg. Current Amada Johannesburg MD Rick Ferreira with History Amada Co.Ltd. Japan President and CEO Mitsuo Okamato Ken Sano, who was responsible for opening the branch and is still fondly remembered from the outset. by many Amada clients, recalls how Amada set up offices, Bauer ran Amada Johannesburg until the end of 1997 a showroom and service facilities in rented premises in Elsburg, before immigrating to Sydney, Australia. For a brief period, Brett Germiston. He then organised an in house exhibition that was Sharp ran the company before current MD Rick Ferreira - who held on the Friday through to Sunday. It was a rude awakening had joined Amada in 1988 as a service engineer and was for him to South African industry as no visitors attended on the formally qualified in machining and fitting and had completed Saturday and Sunday. his NTC 6 Mechanical Engineering at Johannesburg Technical Sano’s next experience was equally challenging to his College - was installed in June 1998. Ferreira would later Japanese culture. Prior to the branch opening, there were a few complete a MBA in 2002. sales of machines, but not enough in Sano’s opinion. This was The company opened up a branch in Cape Town in 1999, one of the primary reasons for Amada to enter South Africa. which is run by Gordon van Rensburg, and one in Durban, Sales of Amada equipment soon started to increase. However, KwaZulu Natal in 2001, which is run by Riaan Kirstein, and one new client decided he was not paying for his machine and moved to its current facility in Meadowdale in 2002. only when Amada removed the PC board from the NC control, The company also services the Southern African region which rendered the machine useless, did the client make with installations in Kenya, Tanzania, Zimbabwe, Namibia, payment. Swaziland and Mauritius Sano remains “Over 1 500 Amada machines are now in operation in very good South Africa with many of them being sold to clients that friends with already have Amada equipment. We are proud to say that this client but once our clients have experienced the state-of-the-art as he says it is technology that Amada sheetmetal and bandsawing equipment ‘give and take’ has gained a reputation for, they are clients for life. One client, in business. for example, has 25 different Amada machines on his Sano, shopfloor. Most clients are in the SME category but we have who is still also supplied machines to bigger clients such as Transnet employed Engineering and Alstom for example,” enthused Rick Ferreira. with Amada “There have been many milestones in the company over in Japan, left the 30 years. We sold our first CO2 laser cutting machine in South Africa 1996, a 1.5 kilowatt LC 1212A, not long after CO2 laser in 1988 after cutting machines made their debut on the metal fabricating handing over scene in South Africa. Laser cutting machines have emerged the reigns to since then and the technology has advanced so much that Erich Bauer, they are now regarded as extremely precise and extremely who had been quick cutting machines. The response time is now measured Sales Manager Barry Page has been with the with the in G-forces. Some machines are up to 3G or 4G in acceleration company for over 10 years company and deceleration.”

26 METALWORKING NEWS v 13. 4 September 2014 “Fiber laser cutting costs and increase machines have now found equipment durability with their way into the industry quicker manufacturing and and they present exciting shorter lead times while not opportunities. Amada is losing quality is a demand, the only machine tool rather than a request, from manufacturer that produces clients. its own fiber power source “We have always been at this point, which is cognisant of this and have utilised on its own laser encouraged our clients to cutting machines. This join us on our yearly places the company at an technical visits that we advantageous position in make to the headquarters terms of furthering in Isehara, Kanagawa developments to current and Prefecture, Japan, and future planned models. experience first hand the The Amada Group, which Amada Solution Center comprises more than The management team also consists of James Mollentze and the Amada Machine 150 companies in Japan - Punching and Bandsawing Service, Jens Hartig - Laser Service, Tool Plaza, where the latest and overseas, manufactures and Hein Van Der Neut - Bending and Automation Service, equipment available from products that incorporate the who have all been with the company over 10 years Amada is on display, all latest technology, many of powered up to give live them as firsts on the world market, meet global standards and demonstrations. They never forget the experience and on their enjoy an excellent reputation.” return easily incorporate the latest innovations into their “Technological advances in the sheet metal work industry businesses.” in the late twentieth century revolutionised the efficiency and “As we celebrate our 30th anniversary we would like to precision with which sheet metal products were fabricated. thank all our clients for their loyalty and support over the years These advances centered in large part on improving tools, in helping us reach this significant milestone. Going forward dies, and other equipment, relying more extensively on we will continue to grow together with our clients as we build automated machinery and embracing the benefits of the towards the future. computer, new software, and the internet. The need to cut For further details contact Amada on TEL: 011 453 5459

METALWORKING NEWS v 13. 4 September 2014 27 City’s incentive plan for Atlantis kicks off with wind tower factory

Construction of GRI Wind Steel South Africa’s new 12 000 m² wind tower mast production facility in the Green Technology Industrial Park in Atlantis has commenced. It is hoped that this facility will be completed in October 2014.

RI Wind Steel South Africa’s factory will have a size, from the City in the Green Technology Industrial Park in manufacturing capacity of 150 three-section wind Atlantis, which is part of a quick access-to-land programme for Gtowers per year. Tower sections of up to 90 tons, industries operating in the green economy. 38 metres in length and five metres in diameter, can be “During the operational phase, more than 200 jobs will be accommodated in the new facility. Completed tower section created of which approximately 150 to 180 employees will be storage will also be available on the site, with permanently from Atlantis and the surrounding area. The contractor is installed logistic machinery to move and load the sections. working with the local Further Education and Training College to This state-of-the-art facility will make use of the latest identify and develop skills that will be needed for the operation energy saving technologies designed to fully exploit the benefits of the factory.” of natural lighting and ventilation. “The success of the pilot project in Atlantis to date gives us This R300 million investment from Gestamp Renewable great hope that this scheme could be rolled out to other areas Industries’ (GRI) is the first to be attracted through the City’s in the metro,” said Councillor van der Merwe. recently established Investment Incentive Scheme. GRI is a In addition, during the first six months of the existence Spanish company with a 100% shareholding in GRI Wind Steel of the scheme, which was approved by Council last year, the South Africa. GRI currently produces 1,200 wind towers strong uptake of the electricity tariff subsidy incentive in per year in four factories around the world. particular contributed to the retention of more than 1,200 jobs. Councillor Johan van der Merwe, the City’s Mayoral The uptake of the electricity tariff subsidy for intensive Committee Member for Economic, Environmental and Spatial energy users has been in excess of R3.8 million thus far. It has Planning, said, “We are very excited about this investment enabled businesses to ride out the economically tough times which has been made possible by our pilot scheme in Atlantis. without having to lay off staff. Atlantis is an area of great strategic importance as it is GRI Wind Steel South Africa (www.gri.com.es) is a division characterised by extremely high unemployment. Partnerships of the wind industrial division of Corporación Gestamp. The are the only way to drive much-needed job creation in Atlantis group, through its wind subsidiary, is constructing a wind farm and indeed city-wide. It is the only way that we will be able to of 75 MW located in the Karoo area on the farm Noblesfontein make progress possible, together.” (Victoria West), with an approximate investment of 160 million GRI has made use of the various incentives that form Euros. Gestamp Wind is also hoping to be awarded with part of the overall scheme, including land-use and building another wind project of 100,8 MW submitted in the application fast-tracking. They also purchased land, 7.8ha in Round 3 of the REIPP public tender process.

28 METALWORKING NEWS v 13. 4 September 2014

Dates announced for the 2015 Johannesburg International Motor Show

In 2013 more than 220 exhibitors were exposed to more than 240 000 visitors at the Johannesburg International Motor Show

he National Association of Automobile Manufacturers of International Motor Show Calendar, recognising the show South Africa (NAAMSA) are pleased to announce the dates as one of the top ten motor shows in the world. Recognition Tof the 2015 Johannesburg International Motor Show by OICA - the International Organisation of Motor Vehicle taking place from 14 - 25 October 2015 at the Johannesburg Manufacturers - highlights the stature of the South African Expo Centre, Nasrec. A number of exciting innovations are in automotive industry as a role player in the global automotive the pipeline and planning stages. manufacturing sector. The Show officially opens to the media on Wednesday The call for exhibitors kicked off on Friday 1 August 2014 14 October 2015 with the first of two dedicated media days. and automotive companies interested in participating can Attendance on Wednesday 14 and Thursday 15 October download booking forms from www.jhbmotorshow.co.za is limited to the media and preview guests. Attracting over 240 000 visitors to the 2013 edition, the The public will get their first opportunity to visit the show Johannesburg Motor Show is once again set to be a highlight of on Friday 16 October 2015, which has been added as an the Southern African motoring calendar in 2015. additional public day providing the public with greater access to the show. The show is open to the public over ten consecutive About the Johannesburg International Motor Show days from Friday 16 - Sunday 25 October 2015. The biennial Johannesburg International Motor Show The Johannesburg International Motor Show is Africa's is a twelve-day comprehensive automotive exhibition and largest and most comprehensive automotive industry event automotive lifestyle event. The exhibition runs in conjunction with a show floor encompassing passenger cars, leisure with two associate shows, the Johannesburg Truck and Bus vehicles, exotic marques, parts and accessories and Show and Auto Shop which collectively offer a complete automotive lifestyle products. representation of the motor industry, serving Sub Saharan Co-located is the Johannesburg Truck and Bus Show Africa and South Africa as the host country. focusing on the commercial vehicle sector featuring exhibits The event is the only motor show in Southern Africa to of trucks, buses, trailers, motor body builders and parts and earn the distinguished sanction of OICA, the Organisation services aimed at the commercial vehicle market. Internationale des Constructeurs d'Automobiles, the The biennial Johannesburg International Motor Show Paris-based alliance of automotive manufacturers and trade enjoys the distinction of inscription on the prestigious OICA associations from around the world.

30 METALWORKING NEWS v 13. 4 September 2014

Denel awarded another multi-million rand tender for Airbus A400M

Denel Aerostructures (DAe) has been awarded a fourth multi-million rand contract to manufacture and produce key parts on the Airbus A400M military airlifter.

he company will, in future, manufacture ISO locks – a combination of aluminium rails and cross tracks – to Tbe fitted into the cargo hold of each of the giant aircraft that are to be delivered to international clients over the next six years. The contract is valued at over R260 million. “The new work package confirms Denel Aerostructures’ reputation as an emerging player in the global aerospace environment. It is a vote of confidence in the South African engineering and high-tech manufacturing sectors,” said Denel Group chief executive, Riaz Saloojee. The tender was won through a bidding process against international competitors. “It is quite clear Airbus Defence and Space is satisfied with the quality of work we have delivered on other contracts over the past nine years and decided to place another work package with Denel,” Saloojee said. The contract will cascade to other companies in the aerospace and high tech sectors with some of the Each A400M has a system of rails and cross tracks inside the manufacturing processes being subcontracted to DAe’s local cargo hold to guide movement of the ISO containers. supplier base. There are four parallel sets of aluminium rails and Ismail Dockrat, DAe chief executive, said the ISO locks 32 cross tracks in the aircraft’s cargo hold. Transported will be manufactured at the company’s Kempton Park equipment is packed inside containers that are then loaded facility to designs received from Airbus Defence and Space. along the rails into the aircraft fuselage. A system of locking

Toolquip & Allied now offers a complete line of large milling, turning and grinding equipment

oolquip & Allied, one of South Africa's largest importers Wickman Bennett designs and machines. and distributors of specialised industrial equipment and An example of the machines that Newlands manufactures Tengineering consumables is now able offer a complete is the NVT 1600 CNC vertical turning centre. The machine line of large CNC milling, turning and grinding equipment. comes with a 1600 mm swing, 3-range table drive gearbox and The range will compliment Toolquip & Allied’s existing range of 20,000 Nm maximum table torque, a 60 kilowatt motor and is CNC metal removal equipment. designed to provide advantages when cutting hard materials The machines, manufactured by Canadian manufacturer like titanium and stainless steel. The higher RPM produces Newland Machine Tool Group, includes vertical turning higher quality surface finishes in smaller diameter bores allowing machines with swings between 1250 mm and 7000 mm, for tighter specifications to be met. The NVT 1600 features an horizontal boring mills with spindle diameters between all cast iron design with box ways and a 1250 mm table with 130 mm and 165 mm, floor type boring mill machines with 11 800 kilogram capacity and 80 mm diameter ball-screws. spindle diameters between 165 mm and 260 mm and vertical The company also manufactures bearing grinders with up to grinders with swings between 1250 mm and 5000 mm. 3100 mm chucks, and horizontal boring mills of both t-type and Newland Machine Tool Group Inc., located in Toronto, floor type with up to 260 mm spindle diameters. These product Ontario, Canada, consists of five companies covering lines include both standard and special machines developed engineering, proprietary design, service, repair and rebuilds. on the basis of the customer’s applications. In 2011 the Newland Machine Tool Group Inc. acquired Newland Machine also offers a proprietary clamping design Vertical Turning Technologies Ltd. (VTT) from Exeter Machine that uses a ground surface with keys to locate the tool, plus Tools Ltd. (EMT) based in Coventry, England. VTT was renamed hydraulic clamping to hold it in place for improved rigidity and Newland Bennett Limited (Newland Bennett) to reflect VTT control. and EMT's 18 year development of Webster & Bennett and In recent times the company has adopted a global model

32 METALWORKING NEWS v 13. 4 September 2014 mechanisms keeps the containers secure in flight. DAe will manufacture and deliver the ISO locks to be fitted to each of the 174 aircraft already ordered from Airbus Defence and Space by international customers. The process of industrialisation has already started and the first ship set will be delivered to Airbus’ fuselage assembly facility in Bremen, Germany, by September. Serial production will be ramped up in 2015 and DAe will deliver at least 20 ship sets a year over the six-year contract period. Dockrat said Denel will also manufacture a different rail system for loading of smaller containers as required by some international customers. The Central Guide Vehicle Restraint System (CGVRS) will facilitate the movement of emergency supplies that are air-dropped by the A400M. The smaller containers are usually filled with humanitarian aid, food and emergency According to supplies. This contract is valued at more than Saloojee, R70 million. DAe is one According to Saloojee, DAe is one of a select few of a select companies outside Europe few companies that manufactures critical parts for the A400M. outside Europe The company is also that manufactures responsible for the airlifter’s wing-to-fuselage critical parts fairing, the top shells for the that protect the wing section and the “ribs, A400M spars and swords” which form the internal structures of the aircraft’s tail section. “The new contract strengthens our relationship with Airbus Defence and Space and sends a signal to the global aerospace sector about the know-how and experience available in the South African manufacturing industry,” he said.

for the business, whereby machine assembly is performed at the plants located in different countries. This allows the company to substantially reduce the cost and, accordingly, selling prices to customers. The first of these countries was Taiwan where machine assembly is located in close proximity to foundries and job shops machining parts according to the company’s drawings. Contrary to the other machine tool builders, who passed their documentation to Asian companies and fully entitled them to reproduce their machines, Newland Machine do all critical manufacturing operations in Canada with Canadian fitters carrying out the manual scraping of basic part surfaces and geometrical accuracy assurance tests. The company has an additional assembly shop located in Indiana, USA for convenience of the North American customers, still the company’s largest customer base segment, and have set up a Joint Venture in China. The major industries consuming Newland Machine machines globally are power generation (nuclear, wind, and hydro), bearing manufacturing, manufacturing and repair of aircraft engines, defense, valves for the oil and gas industry, off road vehicles, mining equipment and job shops. Toolquip & Allied supply a full range of abrasives, blading, CNC and conventional machine tools compressors, cutting tools, engineering consumables, hand tools, machine tool accessories, measuring equipment and welding equipment. For further details contact Toolquip & Allied on TEL: 011 370 2727 or visit www.toolquip.co.za Boeing and Paramount Group to collaborate on defence and security opportunities

he Boeing Company and Paramount Group, Africa’s largest Tprivately owned defence and aerospace business, have signed a memorandum of collaboration to jointly develop defence and security opportunities in key international markets. The agreement, signed during the bi-annual Farnborough Airshow, will allow Boeing and Paramount to apply their complementary strengths in providing aircraft and land systems solutions for customers in Africa and other major markets that face a range of security challenges. These include border security; heavy airlift of products and personnel across vast distances; coastal piracy and anti-poaching; and disaster and humanitarian relief as part of future coalition efforts. Platforms being explored under the Ivor Ichikowitz, Paramount Group Chairman (left), signs a memorandum of collaboration collaboration include various Boeing with Chris Chadwick, president and chief executive officer of Boeing Defence, Space & Security rotorcraft, unmanned aerial systems (right) at the Farnborough Airshow on July 15. The companies will collaborate on aircraft and and related support services, as well land systems solutions for customers in Africa and other major markets

“Boeing and Paramount will be able to provide new or existing customers with a unique partnering of defence solutions and capabilities, including the retrofitting or refurbishment of existing platforms, systems integration, as well as training and maintenance support for any new acquisitions,” said Chris as Paramount’s leading portfolio of land vehicles and solutions and capabilities, including the retrofitting or aerospace systems capabilities currently deployed around the refurbishment of existing platforms, systems integration, world. as well as training and maintenance support for any new “Boeing and Paramount will be able to provide new or acquisitions,” said Chris Chadwick, president and CEO of existing customers with a unique partnering of defence Boeing Defence, Space and Security. “Together we will be able to offer African customers the full scope of defence and security needs from two global leaders in their respective fields.” "Africa is one of the world’s fastest-growing markets for aerospace and defence equipment, and we are very pleased to be partnering with Boeing to combine our various capabilities to better serve our customers in Africa and elsewhere,” said Ivor Ichikowitz, Paramount Group chairman. “Paramount has extensive world-class design, development and manufacturing capability in Africa, which we consider to be an asset of the continent. It has for many years been our policy to identify best-of-breed partners to collaborate with in growing our African capability.” For further information visit the Paramount Group website on www.paramountgroup.biz

