metalworking news

2 Editor’s Comment 4 Viewpoint 6 Industry News TaeguTec; Allied Steelrode; Atlantis Foundries continues to invest; JHPE Precision Engineering; TDC Cutting Tools expands; Volkswagen South Africa rated; Tungaloy to debut new product line; EU seals trade pact; Hurco South Africa; Metso sells its shares; Toyota SA invests; Eskom RT&D - laser beam welding technology; Multitrade Distributors; RAPDASA; Vehicle component production plan; Electra Mining Africa 2016; Paramount Group; ArcelorMittal SA; Gibela 40 Shopfront Focus Better processes, better results at Multi Tanks International; Aiming to do better; Spares, Supplies & Services thrives 60 Better Production Laser power monitoring improves process stability 62 International News EuroBLECH 2016; Voortman’s game; GE reveals largest jet engine; SGS Tool Co.; 9% global growth; 3D-printed mini aircraft; Turning war scrap into steel; Trends impacting global machine tools market 82 Product Review GF Machining Solutions; Mastercam 2017; Hurco’s VCX600i; Iscar; Tongtai; DMG MORI; Jet Edge’s gantry system; Alpha XC lathe; Hypertherm; Solid Edge ST9; Sandvik Coromant GC1130; Panel bending redefined; Yaskawa and Clearpath partner; ATA Garryson and Bulldog Abrasives; New Pratt Burnerd Gripsafe; Edgecam 2016 R2; High-performance circular saw; Akira Seiki; Haas bar feeder; Widia; Leadwell; Control software

METALWORKING NEWS v 15. 3 July 2016 1 editor’s comment

Keep the big picture in mind

n my recent visit to Voortman Steel Volume 15 Number 3 Machinery in the Netherlands, a chance July 2016 remark by one of the South Africans in the O Editor group made me realise that all too often we are happy to operate in our comfort zone and do not Bruce Crawford consider the bigger picture. Online Editor “These days engineers, designers and Damon Crawford draughtsmen believe that at the push of a button we can fabricate material to their specification Editorial Board Professor Dimitri Dimitrov, and design. We realise that with all the software Global Competitiveness Centre and design tools that are available they can in Engineering, Department of Industrial expect more from processors like ourselves.” Engineering, University of Stellenbosch “This is true in many instances, but only Dr Willie Du Preez, Senior Researcher, Faculty because the OEM process machine builders are of Engineering and Information Technology keeping up with the trends in the industry and of the Central University of Technology providing fabricators with equipment that will meet the demands of design, while at the same time offering efficiency and productivity with minimum Production Manager Wendy Crawford human interference, thus reducing costs.” “However, it is not always practical. A machine can only do so much and, Reproduction from an engineering perspective, and despite the structural limitations, the Jericho Graphic Design industry standards, building codes and other important guidelines, they still Advertising expect us to do the impossible.” Bruce Crawford / Wendy Crawford And this is where I swung the conversation. Here we were visiting an Tel: + 27 11 463 0489 internationally recognised OEM that was only too willing to be transparent with Cell: + 27 83 628 7654 the inner workings of their equipment and systems. From the machines to the E-mail: [email protected] tooling to the software, all questions were answered. We even had the Website: www.metalworkingnews.co.za opportunity to visit fabrication entities where Voortman’s machines were being Printed By used, and as a result the wealth of knowledge and ideas that the South African Paarlmedia - A Division of Novus Holdings visitors gleaned will certainly enhance their businesses. I must admit that it was in Voortman’s best interest because here were a group of potential buyers METALWORKING NEWS is published by: of their equipment, and they know that building a relationship between supplier BA Crawford Specialised Publications (Pty) Ltd and end user is vitally important for their sales efforts. PO Box 69299, Bryanston, South Africa, 2021 But what about the end user and their clients, I asked? When last did they invite the engineer, draughtsman or designer to view their operation and see 41 Arklow Road, Bryanston, South Africa, 2021 Tel: + 27 11 463 0489 how it and the machines function, I queried? I could turn it around and say E-mail: [email protected] when last did an engineer, draughtsman or designer request a visit to see how Website: www.crawfordpublications.co.za they operated. I know that for any metalworking shop, one of the biggest challenges is Subscriptions Annual – Local: R140.00 (incl VAT) knowing what is happening on the shop floor so that activities can be International: on application measured, controlled and improved. Automated monitoring systems that are ISSN 1682-8909 available today make it possible to collect data that gives owners, managers, engineers and operators real-time information about shopfloor activities to help Copyright them make quicker and better decisions. All rights reserved. No editorial matter published in Metalworking News may be But this must not always be the focus of the processor, whether it is a reproduced in any form or language without machine shop, service centre or structural steel fabricator. Invite your clients, written permission of the publishers. While the professionals you deal with and your suppliers to come and view your every effort is made to ensure accurate operation. reproduction the editor, authors, publishers and their employees or agents shall not be As they say: “Think like an investor, not a consumer. The consumer responsible or in any way liable for any errors, mentality pushes filling a current need with a commodity based on price. omissions or inaccuracies in the publication The investor mentality pursues lasting value and anticipates growth. whether arising from negligence or otherwise Prepare for opportunity.” or for any consequences arising therefrom. The inclusion or exclusion of any product Keep the big picture in mind. All parties does not mean that the publisher or editorial will have much to gain by keeping one board advocates or rejects its use either another in the loop. generally or in any particular field or fields.

2 METALWORKING NEWS v 15. 3 July 2016

VIEW POINT

Why should I bother visiting a machine tool open house or exhibition?

Go prepared, go with an open mind, be ready to learn and go hungry!

f you operate a machine shop or any manufacturing operation with a focus Ion machining, and all the surrounding process technologies like product and process design, troubleshooting, CAM programming, tool design and selection, quality control, etc., you face a steady flow of new technology and products, updates and improvements intended to address the large and small, general and arcane details that concern machine operators, programmers, shop owners and managers. I'm sure you are familiar with the idea of tyre kicking or browsing and peering in the hopes of spotting that perfect piece of equipment. But when you’re looking to buy something as expensive as a machine tool, every opportunity to make comparisons is important and that means attending open houses. Don’t get me wrong. It’s not like a visit to an open house will suddenly highlight some diamond in the rough that every other shop owner or foreman is going to during an open house can help you learn the cool things about miss. But by visiting open houses you start to get a better idea it as well as it's quirks. These individuals spend a tremendous of what you like and want, what is currently on the market and amount of time helping customers maximise the efficiency of a ballpark budget for it. the machines and have experienced so many different scenarios For instance, I’ve met shop owners who were dead-set on a specific to the brand they represent. That experience alone is certain type of machine or a certain brand until they started to of prodigious value and you should want a part of that! learn more details about the other choices. I also know "I visited the local trade show... I don't need to go! " Well, others that have set their opinion based on their friends or in part, I agree! However, if you want to know more about a peers experiences and recommendations. Sure, we can all certain brand and its support network, I really think visiting navigate websites, watch cutting videos or machine reviews on their facility is a necessary exercise. It will help you set your YouTube but your opinion can completely change after spending expectations of the service support and meet the key people some time with a machine tool manufacturer's applications that will make your investment a success story. In comparison, engineer. A conversation with one of them running a machine trade shows are a good place to make the first contact or give you a first impression, though the costs involved with setting up a booth at one of them is a limiting factor to the amount of machines being displayed. In an open house setting, you can typically see more machines under power and have more in-house experts to help answer your questions. If you have upcoming investment plans, one more reason to attend is the promotions! Many machinery dealers and machine tool manufacturers combine their efforts to develop special promotions to help relieve that capital investment. Although it is typically not the main reason to make the purchase, if the timing is right for your business you could score on some very valuable perks! That could be in the form of extended warranties, special financing rates or additional discount to clear inventory! On a final note, even if you don't plan on investing in equipment in the short term, visiting an open house can be an excellent way to participate in networking activities with other shop owners and industry specialists. In all aspects, I assure

4 METALWORKING NEWS v 15. 3 July 2016 you that time spent at one of these events can only benefit to meet up with other like-minded South Africans and the your business. opportunity to network and discuss business. Without question the value of this is immense. Editors Comment I believe that you have to make the effort to attend an Machine Tools Africa 2017 international exhibition in your field and, not just once, but I know it is not always easy to travel internationally and regularly. I always encourage you to visit these truly the Machine Tool Merchants Association of Southern Africa international exhibitions because you return with a wealth of (MTMA) has recognised this fact and decided to resurrect knowledge and ideas that can only enhance your business. the local exhibition. Nasrec Expo Centre, Johannesburg will I can speak from experience because I have attended many be the venue for metalworking suppliers and manufacturing and I am never disappointed. There are several to choose companies to exhibit their products from 9 to 12 May 2017 at from and listed here are a few that are coming up. EuroBLECH Machine Tools Africa 2017. 2016 takes place in October 2016 in Hannover, Germany. It is It will be an all encompassing exhibition for the niche, but the number one exhibition for sheet metal, plate and lasers. very important, area of industry that we operate in. The MTMA But before that there is IMTS 2016 in Chicago, USA and in are encouraging all the related suppliers and manufacturers to November there is Jimtof 2016 in Tokyo, Japan. Jimtof is participate so that they put on a united and professional front the official exhibition of the Japanese Machine Tool Builders for the metalworking industry. This includes tooling, software, Association and I will be attending for the second time metrology, additive manufacturing, foundries and many others. courtesy of the JMTBA. It is also another exhibition that you Machine Tools Africa 2017 will be unique in the sense that should not miss attending at least once in your working career. it will showcase live working machinery including milling, Then there is EMO 2017 that also takes place in Hannover, turning, metrology, tooling, laser cutting and other sheet metal Germany in September 2017. From machines to tooling to and plate operations, to name but a few. The exhibition will software, you name it, there are exhibitors covering all also bring together the industry’s finest manufacturers across aspects of metal forming, shaping and removal. The individual a range of technologies. country exhibitions are also enlightening and one that At last count Hall 6 had 80% confirmed bookings and Hall is very popular with South Africans is Timtos in Taipei, 7 was 70% full, with a number of international companies Taiwan. booked. This is very encouraging and an exhibition that you Visiting these exhibitions also gives you the opportunity must bookmark in your diary.

This is the viewpoint of Joe Poulin, Regional Sales Manager at Elliott-Matsuura Canada Inc.

METALWORKING NEWS v 15. 3 July 2016 5 industry news

cover story TaeguTec’s century of expertise

or 100 years, TaeguTec has been in the business of Compared to general inserts, the new wiper insert achieves supplying cutting tool products to companies around the equivalent roughness even in double feed rate conditions. Fworld. While times have changed, the one thing that has At equivalent feed rates, the new RhinoRush wiper insert not is the service levels offered by TaeguTec to all the achieves 2-3 times better surface roughness. manufacturing facets in South Africa. As one of the continent’s largest economies, South Africa QuadRush exports more than 25% of its manufactured products to the For parting and grooving, the multi-corner four cutting edge rest of the African continent, claims TaeguTec. That is why QuadRush line is a family of tools known for its high accuracy cutting tools used by the metalworking industry need to be and surface quality, and is also available for threading reliable, efficient, productive, hassle-free and cost effective. applications. Luckily, manufacturing has posted an uptick in growth in South Africa and with that, companies are moving away from low-cost ISO cutting tools and cheap knock-off products toward more reliable brands that offer the most advanced coating and geometries in order to cut costs and increase productivity. TaeguTec is a full-service cutting tool provider with an extensive line of tools for every industry, servicing the rainbow nation.

RhinoRush One of the company’s most popular turning products is the RhinoRush, a line that took the metal removing industry by The QuadRush “TQJ” line offers good chip control, tolerance storm when it was launched a few years ago, and is still being and surface finish and conforms to the DIN 471 standards of updated with features that have yet to be launched. external circlips. The “TQC” type’s improved chip breaking The idea behind the RhinoRush line is to introduce a series properties are for industrial users that require increased of mini tuning inserts that meet the manufacturing industry's productivity in high cutting conditions. Due to its high-feed rate needs of reduced machining costs and competitiveness. the “TQC” is designed to machine hard materials and tough The new 9 and 13mm new line of inserts are just as strong applications, is perfect for general applications on steel, alloy as the 12, 15 and 16mm inserts available, but at a fraction steel and stainless steel, and is designed for good chip of the cost and size, and its unique two directional clamping evacuation in medium to high-feed rate cutting conditions. forces outperform conventional ISO directional clamping force The other QuadRush chip breaker of note is the “TQS” that tools available on the market, says TaeguTec. is made for industrial users who are looking for tools that can TaeguTec has recently expanded the RhinoRush line with outperform others while performing grooving and parting the introduction of wiper inserts that extend tool life as well as applications on products made from soft materials. As it is achieve excellent surface finish. Available in C, D, T and W type available in several width types and cutting shapes, it has the wiper inserts and corner R 0.4/0.8/1.2 sizes, the RhinoRush capacity to reduce the machining cycle time compared to wiper inserts cover a wide range of machining applications. existing tools and its straight cutting edges, with high positive rake angle, reduce cutting resistance.

DrillRush One of industry's favourite choices when it comes to drilling into everything from alloy steel to stainless steel is TaeguTec’s DrillRush. The versatile indexable drill is constantly being expanded to provide dependable, optimal hole drilling performance. The various DrillRush geometries and sizes such as 1.5xD, 3xD, 5xD, 8xD and 12xD not only increase productivity, but improve on tool life due to its reinforced edges and coating that are suitably designed for optimal chip control and hole quality on any material. All DrillRush products eliminate the need to remove the entire drill from the spindle in order to replace the head,

6 METALWORKING NEWS v 15. 3 July 2016 Chase2Mill Another small but powerful milling performer is the Chase2Mill 4NKT 6mm for end mills, face mills and modular cutters. The compact four corners double-sided insert for multiple applications has a 90 degree entering angle, is perfect for high ramp down angle applications, has a high positive geometry that generates low cutting force and its cross edge insert geometry prevents unexpected insert failure. The Chase2Mill 4NKT 6mm’s increased insert thickness and high strength, combined with the cutter’s wide bottom for improved clamping, enables high stability and productive machining. a process that shortens the workload by shortening cycle times and substantially increasing productivity. For high surface roughness and high precision drilling applications, TaeguTec expanded the DrillRush to include a double margin indexable drill that has a diameter range of 8mm to 19.5mm. The newest member of the drilling family is the solid carbide H-Drill NHD that outperforms the existing SHD and SHO drills due to its optimised cutting edges that are designed for improved drilling stability, says TaeguTec. Furthermore, other NHD features include a sharp straight cutting edge with precise web thinning that generates low cutting force and excellent self-centering capability for higher hole accuracy.

Mill2Rush For milling operations, TaeguTec’s benchmark high Furthermore, the 4NKT’s smaller 6mm size compared to productivity double-sided Mill2Rush lines cover the gamut of the 11mm and 16mm sizes increases the number of teeth on industries by providing a highly efficient line that improves the cutter, which is not only good for machining small economic output. components but also makes it a finer pitch tool that increases Because of the Mill2Rush’s huge popularity and recent productivity. developments in casting and forging technologies, TaeguTec has introduced an economical, pressed type 6-corner positive Chase2Feed mini insert for 90 degree machining. Last but not least is the Chase2Feed’s BLMP 13 size insert The Mill2Rush 6NKU 04 cutter that is optimally suited that tackles machining applications of up to 2mm in depth of for low depths-of-cut conditions, is designed with a rigid milling during high-feed conditions. clamping system and a higher number of teeth to With its reinforced unique design, high rake angle for better accommodate the smaller 6NKU 04 insert's high positive helical anti-breakage capabilities, reduced cutting loads and excellent cutting edge for smooth machining and low cutting forces. chip evacuation, the Chase2Feed’s BLMP 13 is specifically TaeguTec also broadened its Mill2Rush line by expanding designed for the milling applications performed in the heavy, the popular TNMX 18 series, and is the first in the business die and mould, power generation and general industries. to introduce a double-sided triangular insert used in extended Other positive attributes to note are its 7mm thickness, six flute cutters, says TaeguTec. cutting edges, and unique pocket seat that allows for stable The TNMX 18 addition is characterised by a double-sided machining in high-feed conditions. triangular insert with an 8mm thickness and a 13mm depth For a complete list of cutting tools and their capabilities, of cut — all factors that enable powerful machining and add to visit www.taegutec.com or contact your local dealer. the Mill2Rush family of cutting tools an even greater choice in For more information contact TaeguTec SA on heavy duty 90 degree machining. TEL: 011 362 1500 or visit www.taegutec.com

METALWORKING NEWS v 15. 3 July 2016 7 Allied Steelrode adds large diameter tube, pipe and beam laser cutting machine for structural processing to its metal fabrication services

The big processor with a five-axis cutting head — the BLM LT 20 Jumbo — is able to cut large round, square and rectangular tubes and pipes, as well as non-tubular open structural sections such as beams, H, I, angle and channel in a heartbeat.

Largest machine of its kind to be installed in South Africa.

abricators use a variety of methods - sawing, lathe cutting, rotary cutting, supported shear cutting, dual-blade Fshear cutting, and laser cutting - to cut from mill lengths into shorter pieces for use in final fabrication of structural sections and components. No single method is optimal for cutting the broad range of materials and shapes produced by this industry. Which type of cutting machinery to use for an operation depends on the requirements. In addition, the expansive growth has required fabricators to increase production and automate cutting operations. Lasers have been in use for industrial purposes for decades, and their capabilities continue to develop. These days many machines can cut sheet and tubular sections, and fabricators are finding that the laser’s programmability really broadens their capabilities. More recently, fibre laser cutting has opened up new possibilities. That said, many equipment manufacturers The new BLM LT 20 Jumbo, an automatic laser cutting system specialise in providing cutting equipment for tube, pipe and with a five-axis cutting head is able to cut large round, non-tubular open structural sections such as beams and square and rectangular tubes and pipes, as well as non-tubular several have rolled out new machines recently. However, it is in open structural sections such as beams, H, I, angle and channel in a heartbeat. The machine was supplied by First Cut the area of processing large, big, hefty — call it what you want — material where there are a limited amount of machine manufacturers and as a result, processors or fabricators. operation. Automated material handling equipment handles The continuing development of technology is expanding material at high speeds, automatically loads into cutting or applications. Today's high-production demands, and the need secondary operations, and stacks processed material into bins for higher-quality parts have led to a trend toward more or bundles. Inline automation has also been developed to automation. It may not be cost-effective anymore to cut parts integrate primary machines with secondary operations. on one machine and manually transfer them to a secondary In response to a growing demand for steel sheet that arrives flat and stays flat after laser, plasma or water-jet cutting, Allied Steelrode last year invested R150 million in a new 9 000m² facility in Midvaal, Gauteng, and a dedicated Red Bud Industries’ cut-to- length line with Suregrip® stretcher leveller technology incorporated. Users and distributors of flat steel now have access to significantly better flat steel, and new competitive advantages. Processing is referred to as all done-in-one Channel, tube, pipe cutting and hollow structural operation. This includes cutting to length, mitre, sections are some of the shapes of material cope and shape, chamfer, drill (laser), slotted, that the BLM LT 20 Jumbo can process Structural processing cut or chamfer any shape, process with Now the company has large-diameters and thick-wall material invested in a BLM LT 20 

8 METALWORKING NEWS v 15. 3 July 2016

Jumbo, an automatic laser cutting specific programmed position according system designed to bring higher to length. Parts up to three metres in levels of precision to the laser length can be unloaded onto the short cutting of large diameter, thick- part unload conveyor and longer parts, walled material. The machine is up to a maximum of 18 metes, will be equipped with a five-axis cutting sent to the long part unloader. head and is able to cut large round, square and rectangular Processing is referred to as all tubes, as well as non-tubular done-in-one operation. This includes: open structural sections such as • Cutting to length beams, H, I, angle and channel. • Mitre, cope and shape The machine was supplied by • Chamfer First Cut. • Drill (laser) The system can be used to • Slotted cut round, square and rectangular • Cut or chamfer any shape tubes, plus non-tubular open Justin Cloete and Warne Rippon • Process with large-diameters from Allied Steelrode structural sections, ranging in and, diameter from 75-508 mm and lengths up to 18 metres. • Thick-wall material The versatile BLM LT 20 Jumbo can process mild, high strength, alloy and stainless steels and bevel edges, and also The automatic laser cutting system is designed to bring countersink holes. higher levels of precision to the laser cutting of large diameter, Laser technology’s inherent flexibility is heightened by the thick-walled tubes, along with the heightened efficiency and fact that the BLM LT 20 Jumbo eliminates the need for special productivity needed to compete with the plasma systems fixtures. This means that high volume production as well as low commonly used to cut this class of material. volume prototype work can both be processed easily, quickly and cost effectively. The structural challenge in the construction industry A key aspect of the system is its high level of automation. Allied Steelrode says that with this investment it will open All loading, cutting and unloading operations are controlled by up a wealth of opportunities for their customers, not just in CNC, and the system control software automatically selects the extra operations and capacity they provide, but also in the the best cutting method. Because all machine operations are speed of response they can offer. performed by programmed commands, no manual set ups or “The BLM LT 20 Jumbo will also increase our capabilities fixtures are required. Once material is placed on the loader, it for the newer and growing requirements in the construction is moved one by one into the feeding line with its automated industry and other markets where high volumes of large chuck system. sections and components are required, often to tight First, the rear drive chuck grips the material and indexes deadlines,” said Allied Steelrode’s Warne Rippon. it into a pair of working chucks and then into the cutting area. “From a purely physics perspective, hollow structural The rear chuck does not release the material until the entire sections have numerous advantages, one being strength. By part has been processed. moving the material away from the center of the section (as The combined action of the two working chucks and drive with a typical hot-rolled beam) toward the periphery, hollow chuck move and position the material under the five-axis cutting structural sections have a high strength-to-weight ratio.” head according to the programme parameters. The interpolation “But from an engineering perspective, wide-flange beams of the cutting head in combination with the material movement have had one main advantage, they’re easy to connect. To allow for processing anywhere along the length. The machine assemble angles and beams, an erector simply bolts through two can cut in front of the main chuck, between the working adjacent flanges, or he bolts through a clip into a web section.” chucks, or behind the main chuck. The design provides “Do that, and you get the slip-critical connection everybody maximum flexibility and access with little or no scrap. wants. But connecting hollow structural sections can be After being laser cut, each finished part is unloaded to a challenging. How do you attach a nut? If you try to fabricate

The BLM LT 20 Jumbo is the After being laser cut, each finished part is unloaded to a largest machine of its kind to be installed specific programmed position according to length. Parts up to in South Africa by BLM and First Cut three metres in length can be unloaded onto the short part unload conveyor and longer parts, up to a maximum of 18 metes, will be sent to the long part unloader

