metalworking news
2
4
6
Editor’s Comment
Viewpoint
Industry News
SpiroGrooving™; G.U.D. Holdings; Wam Metals completes move;
W.D. Hearn sign up with Kitamura Machinery; Atlantis Foundries sold;
Wispeco; Toyota - SA; New automotive centre; Evraz Steel unit;
Component export sales dropped; New Executive Director - SA Institute
of Welding; AfriMold acquisition; Paramount Group; MTool;
Denel Technical Academy grows; Auto components; Airbus A320;
Nordex awarded 111MW project; GMSA;
Vehicle manufacturers forecast to invest
40
Shopfront Focus
68
Better Production
70
International News
84
Product Review
Lighting Innovations; Finishing stainless steel blanks, tube and
pipe efficiently; Cannon Precision Engineering; Oak Engineering
Treat your machine tool
as if it was your car
Additive manufacturing; Messe Düsseldorf; 3D Systems; Gleason;
Air Products; MMC Hardmetal; Mitsubishi Heavy Industries; Prima Power;
Tongtai Group; Laser World of Photonics; Fair Friend Group; Yaskawa;
C-Class; Mahr; 3D printing technique; DMG Mori Seiki; 3D printer pricing
New Hypertherm Powermax30 AIR; Tongtai TMT2000 Series;
Fibre laser cutting machine; New Harrison Alpha XS combination
lathes; AccuteX; Widia’s Vari family; Feeler; Neway CNC Equipment;
BrightLine fibre technology; Iscar; TaeguTec; Okuma; Romer;
Vericut OptiPath; Yamazaki Mazak; Ficep; BLM; Bystronic; Hurco;
Exerial™ 3D printing system; Walter; Nikon Metrology
METALWORKING NEWS
v 14. 2
May 2015
1
e d itor ’ s
c omment
The new technologies
E
very second year I visit the world’s
leading international metalworking
exhibition EMO - and I have done so for the
last two decades. The exhibition always presents
new ideas, advancements in current technologies
and emerging developments. Without fail I
always leave the exhibition bewildered and
always ask myself what next?
As the Viewpoint in this edition says:
“With the emergence of additive machining over
a decade ago, the technology quickly became
a prototyping marvel. As design changes were
made, the result could be quickly visualised into
a 3D solid part. Manufacturers also appreciated
the tool because it enabled them to see
potential process problems in the actual
cutting of the part, meaning modifications could be made on the fly without
part functionality being compromised. Lastly, for the estimators, this tool
allowed substantially better quote preparation.”
The materials being used for 3D printing have also evolved. However, lets
face it, we can talk all we want about the potential of 3-D printing — about all
of the slick new machines, heavy-duty materials and the amazing things you
can make with them — but potential doesn’t go far on the factory floor. For
example the 3D-printed gun may have made the headlines, but it would have
been useless at withstanding an explosion in practice.
Additive manufacturing and machining in the spotlight
Additive manufacturing systems for metals have made incredible
advancements over the past decade, and the arrival of the new hybrid
machines in 2014 have set the latest benchmark for the technology.
Last year DMG MORI launched its Lasertec 65 3D Shape, which allows
highly compact 5-axis milling and laser texturing of 3D plastic injection moulding
tools on one machine and in one setup. Likewise, Mazak Corporation introduced
its new hybrid multi-tasking technology when it unveiled its new
Integrex i-400AM. The value of adding a milling process to a laser sintering
machine continued with the launch of two other machines. The Matsuura
Lumex Avance-25 and Sodick’s new metal 3D printer, the OPM250L, are very
similar hybrid laser sintering/high-speed milling machines.
Compared to CNC-machined components, most metal parts produced by
additive layer manufacturing processes often require post-machining due to
their sub-standard surface finish, and are subject to inferior production rates.
Furthermore, the cost of metal additive manufacturing systems can be difficult
for manufacturers to justify, even for high-performance components.
Now a brand new 3D printing technique working 100 times faster than
conventional 3D printing, and making objects within minutes by simply lifting
them out of a pool of resin, has been created by scientists from the University
of North Carolina. The technique, which could transform 3D printing, works up
to 100 times faster than current methods and produces objects that are
considerably stronger.