34 METALWORKING NEWS v 13. 4 September 2014

The Dickinson Group Anchor Division takes delivery of new AFM 3D CNC wire bending machine to manufacture refractory anchor systems

The company, based in Vereeniging, Gauteng, manufactures and installs anchor systems for all types of monolithic, ceramic fibre and brick refractory linings.

he company has been manufacturing these anchors for Athens and Chicago and also through a web cam and direct link 30 years. The manufacture of the anchor systems was over the internet.” Tdone by the labour intensive and time-consuming method The machine has been supplied by Automated Industrial of using two 60 ton eccentric presses and one 10 ton hydraulic Machinery (AIM), a US manufacturer of 2-dimensional and press. Because of the workshop always being under pressure 3-dimensional CNC bending machinery based in Chicago, to get product out, management looked at improving Illinois. It is the first machine to be installed in Southern Africa production efficiencies and in 2006 decided to go the CNC by AIM Inc. a company that manufactures 35 models of 2D and route and purchased a Robomac CNC wire forming machine 3D CNC benders, including single head benders and double with an automatic decoiler. The machine was ideal for head benders. prototype, short and medium run requirements and capable of forming wire from 4 to 12 mm. Refractory anchor systems as described by the experts However, since the introduction of the CNC machine A method for lining furnace walls with insulation is provided production soared, so much so that it put pressure on where a plurality of hanger assemblies, which are elongated further down the production line. For example a run that lengths of metal, support members each having a plurality previously took two days to manufacture now only takes of elongate studs secured to one surface in a predetermined 12 hours, depending on the actual anchor type. spaced alignment, and which extend perpendicularly from the surface of the support member, and are positioned over the Excess capacity surface of a furnace wall by first securing one length of the “The machine exceeded our expectations and we were able metal support members horizontally adjacent the top end of a to offer the excess capacity to furnace wall, and then outside clients, other engineering sequentially vertically positioning companies that need wire other lengths of the metal formed,” said company director support members on the furnace Miles Simpson. wall with the spaced aligned “Our production of anchors elongate studs extending from can reach up to 1,5 million a year the surface of the support which equates to about 90 tons members in vertical alignment, of material. 98% of the product is with an elongate stud extending made up of stainless steel grades from the surface of the horizontally 253 MA, 304, 316 and 310, all positioned support member. of which is imported because the local mills do not produce these The Dickinson Group grades,” Simpson stated. The Dickinson Group was “We have now reached a point established in 1910 and has where the growing focus in plant been successfully trading in the automation, in a bid to enhance productivity, reduce downtime specialised field of refractories since then. The company has and conserve energy, has caught up with us and our eight year been involved in the initial construction and shutdown projects old machine either needed to be upgraded at great cost, or we on the smelters and process units of most of the major mining needed to take the decision to invest in a new machine that has and smelter companies in Southern Africa, and has expanded evolved with the technology over the years.” its projects business internationally into East Africa and exported refractory precast shapes and equipment to numerous New AIM 3D CNC wire bending machine countries around the globe. “In August we took delivery of a new 3D13-T CNC wire The Group head office is in Vereeniging and is made up of a bending machine, a well-known model in the wire forming number of different companies all serving the mining, smelter, industry, capable of high precision repeatability, fast output and mineral processing and metallurgical refractory consuming low cost maintenance. The effective capacity from 4 mm to industries. It has offices in Maputo, Dar Es Salaam, Tanzania 12 mm provides us with superior flexibility and competiveness and Zambia. in the marketplace and allows us near instant production of any The Anchor Division has also been the African agents for part, whenever needed.” the drawn arc and capacitor discharge range of stud welding “The completely automated work cell takes wire from coil, equipment manufactured by Taylor Stud Welding Systems (UK) forms it according to the tooling and systematically arranges the for 20 years, and Soyer (Germany) stud welding equipment and finished parts. In all instances, wire can be fed directly from a steel fibre reinforcement products for seven years. coil, straightened, bent and cut using a software package that For further details contact The Dickinson Group Anchor provides flexibility and simplicity in programming and is offered Division on TEL: 016 421 3720, email [email protected] or in all ‘universal languages’. Backup is offered from an office in visit www.dgrp.co.za

36 METALWORKING NEWS v 13. 4 September 2014

Jetstream Cutting Solutions appointed Jet Edge Waterjet Systems distributor for Southern Africa

Jet Edge waterjet technology includes precision waterjet cutting machines, waterjet pumps, and mobile waterjetting equipment.

et Edge, Inc., a leading manufacturer of ultra-high pressure waterjets for Jprecision cutting, coating removal and surface preparation, is pleased to announce that Jetstream Cutting Solutions CC of Johannesburg, South Africa, has been selected as its waterjet systems distributor for Southern Africa. Jetstream Cutting Solutions carries Jet Edge’s full line of waterjet cutting and surface preparation equipment, including waterjet cutting machines, waterjet intensifier pumps and portable waterjetting systems. The company also supplies genuine Jet Edge OEM waterjet parts and is authorized to service Jet Edge waterjet equipment. In addition to Jet Edge waterjets, Jetstream sells, installs and services other 3-axis waterjet systems and UHP pumps. “We are very proud to have Jetstream represent Jet Edge in Southern Africa,” said Dave Anderson, Jet Edge international sales equipment were serious waterjet users. There was no reason manager. “They are a recognised Jetstream system supplier not to use the Jet Edge pump,” said Cruickshank. in their market, and their extensive experience with CNC "This is a very exciting time for us in that we’re involved technology and other waterjet systems will be a tremendous with such a world renowned name in the waterjet industry. Our benefit to Jet Edge customers. Jetstream already supplies biggest market so far has been the glass industry, but the Jet approximately 25 percent of the market in their territory. Edge products will allow us to reach the larger metal cutting Jet Edge believes there is tremendous growth potential for our industry and to take on specialised projects as well.” waterjet equipment on the Sub-Saharan African Continent.” Malcolm Cruickshank, Jetstream’s founder and Jet Edge celebrates 30 years director, said he decided to carry Jet Edge waterjets after Founded in 1984, Jet Edge entered the waterjet industry integrating a Jet Edge X-Stream pump with another 3-axis during the industry's infancy. system. "We've come a long way since 1984. We've seen waterjet “We know waterjet pumps and we could see this is a technology evolve from its 36,000 psi (2,500 bar) water-only quality product. After investigating Jet Edge and checking its past to today's sophisticated and highly precise 5-axis and customer references, I could see that the companies who were robotic systems that can reach pressures exceeding 90,000 psi using Jet Edge (6,200 bar),” says Jude Lague, Jet Edge president. "Back in 1984, or even in 1994, waterjet was such a niche technology that many people hadn't even heard of it. Today, it's as common as any machine tool and is used to manufacture countless everyday items, from sliced fruit to titanium joint implants."

Jet Edge's newest Edge X-5 5-axis waterjet cuts highly precise 3D parts from virtually any material Jet Edge's Edge X-5 5-axis waterjet system with Aquavision Di controller cuts complex taper-free and 3D parts from virtually any material. Featuring Jet Edge's innovative Permalign Edge cutting head technology, the Edge X-5 dramatically increases your waterjet cutting capabilities by allowing you to produce chamfers, weld bevels and sophisticated 3D parts such as impeller blades - all with a taper-free finish.

38 METALWORKING NEWS v 13. 4 September 2014 digital servo motors and single or double carriages. Critical bearing components are protected by heavy metal covers with brush seals and positive air pressure. The Edge X-5 5-axis waterjet cutting system is powered by a Jet Edge waterjet pump. Jet Edge offers the widest selection of pumps in the industry. 30-200hp (22-149kw), 60,000-90,000 psi (4100-6200 bar); hydraulic intensifier and direct drive pumps are available. "We were born problem solvers. Our company's founder, Chris Possis, couldn't find a satisfactory waterjet pump, so he built his own,” said Lague. "Since then, we've had the opportunity to help hundreds of customers improve their manufacturing processes and we've responded to The Edge X-5 features an industrial PC controller some of the world's designed specifically for 5-axis waterjet cutting. The greatest crises, including powerful and flexible AquaVision Di Controller features an the Kuwait oil fires, the open architecture design that gives operators the freedom Kobe earthquakes, and to fine-tune programs from any CAD/CAM/nesting the Gulf of Mexico oil spill." software, utilising standard G&M code. The system's Jet Edge systems Intelligent Work Envelope automatically adjusts depending are used around the on the angle of the cut to protect the operator, material, world in a broad range and system components. of industries, from the Like all Jet Edge waterjet systems, the Edge X-5 is world's leading designed to provide years of dependable service in harsh airlines to automotive, industrial environments. Its rock-solid design separates the aerospace, industrial motion system from the catcher tank, eliminating vibration and manufacturers, machine and job shops. ensuring maximum part quality. It is ball-screw driven for For more information contact Jetstream Cutting Solutions CC optimal precision and features direct-couple AC brushless on TEL: 011 468 1093 or visit www.jetstreamcutting.co.za

METALWORKING NEWS v 13. 4 September 2014 39 AHRLAC takes to the skies

he first public flight of its Advanced High-Performance and environmental protection. AHRLAC also has the ability to Reconnaissance Light Aircraft (AHRLAC), at the carry a comprehensive weapons suite for specific mission TWonderboom Airport in Pretoria took place recently. applications. AHRLAC is the first military fixed wing aircraft to be fully The aircraft was designed and built by over 60 engineers designed, tested and developed in Africa. and technicians. One of the most innovative aspects of the The aircraft, a global first, addresses a key industry need construction phase is that 98% of all 6 000 parts of the aircraft by performing the combined tasks that previously required four were designed and produced locally by the engineering team. separately configured planes. It integrates designs from attack Since the launch of the project in September 2011 the team helicopters, surveillance platforms and reconnaissance aircraft spent 315 000 labour hours completing detailed designs and with ability to carry surveillance, manufacturing the first weapons, radar and electronic prototype. warfare systems. This has Dr Paul Potgieter, CEO brought advanced operational AHRLAC Holdings says: "Every solutions, historically requiring single part of the aircraft was more costly aircraft or complex pre-designed on a computer unmanned aerial surveillance which allowed it to have a systems. jigless construction. This AHRLAC is a ground-breaking means that every part fits example of what Africa is together, much like a Meccano capable of producing and will set, which saves vast amounts be a key solution to bolster of money and time – especially Africa's capability to deal with when exporting globally" its security issues. However, "The jigless manufacture AHRLAC is not only a solution was made possible by parts for Africa but for defence forces being pre-drilled and machine around the world, whether from developing countries or from made, allowing for accuracy, reduced need for hand skills and nations with advanced and sophisticated defence capabilities. therefore less time to build.” AHRLAC has been specifically designed for both civilian and "We have made all the tools for production for all sheet military tasking, and features a variety of configurations thanks metal pressings and composite parts so it enables us to hit to its innovative pod system design. These include patrol and production much quicker than other aircraft," adds Potgieter. reconnaissance with typical missions encompassing intelligence Key local suppliers will include: Paramount Advanced gathering and close air support. The aircraft can also be Technologies, CSIR and Denel. Key global suppliers include configured for training, cargo and light attack capabilities. This Pratt and Whitney, Cobham and Zeiss. enables the aircraft for multi-role use which includes disaster For further information on AHRLAC visit www.ahrlac.com or visit management, internal security, border control, maritime patrol the Paramount Group website on www.paramountgroup.biz

Trade and Industry Minister Davies approves revised AIS guidelines

rade and Industry Minister Dr Rob Davies has approved component manufacturers. the revised guidelines for the Automotive Investment Accelerated grant disbursements for component TScheme (AIS) and the People-carrier Automotive manufactures on a 40:30:30 split had also been included in Investment Scheme (P-AIS). the guidelines. The amended AIS guidelines provide clarity on the Meanwhile, the P-AIS guidelines have been amended to non-taxability of the grant, as well as on the eligibility of tooling align them to the revised AIS guidelines, specifically on companies to apply for the same benefits as those enjoyed by conditions applicable to competitiveness improvements, component manufacturers (CM’s) under the scheme. administrative requirements and increased grant support for “Empowerment is now included as part of the economic CM’s and tool-making companies. benefit criteria and a clearer description of research and Two applications have, to date, been approved under the development requirements has been provided.” P-AIS, a subcomponent of the AIS. Both applications were “The guidelines also make provision for increased support from OEM’s. The total incentive approved amounted to for component manufacturers, with the grant increasing to R26.1 million, while 191 jobs have been created in this between 25% and 35% of the value of qualifying investment in sector. productive assets approved by the DTI,” said Davies. Meanwhile, by March, 195 projects, with a total incentive The amended guidelines also provided “relaxed and value of R6.2 billion, had been approved under the AIS. more inclusive” requirements for strengthening the R4.8 billion had been disbursed to OEM’s and R1.3 billion to supply-chain criteria and introduced support towards CM’s. A total of 46 373 jobs were sustained and 9 850 enterprise level competitiveness improvement costs for created as a result of the investments, the DTI reported.

40 METALWORKING NEWS v 13. 4 September 2014 shopfront focus

S&D Precision Toolmakers celebrates 40 years in business

Introduces a host of innovations.

A view of the S&D Precision Toolmakers machine shop floor

job shop, based in Vereeniging, Gauteng, is delivering a month. The majority are shipped within two business days to variety of high accuracy components including (but not clients in South Africa, Australia, Japan, Germany, USA, Canada, Alimited to) tooling, dies, jigs, impellers and gears to the Italy and Switzerland. petrochemical, defence and mining industries. This year S&D Precision Toolmakers celebrates 40 years in However, S&D Precision Toolmakers has also been business. Current owner Allan Pace joined the company in 1975 manufacturing gear cutters, with an emphasis on the rack-type at the age of 21. At the time that he joined the company, which (Maag, Sunderland) and disc-type (Fellows) cutters, since the was founded by Joe Schmidt and Cyril Day (hence the S&D), 1990s. The company can manufacture up to 200 cutters a Pace was just completing his toolmaking apprenticeship at Allyn Precision Tools. Schmidt and Day had been Pace's former journeymen. Pace’s share of the business grew to 50% when he and Day bought out Schmidt in 1977. Ten years on Pace became the majority shareholder, and ten years following that the sole owner when Day immigrated to the UK. In the early days the business concentrated on manufacturing a variety of components for the defence industry and this accounted for 90% of the turnover. Although it left the business vulnerable to a handful of clients it also forced the company to operate under a high precision environment. This resulted in the company continually upgrading its equipment, making use of the most modern machines available at the time. The company client portfolio has changed somewhat since those days and the defence industry now makes up a small percentage of the component portfolio. But the high precision philosophy has remained with the company and Pace ensures that the business is equipped with the latest technology, not just S&D Precision Toolmakers has five 5-axis DMG Mori machining in the machine department. centres and two 4-axis DMG Mori machining centres on the For example, S&D has recently purchased a Steinbichler machine shop floor, all supplied by Retecon Machine Tools Comet L3D 3D scanning system that features innovative blue 

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Fondly known as Wildebeest, Andre Perry, 5-axis machining The machine shop includes seven GF Agie Charmilles wire specialist working on a DMG Mori Deckel Maho 250 linear CNC EDMs supplied by Retecon Machine Tools 5-axis vertical machining centre supplied by Retecon Machine Tools light technology to quickly produce small and large 3D models “Gears are complex. By nature, even the simplest of gears of physical parts. The extremely compact high-performance consists of numerous physical features and a pattern of 3D sensor with LED lighting adds a new dimension to efficient repeated shapes, most notably the teeth.” 3D data acquisition. Together with Polyworks software, “Many mechanical objects that move have gears. Vehicles sophisticated reverse engineering, prototyping and quality from automobiles to spacecraft rely on gears for power inspection can be performed to an achievable accuracy of less transmission. Gears link the rotation of an engine or motor than 50 micron. Pace is looking to add to this capability by shaft to the turning of wheels that propel the vehicle.” purchasing sophisticated software specifically for Gear “The science behind gear technology is substantial and inspection. well-developed, yet ongoing in its theoretical discoveries and The Comet is an ultra-compact scanner and because its practical applications. Based on the laws of physics and rooted lightweight it is portable. But in the case of S&D it is set up in a in mathematics, the science of gears is a powerful force driving permanent position with a rotary table and a Monfrotto tripod. gear technology forward.” Another recent purchase has been an OR Laser permanent “Gear manufacturing is a dynamic and rapidly evolving marker, which has transformed the company’s marking and field. Currently, it is undergoing a number of significant traceability requirements. transformations. The ‘who, when, where and how’ of gear Knowing that it is key to survival, staff are made to keep production is changing. New opportunities and fresh challenges abreast of advances in technology. Pace took six staff members abound.” to the recent EMO exhibition in Hannover, Germany and let “New gear-making processes are emerging as the them loose. According to Pace it was a learning curve second convergence of innovative tooling designs, five-axis multitasking to none for them, but the ultimate objective of each individual machines and capable software is revolutionising small and seeking out new methods or processes to enhance the medium batch gear production.” productivity and quality of components manufactured by the It therefore is obvious that as a class of workpieces, gears company paid immediate dividends. may be one of the most important, and certainly one of the The diversification of the client mix at S&D began almost most interesting, in the manufacturing industry. by chance. The company had an association with David Brown Pace has recognised this in his endeavours to manufacture Gear Industries and was asked to see if it (S&D) could solve and deliver the finest, most competitive tools and components. a problematic supply situation. Gear cutters were taking over He has surrounded himself with an array of high quality three months to arrive from Europe and the company needed machines that includes seven GF Agie Charmilles wire EDMs, an alternative supplier. This made Pace realise that gear five 5-axis DMG machining centres, and two 4-axis machining manufacturers are constantly under competitive pressures and centres, CNC lathes and grinding machines. need to employ cutting edge technology, and rely heavily on the This has enabled S&D Precision Toolmakers to manufacture manufacturers of the gear cutters. gear cutters to order and generally dispatch them within two Mark Albert of MMS confirms this in his elucidation of gears: working days. Components are also manufactured to order from