10 METALWORKING NEWS v 15. 3 July 2016 structural construction. We have to educate them to design in tube as it gives you unrestricted capabilities. Aesthetically it gives them a new vision and variability.” “Instead of constructing pods and sliding them into a frame built on-site, when using hollow structural sections, the steel frame itself is broken up into a chassis, or cubical (or rectangular prism) steel frames. That can then be fabricated in the controlled shop environment allowing each chassis to then be outfitted into a complete module with flooring, electrical, HVAC, sprinkler systems, tiles, and even drywall and the building façade.” “Very real time and cost savings can be The system can be used to cut Any form or shape of tube and pipe can realised as a result.” round, square and rectangular now be processed by Allied Steelrode tubes, plus non-tubular open The new BLM LT 20 Jumbo laser structural sections, ranging in connection points out of processing machine has been installed in diameter from 75-508 mm and pieces of plate, then you’re a renovated 17 500m² facility that the company owns, and lengths up to 18 metres. The going back more than a is situated adjacent to its main processing facility in Alrode, versatile BLM LT 20 Jumbo can century, back before the Gauteng. The facility consists of eight bays, all under crane, process mild, high strength, wide-flange beam was in that will house and process all of its long hollow structural alloy and stainless steels and common use, when individual sections and beams. bevel edges, and also plates were riveted together "Crucially, these computer controlled operations allow us countersink holes to make structural beams.” to guarantee repeatability in terms of accuracy, tolerances and “This is where steel cast connections fill the need. finish. These enhanced strengths also mean that Technology has advanced so much that this is now a real customers can now order stock and tube and beam cutting solution. It is now up to us to educate structural and design from one source." engineers in South Africa that hollow structural sections, For any enquiries please contact Allied Steelrode on besides having greater strength in true weight to loading, are TEL: 0861 777 777, email [email protected] or visit straighter and lighter and, as a result, are cheaper for use in www.alliedsteelrode.co.za

METALWORKING NEWS v 15. 3 July 2016 11 Atlantis Foundries continues to invest for the future

Since the sale of Atlantis Foundries to Neue Halberg-Guss GmbH in June last year, the company has continued to invest in the South African operation’s future in terms of technology, efficiency and environmental impact.

erman metal casting group Neue Halberg-Guss GmbH, which acquired GAtlantis Foundries in June 2015, has subsequently invested significantly in the South African foundry. As a result, the Western Cape based foundry in Atlantis has undergone some significant changes in terms of technological advancements. Recent projects at Atlantis Foundries include the installation of a second 12t ABP Induction Systems pressure pour furnace, an additional 6.1 MW ABP Induction Systems power pack for the four ABP Induction Systems induction furnaces that Atlantis Foundries uses in its melting department, the installation of a new sand drying plant, as well as the installation of a new core drying oven. The new pressure pour furnace, installed by ABP Induction Systems The new pressure pour furnace, installed by ABP Induction Systems, aims to limit the company to continuously improve on their product impact of metal specification changes and product quality. changeovers. Additional benefits of this second furnace will The investment in an additional ABP Induction Systems also permit regular refractory work to be performed on either power pack has given Atlantis Foundries the ability to now furnace whilst the other furnace continues with production, operate four furnaces simultaneously, particularly when the thus creating efficiencies and capacity in the production bulk energy supply is available, consequently increasing the process. The second pressure pour furnace also enables overall melting capacity of the foundry. Atlantis Foundries to produce other grades of metal such as The installation of a new 27t/hr LPG sand dryer is not only SG and CGI. a more cost effective and efficient method of drying the sand The second pressure pour furnace will also allow Atlantis than the existing two old kiln type dryers, but significantly Foundries to carry out trials with new metal specifications reduces the electricity consumption at Atlantis Foundries, without impacting on ‘normal production’, thus enabling the something that all businesses and foundries need to consider when electricity demand exceeds availability, the company says. The sand drying plant was designed and manufactured by UK based Orthos Projects, and the sand conveying system (full pipe pneumatic) was supplied by Endeco Omega.

Alcohol to water-based coatings Another new development has seen the installation of a new core drying oven. This has prompted Atlantis Foundries to change from alcohol to water-based coatings that will bring safety, health and environmental enhancements, as well as quality improvements.

New core drying oven The new core drying oven, designed and manufactured by Italy based ProService s.r.l., uses a combination of heat radiation and convection. As a result of this combination, a lower drying temperature is required when drying the cores. This improves the quality of cores and requires less drying The installation of a new 27t/hr LPG sand dryer is not only time compared to conventional technologies. This all adds to a more cost effective and efficient method of drying the sand than Atlantis Foundries vision to reduce energy consumption the existing two old kiln type dryers, but significantly reduces the and costs in the foundry, while at the same time improving electricity consumption at Atlantis Foundries quality.

12 METALWORKING NEWS v 15. 3 July 2016 Working closely with Foseco South Africa, Atlantis Foundries Atlantis Foundries have installed a new invested in an ITACA™thermo-chemical analysis system. core drying oven, designed and manufactured This was introduced at the same time as the Coating Preparation by Italy based ProService s.r.l., that uses a Plant and a dip tank, also manufactured by ProService s.r.l. combination of heat radiation and convection

The drying oven that was installed earlier this year, has ing the core packages and helps us to remain cost been custom designed according to Atlantis Foundries competitive. In addition, with the change to water-based specifications. The drying oven can process approximately coatings, we have noticed an improvement in the casting 80 core blocks per hour (single weight up to 350 Kg). surface that has improved the overall quality of our products, The scope of the installation includes the drying oven, a and helped to reduce our finishing costs,” added Chief conveying system for pallets, drilling and inspection stations, Commercial Officer Sally Redshaw. a cleaning station for the pallets and intelligent database for Atlantis Foundries manufactures and sells automotive process control related to the single core. The data includes castings for the commercial vehicle industry including block coating density, viscosity and temperature coming from the castings for use in long distance trucks, V-block castings for Coating Preparation Plant™, dipping time, drying time and use in heavy industrial, marine, agricultural and power temperature, gas and power consumption. generation applications, and medium duty castings for use in Heat for the drying oven is generated using efficient light industrial, material handling equipment. gas burners or electrical heaters, depending on the required For further details contact Atlantis Foundries on specification. TEL: 021 573 7200 or visit www.atlantisfoundries.com

Coating Preparation Plant and ITACA™ thermo-chemical analysis system The drying oven completes the line that was first started in 2013 with the installation of a Coating Preparation Plant (CPP™) and a dip tank, also manufactured by ProService s.r.l., the first step taken by Atlantis Foundries to improve the consistency of its coating applications. Working closely with Foseco South Africa, Atlantis Foundries invested in an ITACA™ thermo-chemical analysis system. This was introduced at the same time as the Coating Preparation Plant. This system has since been upgraded in 2015 and is now one of the most comprehensive systems for metallurgical process control available globally. The iron quality is continually evaluated, so that the final metallurgical behaviour and properties of the casting produced is available in real time on the shop floor. This has resulted in significant cost savings from yield and efficiency improvements, and a reduction in the amount of scrap castings. “The health and safety of our employees is always at the forefront of our minds. With the switch to water-based coatings, our employees are no longer exposed to the inhalation of vapours given off from alcohol-based paint. In addition, the risk of fire is significantly reduced as the water- based coatings are non-flammable, versus the high flammability of alcohol-based coatings previously used,” says Atlantis Foundries Chief Executive Officer Pieter du Plessis. “Investment in our future is critical to survival. The foundry business is extremely competitive with only a handful of major foundries across the globe able to produce high quality heavy duty truck blocks castings for the OEM’s. We have to keep up-to-date with technological advancements and efficiency improvements to remain ahead of the game. The use of water-based paint is also a more cost effective method of coat-

METALWORKING NEWS v 15. 3 July 2016 13

JHPE Precision Engineering expands product range and moves into larger manufacturing facility

am often asked by industry if finding good news among current reports about I the metalworking industry and, industry in general, is an easy task. The pessimists view is one of a combination of weakened demand for industrial products and components, the declining value of the Rand, a nagging shortage of trained workers and strong foreign competition having led to some serious concerns. While I do admit that business is tough and may not be at the levels that most of us want, my answer is always a resounding, “No!” And it is not because I focus on the so-called ‘islands of exception’. There are many examples of businesses focusing on what they do best and getting on with boosting their competitive advantage by increasing their productivity and service levels, investing in equipment and new ideas and, as a Eugene Hugo with his father Jan result, expanding. One such company is Gauteng-based machining company JHPE Precision includes various stainless steels, aluminium, engineering Engineering. The company specialises in CNC milling, plastics and other exotic materials. The shop machines these turning and wire eroding for small and large batches in materials into complex components using a variety of a wide range of materials to produce a variety of components. CNC milling and turning machines. Post-machining services include inspection and quality checks However titanium still accounts for between 50 and and finishing. 60 percent of JHPE Precision Engineering’s material mix. The 84 employee-strong company’s product range “In recent years, titanium has become dramatically more includes orthopaedic and dental devices, as well as high significant as a workpiece material in machine shops. Two precision components for the defence and aerospace industries are driving this. One is aerospace. The latest aircraft industries. designs use considerably more titanium than planes of the Established in April 2001, the BSI ISO 9001:2008 past. The other is the medical industry. Titanium is a accredited company was originally set up specifically to common material used for implants and devices used within machine and supply titanium medical implants for its client. the body. Titanium’s high hardness and low thermal The company has since diversified its product mix and now conductivity make it more challenging to machine than other metals that most machine shops are accustomed to facing,” explained Jan Hugo, the founder of JHPE Precision Engineering. “Because it’s less affected by cyclical fluctuations in consumer and government spending than other manufacturing sectors, medical machining continues to enjoy strong and steady growth. Furthermore, the international demand for high-quality medical devices and products marketed by our clients, promise to make medical machining a very strong business for years to come,” says Jan Hugo.

High precision for aerospace “Similarly, we can say the same about the defence and aerospace industries. We diversified our product mix a few years ago so that the company was not locked into one industry. But we made a strategic decision to focus in on the upper scale of the high precision machining sector, where there is no room for error,” continued Hugo. Various high precision components manufactured Today the company has a 50/50 split between medical by JHPE Precision Engineering and defence/aerospace components and products that it 

16 METALWORKING NEWS v 15. 3 July 2016 machines and manufactures for recent years. An example of its clients. this is that the staff “Aerospace and defence compliment in 2013 numbered components are always a 57 employees and today this challenge because they require figure is 84. Annual turnover has high precision, but they are also grown correspondingly and in the a small volume business. There last five years there has been a are certain components we make 132 percent growth in that more frequently than others, but turnover. we still have to run at tolerances that push all of our machines Preparing for tomorrow to the limit. More sophisticated “Referring to our staff processes and more complex compliment, we have attended machines mean more unusual a number of industry seminars machine problems, including wear recently and what we have learnt and tear, compared with a is that those companies that are traditional job shop or high doing well have employed high volume shop.” caliber staff and set up training programmes for existing Larger, more efficient employees. Training has always manufacturing facility been a very important While the company was component in the success of steadily growing, maintaining JHPE Precision Engineering, this momentum required a and every year we take on new better, more efficient apprentices so that they can manufacturing approach as qualify as artisans. We regularly JHPE Precision Engineering have two to three apprentices expanded. qualifying every year.” “We are a typical machine “We also now employ two shop that started off in a garage degree qualified industrial with a couple of machines, then engineers in the planning and moved into a facility that at first Inspection, measurement and quality are key factors drawing office, where we have we thought was too big for us at JHPE Precision Engineering three seats of SolidWorks, and but, as we added more in our certification and quality CNC machines and other department we have employed supporting equipment, it soon became like a rabbit warren.” an accountant. This is important to us because we are In 2010 the company was forced to rent a further 300m² demonstrating that our machining operations and services but this facility was off-site, which is not ideal for many will meet the expectations of our clients. We have been reasons and has led to JHPE Precision Engineering purchasing ISO 9001 certified for many years now and are currently a site in Kruger Avenue, Lyttelton, Centurion, Gauteng. implementing ISO 13485, a certification standard for medical “We had to completely renovate the building before moving devices.” in but it gave us the opportunity to set it up according to our “Producing quality components and products isn’t good needs. This we did in January 2016. We now have 800m² at enough in today’s market. You have to do so while following our disposal.” regulatory standards in a way that remains cost JHPE Precision Engineering has seen fairly rapid growth in competitive.” 

The new Haas VF2 mill that is equipped with a 4th axis, Machines have been organised at coolant through spindle and has a Renishaw probe on it and JHPE Precision Engineering so that the same type an expanded memory that allows the company to machine more of machines form a cell complicated components that require a longer machining time and programme at a higher speed

18 METALWORKING NEWS v 15. 3 July 2016

“Additionally my son Eugene, who is also degreed in accounting aspects, joined the company 18 months ago specifically to manage the implementation process of JobShop software to improve our manufacturing and production processes. He is also part of my succession plan.”

Standardising on CNC equipment — Additions made to the line-up of Haas machines “Advanced manufacturing applications are placing even greater demands on machine tooling and components, with equipment expected to operate faster, more reliably and with increasing efficiency. The move to the new facility has allowed us to set up the machines in cells depending on the requirements and complexity of the components being manufactured. Some components can be milled and turned, A recent addition to the shopfloor is a then turned again, then wire cut and finally milled again. Haas SL 10 CNC lathe As one can imagine close tolerances are needed for medical components so there are a number of intervals for Haas VF2 mill that is equipped with a 4th axis, coolant through inspections. In some cases there is even broaching spindle and has a Renishaw probe on it and an expanded involved.” memory that allows us to machine more complicated “On the floor we have a total of 20 Haas CNC machines, components that require a longer machining time and a further two Takisawa lathes, a Doosan mill turner and programme at a higher speed. One example I can give is that three wire cutters. We have standardised on Haas equipment of a component that was previously done on mini-mill, now because it helps us to maintain a close relationship with being done on the VF2, where we are realising a 50% saving

The 84 employee-strong company’s product range includes orthopaedic and dental devices, as well as high precision components for the defence and aerospace industries

Haas CNC Machine Tools South Africa. As a result they are in machining time.” able to handle any ongoing needs, and because each “Going forward it is our aim to replace older machines with department uses machines of the same brand many parts the latest equipment available, but still with the same supplier.” are interchangeable. This lowers the cost to stock spare parts “We regard ourselves as a contract machine shop and and helps reduce downtime when repairs or maintenance is intend to keep it that way. We have grown because of obtaining necessary.” more contracts from our existing clients. We will also be The latest machine to be installed, earlier this year, was a looking at obtaining some international contracts because the Rand is very favourable toward exporters currently.” “We believe we operate in a very niche space that not many are prepared to venture into. There is definitely a shortage of high precision operators with all the systems in place to make them stand out.” Bottom line: JHPE Precision Engineering is today one of the most organised manufacturing facilities you'll find anywhere, and that is credited to their ability to meet demanding customer standards. For further details contact JHPE Precision Engineering on TEL: 012 667 5580 or visit JHPE Precision Engineering has 20 Haas CNC machines on the floor www.jhprecision.co.za

20 METALWORKING NEWS v 15. 3 July 2016

TDC Cutting Tools expands its operations to South Africa

Company will initially concentrate on HSS twist drills.

DC Cutting Tools Inc., one of the fastest growing cutting tool manufacturing Tcompanies in the world, and one of the world’s market leaders for high speed steel cutting tools has recently established a subsidiary in South Africa that is headed up by David Risk. “With significant TDC manufacturing and sales volumes on every continent apart from Africa, a decision was taken to open a TDC subsidiary in South Africa. Its objective is to supply the African market with the Cleveland range of industrial cutting tool products, initially concentrating on the range of high speed steel twist drills that the company manufactures,” said Risk, who has extensive experience in marketing these products to the engineering fraternity, both locally and internationally. “A stock hub has been established in Johannesburg, and TDC Cutting Tools South Africa (Pty) Ltd will import and distribute TDC’s industrial brand of cutting tools to the metal working industry locally. Products that will be available include HSS straight shank drills and HSS MTS drills, with other cutting tool product groups to be phased in.” built a state-of-the-art 250 000m² industrial park employing TDC is a global cutting tool organisation, established in over 2 000 skilled cutting tool specialists. On this site, 1995 by owner Jeff Chee, which today employs over 4 000 TDC’s numerous specialised cutting tool factories produce staff worldwide, spanning North and South America, Canada, world class HSS and carbide drills, taps, end mills, saws of Mexico, Europe and the Far East. The company is a various types, steel coil and bar, coating plant, machine tools manufacturer and exporter of fully ground straight/taper shank used in the manufacture of cutting tools, mining teeth drills, hot roll forged drills and milled taper shank drills. and buttons, and grinding wheels, amongst other products. “TDC enjoys a 20% share of the global HSS cutting tool “Part of the success of TDC has also been its focus on market — every one in five industrial grade HSS drills sold the successive acquisition of well-known international worldwide is manufactured in TDC’s cutting tool factories,” cutting tool manufacturing companies and brands such as says Risk. Werko in Germany, Manigley in Switzerland and Greenfield TDC is headquartered in Dalian, China, where in 2012 it Industries in North America. Through these successful acquisitions, TDC today owns 14 internationally recognised brands, including Cleveland, Chicago Latrobe, Vermont Tap & Die, Bassett, Cle-Line, Putnam Tools, H&G, Geometric, Vers-O-Tool, Acme-Fette, Werko, Manigley and Greenfield Industries,” said Charlie Lougasy, who is President and CEO of TDC Cutting Tools Inc. and is very well known in South Africa. Every year, TDC achieves a production volume of 300 million pieces of cutting tools and 10 million metres of various bi-metal saws. “One of the recent achievements of TDC has been the development of a carbide insert division, and the company has now started to manufacture carbide inserts that will shortly be released to the market.” "Through this expansion, TDC has positioned itself for strong future growth in its overseas markets.” For further details contact TDC Cutting Tools South Africa TDC Solid carbide drilling and cutting tools are on TEL: 033 342 1160 or 010 492 3737, or David Risk on manufactured to the highest spec 060 741 4957 or visit www.tdc-tools.co.za

22 METALWORKING NEWS v 15. 3 July 2016

Volkswagen South Africa rated as the top plant in the global Volkswagen production network

he Volkswagen Group South Africa (VWSA) plant in Uitenhage has been Trecognised as the top manufacturing plant in the global Volkswagen production network in 2015. VWSA achieved the highest index score of 113.2% amongst the 13 Volkswagen plants around the world. This was the first time that Uitenhage was rated as the top manufacturing plant since the Beetle production started in August 1951. The 13 global Volkswagen production plants are all measured on the same key performance indicators such as production volumes, production quality, costs per unit, units produced per employee, Health and Safety incidents and the factory’s improvements in reducing its carbon footprint. Key in VWSA achieving these results were the 120 000 Polos and Polo Vivos An aerial view of the VWSA plant produced in 2015 at much better than in Uitenhage, Eastern Cape budgeted cost levels. Another key contributing factor was exceeding the Schaefer added: “This exciting news will bolster our Think Blue Factory targets that were set in 2010 to reduce shareholders’ confidence in our company as we have energy consumption, water usage, waste and emissions by commenced with our R4.5 billion investment plans for new 25%. By the end of 2015, VWSA had exceeded the target by products announced last year. It will further enhance VWSA’s 17.2% achieving 42.2%. status and ability to deliver and exceed its targets at the Of the 120 000 cars produced in 2015, over 66 000 Polos required quality levels for both the domestic and important were exported to predominantly right hand drive markets such as export markets.” the United Kingdom, Australia, Japan and Ireland. In addition, “I am extremely proud of all the employees at Volkswagen 113 000 engines were also produced of which 81 000 were Group South Africa, who have made this recognition by our exported to markets such as India, China and Mexico. parent company possible, and thank them for their hard work In South Africa, Volkswagen maintained its dominance of and contribution,” Schaefer said. the passenger car market for the sixth consecutive year with Schaefer further added that Volkswagen Group South Polo Vivo and Polo being the first and second best-selling Africa will continue to strive to be the number one passenger passenger car models respectively. car company in South Africa whilst meeting and exceeding “This recognition could not have come at a better time for its internal targets to remain a respected member of the our company,” said Thomas Schaefer, Chairman and Managing Volkswagen production network as well as by delighting its Director of Volkswagen Group South Africa. customers.