As organisations recognise the competitive advantage that these
new technologies offer, everything from optimised product designs to value
optimisation through streamlined supply chains and reduced inventories,
I am sure there will be other technologies
launched that will be in big competition to
traditional fabrication methods.
2 METALWORKING NEWS
v 14. 2
May 2015
Volume 14 Number 2
May 2015
Editor
Bruce Crawford
Online Editor
Damon Crawford
Editorial Board
Professor Dimitri Dimitrov,
Global Competitiveness Centre
in Engineering, Department of Industrial
Engineering, University of Stellenbosch
Dr Willie Du Preez, Senior Researcher, Faculty
of Engineering and Information Technology
of the Central University of Technology
Production Manager
Wendy Crawford
Reproduction
Jericho Graphic Design
Advertising Bruce Crawford / Wendy Crawford
Tel:
+ 27 11 463 0489
Cell:
+ 27 83 628 7654
E-mail:online@engnews.co.za
Website: www.metalworkingnews.co.za
Printed By
Paarl Media
METALWORKING NEWS
is published by:
BA Crawford Specialised Publications (Pty) Ltd
PO Box 69299, Bryanston, South Africa, 2021
41 Arklow Road, Bryanston, South Africa, 2021
Tel: + 27 11 463 0489
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ISSN 1682-8909
Copyright
All rights reserved. No editorial matter
published in Metalworking News may be
reproduced in any form or language without
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every effort is made to ensure accurate
reproduction the editor, authors, publishers
and their employees or agents shall not be
responsible or in any way liable for any errors,
omissions or inaccuracies in the publication
whether arising from negligence or otherwise
or for any consequences arising therefrom.
The inclusion or exclusion of any product
does not mean that the publisher or editorial
board advocates or rejects its use either
generally or in any particular field or fields.
VIEW
POINT
Hybrid and standard CNC machines
work together
W
hen additive machining
emerged a bit more than
two decades ago, it
quickly became a prototyping
marvel. As design changes were
made to a part or product, the
result could be quickly visualized
in a 3D solid part. Manufacturers
also appreciated the tool, as it
enabled them to see potential
process problems in the actual
cutting of the part. Modifications
could be made on the fly
without part functionality
being compromised. Lastly, for
the estimators, this tool
allowed substantially better
quote prepping.
Then it happened.
The materials being used for
3D printing evolved at light-speed
and the market quickly realised
this technology had production
potential. Making a short run
of parts on such a machine
became a reality. While
3D printing machines are still 5–10 years away from being
everyday shop production units, according to the best industry
sources, another development has seen the fusion of
additive and subtractive technologies into a new generation of
hybrid machines. In similar fashion, seemingly incompatible
technologies such as laser metal deposition and chipcutting
machines have emerged.
While some people believed that existing CNC technology
has been patiently standing by, waiting to pass into
obsolescence as additive manufacturing evolves to take its
place, the well-proven CNC technology has been implemented
on these hybrids. Whether the physical parameters involve
laser gases, powdered metal deposition and inert atmosphere
vacuum or five-axis rotation of a milling head or rotary table,
the function of the control remains nearly identical.
In this way, a single control can run two varying
technologies for fabrication and chipcutting, either on a
single channel or on a two-channel unit, often in tandem
with a robot head, transfer mechanism or gantry for part
articulations.
As you might have seen at the last IMTS, when that
technology was introduced to the market, running a lathe and
a robot on the same CNC was already possible, without the
need for a secondary PLC and unique robot language
commands. This has now gone to the next level, as additive
and subtractive technologies are joined on the same machine.
And it gets better.
Parts made from titanium, stainless or disparate
powdered metals are being built up, joined, machined or
otherwise processed on these machines — today. Driven gears,
for example, are now laser welded from machined and stamped
components into a single assembly, on a single machine.
The CNC, when controlling these radically different
machine operations, uses a modified set of code but not a
different language, as was necessary previously with robotic
integration.
Since advanced CNC units carry a secondary channel,
the commands can easily be set up there, if not incorporated
into the main channel. It all depends on the complexity of the
motion and total number of parameters being controlled. The
simultaneous control and monitoring of laser metal deposition
and five-axis milling functions actually present little challenge
to the high-end CNC on the market today.