Production Manager Alan Chrich, C+ coding and CAD/CAM programmer Piepies Maritz, Peter Jackson working on the and Brian Pace, Electrician, CNC milling and EDM a toolmaker apprentice, DEA CMM machine machinist working with some 3D computer models working on a grinding machine

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agile project management solution in manufacturing. Developed by ThoughtWorks, Pace has customised Mingle to follow a Kanban process. Kanban is a visual scheduling system particularly used in Lean manufacturing – at the heart of Kanban lays transparency and simplicity. Work is divided up into to-do, doing and done tasks. Every member of the company from the receptionist to the person buying material to the men in the workshop - interact with mingle. Mingle gives a real time visual of the A component that has Various components for landing gear exact progress of each task. A computer-run been machined by machined by S&D Precision Toolmakers electronic board (1.5 x 2 m) is centrally S&D Precision Toolmakers situated in the workshop. The setup is excellent in making visible what was otherwise draft drawing, a CAD/CAM model or an original part (using the being swept under the carpet in multiple individually owned Comet L3D scanning system). excel spreadsheets. Each operator or machinist is now In short the company does not want to compete for accountable for knowing his next highest priority task and then ‘rats and mice’ business but rather be looked upon as a upon completion moving it to its next destination whether it be high-end precision component manufacturer. milling, heat treatment or delivery. Mingle has made the macro view of what is going on Procedures, processes and cost calculating scenarios throughout the company, as well as where each job is allocated, However, S&D Precision Toolmakers has also kept abreast much easier to know and manage. Mingle runs on one with its procedures, processes and cost calculating scenarios. computer ("server") and is accessible from as many other Besides having a comprehensive range of plant, which is at network computers as you wish. their disposal to provide a quality product that meets customer Mingle is not just about the shopfloor and the operators and expectations, S&D’s staff, whether he be the owner, engineer or machinists. Everyone has to use Mingle. The person doing the machinist has the latest software analysis programs that enable invoices, the person doing the material purchasing, the guys them to disseminate information and have a collective visual doing the quotations, the guys doing the CAD/CAM design, even management perspective. the driver doing deliveries has to use Mingle. Pace has employed the QuoteCam cost management Basically it is a computer-run electronic board, similar to software, which easily allows him to see exactly what the real those used at airport terminals to disseminate flight arrival cost of manufacture is and therefore to know precisely how and departure schedules most effectively but in the case of much profit will be generated, in his business for over eight S&D Precision Toolmakers it is communicating the current years. work status. More recently Pace purchased Iscar’s automated tool Importantly though the system can be controlled by dispenser Matrix, which allows operators to run tooling management with strategic passwords. For example an invoice inventories for the machines, thus eliminating wastage and can only be generated once management has given the go keeping costs down. ahead. The company has also developed its own quality assurance Mingle visual management system and inspection software package that will take the process However, since the company has installed the Mingle through to packaging, which is outsourced. visual management system, Pace now feels comfortable One aspect that Pace has ensured is that these software with almost being in control of his shop. Tailored to suit programs ‘talk’ to each other so that there is no duplicate data S&D’s environment the company is one of the first to use the entry as that is tedious, time consuming, and costly.

S&D Precision A computer-run electronic board (1.5 x 2m) Another recent purchase has been an Toolmakers has recently is centrally situated in the workshop. Mingle, OR Laser permanent marker, which has purchased a Steinbichler a visual management system, gives a real time transformed the company’s marking and traceability Comet L3D 3D visual of the exact progress of each task requirements scanning system

46 METALWORKING NEWS v 13. 4 September 2014 Pace’s daughter, qualified as a Lean Six Sigma Black belt, generates power. Fondly named the ‘Woer-Woer’ it caused a is regularly brought into the company to consult on optimising traffic jam in Vereeniging when it was erected. the end to end “order-to-door” process. Whether by introduc- The WindCarrier has a rotor design that is based on the ing various technologies or simplification, S&D strives for small Darrieus principle, with a vertical axis, where the aerodynamic continual improvement. lift is used very effectively to generate electricity. This special shape forces the air on the curved upper Power saving surfaces of the blades to flow more quickly S&D Precision Toolmakers have embraced than the air on the lower surfaces. Thanks to the green/clean energy revolution to reduce the smart sensor technology, the controller will environmental impact while taking into account already start up the turbine when the wind the cost savings that the company can achieve. speed reaches a mere 3.5 m/s. The operation LED lighting has been installed throughout is virtually silent; meaning that noise pollution the factory and offices, machines are only for adjacent buildings is non-existent, which, powered up when needed and in May 2014 in turn, allows the system to be used right 300 solar panels were installed. The system beside company premises and production might not be able to run machines at this stage sites. but with all the other savings that are going to The WindCarrier’s stable, space-saving be made S&D Engineering are only looking at a design can be installed within a few hours 45-month payback period. and can handle any weather situation. For Looking ahead, the company has also example, in high winds from 16 m/s, the installed a ‘backward’ running meter so that speed of the system will be gradually reduced when it is legislated it can put power back into to guarantee absolute safety. the national grid, especially on weekends when The WindCarrier installed at S&D the shop is not working. Precision Toolmakers is more of a marketing tool than a power generator because of the ‘Woer–Woer’ - Small wind turbine from lack of wind where it is situated. Gildemeister For further details contact S&D Precision The newest addition to S&D facility in Toolmakers on TEL: 016 421 3093 or General Smuts Road is a Gildemeister ‘Woer–Woer’ – a small wind turbine visit www.sdprecision.co.za where a sample WindCarrier, a small wind turbine that from Gildemeister portfolio of work is showcased.

METALWORKING NEWS v 13. 4 September 2014 47

Scientific Engineering is more than a metal basher

he management team at Scientific Engineering has seen platform, orbital and incubating shakers, ovens, incubators, the manufacturing landscape change greatly over the waterbaths, circulators, circulating baths, steambaths, Tlast 25 years, including the company’s manufacturing heatable baths, hotplates, furnaces, accessories, trolleys, processes and the product mix. clean air laminar flow work benches, electrode baking and Scientific Engineering (Pty) Ltd has been around since holding ovens and hot boxes for the welding industry. 1966 as a leading manufacturer of laboratory and scientific An industry builds to a boom, seeks cheaper manufacturing equipment in Southern Africa. The company designs and sources overseas, and ultimately comes back when these manufactures its own range and does very little marketing “legacy” products return to be made locally because the low of its own products. Product sales are generated through a volumes no longer justify overseas manufacturing. It sounds worldwide dealer network and the laboratory products include like a cycle that could drive a supplier of products that require “For each product produced by the company, meticulous care to design, quality aspects and market research has to be considered, reviewed and applied before anything can be manufactured.”

large amounts of metal fabrication to the brink of extinction. It is a scenario that is a reality for many local manufacturers in the face of the Chinese onslaught, but that’s not the case for Scientific Engineering. The company counters this by continuing to produce products of a quality that cannot be matched by mass production, where quantity supersedes quality. More importantly it has built a reputation in tough markets like the USA, where stringent safety and quality tests have to be passed before a product is allowed to be imported, while still maintaining a leading position in South Africa. The Managing Director of Scientific Engineering is Bernard Parschau, a passionate man who is carrying on the company started by his late father. This family foundation is infused in the culture Managing Director of Scientific Engineering Bernard Parschau with of the overall company, where an open door Production Director Fernando De Jesus in front of the Bystronic BySprint Fiber 3015 policy and a lateral structure ensures that three kilowatt fiber laser supplied by First Cut everyone is an equally valued and 

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The Bystronic BySprint Fiber 3015 three kilowatt In December 2013 Scientific Engineering installed three Bystronic fiber laser comes equipped with a Bystronic ByTrans Extended Xpert 150 hydraulic press brakes, supplied by First Cut sheet loading and unloading system productive member of a team that shares a commitment These standards are in addition to the ISO 9001 certification to quality. we have.” “The company was established at a time when there was “The resultant disciplines and standards that we now a drive to build up the manufacturing base in South Africa. apply to our manufacturing techniques mean we deliver Coupled with a burgeoning mining industry at the time and quality and reliability and manufacture our equipment to a the potential prospects in such markets as biochemistry, very high standard. We are glad that we have paid our ‘school research, pharmaceuticals and industry in general, the fees’ because today the market is even more competitive” product mix was carefully chosen,” said Parschau, a Mechanical Engineer, who joined the company in 1990. Equipment for the food service industry The company’s entry into the USA market virtually Growth and product diversification coincided with the product diversification that it undertook. Up until then the company had focused on the local In 1993, a South African catering distribution company market but if it wanted to grow it would have to seek approached the Scientific Engineering team with a proposal to alternatives, such as exports. develop a range of equipment for the food service industry. “Although the export market had huge potential it also “The way we manufacture our presented challenges that would be a barrier to entry for most type of laboratory and companies. I am talking in particular about the US market. scientific equipment is But the company had always thrived in a competitive very similar to the way environment and if it meant that we would have to place an you would manufacture emphasis on making sure our equipment complies with food service equipment. regulations, we were up to the challenge.” Simply put, the shell “These included the UL Standards and NSF Listing, two or body is made independent bodies in the USA that validate, test, inspect and up of sheet metal audit your products for compliance and safety to a certain components standard before certifying you to enter the market. Ultimately that have been they perform functions that level the playing fields with their either cut to benchmark guidelines, safeguard the integrity of your size, pressed or product and enable consumers and businesses to feel bent, based on confident about the products and services they purchase. the shape of the component and then assembled with the various electrical, gas and A cabinet with other accessories being a trolley incorporated. The fit for our production capabilities coincided perfectly,” explained Parschau.

Anvil food service equipment The company branded its new range of equipment Anvil, and it has now become synonymous with the industrial food service equipment in South Africa and worldwide. “In the early days we developed a range of Scientific Engineering (Pty) Ltd has been around since 1966 as Sheet metal a leading manufacturer of laboratory and scientific equipment that has been niche equipment, but 20 years later the in Southern Africa. Drying and industrial ovens, furnaces, formed and division manufactures a broad range of incubators, chambers, laboratory circulators, shakers, baths assembled products that can be found in restaurants, and accessories are part of the product mix take away businesses, canteens, hospitals, 

52 METALWORKING NEWS v 13. 4 September 2014 supermarkets, hotels, bars, industrial kitchens and even “We keep things nice and simple in the way in which we school tuck shops, and is used by professional chefs and produce our appliances with the aim of making sure they are caterers. The range of plug-in, easy-to-use industrial food user friendly. There is equipment that we have manufactured service equipment is used in either hot or cold processing 30 to 40 years ago that is still fully operational. This bears situations whether it be in a permanent location or an outside testimony to the fact that it has been designed to last.” catering venue.” “For each product produced by the company, meticulous “The Anvil brand consists of three sub brands – Apex, Axis care to design, quality aspects and market research has to and Aire – and all products are manufactured to SABS stand- be considered, reviewed and applied before anything can be ards. The range includes convection, deck, pizza and baking manufactured. From the time of inception to the time a ovens, dough and other mixers, fryers, boilers, proofing and product reaches the market, can easily take up to other cabinets, rotisseries, cake fridges, display units, 15 months,” Parschau explains. warmers, salamanders, grillers in either electric or gas “We are very in touch with the configurations, as well as a number of accessories.” end user. If we see an opportunity in the market, our team looks at Butcherquip gaining market intelligence to Laboratory equipment in the test stage identify whether there is room for us to operate in, as well as whether A natural progression for Scientific Engineering, the product falls in line with our which is the manufacturing arm of the company, was core business and abilities. If it to enter the butchery equipment supply market, which passes the first gate, we then make it did in 1992. Here the company manufactures meat sure we have something which bandsaws, biltong slicers, cooker cabinets, mincers, adds value compared patty machines, sausage fillers and smoker cabinets for Scientific Engineering to what existing this area of the food service equipment market. You can manufactures and offers are out there. supplies a range find the company’s equipment in butcheries as well as of butchery This is then taken a in fish, meat and poultry deli shops. equipment such as step further as we a meat band saw start designing using Manufacturing and design SolidWorks and then Approximately 80% of Scientific Engineering’s sheet developing prototypes. metal work, whether it is cut to size, pressed or bent, If these pass internal tests we send consists of light gauge stainless steel and 90% of this figure them out for field tests. This helps to ensure that the product is grade 430, a non-hardenable steel containing straight designs are in line with market requirements. Once we have chromium that belongs to the ferritic group of steels. This achieved that, we start a pre-production run of between five steel is known for its good corrosion resistance and or ten units and double check that the unit is suitable enough formability, coupled with practical mechanical properties. for its intended purpose. When we are comfortable with the It can be used in certain chemical applications due to its result, we approach our dealers so that the product may be resistance to nitric acid. The remainder is made up of mild launched.” steel. The company employs lasers, press brakes, punch New sheet metal processing equipment presses and guillotines to carry out its sheet metal work and The company embarked on an equipment upgrade processes between 30 and 40 tons of metal a month. recently. “In December 2013 we installed three Bystronic All assembly and packaging is done in house as is the wire Xpert 150 hydraulic press brakes, which are equipped with a harnessing. However, certain components are outsourced. comprehensive database of material bend allowances and These include aluminium high pressure and gravity sand extensive bending configurations. The 150 ton capacity castings, ferrous castings and some assemblies. Bystronic Xpert press brakes feature a 3 000 mm bed length, Despite an abundance of modern technology now dynamic crowning, dynamic sheet thickness detection, LED available, Parschau confesses that in most instances they use optical bend guiding, high-speed ram, and the ByVision bending standard controls that make it easy to service and operate the control with a 22” touchscreen interface that allows equipment. functionality and simple and rapid set-up.” 

Sheet metal that has been formed and then welded onto fixtures Water urns being assembled

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by not adding the sheet automation,” continued A gas floor standing De Jesus. fat fryer manufactured by “The machines are run on the BySoft proprietary Scientific Engineering software. The BySoft software not only provides a flat blank development, it will tell us whether we have the tools available and run a simulation of the bending sequence. Ultimately it has taken the skill out of the operation and returned it to the office, where it should be. Skilled press brake operators are hard to find, and if they take leave or become sick, the customer gets let down. We won't have this problem in future." “The new Bystronic equipment suites our type of sheet metal production environment as we are not a service centre. All our work is for in-house use.” Scientific Engineering operates A pie warmer from a 10 000 m² facility in Roodepoort, Gauteng and employs 130 staff. “Many manufacturers try and give the market what they think it needs. We at Scientific Engineering believe it is very important, and possible. With sufficient market intelligence, one is able to analyse the market carefully and distinguish between “Although we already have a what is required and not what is Bystronic 3015 CO2 laser on the assumed to be required. There is a shopfloor, increased use of fiber very subtle difference,” said Parschau optic technology in lasers is making in finishing. A double pan fryer laser cutting equipment more productive “Scientific Engineering certainly manufactured by and cost-effective. This is the reason why we Scientific Engineering knows what the market requires have now purchased a Bystronic BySprint Fiber 3015, and this comes from many years a high-power fiber laser cutting machine based on the of close relationships with our dealers and end users in BySprint Pro platform. The BySprint Fiber 3015 fiber laser the field. We are industry leaders but one has to respect is equipped with a 3-kilowatt fiber 3000 fiber laser, and one’s competition. I think arrogance in any form is very even though it is powerful enough to cut steel, aluminium dangerous. There are many first rate players out there and non-ferrous metals such as copper and brass, we are that are also able to satisfy their customers, we just only using it to cut our stainless steel sheets,” explained have to be better at the game than they are. The capital Production Director Fernando De Jesus, who has been investments we have made recently shows that we with the company since 1987. are serious about this. We believe in our products “The fiber laser was installed three months ago and and are a proudly South African company,” Parschau comes with a Bystronic ByTrans Extended sheet loading explains. and unloading system. The output of the new For further details contact Scientific Engineering BySprint Fiber 3015 fiber laser has increased our production on TEL: 011 473 1080 or visit www.scientific.co.za throughput, so much that it made no sense to slow it down or www.anvilworld.com

Part of the assembly area. Scientific Engineering Scientific Engineering has a call for punching operations. manufactures its own wire harnesses The company has a Trumatic 200 punch press supplied by Retecon Machine Tools

56 METALWORKING NEWS v 13. 4 September 2014

Not just a service centre

trategic alliances and partnerships will always form Sthe basis of a sound future for a company. However, developing your own opportunities and not just waiting for RFQ’s to come in the door via the Group structure should steer the company toward becoming proactive and discovering new business. Getting out of the comfort zone though is not always easy. People tend to think the same way they always have. Chances are everyone was looking at the successes of the past, and no one focused on the future. When you are in a crowded market like metal fabrication it is even more important to take note and stop any possible bleeding. One such company that has done this is Plasma Cut. The company was established in 1986 and subsequently purchased by the Afmetco Group in Plasma Cut has recently taken delivery of two new Gasparini X-Press 330 press brakes, 2008. supplied by Talmac Machine Tools