Volkswagen's Uitenhage plant assembly line

24 METALWORKING NEWS v 15. 3 July 2016

Tungaloy to debut new product line in a series of seminars

Product launch from 15 to 18 August 2016 features 1 050 new products for milling, drilling and turning.

anufacturers and it will not improve your machine shops productivity. If you look Mfrom South at price, tool life and Africa, as well tooling productivity, the one that distributors, will be able will reduce your cost per to view Tungaloy's launch part is productivity." of TunGForce, a new line of tooling. Star Tooling, New products Tungaloy’s representative Tungaloy's TunGForce and distributor in product launch will South Africa, will host feature a multitude of the launch, the first new products that will of its kind and size for just touch the surface of Tungaloy in South Africa. the 1 050 new tooling “We will be solutions that are part of presenting innovative the new line. The tooling solutions to today's solutions include new cutting tool problems inserts with innovative over a series of seminars geometries, coatings and and live demonstrations to be held at Star Tooling’s offices special surface post treatments for milling, drilling and from 15 to 18 August 2016. Tungaloy generate a significant turning applications. percentage of sales from new and innovative products. And By way of example, in the TunGForce milling family, that's because of the focus on research and development. Tungaloy's new DoTwistBall inserts feature a unique twisted New products less than five years old represent 40 per cent shape insert in radius and high feed geometries. The of Tungaloy's revenue,” said Chris Schmidt, MD of Star Tooling. rectangular shape and twisted clamping insert seat provides anti-rotation, something difficult to achieve for radius cutters, "Accelerated machining" according to the company. The inclination on the helical The trend towards "non-stop 24-hour continuous cutting" cutting edge forms small chips for high performance, while a requires high productivity tools. And to operate in such an raised cutting edge from the seating surface avoids chip environment means "accelerating machining" at the cost of contact with the screw head to extend screw life. tool life. In turning, one of the new products includes the

“While the argument may sound counter-intuitive to some, Harpaz's point is that to achieve accelerated machining, and hence make productivity gains, it requires increasing speeds and feeds during a machining cycle, which, of course, reduces tool life. But since tooling represents only three per cent of the total operating cycle time, focusing on the cost of tooling will not improve your productivity,” explained Schmidt

These are the words of Jacob Harpaz, the charismatic and MiniForce-Turn, a double-sided insert with positive cutting high-energy president and CEO of Tungaloy's parent company edges clamped into a pocket with a dovetail structure for high IMC. insert stability. The same insert can be used for both bore "The only way to improve productivity is to improve cutting and external applications. speeds and feeds, and reduce tool life." In drilling, the DrillForceMeister drills in large diameters “While the argument may sound counter-intuitive to some, feature a quick indexing mechanism and unidirectional Harpaz's point is that to achieve accelerated machining, and clamping of the insert. The unique corner geometry of the drill hence make productivity gains, it requires increasing speeds head reduces burr at exit and the overall optimised geometry and feeds during a machining cycle, which, of course, reduces results in what Tungaloy describes as "excellent chip tool life. But since tooling represents only three per cent of formation and smooth chip evacuation." the total operating cycle time, focusing on the cost of tooling For further details about the seminar dates and times will not improve your productivity,” explained Schmidt. contact Star Tooling on TEL: 011 818 2250 or visit Harpaz says, "Even if we provided tooling free of charge, www.startooling.co.za

26 METALWORKING NEWS v 15. 3 July 2016 EU seals trade pact with African Nations after 12 years of talks

he European Union and six southern African nations a 32 million euro trade-related facility, Malmstrom said. signed off on a trade accord on June 10 after 12 years of The funds were set up to help countries fully benefit from Tnegotiations that were stalled mainly by differences over the concessions offered by the EU by boosting their market access for agricultural products. productive capacity and improving the quality of their The so-called Economic Partnership Agreements gives exports. products from Botswana, Lesotho, Mozambique, Namibia, and Swaziland duty- and quota-free access to the EU. South Africa, which has the region’s most- developed economy, will enjoy enhanced market access that goes beyond an existing preferential trade pact. The new accord is open-ended and will be reviewed every five years. Despite the delays, the fact that some EU economies were struggling and the uncertainty of the UK leaving the EU, the deal is the most favourable yet clinched by the African nations, EU Trade Commissioner Cecilia Malmstrom said. “It opens up fully the EU market for all goods and commodities on an asymmetric basis,” she said on June 8 in Gaborone, Botswana’s capital. “It contains safeguards for vulnerable sectors and is a long-term cooperation on economic development. More trade is better but ours is the most advantageous” deal, she said. In June last year, the US renewed its African Growth and Opportunity Act. First adopted in 2000, the pact eliminated import levies on more than 7 000 products from Africa, ranging from textiles to manufactured items. That accord benefits 39 nations. The African nations signing the pact with the EU will gain access to its 100 million euro ($134 million) fund for economic integration and

METALWORKING NEWS v 15. 3 July 2016 27 Hurco South Africa appointed Röders representative in South Africa

Ultra-high-precision 3 and 5-axis HSC milling machines incorporating, where necessary, jig grinding in the same machine and set up.

or the past 10 years Hurco Europe years, which Jürgen Röders Ltd have been successfully attributes primarily to the Frepresenting the company quality of his machine tools. Röders Tec of Germany, in the UK. Further growth is planned with There are now many Röders machines the completion of additional throughout the UK and Ireland, capacity by the middle and on the back of this success of 2016. Hurco South Africa have now There are now over been appointed the exclusive 2 000 Röders machines representative for Röders in installed in 50 countries South Africa. worldwide serving the most The Röders machines have demanding of customers in a very specific application and industries such as aerospace, compliment the Hurco automotive, dental, medical, machines perfectly. Where the mould and die, minting, watch, application calls for ultra-high optical, gear and general precision, mirrored finishes, production. combined milling and jig Röders have an exceptional grinding, then the Röders range depth of development in design, of HSC machines have the perfect control and drive technology. solution. The high speed cutting machines Working with a wide selection of are optimised for the highest materials including ceramics, plastics, and graphite and possible performance in respect of machining precision, with both non-ferrous and ferrous metals with harnesses surface quality and dynamics. Various production processes up to 62 HRC, Röders machines consistently produce can be combined in the HSC machines including milling and components with accuracies to +/-1 micron using speeds of jig grinding for the finishing of components without the need up to 96 000RPM. for final polishing. Where necessary, the machines are The Röders Company is situated in Soltau and is the automated by means of Röders own solutions. All Röders largest industrial employer in the area with 340 employees, products are well known for their durability and excellent 38 trainees and another 450 employees worldwide. The retention of value. business is now 200 years and six generations old. With the The full range of Röders HSC machines; 3-axis and development of Ultra-precision machines being a natural 5-axis models with single spindle and dual spindle options progression from the original business when the required in various designs including RXP, RXU, RXS and RHP can be machine accuracy was at the time unavailable on the market, seen on the Röders website — www.röders.de and as a necessity developed in-house by Röders engineers. For further details contact Hurco South Africa on The company has grown approximately 30% during recent TEL: 011 849 5600 or visit www.HURCO.com

28 METALWORKING NEWS v 15. 3 July 2016 Metso sells its shares in Metso ND Engineering in South Africa

etso has sold its shares in Metso ND Engineering (Pty) Ltd to the current minority owner Mr. Elvis Green. MMetso held 70% of the stock. The transaction came into effect on May 31. The value of the transaction will not be disclosed. Metso and ND Engineering have agreed to cooperate closely in the future. Metso ND Engineering is a manufacturing workshop with about 250 employees that operates in many fields including the pulp and paper, mining, petro-chemical and sugar industries. The company, which is now 100% South African owned and in future will be known as ND Engineering has offices and manufacturing facilities based in Durban. The company, which has facilities in the Queensburgh and Bayhead areas of Durban, is a manufacturer of stainless, alloy and carbon steel products. They specialise in the manufacturing of pressure vessels, storage tanks, heat exchangers, filter drums, distillation columns, mechanical equipment, conveyors, and turnkey projects. Metso ND Engineering was established in 1975. In 1992, 60% of the company was acquired by Sunds Defibrator, which later became part of the Metso Group. In 1994 Sunds Defibrator acquired the remaining 40% and became the sole shareholder. In 2004, Mr. Elvis Green acquired 30% of the company shares. Metso’s pulp, paper and power professionals specialise in processes, machinery, equipment, services, paper machine clothing and filter fabrics. The company’s offering and experience covers the entire process life cycle including new production lines, rebuilds and services. Metso is a global supplier of technology and services to customers in the process industries, including mining, construction, pulp and paper, power, and oil and gas. The company’s 30,000 professionals based in over 50 countries contribute to sustainability and deliver profitability to customers worldwide. Metso’s shares are listed on the NASDAQ OMX Helsinki Ltd. For further details contact ND Engineering on TEL: 031 464 0510 or visit www.ndengineering.co.za Toyota SA invests R6,1 billion to build new Hilux and Fortuner

apanese automaker Toyota, has announced that it has invested over R6,1 billion to facilitate Jproduction of the all-new Hilux and Fortuner at its Prospecton plant in Durban. This reaffirms Toyota South Africa Motors’ (TSAM) position as the largest automaker in South Africa, manufacturing no fewer than five individual models (Hilux, Fortuner, Corolla, Corolla Quest and Quantum) in CKD or complete-knock- down form, as well as selected Hino and Dyna models producedas SKD or semi-knocked-down assemblies. “This latest announcement gives evidence of a company that is defiantly committed to South Africa by strategically investing in the people, tools and equipment to produce cars and commercial vehicles of a world-class standard that are not only destined for the domestic market, but will also fly our flag high on the international stage thanks to a robust export plan.” achievements of the motor industry “But it is in fact more than in growing production and that — it’s also a celebration of especially exports post-1994, we the pivotal role that both Hilux and must remember that South Africa Fortuner play in the overall currently produces less than 1% of development of the South African the 90-million vehicles made motor industry,” TSAM President and worldwide each year.” CEO Andrew Kirby said at Toyota’s “We have to remain world Prospecton Plant. competitive not only in terms of Dr Johan van Zyl, Chairman wages and productivity, but also of Toyota South Africa and Chief regarding labour stability. I cannot Managing Officer of Toyota Motors stress enough the importance of Europe echoed Kirby’s sentiments, adding that, “the TSAM of engagement — engage, engage and engage again — the need today is vastly different to the same company only 10 years to employ dispute resolution as the first and ultimately only line ago. This is all due to an ability to change with the times and I of defense rather than resorting to strike action as the solution.” am glad to say that as we have changed, we have become “Nevertheless, I am confident that a fair and equitable better and more focussed to the benefit of our customers.” labour agreement can be reached and rest assured, that no Van Zyl did however reiterate the importance of stability on matter what, Toyota will do its utmost to continue to put its the production line: “Although we are justifiably proud of the customers and South Africa first.”

Eskom RT&D develops laser beam welding technology for power station applications

skom Research, Testing and Development (RT&D; interest is rebuilding blades with erosion as well as Johannesburg, South Africa), in collaboration with the mechanical damage. ECouncil for Scientific and Industrial Research (CSIR) A large number of turbine blades are scrapped during National Laser Centre (NLC; Pretoria, South Africa), has turbine maintenance and repair projects since the tenons of developed a mobile laser beam welding (LBW) system for blades need to be ground down to remove the blades from the repairing leaks and cracks in stainless steel water turbine rotor. Removed blades cannot be used again, as the reservoirs. remaining tenon stub is too short to be riveted a second time. An LBW research facility has been established at CSIR NLC Rebuilding the tenons by welding is a viable and cost-effective to support Eskom's maintenance programme for dealing with option to repair the blades for further use, and should result in various maintenance challenges on high-value equipment, substantial cost savings. such as precision weld repairs on turbine blades. Of particular For more information please visit www.eskom.co.za

30 METALWORKING NEWS v 15. 3 July 2016

Multitrade Distributors cuts ribbon on new headquarters

ultitrade Distributors, a wholly owned South African ever to assist our customers and partners in that effort.” company that supplies tungsten carbide cutting tools Mas well as holding tools to the engineering and New appointments manufacturing industries, has recently moved to a new office Multitrade Distributors have also taken the opportunity to and warehouse facility. appoint Mark Lotter as National Sales and Technical Manager, Located in the Edenvale suburb of Illiondale, Multitrade Chris Smuts as Johannesburg Sales Manager, and Riaan van Distributor’s new headquarters is designed to help facilitate the Heerden is now branch manager in Cape Town. company’s growth in the South African marketplace. The new address is 2 Peter Road, Illiondale, Edenvale, Gauteng. Mitsubishi Materials catalogue now available on Founded in Port Elizabeth in 1983, the main objective of MachiningCloud the company is to introduce and maintain total tooling solutions The tooling catalogue of Mitsubishi Materials to these industries. Since inception, Multitrade Distributors (MMC Hardmetal), the international carbide cutting tool has been the sole distributor for Mitsubishi Materials carbide manufacturer that Multitrade Distributors has been associated products in the Southern African regions, and later introduced with from inception, is now available on MachiningCloud. various other product offerings to its range such as SsangYong This cloud-hosted offering makes available multiple Ceramic Cutting Tools, NT Tool Corp, Komet Group, Arno cutting tool and workholding vendors’ product data in Werkzeuge and Kintek. standardised format. The cloud-based platform supports tool The company head office is situated in Johannesburg recommendations, building tool assemblies, feeds and speeds, with branches in Cape Town, Port Elizabeth and Durban. They report generation, downloads of 3D models and 2D drawings, service other areas through a network of smaller distributors plus more, says the company. This web-based system can be outside the reach of the branch offices. Multitrade Distributors accessed on PCs and tablets, but direct integration with pride themselves in the quality brands that they represent. CAM systems requires an interface — Esprit, TopSolid, The level of expertise of their management and staff is their Mastercam and Vericut, for example, have these. biggest asset that includes the full backing of their technical There are currently 15 000 Mitsubishi products, including applications department providing guidance from basic milling and turning tools, on MachiningCloud with a projected tooling requirements to full CNC programming in many 25 000 more in the coming months. disciplines, including turnkey projects. "Our partnership ensures that customers of Mitsubishi “Our new headquarters give us the opportunity to better Materials will save a tremendous amount of time, produce showcase our technology and service our customers,” says improved results by working with up-to-date knowledge and Johny Hansen, Managing Director of Multitrade Distributors. data, and reduce errors by eliminating manual data entry," says “As the South African metal cutting industry gravitates Christophe Rogazy, Cloud Evangelist for MachiningCloud. toward higher precision to reduce their machining times and For further information contact Multitrade Distributors on stay globally competitive, we are now better positioned than TEL: 087 803 2377 or visit www.multicarb.com

32 METALWORKING NEWS v 15. 3 July 2016

RAPDASA 17th Annual International Conference

he Rapid Product Conference package Development Association The conference will Tof South Africa (RAPDASA) be held at the VUT Southern will hold its 17th Annual Gauteng Science and International Conference from Technology Park, located 2 to 4 November 2016 at the in Sebokeng, just north of Vaal University of Technology, VUT Southern Gauteng Science Vanderbijlpark in the Gauteng province. The conference fee and Technology Park, Vanderbijlpark, South Africa. will be R4,100 for delegates and R2,750 for students** The theme for this year's conference is: "Building on the which will include: foundations - consolidating impact into products to enhance • 3 days full conference participation quality of life for all South Africans". • Lunch and refreshments (tea/coffee breaks) In support of this theme, the first day of the • Cocktail function conference will build on the success created during • Gala dinner RAPDASA 2015 and again be dedicated to a special event • Advanced Manufacturing Precinct tour entitled the “South African Additive Manufacturing Innovation Showcase”. This event will bring together the leading The organising committee would like to extend a special innovators / entrepreneurs in Additive Manufacturing invitation to SMMEs, entrepreneurs, inventors, engineers, (3D printing) in South Africa, allowing them to share their product designers, toolmakers, production staff, technical ideas on innovation and product development using additive directors and managers from industries involved in the design, manufacturing. As the conference will be presented at the development and manufacturing of products and components. VUT Southern Gauteng Science and Technology Park, You are welcome to participate and share experience and daily visits to the Advanced Manufacturing Precinct, hosting learning in the field of AM, or simply attend the conference and one of the largest AM installations in South Africa, will be gain a better understanding of AM’s possible impact on your conducted. business.

With respect to the conference theme, papers can be Pre-conference workshop submitted under any of the following topics: Pre-conference workshops will be presented on • AM business development 31 October 2016 and 1 November 2016. The workshops will • New AM applications include “Additive Manufacturing of Titanium Parts”, hosted • Impact of AM on the intellectual by the Central University of Technology, and “Idea 2 Product” property environment hosted by the Vaal University of Technology (VUT). Further • Design for Additive Manufacturing information and cost will be given in future communications. • Reverse engineering For more information regarding the pre-conference workshop, contact: Jenny van Rensburg [email protected] or • Simulation and modelling Tel: 051-507 3456 • Process monitoring and control Online registration has opened on the RAPDASA website • Material evaluation and selection and there are calls for papers, and an early bird registration • Post processing and qualification fee discount will apply. • Material / Process development For further information, please contact Sarah Tlale on • Product development TEL: 016 930 5023 or email [email protected] Vehicle component production plan expected to boost local car OEMs

outh Africa’s plan to increase local vehicle component development policy and a weak rand that will continue to drive manufacturing will help local car makers increase investment into the local autos industry and bolster car exports Sproduction by an average of 2.4% a year for the next four over our forecast period," BMI said. years, ratings agency Fitch’s Singapore-based subsidiary "South Africa’s plan to increase investment in local parts BMI Research said in a report. production will result in cost and efficiency gains for South Africa’s drive to increase local vehicle parts (car makers) in the country. It will also create opportunities for production included the KwaZulu-Natal government’s purchase new and existing automotive suppliers as vehicle production of 1 000ha of farmland in May to develop an R11.5 billion expands over our forecast period of 2016-2020.” automotive supply park south of Durban in 2018. "The strengthening of automotive supply chains in the country As part of this project, it will target suppliers, including ones will support our positive outlook for vehicle production in South already working with vehicle manufacturers in the country, to Africa over the next five years as (car makers) benefit from the set up there. cost and efficiency gains as a result of the increased localisation "We forecast vehicle production growth of 1.9% in 2016, of parts production. It will also create new opportunities for with annual average growth of 2.4% over our forecast period foreign original equipment manufacturers and local producers 2016-2020. Driving this growth will be a supportive automotive to establish new partnerships," the researchers said.

34 METALWORKING NEWS v 15. 3 July 2016 Electra Mining Africa 2016

Takes place 12 to 16 September 2016 at the Expo Centre Nasrec, Johannesburg.

he South African mining industry is facing another Africa, SADC and the rest of Africa, South America, USA, challenging year with slower than expected economic Canada, Europe, Asia and Australia attend Electra Mining Africa. Tgrowth, a prolonged and continuing downswing in The show is expected to have a remarkable display of new commodity prices, an increase in short-term volatility, increased and emerging technologies that will continue to revolutionise pressure on operating models, and regulatory uncertainty. the manufacturing world. These innovations, coupled with Adding to these challenges is the increased difficulty in raising traditional equipment, offer solutions to all manufacturers who capital due to a loss of confidence by investors. However, this seek increased productivity and lower cost. situation is not unique to South Africa, with mining companies Some of the metalworking related exhibitors that will take The show is expected to have a remarkable display of new and emerging technologies that will continue to revolutionise the manufacturing world the world over facing the same challenges. part include A J Charnaud, Afrox, Amada, Fast Cut Tooling and It is at times like these that trade exhibitions and Supplies, M-Tool, Mafema Sales Services, Microstep SA, Talmac face-to-face interaction with customers becomes even more Machine Tools, TDC Cutting Tools South Africa, Toolquip & Allied important in order to ensure business survival. and World Power Products. Since its inception more than 42 years ago, Electra Mining For visitor pre-registration, go to www.electramining.co.za Africa has grown to become one of the largest mining and or for further information contact Leatitia van Straten at industrial exhibitions in the world. Visitors from all over South email [email protected]

METALWORKING NEWS v 15. 3 July 2016 35 Paramount Group unveils new generation 8x8 infantry combat vehicle for global defence market

Latest 8x8 combat vehicle showcases world-class technologies from leading African defence Group.

aramount Group, the African-based global defence and aerospace company, has unveiled a new generation 8x8 PInfantry Combat Vehicle, representing the pinnacle of land system technologies that are designed to meet the world-wide demand for sophisticated, but affordable military equipment that provides unrivalled protection for land forces personnel, in an era of unprecedented asymmetrical threats and conflict. The highly advanced Infantry Combat Vehicle, Mbombe 8, made its debut at Kazakhstan Defence Expo (KADEX 2016) in Astana on the 2nd June 2016. The Mbombe 8 is at the vanguard of armoured vehicle technologies and has been developed to meet the increasing demand for multi-role, high mobility and mine hardened platforms, and for the changing demands of the global battle- field. Paramount Innovation and Design (a Paramount Group configuration, positioning the powerpack at the front of the Business) has been responsible for the development and vehicle and along its centre line. This configuration results in production of a broad range of advanced armoured and mine far greater efficiency in terms of the transfer of power from the protected vehicles that are in operation around the world. powerpack to the wheels, as the loss of power associated with The Founder and Executive Chairman of Paramount Group, a second transfer gearbox necessary for ‘unconventional’ Ivor Ichikowitz said: “This is a momentous occasion in the drivelines, such as with side-engined vehicles, is eliminated.” evolution of Paramount’s Group’s offering and we are very Ichikowitz added: “The Mbombe 8 is world-leading in its excited to develop this high speed, long-range and low class, this is a product that we are very proud of. We pioneered profile 8x8 armoured combat vehicle. In less than a decade, mine-resistant flat floor technology that is central to the design Paramount has designed, developed and industrialised an of the new 8x8 platform. Another important feature is the drive- armoured vehicle nearly every two years, from a clean sheet line commonality across our family of vehicles, as is the case design. Without exception we have built a reputation for pushing with the Marauder XT (4x4), Mbombe 6 (6x6) and Mbombe the boundaries and creating armoured vehicles that are 8. This presents a unique opportunity for the global market, groundbreaking in their design, protection levels and mobility.” affording a prospective end-user of all three vehicles significant Ben Jansen, CEO of Paramount’s armoured vehicle savings in the areas of maintenance and logistical support.” business said: “The development of Mbombe 8 has enabled The Mbombe 8 is based on the design of Paramount’s Paramount Group to provide potential customers with a complete Mbombe 6 that employs an innovative new form of family of 4 x 4, 6 x 6 and 8 x 8 AFVs which share over 80% of construction to give unprecedented levels of protection, while common components to reduce through life costs and make keeping profile to a minimum. The 8x8 also draws on the for easier training and logistics. This commonality relates to company’s experience of designing the highly effective and both the driveline aggregates, as well as the fact that all three battle-tested Marauder and Matador mine-resistant vehicles. vehicles utilise a ‘conventional’ or ‘in-line’ automotive driveline For further details visit www.paramountgroup.com ArcelorMittal SA’s Saldanha plant will keep operating

rcelorMittal South Africa‘s Saldanha have since ensured the plant’s viability, said plant will keep operating, its chairman acting Chief Executive Dean Subramanian. Asaid recently, after the facility was placed South Africa’s currency lost about a under review earlier this year due to low steel quarter of its value from the end of May last prices and rising costs. year until now, providing relief to some of the The plant, north of Cape Town, is the nation’s exporters. newest in the company’s fleet and was opened Subramanian and Makwana were in 1998 to focus specifically on steel exports, speaking at the release of a report on but low steel prices and high electricity and ArcelorMittal’s contribution to South Africa’s transport costs made it unprofitable last year. economy, which also stated that the plant was “As the board, we are comfortable that responsible for 16% of the steel produced in we will have a Saldanha that is a good, healthy, performing Africa’s most industrialised country. business for a long period,” said ArcelorMittal South Africa ArcelorMittal will start maintenance at Saldanha in August, Chairman Mpho Makwana. which Subramanian said would increase the plant’s life by The weaker rand and a pickup in West African steel demand up to five years.

