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Metalworking News November 2012.Pdf METALWORKING NEWS 2 Editor’s Comment 4 Viewpoint 6 Industry News Retecon; Denel Aerostructure; Nissan to invest R1 billion; Local aerospace sector; BAE systems; Ode to automotive design; Jaguar; Airbus to partner with CSIR and Aerosud; Prasa fleet tender; SA motor industry; Gigaba: Paramount; Save the rhino cause; Siemens; Machine Tools Africa 42 Shopfront Focus Looking after your visual communication; Denel Technical Academy; Cutting gear challenges; Nu-Co Design & Manufacturers 58 Better Production Digital photonic production; Tips for optimising tooling selections for lathes 62 International News Sandvik; BMW South Carolina; Voestalpine; EuroBLECH; Valve World Expo; Gildemeister; Catalogues for cutting tool industry; Meps; Volvo; Japanese merger; GM’s fuel-economy efforts 76 Product Review Hyundai; Spindles for VMCs; Widia; New coolant; Pipe cutting; TaeguTec; Vacudest®; Dassault Systèmes; Improving robots’ efficiency; Motoman; Prima Power; Quantalube®; Mitsubishi Carbide; Sandvik; Heavy duty die sinker; Henkel; Doosan DNM 750L; Samsung; Kaltenbach; Waterjet cutting systems; BLM Group; Walter; Kennametal; Heidenhain; KOMET; Vardex; T Series; Toolholders METALWORKING NEWS V 11. 5 November 2012 1 EDITOR’S COMMENT Is the localisation programme benefitting you? here are many different local Volume 11 Number 5 infrastructure projects either nearing November 2012 completion or about to get off the ground. T Editor It is very encouraging that these major projects Bruce Crawford have been mooted and by all accounts look like Editorial Board going ahead. Once completed, all of them should Professor Dimitri Dimitrov, be to the benefit of South Africans as they are Global Competitiveness Centre in Engineering, Department of Industrial energy and transport related, aspects that have Engineering, University of Stellenbosch an effect on our everyday lives. Dr Willie Du Preez, Competence Area But as a manufacturer or a supplier Manager: Metals & Metals Processes CSIR Materials Science & Manufacturing how much are they benefitting you in terms of winning new contracts and / or enhancing Production Manager Wendy Crawford your production capabilities with the implementation of new technology? Reproduction One of the pre-requisites in the tender documents issued is that bidders Jericho Graphic Design would have to adhere to government’s set localisation target of between Advertising 60 and 65%. A preferred bidder would be required to set up a factory and Bruce Crawford / Wendy Crawford Tel: + 27 11 463 0489 supply chain in South Africa, employ local people and transfer skills. Cell: + 27 83 628 7654 There is also the so called and well-intended UNIDO SPX program, which is E-mail: [email protected] part of a large regional programme that comprises several interlinked Printed By components, one of which is for establishing in each country a sub-contracting Paarl Media and partnership exchange (SPX) centre for linking suppliers to large scale METALWORKING NEWS buyers in the countries. The overall aim of the SPX program is to maximise is published by: BA Crawford Specialised the economic impact of large scale international and local investors as well as Publications (Pty) Ltd state owned companies (SOC) by developing capacity of the local supplier base PO Box 69 299, Bryanston, South Africa, 2021 in selected African countries to successfully compete. I wonder how many of you actually know about this program or have benefitted from it at all? 41 Arklow Road, Bryanston, South Africa, 2021 Very few I suspect. The couple of companies that I know that have submitted Tel: + 27 11 463 0489 their details have complained that suddenly their opposition are tendering for E-mail: [email protected] the niche products they were supplying to SOCs. Subscriptions Now I read about a “Buy Back South Africa" campaign that is intended to Annual – Local: R130.00 (incl VAT) International: on application emotionally blackmail you into buying products made in South Africa, as it is us who have "lost South Africa" by supporting imported products, thereby ISSN 1682-8909 losing many jobs for South Africans. It goes on to say “We can turn this Copyright around, and create jobs, if we support and buy locally produced products.” All rights reserved. No editorial matter published in Metalworking News may be I am sure there are similar initiatives to boost South African reproduced in any form or language without manufacturing that I do not know about and they all have the “good written permission of the publishers. While every effort is made to ensure accurate intentions” feel about them. However there are too many reports that you reproduction the editor, authors, have read about where another international company has been awarded a publishers and their employees or agents shall not be responsible or in any way liable government contract. I understand that we do not have the manufacturing for any errors, omissions or inaccuracies in capacity or know-how in some instances, but in many cases we have a the publication whether arising from negligence or otherwise or for any manufacturing base that is very first world so let’s localise and stop consequences arising therefrom. eroding the very essence and success, The inclusion or exclusion of any product I believe, of a developing country. does not mean that the publisher or editorial board advocates or rejects its use either Take our BRICS partners as examples. generally or in any particular field or fields. 