Afmetco Group to the oil, gas, petrochemical, chemical and Afmetco (African Metals Corporation) was established in metallurgical industries, Alsysco Aluminium – a provider 1993 as a niche supplier of specialised stainless steel plate, of custom extrusions solutions, and projects company sheet and related products but has evolved into a group of AMS Projects, a company that is focused on the power, companies whose core focus is the stocking, processing and mining and transport industries. distribution of stainless steel and aluminium throughout The group is predominantly positioned in South Africa Southern Africa. with branches in all the main centres, but also has operations Within the Afmetco Group, Plasma Cut has strategic in neighbouring countries. alliances and partnerships with associated companies: Euro Steel – a stockist and distributor of stainless steel, Plasma Cut special steels, aluminium and other corrosion resisting Plasma Cut was formed by Mischel Frljak and had a materials in almost every commercially available form, long association with its supplier Euro Steel, now a group Specstrip/Berrick Trading – a stainless steel decoiling and associated company. The company initially operated as a reslitting company, Euro Steel Pipe – a fabricator of stainless steel and aluminium service and solution centre, large-bore longitudinal stainless steel welded pipe, however, through the acquisition of modern CNC equipment, East Cape Manufacturing – manufacturers of stainless steel it can now offer cut–to–size laser cutting (including laser tube pressings for catalytic converters, Euro Special Steels – a cutting facilities), high definition plasma cutting, guillotine fabricator of abrasion resistant high impact high strength cutting, bending, rolling, cylinder and flange rolling on edge, carbon steel plate, All Alloys – a specialist supplier of exotic flanges (standard and to spec), bars (flat and angled), metals and alloys in sheet, plate, tubes, pipes, fittings and bar channel, plates (standard and polished), pipes, tubes, 

Plasma Cut has three Trumpf CO2 lasers supplied Plasma Cut has two Davi CNC pinch plate rolls, from Italy, for by Retecon Machine Tools rolling shells and cylinders, which range from 0,7 mm to 16 mm thick

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The bellmouth screens, which involve cutting, bending, machining Plasma Cut had been contracted to manufacture and welding, weigh about 200 kilograms each and are fitted in front 70 stainless steel bellmouth screens for a new dam of the bellmouth intakes on the dam wall. The screens can either be that is being constructed in a neighbouring country raked or removed for cleaning and the primary purpose of them is that they are used to prevent floating material entering the power station turbines or the outlet works fittings, CNC machining, brushing, polishing and fabrication equipment that are the hallmarks of a service centre, services. including three Trumpf lasers that can cut up to 25 mm in The company has for a long time focused on stainless mild steel, 20 mm sheet thickness in stainless steel and steel and aluminium, although it is not limited to these 12 mm in aluminium, a plasma cutter that processes plate materials. It moved into its 8 000 m² facility, which is up to 90 mm in stainless steel and 30 mm in mild steel, a situated in Wadeville, Gauteng, in 2008 and adjoins the couple of guillotines, a seven-axis CNC bending press, from associate company Euro Steel facility. This offers a number of Amada Japan, for light-gauge precision bending, which advantages for Plasma Cut. It partly acts as a service centre coincides with its precision-cutting facilities, and another for Euro Steel, whose business is the processing of stainless 300 ton press brake, it has invested in other metal fabrication steel and aluminum flat product, such as plate, sheet and coil, and manipulation equipment that certainly takes it away from long products such as angle, flat and round bar, wire and operating just as a service centre. tubing, and a range of extruded aluminium products. “In fact we do not like to call ourselves a service centre “However, one of the biggest advantages of having anymore,” said Manny Da Silva, who has been Technical Euro Steel on your door step and being one of our main Director at Plasma Cut for the last eight years. material suppliers is that it can save you a huge amount on “Even before the company joined the Afmetco Group transport costs and material delivery times,” said Colin Gray, Plasma Cut had already diversified into adding value by MD of Plasma Cut. manufacturing components, offering fabrication and “Metal service centres are finding assembly of themselves under increasing pressure to cut cut-to-size costs and deliver on time so any advantage components,” you gain can be the difference between you continued winning an order or not,” continued Gray. Da Siva. Two Davi Not just a service centre CNC pinch Although the company has all the plate rolls, from Italy, for rolling shells Polished components and cylinders, for balustrading which range from 0,7 mm to 16 mm thick, two vertical boring mills, a Doosan CNC lathe and a Doosan CNC machining centre compliment the cutting and bending equipment. Additionally, the full range of welding, polishing and brushing are included in the company’s service offerings. An example of the company’s diversification was on view when I visited. Plasma Cut had been contracted to manufacture 70 stainless steel bellmouth screens for a new dam that is being constructed in a neighbouring country. The bellmouth screens, which involve cutting, bending, machining and welding, weigh about 200 kilograms each and are fitted in front of the bellmouth intakes on the Plasma Cut is not just a service centre dam wall. The screens can either be raked or 

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manufactured under Gasparini’s Eco Concept, and are said to be environmentally friendly, offer energy savings, speed, noiselessness, limited maintenance, less waste and extreme precision and repeatability. The machines have a 330 ton force and 3 000 mm bending width and were specifically purchased by Plasma Cut so that the company can now offer larger and wider bending operations. “We were always restricted by our width. Talmac came up with the solution of putting two 3 000 mm machines together so we can now offer up to six metre width bending. More importantly, we saved quite a bit of money because we did not have to put in foundations for a much heavier machine, and we can now either use both machines in tandem, Two vertical boring mills, a Doosan CNC lathe and a Doosan CNC or singularly,” explained Da Silva. machining centre compliment the cutting and bending equipment “Going forward we are investigating the possibility of a new high definition plasma cutting machine as well as removed for cleaning and the primary purpose of them is that adding to our rolling department.” they are used to prevent floating material entering the power station turbines or the outlet works. E-Track Online Plasma Cut has also supplied the large bore piping “The best metal fabricating partner in a supply chain (1 200 mm nominal bore) and the end brackets for a is the one that not only provides on-time delivery of quality 200 metre piping project at the same dam construction. products, but also provides complete and open Each pipe weighs in at four tons and is nine metres communication. Today the only means to do that is by in length. opening up information technology systems to those important “Many of today's consumer products, commercial and customers,” explained Colin Gray. industrial processing machines, and automotive components “We have developed an online system whereby the are being exposed to continually higher temperatures and client can log in online via our website to view the status of more severe corrosion. As this transition to more challenging his order. It will give you a real-time status of where you are environments occurs, an on-time supply of high-quality in the production line and when delivery can be expected. It processed stainless steels and other specialty metals gives the clients peace of mind; it helps us to improve our becomes vital to industry. Many steel suppliers that process service and of course facilitates planning. That is of course carbon steel grades are being asked to slit more exotic and if we do not have a metals industries strike.” often more difficult stainless steels. All too often both the “The best way for you to maintain or earn “preferred” processor and the customer are disappointed with the results. status with your clients is to show them that they can have We regard ourselves as specialists in the field of stainless visibility into the your operations and tell them that they are steel. Working with clients to provide the best solution and always welcome to check on things, such as a job status or then completing the processing and assembly aspects,” shipment delivery date.” explained Colin Gray. “Your clients have always demanded the best quality, There were also numerous examples of stainless steel lower prices, and streamlined delivery. But today your clients components that were being manufactured for balustrading. want something a little more … revealing. They want access Most components would be brushed and/or polished before to information about their parts, orders, shipments, product being welded and assembled, and then erected on-site. Da Silva believes that the company’s competitive advantage lies in the fact that it is not just a service centre and thus it does not outsource, but is able to add value by cutting components to customers’ specific requirements, and then offering the add-on value services. Also, the company’s partnership with supplier Euro Steel enables it to source the material at competitive prices, which are passed directly on to the client. The 80-strong employee company services the chemical and petrochemical industries, as well as the automotive, catering, mining and general engineering sectors. It is also ISO 9001-2008 TUV certified.

New equipment Adding to its services, Plasma Cut has recently taken delivery of two new Gasparini X-Press 330 press brakes, Colin Gray, Managing Director and Manny Da Silva, delivered by Talmac Machine Tools. The machines are Technical Director at Plasma Cut for the last eight years

62 METALWORKING NEWS v 13. 4 September 2014 documentation, account status, and even deeper access to your business data, such as quality or job status.”

Sealing the deal with an electronic handshake “Your clients are dealing with marketplaces that increasingly demand service delivered right away and their way. This need is in turn driving them to evaluate their supply chains — of which you are a part — and address their weakest links. Will your metal fabricating operation be identified as that weakest link, forcing your clients to seek other partners better equipped to meet these real-time information requirements?” “There was a time when business was done with a handshake. Today this has been replaced with an electronic handshake. Your data systems must shake hands with your A general view of the shop floor clients’ data systems.” “As with any inflection point when it maintain their preferred supplier status.” comes to embracing innovation, leaders and laggards will “Plasma Cut has a simple policy as is relates to client emerge. Manufacturers that standardise their business on service: Jobs are turned around in days, not weeks. If the the latest ERP technology have a competitive advantage company’s best clients need same-day service, they get it if at through an end-to-end system that supports their all possible, while at the same time embracing the electronic manufacturing business processes, improves client revolution. We believe we have mastered this with E-Track relationships, and fosters supply chain collaboration that Online,” said Gray. leads to enhanced productivity and cost efficiencies. For further details contact Plasma Cut on These leaders will master the show-and-tell game to TEL: 011 902 5550 or visit www.plasmacut.co.za

METALWORKING NEWS v 13. 4 September 2014 63 Steelbank unwinding the way forward

o maintain a manufacturing sector in this country, industry must continually improve upon efficiency. TManufacturers and processors can and should specify new machines that run at high speeds and allow quick setups, which are two essential ingredients for efficient operation. When you operate in the competitive coil processing and blanking arena, which has taken on the characteristics of commoditisation in recent years, with the cost of steel rising and profit margins shrinking, you have to look for ways to reduce costs and streamline operations while maintaining quality. This takes on a new dimension in coil processing because coil handling and blanking equipment can take up plenty of space and smarter and more capable machines are already operating more effectively and delivering productively. To keep ahead of the opposition you An aerial view of Steelbank’s could consider different equipment configurations and new Gauteng facility options that may deliver much-needed floor space. But there comes a time when you simply run out of space and important that generates actual competitive advantage. decisions have to be made. In March 2014 the company moved 40 kilometres south The Gauteng branch of Steelbank reached that ‘point from its 4 300 m² facility in Linbro Park to a purpose built of no return’ and management was having trouble sleeping 12 000 m² facility in Alrode, Gauteng. at night. In the background, the company’s policy of “This is only the first phase of our expansion programme constantly updating its equipment and aligning itself to in the Gauteng area,” quipped Group MD Leon Freese, who global industry standards to ensure it remained a world-class has been with the company since 1981. processor and supplier of steel products was also a nagging influence. What Steelbank is about Steelbank’s head office is situated in Pinetown, Steelbank is on a new and exciting path KwaZulu Natal. Roy Meaker purchased an existing steel The expansion that is presently underway at Steelbank company in 1978 and immediately set out to change the has been planned over a long period. Steelbank management status of the company, a task that he has done very decided to increase capacity comprehensively, a decision successfully if you judge it by the size of the company now - which is bound to take the company forward and address the and the recent investments it has made. Meaker remained conditions necessary to create real improvement - the kind as chairman of the Group until 1997 when his son, Lloyd Meaker, took over the position. Pinetown has expanded over the years and it now occupies an 8 000 m² facility in Trotter Road. The processing department is aided by 13 machines, 150 staff and at this stage, is working seven days a week on a double shift basis. Additionally, the company has increased its capabilities this year with new equipment being installed, and it now also offers tube processing services. All tube, which comprises both mild steel and stainless steel tubing, is imported. This is the first time that Steelbank have moved out of flat sheet processing since 1997, and according to management, it is has made some significant inroads into this market. Steelbank Gauteng’s MD Robin Gray In 2000 the company opened with Group MD Leon Freese up a branch in Cape Town, which

64 METALWORKING NEWS v 13. 4 September 2014 is run by Russel Dennis. This branch expanded when it moved into a 2 000 m² facility in Parow in 2012. Plans are in the pipeline to add processing equipment in the future for both stainless steel and mild steel. Prior to 2007, Steelbank did not have a significant presence in the Gauteng market and surrounding areas. However, that all changed when the company purchased Metpar (Pty) Ltd., which had operations in Gauteng and Cape Town. “This was done in order to cover areas that Steelbank was already servicing from the Durban operation, on an increased level, but logistically became more difficult to service as the turnover increased. We immediately set out Steelbank Gauteng’s new slitting line to expand the operation in Gauteng, and we merged the Cape Town branch with the existing Steelbank operation. Both these activities proved very successful,” explained Leon Freese. Metpar was established in 1980 by Robin Gray and the late Henry Oosthuizen, as a specialist processed steel supplier to the second tier automotive industry. The company subsequently branched out into other areas that required processed flat steel products. Gray has remained on with Steelbank and is now MD of the Gauteng branch. Steelbank also has a sales branch in Port Elizabeth, which is headed up by Andy Cheeseman.

New direction Three years ago Steelbank ventured into a new direction by opening a new company in Cape Town specifically to stock and trade stainless steel and aluminium. After a The new slitting line comes with a shuttle shaky start, the operation prospered to such an extent that  for quick change over

METALWORKING NEWS v 13. 4 September 2014 65 Material being slit in the new Steelbank 12 000 m² facility Packaging is important to Steelbank. A new material in Alrode, Gauteng handling magnet has been installed the company has now expanded its stainless steel applications e.g. garage doors, domestic appliances, footprint into the Gauteng area through the acquisition of road signs, doors and general engineering), aluminium zinc Pro Trading cc in May 2014. The company has changed the coated steel (used in roof sheeting, steel roof trusses, name to Steelbank Stainless to reflect the primary focus of electrical switchboard cabinets, structural sections, the business, which is stockists and suppliers of imported domestic appliances, refrigeration, air conditioner air ducting, and local stainless steel materials. This includes sheet, flats, light fittings, computer casings and electronic boxes), round bar, angles, rectangles and square and round tubing. aluminised steel (used in bakery trays, automotive exhaust Processing of coil is available as well. The client base is systems, automotive heat shields, chimney ducts, construction general engineering companies, and this operation is headed profiles, heating boilers, air conditioners and tanks) and tin by Jürgen Freese. plate. Depending on the type of material, slitting is offered from Products 0,3 up to 8 mm, blanking up to 3 mm thickness, cut-to-length The company’s primary focus is on flat steel products up to 4 mm thickness and up to 1 850 mm width. Materials and components processed from coil. Their slitting, cut to are either supplied by ArcelorMittal or imported from Europe, length and guillotining processing capabilities are based the East, South America and elsewhere. Management has on mild steel with a tensile strength of up to 510Mpa. spent substantial time and travelled to find the correct The client list includes, but is not restricted to, those sourcing of steel from around the world focusing on quality companies adding value to the automotive parts, domestic and continuous availability. appliances, structural applications, security gates, furniture, air conditioning, roof trusses, garage doors and general New Alrode facility engineering. “The decision to move to Alrode was initially prompted Although Steelbank has now added new services through by a space constraint but it soon became necessary by the its recent acquisition and stainless steel tubing division, mild ever-increasing demand for our services and our desire to steel processing is what the company is all about. Stock range expand,” explained Robin Gray. includes all commercial quality items, but also includes graded “A suitable site was found but the buildings did not suit items such as cold rolled drawing and forming, hot rolled our operation and there was no chance that we could make steel sheet (forming grades, pickled and oiled), electro- alterations. Phase one of our expansion involved demolishing galvanised steel sheet, galvanised (hot dipped galvanised an existing building on the 57 000 m² site and erecting a steel), colour coated steel sheet (used in building 12 000 m² facility, which is designed to optimise the 

A new cut-to-length / blanking line has been Blanks being cut on the new supplied by Reef Engineering Reef Engineering line

66 METALWORKING NEWS v 13. 4 September 2014

completed within the next five years.”

New equipment “In our planning we made provision for an equipment capex expansion to increase our capabilities. Added now to the existing slitting line, one cut-to-length line, one blanking line and two slitting/blanking lines, are a new slitting line which can slit material from 0,3 up to 4 mm, a new Reef Engineering cut-to-length/blanking line that blanks components up to 3 mm thickness and 850 mm width, and a cut-to-length line with capabilities for mild steel up to 4 mm thickness and 1 600 mm width,” explained Leon Freese. “With the addition of the new equipment we have now increased our capabilities by 50%, and these will increase even more once phase two and three are completed.” The existing slitting line that was "Our team in Gauteng, from construction to operations, moved from Linbro Park has done an outstanding job relocating and expanding the capabilities of the company, and we are grateful that the move company’s existing manufacturing equipment and bays. The went relatively smoothly with a minimal loss of production and new layout will significantly improve work-flow, worker security, not letting our clients down,” said Freese. and industry demands for higher levels of service.” The Gauteng branch employs 100 staff. Overall, the group

The expansion that is presently underway at Steelbank has been planned over a long period. Steelbank management decided to increase capacity comprehensively, a decision which is bound to take the company forward and address the conditions necessary to create real improvement - the kind that generates actual competitive advantage

“Once the building was complete the logistics in relocating the equipment from Linbro Park and adding three additional lines took some planning. Our existing slitting line was constrained by space but now it is being used to its full length,” continued Gray. “Another important factor is the area that we now have available for coil delivered, and processed coil and components. We are not falling all over the materials and the loading, off loading and packaging aspects have increased our efficiencies tremendously.” “This first phase will be followed up shortly with a duplicate 12 000 m² building, and phase three will involve erecting a 9 000 m² building. These projects should be

Processed coil ready for shipment

applies an effective quality control system and has certification for ISO 9001, ISO/TS 16949 and ISO 14001. The Quality Management System is assessed by SABS and meets the requirements of SABS/ISO 9001, as well as the automotive industry requirement of ISO/TS 16949. For further details contact Steelbank Gauteng on TEL: 011 201 5900, the head office on TEL: 031 701 4821, Cape Town on TEL: 021 934 4251, Port Elizabeth TEL: 041 583 2484 and Stainless Steel and Aluminium on TEL: 021 934 4251 (Cape Town) and TEL: 011 397 5246 (Gauteng) Coils that have arrived at the Steelbank Gauteng facility or visit www.steelbank.co.za

68 METALWORKING NEWS v 13. 4 September 2014 better production

Current trends in the machine tool industry

Industry 4.0 and increased efficiency are the key topics for machine tool manufacturers and their partners.

he machine tool industry is confronted with a large number of developments, which are Tinfluencing investment decisions by its customers. In addition to the still dominant topics of Industry 4.0 and increased efficiency, other topics must be considered, i.e. hybridisation of machines, software and IT security, increasing intelligence of machine peripherals and simulation of complete machining processes. Answers to complex requirements will be provided at AMB, International Exhibition for Metal Working, which is being held in Stuttgart from 16 to 20 September 2014.