36 METALWORKING NEWS v 15. 3 July 2016

Gibela appoints 32 local suppliers for R51 billion PRASA contract

Makes progress towards meeting local content target and reinforces company’s commitment to economic development.

he first 32 South African suppliers in the R51 billion itself as part of efforts to develop a robust and sustainable contract to provide local content for 600 new passenger South African supplier base. Ttrains being built by Gibela for the Passenger Rail Authority Siyahamba Engineering is responsible for the supply of of South Africa (PRASA) have been appointed. cabin doors and partition walls for the new trains. CEO Julius In terms of Gibela’s contract with PRASA, the first 20 Motshopi said: “Gibela brought in a specialist from the UK to new trains are being built in Brazil and the balance of 580 at work with us to help us industrialise and organise ourselves. Gibela’s new South African manufacturing facility at Dunnottar We have gone through a steep learning curve and developed a in Ekurhuleni. South African-made components are being made good working relationship in the process.” in South Africa, using South African materials, and are being LED Lighting SA, a Cape Town-based medium-sized shipped to Brazil for the first 20 trains. company, supplies Gibela with one of the world’s first set of Gibela CEO Marc Granger says his company has no exterior LED lights to comply to international rail standards. contractual obligations to add local content to the Brazilian-built CEO Andrew Glenday commented: “There’s much more of a trains. However, Gibela took a strategic decision to get a head buzz in South Africa around rail and I believe that start, in an effort to ensure that local suppliers are well well-structured investment in our local rail business will be prepared in terms of technical capability, capacity and repaid many times over through export, employment, skills investment for what will be an intensive manufacturing development and even intangibly in national pride.” programme once local production starts in 2017. “I am proud of the offices and factory we have set up. Welcoming the suppliers, Gibela CEO Marc Granger said They are as well established as any factory in the United States that, in just two years, or Europe; we’re Gibela’s journey in making world-class delivering the next products and we are generation of trains to gearing up to export.” South Africa’s rail-commuter At full production public has gained locally, Gibela anticipates momentum on all fronts that a panel comprising and in particular, in the 200 local suppliers will be sourcing and supply of manufacturing equipment local equipment and and components for the components of a standard 580 locally produced trains that is meeting Gibela’s from 2018 onwards. steep quality and other requirements. The list of the He added: “By local suppliers to producing quality Gibela includes: components such as these, Siyahamba local suppliers will — in Engineering — cabin doors, addition to being able to cabin interiors, including service Gibela and the partition walls; South African rail sector as a whole — be able to compete in Booyco — saloon heaters, driver footrest; ILVA General global markets, opening up real potential for significant exports Engineering — air tank — reservoirs; KAMA Industries — horns; and resultant foreign exchange earnings for South Africa. We Profibre — passenger seats, longitudinal benches; are starting to make very substantial progress in rejuvenating KARE — battery box; First National Battery — batteries; our local rail manufacturing industry’s capabilities and capacity.” Denel — baseboard ducts; Global Composite — luggage racks, While making it clear his list was not exclusive, Granger equipped ceiling, cab and saloon air ducts; flagged a broad range of South African-made components Delberg Engineering — handbar and backrest; visible inside and outside each train, and others — equally as Radel — passenger and cab lighting, door light indicator, important but are not visible to passengers — such as batteries, voltage indicator; Gibs — insulation; Crest Information Systems heating and braking systems. — door external fairing, extract air duct in cubicle; At the peak of production in South Africa, Gibela will be Laser Junction — brackets, cab foot step; Laser Junction/ producing 62 cars a year (each train set comprising six cars). General Profiling Matla Steel — coupler push back; Laser For each train that has already been built in Brazil, 22% of Junction/SPE — tool box; Jandinox — equipment support; procurement spend is on components sourced from South Buzas — obstacle deflector; Columbus/Macsteel — stainless African suppliers, a large percentage on interiors, energy and steel; Arcelor Mittal SA/Macsteel — carbon steel; sheet metal work domains. LED Lighting — external front/cab lighting; Aberdare — cables, Contributing to the success of the suppliers has been the wires; Forminox — piping. technical advice and assistance provided to them by Gibela For further details visit www.gibelarail.co.za

38 METALWORKING NEWS v 15. 3 July 2016

shopfront focus

Better processes, better results at Multi Tanks International

onsidering the variety of welding processes available, selecting the right Cone for your shop could be a confusing and difficult decision. In any manufacturing operation, matching the best process to the application can be the difference between profit and loss on a job. Likewise, welding has many variables in terms of matching methods and materials. By properly selecting a welding process, many hours may be saved in production, repairs, polishing and grinding, or rejected welds. The object of welding, whether it's done on a production basis or occasionally, is the same: To produce a quality weld in the least amount of time. Welding quality is determined by the success one has in creating a weld that penetrates sufficiently, without pores, pockets or gaps. Good surface finish is also a factor. When you have 139 years of collective An example of a fitted tank experience in welding between the management team, you figure that this addition to a low melting point and high thermal conductivity, company can weld. aluminium is especially prone to burn-through on thin sections It all starts back in 1957 when Arthur Johnson, now 75, and and may experience lack of fusion on thick ones. Weld defects still very active in the business, completed his welding training like cracking, weld smut/soot, and porosity are also real in the UK. For the next eight years Arthur worked for engineering concerns.” companies, started his own business and family, and generally “Still, aluminium’s ability to resist corrosion, its high learnt the art of metalworking, but always with an emphasis on strength-to-weight ratio, as well as its high electrical welding, and more specifically with a bias towards aluminium conductivity make it an excellent choice for many applications welding. This experience would be invaluable when he decided from aerospace to heat exchangers, trailer fabrication and, to uproot the family and move to South Africa in 1972. most recently, automotive body panels and frames.” It did not take Arthur long to get on his feet, and by 1975 he “To avoid a negative impact on productivity and quality, it is established his first South African company, A Johnson & Sons, important to understand the causes of aluminium weld defects, a company that grew over the years on welding applications implement steps to prevent them, and find ways to quickly and general fabrication. rectify errors should they occur.” “I had almost become a specialist in aluminium welding “As with any welding process on any material, following during this time,” said Arthur. some basic guidelines is critical to obtaining the best results. “Welding aluminium poses some unique challenges. In Aluminium’s mechanical and chemical composition can make the process a bit tricky. Always follow best practices for cleaning and storing the material and filler metals, and carefully select the right equipment. After all, having everything in order before welding is easier than trying to fix problems later.” Today aluminium welding is still one of the processes used in the company that has changed its name to Multi Tanks International, however the company is much more than that. Multi Tanks International is a family-owned business that manufactures affordable high quality after-market aluminium fuel tanks for a variety of companies. There are no formal job titles in this tight-knit family-owned business run by Arthur Johnson and his two sons, Lee and Craig. Lee joined the company shortly after leaving school in 1992, and the young Craig joined in 2002. Multi Tanks International began operating in 2000, and tank manufacturing has been the core of the business for the Various tanks manufactured by Multi Tanks International last 16 years. 

40 METALWORKING NEWS v 15. 3 July 2016

“Our first attempt at manufacturing a fuel tank was 20-odd years ago. Out of the blue we received a call from a truck distribution company who knew that we had some experience in aluminium welding. They wanted us to manufacture some aluminium chequered-plate mud guards, which you couldn’t buy in South Africa.” “When we delivered the mud The Yaskawa Motoman robotic welding machine “With manual welding you will welding the tank ends never achieve the same guards, we were consistency of a weld over the intrigued to see that length of the tank that could be their trucks didn’t have aluminium tanks so we decided to ‘test the accessories used to make 1500mm, and you can’t the waters’ and manufacture one. It was at a time when OEMs up the various tanks that we duplicate the same weld, but were under pressure to look at reducing the weight of vehicles manufacture.” with a machine you can, as long and trucks so as to achieve cost reductions and take “Many of these as you have a fixture to hold the environmental considerations into account. Aluminium was a components have to be material in place.” The latest great alternative and an intelligent solution to allow maximum machined or cast, and press addition is a two station Yaskawa Motoman robotic welding weight savings while still retaining the integrity and safety formed in the case of the machine equipped with a of the product or component. The added advantage is that the fuel tank ends. We were not manipulator and a jig that the material is corrosion resistant.” equipped with any of the company has manufactured itself “You can achieve weight savings of up to 45% when using equipment to perform these aluminium, whether it is formed, machined or cast. It is not processes and in the beginning we had to outsource most of ideal for every application but time has shown that the use of the components,” continued Lee. aluminium in the transport industry has grown beyond “The number of different varieties of standard tanks that expectations.” we manufacture is 40, but we are not limited to just being a The prototype aluminium fuel tank was the beginning of a production operation because we have many requests for new era in the lives of the Johnsons, one that would lead to custom made tanks and other products. Another one of our them changing the company name and the services it offered. standard products that we offer is hydraulic tanks that are used “Our focus had always been on welding, but with the on heavy equipment such as backhoes, excavators, cranes, introduction of the fuel tank manufacturing we realised that to side tippers, large off-road trucks, and generator and pump offer an off-the-shelf product, it entailed more than just sets,” explained Lee Johnson. welding metal together. There is plasma cutting, shaping, roll “The tank sizes on the fuel side range from 160 litres to and press forming and welding of the sheet. But then there 1000 litres and we now manufacture fuel tanks for about are all the accessories that are part of the final product. These 90 percent of all truck vehicle makes on the road. This includes include nipples, caps, sockets, filters, flanges, shoulder fittings, Volvo, Freightliner, Hino, Isuzu, Ford, MAN, Nissan, Mercedes ant fuel theft necks and components and many others. In total Benz, Scania, Peterbilt, Iveco and International. The tanks are there are about 45 different components that we regard as also used on the buses of the various OEMs. However, we must emphasise here that we are not manufacturers for and suppliers to the OEMs. We supply the aftermarket sales industry and the panel beaters are probably our biggest clients.” The latest version of fuel tank products that Multi Tanks International has added to its range is one that accommodates AdBlue. AdBlue is a diesel exhaust fluid used in modern trucks that have a selective catalytic reduction (SCR) system. Using AdBlue in line with manufacturers' requirements and a catalytic converter reduces the level of oxides of nitrogen emitted from engines. It is not a fuel, nor a fuel additive but a high purity urea solution that must be used in a dedicated tank. “Vehicle manufacturers, and first and foremost those of large goods vehicles, have had to re-think the exhaust system on their vehicles. More and more diesel cars, tractors and other off-road vehicles are also now equipped with the SCR system in the exhaust,” explained Craig Johnson. “There is a separate tank used for AdBlue that is generally Lee, Arthur and Craig Johnson from located next to the fuel tank. AdBlue and diesel mixed can do Multi Tanks International — a local fuel tank manufacturing un-repairable damage so the two must not be mixed, hence company, creating products as good as any OEM could offer the second tank. In our case we are still manufacturing the one

42 METALWORKING NEWS v 15. 3 July 2016 tank system for clients machine and have but within this tank there subsequently manufactured is a separate compartment a further four presses for the AdBlue.” ourselves. We made our Multi Tanks own mould for the forming International has grown of the tank ends, and the impressively over the collection of moulds grew as years and can now easily word spread about our manufacture 50 tanks in capabilities,” explained a week. So too has the Craig. equipment and processes “We are also making it uses to manufacture other components in this the tanks and other area now and they are equipment grown. realising big cost savings “Shortly after for us. An example is an manufacturing our first aluminium flange that we few tanks and deciding used to have cast at a local that this was the direction foundry. The castings were the business was going to The first area Multi Tanks International gave attention to was in the never on time and the press department. The company invested in a 100 ton hydraulic forming evolve in, we soon found machine and have subsequently manufactured a further four presses blow-hole problems were out that relying on always a challenge. We outsourcing was not going would be welding the to work for us. We needed to be independent of suppliers’ component to a tank and it would virtually explode in our faces. whims and embarked on a plan to bring everything in-house. So we designed and manufactured our own pressing mould and Besides relying on material suppliers we are now capable of we do not have these problems anymore.” completing all the processes that we need in our manufacturing “Forming components with more consistency than we operation. We are lacking in a few of them in terms of had been receiving with the sourced supplier results in better productivity but we are addressing them as we speak. Punching repeatability and has streamlined our downstream welding and rolling is one area that we are addressing,” said Craig. operations.” “The first area we gave attention to was in the press A press brake, guillotine and two roll roller soon followed. A department. We soon invested in a 100 ton hydraulic forming ClearCut CNC plasma was also a welcome addition to the  consistency of a weld over the length of the tank that could be 1500mm, and you can’t duplicate the same weld, but with a machine you can, as long as you have a fixture to hold the material in place.” “So it is not only the quality of the weld that improves, but also the big savings in time as an additional benefit. Where it used to take me about seven or eight minutes to weld the ends on a tank, the robot will do it in two and a half minutes.” “Because of the positive results that we have achieved with the Yaskawa Motoman robot we are now seriously considering installing a second robot. The robot An example of an aluminium flange that Multi Tanks Another one of Multi Tanks installation has not replaced any members International used to have cast at a local foundry International’s standard of staff, it has just given us an opportunity but are now pressed in the press department. products that they offer are to improve the aesthetic look of the tanks as The castings were never on time and the blow-hole hydraulic tanks that are well as the quality.” problems were always a challenge. They would be used on heavy equipment The company has been able to develop welding the component to a tank and it would such as backhoes, excavators, rapidly in the last five years because it virtually explode in their faces. So Multi Tanks cranes, side tippers, large International designed and manufactured their own off-road trucks, and moved into a new 1200m² factory in 2010 pressing mould and no longer has these problems generator and pump sets in Delporton, Krugersdorp, Gauteng. The spotlessly clean facility has been divided into process operations, including a wash bay, shopfloor equipment. The company then addressed the and has allowed Multi Tanks International’s component-manufacturing headache. production capabilities to expand, evolve and respond to rapidly “We are not a production shop but still need many of the changing market challenges. components that are welded on to the tanks to be machined. Lee points out that their products are already at an interna- Here we acquired a Yunnan CY Group flatbed CNC lathe. It tional level. He says they recently made a tank for a vehicle that more than takes care of our machining requirements.” went to a major manufacturer’s head office, and when it arrived, the guys couldn’t believe the tank was made in this country. The introduction of a Yaskawa Motoman robot After hearing all this, it’s no surprise to learn that the While always introducing new equipment into the company company’s tanks are used all over Africa in countries such as the Johnsons have continually looked to improve on their Mozambique, Zambia, Zimbabwe, Namibia and Botswana. manufacturing processes and production methods. Arthur points out that the company doesn’t only “Innovation has been a part of our culture since the manufacture tanks. It can make anything out of aluminium. establishment of this company. One tank used to take us a “We manufacture side-skirts, line hauling under-belly tanks whole day to manufacture, but now it takes us about an hour, on trailers and exhaust covers, truly anything in aluminium on all because we have constantly looked at improving our a truck or bus. The latest product that we are gearing up for is operating procedures,” says Lee. tanks to be used on a pontoon. We have the equipment, so it The latest addition is a two station Yaskawa Motoman wouldn’t make sense not to, however the manufacture of tanks robotic welding machine equipped with a manipulator and a jig will remain our core business.” that the company has manufactured itself. “Everything we manufacture is welded in some form or “While visiting exhibitions in Europe we learnt that many another. We were lucky that we recognised that there was a aspects of welding are robotically done. We recognised this as an niche in the market for fuel tank manufacturing, and we have opportunity for a significant process improvement. Many of the the expertise in aluminium welding and can create products as tanks that we manufacture are in a cylindrical form and the sheet good as any OEM can offer.” needs to be welded together before you weld on the tank ends.” For more information contact Multi Tanks International “With manual welding you will never achieve the same on TEL: 011 665 3022

A tank in its final stages of manufacture. Multi Tanks International Multi Tanks International is The tank sizes on the fuel side range from is not restricted to just not a production shop but still 160 litres to 1000 litres and Multi Tanks manufacturing tanks. Any needs many of the components International now manufactures fuel tanks fabrication that needs welding that are welded on to the for about 90 percent of all truck vehicle they are able fabricate tanks to be machined makes on the road

44 METALWORKING NEWS v 15. 3 July 2016

Aiming to do better

hen you are in the business of manufacturing and selling products Wthat require accuracy you need design, process planning, component manufacturing and supplied materials to all come together in assembly and work. There is no better measurement of the success of a manufacturing operation than the assembly of the various components that go together to make a product. Whether the product is an automobile or a pocketknife, how the components fit There are clearly determines product performance. opportunities for growth in This could be said about most manufacturing companies these markets. Indeed when I visited but when your product lines are vehicle speed measurement Truvelo Manufacturing in Midrand, Gauteng it looked like the and related equipment, as well as rifle and barrel whole of the Limpopo traffic law enforcement department was manufacturing, the word accurate is synonymous with the there. Thankfully they were not interested in me but it did put products. you on edge. The product mix at Truvelo Manufacturers could not be Once inside the company it was all abuzz with more diverse, but both have high tolerance and precision as a excitement and last minute planning for the company’s common denominator. participation at HuntEx2016, an annual exhibition held at Truvelo Manufacturers (Pty) Ltd was founded in 1966 Gallagher Convention Centre showcasing the latest in hunting, by FJ (Franz Josef) Gebert when he established the need sports, tactical and defensive firearms, ammunition, gear and for accurate vehicle speed measurements in the traffic law related accessories and equipment. enforcement field. He patented the use of piezo sensor cables There was much anticipation as Truvelo Armoury Division to accurately detect the passage of a vehicle’s wheels. This were due to launch a new addition to the company’s CMS result was the first accurate and reliable vehicle speed Rifle Range, the Truvelo CMS 6.5 x 47. Truvelo says the new measurement. Hence the company name “Truvelo”, or lightweight and compact rifle weighs six kilograms (including true-velocity. telescope and magazine), with an overall length of 1180mm, Truvelo Manufacturers’ Armoury Division was established and will achieve sub MOA (minute of angle) results, at in 1994 when it entered into the field of rifle and barrel distances up to 500 metres. The effective range is manufacturing. The company’s unique manufacturing process 1200 metres, depending on ammunition. resulted in the development of a combination of a Truvelo So when I say this company has accuracy in its blood I am barrel range with sophisticated precision sniper rifle not wrong. technology. The proud result of this combination is Truvelo’s Alexa Gerrard, Marketing Manager at Truvelo, says that range of highly accurate, long-range rifles with calibres the rifle has been built primarily for the civilian sport shooting ranging from 7,62 x 51 to 20 x 110 Hispano. market, but it can be used in a military context as well as it has been developed and manufactured according to military standards. Truvelo’s CEO is Ralf Gebert. He is also the son of the founder of the company and holds an Electronic Engineering degree from the University of Pretoria. He took over the family business from his father who sadly passed away a few years ago. “My parents arrived in South Africa in 1958 with very little. Their long hours of hard work were an example for all of us siblings. They started working from home and using the garage for extra space. I especially benefitted from the hardship and perseverance and being satisfied with very little. From early on in my childhood I was always at the company and grew up with it. Nobody can replace this experience and its associated learning curve,” said Gebert. “The company started operating from our home in Lyttelton just outside Truvelo’s CEO Ralf Gebert Pretoria. In 1979, we acquired this 

46 METALWORKING NEWS v 15. 3 July 2016 site in Midrand and “We are the business moved to constantly it. It was a functional challenged and building for what the measured against company needed, international but as the company standards and expanded so too did competitiveness with the demand for these products. We operating and have conquered this manufacturing space by developing our grow.” own designs and “We occupy a by employing highly 11500m² site so skilled engineers that there was plenty of have qualifications in room for expansion. mechanical and We have just recently electrical completed our engineering, as well renovations and as mechatronics. expansions and now The products do not have 3600m² under infringe on other roof available to us. Most of the components that Truvelo manufactures are put through patents. In fact we The building now the vibrating surface finishing machine that uses ceramic media to deburr components have over 50 of our includes a modern own patents.” factory, laboratory, training and testing facilities, assembly “We are also proud to say that you will find our products areas for the respective divisions and, what could be being used by authorities worldwide. However, we see great unique in South Africa, a 70 metre underground potential in Africa in the future and even established the shooting range.” company Truvelo Africa in 2014. It is 51% black-owned and concentrates on the South African and African Lights, camera, action markets.” “As we have said, Truvelo Manufacturers’ main function is Equipment manufactured in this division is available for to design, develop, manufacture, install, service and market hand-held, mobile and fixed site applications. The range our range of traffic related equipment for traffic law covers digital speed and red-light cameras, digital enforcement and vehicle data gathering. Our products are mobile/portable speed cameras, and hand-held devices. manufactured mainly for police/traffic departments, local and state/governments’ law enforcement agencies, civil engineers Truvelo Manufacturers’ Armoury Division and road construction agencies,” said Gebert. “The armoury division was formed as a result of my “The company’s products were built on the characteristics father’s passion for firearms which was also his hobby. This of speed, accuracy and precision. The traffic related products division has now become an integral part of the company have evolved over the years and today incorporate aspects of accounting for about 50% of turnover with 90% of product the modern technology that is available to us. You will be being exported.” surprised to see the tools that are now available to authorities “Our weaponry is utilised by military agencies, law to monitor and collect information. If used correctly, without enforcement departments, gunsmiths, hunters and shooters any sway or persuasion, we would have much safer roads to and enthusiasts of all types.” travel on.” “Although the company has a total staff compliment of 60, “They are not well liked products in terms of motorists this division currently employs a small select team of who would rather dodge fines when committing a road engineers and machinists, including four gunsmiths.” travel related offence, but are very necessary to keep law “We operate in an area of the market where people who and order.” buy our products like guns and rifles, like to know how they’re

Truvelo Manufacturers’ Armoury Division was established in 1994 Components that will be machined when it entered into the field of rifle and barrel manufacturing to specification

48 METALWORKING NEWS v 15. 3 July 2016 “We are constantly challenged and measured against international standards and competitiveness with these products. We have conquered this by developing our own designs and by employing highly skilled engineers that have qualifications in mechanical and electrical engineering, as well as mechatronics. The products do not infringe on other patents. In fact we have over 50 of our own patents.”

made, where they’re made and of customers. In the past, gun manufacturers were much more what they’re made. They want to know vertically integrated, in that they would manufacture, exactly where the parts for any given assemble and distribute all under one name and all in one product are manufactured and place.” assembled. Also, customers in this “We are part of this old school thinking and don’t intend industry want a product that will fire to change it in the near future.” 100 000 rounds and at the same time “What we have moved away from though is customisation. The new Victor for it to look like a highly polished, With us developing our own products, most of which have Vturn-X200 five-axis precision piece of jewellery.” their own patents for design and components used, we are multitasking turning “Further, we understand that to now able to focus on batch manufacturing. The benefit of this centre allows the manufacture for the firearms industry, is that it reduces the variances in component manufacture.” company to perform more operations in you have to have special permits and one setup, thus abide by international laws. This task New Victor Vturn-X200 five-axis multitasking eliminating the virtually creates a whole admin turning centre possibility of the division on its own.” “The Victor Vturn-X200 allows us to perform under component going “Generally speaking, a pressure, running bolt carrier components one day, and out of spec manufacturer in this area is an OEM. chamber components the next. The machine is extremely All components for the product, and versatile because we have got Victor Taichung to manufacture this can be over 50 per product, are manufactured in-house it to our specifications so as to make it the perfect machine except for components such as springs. The coating of the for our requirements. The reason is that we wanted to have products is also outsourced, as are the materials that we use. full multitasking capabilities at our disposal, while also having All of our materials are imported as they are not made the basic capabilities when using the lower turret, we needed locally.” lots of power on the upper turret and the rigidity to hold tight “We use various steels, depending on the component, tolerances.” and the frames are made of aluminium. The most important “The machine comes with a sub spindle instead of a features of these precision weapons are that they have to be tailstock and the upper turret is equipped with BT40 tooling, lightweight, adjustable and accurate.” 26kW motor and live tooling for added milling operations as “The trend in the industry has moved towards where you well as a bigger bore. The chuck size was increased to have component manufacturers, assemblers, distributors and 10 inch and the XZ travels are 600 x 1100mm.” 