2 METALWORKING NEWS V 11. 5 November 2012 VIEW POINT The growing importance of multitasking he earliest multitasking mill/turn, turn/mill machine A second example involves hobbing of propeller shafts for tools began showing up on the floors of job shops and marine outboard motors. The propeller shaft is turned and Tindustrial-scale production facilities in the early to hobbed out of 630 stainless for corrosion resistance. The mid 1980s. These were the result of the demand to do way these shafts were made involved a multiple-step process: more with less — more operations, less setup and operator Turning on a lathe, dropping the shaft out, taking it to a involvement. vintage dedicated Barber Coleman hobbing machine An important driver in today’s multitasking environment (with very time-consuming, labour intensive setups), cutting are smaller lot sizes. The days of doing million-part the spline, then removing the part to a grinding operation. production runs are few and far between. The challenge It used to take 3 min just in turning alone. Now turning today is for shops of all sizes to machine as many part and hobbing in one machine takes just 3 min, 40 sec. This features as possible in a single setup on a single machine. example of multitasking technology with a hob assembly is Central to accomplishing this is a universal control to address doing away with some dedicated hobbing, while maintaining the exploding range of machining technologies used in similar throughput and excellent quality with one machine metalworking operations (turning, milling, drilling, grinding, performing the operations of two machines. hobbing, nibbling, punching, marking and more). Yet another new application produces spur and helical Benefits of doing more with less include compressing gears. The process uses a disk-shaped milling tool that lead times, from days to hours, and reducing lot sizes with rolls radially following an involute path with simultaneous no cost penalty. Lots as small as one piece can be done motion of the X–B or Y–B axes. Variations in the gear shapes efficiently and cost-effectively. Multitasking improves are generated by the tool path, not by the tool geometry, cash flow through higher throughput and shipment so a simple tool can produce a range of different gear frequencies. It also slashes non-value added time, with configurations. An important driver in today’s multitasking environment are smaller lot sizes. The days of doing million-part production runs are few and far between fewer fixtures, tools and far less labour. Furthermore, it Hyundai WIA not only develops and builds multitasking improves part accuracy by reducing tolerance stack ups machines for the market as a whole, they also employ the between multiple fixturings. latest technology in their own plants to manufacture engine, What's more, multitasking reduces shop burden — fewer transmission and suspension components for their parent machine tools, reduced floor space and more cost-effective company, Hyundai Motors. use of utilities. You can also run untended — one operator It’s not always about reducing labour costs or can run several machines, or you can run an entire third burden rates. Again, as a global manufacturer in both shift untended — which increases cutting time without the mature and developing markets, the company has attendant labour costs. Bottom line: Doing more with less learned first-hand that in many cases multitasking results in increased profitability. machines are required to provide the consistency they Further, multitasking is an evolutionary process: When you need in machining components for the many finished think you have figured out how to do everything possible on a goods they produce. multitasking machine tool, someone comes up with another In the future there will undoubtedly be many more set of ideas for more applications. multitasking functions. However, a word of caution: Among those ideas is broaching features such as Adding all of these capabilities in a single machine is one keyways, ID splines and fir-tree root forms on disks for thing; knowing how to use them correctly is another. aerospace engines and steam turbines. The broach for ID This requires the end-user to work very closely with the work is an axially oriented tool. The B-axis of the multitasking machine tool vendor. It’s often very difficult to come to machine is oriented as if one were going to drill the ID. The terms with the reality of doing so much in a single machine.
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