Industry 4.0: high complexity is both a challenge and an opportunity The topic of Industry 4.0 is "varied and interdisciplinary”. This conclusion was drawn by the Fraunhofer Institute for Production Engineering and Automation (IPA) in the structural study entitled "Industry 4.0 for Baden-Württemberg” that was conducted on behalf of the Federal State of Baden-Württemberg. Many of the statements probably apply in principle. In addition to mechanical engineering skills, for example, purely technical implementation of Industry 4.0 also calls for knowledge of electrical engineering, software Federal State of Baden-Württemberg, also regards Industry and information and communication technology. Other areas 4.0 as one of the mega-trends in production: "It involves such as work organisation must be included for the purpose intelligent cooperation between different industries which of implementation at the organisational level. In order to creates optimised value-added chains and leads to greater successfully implement Industry 4.0, it is also necessary to resource efficiency. The main topics here are new working include company-related services such as technology environments, security, standardisation and development of development, introduction, maintenance or service, as well new business models." as technology upgrading and non-technical areas such as Exhibitors at AMB concur with Dr. Schmid. Holger general and advanced training. Langhans, Director Walter Multiply at Walter AG in Tübingen, This poses major is therefore convinced: "Only those companies which help challenges for companies their production to think will be able to ensure the necessary both during introduction as quality, flexibility and availability to be globally competitive in a user and as a provider. future. We are therefore working on solutions which achieve The positive aspect: precisely this objective." Dr. Niklas Kramer, Head of Research individual companies and Development at Komet Group GmbH, Besigheim, sees can gain leading future tool management in the Cloud: "Digital and networked edges, for production provides ideal solution approaches. Crowd example through Intelligence creates new business models for tools and higher productivity is a key factor for Germany as a production location." or new unique characteristics by Energy efficiency: initial successes are just the beginning means of other The efforts to use energy more efficiently have certainly accompanying been successful for some time now. Experts from the Centre services. Dr. Nils for European Economic Research (ZEW) in Mannheim reached Schmid, Deputy this conclusion some years ago. During a study on behalf of Minister-President the German Federal Ministry of the Environment, they ascer- and Minister of Finance tained that energy efficiency worldwide had improved by 18 and Economics of the percent between 1995 and 2007. Improved

70 METALWORKING NEWS v 13. 4 September 2014 technologies, in particular, had made an important on an interdisciplinary basis. Buildings, the technical contribution to this increase in most countries, including building infrastructure and production machines will be Germany. However, this actually only represented a kind of perfectly matched to one another. For example, the waste starting signal for the production researchers. Darmstadt heat from the machines is thermally stored in order to reuse Technical University has been examining the topic of energy the energy in a different place and at a different time. efficiency for many years. Scientists there are now developing The participants in the project include AMB exhibitors such the "eta factory", which is being financially supported by the as Bosch Rexroth AG, Grob-Werke GmbH & Co. KG, Gebr. German Federal Ministry of Economics as part of the German Heller Maschinenfabrik GmbH, MAG IAS GmbH and Siemens Federal Government's high-tech initiative regarding Industry AG. The Project Director is Prof. Dr.-Ing. Eberhard Abele from 4.0. The overall structure of the "factory" is being optimised the Institute of Production Management, Technology and 

METALWORKING NEWS v 13. 4 September 2014 71 the maximum speed was almost tripled. Uwe Zoller, Sales Manager, said that his company was therefore complying with an increasingly more frequent request from customers for lightweight components: "The inquiries which we receive often contain weight stipulations or customers ask us what a chucking tool for a specific task weighs." However, Markus Michelberger, Sales Manager Chucking Systems at Schunk GmbH & Co. KG, Mengen, is skeptical as regards carbon. To date, he has regarded composites, at least for lathe chucks, as not stable enough to "absorb the high static and dynamic loads of conventional machining operations as efficiently as steel lathe chucks." Nevertheless, Schunk is also making weight reductions. Michelberger: "Lightweight lathe chucks made of hardened steel minimise energy consumption and are also impressive in terms of their safety, accuracy and service life. Lightweight construction will also play an important role at AMB in the accompanying programme. For example, Wirtschaftsförderung Region Stuttgart (WRS) will devote several topics to the themes of composites and lightweight construction in its "Region Stuttgart Lounge”. The Fraunhofer Institute for Production Engineering and Automation (IPA) and Universität Stuttgart will also jointly talk about, for example, "machining in lightweight construction". Other talks will be given by the Baden-Württemberg State Agency for Lightweight Construction and the Baden-Württemberg Alliance for Fibre-Based Materials (AFBW). The talks will start each day at 09.30 from 17 to 19 September 2014.

"i-software“ makes operation easier Machine tools are increasingly penetrating new areas. The Mühltal-based manufacturer Datron AG created the D5, a machine for use in dental laboratories, some years ago. Other machine tool manufactures are now following suit. One current example: GF Agie Charmilles with the Mikron HSM 200U that is also aimed at the medical technology industry Machine Tools (PTW) which will demonstrate the future of and generally at manufacturers of small precision tools like in production at AMB 2014 with its "PTW Innovation tour of the watch and jewellery industries. However, the question of metal working - trends of tomorrow". user-friendliness is therefore being raised to a greater extent. Another aspect: Only in a few regions of the world can the Lightweight construction: also a trend topic in highly export-oriented German and European machine tool mechanical engineering industry expect to find workers who are as similarly In addition to looking at the big picture, however, the well-trained as those here. Datron also went one step further: potential also found in the details should not be ignored. the D5 is operated via an Apple iPad and also uses its For example, lightweight construction is not only making app-based operating philosophy. So called "i-software” in the inroads into the mobility industry, but also to an increasing style of Apple is in vogue. DMG Mori, a major player, then extent into mechanical engineering. And always in the case made its entrance a few months ago when it presented the of highly dynamic processes in which large masses have to new user interface "Celos”. However, DMG is going much be accelerated as quickly as possible and then slowed down further than Datron. The company promises nothing less again. The Karlsruhe Institute of Technology (KIT) provides a good example of this. The wbk Institute for Production Engineering at KIT developed a new lightweight sledge made of carbon fibre-reinforced plastic (CFRP). It is not only much lighter than its steel rivals, but can be changed primarily by adding mass in its vibration behaviour in order to influence the natural frequency behaviour and therefore improve the efficiency of the machine. "We therefore assume that corresponding components will be available on the market in around five years," emphasised wbk Director Prof. Dr.-Ing. Jürgen Fleischer. A lightweight chuck from Emuge-Franken GmbH & Co. KG in Lauf an der Pegnitz is already being used. Friedrich Schmauss, Head of Design: "Carbon and steel are used as a material mixture." The results are impressive: the weight was reduced in a specific application from 460 to 130 kilograms. Annual energy consumption was therefore reduced from 22,470 kWh to around 4,000 kWh. In addition,

72 METALWORKING NEWS v 13. 4 September 2014 than simplification and acceleration of the entire large-volume components can be produced generatively with process "from the idea to the finished product". almost any inner geometry. Hipp: "Material coating and metal The actual advantages come from different apps such as cutting are therefore carried with one clamping operation in "Job Manager” or "Job Assistant” that help the machine one machine." operator in network-integrated planning, preparation, optimisation and systematic implementation of new Simulation increasingly more important production tasks. Christian Thönes, a member of the However, the demands on workers are also growing as Board of Management with responsibility for product "hybridisation" increases. Eberhard Beck, Head of Control development, technology and internationalisation of the Technology at Index-Werke GmbH & Co. KG, Esslingen, production plants of DMG Mori: "During AMB we will see therefore warns that it is first necessary to find an answer Celos in several machines and with even more than as to "how users of these machine concepts can master this the 12 apps which we demonstrated during the presentation additional functionality so that it can be used economically of Celos." and profitably." Conventional planning methods and coating processes were no longer sufficient to cope with the Hybridisation: combining the best of everything substantial increase in the requirements for new machine Another trend is the combination and concepts because planning and implementation of superimposition of different processes in a machine tool. "multi-technological" metal cutting processes include One current example of this trend is the MT (Mill/Turn) machining sequence and tool planning, as well as extensive Technology from Maschinenfabrik Berthold Hermle AG, and experience-intensive programming in particular. Gosheim. In the new MT version the CNC 5-axis machining This is almost impossible to attain manually on a competitive centres C 42 U dynamic and C 50 U dynamic have a fully basis. Beck gives the following advice: "It is necessary to use integrated rotary table that can be used to perform complex 3-D machining simulation, which is absolutely authentic in lathe turning/milling processes in one clamping. Marketing its presentation and time sequence behaviour, and can be Manager Udo Hipp: "The special aspect of the MT concept is verified and validated with all programme-related machine that lathe turning can be carried out in any position between actions and order processes on the PC before the start of the the 0° and 90° setting of the NC swivel rotary table with order." The company was therefore one of the first machine the result that very short turning tools can be used.” tool manufacturers to create a 1:1 image of its machines Hermle is going one step further by integrating the on a computer. Beck: "We will also systematically continue generative MPA process in a 5-axis machining centre. along the path of the virtual machine and our own Thanks to the thermal injection process for metal powder, CAD-CAM-CNC process chain at AMB 2014."

METALWORKING NEWS v 13. 4 September 2014 73 international news

Global robotics industry: Record beats record

"In 2013, about 179,000 industrial robots were sold worldwide, again an all-time high and 12 percent more than in 2012," said Arturo Baroncelli, IFR President in June at the Automatica exhibition in Munich, Germany.

ncoming orders in the first four months of 2014 increased remarkably and requests from all customer industries are "Ion the rise. Therefore, we expect that in 2014 growth of unit sales will continue with the same pace like in 2013," stated Baroncelli.

Remarkable increase in all regions Robot sales reached record levels in Asia/Australia, in the Americas and in Africa. Almost 100,000 new robots were installed in 2013 in Asia/Australia, 18% more than in 2012. The European market increased by 5% to more than 43,000 units almost reaching the all-time-high of 2011. Robot supplies to the Americas continued to increase by 8% to more than 30,000 units. More than 700 industrial robots were sold in Africa, 87% more than in 2012.

China biggest and fastest growing robot market supply of 2013 was produced by Japanese companies. In 2013, China is by far the biggest robot market in the world sales of industrial robots decreased by 9% to about 26,000 regarding annual sales and it is also the fastest growing market units due to reduced investments of the automotive and the worldwide. For the first time ever, the sales figures of Chinese electronics industries in Japan. However, exports of Japanese robot suppliers are included in the IFR statistics survey. robots increased. Almost 37,000 industrial robots were sold in 2013 in China. Robot installations in the United States continued to Chinese robot suppliers installed about 9,000 units according increase by 6% to the peak level of almost 24,000 units. to the information supplied by the China Robot Industry Alliance Between 2008 and 2013, annual sales in the United Sates (CRIA). Their sales volume was almost three times higher than increased by 12% on average per year. Driver of this growth in 2012. Foreign robot suppliers increased their sales by 20% in was the ongoing trend to automate production in order to China. Between 2008 and 2013, total supply of industrial robots strengthen American industries on the global market and to increased by about 36% per year on average. In 2013, every keep manufacturing at home, and in some cases, bringing back fifth robot sold in the world was installed in China. manufacturing that had previously been sent overseas. In 2013, robot sales to the Republic of Korea increased by 10% Japan, USA, Republic of Korea and Germany represent to more than 21,000 units due to increased investments of the 50% of the global robot market automotive industry. The electronics industry, which is the main Japan was the second largest market regarding annual customer of industrial robots in Korea, reduced its robot orders. sales, but it still has, by far, the highest number of industrial Robot sales to the German market were 4% higher in 2013 robots in operation, more than 300,000 units. It is the most compared to 2012 and reached more than 18,000 units, the automated country in the world. Japan is the predominant robot second highest level ever recorded. The automotive industry manufacturing country. More than half of the global robot was again the driver for the growth. Between 2008 and 2013, robot sales to Germany increased by 4% on average. These four markets represent 50% of the sales volume in 2013. There was a considerable increase of robot installations in other Asian markets especially in Taiwan (Province of China), India and Indonesia. Also, important European markets such as Italy and Spain started to recover. Robot installations in Central and Eastern European countries as well as in Mexico and Canada continued to increase considerably. The robot market in Brazil lagged behind expectations.

Automotive and metal industries were the main drivers of the growth The automotive industry increased robot investments continuously and considerably between 2010 and 2013, by 22% on average per year. The main countries involved were China, Germany and the United States. In 2013, robot sales to the

74 METALWORKING NEWS v 13. 4 September 2014 automotive industry increased by 5%. Also the metal and machinery industry had an average annual growth rate of 22% in the same period. In 2013, robot sales to this industry were up by 17%. The food industry as well as the pharmaceutical industry increased robot investments substantially in 2013. The electrical/electronics industry - which wide range of new customers and new applications for had reached a peak level in 2013 - increased robot orders robots. A main example for this category of robot use is by 9% in 2014. the human-machine-collaboration. The robots working together with the worker in the factory or also in The trend towards automation fuels further growth non-manufacturing sectors are capable of understanding The main drivers of automation are: human-like instructions (by voice, gesture, graphics) and 1. Energy-efficiency and new materials, e.g. carbon- have modular plug-and-produce components. This enables composites, requiring new production output people without experience in using robots to program and 2. Global competiveness requiring increased productivity integrate a robot in the process. But a major challenge of this and higher quality application is safety, because the robot is working close to the 3. Growing consumer markets requiring expansion of worker without protection. production capacities Lightweight robots with integrated vision guidance 4. Decreasing life-cycles of products and increasing and better sensor integration that are more adaptable to variety of products requiring flexible automation their environment have been developed and will still 5. Robots improving the quality of work by taking over be improved. The International Organisation for dangerous, tedious and dirty jobs that are not possible Standardization (ISO) is working on a technical specification or safe for humans to perform for collaboration of humans and industrial robots in order to provide reliable safety requirements. The break-through Easy to use robots - challenge and chance to capture of the human-machine collaboration is just beginning. new applications and customers Easy to use and easy to integrate robots will open up a For further details visit www.worldrobotics.org

METALWORKING NEWS v 13. 4 September 2014 75 CIMdata publishes global NC market analysis report

NC market grew 5.4% in 2013.

IMdata, Inc., the global PLM strategic management report also confirmed that Vero Software is the fastest growing consulting and research firm has announced the release company out of all top 25 ranking companies named in the Cof the 2014 CIMdata NC Market Analysis Report (MAR), NC Market report. the twenty-third annual study of the global Numerical Control Headquartered in England, Vero Software designs, (NC) market. CIMdata estimates that based on end-user develops, and supplies CAD/CAM/CAE software. The company’s payments, the worldwide NC software and related services brands include Alphacam, Cabinet Vision, Edgecam, Machining market grew by 5.4% in calendar year 2013. The estimated Strategist, PEPS, Radan, Smirt, Surfcam, WorkNC and VISI. end-user payments grew from $1.56 billion in 2012 to Vero sells and supports its range of products through its $1.64 billion in 2013. The market growth rate reflects solid direct offices in the UK, Italy, France, Germany, Netherlands, overall NC spending, continuing the recovery from the downturn USA, Brazil, India, Japan, South Korea and China, and through in the global economy. CIMdata projects that in 2014 growth in a comprehensive global reseller network across more than manufacturing will continue 45 countries. and end-user payments for CAM Software is used NC software will increase by to generate machining 6.3% to $1.74 billion. programs corresponding Since 2002, the NC to part designs. Short for software market has shown “computer-aided modest but steady growth as manufacturing,” CAM creates global economies generally these programs for CNC improved. There has been machine tools including worldwide growth in the sale of machining centers, lathes machine tools and manufacturing and EDM machines. output, greater emphasis has Sometimes, machining been placed on the efficient programs can be written operation of machine tools and input manually, right as manufacturing firms have at the machine’s control. strengthened their competitive However, if the workpiece positions and the overall PLM geometry is at all complex, (Product Lifecycle Management) Market share of NC providers based on industrial seats installed or if the machined features market, of which CAM software (source: CIMData) are numerous, then generally is a component, has continued CAM software is essential on a strong growth path for generating the program during this period. CAM both accurately and quickly. software purchases are related In general, CAM development to all of these factors — has proceeded along two particularly machine tool sales. different tracks. Geometry- The size and growth of based CAM systems used in the NC software and related die/mold machining and other services market based on applications focus on complex end-user payments is shown in milled geometries. Algorithms the chart below. It can also be provide specific and efficient seen that approximately one- ways for machining complex third of the end-user payments geometries with both high result in reseller revenues and precision and long tool life. By approximately two-thirds of the contrast, feature-based CAM revenues are payments made systems are generally used directly to software suppliers. in the production machining of geometrically simpler Report lists Vero as top Market share of the largest components. These latter CAM software supplier NC Providers by Direct Revenue (source: CIMData) CAM systems are often The CIMdata report details engineered to automate how Vero has more than double the number of installed otherwise repetitive programming tasks such as assigning software licenses than any other software vendor and similar tools to similar features. represents more than 20 percent of market share in the The 2014 version of the NC MAR is a 120-page report CAM-focused software business. containing 22 charts and 39 tables of data detailing the In addition, CIMdata found that Vero was again able to worldwide NC market along a number of dimensions. It also increase its market share in terms of direct revenue. includes a discussion of trends in the CAM industry and The company’s share of vendor direct revenues grew to more updates on the top CAM solution providers. The 2014 CIMdata than $110 million, representing a market share in excess of NC Market Analysis Report is available for purchase at: 10 percent, with further growth predicted for 2014. http://www.cimdata.com/en/research/plm-market-analysis- Finally, with a growth rate of 49.3 percent, the CIMdata report-series.