Below left: The new Victor Vturn-X200 five-axis multitasking turning centre allows the company to perform under pressure, running bolt carrier components one day, and chamber components the next. The machine comes with a sub spindle instead of a tailstock and the upper turret is equipped with BT40 tooling, 26kW motor and live tooling for added milling operations as well as a bigger bore. The chuck size was increased to 10 inches and the XZ travels are 600 x 1100mm

Various rifle components

METALWORKING NEWS v 15. 3 July 2016 49 The success of Truvelo Manufacturers’ Armoury Division has been the manufacturing of highly accurate barrels, which led to the development of a combination of their own barrel range and sophisticated precision sniper rifle technology

More rifle components that Truvelo Manufacturers’ Armoury Division also manufactures have been machined its own rifle magazines

“So, not only do we use the left spindle, but we also pass we were able to do in the past.” the component off to the right spindle to get the component in a single hold, and use the upper and lower turrets to do Assembly and testing simultaneous multitasking machining to get our cycle time as “As we have said, how the components fit when low as possible when we manufacture components.” manufacturing rifles, determines the product performance. “With the high tolerances that are required of us when This aspect is enhanced in our products and therefore assembly machining, this machine now allows us to carry out more is a critical operation in the process. Most components have operations in one setup, thus eliminating the possibility of the to go through crack testing before assembly and once component going out of spec.” assembled, the final product is taken to our underground “A lot of companies are running components with shooting range where the final test of accuracy is carried out.” relational tolerances from the milling operations to the “However, the success of this division has been the turning operations. Being able to do that in a single platform manufacturing of highly accurate barrels, which led to the by passing the component from the left spindle to the right development of a combination of our own barrel range and spindle and having the capability to mill in either turret sophisticated precision sniper rifle technology.” via the B axis, we’re able to maintain our tolerances and The Truvelo ‘Counter Measure Sniper’ (CMS) series was are capable of doing more challenging components than developed for urban type warfare at a shorter range. The rifles are compact and allow for easy maneuverability. The stock is foldable and the rifle lighter, which makes it easier to carry in confined areas. Truvelo currently fields AMR (anti-material rifles) in four calibres, namely the 12,7x99mm, the 14,5x114mm, the 20x82mm and the 20x110 Hispano. In addition to this, the Truvelo APR (anti-personnel rifle) series is available in 7,62x51 Nato and .338 Lapua. For further details contact Truvelo’s weaponry is utilised by military agencies, Rifles in the Truvelo Manufacturing on law enforcement departments, gunsmiths, hunters and shooters assembly department TEL: 011 314 1406 or visit and enthusiasts of all types www.truvelo.co.za

50 METALWORKING NEWS v 15. 3 July 2016

Spares, Supplies & Services thrives in repair and refurbishment industry

ore than ever, processors repairable parts as components can within the mining, mineral weigh between 15 and 120 tons Mand aggregates industries are costing thousands of rands, and the cashing in on economies of scale by environment that the machine equipping their plants with huge operates in compounds the grinding tables, roll crushers, kilns difficulties. and material-handling systems in an Unfortunately, the gargantuan effort to cut costs and boost size of the respective components of productivity. these machines does not necessarily The mining industry in South widen the margin of error when Africa is, at present, not at the levels manufacturing them. If anything, that it used to be at for a multitude of flaws in castings or machining reasons. Mining conglomerates and mistakes are magnified, so attention houses are therefore looking at all to detail and accuracy are just as angles to stay afloat, let alone make a important as they are with smaller profit for their shareholders. components. In the heydays purchasing new Specialising in refurbishing this mining equipment was never type of equipment, as well as questioned. But today with the supplying new components, is pressures that the mines face, Anderbolt, Boksburg based Spares, alternatives have to be looked at. Supplies & Services. Refurbishing existing equipment is The older generation of the one of them. This could include gears, family owned business — Johan van condensers, heat exchangers, kilns, der Westhuizen and Kobus Louw mills, screens, dredges, conveyors, — have been in the mining related classifiers, cyclones and rock-crushing industry all their working careers. equipment cones, gyratory and jaw By coincidence Johan and Kobus’ crushers. Just arrived on the floor is the newest addition paths crossed when they met at The components making up this to the company’s machining division. The machine Bateman Equipment, where they type of equipment are generally large is a new Radar Industries CNC RAL-16 vertical were both employed as quality castings and forgings, such as top turning lathe that is part of the company’s control inspectors, project engineers and bottom shells, main shafts, swing Kingfisher range and was supplied by EDM Shop and repair and refurbish managers stocks, hydroset cylinders, liners, in the crushing and process pinion shafts and bronze bearings. Take a crusher for equipment departments. example. It is a machine that is built to crush rock and you’d Johan had previously worked at Iscor Van der Bijl expect it to handle pretty much anything you feed it, but you (now ArcelorMittal) and then Vecor, and Kobus qualified as would be wrong. Anything can stop a crusher cold and cause a fitter and turner at an engineering company in Denver, some extensive damage in the process. Long delivery times Johannesburg. make it difficult to replace damaged and or beyond Bateman Equipment Ltd, which is now known as the 

Spares, Supplies & Services is very much a family owned A main shaft in for repair and run company with all the partners hands on individuals. The shareholders are Johan van der Westhuizen, Kobus Louw, Jaco Louw and Peter Pienaar

52 METALWORKING NEWS v 15. 3 July 2016

ELB Group, is a supplier of engineered products to the infrastructure, mining, processing and construction industries. The crushing department was eventually sold to Svelda before being acquired by Sandvik Mining Equipment. Both Johan and Kobus gained invaluable experience during their time at all of these companies. You could say they got to know the crushing equipment like the back of their hands. Johan was the first A granulator frame top cover fabricated A granulator rotor shaft to break ranks when he by Spares, Supplies & Services that has been refurbished decided to start his own company in 2001, specialising in the repair and refurbishment CNC machining.” of crusher components for the mining industry. “That year we purchased a conventional lathe, a “The conception of the company was born around project milling machine, a radial drill and a 400 amp Mig/Mag management and this is still a vital element of the company’s welding machine. It was the beginning of a new era in the services, although we offer a great deal more these days. I company that has now culminated in us purchasing a had plenty of experience and contacts in the industry, and state-of-the-art CNC vertical turning lathe.” was confident that I could deliver value to both the OEM “We are still reliant on subcontractors for the larger market and the customer.” components, 20 tons and above, and all of our plate work is “I operated from an office and coordinated all the project done by TW Profile as our volumes do not justify us engineering, site supervision and post-installation support. purchasing this type of equipment.” I was the single point of contact. This approach ensures the most efficient and detail-oriented planning, development and OEM specification installation of any multi-vendor project.” “Since inception, we have successfully repaired most “At first it was intimidating but I was soon looking for a major components on cone, gyratory and jaw crushers. As far partner. I approached an ex colleague of mine, the late as possible, all components are restored back to original and Manie Pienaar, and he joined me about a year after the OEM specifications to ensure compatibility with spares company was established. Kobus then joined Manie and me a available from OEMs. Welding, heat treatment, NDE testing further year on into the company’s history.” and machining stages are monitored and documented “We had plenty to offer the OEMs in terms of our to ensure sound and acceptable engineering practices. knowledge in the industry, while at the same time offering a Mechanical repairs of components up to 20 ton capacity can solution to an area of their business that they were not always be handled on our premises.” comfortable with. We outsourced and sub-contracted “All of the above are manufactured from approved everything in those early days. That included drawings and machining.” material “We continued to operate the business in this way specifications as until 2007. However, the fact that we were always per the OEM reliant on suppliers did not sit comfortably with us. specifications. Up until then it had suited our business plans but we Quality requirements always knew we would have to change. Besides we as per the were wasting Kobus’ talents who, while qualifying as a manufacturing fitter and turner, had already progressed to processes are strictly adhered to and certification issued as required.” “When a A fan hub that is in the process component arrives of being refurbished on our floor it is stripped, measured, NDE tested where needed and analysed for whatever repair work is required. Machining, welding and testing operations are then carried out before final inspection and painting where necessary. We like to say that when the component leaves our shop it is a ‘new’ component.” “However, we are not restricted to doing repairs and refur- bishment. For example, we have just had two 80 ton top shells and a 120 ton bottom shell cast at ArcelorMittal foundry for our client Tenova Takraf. The first top shell is complete and The Titan vertical turning lathe machining a fan hub the second is nearing completion at DCD Heavy Engineering 

54 METALWORKING NEWS v 15. 3 July 2016

Vanderbijlpark works whilst the bottom shell is in the final A gyratory stages of upgrading. Due to the mass of these castings spider bush and the close proximity of DCD Heavy Engineering and on the new ArcelorMittal, they were the obvious choice to do the proof Radar Industries and final machining. We have and will manage the project CNC RAL-16 for our client from start to final release, which includes the vertical turning scrutinising of drawings right through to the lathe witnessing of destructive testing and final inspection after machining. Again, all the manufacturing has been done according to OEM specification.” “The business has also diversified over the years in terms of the products and components that we repair or manufacture. We are not just limited to crushers anymore and now have experience in a number of other heavy duty equipment.” “Most of the equipment that we have either repaired, refurbished or manufactured new is used in the coal and platinum mining industries and you can see equipment that we have worked on in South Africa, Tanzania, Zambia, Ghana, Mali, Namibia, Botswana and other African countries.” “Our biggest clients are Sandvik Mining, the ELB Group and Tenova Takraf Africa. We Left: A new gyratory eccentric sleeve still carry out work for our first client, who is manufactured by Spares, Supplies & Services in iron ore mining.” of equipment can also be done.” Site visits, inspections and supervision “We have established a very satisfactory customer base Welding division as a result of our inspections on equipment, especially “Our welding division now consists of two 600amp Lincoln during breakdown and normal shut down periods. Inspection welding/gauging machines. For our cladding needs we have a and condition reports after visits have been well received 2,4mm Lincoln sub-merged arc welding head. For maximum especially in highlighting areas of concern and possible efficiency and quality we have manufactured our own failures. Supervision on the assembly and or stripping 2,5 metre welding manipulator with horizontal and vertical turning capabilities.”

Fabrication division “This division was only established in 2009 and was a natural extension of our business capabilities. Most of our plate work is outsourced, as is all of our profiling, rolling and bending requirements. We will then fabricate, weld, fettle and paint. This department is equipped with a 10 ton overhead crane so we are limited to this size, but it is not often that we need more than this requirement. Some of the products that we have manufactured and assembled in this division include granulators, conveyor systems, base frames for coal breakers and ring chutes for stacker reclaimers.”

Machining division “Our 20 ton overhead crane takes care of loading and offloading our machines. Our conventional lathes can handle components of up to 740mm in diameter and 5 metres in length. We have horizontal turning machines that can handle up to 2,5 metres in diameter and a maximum height of two metres. The drilling division is able to drill products of up to two metres in height and two metres in diameter in a single setting. We also cover milling applications as well as slotting.”

The new Radar Industries CNC RAL-16 vertical turning lathe has a table diameter of 1600mm, a maximum swing of 2000mm, maximum turning diameter of 1900mm, maximum turning height of 1600mm and a maximum workpiece weight of 10 000 kilograms. More importantly, it covers the company’s requirement of the ram feeding down. The machine is the first of its kind to be installed in South Africa and it was supplied by EDM Shop

56 METALWORKING NEWS v 15. 3 July 2016

“The machine is the first of its kind to be installed in South Africa and it was supplied by EDM Shop.”

Family owned company Spares, Supplies & Services is very much a family owned and run company with all the A top shell upper 80 ton casting partners hands on cast by ArcelorMittal and drilled at DCD Heavy Engineering individuals. Johan’s brother, Eben van der Westhuizen, works in the quality inspection division and his son-in-law works in the contracts department. Kobus’ son Jaco Louw joined the company in 2007 and is in charge of production. Jaco’s wife Donna works in the administration department. The late A submerged A bottom shell, a 125 ton casting being Manie Pienaar’s son arc welding manipulator upgraded in ArcelorMittal's foundry Peter joined the company in 2002 and is “One of the machines we have in this division is a Titan responsible for the contracts department, and Peter’s wife vertical lathe that has a swing of 2,6 metres with a height Zelda works in the creditors department. Both Peter Pienaar restriction of 1,9 metres.” and Jaco Louw are also shareholders. “On site, renting space in our facility, is a subcontractor The family connections even permeate down to the rest of that machines all our small component requirements. These this 37-strong employee company where there are a number are mainly crusher spares and wear parts such as sleeves, of brothers, sisters and cousins that are employed. step bearings, spiral bushes, head nuts and many others.” “We did not intentionally have this idea from the beginning. It is just how it has evolved and what we have New Radar Industries CNC vertical turning lathe learnt is that it creates a very good vibe in the company.” Just arrived on the floor is the newest addition to the “Going forward, we would like to move into a new factory company’s machining division. The machine is a new Radar once we can locate a suitable one. We moved here in 2009 Industries CNC RAL-16 vertical turning lathe that is part of the and did not think we would fill the space, but now we are company’s Kingfisher range. bursting and restricted to a 20 ton overhead crane. We have “The machine has a table diameter of 1600mm, a had 20 to 25 percent growth per year since inception and maximum swing of 2000mm, maximum turning diameter of would like to continue in that fashion. So we desperately need 1900mm, maximum turning height of 1600mm and a maximum to find a bigger facility.” workpiece weight of 10 000 kilograms. More importantly, it For further details contact Spares, Supplies & Services on covers our requirement of the ram feeding down.” TEL: 011 892 2925 or visit www.ssscrusher.co.za

A jaw crusher ready for delivery to client A completely refurbished cone crusher after refurbishment and repair

58 METALWORKING NEWS v 15. 3 July 2016

better production

Laser power monitoring improves process stability

aser systems are used in industrial Most laser processing for applications such as systems Lcutting, welding, or marking. The exhibit careful adjustment of the power of a laser variations system needs to be ensured to achieve of the light high-quality results and reproducibility. A part intensity over might not be cut with too low power, whereas time. There the raw edge might be rough at too high power. are short-term Monitoring the laser power is therefore crucial fluctuations for an effective process control. due to the laser source stability and/or a thermal drift. These modulations are of the time scale of minutes or hours. Additionally, the laser power drops in the course of the laser lifetime by up to 20%. The deterioration of optics aligned along the beam path causes a decrease in output power as well in the long term. Both types of fluctuations might cause a lowered throughput due to defective products or additional maintenance times.

Continuous or intermittent power measurement The implementation of a laser power monitor along the optical path inside the system can either be at the source (e.g., behind the back mirror) or close to the beam output (e.g., inside the processing head). It allows for the continuous detection of power instabilities and helps to adjust the pump power immediately. Continuous monitoring of power is beneficial for both the user as well as the manufacturer because the operation scheme can be logged without gap and malfunction is easier to track down. Alternatively, the measurement can be carried out intermittently. This is often realised with a measurement unit located next to the machining area. For example, after each 10 machining cycles, the processing head moves to the power detector module and a measurement is taken.

60 METALWORKING NEWS v 15. 3 July 2016 The careful adjustment of the power of a laser system needs to be ensured to achieve high-quality results and reproducibility

Both methods have similar requirements on the power monitors as they demand accurate, fast, and compact detectors. Thermopile laser power detectors such as the gRAY line produced by greenTEG are designed for OEM integration into laser systems at all wavelengths from UV to MIR. Various detectors are available with their specifications adjusted to the requirements of different measurement scenarios. In the following sections, the benefits for different measurement tasks will be presented and compared to conventional detectors.

Fast detectors for real time control and high throughput An effective feedback loop allows for instant control of the critical parameter. The measurement of the signal is a crucial component of the overall time necessary to carry out a control cycle. Thermopile disc detectors are most commonly used to measure laser power above 100 mW. Physics, however, puts a limit to the measurement speed of such detectors. Because of their working principle, the thermal capacitance of the detector determines the rise time, resulting in typical values of 1-5 s. greenTEG has developed a thermopile detector for medium powers up to 50 W. As its key feature, the detector exhibits a rise time of just 200 ms. Such low rise times are achieved by an axial pile arrangement combined with a minimised thermal mass. Both characteristics, a short heat path and low thermal capacitance, lead to fast thermal equilibration. The robust housing provides both mechanical and thermal stabilisation. Further, amplification electronics are integrated in the housed detectors. The analogue voltage signal is internally amplified and normalised to facilitate read-out. In applications where power is measured intermittently, such a fast sensor lowers the measurement time significantly and hence increases production throughput. In continuous measurement scenarios, countermeasures for a fluctuating laser power can be taken immediately.

High accuracy at lowest power The two key specifications for a power detector are its power range and its wavelength range. Within this parameter space, greenTEG has identified a region where no convenient detectors currently exist. This gap is located at long wavelengths (beyond the sensitive spectrum of photodiodes) and low powers (below the resolution limit of conventional thermopile discs). This gap is now covered with the gRAY sensor components and PCB-mounted detector. Both are sensitive even at micro Watt levels and detect the smallest power fluctuations. With their compact size (down to 4x4mm²) they can be mounted into any system where space is limited. Compared to photodiodes, no angular dependence of the sensitivity is observed and because of the flat absorption spectrum of the broad band absorber coating, the spectral dependence of the sensitivity is very small.

By Dr. Susanne Dröscher of greenTEG, Zurich, Switzerland international news

EuroBLECH 2016 reflects trend towards smart manufacturing in sheet metal working

rom 25 – 29 October 2016, EuroBLECH 2016 will open its Fdoors in Hanover, Germany. The exhibition will once again be the meeting place for sheet metal working professionals from all over the world looking to find enhanced machinery and innovative production solutions. Visitors will be able to discover an extensive variety of products, from conventional systems to high-tech solutions, and gain an insight into the latest technological advancements in sheet metal working. With this year’s theme “The New Generation of Sheet Metal Working”, EuroBLECH 2016 reflects the trend towards digitalisation and smart manufacturing in modern sheet metal processing. Five months companies have booked bigger stands to demonstrate an ahead of the show, the organisers, Mack Brooks Exhibitions, even larger choice of enhanced machinery and cutting-edge have announced a further increase in exhibition space for the solutions. Major exhibitor countries are Germany, Italy, China, world’s leading trade show for this industry sector. Turkey, the Netherlands, Switzerland, Spain and Austria. With this year’s theme “The New Generation of Sheet Metal Working”, EuroBLECH 2016 reflects the trend towards digitalisation and smart manufacturing in modern sheet metal processing

A total of 1,410 exhibitors from 40 countries have already EuroBLECH is traditionally renowned as a highly international secured their stand space at this year’s EuroBLECH, the 24th event. The previous exhibition was more international than International Sheet Metal Working Technology Exhibition, ever, with 52% of exhibitors and 37% of visitors coming from covering a net exhibition space of 89,000 square metres outside Germany. A total of 59,618 trade visitors from across eight halls at the Hanover Exhibition Grounds. This 105 countries attended the event in 2014. represents an increase in net floor space of 3% compared with For further details visit www.euroblech.com the previous exhibition and reflects the fact that exhibiting Trade Fair Travel and Metalworking News tour to EuroBLECH 2016 Travel with Metalworking News and Trade Fair Travel, in association with the Southern African German Chamber of Commerce and Industry, to view the latest metalworking technology at these internationally recognised metalworking related exhibitions. Trade Fair Travel, a specialist travel agency for trade fairs internationally, has put together a very reasonable tour to visit this exhibition. The tour includes return airfare Johannesburg/Hannover, Germany, airport taxes, airport/hotel transfer, accommodation, full breakfast daily and medical and travel insurance. For more details see the advertisement further on in this issue, and for a booking form contact Trade Fair Travel on TEL: 031 916 1414 or email [email protected] or visit www.tradefairtours.com

62 METALWORKING NEWS v 15. 3 July 2016

Automated structural steel processing machines are Voortman’s game

Advances in automated layout, systems and software are accelerating the process and eliminating many potential errors.

he decision of whether or not to select a concrete or resistance of an inch of steel, and it still would not perform to steel core or framing system for a modern high-rise is not the same level as the steel wall because the surface concrete Ta safety issue. Rather, the determining factors remain the always becomes flying debris in a blast, which could architectural and structural design requirements, construction potentially injure any people nearby. costs and scheduling, and the preferences of the specific With dozens of specifications applicable to steel building contractor and designer. Steel framing is the preferred design and construction, whether it be for an office building, construction material and some say that three steel-framed a residential tower, a school or a factory, it can be a challenge buildings are built for every one concrete building. History to keep the standard designations used in current contracts. shows steel offers unmatched cost, schedule and Then there is the demand from owners and designers to make environmental benefits. their project ‘stand out’ while at the same time keeping costs The reality is that steel-framed buildings are the most to a minimum. Given the developments in computational robust buildings on the market today. In the USA, where hardware, structural analysis software and new design aids terrorism and 9/11 are on the front pages every day and that are available today, early cooperation between the owner, engineers, contractors and designers have to take into designer and contractors will help them to optimise the account these awful incidents when designing a new building, construction and steel design. The benefits of employing reports state that all concrete-framed buildings need special modern tools and methods will permit practicing engineers to design requirements to make them blast resistant whereas in take full advantage of such capabilities, while also taking into contrast, an equivalent steel-framed building would not account industry standards, building codes and other collapse at all, even without any special treatment in design. important guidelines and, for example, sound isolation and The report shows that steel is more robust and analysis noise control issues such as speech privacy, footfall noise, demonstrates it takes a foot of concrete to equal the blast background noise criteria and airborne sound isolation.