Additionally, the remote operation of the CNC and
independent “handshaking” between CNC and master PLC or
other HMI units are well-positioned to facilitate integration of
the hybrid machines with other devices in the shop or
production department.
I cannot begin to know where things are headed from
here, but the next decade will surely be an exciting and
game-changing time in the machine tool and fabrication
world. Just remember, CNC is in control.
This article was written by Randy Pearson, International Business Development, Manager, Siemens Industry Inc., Drives
Technologies, Motion Control — Machine Tool Business and was first published in Manufacturing Engineering.
4 METALWORKING NEWS
v 14. 2
May 2015
industry
news
cover story
SpiroGrooving™ —
A new Sandvik revolutionary boring
tool system solution for seal ring
groove machining
SpiroGrooving™ an innovative method
for seal ring grooves
S
piroGrooving™ is an innovative method for seal ring
grooves developed by Sandvik Coromant that ensures
high output of quality components and meets tough
security demands. Used with the CoroBore® XL system,
it utilises a spirograph tool path to create close-tolerance
seal ring grooves in a very secure and productive way.
Machining challenges
Requiring close tolerances and high-quality surface
finish, seal ring grooves is a critical feature on many oil
and gas components. Conventional methods for machining
seal ring grooves often suffer from slow production and poor
process security. Multiple-operation approach, incorporating
both roughing and finishing sequences, is another time thief.
The tools that are being used are single point or plunging
cutters that are prone to vibration. Adding to the challenges
is the common use of difficult-to-machine materials such as
solid Inconel 718 and cladded Inconel 625. SpiroGrooving is
a machining method used with the CoroBore® XL system that
utilises a spirograph tool path to create close-tolerance seal
ring grooves in a very secure and productive way.
High
quality and
process security
This solution is ideal for making
seal ring grooves in pre-clad machining of steel and stainless
steel. The unique internal coolant feature of CoroBore XL
facilitates machining in advanced materials. Roughing
and finishing are carried out in the same operation, which
significantly reduces machining time and improves productivity.
Altogether, this ensures high output of quality components
and process security when machining seal ring grooves.
How it works
SpiroGrooving uses
a circular spirograph
tool movement in a
taper. This reduces
chip thickness,
enabling light cutting
action and increased
feed. Parts of the
insert cutting edge
have an interrupted
cutting behaviour,
eliminating long chips
tangling to the tool and
spindle. With a unique
NC-code generator,
SpiroGrooving is
programmed just in a
few easy steps.
New vibration damper
for deep hole machining
6 METALWORKING NEWS
v 14. 2
May 2015
New vibration
damper for deep
hole machining
Sandvik Coromant
has introduced a new vibration damper that helps to
maintain stable production during Deep Hole Machining
(DHM) operations and support increased machine tool
utilisation. Using the machine control adjustment unit, the
new device allows operators to step away from the machine
and manage process modification without hand tools or the
risk of personal injury.
High material removal rates and precision are the
defining characteristics when it comes to DHM, along with
hole straightness, dimensional tolerances and surface finish.
With this in mind, it comes as little surprise that security is
paramount to success.
When producing long parts on STS (Single Tube System)
machines, operators face a number of process-critical
challenges. Many DHM operations are extremely demanding,
pushing machining performance to the limit. This can
generate higher forces and stresses within the tooling system,
which in turn can become problematic in terms of vibration.
As a consequence, operators are often faced with manual
adjustment of the clamping unit on the vibration damper.
When a large workpiece is rotating, adjusting the clamp by
hand is not a straightforward operation — it is difficult
to get right immediately because of the accuracy
needed. What’s more, the risk of injury is elevated
considerably.
The Sandvik Coromant vibration damper provides the
solution. The device dampens vibration, leading to first class
precision and surface finish. In addition, it does this using
the machine control, facilitating a stable production process,
safely. There is even a self-locking unit in the event of a power
loss. Of course, when vibration is under control, another
benefit arrives in that excessive tool wear is no longer an
issue. The result is increased machine uptime and a safer
working environment.
The new vibration damper from Sandvik Coromant offers
bi-directional functionality ensuring it can be deployed for
both push and pull applications.