76 METALWORKING NEWS v 13. 4 September 2014 Hexagon acquires Vero Software

exagon AB, a leading global provider of design, manufacturing efficiencies with high-quality output. measurement and visualisation technologies, has Several well-known brands in Vero Software’s portfolio Hannounced the acquisition of Vero Software, a world include Alphacam, Cabinet Vision, Edgecam, Radan, leader in SURFCAM, VISI, and WorkNC. The company has large market Computer Aided coverage with offices in the UK, Germany, Italy, France, Japan, Manufacturing USA, Brazil, Netherlands, China, Korea, Spain and India (CAM) software. supplying products to more than 45 countries through its Vero Software wholly owned subsidiaries and reseller network. is a UK-based The acquisition strengthens Hexagon’s software offerings, software providing the means to close the gap of making quality data company with a fully actionable by extending the reach of the newly developed strong brand and MMS (metrology planning software) to include CAM proven customer (manufacturing planning software). satisfaction track “Together with its unique suite of manufacturing software record. Their solutions, Vero Software has the expertise, knowledge and software aids the resources to deliver even higher levels of productivity to our design and customers,” said Hexagon President and CEO Ola Rollén. manufacturing “Leveraging our global footprint, the synergies from our process with combined technologies will advance our strategy, supporting solutions for the growing need to integrate all data and processes across programming the manufacturing lifecycle.” and controlling Vero Software will be fully consolidated as of machine tools, August 2014 (closing being subject to regulatory approval) addressing the and will positively contribute to Hexagon's earnings. rising challenge The company's turnover for 2013 amounted to of achieving approximately 80 million Euro.

METALWORKING NEWS v 13. 4 September 2014 77 EuroBLECH 2014 – The technological showcase for the sheet metal working industry

rom 21-25 October 2014 the international sheet metal downloadable application form and information on all working industry will meet again for its leading industry other requirements. Ffair EuroBLECH 2014 in Hanover, Germany. A total of Besides your passport (must contain at least two empty 1,550 exhibitors from 40 countries will put their innovative pages), cash to pay for the visa and specific photographs, you products and services on display in eight exhibition halls. will require the following documents if you are applying for a As the technological showcase and business barometer business visa. Don’t overlook these because you will be turned of the sheet metal working industry, EuroBLECH offers its away. audience a comprehensive overview of the prevailing • Document confirming employment situation technological trends. For companies in sheet metal working • Document reflecting the nature or purpose of looking to find suitable machinery and smart solutions for the trip modern production, the exhibition is the key global event. • Documents confirming sufficient funds are available Visitors can find an extensive product range, from conventional for the trip systems through to advanced, high-tech processes and also • Flight-ticket and proof of accommodation gain an overview of what is available worldwide. • International medical insurance Production processes in sheet metal working have, once again, strongly advanced over the past two years. Solutions Important: Your trade show exhibitor stand confirmation offering more flexibility, higher precision and excellent quality or visitor entrance ticket, along with the proof of payment/ are high on the agenda of manufacturing companies. The use invoice, serves as your invitation letter and these documents of automation and robotics in sheet metal working continues must be submitted along with all other documentation to grow. Lightweight construction and laser processing are required by the consulate. continuously creating innovation in the field of sheet metal working. EuroBLECH 2014 Trade Fair Travel and Metalworking The show profile of the 23rd International Sheet Metal News travel package Working Technology Exhibition represents the entire sheet For details on the Trade Fair Travel and Metalworking News metal working technology chain: sheet metal, semi-finished tour contact Peter Stephenson on TEL: 031 916 1414 or and finished products, handling, separation, forming, flexible visit www.tradefairtours.com sheet metal working, joining, welding, tube / section processing, surface treatment, processing of hybrid structures, Technology sectors by hall tools, quality control, CAD/CAM systems, factory equipment EuroBLECH takes place at the world's largest exhibition and R&D. grounds in Hanover, Germany. The EuroBLECH exhibition EuroBLECH 2014 is open from Tuesday, 21st October covers the entire sheet metal working technology chain within to Friday, 24th October 2014, from 09.00 – 18.00 and on halls 11, 12, 13, 14, 15, 16, 17 and 27. The following are Saturday, 25th October 2014, from 09.00 – 15.00. where you can find the various technologies and the map gives you an easy reference. Keep informed with social media • Sheet metal, semi-finished and finished products EuroBLECH 2014 is present on many social networks (ferrous/non-ferrous) Halls 16, 17 including Twitter, Facebook, YouTube, Foursquare and • Handling technology - Halls 16, 17, 27 LinkedIn. Follow our social media pages and always keep • Separation technology - Halls 11, 12, 14, 15, 16, 17 up-to-date with EuroBLECH 2014. The official hashtag for • Forming technology - Hall 27 Twitter is #euroblech. • Flexible sheet metal working technology - Halls 11, 12, 14, 15, 16, 17 Visas for visitors • Tube / Section working - Halls 11, 14, 15 All visitors travelling on a South African passport need a • Processing of sheet metal / plastic hybrid structures - Schengen visa. Since November 2009, the German consulates Halls 13, 16, 17, 27 based in South Africa, have implemented a new appointment • Machine elements and components - Halls 11, 12, system to eliminate applicants standing in queues. Please 14, 15, 16 book your appointment 6-8 weeks in advance of your trip to • Joining and fastening technology - Hall 13 avoid unnecessary stress and disappointment. Although a visa • Surface technology for sheet metal / plate currently may take 5 working days, or longer, to process, you (process-related) - Hall 13 have to consider obtaining an appointment as well. • Tool technology for sheet metal / plate working - Please note that all Schengen visa applicants must appear Halls 13, 27 in person in order to fulfill the latest biometric requirements. • Process control and quality assurance - Halls 11, Appointments can be made online at www.visa-germany.co.za 12, 14, 15, 16 or Tel: 0861 00 22 45. The appointment incurs a fee as does • Data processing (hardware and software) - the Schengen visa - please visit the website for the latest Halls 11, 12 prices. • Factory and warehouse equipment, safety at work, The following link will refer you to the web link environment protection - Halls 11, 12, 13, 14, 15, of the German consulate closest to you: 16, 17 http://www.visa-germany.co.za. Once you have made • Services, information and communication - your selection, refer to the visa section for the Halls 11, 12, 13, 16, 17, 27

78 METALWORKING NEWS v 13. 4 September 2014

Autonomous living

ust a few years ago, the very concept of a self-driving car environmental benefits.” That was the statement Mark Fields, was the stuff of science fiction. Ford Motor Company’s CEO, made at the Washington, D.C. J However, in the past year alone, technologists have Auto Show in January of this year, in connection to Ford’s made huge strides in developing autonomous vehicles, with announcement that it was joining two U.S. universities to varying levels of operational autonomy now being tested. launch research into automated driving technology. Yet, much of the underlying technology required to build truly There is no doubt that within the next two decades fully autonomous vehicles, such as cameras, sensors, radars and automated vehicles and advanced vehicle-to-vehicle imaging systems is already available. We already let aircraft communications will be a major part of the transportation and ships make decisions and pilot themselves. What’s the red industry. Indeed, much of the technology is already here light holding up cars? (think Google’s driverless car), but in the next few years the Clearly, more autonomous cars that build on a few rate of advancement in this technology will accelerate. fundamental technologies are a feature of the near future. Autonomous technology has already had a significant Google has already logged more than 700,000 accident-free impact on the manufacturing industry. Technologies such as miles in its self-driving cars on the streets of Mountain View, vehicle-to-vehicle communication systems, road monitoring California, without the assistance of a human driver. General capabilities and adaptive cruise control are influencing Motors, Toyota, Mercedes-Benz, Audi, BMW and Volvo are all changes on the machine shop floor. Just like vehicles, testing their own full or partially autonomous systems. machine-to-machine communication, and machine and shop Volvo has demonstrated its ‘autonomous valet parking cars’ in floor monitoring systems are playing a bigger role in machine Europe, and Nissan has said it intends to launch autonomous shops. Increasingly, we are seeing machine-to-machine cars by 2020. communication platforms such as MTConnect, THINC and The move towards the development of autonomous associated software application technologies emerge on vehicles, however slow, is inevitable and is likely to progress machine shop floors of large and medium sized companies. with incremental developments such as advanced driver Adopting these growing autonomous technologies is not assistance systems, park assist systems, integrated vehicle just smart thinking, but a smart investment in the future of health monitoring and autonomous systems. your manufacturing business. In the race to be the best in the By 2025, a commute to work may become something global manufacturing industry, these emerging technologies people look forward to if the automotive industry is able to will become an essential ingredient in the recipe for success achieve its plans to sell commercially viable autonomous for Canada’s manufacturing sector. vehicles. While your vehicle made its way to your office, you If you want learn more about these emerging technologies, could enjoy your café latte, work on your laptop and talk on your IMTS - The International Manufacturing Technology Show is a cell phone with no worries about being pulled over for breaking good place to start. As North America's largest manufacturing the law. And better yet, your vehicle could pull into that tight trade show, it is one of the best platforms to see manufacturing parking spot or perform a parallel park perfectly the first time. innovations in action. “In the long term, we see a future of connected cars that Mary Scianna is the Editor of Shop Metalworking Technology communicate with each other and with the world around them Magazine. A version of this column appeared in the June 2014 to improve safety, reduce traffic congestion and achieve major issue of Shop Metalworking Technology Magazine.

The DOMI autonomous car is a standout in the concept field, combining self-driving cars with a unique design that flips automotive interiors on their head. Designed by a South Korean team, this “pod car” won the 2014 Michelin Challenge Design, took a silver prize in the Hyundai Pinup Design Competition, and won 1st place in the APM Shopping Center, a Korea promotion video competition

80 METALWORKING NEWS v 13. 4 September 2014

Amazon launches 3-D printing store

'With 3-D printing, a customer's wants are no longer limited to what is in stock but instead by what they can imagine.'

mazon has announced potentially infinite number of the launch of an online products at great prices across Astore for 3-D printed many product categories." items to allow consumers to The new store also allows customise and personalise designers the opportunity to items like earrings, pendants, offer new items that can be dolls and other objects. The store customised. Consumers will be offers more than 200 able to view the item from any items including nylon wallets, angle with a 360 degree rotate wax seals, cookie cutters and view. bobbleheads. Amazon will work with "The introduction of our companies that make 3-D printed

"The online customer shopping experience will be redefined through 3-D printing. When you take into consideration the investment needed for manufacturing products, 3-D printing offers a cost effective alternative that benefits customers by limitless product options," said Sculpteo co-founder and chief executive Clement Moreau

3-D printed products store suggests the beginnings of items including Mixee Labs and the French-based Sculpteo. a shift in online retail - that manufacturing can be more "The online customer shopping experience will be nimble to provide an immersive customer experience. redefined through 3-D printing. When you take into Sellers, in alignment with designers and manufacturers, consideration the investment needed for manufacturing can offer more dynamic inventory for customers to products, 3-D printing offers a cost effective alternative personalise and truly make their own," said Amazon's that benefits customers by limitless product options," said Petra Schindler-Carter in a statement. Sculpteo co-founder and chief executive Clement Moreau. The store "allows us to help sellers, designers and "With 3-D printing, a customer's wants are no longer manufacturers reach millions of customers while providing limited to what is in stock but instead by what they can a fun and creative customer experience to personalise a imagine."

Iscar Ltd. partners with Machining Cloud GmbH

aving direct access to the Iscar cutting-tool product access to a rich set of software features including selector, data on the cloud reduces the frustration and time configurator, job management, reporting and commerce. "Hassociated with obtaining the tooling information Through the Machining Cloud, Iscar's product data - needed for running their CAM systems, tool-management descriptive, usage and geometric information and application software, cutting-tool presetters and machine tools," says knowledge - will be more accessible to a larger group of its Stephane Julien, Cloud Evangelist for Machining Cloud GmbH. customers and may be transferred directly into their "This collaboration helps Iscar customers to increase data-hungry shop equipment. their productivity by offering instant access to the company's "This partnership will create significant value and time complete and up-to-date cutting tool data, without the hassle savings by providing a solution to facilitate the flow of of searching through printed catalogues and various websites product data from Iscar to their customers," says to find ideal tooling and then manually entering the data into Meir Noybauer, Business Development Manager at the shop's software." Iscar Ltd. Machining Cloud's mission is to provide the manufacturing "The cloud-computing technology that has dramatically community a single-source of access to complete and changed the shape of industries such as music, television, up-to-date product data from leading manufacturers of news, social networking and many others is now materialising cutting tools, machine tools and workholding. Using the in the metalworking market with Machining Cloud." Machining Cloud tablet and desktop apps, users have For further details visit www.iscar.com

82 METALWORKING NEWS v 13. 4 September 2014 product review Sandvik Coromant unveils easy-choice, secure tapping series

CoroTap™ -XM simplifies tapping in multiple materials.

he new CoroTap™ –XM is an easy-to-select range of three different grade options available in CoroTap –XM to taps for customers faced with working in a multitude meet almost every requirement across all industry segments, Tof materials and/or the need to switch almost including general engineering, automotive (transfer lines) and constantly between medium and small batch sizes. subcontracting. The flexibility of these innovative taps is a result of optimized Other drivers behind the development of this innovative grades and unique geometry created especially for working product range include the lack of non-optimized cutting data in ever-changing machine shop environments. with existing tap generations and the requirement to minimize run-in times for new components. Of course, another Secure, stable, flexible advantage of deploying a tap suitable for Achieving maximum productivity in holemaking multiple materials is the associated operations is always a high priority. When working in reduction in tool inventory and costs. various workpiece materials and switching between batch sizes, keeping machine stops few and short is highly Design innovation important. By introducing CoroTap –XM, Sandvik Coromant Providing a long and consistent is making sure that the potential for maximum productivity is tool life, the spiral flute design of achieved through total machine utilisation. CoroTap T300–XM secures a constant CoroTap –XM reduces the time spent on set-ups rake angle for continuous cutting and can be used in a range of applications whenever processes. Furthermore, high spiral customers need a secure, stable and flexible angles ensure excellent chip evacuation. process. With easily applied cutting data, these The CoroTap T200-XM has a superior gun taps deliver high productivity and robust nose to help reduce torque and improve machining potential. thread quality. For this reason, CoroTap –XM can be applied to both through-holes Three grade choices and blind holes to depths of up to Depending on customer demands, there are 2.5xD.

Sandvik Coromant is to host a series of business seminars at its Productivity Centre in Jet Park, Gauteng. The first of these took place in June 2014 and the focus was on gear milling, an event where participants could discover the capability of CoroMiIl®170 and CoroMiIl®176 entitled: Discover the capability of CoroMill®176.The seminars will make available new advanced knowledge and production methods that will allow manufacturers to reduce cost while maintaining high quality standards. Presentations and demonstrations will provide new product information, technical solutions and processes in a variety of metal cutting areas. The programme will include modern cutting tools and application techniques. At the event were Arno Minnie of Sandvik Coromant, Franz Studer of Retecon, Ken Pitter of Factoria Engineering Works, Henrik Nydahl of Sandvik Coromant Sweden, Julian Burns-Thompson of Sandvik Coromant and Doug Pitter of Factoria Engineering Works

84 METALWORKING NEWS v 13. 4 September 2014 In terms of hardness, the taps are suitable for materials that assortment and introduces the new grades GC4315 up to 350 HB. and GC3330. All three grades feature Inveio that brings endurance, predictability and long tool life to the machining Inveio™ for steel turning and cast iron milling process. Sandvik Coromant has introduced new insert grades for steel turning and cast iron milling with Inveio; the technical The technical breakthrough breakthrough in material science that provides inserts with The performance of these grades is made possible by exceptional wear resistance and tool life. the Inveio uni-directional crystal orientation. Normally, the In today’s manufacturing, predictability is becoming crystal orientation in inserts’ CVD alumina coating is random. increasingly important. Production that runs smoothly, The breakthrough came when Sandvik Coromant found without unexpected interruptions, opens the way for secure a way to control the crystals, making them all line up in unmanned production and high machine utilisation; the same direction – towards the top surface. These a cornerstone for profitable production processes. tightly-packed crystals create a strong barrier towards the Following the successful introduction of the insert grade cutting zone and chip. GC4325 in October 2013, Sandvik Coromant now extends The result is grades with incredible wear resistance and cutting edges that stay in shape for long times in cut. The long, predictable tool life of GC4325, GC4315 and GC3330 enables secure unmanned production with high metal removal rate.