64 METALWORKING NEWS v 15. 3 July 2016 Inside the Voortman Experience Center Voortman Steel Machinery launched The Fabricator at EuroBLECH 2014 and the system forms part of the new thinking at Voortman

But what about the structural steel fabricators? headed up by CEO Mark Voortman (45) and Voortman Steel “These days engineers, designers and draughtsmen Machinery has designed, developed and manufactured believe that at the push of a button we can fabricate material machinery for steel fabrication and the plate processing to their specification and design,” is a common complaint related industries for more than 45 years. amongst fabricators. This is true in many instances but only The Group can trace its origins back to 1968 when Mark’s because the OEM process machine builders are keeping up father Gerrit was working in the family business - a concrete with the trends in the industry and providing fabricators with factory that operated in a barn on a farm in Middeldijk in equipment that will meet the demands of design, while at the Rijssen. At the time, Gerrit was responsible for the same time offering efficiency and productivity with minimum maintenance and repairs of the equipment that the company human interference, thus reducing costs. used. In the early seventies, Gerrit Voortman started his own One such company is Voortman Steel Machinery, a company that had maintenance and repairs of construction company that is part of the Voortman Steel Group, with equipment as its main activity. The company soon began its headquarters in Rijssen, the Netherlands. The Group is manufacturing equipment for the steel construction industry, 

METALWORKING NEWS v 15. 3 July 2016 65 and subsequently began a second equipment manufacturing company that had steel fabricating facilities in the Netherlands, and as its focus that is still one of the one in Germany that manufactures companies within the Group. handling systems for the steel Voortman Steel Machinery has processing industry. Additionally, it now developed into a company that has 50 dealers in more than offers a packaged service, including 90 countries. planning, machinery, implementation “Voortman has developed and after-sales service. The product machinery to cover all aspects in range of equipment that Voortman processing structural steel. The Steel Machinery designs, extensive range of equipment manufactures and markets to the guarantees the right solution for structural steel processing industry every application. All the machines includes: can be combined and configured to • Beam processing - suit the end user. The final layout drilling, sawing, marking, depends on several factors, such as coping, cambering the available space, the production • Plate processing - output required and the type of cutting, drilling, drilling project undertaken. Voortman and cutting (combined), guarantees you a solution.” drilling and cutting (split) “Beam processing machines • Flat and angle processing - of open structural sections such punching and shearing, as H, I, angle and channel are all numbering and storage designed to have minimal human • Surface treatment - interface, to eliminate waste, shot blasting and painting reduce the labour hours per ton, get materials out faster and have Since 1995 Voortman Steel better quality control in the modern Machinery has had CNC and structural steel facility. Automated The Fabricator is an automated beam and plate automation of the machines that cutting and welding system. The Fabricator has coping, cutting, drilling and marking it manufactures as its core focus, three welding robots and one plate handling robot. machines, all connected with while at the same time There is no human interference from the time the automated material handling incorporating automated layout for beam starts off in the initial drilling stage to the systems to limit the need for forklift material handling to attain the finished product fully welded trucks and overhead cranes, maximum efficiencies for material prepare structural steel members flow. This includes conveyors, gripper carriages, roller feeds, just as the CAD programmes dictate. This structural steel measurement devices, sensors, buffers and others. processing technology can even lay out and mark the “Voortman continually develops its equipment range to position of other items that need to be welded to the main stay at the forefront of technology and in step with any new beam. Voortman now has a machine that satisfies all these development in the market,” says Henk Maassen van den requirements.” Brink, Sales Manager of Voortman Steel Machinery. “For plate processing entities with the need to “We are now amongst the top five machine manufacturers manufacture base plates, end plates, gusset plates, servicing the steel processing industry, and sell in the region stiffeners or brackets and industries with different kinds of of 250 machines and systems worldwide each year. 95% of requirements in plate drilling and cutting, Voortman is able our production is exported.” to offer a wide range of CNC plate processing machines. Our Today, the company has sales and service subsidiaries machines have been designed with one goal: To integrate all in the USA, Russia, Germany, France, the UK and India and the functions that are required in plate processing.” 

Lawrence Bartlett, Rodney Moonsammy, Alex Lutzeler, Steve Van Wyk of First Cut, Kevin Redpath and Bert Jan Ligtenberg Rayvin Jacobs and Henk Maassen van den Brink, Sales Manager getting to know a Voortman plate processing machine of Voortman Steel Machinery

66 METALWORKING NEWS v 15. 3 July 2016

Voortman Steel Machinery packaged and ready A Voortman machine in the for delivery to steel processors assembly area

The automation of the structural steel industry countersinking and center point marking. Structural steel fabricators now realise what their sheet But it is all in the planning that will determine a metal counterparts have known for several years. It doesn't fabricators’ efficiency. Placing of the equipment, whether it make sense to pay people for the non-value-added activity of is for drilling, cutting or marking, and then the placing of the handling beams. Fabricators are looking to minimise labour conveyors and cross transfers where needed, and the placing costs while simultaneously attempting to address the of the material handling equipment is vitally important. Does impending retirement of valuable veteran workers. drilling come before marking or vice versa are strategic During the course of the last decade the sheet metal decisions that have to be undertaken at the planning stage. world warmed up to the idea of automated material handling For example, a drill operates much faster than a band saw. as a way to address those two major concerns. Many sheet To keep the drill operating at an acceptable rate, a fabricator metal service centres no longer pay machine operators to load might want to have a buffer of cut-to-length structural parts blanks and unload parts - a mundane chore. Pallet systems between the band saw and the drill. This allows the drill to now continually whisk new blanks onto cutting tables and churn out parts, and the band saw to keep operating at an sophisticated tower systems store a variety of blanks. optimal speed that doesn’t jeopardise the quality of the cuts. All the operations have to be considered carefully and a But what about the structural steel shops? solution found for the individual processor. The simple truth is that shops have to process beams more As much as shop management may want to dictate how efficiently if they want to be more competitive. Automated much steel exits the door, the machines on the shop floor material handling technology and modern, fast multi-faceted determine the pacing of parts flowing through it. Planning is processing machines are helping shops to solve this dilemma. essential not only for current needs, but also for future plans. These structural steel fabricators are increasing the tonnage Good decisions made today will make changes in the future of metal processed through the shop, without adding easier to implement. resources. Voortman delivers a total integrated solution called “Multi System Integration” (MSI). Each Voortman machine is Planning equipped with its own Today steel processing state-of-the-art VACAM machines can deliver more control software. By than one operation. Coping interconnecting the handling and plasma cutting on beams systems and the VACAM for example or, plasma and Software on the machines, oxy-fuel cutting on a plate virtually one integrated machine or, plate drilling and production system is cutting combined. But it is created that increases the generally accepted that, in productivity while the case of beam processing, man-hours are being saved. these operations are kept The Multi System separate. However, the Integration creates a great versatility that these deal of interest as a individual machines offer complete beam line for the various operations including a beam layout needed in beam processing marking machine, and is has advanced tremendously. able to be operated by one Marking by plasma can be person for example. done on the same plasma For years Voortman Steel Machinery have had the cutting robot “As long as you put the in their portfolio and this is demonstrated in the Voortman V808, cutting machine and a correct beam on there, the a machine that processes the front and back end of a raw material drilling unit can now cater to length with only one measuring unit. The Voortman V808 has machine will know because use HSS drills, carbide tipped two completely free processing areas and can process on all four sides it’s in the file and it will drills, solid carbide drills and of the material with a plasma coping / plasma cutting system perform the required be used for thread tapping, with an eight axis robot operations. If you put the

68 METALWORKING NEWS v 15. 3 July 2016 incorrect beam on there, it’ll tell the operator. It’s called rolling into the right place at the right time,” said Henk Maassen van den Brink.

Voortman Rijssen, the Netherlands For many years, Voortman Steel Machinery and Voortman Staalbouw have operated autonomously alongside each other in the industrial area of Plaagslagen, Rijssen. The demand for processed material and processing machines has seen both companies grow. In 2013 the Voortman Steel Group was formed with a corporate identity being spread across both companies. In March this year Voortman Staalbouw and another one of the Group companies, Voortman Dak en Wand, which specialises in supplying and installing roof and wall cladding, merged to form Voortman Steel Construction. Voortman Steel Machinery, operating from its own facility, is essentially an assembly plant — and a state-of-the-art one. Most of the components are outsourced as it does not make economical sense for the company to have a machine shop or sheet metal fabricating shop because the volumes do not meet production levels. However, all assembly is strictly controlled and tested. The facility also has its R&D section where the company is continually developing and testing. “Our focus is on IP and design. We are able to offer you a total package. Our products are of high quality and are offered at a competitive price. This is made possible because of innovative applications and smart techniques allowing us to work even more efficiently,” says Maassen van den Brink.

Voortman Experience Center Inside a Voortman In March beam drilling machine 2014 Voortman Steel Machinery Construction across the road from us where we opened the can take clients to see our machines operating in Voortman a working environment, it is not always possible Experience to show them the latest equipment and process Center - a developments that we are regularly launching,” showroom and says Frank Scherphof, Managing Director of training facility Voortman Steel Machinery. in Rijssen. All of “The Experience Center allows us to do that. Voortman’s latest For example we have just introduced the very beam, plate, flat compact Voortman V302 plate cutting machine, and angle and this machine is on the floor for clients to see processing live demonstrations.” machines are Plate being cut on a Voortman plate processing machine “We also have The Fabricator, an automated available beam and plate cutting and welding system, set up for live to operate in a live environment. We launched The demonstrations in the Experience Center that operates Fabricator at EuroBLECH 2014 and the system forms part of under showroom conditions. Voortman manufactures our new thinking at Voortman.” machines to cover all aspects in processing structural steel “In order to remain innovative and distinctive, robotics is including drilling, sawing, cutting, coping, assembling, welding, becoming increasingly more important. For years we have marking, cambering, punching, shearing, shot blasting and had the cutting robot in our portfolio and this is demonstrated painting. in our Voortman V808, a machine that processes the front “Even though we have a great example in Voortman Steel and back end of a raw material length with only one 

“Voortman has developed machinery to cover all aspects in processing structural steel. The extensive range of equipment guarantees the right solution for every application. All the machines can be combined and configured to suit the end user.”

METALWORKING NEWS v 15. 3 July 2016 69 A Voortman 1250 bandsaw A Voortman 630 beam drilling machine and a Voortman 1250 bandsaw strategically positioned within a beam processing line measuring unit. The Voortman V808 has two completely free as well as train the operators there. Now the operators are processing areas and can process on all four sides of the asked to undertake the necessary training at the Experience material with a plasma coping / plasma cutting system with Center where they are able to gain experience on the an eight axis robot. The extreme flexibility of the robot in machine they will be operating, as well as the others that combination with the machine structure enables the machine Voortman manufactures. Added advantages are that the to cut every 3D shape possible and mark all four sides of your training takes place in a classroom environment with material.” trainees exposed to more than one trainer, they get to “All our machines either process beam profiles or plate experience the company behind the machine and get to and the components are married together in the welding know the helpdesk first hand. With about 95% of Voortman’s department. For some time now, we have been working on machines going abroad, this is a much more viable and the development of using welding robots and manipulators rewarding experience. to bring the flow of the components of the two processes together and end up with a final product. The result is The Voortman SteelTECH events Fabricator, an automated beam and plate cutting and welding Voortman Steel Machinery also organises Voortman system. In it, plate and beam cutting, as well as welding, are SteelTECH events, which I was part of when visiting the entirely automated. It’s a done-in-one concept expanded to the company in June 2016. Voortman SteelTECH three-day shop floor.” events allow dealers and their clients to be introduced The Fabricator has three welding robots and one plate to the newest developments in steel processing machines handling robot. There is no human interference from the time and systems that Voortman has to offer. Participants are the beam starts off in the initial drilling stage to the finished also able to experience the working environment of product fully welded. By connecting The Fabricator Voortman Steel Construction as well as visit integrated solution to other Voortman beam and plate Voortman Steel Machinery clients using the company’s processing machinery, they are able to offer a solution that equipment. has never been done before - fully automatic structural steel I would like very much to thank the Voortman Steel fabrication. Machinery personnel that were so hospitable during my visit, and Steve van Wyk of First Cut for inviting me and Training organising my trip. The Voortman Experience Center also offers an For further details contact First Cut on opportunity for operators to be trained. Previously Voortman TEL: 011 614 1112, email [email protected], or would install a machine or system at the client’s location, visit www.firstcut.co.za or www.voortman.net

Inside the The trip included visits to Voortman Steel Construction facility Voortman Steel Machinery’s clients

70 METALWORKING NEWS v 15. 3 July 2016

GE reveals the world’s largest jet engine that is wider than a 737’s fuselage

The GE9X Engine designed specifically for the Boeing 777X 406 seat 'megaplane', will be the most fuel-efficient jet engine GE has ever produced.

he world's largest commercial aircraft engine has been started up for the first time at GE Aviation's TPeebles Test Operation in Ohio. According to GE, ground testing of the GE9X development engine will enable data to be gathered on the engine's overall and aerodynamic performance, mechanical verification, and aero-thermal system validation leading up to flight testing and certification before entering service at the end the decade. With a front fan spreading a full 3.35 metres, the GE9X is a world record holder and generates thrust in the order of 45 360 kilograms. To accommodate the aeronautical behemoth, the Peebles facility was recently upgraded with a larger air intake, extra fuel tanks to feed the giant engine, and high temperature gear to deal with the hotter, more efficient design. GE says that the GE9X is currently undergoing its first 11-stage high-pressure compressor with a 27:1 Full Engine To pressure ratio. Weight is saved by the extensive Test (FETT). This use of ceramic matrix composites (CMC), which is the next level allows the combustor and turbine to handle of the test series, temperatures of up to 1,315º C for greater fuel which began efficiency and lower emissions. in 2011 at the In addition, the GE9X incorporates 3D-printed component level, fuel nozzles, the complex architecture of which has and marks the not been made public by the company. first test of the "These tunnels and caves are a closely guarded complete system, secret," says GE Aviation spokesman Rick Kennedy. "They which comes only determine how the fuel moves through the nozzle and sprays six months after inside the combustion chamber." the engine design To harness the power of the engine, the GE9X is equipped was finalised. GE says that this relatively early testing was to with a low-pressure turbine module and the Accessory Drive ensure that the test data was available as soon as possible for Train (ADT) kit, which regulates the unit and distributes its the certification engines, which are scheduled to be installed energy for secondary functions by means of an inlet gearbox, in GE Aviation's flying test bed for certification of flight testing transfer gearbox, and Accessory GearBox (AGB). in 2018. The latter powers the fuel pump, oil pump, hydraulic pumps Developed for the 777X airliner, there are over 700 GE9X for the flight controls, an air turbine to start the engine, and engines on order at an estimated value of US$29 billion. It other onboard systems, yet has 10 axles and nine accessories features a composite fan case containing 16 fourth-generation as opposed to the previous GE90, which has 11 axles and carbon-fiber composite fan blades, which push air into an only eight accessories. In addition, the AGB has a small fuel adapter for a simpler external pipe system and an improved engine profile. "The reduction in the number of axles not only benefits weight, but also reduces the part count and simplifies the supply chain," says Rocco Pellettieri, project engineer for the GE9X at Avio Aero. "The design with fewer axles but more accessories compared to the GE90 was made possible thanks to complex optimisation studies that allowed us to achieve more with less." GE says that a second engine will be ready for testing next year and that the GE9X is scheduled to enter service around 2020.

72 METALWORKING NEWS v 15. 3 July 2016 SGS Tool Co. acquired by Kyocera of Kyoto, Japan

apanese electronics and ceramics manufacturer Kyocera U.S. and U.K. with strength in products for the medical, has completed its share purchase agreement regarding automotive, aerospace, and energy industries. Jthe acquisition of U.S.-based tool manufacturer SGS Tool By incorporating SGS Tool into the Kyocera Group, Company and its group companies. Kyocera will acquire 100% Kyocera will create a business structure capable of providing ownership of SGS Tool, and total solutions and will rename the company strengthen its business as KYOCERA SGS Precision globally as a valuable Tools, Inc. effective May 2. comprehensive cutting tool Kyocera says the addition of manufacturer. SGS Tool will increase sales SGS Tool was of its cutting tool business in established in 1951 and is North America by 2.5 times headquartered in Munroe by fiscal year ending Falls. The company employs March 31, 2019. 335 people in the Currently Kyocera is manufacture and sale of expanding its cutting tool solid cutting tools business globally with its Kyocera Corporation, main lineup of indexable the parent and global cutting tool products; while headquarters of the Kyocera SGS Tool is a solid tool Group, was founded in 1959 manufacturing and sales as a producer of fine company developing its ceramics, also known as business mainly in the Advanced Ceramics.

METALWORKING NEWS v 15. 3 July 2016 73 9% global growth for laser cutting machine market: Report

he outlook for the global laser cutting market is good according to a forecast Tby Technavio, a technology research and advisory company. The company forecasts the market will experience close to a 9 per cent Compound Annual Growth Rate (CAGR) between 2016 and 2020. The report highlights three factors contributing to the growth of the global laser cutting machine market: a need for automation; a growing demand from end-user industries; and the increasing need to develop high quality products.

Need for automation The report notes that companies are increasingly resorting to automation as a way of meeting the anticipated quality standards that have been necessitated due to globalisation. Investments in the global process automation market are increasing and projected to touch US $120 billion by 2019, a growth rate industry, the commercial aerospace sector is projected to of more than 6 per cent. The growth is specifically related to show a robust CAGR of 8 per cent during the forecast period. sectors such as technology, software, hardware, services, and The commercial aerospace sector is driven by factors such as the communication protocol used in automation. increasing aircraft size, high replacement rate, technological According to Anju Ajaykumar, a lead analyst at Technavio advances, and growing number of high net worth individuals (HNI). for engineering tools, “many companies implement process Similarly, with the global automotive industry in a better automation to enhance their productivity and increase profit condition now than it was five years ago, this sector is being margins. The use of automation in ports is a recent trend in driven by the rising demand for vehicles in emerging economies the market. For example, the automation of Rotterdam port has such as India and Indonesia. But due to the economic resulted in effective management of the largest port in Europe. instability in the US and more recently in China, the sector may Other ports have also adopted automation with the aim of take some more time to recover its profit margins to pre-crisis controlling their losses and regulating resources.” levels. It is expected that profit margins will grow by almost 50% by the end of the forecast period. Growing demand from end-user industries Industrial outputs that had taken a hit in many countries Increasing need to develop superior quality products following the global economic recession of 2008 are showing The manufacturing scenario is different from what it used signs of a slow recovery. Industrial sectors in which automation to be even a decade ago. With advances in technology and is employed on a full scale such as automotive, aerospace and innovation, it is possible to produce parts quickly, efficiently, defense, electrical and electronics, medical devices, industrial and at lower costs. “One such advanced technology is laser machinery, and cutting that uses advanced equipment and machines to renewable energy produce parts at record speeds in industrial manufacturing are showing signs while simultaneously saving on costs,” says Anju. of positive growth, Despite the deployment of several high-quality machining which is reflected centers and other such machines, the use of the right cutting in the stabilised tools for machining components is a prime factor that manufacturing determines the quality of the products manufactured. purchasing With the use of laser cutting, it is possible to cut a variety of managers' indices materials including metallic, non-metallic, and synthetic materials (PMIs). of varying thickness. During the process, a laser beam is used Growing air to cut the material precisely. Depending on the particular traffic is spurring material, lasers can be produced through vaporisation, thermal the commercial stress cracking, melt and blow, cold cutting, or other methods. aviation sector to It is also possible to manipulate the laser with a multitude of higher growth. The reflective surfaces. Precision is the most important quality global aerospace offered by the lasers. A laser cut part is more accurate, and market is expected has smoother edges. Since there is less operator involvement to reach US in laser cutting, the possibilities of human error are also less. $352.5 billion by Another economic advantage of laser cutting is the less time 2023. In this required for the process compared to conventional cutting.

74 METALWORKING NEWS v 15. 3 July 2016

Airbus introduces 3D-printed mini aircraft

warfed by huge jets all around, the mini-plane Thor — the world’s first D3D-printed aircraft — was nonetheless an eye-catcher at the Berlin air show. Windowless, weighing in at just 46 pounds and measuring less than 13 feet long, the drone Thor, short for “Test of High-tech Objectives in Reality,” resembles a large, white model airplane. Yet to the European aerospace giant Airbus, the small pilotless propeller aircraft is a pioneer that offers a taste of things to come — an aviation future when 3D-printing technology promises to save time, fuel and money. “This is a test of what’s possible with 3D-printing technology,” said Detlev Konigorski, who was in charge of developing Thor for Airbus, speaking at the International Aerospace Exhibition and Air Show at Berlin’s southern In Thor, the only parts that are not printed from a substance called Schoenefeld airport. “We want to see if polyamide are the electrical elements we can speed up the development process by using 3D printing not just for little plane “flies beautifully and is very stable,” individual parts but for an entire system.” said its chief engineer Gunnar Haase, who conducted In Thor, the only parts that are not printed from a Thor’s inaugural flight last November near the northern substance called polyamide are the electrical elements. The German city of Hamburg. Turning war scrap into steel for construction in Angola

he remnants from a brutal 27-year civil war in the tanks and weaponry is being collected and recycled into southern African country of Angola are still littered steel at the country’s first steel mill — and the largest in Tthroughout its capital city, Luanda. Under a new west and central Africa — which recently started project, an abundance of scrap metal from decommissioned operations at the $300 million Aceria de Angola (ADA) facility, about 25 miles north of Luanda, reports CNN. The project is the work of French businessman Georges Choucair, chairman of K2L Capital, who has worked in Angola for more than 20 years in a diverse range of businesses before becoming the country's main steel importer (Angola currently relies on imports for steel). He estimates that domestic demand for steel is around 400,000 tons per year, which will increase with population and associated development needs. He claims the new mill will produce 280,000 tons in its first year and then 500,000 tons per year thereafter, which could significantly lower the cost of construction projects. "I believe that by 2020 we will have the capacity to supply, not import," says Choucair. "Angola can be a hub of Africa, and even South America."

76 METALWORKING NEWS v 15. 3 July 2016

Trends impacting global machine tools market

The global machine tool market is expected to grow only modestly in 2016.

he German Machine Tool TBuilders’ Association (VDW) and the British economic research institute Oxford Economics expect in their latest forecast (status: April 2016) a growth of global consumption by only 1.9% to reach € 68.6 billion. As in the previous years, the autumn forecast (2015: +4.1%) was significantly corrected downward, currently, this year by 2.2 percentage points. Global machine tool consumption boomed from 2003 to 2011, Increased productivity is a major factor that benefits companies according to that use process automation. Using robots is one way of doing this Gardner Business Media’s latest survey. According to Anju Ajaykumar, lead analyst at Technavio Despite the drastic decline in 2009, when it was down for tools and components research, “Industrial sectors where 35 percent from the year before, consumption rocketed up automation is employed on a wide scale such as automotive, the next two years and in 2011 reached the highest level ever. aerospace and defense, electrical and electronics, Since then, however, global machine tool consumption has medical devices, industrial machinery, and renewable energy contracted in every year except 2014. are showing signs of positive growth which will augur well for Global production of machine tools declined 11.9 percent the growth of the machine tools market during the forecast in 2015 from the previous year the Gardner Business Media period.” report states. However, Asia was the only region where the The top emerging trends influencing the global machine decrease was lower than the world total, having fallen tools market according to Technavio’s heavy industry research 10.7 percent. With Asia also accounting for the largest share analysts follow. of the decline in consumption, it stands to reason that the major producing countries in Asia became more reliant on Integration of 3D printing technology with machine tools exports in 2015 than the other regions. In Europe, production The original application of 3D printers was to create small decreased 13.1 percent, and in North America production was plastic models and prototypes. Currently, 3D printers are down 15.2 percent. The order of the top 11 producing increasingly used to create prosthetics, full-scale clothing, and countries remained unchanged in 2015 compared with 2014. electronic products. These printers also have a tremendous The United States was a top-five producing country in 2013, potential in the industrial sector. and just barely missed being in the top five in 2014 and The dramatic changes that 3D printing technology has 2015. brought about are likely to have an impact on machine tools Italian machine tool manufacturers posted a 14.3% and plastic injection molding. 3D printing technology reduces annual increase in new orders for the first quarter of 2016, material usage by nearly 30% to 70% as compared to mainly on the strength of the domestic manufacturing traditional techniques. This results in faster speed to market sector. Export orders increased only slightly (1.7%) by for new products and a reduction in development costs. comparison. The results are reported by UCIMU - Sistemi Many machine tool manufacturers are incorporating this per Produrre. technology into their machine tools. 