Get new cutting tools and solutions on your
smartphone or tablet
With the Product news app on your smartphone or
tablet, getting information about the latest cutting tools and
solutions from Sandvik Coromant becomes a fun and unique
virtual experience that starts at your fingertip.
Accompanied with interactive graphics and animations,
the app gives you a clear picture of the tools, their benefits
and how they work. Depending on your area of interest,
the content can be customised to your choice. Just pick
and choose from the available folders in the Product news
library.
In the CoroPak 15.1 update you will find out more about
CoroMill® Plura Heavy Duty end mills, CoroMill® QD and
InvoMilling™.
Using new tools with the latest technology is often the key
to stay competitive on the market. Stay ahead of competition
— stay updated with the Product news app.
For further details contact Sandvik Coromant on
TEL: 0860 101 008 or Mary-Ann Haylett on TEL: 011 570 9615
or email: mary-ann.haylett@sandvik.com
METALWORKING NEWS
v 14. 2
May 2015
7
G.U.D. Holdings unveils state-of-the-art
630 ton Schuler servo press
L
ocal automotive
component
manufacturer will
increase its product offering
to the automotive sector
following its R100 million
investment in the transfer
press and a new
manufacturing site in Port
Elizabeth, Eastern Cape.
Following the
acquisition of Precision
Press in 2014 G.U.D.
Holdings has announced
that it is increasing its
presence in the automotive
component supply market
with the opening of a new
manufacturing operation
in Greenbushes Business
G.U.D. Holdings has invested in a new state-of-the-art 630 ton Schuler servo press
Estate, Port Elizabeth, Eastern
to manufacture automotive components
Cape, close to a number of
to the process parameters of the die and automation functions,
automotive OEMS in the area.
something which not only increases the die life but also
Precision Press is one of the few medium-sized metal
improves component quality. A freely programmable stroke
pressing operations in South Africa focused entirely on the
height and dynamic reversing movements of the motor
automotive sector, and MD Simon Ledgerwood was very
(oscillating stroke) significantly increases output and energy
instrumental in persuading G.U.D. to invest R70 million
efficiency.
in the new facility.
The pendular stroke mode is exceedingly energy efficient
“We have to compete with India, China, Thailand and
and permits operator-programmable slide strokes without any
Eastern European countries in terms of metal pressing. The
additional mechanical stroke adjustment. In addition, the
strategic investment in the press presents an opportunity
pendular mode results in significantly higher stroke rates.
for us in South Africa to create a competitive advantage over
Thanks to the operator-programmable time / travel motion
conventional metal-pressing operations, and offer the local
sequences as well as the ability to provide rest times for in-die
OEMs a product that matches their quality standards,” said
functions, processes such as welding and lasering can be
Ledgerwood.
integrated reliably into the press cycle.
The facility includes a Schuler MSD 630 servo press line
The press installed in Port Elizabeth is four stories high,
which is the first of its kind to be installed in South Africa by
with one of the stories submerged underground. The press can
Schuler and only the 45th to be installed worldwide.
accommodate progressive and transfer dies with an impressive
15 minute die changing process. Various sizes of dies between
Servo direct technology
2.8 and four metres by 1.8 metre dies are effortlessly fitted
Schuler SDT Servo presses in monoblock design are driven
into the press.
directly and via torque motors, which are the ideal drive for
In addition the servo press can weld nuts and studs
dynamic punching and forming processes because of their high
as well as perform other value adding operations within
torque. The slide kinematics can be quickly and easily adapted
The Schuler servo press can weld nuts and
studs as well as perform other value adding
operations within the cycle of the press
8 METALWORKING NEWS
v 14. 2
May 2015
A Romer Absolute Arm
has been purchased for
quality inspection
The press is fitted with an
inline sensor that automatically detects
any damage to the dies
At present the press will manufacture airbag inflator holders, spare
wheel housings and vehicle bumper brackets, as well as seats and
window metal parts, but G.U.D. Holdings is looking to gain a large
portion of automotive components that are currently being imported
the cycle of the press.
Additional equipment manufactured and supplied by
Schuler for this installation includes a modular coil feeding line
that accommodates coil strip widths of 300 to 800mm and a
bridge type straightener feeder.
The press is fitted with an inline sensor that automatically
detects any damage to the dies, and to optimise the production
capabilities an automatic scrap conveyor system that
transports offcuts to an external bin.