Application area GC4325 is the first choice grade for steel turning. When GC4325 reaches a limit in metal removal rate due to high speed and long time in cut, GC4315 withstands the high cutting temperatures that occur. GC3330 is the first choice grade for milling in cast iron materials. For further details contact Sandvik Coromant on TEL: 0860 101 008 or Mary-Ann Germishuys on TEL: 011 570 9615 or email: [email protected] or visit www.sandvik.com

METALWORKING NEWS v 13. 4 September 2014 85 The new size for entry level five sided machining – DMG Mori DMU 70 ecoline

ith the DMU 70 ecoline, DMG Mori is now offering is automation-ready. The user can choose between two a further high-accuracy universal milling machine CNCs: Siemens 840D with Operate 4.5 and Heidenhain for 5-sided machining of simple to highly complex TNC 620 – both integrated into the ergonomic W ® workpieces in the entry-level sector alongside the highly SLIMline Panel. popular DMU 50 ecoline. For further details contact Retecon Machine Tools on With longer travels and more powerful spindles, the TEL: 011 976 8600 or visit www.retecon.co.za DMU 70 ecoline continues the successful concept of 5-sided machining for price-conscious and quality-oriented users. Following the success of the DMU 50 ecoline, DMG MORI is now offering a universal maestro in its entry-level range in the form of the DMU 70 ecoline, which, with significantly longer axis travels of 750 × 600 × 520 mm in X / Y / Z, also enables complex workpieces to be machined precisely and efficiently. Furthermore, the machine features digital drives and hydraulic clamping. A powerful 12,000 rpm milling spindle as well as rapid traverse rates of 24 m/min in the linear axes ensure high performance, while the 32-pocket SK40 chain tool magazine with double gripper provides the necessary versatility. Moreover, the machine comes with a 3D quickSET for precision calibration of the machine kinematics and

Hypertherm introduces HyPrecision Waterjet, a complete line of waterjet products with Advanced Intensifier Technology

ypertherm has announced the provided an opportunity to learn where introduction of HyPrecision Waterjet, and why failures occurred. These Ha complete line of waterjet products. experiences led him to create his own These products include pumps ranging waterjet system and continually from 15 to 150 horsepower, precision refine and improve it through the cutting heads, and abrasive delivery years.” equipment. The announcement is the Examples of the practical engineering result of Hypertherm’s acquisition of found only in HyPrecision waterjet pumps AccuStream, whose background and include optimized plunger length and expertise in waterjet cutting started in diameter, combined with long bearing the mid 1980's with the development, engagement for better alignment, application and sale of waterjet products. resulting in maximum component life with The systems feature Advanced minimum pressure fluctuation and Intensifier Technology to extend placement of hydraulic rod seals and maintenance intervals, reduce plunger bearings outside the hydraulic maintenance time and maximize end cap for easier access and performance. Hypertherm estimates the servicing. The addition of an advanced total cost of ownership for a HyPrecision piston design minimizes seal wear and system is up to 20 percent less than greatly extends part life. competitive systems, resulting in Hypertherm HyPrecision Waterjet increased profitability for customers. systems are part of Hypertherm’s Built for “The inventor of HyPrecision waterjet ran his own job shop Business Integrated Cutting Solutions in which Hypertherm’s for many years seeing first-hand what could and did go wrong ProNest nesting software, computer numeric controller (CNC), with the systems he was using,” explained Sara Mancell, THC, and HyPrecision Waterjet work together to automatically Hypertherm’s waterjet marketing manager. “That, combined apply the right cutting parameters and adjust things like the with more than a decade of experience designing waterjet feed rate, abrasive flow rate, pump pressure and more. equipment, drove him to develop replacement parts for a Learn more about HyPrecision Waterjet by visiting variety of systems. The knowledge gained selling those parts www.hypertherm.com/waterjet

86 METALWORKING NEWS v 13. 4 September 2014

Victor Vcenter-AX350 advanced 5-axis vertical machining center

he Victor Taichung AX350 VMC is a fully simultaneous With the innovative mechanism “Roller CAM Driver” 5-axis machining centre. Driven by a Fanuc control inside, this non-backlash 5th axis table guarantees high Tsystem, this machine is built utilising the strengths machining accuracy and reliability. A supreme rigid and already established on the two, three axis VMC ranges. tough column enables the Z-axis acceleration of 0.75G. The advanced 5-axis application (by integrating a trunnion CAE (Computer Aided Engineering) design with a span of table into a Vcenter-A72) has lowered the table surface 700 mm in the Y-axis, results in a maximum stiffness to to facilitate the loading of larger and heavier parts than ensure the minimum overhang distortion for the whole by fitting a 5th X-axis traveling range of 720 mm and 350 mm on axis table the tilting rotary table. onto a The machine comes with a directly-coupled spindle 3-axis VMC. (DCS) with a high torque spindle motor to avoid the vibration and enhance the surface finish on components. The 15 000 rpm spindle speed with chiller and high torque output accommodates both heavy cutting at low rpm and high speed machining. The AX 350 is equipped with a fully integrated 2-axis tilt/turn table, providing engineers the platform to machine both 3 + 2 and full 5-axis. The machine is constructed as a Fixed column C-framed VMC with high rigidity for heavy cutting, with the offering of either a 12000 or 15000rpm spindle and high rapid feeds. The machine also has a Large Z-axis travel which is preferable for the tilting table concept. The tilting table offers a workpiece capacity of 170 mm or 250 mm diameter. The axes travel on the machine is XYZ of 650 x 480 x 540 mm. For further details contact Victor Fortune on TEL: 011 392 3800 or visit www.victor.co.za

TaeguTec’s ApexMills offer economical solutions

aeguTec is now offering economical solid carbide line comes in a diameter range from 3 to 20 mm while end mills for general purpose machining on small optimised grades applied to the end mills includes the TT5525 Tdepths-of-cut applications. The ApexMill economical grade for flat types and the TT5515 grade for ball nose types. type’s two and four flute flat end mills are offered in Its strong rigid design increases productivity and various lengths to cover a wide stabilises the machining range of roughing and finishing operations. application on various materials In one case study conducted such as alloy, carbon, cast iron, at TaeguTec’s headquarters, the tool, stainless, hardened and ApexMill recorded a 100 percent pre-hardened steels. increase in tool life versus a For slotting applications, the leading competitor’s similar tool. new offering is also available in During another case study in three flute flat end mills, which which, like the other test, all include a high helix angle. The cutting conditions were the same, short and medium two flute ball TaeguTec’s ApexMill witnessed a nose end mill type is specifically 25 percent increase in tool life. suited for shops looking to save on For more information cost on semi-finishing and finishing contact TaeguTec SA on applications. TEL: 011 362 1500 or visit TaeguTec’s ApexMill economical www.taegutec.com

88 METALWORKING NEWS v 13. 4 September 2014

A-Tap - new product that showcases OSG's 75 years

he A-Tap is an all-purpose tap series designed to simplify these problems, customers often have to compromise tool management and to excel in a wide variety of efficiency and would run their taps at much slower speeds, Tmaterials and applications. The A-Tap is made from even when their machining centers were capable of higher powdered metal HSS and has OSG's patented V coating to performance. With this in mind, our goal was clear. We needed achieve excellent wear resistance. The spiral flute series has to develop a tap with zero evacuation trouble so as to allow adopted a variable helix flute design, which encourages stable our customers to achieve maximum performance based on chip evacuation and reduces cutting forces. The spiral point their machining center's capability.” series has unique geometry that enables greater chip control For further details contact Pilot Tools on that can help produce tightly compacted chips for easy TEL: 011 607 1800 ejection from the hole. The developer of the A-Tap®, Takayuki Nakajima, explains the concept behind this series in detail – “OSG turned 75 in 2013. In celebration of our 75th anniversary, I developed the A-Tap® as the first of a number of new products to help us advance toward OSG's 100th anniversary. OSG offers a number of all-purpose tooling such as the EX series, TIN series, V series, and now the A-Tap series. The A-Tap is one of our greatest innovations in the last 20 years since the V series. The biggest advantage of the new A-Tap® series is its versatility. It is engineered to excel in any material, any application, anytime!”

A-Tap® 's inspiration “After a careful analysis of our customers' feedback on common tapping problems, we have discovered that the top three tapping issues include "chipping and breakage," "dimensional errors," and "galling." All of the mentioned problems are caused by the inability to evacuate chips effectively, creating conditions such as bird nesting. To avoid

SMTCL Brio Miller 8 vertical machining center

MTCL’s Brio Miller 8 CNC vertical machining center spindle box are made of high-strength resin bonded sand is available for machining complex parts demanding casting. All structural components are optimised to improve Shigh precision such as plates, discs, shells and rigidity and stability. Vibrations and deformations generated moulds. It performs a series of processes like milling, by cutting forces are effectively minimized. Guide way pairs drilling, tapping, boring, reaming and contouring. Main use roller-type linear guide rails, which have the advantages components such as bed, table, slide carriage, column and of minimum friction, high sensitivity, low vibration at high speed, no creep at low speed and high positioning accuracy. Thus the accuracy and stability of the machine are highly improved. The servo motors are directly coupled to the high precision ball screws via flexible couplings to achieve seamless transmission. Thus, feed flexibility, positioning accuracy and transmission precision are enhanced. The Z axis servo motor featuring automatic brake function holds the motor shaft when power shuts down. Standard features are a Siemens Sinumerik 808D control, an auto lubrication system, an umbrella-type tool magazine and a chain-type chip conveyor. The Brio 8 is said to shorten your production period, improve precision, reduce labour costs, reduce tooling investment, maximise floor space and reduce energy usage You can view this machine at the Electra Mining Exhibition 14 to19 September 2014 in Hall 9 stand D14 at the Harp Machine Tools stand. For further details TEL: 011 918 5138 or visit www.harp.co.za

90 METALWORKING NEWS v 13. 4 September 2014

Edgecam 2014 R2 released

Vero Software has launched Edgecam 2014 R2 with features that enhance functionality, such as Adveon integration, an updated Workflow, direct tooling information and job reporting.

ew functionality in Edgecam 2014 R2 includes Nautomatic conversion of 2D design data to a 3D model, and other significant enhancements to Edgecam Worfklow, from the user interface to improved automatic machining processes. In addition to the 2D to 3D for Part Modeller feature, Edgecam 2014 R2 includes a new Edgecam Workflow Solids modeller, comprehensive machining strategies in Edgecam Workflow, and dynamic co-ordinate system creation. Job reports are also now available on portable devices. The 2D to 3D for Part Modeller ensures old 2D legacy design data can be used in Edgecam Workflow without the need for total part re-modelling. A 2D drawing can Edgecam Workflow has been enhanced in all areas, with now be converted automatically into a 3D model quickly and the inclusion of EWS, customisable ribbon bars laid out in a accurately by simply selecting the views and tracing the part logical process order, and improved machining strategies to outline. enable toolpaths to be generated quickly and efficiently while Edgecam Workflow Solids (EWS) offers a fast and simplistic considering the component stock, fixtures and material. approach to creating simple CAM-ready 3D solid models, Dynamic co-ordinate system creation provides an delivering standard modelling functions such as extrude, interactive way of creating construction planes (CPLs), by revolve, and blend, supported by parametric sketching. simply dragging the CPL marker from the bottom left of the A feature wizard allows for the rapid creation of specific screen onto a face, vertices or edge, and the CPL marker hole types. An interactive story board means users can remodel automatically snaps and orientates as required. Dragging the and edit the original design by quickly selecting the process to marker over the model instantly offers options of alignment be edited, and re-applying the changes. and location, making it easy to find the preferred origin.

Edgecam Workflow has been enhanced in all areas, with the inclusion of EWS, customisable ribbon bars laid out in a logical process order, and improved machining strategies to enable toolpaths to be generated quickly and efficiently while considering the component stock, fixtures and material

Edgecam 2014 R2 will be the first CAD/CAM platform to integrate Sandvik’s Adveon Tool Library. Adveon is a single tool library, managing tools from a number of manufacturers, and guarantees accurate geometrical information. While the engineer’s input is reduced, users can rapidly build tooling databases, and have access to 3D CAD models for accurate simulation and visualisation. For more information contact Stillam on TEL: 011 663 2600 or visit www.stillam.com

92 METALWORKING NEWS v 13. 4 September 2014

Renishaw introduces surface finish measurement for CMMs with new probe for Revo® five-axis system

enishaw’s new SFP1 probe option for the Revo® five-axis surface data is acquired. This enables flexible access to measurement system is the first to allow surface finish component features, combined with the consistency of fully Rinspection to be fully integrated within coordinate automated CNC control. Using the straight stylus, the SFP1 measurement routines. With a measurement capability of can perform a measurement trace within a 10 mm diameter 6.3 to 0.05 Ra, the SFP1 surface finish probe makes the bore to a depth of 100 mm. CMM a “single platform” metrology system. It eliminates A skidded probe with a 2 µm radius diamond stylus tip, the the need for hand-held surface SFP1 probe outputs Ra, RMS and measurement devices or transporting raw data formats to the metrology parts to a dedicated surface application software via Renishaw’s measuring machine, reducing labor UCCServer software, using the costs and inspection lead times. ++ DME protocol. The raw data can The system allows automated subsequently be presented to switching between dimensional specialized surface analysis software measurement and surface finish for more detailed reporting. measurement, with the analysis contained in a single report. Automated surface finish The SFP1 probe is a fully probe calibration integrated option for the Revo 5-axis Calibration of the probe is also measurement system, supplied with automated under the CMM program. two dedicated styli, straight and A surface finish calibration artifact cranked, which are selected via the (SFA) is mounted on the MRS rack measurement program control using the system’s modular rack and is measured using the SFP1 probe. Software then adjusts system (MRS). The probe incorporates a C axis that, combined parameters within the probe in accordance with the artifact’s with the infinite positioning of the Revo head and choice of calibrated value. stylus holders, allows the probe tip to be automatically oriented For more information about Renishaw’s CMM probe systems, to any angle to suit the part, ensuring that the highest quality software, or CMM retrofit service, visit www.renishaw.com/probes.

Hurco’s five-axis machine with large work zone

urco’s five-axis VMX42SRTi milling center has a said to reduce cycle time flush-mounted, direct-drive C-axis rotary table that by 30 percent while Hprovides a larger work zone than other models, the improving part company says. surface Hurco’s five-axis VMX42SRTi milling center has a finish. flush-mounted, direct-drive C-axis rotary table that provides a The larger work zone than other models, the company says. The company embedded rotary table design offers 89 mm of added Z-axis also offers capacity for five-axis work. For three-axis work, the increased its Max5 table size supports parts as large as 1065 x 610 mm. control The XYZ travels measure 1065 x 610 x 610 mm with rapid console, traverse rates of 35, 35 and 30 mpm. The machine has a the HBMX55i 12,000-rpm spindle; a 40-station, swing-arm automatic horizontal bor- toolchanger; and the company's integrated control that ing mill, includes both conversational and NC programming modes. the three-axis VMX6030i, In addition, the machine features the five-axis, high-speed UltiMotion, the company's motion VMX30UHSi, the five-axis VM10Ui, control system designed for the three-axis, high-speed longevity and rigidity with larger VMX42HSi, the three-axis VM20i linear rails that are wedge-locked with rotary table, the three-axis to the frame to reduce vibration. VM5i, the TMM12i turn-mill lathe The control uses software and the TM8i lathe. algorithms for motion planning For more information instead of conventional contact Hurco South Africa on hardware, optimizing look-ahead by TEL: 011 849 5600 or visit as much as 10 000 blocks, and is www.hurco.co.za

94 METALWORKING NEWS v 13. 4 September 2014

Iscar’s latest developments in parting and grooving systems

hrough the work of the company’s prolific R&D The high-quality IC5400 and the IC808 Sumo-Tec grade Department, and prompted by the evolving needs of blades feature an engraved ruler to assist in overhang Tglobal industry, each year Iscar introduces a multitude of adjustment and are supplied in standard sizes, which fit advanced new cutting tools. This desire to provide customers Iscar's blocks. with the very latest, most efficient metal cutting technology is reflected in the recently launched additions to Iscar’s Penta-IQ-Grip - A five star pentagonal parting and comprehensive Grip range of parting and grooving tools. grooving insert for up to 20 mm depth of cut Following the successful Tang-Grip- A unique tangential introduction of the Penta 24 and single ended insert with a Penta 34 inserts, Iscar has recently revolutionary clamping method introduced the latest evolution of Iscar's Tang-Grip is a high quality, the renowned Penta family - single-ended insert that was Penta-IQ-Grip. developed to enable highly efficient As the Penta prefix suggests, parting. A revolutionary secure Iscar’s advanced new parting insert clamping method using a tangentially boasts 5 cutting edges. Penta-IQ-Grip orientated pocket provides pocket life inserts, available in 2 and 3 mm three times that of any other widths, are ideal for parting up to a conventional self-grip system. 40 mm part diameter or up to a Tang-Grip’s robust clamping method 20 mm depth of cut. enables machining at high feed rates An innovative dovetail wedge and provides excellent straightness clamping system ensures very and surface finish characteristics. stable Penta-IQ-Grip insert Iscar’s latest Tang-Grip clamping, secure edge indexing innovation is the introduction of highly and rapid insert replacement. In economical blades. Tang-Grip flat top addition, the robust structure economical blades now feature four enables the application of high pockets compared to the previous machining parameters, resulting version which had two pockets, whilst in reduced cutting time. In the integral shank tools feature two addition to guaranteed performance pockets compared to its predecessor advantages, Penta-IQ-Grip provides which had just one pocket. excellent straightness and surface By doubling the number of insert finish characteristics in parting pockets the advanced new shank applications. tools and blades deliver the Penta-IQ-Grip outclasses all other cost-effective advantage of half the self/screw clamping mechanisms price per pocket, when compared currently available, says Iscar. Also, with other tools and blades. No other when compared to competitors’ company is able to offer such an parting inserts that have more than economical advantage, says Iscar. two cutting edges, Penta-IQ-Grip The new Iscar's Tang-Grip blades provides double the depth of cut. and tools are extremely rigid and Iscar’s advanced new are capable of bearing heavy tooth Penta-IQ-Grip is able to outperform loads (high feeds), resisting lateral competitors’ single, double, or loads and delivering excellent surface triple-edged inserts for grooving and straightness. The 35 mm blades, parting applications, says the which are 30 mm longer than any company. Penta-IQ-Grip assures other standard blades, can be used prolonged insert tool life, at least for deep grooving and parting double that of single, double or triple applications. ended parting inserts. Penta-IQ-Grip Due to Tang-Grip’s flat top inserts are available in three sizes configuration, no chip obstructions for parting: D22 (up to 22 mm part are encountered under all possible dia), D32 (up to 32 mm part dia), machining conditions. and D40 (up to 40 mm part dia). D22 and D32 mm sizes can Covering all parting and grooving applications, the Tang-Grip also be used on Swiss-type and small CNC machine tools. range of high quality inserts are available with a large variety All inserts feature C and J-type chipformers to of chipformers with both neutral and angular frontal cutting accommodate a wide variety of machining and material edges. The extensive Tang-Grip range includes blades and applications, Penta-IQ-Grip is produced from grade IC808G, a inserts in 1.4-12.7 mm widths in IC830 and includes an hard, fine grain substrate with excellent chipping resistance, easy to use clamping and extracting device. whilst a TiAlN PVD coating provides impressive wear resistance.