78 METALWORKING NEWS v 15. 3 July 2016

“Industrial sectors where automation is employed on a wide scale such as automotive, aerospace and defense, electrical and electronics, medical devices, industrial machinery, and renewable energy are showing signs of positive growth which will augur well for the growth of the machine tools market during the forecast period.”

Technological advances manually controlled conventional machines. The new and The machine tools industry has evolved with the advanced machines operate using programmed commands development of both hardware technology and software and computers to enhance productivity. applications. This has resulted in machines becoming faster, “Increased productivity is a major factor that benefits intelligent, and versatile. Machines have now become companies that use process automation. Moreover, multifunctional and are capable of performing a broad range implementing process automation not only enhances profit of tasks inside a single set up. Electrical discharge machines, margins but also has a positive impact on resource regulation ultrasonic, and electronic beam technologies have and loss control,” Anju says. revolutionised manufacturing technology. Multiple software products can be standardised on one Complete, effective remote diagnostics platform. Advanced CAM technology is being used for Manufacturers of all kinds are being challenged to deliver multi-axis, multi-spindle, and multi-turret machines. Software new products in record time using an increasingly complex is increasingly being used in automation of manufacturing internal and external supply chain that includes experts who and engineering processes. Software applications provide an are located all over the world. But equipment downtime, lost integrated view of operation through direct integration with production, delays in product reviews and high travel costs to product lifecycle management, manufacturing execution troubleshoot problems can kill the bottom line. With services, process planning, and enterprise resource operations often spread across the globe, delayed decisions planning systems. can cause costs to mount quickly. Commonly, an expert (or whole team of experts) boards a plane to go to solve a problem, Surge in automation causing further delays and incurring expensive travel costs. The growing demand for superior-quality products has The use of outsourced offshore partners, as well as propelled companies to undertake automation in shrinking product life cycles, has increased the demand for manufacturing. Investment in global process automation is an operations-driven, mobile, video collaboration that continuing to grow at 6% and is projected to reach immediately connects experts. Such equipment can be $120 billion by 2019. This growth is focused on areas such suitable in a variety of applications including plant maintenance as technology, hardware, software, services, and the management, internal and field service equipment trouble- communication protocol used for automation. shooting, heavy equipment maintenance and repair, product The machine tools sector in the developed and developing and process design, and safety audits and inspections. countries, especially those in mid and small-scale industries, Of course, this remote connectivity allows some issues to are increasingly using NC and CNC machines rather than be diagnosed and fixed without the need for an on-site service call. If, however, the diagnosis determines that an on-site service call is required, intelligent dispatch ensures that the service engineer arrives with advance knowledge of the problem, its solution and the necessary parts in-hand. Machines can be connected on an “as-needed” basis or in “always-on” mode, depending on how the manufacturer chooses to operate. When connected in “always-on” mode, machines can be monitored to provide proactive alerts and regular status alerts, improving information Smart automation solutions has allowed production gathering and sharing to be enhanced by machine tending robots and decision making.

80 METALWORKING NEWS v 15. 3 July 2016 product review

GF Machining Solutions ‘E’ class wire EDM range

F Machining Solutions, the EDM, milling and laser machine tapers/cones up to 30 degrees over 45mm ablation machine tool specialist and automation systems (part height). Gsolutions provider has introduced a new range of As well as being easy to understand and use, the compact wire EDM machines into the market, the CUT E 350. CUT E 350’s control system and interface - AC CUT (HMI) The CUT E 350 machines can handle relatively large - features powerful job management functionality including workpieces (820mm x 680mm x 220mm) weighing up to Information about geometries, machining processes and 400kg — and features, such as the machines’ drop down command programmes which are processed in one file, doors, enable easy access to the work area and trouble-free l enabling jobs to be transferred between CUT E series machines oading/unloading of (if required), and all parts. modifications to be At the heart of the managed automatically. CUT E 350 machines is More than 10 GF Machining Solutions’ automated digital generator measurement cycles technology. The are available to ease Intelligent Power work-piece Generator (IPG) helps preparation, and with manufacturers cut the standard, on-board parts faster and deliver AC CAM Easy software exceptional accuracy package, operators and surface finishes can prepare ISO files (Ra 0.16 µm) — and a and post-process number of integrated them into jobs during and built-in machining. technologies help The CUT E 350 is customers exploit the supplied with a large machines’ full 19” touch screen with potential. pinch n’ pull These include the capability, and a new Power-Expert technology hand box (designed module that in real time for one-handed use) is monitors the cutting a big advantage in job conditions and part set-ups and job shape requirements preparation. ensuring that optimum The power is always CUT E 350 machines delivered to the wire. are equipped with a This functionality is reliable wire system especially useful and At the heart of the CUT E 350 machines is comprising: efficient when GF Machining Solutions’ digital generator Thermocut module machining intricate part technology. The Intelligent Power Generator (IPG) (for easy wire features i.e. stepped preparation prior to parts etc. helps manufacturers cut parts faster and deliver threading); a wire Similarly, the Corner exceptional accuracy and surface finishes circuit design that Strategy module ensures perfect automatically adjusts (Ra 0.16 µm) — and a number of integrated and rolling-out and that and recalibrates built-in technologies help customers exploit the does not disrupt the machining parameters EDM process during the cutting machines’ full potential during machining, process, making and; Automatic provision for any change in direction, thereby enabling sharp Wire Threading/Re-Threading capability to increase productivity. angles and small radii to be produced. The CUT E 350’s Intelligent Collision Protection (ICP) The machines’ functionality is further enhanced by on the X, Y and Z axes eliminates costly collision-related on-board dedicated ‘speed’ processes which can reduce cutting downtime. times by as much as 18% over standard wire EDM machines, For more information contact Retecon Machine Tools on and the provision of a Taper-Expert module allows customers to TEL: 011 976 8600 or visit www.retecon.co.za

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Mastercam 2017 released for public testing worldwide

• Dynamic Motion advances bring new options to the developer’s groundbreaking technique, delivering toolpaths that are more efficient, less complex, travel a shorter distance, and improve cycle time. • Expanded CAD for CAM delivers more practical design tools for shop-floor programmers. Mastercam 2017 speeds design for items such as molds and electrode tools, offers auto-repair on imported solids, and improves current tools such as Solid Disassemble. • New Maximum Stock Engagement option for 3D HST Finishing toolpaths allows you to select a previously made stock model and set the maximum amount of depth so that you can limit how deeply the cutter engages uncut material. • Powerful Multiaxis enhancements include optimised astercam 2017 is now in public beta, which means the Multiaxis Drill, with stock model recognition for depth next version of the software is available for testing by and top of stock purposes. Additionally, the various M“currently maintained” Mastercam customers, ways of selecting stock have been updated to have according to a recent news release from CNC Software. consistent workflow and selection methods. “Shops all over the world, from small job shops to Fortune • Lathe enhancements such as the new Align Solid Body 100, get a chance to test Mastercam 2017 before it is which simplifies the process of aligning solid models released, and provide valuable feedback that helps shape the for turning. Chip Break has a new option and a dialog final product,” the company announced. “Participants in the box has been added to the Lathe Rough and Lathe Public Beta get an early look at the new streamlined workflow Contour Rough toolpaths to establish when chip and optimised interface that Mastercam 2017 delivers, along breaks occur. with dozens of powerful new tools for simple to complex jobs.” • Overall streamlined workflow with improved plane management, level and geometry control, view sheets, CNC Software highlighted the following features of the chaining and more. The new Analyze Toolpath feature new version: further improves workflow by displaying useful • New optimised interface organises and streamlines information when you hover over a toolpath programming. Based on the successful “Ribbon” section. interface, Mastercam 2017 capitalises on your experience with other Windows software, making it For more information contact the local agent easier to find the functions you need to complete Mecad Systems on TEL: 086 111 2236 or visit the your tasks. website www.mecad.co.za

Hurco’s 5-axis machining centre VCX600i

he new Hurco VCX600i vertical-spindle, 5-axis machining WinMAX control includes patented Ultimotion software, which centre, a travelling-column model, has a 600mm diameter ensures smooth, high-speed contouring of 3D surfaces. Trotary table mounted on a swivelling trunnion, a Machining accuracy and effective vibration damping are configuration popular amongst users as it allows components promoted by wide linear roller guideways and a base frame to be machined on five sides in a single set-up. An octagonal made from the concrete and steel composite, Hydropol. support for the table means that clamps can be positioned Axis travels are X: 750 mm, Y: 550 mm, Z: 500 mm, glass clear of the surface, ensuring that the full area is available to scales ensuring high precision positional feedback to the accommodate workpieces weighing up to 350 kilograms. Control. Similarly, absolute angle encoders provide feedback The integral, ± 110 degree B-axis trunnion from the rotary axes. The table is of robust construction offers generous Z-axis clearance and unrivalled and can be supported on the non-driven side by a undercutting capability. Together with a counter bearing, the load on which can be 16 kW / 12,000 rpm / 109 Nm direct-drive transmitted through to the floor to allow heavy spindle, 30 m/min rapids and a 40-station milling to high accuracy. The doors, which open magazine for BT40 tools, the machine is on two sides of the working area, simplify access suited to applications across the whole for automation systems. manufacturing industry but is especially For further details contact applicable to motorsport and aerospace. Hurco South Africa on TEL: 011 849 5600 or The manufacturer’s proprietary visit www.HURCO.com

84 METALWORKING NEWS v 15. 3 July 2016 Iscar Trideep gundrills and deep drilling heads carrying inserts with three edges

scar has introduced innovative new gundrills and deep drilling • GD-DH - Gundrills for machining centres and gundrill heads, in the 16 to 28mm diameter range and in 10, 15 and machines. Longer gundrills in the diameter range of I25 drilling length to diameter ratios that carry three cutting 16 to 28mm diameters can be supplied with up to edged TOGT indexable inserts with chip splitters. 2400mm length on request. The TOGT inserts feature a positive rake chipbreaker and a wiper to ensure high hole surface quality and high feed. The Advantages include deep drills with a three cutting edged new inserts, made from IC90, a versatile PVD coated grade, insert (other manufacturers only offer inserts with one or two are available in five sizes. cutting edges), highly accurate peripherally ground insert providing high hole diameter accuracy of IT10, produces narrow Based on the new TOGT inserts, Iscar/Unitac introduced chips for efficient chip evacuation, enabling higher feed rates the following new deep drilling lines: compared to other currently available • BTA heads extend the lower drills, an insert wiper provides extra fine drilling diameter capability surface finish, direct insert mounting so to 16mm no adjustment is needed for accurate • DSD-EF-FT - Deep single tube drills hole diameter, and the drills carry a new with external four start thread economical solid carbide or brazed guide connection pads. • DDD-EF-FT - Deep double tube Main potential industries for deep drills with external four start drills include the die and mould, thread. Drills in 18.4 to 28 mm automotive, oil and gas and the power diameters are also available by generation sectors. special order. For more information contact Iscar • DSD-IF-FT - Deep single tube drills South Africa on TEL: 011 997 2700 or with internal single start thread visit www.iscar.com

METALWORKING NEWS v 15. 3 July 2016 85 Tongtai’s iTD-2000YBC new CNC turning centre

ongtai’s iTD-2000YBC is an advanced, high precision perpendicular to the X-axis for complex off centre milling CNC turning centre cast from Meehanite iron. This functions and easy programming. The Fanuc OiT-F CNC control Tmachine features a rigid, ergonomic, and super accurate is standard and fully loaded with operator-friendly features 75° bed design for excellent chip flow and operator including Manual Guide i Conversational. accessibility. The 75° bed also simplifies the programming For further details contact PBS Machine Tools on of the optional Y-axis as the Y- axis is perpendicular to the TEL: 011 914 3360 or X-axis like a vertical machining center. High rapid-traverse visit www.pbsmt.co.za rates using 45mm roller type linear ways are also achieved to reduce non-cutting time. X-axis cross travel is 230mm, Z-axis longitudinal travel is 600mm, B-axis sub-spindle travel is 630mm, and optional Y-axis travel is +/- 50mm from the centre line. The main spindle is driven by a 15kW, high torque motor that provides power and fast acceleration at 4,500 rpms. The 5,000 rpm sub-spindle is driven by a 7,5kW high torque integral motor spindle. The spindles are synchronised on the fly for part transfer to the sub-spindle. Rapid traverse feed rates for X, Z, and B-axes are 30m/min. and 15m/min. on Y. Standard equipment also includes a tool setter and chip conveyor. A 12-station bi-directional servo BMT-65 (16 station BMT-55 optional) turret provides 0.3 second indexing and coolant through the tool holders. A full C-axis with live tools is standard for milling operations on both the main sub-spindles. The true linear Y-axis provides turret movement

DMG MORI Ultrasonic 20 linear 2nd generation milling machine

Capable of five-axis grinding of advanced materials as well as HSC milling.

he second generation of the Ultrasonic 20 linear, (A-axis) more powerful drive motors, a 15kg higher load developed in collaboration with Sauer, DMG weight and the use of larger tool diameters of up to 50mm. TMORI said this new machine Another highlight is the high-speed C-axis (1 500rpm) for expands the use of ultrasonic high-precision and productive internal and external cylindrical assistance to applications with a de- grinding of rotational-symmetric workpieces made of advance fined cutting edge, such as the milling materials. and drilling of nickel or titanium-based Where control is concerned, the superalloys and more. It is ideal for the Ultrasonic 20 linear 2nd Generation optical, clock/watch,medical and supports users with a multitude of high-precision mold sectors. In new functions. The Ultrasonic addition to a high removal rate, it parameters are automatically allows for accurate edge machining determined and tracked during and 40% reduced process forces for processing. In the clearly arranged advanced materials such as glass, Celos® control a Celos® APP ceramics, corundum, composite expressly developed for the purpose materials and hard metal. shows the Ultrasonic technology Even externally, the completely cycles and key process parameters revised Ultrasonic 20 linear 2nd such as frequency, amplitude and Generation with its new, functional output, thus enabling maximum design and a reduced footprint of just utilisation of the Ultrasonic and 3.5 m² is impressive compared machine performance. to its predecessor. The diverse For more information contact technological optimisations include Retecon Machine Tools on the now optional 60 000rpm speed TEL: 011 976 8600 or of the spindle, the up to 47 percent visit www.retecon.co.za

86 METALWORKING NEWS v 15. 3 July 2016

Jet Edge’s gantry system supports 12 waterjet cutting heads for high throughput

et Edge’s high-rail-gantry waterjet motion system is ways. Precision ballscrews are directly coupled to designed for use in high-production industrial waterjet servomotors. Jshops that require performance, precision and accuracy. Mechanical components along the X and Y axes are This waterjet system supports as many as 12 cutting heads protected from the abrasive jet environment by a lip seal for maximum throughput, system. This system uses brushes, enabling shops to process jobs labyrinth passages, lip seals, and faster and take in more work. high-volume, low-pressure filtered It is available in sizes ranging air to protect critical motion from 1 200 x 1 200mm to components, providing longer 7 300 x 4 200mm. The machine service life compared to features a 300 or 455mm conventional bellows arrangements. Z axis and an extra 75 mm of The system’s overhead design travel can be added with an enables full access to the work optional sub-Z assembly. envelope and raises critical According to Jet Edge, the components out of the waterjet gantry system provides process environment. ±0.0254mm linear positional The high-rail-gantry system accuracy (over 305mm) per axis, features Jet Edge’s fully- ±0.0254mm repeatability networkable Aquavision Di (bi-directional) and 0.01mm controller, which guides the user maximum backlash. A from job setup to production, stress-relieved, steel-fabricated including single parts, mirroring, frame provides high rigidity, and coupled with rigid, rotation, plate alignment and part arrays. honeycombed steel beams, enables stable and fast For more information contact Jetstream Cutting Solutions operation. Moving elements are supported on THK linear CC on TEL: 011 468 1093 or visit www.jetstreamcutting.co.za

600 UK puts a new slant on single-hit turning with flatbed c-axis Alpha XC lathe

aking its debut at MACH 2016 was the New Harrison The Harrison Alpha XC can now conduct off-centre drilling Alpha XC combination CNC lathe, now incorporating and boring, hexagonal milling and much, much more. What Mdriven tooling and full c-axis interpolation. This this lathe gives customers is the facility to perform secondary feature, a significant addition to the unique, simple to operations that would be commonly reserved for a full operate, CNC Alpha lathe now allows operators to carry out production, slant bed CNC Turning Centre. The turret has eight secondary operations at the machine in one set up. stations and all positions can be driven at up to 5000rpm. The Harrison Alpha XC is a new model that is based on The VDI tooling set-up is based upon the size of the machine the globally recognised Harrison Alpha XS lathe and was and has either a 20 or 30 VDI configuration. designed and manufactured as a result of Alpha customer Shown at MACH 2016 was the new Harrison Alpha feed back who said that they wanted a full interpolating C-axis 1400XC with a 1250mm centre distance, swing over bed of on the machine. 400mm and a 55mm through bore spindle. The larger capacity Alpha 1460XC and Alpha 1550XC are now available from Harrison and 600 UK, with a swing over bed up to 550mm and centre distances up to 3000mm. The control unit on the machine is the renowned Fanuc 0i-TD system and as engineers will recognise, Harrison has its very own Alpha programming system that is unique to 600 UK and favoured by users worldwide. This is in addition to the Fanuc Mgi (Manual Guide) system that is fully conversational for the end-user, using pictorial guides as well as the full G-Code CNC system, giving the Alpha operator unrivalled programming options. For further details contact F & H Machine Tools on TEL: 011 397 4050 or visit www.fandhmachinetools.co.za

88 METALWORKING NEWS v 15. 3 July 2016

Hypertherm announces ProNest 2017, a major version upgrade to its CAD/CAM nesting software

Company is also “Shaping Possibility” with new company vision and website.

ypertherm, a manufacturer of Hplasma, laser, and version release. Hypertherm waterjet cutting systems, nesting software for cutting has announced a major in production environments, version upgrade to its formerly named TurboNest®, ProNest® advanced CAD/ is now called ProNest LT. Also, CAM nesting Hypertherm nesting software software for automated for cutting in job shop cutting. ProNest® 2017 environments, formerly contains a number of NestMasterTM, is now improvements designed ProNest LTS. ProNest LT and to make customers more LTS contain many of the efficient and profitable. features found in ProNest 2017. Users with an active New features software subscription can include: upgrade to the new version of • Manual nesting improvements, including drag array, their respective product at no additional charge and continue anchor part to cursor, and automatic bumping to receive unlimited technical support, and other benefits. functionality for greater control and faster nesting. More information is available at www.hypertherm.com/CAM. • Color by part property that fills parts with different colors based on a designated attribute (name, priority, Hypertherm has unveiled a new tagline - “Shaping work order number, due date, etc.) and ProNest Possibility” — and new website reports that show fill colors in part images making Hypertherm has also unveiled a new tagline in support of it easier to locate parts. its company vision and a new website designed to support the • Redesigned drill machine interface for plasma or industrial cutting and robotic needs of individuals and oxyfuel machines that incorporate drilling, tapping, companies around the world. and other spindle operations to seamlessly tackle jobs Hypertherm’s new “Shaping Possibility” tagline replaces directly in ProNest. the “Cut with Confidence” tagline in use since the beginning • Native 64-bit support allowing ProNest to take of this decade. The new tagline conveys the company’s role in advantage of the extra accessible memory available providing products, services and expertise to help customers on a 64-bit CPU/Operating System. achieve their vision, and expresses all that is possible with

“ProNest 2017 contains more embedded cut process expertise in the NC code than any other software, allowing our customers to leverage patented technologies like True Hole®, True BevelTM, and Rapid PartTM.”

“The outcomes our customers expect as a result of using Hypertherm products in the hands of hard-working Hypertherm CAD/CAM software drives us to deliver manufacturers and fabricators. exceptional solutions so they may achieve more and do it Hypertherm is also introducing a completely new more profitably. ProNest 2017 will deliver increased material website. Site visitors can compare different cutting savings, boost productivity, lower operating cost and improve technologies and platforms, troubleshoot cutting challenges, part quality,” said Derek Weston, Product Marketing Manager and connect with Hypertherm experts around the world. for Hypertherm CAD/CAM software products. The site includes major navigational changes and powerful “In addition, ProNest 2017 contains more embedded cut search features that make it easy to find content, while smart, process expertise in the NC code than any other software, responsive design aids viewing on computers, tablets, and allowing our customers to leverage patented technologies like smart phones. True Hole®, True BevelTM, and Rapid PartTM.” For further details contact Craig Sterley of More changes to Hypertherm’s nesting software family of Hypertherm on email [email protected] or products are also taking place as part of this major visit www.hypertherm.com

90 METALWORKING NEWS v 15. 3 July 2016

Siemens releases Solid Edge ST9 for CAD

New cloud capabilities revealed.

he latest release of Siemens’ Solid Edge software (Solid Edge ST9) for mainstream CAD provides flexible Tand easy access to the full capabilities of Solid Edge with cloud-based licensing, user preferences, and collaboration tools. In addition, the new built-in data management capabilities, with zero IT support requirements, enable users to easily index their CAD models, while the new migration tools enable rapid conversion of legacy design data from virtually any CAD system. For more comprehensive data management capabilities, Solid Edge ST9 facilitates an easy upgrade to Siemens’ Teamcenter portfolio, the world’s most widely used digital lifecycle management software. Solid Edge ST9 also offers significantly enhanced integration with Teamcenter to help simplify completion of critical data management tasks.