Once processed on the press components are then
transported, also via a conveyor system, to a washing machine
before passing through quality inspection.
Various guests were invited to the
launch of the new Schuler press.
These included Simon Ledgerwood of
Precision Press with Albert Hintenaus of
Coastal Engineering Supplies
At present
the press will
manufacture
airbag inflator
holders, spare
wheel housings
and vehicle
bumper brackets,
as well as seats
and window metal
parts, but G.U.D.
Holdings is looking
to gain a large
portion of
automotive
components that
are currently
being imported.
The company
is also negotiating
with Schuler for the
Various sizes of dies between
supply of a second
2.8
and four metres by 1.8 metres
press that will be
are effortlessly fitted into the press
installed at the
same facility.
G.U.D. Holdings stable of companies include automotive
brands G.U.D. Filters, Fram Filters, Safeline Brake Pads and
Indy Oil. G.U.D. Holdings is a leading manufacturer of original
equipment, parts and accessories and aftermarket automotive
products in South Africa.
For further details contact G.U.D. Holdings on
TEL: 041 372 1247 or visit www.gudholdings.co.za
Andreas Kinzyk, Richard Stauder
and Oliver Beisel, all of Schuler Group
Barry Elliot and Tanya Browne, both of G.U.D. Holdings
with Steven Pohlmann of Midas
Leon Freese of Steelbank with
Hartmut Heckermann of Bilstein Gruppe
Flip Gunter of G.U.D. Holdings, Michael Nel and Paul Charlton,
both of VWSA with Chris Haworth of G.U.D. Holdings
METALWORKING NEWS
v 14. 2
May 2015
9
Wam Metals completes move
to new facility in Benoni
S
ince its inception in 1984,
management at
Wam Metals has had the
goal of manufacturing completed,
fully assembled components for
their customers, combining
flexible manufacturing with
volume production capabilities
within its niche of brass,
aluminium and copper
components and assembled
products.
More recently the
company has added plastic
injection moulded components
to its long list of component and
product offerings.
“We have been very
progressive in our research
and development to investigate
manufacturing components and
products that can be replaced
with plastics. In some cases,
where the integrity of the
Wam Metals have moved into a new 12 500m² facility in Benoni, which is six times
the size they previously had. The company has added a number of Tongtai CNC machines
components cannot be
to their machining department and tool room section
compromised, we have designed
and developed them so they are
assembled or manufactured
combining both metal and plastic. Our progression in this area
New facility demonstrates growth
is due to the rising cost of the non-ferrous metals and the
“The growth in this capacity, as well in our other areas of
continuing theft of products manufactured from these metals,”
activity forced us to seek a larger and more modern facility. We
explained
were falling over each other and the machines in our 2500m²
Nigel Brown, MD
factory in Skew Road, Anderbolt, Boksburg, Gauteng. In fact
of Wam Metals.
we were losing money because of the volatile production
“An example
environment that we found ourselves in, and it could no longer
of this is in 2012
offer the infrastructure required to support the business.”
we designed and
“Our efficiencies had virtually reached rock-bottom and
developed a plastic
production capacities were starting to be affected. It also left
drain cock for geysers
us no room for growth and adding more processes to our range
which was previously
of capabilities.”
manufactured from
“We looked for a new location with the proviso that it must
brass. The drain cock
allow the company room to achieve objectives, such as the
has been tested by The
layout must minimise product throughput time and material
South African Bureau
handling, so that the company can offer the most competitive
of Standards to SABS
lead times and effective use of our machines and equipment.”
1808-53, and carries
“Fortunately we found a building a few kilometres away in
the SABS mark.”