96 METALWORKING NEWS v 13. 4 September 2014 Do-Grip – The one and only double sided twisted parting Jet-Cut Do-Grip vastly reduces or even eliminates built-up insert with no depth of cut limitation edge, especially when machining stainless steel and high In addition to highly efficient parting inserts in single and temperature alloys. double-ended conventional configurations, Iscar offers a Materials such as titanium, inconel, or austenitic stainless unique double-ended twisted geometry for unlimited depth of steel tend to harden during the cutting process and form long penetration. The Do-Grip ranges also include the largest choice and tangled chips. The efficient delivery of coolant to the of parting widths available in today's market, covering all cutting zone by the use of Jet-Cut Do-Grip parting inserts application ranges. Iscar offers a wide variety of chipformers improves chip formation and slashes flank and cratering rates. and the most advanced grades to ensure unbeatable A common problem in grooving and parting applications is performance and extended tool life. that chips can prevent the coolant from reaching the cutting edge, thus reducing the insert’s life. Again, the unique design Jet-Cut – A cool answer to a hot problem - double ended of the DGNC inserts enables the efficient delivery of high inserts with internal coolant provide efficient coolant directed levels of coolant contributing substantially to prolonged to the cutting zone tool life. Iscar now provides the most comprehensive range of When machining materials such as stainless steel or high highly efficient products for all parting and grooving temperature alloys, the temperature near the cutting edge area situations. becomes extremely high. In addition, this kind of material tends Iscar says it fully understands that parting and grooving to adhere to the tools cutting edge, causing built-up edge. operations are extremely important aspects of the turning These problematic phenomena can be moderated by the process. As multiple factors need to be considered in all efficient cooling of the cutting edge. parting and grooving operations, including the machine tool Although the principle of through insert cooling is now being used, the kind of material being parted/grooved, the well established, Iscar’s legendary DGNC inserts, that were required depth of cut and feed and speed rates, Iscar is now specifically designed for the parting and grooving of materials able to supply the most appropriate, highly efficient parting and such as stainless steel and high temperature alloys, deliver a grooving solution in all circumstances with the widest range of range of major advantages. insert geometries, chip breakers, carbide grades and a wide Jet-Cut is Iscar’s Do-Grip high quality parting insert that range of tools tailored for an extensive range of machine tools. features an ingeniously designed internal coolant channel Iscar’s ongoing research and development investments in which passes through the insert. This arrangement ensures parting operations guarantee improved performance for each that the inserts body is internally cooled whilst also delivering cut the company says. an efficient coolant jet close to the cutting edge. For further details contact Iscar South Africa on In addition to providing improved surface finish, the use of TEL: 011 997 2700 or visit www.iscar.com

METALWORKING NEWS v 13. 4 September 2014 97 Yaskawa presents new high-end DX200 controller for Motoman robots

he DX200 controller for Motoman robots from Yaskawa simultaneously in the area where the workspaces of the will be exhibited at EuroBLECH 2014. The new high-end robot and the human operator intersect. The pertinent safety Tcontroller is an extension of the highly successful DX100 standards are met at all times. model with a range of additional options, e.g. safety features, Another new feature of the DX200 is that it has been and offers more than 120 application-specific functions. This designed for simplified integration of peripheral devices by particularly benefits system integrators and industrial end means of corresponding bus interfaces. Using the patented customers who use Motoman robots for Multi-Robot technology, up to eight welding and handling tasks. robots or 72 axes can cooperate in As one of the world’s most synchronized operation. Since each experienced robot manufacturers, robot knows the positions of the other Yaskawa has drawn on the many years robots, the likelihood of a collision is of experience of its engineers for the ruled out. This allows the robot new DX200, building on the service- density per unit of area to be proven quality of the DX100. In this way, maximized. Advanced Robot Motion all the advantages of the successful technology (ARM) ensures high predecessor model have been retained. performance and availability, path Numerous new functions and function control that is setting new industry packages have been added, further standards, and reduced teaching times. simplifying the application-specific Windows CE programming is carried solution and programming of robotic out using a compact colour touch panel tasks. Moreover, the new DX200 is weighing just 990 grams. A range of being market-launched together with application-specific function packages a whole range of new and technically and more than 120 functions simplify enhanced manipulators. not only programming, but also Other new features include the Yaskawa’s new DX200 controller for Motoman commissioning for the end customer. standard and safety-oriented bus robots offers more than Preset application patterns are available systems and the integrated safety 120 application-specific functions for spot and arc welding, for example, controller. The latter transforms the as well as for handling and general tasks. DX200 into a complete Functional Safety Unit (FSU) that Furthermore, the design has been reworked. The housing conforms to category 3, PL d, in accordance with EN and the teach pendant of the DX200 are not only made of ISO 13849-1. With up to 32 definable safety zones and the particularly resilient materials, they are also designed ability to monitor up to 16 tools, it enables smaller working throughout in colours that are insensitive to dirt. ranges and optimal utilization of the production area. Another For more information contact Yaskawa Southern Africa on advantage is that multiple sub-processes can be carried out TEL: 011 608 3182 or visit www.yaskawa.za.com

Feeler FT-Series CNC turning centers

he Feeler FT-Series CNC turning centers line has been ensure a solid machine base with excellent overall structural expanded with the new FT-250SY. The FT-250SY features rigidity and stability. The machine also offers exceptional Ta true Y-Axis with 100 mm (+/- 50 mm) of travel, which capacity with a 30 HP, 3,500 RPM 10-inch (chuck diameter) provides increased rigidity and a more robust machining primary spindle in addition to a 15 HP, 4,500 RPM 8-inch environment. Also, by offering an 8-inch sub-spindle in addition (chuck diameter) sub-spindle. to the primary 10-inch spindle, the The Feeler FT-250SY FT-250SY provides more capacity than offers an XYZ axis travel of competitive turning centers. 210 x 100 x 50 x 795 mm. The For excellent vibration dampening machine comes standard with a when turning in hard materials, premium Fanuc 31i-TB CNC control. including interrupted cutting, the A BMT-65 tool system features a solid FT-250SY features a single-piece interface for tool holding. For maximum structure with boxways, 45-degree machine component longevity, a fully slant bed and robust base. Extra enclosed CE cabinet prevents dust rigidity from a heavy duty 12-station and fumes from entering. turret results in high metal removal For further details contact rates, superb finishes, and ensures Craft Machine Tools on long term accuracy. For maximum TEL: 011 845 2030 or visit integrity, FEA analysis is used to www.craftmachinetools.co.za

98 METALWORKING NEWS v 13. 4 September 2014

Mastercam’s Dynamic Motion technology slashing time, cost, wear

Software simplifies constructing, editing solids.

achining program developer CNC Software Inc. (Mastercam) is Mpromising a new look at its toolpath engine — Dynamic Motion, describing it as a time saver for programmers and machine operators, one that “can slash machine time by as much as 75%.” Dynamic Motion is the title given to a toolpath generating method that Mastercam developed for milling and turning operations. It has said the method results in 20-75% faster machine cycle times, with “dramatically extended” service life for tooling, and reduced wear on CNC machines. It added that Dynamic Motion toolpaths will help machine shops optimize the performance of any machine, tasks. Panels in Mastercam (e.g., the Toolpaths or Solids new or old. Mastercam programs have included Manager), can be hidden automatically to show more Dynamic Motion technology for over five years, though it has graphics at either side of the Mastercam window, or been expanded across the Mastercam suite with successive undocked and placed outside of Mastercam, e.g., on a releases. second monitor. In addition to the time, cost and equipment saving Mastercam X8 includes over 750 new icons that advantages, Dynamic Motion reportedly cuts very hard provide a consistent colour palette that is modern, clean, materials with greater ease. and “colourblind friendly”, the developer noted. The new Mastercam release, Mastercam X8, introduces Mastercam X8 arrives with several toolpath a new solids workflow function that makes constructing enhancements of its own, including multicore processing and editing solids more intuitive than in the past. All of on all 2D toolpaths, “Air Region” chaining to define an open Mastercam’s existing solids functions have been updated to side of a closed region, where tools can safely enter a region reflect the new workflow approach, including a new interface for machining and 3D HST finishing toolpaths with five-axis that allows machine operators to work in the interface and motion for automatic collision avoidance. The stock model on screen, as needed, and a live preview where results of is supported in Mastercam lathe toolpaths now, and the changes can be seen as work continues. Mill-Turn model supports Mill Level 1 for twin turret Solid Direct Editing also has been expanded to simplify machines that do not require surface machining. Also, the process of model preparation. it supports drag and drop for placing tools on locators CNC Software claimed Mastercam X8 improves users loaded on turrets. programming experience (“usability”) and the ability to For further details contact Mecad on 086 111 2236 customise the way that they set-up and operate machining or visit www.mecad.co.za

Tongtai Q5 gang-type CNC lathe, engineered for fast production of small workpieces

he Tongtai Q5 gang-type CNC lathe, a 1 490 x 1 870 mm compact footprint. engineered for fast production of small Optional automation systems can improve Tworkpieces. In addition to a 25 mm the machine’s productivity. One configuration through-spindle bar capacity, the machine combines a bar feeder, part catcher and part features a 6,000-rpm, 5.6-kW spindle motor, conveyor. For longer-term, higher-volume and offers a rapid traverse rate of 30 mpm. automated production, eight-pallet or An 8,000-rpm spindle is also available as an two-pallet gantry-loader-type part stockers option. The turning center’s straightforward are available to handle parts ranging to gang tooling and lack of subspindle further 50 mm in diameter and 38 mm in length. promote fast machining. Tool capacity, For further details contact PBS Machine depending on the workpiece being processed, Tools on TEL: 011 914 3360 or is 4 to 6 ID or OD tools. The machine occupies visit www.pbsmt.co.za

100 METALWORKING NEWS v 13. 4 September 2014

Precision grain technology reinvents grinding wheels - 3M

M is effecting a paradigm shift in South Africa’s metal fabrication, casting and forging industry with its 3Cubitron™ II metallurgical grinding abrasives. Industries that have generally utilised generic, low-grade abrasive technology in metal fabrication, now have access to a product that produces a more consistent finish at a faster rate, over a service life that is at least double that of its nearest competitor, according to the company. The precision-shaped grains in Cubitron II grinding wheels from 3M continuously fracture to form sharp points and edges and help abrasives slice cleaner and faster, stay cooler, and last longer than conventional wheels. 3M Abrasive Systems’ 3M™ Cubitron™ II bonded abrasive grinding and cut-off wheels is a revolutionary new technology that reinvents heat buildup, slower cutting and shorter life. But the grinding process. the precision-shaped grains in Cubitron II grinding With Cubitron II wheels continuously fracture to form sharp points abrasives, users get and edges. This technology helps Cubitron II precision-shaped grain abrasives slice cleaner and faster, stay cooler, and technology that cuts last longer than conventional wheels. faster, stays sharper Cubitron II abrasives offer performance that longer, and requires dramatically surpasses that of traditional grinding less pressure than wheels made with aluminium oxide, alumina conventional grinding zirconia or ceramic grain. In fact, competitive and cut-off wheels. products require up to three times the amount of In addition, the pressure to match the cut of Cubitron II abrasives. abrasives can help With the advantages of this technology, operators reduce operator fatigue are subjected to less wear and tear, and can and increase productivity. This technology is the most remove more material with the same amount of effort. important change in abrasives in the last 20 years. Cubitron™II is available from 3M certified channel Conventional ceramic abrasive grains are irregular in partners across South Africa. For more information, shape and work by “plowing” through metal, which can cause visit www.3M.com or follow @3MNews on Twitter.

Okuma’s LB4000 EX-II CNC lathe accommodates large workpieces

he LB4000 EX-II 2-axis CNC lathe is equipped with architecture THINC®-OSP control allows for ease of operation Okuma’s high power, high torque PREX motor, delivering and integration with other peripheral equipment. A wide Thigh quality machining for heavy to high-speed cutting variety of bed lengths, bore sizes and options, including with a through-hole diameter that can accommodate larger live tooling, sub-spindle and Y-axis, means there is a work pieces. This versatile machine configuration to meet any shop's provides the capacity to efficiently requirements. turn and mill pipe-type products Key specifications of the for the oil and gas industry. LB4000 EX-II CNC lathe include At IMTS 2014 this machine will maximum machining diameter be shown cutting a downhole part of 480 mm, maximum machining using tooling from Sandvik, a length 750 mm, spindle nose member of Partners in THINC. type JIS A2-8, rapid traverse The LB4000 EX-II is built using X-Z 25/30 m/min with standard Okuma’s Thermo-Friendly Concept power 30/22 kW. to minimize thermal growth, and For further details contact slanted box bed construction, F & H Machine Tools on which combine to provide long term TEL: 011 397 4050 or visit quality and rigidity. The open www.fandhmachinetools.co.za

102 METALWORKING NEWS v 13. 4 September 2014

Doosan’s all-new Puma SMX 3100 S mill-turn multi-tasking machine

he Puma SMX Series is Doosan’s third generation mill-turn multi-tasking Tmachine, integrating the capabilities of a vertical machining center and horizontal turning center into one platform. The Puma compensation functions. SMX Series distinguishes itself with a more The Y-axis machining rigid 90 degrees vertical axis and forward area has been positioned automatic tool changer, for maximized through improved milling capabilities as well as orthogonal design. enhanced operator ergonomics. Ergonomic design The Puma SMX Series will initially be enhances operator made available in two sizes, the convenience, and efficient Puma SMX2600, with a 10” chuck and 78 mm maintenance provides an bar capacity, and the Puma SMX3100, featuring a larger optimal solution that meets customer needs. 12” chuck with 102 mm of bar capacity. Both Puma SMX models have the capacity to machine parts up to Enhanced precision 1525 mm in length and 660 mm in diameter. The X1-axis High accuracy control functions maintain excellent travel is 630 mm, Z1-axis travel is 1585 mm and the Y-axis is precision during long-term machining processes by minimising 230 mm. Rapid Traverse, X1, Z1 & Y: 50/50/36 m/min. the thermal deformation of the spindle and the feed axis, and by maximizing the precision through the 0.0001° B-axis Higher productivity and C-axis. Oil cooler minimizes thermal deformation of the The powerful multi-tasking functions decrease the total spindle and feed axis and high-rigidity and high precision processing time and number of machining operations by are achieved through the use of roller-type linear motion using a single setup. This provides excellent high-speed guides on all carriages. performance for component manufacturing processes that require accurate and complex machining capabilities Easy and convenient operation for turning, milling and secondary operations using the Ergonomic design features easy access for SMX sub-spindle, which is optional. maintenance as well as optimum operator convenience by including customized functions — including front located Machine construction tool magazine (80 tools max), side-to-side movable, The Puma SMX Series provides excellent performance for 85° swiveling Fanuc 31i control panel with adjustable high precision machining by use of a high-rigidity machine height and convenient ATC operation panel (tool to tool construction using finite element analysis (FEA) in structural change: 1.8 sec). design and minimizing thermal deformation via oil cooler For further details contact Puma Machine Tools on and an accuracy control feature based on multiple thermal TEL: 011 976 8600 or visit www.puma.co.za

The world’s fast fastest indexer - Kitagawa RK200

itagawa’s new RK200 model is The roller gear cam reducer an incredibly quick rotary table also greatly reduces heat Kthat is suitable for aluminium generation. This means that even work pieces of automotive, medical, under constant operation, accuracy electronics and optical parts where of the RK200 will not deteriorate multifaceted machining or multi-hole due to heat expansion. As the drilling is required. roller gear cam reducer is long- Rather than utilising traditional term maintenance free, downtime gear sets, the RK200 is fitted is minimised, improving efficiency with a free roller gear cam reducer. even further. The removal of parameter The RK200 has a table adjustment that is required by diameter of 114 mm with a direct drive rotary tables means that centre height of 150 mm. The a shorter indexing time is achieved through-hole diameter is 70 mm, to 180°, with the RK200 able to whilst the load capacity is 60kg. index through 90° in just 0.31 seconds and 180° in just For further details contact Feedback Systems on 0.46 seconds. TEL: 011 708 0510 or visit www.kitagawaeurope.com

104 METALWORKING NEWS v 13. 4 September 2014