New cloud capabilities New cloud capabilities provide faster and more flexible deployment options, improved user access and collaboration across remote designs teams. Licenses and user preferences can be stored on the cloud enabling users to access their personal environment anytime and anywhere. Solid Edge ST9 also adds data storage options via cloud-enabled vaulting so users can store and share design data in a controlled manner with external suppliers and customers, using popular software like Dropbox, OneDrive software, Google Drive online storage Copyright: Zumex service and Box. While this allows users to efficiently work online, the option to work locally, i.e. offline, is always and a new embedded window for Active Workspace. available. The ribbon bar helps designers quickly perform where-used New built-in data management capabilities enable users searches and initiate Teamcenter workflows; easily view and to take control of ever increasing volumes of CAD data, with edit properties information; and see how the data is instant searches for files and properties, as well as impact synchronised. This will help speed up the learning curve for analysis. There is no database software to install or database new users and help existing users complete these tasks faster tables to maintain. The new design manager utility provides and more consistently. Active Workspace, an intuitive, highly for fast and simple revision and release management, visual, and personalised environment for instantly accessing significantly improved data organisation and consistency, and information, will provide designers the ability to perform faster completion of everyday data management tasks. simple text based “filter” type searches to find the data they The enhanced Teamcenter integration includes a new need, and then drag parts into Solid Edge for editing, or place ribbon bar for consolidated access to data management tasks them into an assembly. New migration tools build on the existing toolset for importing CAD data. For example, the associativity between SolidWorks software models and drawings can now be migrated to Solid Edge. Additionally, a robust Solid Edge 2D to AutoCAD software export tool ensures seamless mapping of Solid Edge drafting elements to AutoCAD. Solid Edge ST9 also provides easy access to the 2D designs created in Siemens’ newly announced Catchbook software, to rapidly create 3D models and professional engineering drawings from sketches. For further details contact Susan Krüger, Events & Office Manager at ESTEQ on TEL: 012 809 9500, email: Copyright: Zumex [email protected] or visit www.esteq.co.za

92 METALWORKING NEWS v 15. 3 July 2016

Highly reliable Sandvik Coromant GC1130 overcomes challenging machining conditions

Steel milling grade offers greater security and productivity.

achine shops faced with identifying ways of achieving production. That saves them time and money.” secure machining with long and predictable insert life When repeated shoulder milling is Min steel milling operations can turn to GC1130, an required, the combination of GC1130 with insert made with the Zertivo™, a unique production CoroMill 490 provides a suitably light technology from Sandvik Coromant. cutting action and smooth profile that can GC1130 helps to overcome efficiently reduce the need for a challenging machining conditions finishing operation. Also available with a clean and intact edge, for the CoroMill 390, this grade is delivering high metal removal best when multiple rates and performance component features are levels in both wet and dry required. Bringing an machining operations. The added dimension of grade is offered as the first security and predictability choice for shoulder milling to machining in cutters, CoroMill® 390 and challenging conditions, CoroMill®490 and chamfer the assortment includes cutter, CoroMill® 495. many different types of Flaking, abrupt chipping tools and a wide selection and thermal cracks are of corner radii. Applications common issues encountered such as shoulder milling, when milling materials in linear and helical ramping, steel applications, especially turn-milling, deep shoulder when faced with unfavourable milling, edging and pocketing can be tool paths and deep cavities or when performed. using coolant. GC1130 has been specifically developed to help production Combining GC1130 with CoroMill® 490 engineers combat the subsequent unwanted provides a light cutting action and smooth profile

“The choice of insert geometry and grade is just as important as the choice of tool when looking for secure machining. The tool and insert together is what contributes to the overall performance in an operation. Many times, when using grade GC1130, customers can move from one component to the next without having to stop production. That saves them time and money.”

effects of short insert tool life and unstable production. In applications where trouble-free chamfering in various Manufactured with Zertivo, a unique production steel types is required, pairing CG1130 with CoroMill 495 technology that helps amplify the grade’s benefits offering reduces downtime and allows for higher machine utilisation. peace-of-mind through greater edge-line security and reduced Along with the chamfering of holes and edges, typical applications flaking. Furthermore, a high-Cr content fine-grain substrate include back chamfers, welding preparation and deburring. delivers high resistance to thermal cracks generated as a Product manager for shoulder milling at Sandvik result of temperature fluctuations during machining, helping Coromant, Thomas Wikgren, states, “Greater process security, to ensure long and reliable tool life. productivity and tool life are all within reach with GC1130. At According to Mikael Eiritz, product manager for milling the end of the day, our customers are looking for a reliable grades at Sandvik Coromant, “The choice of insert geometry tool and insert combination that will help them achieve a and grade is just as important as the choice of tool when lower cost per component.” looking for secure machining. The tool and insert together is For further details contact Sandvik Coromant on TEL: what contributes to the overall performance in an operation. 0860 101 008 or Mary-Ann Haylett on TEL: 011 570 9615, Many times, when using grade GC1130, customers can move or email: [email protected] or visit from one component to the next without having to stop www.sandvik.coromant.com

94 METALWORKING NEWS v 15. 3 July 2016 Panel bending redefined

rumpf’s TruBend Center 5030 panel-bending machine, part manipulator performs all additional material handling presented as the perfect complement to its TruBend required for bending steps along that edge; the bending tool Tpress-brake product line, can produce positive and moves to form each bend. The machine operator then turns the negative bends, folds and circular bends with a variety of radii, sheet and the process begins again. all while minimising setup times and tooling A unique design feature is the costs. With a bending length of three metres, the machine’s additional vertical axis for TruBend Center 5030 is a thin-sheet processing the part manipulator. Since the part specialist. Operators insert the workpiece manipulator can fix parts at a range of material against the backgauge and the two-axis positions, this axis optimises flexibility and provides for easy removal of parts with downward edges. With standard tools, the TruBend Center can form aluminium and mild-steel sheets to 3mm thick and stainless-steel sheets to 2,3mm. Possibilities include short side lengths, deep boxes and small profiles, as well as parts with formed sections, recesses and diverse radii. The machine can also productively process galvanised and painted sheetmetal. To form parts with challenging geometries, such as very small profiles, formed sections near the bending line, flanges or staggered bends, additional blankholders and bending tools are available. The machine’s optical angle assistant ensures accuracy and proves particularly helpful when setting up new parts. For more information contact Retecon Machine Tools on TEL: 011 976 8600 or visit www.retecon.co.za

METALWORKING NEWS v 15. 3 July 2016 95 Yaskawa and Clearpath partner to develop mobile manipulation system

askawa and Clearpath have partnered to develop a 1 500 kilograms and is built with mobile machine tending and material movement system industrial-grade components to suitable for shop floor environments. This fully inte- withstand the rigors of industrial Y ® grated system features a Motoman MH12 robot equipped environments. with an end-of-arm tool (EOAT) and vision system, mounted on “We’re really excited to partner Clearpath’s OTTO 1500 self-driving vehicle. The project is with Yaskawa to develop the future currently under development and supported under the of mobile manipulation and advanced research division of Clearpath. collaborative robots. Combining our “Our partnership with Clearpath will provide industry with cutting-edge self-driving industrial a robust, tightly integrated solution for moving robots vehicles with Yaskawa’s to the work in a very flexible and dynamic way,” said industry-leading robot arms Roger Christian, divisional leader, new product will enable a new category development, at Yaskawa Motoman. of automation for machine “This autonomous modular solution provides users tending,” said Matt an alternative to arranging the work to a fixed robot Rendall, CEO of Clearpath. station.” For further details The robot has a 12-kg payload capacity, a hollow contact Yaskawa Southern wrist for EOAT cable management, and a 1 440mm Africa on horizontal reach. TEL: 011 608 3182 or visit The vehicle has a payload capacity of www.yaskawa.za.com

New products from ATA Garryson and Bulldog Abrasives

New oil free pencil grinder - The SPT100R ATA Garryson have announced the latest addition to their comprehensive range of pneumatic air tools — the SPT series oil free pencil grinder. The SPT100R Pencil Grinder has been designed to include an innovative propulsion motor operating at 100 000rpm, perfectly suited to 3mm miniature tungsten carbide burs. This allows for higher peripheral bur speeds resulting in improved control, greater precision and a superior finish. The unique motor design contains no vanes, rotor or cylinder, minimising maintenance and repair costs. No lubrication is required eliminating contamination of the work piece. Also available is a replacement motor that can be quickly and easily installed, minimising tool downtime.

High performance burs with the new Inox and steel ranges ATA Garryson have also recently launched a comprehensive range of Inox and steel burs that are specially designed to suit growing market demands for stainless and cast steel applications. These new burs offer a real competitive advantage thanks to their new cut performance allowing for a greater stock removal on all austenitic, rust and acid-resistant steels. The bur’s unique geometry enables the operator to work more efficiently through the generation of less heat at the intersection of the cutting edge and work piece. For further details contact Bulldog Abrasives on 011 786 5991 or visit www.bulldogabrasives.co.za

96 METALWORKING NEWS v 15. 3 July 2016 New Pratt Burnerd Gripsafe gripmeter makes health and safety a thing of the past

ratt Burnerd International, a division of 600 UK, has • able to connect to any WiFi compatible launched their new chuck force measurement Gripsafe device Pgripmeter. The Gripsafe accurately measures and records chuck gripping forces within seconds. Additionally, the in-built Gripsafe software provides This new, innovative product, suitable for use on all makes real-time data capture incorporating all essential functions of chuck, has been developed to help customers comply with needed to conclude analysis. health and safety legislation, allowing them to ensure that their chucks remain fit for purpose. Its main features include: The Gripsafe is a vital health and safety instrument. • Rechargeable battery with USB charging interface The facts are clear. If your chuck is poorly maintained, has and battery level indicator damage or excessive wear, grip force can be seriously • No additional software is required as all application compromised. software is embedded into the Gripsafe device This is relevant on all lathes, from manual through • Multiple machine ‘file save’ and ‘session’ features to full CNC lathes and turning centres, whether industrial or • Data export to .CSV file function educational. No one can afford to ignore the loss of grip that • Test certification print facility with automatic time chucks succumb to over time, which can rapidly and date stamping become a hazard if not maintained and monitored • Automatic re-calibration reminder regularly. Pratt Burnerd believe that the Gripsafe will prove to become a welcome tool for Health and Safety managers The Gripsafe gripmeter can be purchased outright, or and lathe operators alike, who have to meet exacting safety alternatively be rented for an agreed timeframe to suit standards. individual maintenance schedules. The Gripsafe ensures reliable and accurate measurement For further details contact F & H Machine Tools on of the gripping force being applied by the chuck under both TEL: 011 397 4050 or visit www.fandhmachinetools.co.za static and rotating conditions. All that is The Gripsafe, utilising the latest WiFi communication required is to clamp the Gripsafe unit in the chuck technology and unique embedded software provides and quickly run the tests, end-users with many valuable features including providing with instant results. You will know extensive data collection and analysis and storage immediately if your chuck needs attention or replacing. The Gripsafe, utilising the latest WiFi communication technology and unique embedded software provides end-users with many valuable features including providing extensive data collection and analysis and storage.

The Gripsafe accurately measures static and dynamic chuck gripping forces up to 100kN per jaw at a rotational speed up to a maximum of 6000 rpm and is: • compatible with all 3 and 2 jaw chucks • supplied with extension rings to enable use with increased diameter chucks

METALWORKING NEWS v 15. 3 July 2016 97 Edgecam 2016 R2 delivers a number of new features

The 2016 R2 version of Edgecam CAM software for milling, turning and wire EDM is said to offer time savings when loading solid model part files. During trials, files loaded around 20 times faster, chiefly because less time is taken opening files due to ‘tessellation.’ This sees Edgecam break the model down into triangles, which are then stored in such a way that they can be read back faster than before.

dgecam 2016 R2 Edelivers a number of new features and milling, turning and wire EDM users will benefit from over 30 important new and enhanced items of CAD and CAM functionality, with developers working on more. User experience developments Edgecam 2016 R2 64bit application include super-fast file loading for large assemblies, auto indexing when In addition, support for probing cycles has been enhanced moving between features on different planes, and colour with direct solid picking and full associativity to the parent filter selection when selecting geometry and features. geometry. A number of machining cycles have been enhanced, For turning, the rough grooving cycle has been improved to including the ability to support a number of sharp corner add control to manage ‘nibbles’ on corner radii by adding or profiling methods such as loop, break-corner, chamfer removing intermediate cuts. This technology will provide the and others with significantly reduced code output. ability to better control the remaining stock for semi-finishing operations. Additional turning enhancements include the ability to manually edit a turning feature which has been detected by the feature recognition routines. This manual interaction allows the user to pick out additional machining areas on particular complex geometry. Machine configurations has been a focus of Edgecam development for this release and 2016 R2 sees the introduction of support for non-linear turrets on a 4 axis lathe, support for turning with rotating heads (Trevisan machine tools), and turning on milling machine improvements with support for nutated head configurations. Finally, Wire EDM developments include the ability to translate associative machining operations for multiple copies and support for rotary wire movements for features on different planes. For more information contact Stillam CNC Programming Solutions on TEL: 011 663 2600 or visit Turning with rotating heads Trevisan style machines www.stillam.com

98 METALWORKING NEWS v 15. 3 July 2016

High-performance circular saw with outstanding automation potential

hether in press shops or forging plants, at end-to-end material flow that includes the sawing manufacturers of fittings or electrical parts, at operation itself. Industrial robots are able to remove the cut Wsteel stockholders or automotive industry parts automatically and accomplish numerous other tasks, suppliers: In countless industries, there is a demand for from deburring and chamfering, through centring, tapping, sawing solutions that combine high cutting performance with marking and printing and on to sorting, stacking and efficiency and precision. With its KASTOspeed range of picking. This robot-saw solution can be further integrated products, the sawing specialist KASTO has just such a with a container management or driverless transport solution in its portfolio: The high-performance automatic system. circular saws have been specially designed for economic Depending on the customer's requirements, KASTO series production and excel thanks to their reliability and excellent The KASTOspeed offers many different ways results, even during of improving efficiency. The KASTOsort robot continuous operations. By means of the KASTOsort interface makes it possible to automate upstream robot interface they can and downstream production processes and integrate easily be integrated in a controlled, end-to-end these in a controlled, end-to-end material flow material flow. that includes the sawing operation itself KASTOspeed is available in two variants, for sawing steel or non-ferrous metals. Furthermore, users can choose between two sizes, with a cutting range of 90 or 153 millimetres (for round materials). The automatic circular saws help minimise cycle times and makes it possible to produce millions of high precision cut parts every year when operated for two or three shifts per day. Thanks to its outstanding reliability and precision in continuous operation, KASTOspeed is one of the most frequently purchased high-volume circular saws in the world. The high-performance automatic circular saw KASTOspeed has been specially designed Depending on the for economic series production. Industrial robots are able to remove the cut parts automatically and ease of machining of the accomplish numerous other tasks, from deburring and chamfering, through centring, tapping, material and the and printing and on to sorting, stacking and picking production requirements, HSS full steel or disposable carbide saw blades are used on the KASTOspeed. integrates the robot controller into the saw controller, The right cutting speed can be selected for each job. The its own KASTOlogic Warehouse Management System or an optimum positioning of the saw drive and the four-point existing ERP system. As a result, the user can control and workpiece clamping arrangement enable an extremely short monitor all the processes over a single interface and saw stroke. The robust machine construction with helical benefits from a perfectly harmonised process chain. gearbox, combined with a hydraulically damped measuring A number of different magazine variants are available stop and a bar pusher that can be moved rapidly into position, to allow large quantities of raw material to be stored permits accurate cutting and very high output. upstream of the machine. This means that companies can What is more, the KASTOspeed offers many different ways run the system fully unattended even for long periods when of improving efficiency. The KASTOsort robot interface required. makes it possible to automate upstream and downstream pro- For further information contact Retecon Machine Tools duction processes and integrate these in a controlled, on TEL: 011976 8600 or visit www.retecon.co.za

100 METALWORKING NEWS v 15. 3 July 2016 Akira Seiki Performa SR3 XP vertical machining centre

kira Seiki manufactures a variety of vertical table load is 1 100 kilograms. The spindle power is machining centre models. However they all use the 11 000 rpm and the machine comes with Abasic same construction such as the iron casting a chip conveyor, Mitsubishi Mi 745 frames in Meehanite. control system with memory card The Akira Seiki Performa SR3 XP readers and a network connection. vertical machining centre has All axis in linear motion guides extra spindle speed, 12 kW, and with full support ensure the quicker rapids. The XP comes superior acceleration/deceleration standard with through spindle capability. Six leveling supports coolant, SD card reader, a wash provide an impregnable down system and chip auger. foundation base. Advanced FEA The 20-station arm type digital analysis is carried out on BT40 tool changer is all machines to achieve optimum impressive and over the design and the rigid structure to small area the XYZ rapids of provide dynamic accuracy and 36/36/40 m/min are amazing. vibration absorption while rapid If you tweak a few standard cutting. Accuracy positioning is parameters the rigid tapping is ± 0.004mm and repeatability is lightning fast. ± 0.002mm. The machining centre travel For further details contact range of motion on the XYZ are Akira-Seiki Factory Outlet 762 x 410 x 460mm, the table South Africa or visit size is 910 x 380 mm and the www.mjhmachinetools.com

METALWORKING NEWS v 15. 3 July 2016 101 All-new Haas bar feeder

hen Haas Automation introduced the Servo Bar Haas bar feeder apart 300 bar feeder in 1999, it was instantly popular, from the competition. Wbecause it was compact, easy to use, and It features an affordable. In 2015, Haas engineers went back to the innovative rollaway drawing board to make bar feeder operations easier, more design that provides efficient, and faster. easy access to the rear The result is the all-new Haas bar feeder that provides of the lathe spindle for a simpler and more affordable way to automate part quick liner adapter and production on Haas turning centers. It features a liner changes. Simply press re-engineered, heavy-duty yet still compact design that boosts the foot-pedal release, and productivity and streamlines turning operations. the bar feeder easily rolls Designed and built by Haas Automation exclusively for use out of the way for access. When on Haas ST-10 through ST-35 and DS series CNC turning pulled back into position, the bar feeder centres, the Haas bar feeder connects directly to the Haas locks into place completely, eliminating accidental bumps or control, and is powered by the turning centre. alignment issues. And making bar height adjustments is easier Fast set up and quick changeovers are what sets the new than ever, using a single handwheel right where it’s needed to make visual “on-centre” adjustments. Quick-change pushrods snap into place without tools, and both sizes store conveniently in the cover of the bar feeder. Built-in racks on both ends of the bar feeder provide storage for and easy access to all Haas extruded spindle liners, so there’s no need to walk around the machine, as with the previous version. To reduce cycle times, the Haas bar feeder uses a new belt-driven bar-shuttle system that is seven times faster than the previous version, with lightning-fast retract speeds. Optical sensors accurately determine bar position, even on bars with chamfers and ragged ends, and stainless steel runners on the charging tray help bars roll down to the loading area much easier. Even square and hexagonal stock glide down smoothly to the new bar feeder tray. Because it’s integrated with the Haas control, all bar feeder parameters are set directly at the lathe. Easy-to-read, on-screen icons indicate if the bar feeder is out of position, has the lid open, or needs to be latched back into place. For further details contact Haas Factory Outlet South Africa on TEL: 011 974 2301 or visit www.Haassa.com

Widia’s VariMill III ER solid-carbide end mill

VariMill solid-carbide end mills are available through Novo.

ith a new seven-flute, eccentric relief (ER) design, This also means VariMill III ER customers can use the newest addition to the Widia VariMill family, the high-speed machining techniques such as peel milling or WVariMill III ER solid-carbide end mill, is engineered for trochoidal machining in high-strength alloys. higher metal removal, longer tool life, and improved surface Widia is offering the VariMill III ER in a full line of options, finishes in demanding workpiece materials such as titaniums including two, three, and five times diameter length-of-cut and and stainless steels. all common aerospace radii and chamfered corners, metric WidiaVariMill III ER is a true finishing endmill for higher and inch. With more and more additive layer manufacturing metal removal rates, longer tool life, and improved surface in the aerospace field, the trend going forward will be from finishes in demanding workpiece materials such as titaniums roughing to semi-finishing and finishing operations, perfect for and stainless steels. the increased efficiencies VariMill III ER provides. VariMill III A newly developed coating and proprietary pre- and ER end mills also come standard with the Safe-Lock option by post-coat treatment significantly improves cutting edge Haimer, eliminating pull-out risk, and making the tool consistency. Consistent cutting edges mean higher assembly more stable and concentric, which in turn increases metal-removal rates, longer tool life, and improved workpiece surface finish and tool life. surface finishes in expensive demanding materials. The tool is For more information contact Widatech on designed to be a true finishing endmill with the ability to take TEL: 087 150 3266, email: [email protected] or visit up to 30% radial engagement. www.widatech.co.za

102 METALWORKING NEWS v 15. 3 July 2016

Leadwell BC-600 machining centre with B axis and built in rotary table - 5 axis at its best!

ew to the Leadwell range, this machine is equipped 610mm, Z axis vertical travel of 610mm, Z axis horizontal with all the necessary options to deliver precision, travel of 790mm and an embedded removable rotary table of Nhigh speed 5-axis machining. The machine comes as 600mm diameter. standard with linear scales and offers a full B axis and an The Leadwell BC-600 has rapid feed rates of integrated C axis table, providing complete flexibility. 36/36/30 m/min, a spindle speed of 15,000 rpm, a spindle The Leadwell BC-600 represents the latest and greatest motor of 18.5 kW, programme storage up to 21 GB, a low in technology now available in 5-axis machining, this backlash swivel head, B-axis with standard optical scale and 5-axis machining centre not only offers a B axis rotary head tool storage of 40 tools. but also an in-built rotary table for complete flexability The 5-axis simultaneous processing, can reduce the to machine any work piece. The leadwell BC-600 uses times of workpiece unloading and the requirement of a Heidenhain controller that is reknowned for being the jigs, shorten the processing time and improve one of the preferable controllers for 5-axis performance. C-axis table using the machining. The advantage of DD motor provides high torque this type of machine is that and rigidity, and can solve the you can also use it as a traditional worm gear backlash normal 3-axis machining and worn problems. High torque centre by not using the and efficiency of spindle with a rotary table. complete high-rigidity structure The features of the applied results in roughing to Leadwell BC-600 include a finishing can be completed on table size of 1280 x 610mm, the same machine, suitable for direct drive design provides machining hard materials and backlash free movement, non-ferrous materials processing. 5-axis simultaneous For further details contact machining, X axis travel of WD Hearn on TEL: 021 534 5351 1100mm, Y axis travel of or visit www.wdhearn.co.za

Control software eases laser drilling of shaped holes

rima Power Laserdyne’s ShapeSoft, a feature of the is available for download to Laserdyne system users on the SP94P control for its multi-axis fiber laser systems, company’s website. Psimplifies the creation of programmes for producing The software enables the selection of process parameters cone, oblique cone, fan, racetrack and a variety of shaped for each of the steps involved in creating shaped holes at high holes in a range of turbine engine components such as speeds. Users set the parameter database record to be used, blades, nozzle guide vanes, and combustors for airplane feed rate and dwell time after the shutter is open before engine and industrial gas turbine applications. The software processing begins. System motion is modified as required to produce the shaped holes at whatever orientation of the BeamDirector or rotary/tilt tables specified in the drilling programme. This enables a single shape and a single macro to be repeated as many times as needed to produce the specified shape at various locations on a contoured, 3D surface. ShapeSoft is one of the many ongoing advancements for the Prima Power Laserdyne’s multi-axis fiber laser systems. ShapeSoft is a standard feature within the S94P control used on the Laserdyne 3 to 7 axes systems that include the Laserdyne 795 and Laserdyne 430BD laser systems. For further details contact Talmac Machine Tools on TEL: 011 827 6539 or visit www.talmac.co.za

104 METALWORKING NEWS v 15. 3 July 2016