Benoni that did have some drawbacks but ones that we could
“Such has been
solve. We added 4500m² to it, did some renovating and we
our success and
now have 12 500m², which is six times the space we had
penetration in this area
previously. It gave us an open canvass and we have taken
is that we now have
particular care to group machines and equipment into cells,
over 700m² of space
while keeping the different production divisions separate.”
dedicated to our
“We now have clearly demarcated areas which include a
plastic production
small sand foundry, the continuous casting foundry, a
New development — Wam Metals has
capabilities, which
pressure die casting machine, an extrusion press operation
purchased a 3D printer so as to
includes seven
that is robotically loaded, the forging and clipping area that
drastically reduce the numerous hours
injection
moulding
includes our two NC saws and five bandsaws, a heat treatment
in product development. The 3D printer
machines ranging in
area and a cleaning and fettling area that includes shot
in this shop supports machining by
sizes from
blasting equipment and polishing bowls.”
simplifying prototyping and to help
30 to 430 ton.”
customers validate their designs
“As done previously, we have a dedicated tool room that 
10 METALWORKING NEWS
v 14. 2
May 2015
Wam Metals manufactures and machines many
different brass, copper or aluminium components
Left: Wam manufactures over 600 000 components
for local and international customers, with 25%
of the demand destined for the international markets.
For this reason the company has now invested in
an Automator Vis 20 watt laser marker supplied by
Traceability Solutions
has a spark eroder, surface grinder, three milling machines,
two conventional lathes and two high speed CNC mould
making machining centres that are specifically employed to
manufacturing new dies and moulds, and maintain existing
ones as well as any other equipment in the organisation.”
“We keep the machine shop as a separate entity for
obvious reasons, one of them being that we can run production
batches of many hundreds, whereas the tool room is like a job
shop.”
“I have already mentioned the plastic injection moulding
area which is housed in a separate building so as to not have
any contamination, and last but not least we now have a
Wam Metals have added eight new
Tongtai CNC machines to the machine shop including a
Tongtai TMV-720A vertical machining centre
12 METALWORKING NEWS
v 14. 2
May 2015
Wam Metals has always had
the goal of manufacturing
completed, fully assembled
components for their customers,
combining flexible manufacturing
with volume production capabilities
within its niche of brass,
aluminium and copper components
and assembled products
dedicated maintenance shop and assembly area.”
New equipment new processes
“Wam has always invested in its processes and equipment
such as high speed fully automated robotic fed CNC machines
to reduce time and cost factors.”
“This has now been further enhanced with three new
Tongtai CNC machines added to the tool room and eight new
Tongtai CNC machines added to the machine shop.”
“In the tool room we have added a Tongtai TMV-720A
vertical machining centre, a Tongtai TMV-1050A vertical
machining centre and a Tongtai TMV 510 Super Tapmill 3-axis
vertical
machining
centre. This
compliments
our existing
two Tongtai
machines and
a Deckel Maho
DMC 70V hi dyn
CNC vertical
machining
centre.”
“We have
added five extra
machining
Included in the line up are two new
centres in the
Tongtai HS-22 Series CNC lathes with robotic loading and
machine shop,
unloading for small component batch machining
a Tongtai CNC
mill turn lathe
TB 25YB and
two Tongtai
HS-22 Series
CNC lathes with
robotic loading
and unloading
for small
component
batch
machining.
We now have
14 machining
centres and
15
CNC lathes,
Wam Metals now have 14 machining centres
four of them
and 15 CNC lathes, four of them with bar feeders,
with bar feeders,
in the machine shop
in the machine shop.”
“All of these new
machines are Tongtais
supplied by PBS Machine
Tools, which were installed
since we moved into our
new facility. Some have
four and five axis
capabilities.”
that we contract, as well
as for the prospective
client. We already offer
reverse engineering,
however this relatively
new technology of 3D
printing is transforming
how we operate. More
importantly, the costs it
saves in time and money
Laser marking machine
as compared to the old
Wam manufactures
way whereby you made
over 600 000 components
the mould or die and
for local and international
then proceeded to make
customers, with 25% of
the component are
the demand destined for
enormous. In hours you
the international markets.
can have a component
For this reason the
that a customer can
In the tool room Wam Metals have added a Tongtai TMV-720A vertical
company has now invested
touch and feel and see.
machining centre, a Tongtai TMV-1050A vertical machining centre and a
in an Automator Vis 20 watt Tongtai TMV 510 Super Tapmill 3-axis vertical machining centre, all supplied
You are also able to
laser marker supplied by
experiment and
by PBS Machine Tools. This compliments their existing two Tongtai machines
and a Deckel Maho DMC 70V hi dyn CNC vertical machining centre
Traceability Solutions.
explore new markets,”
explained Homan.
Tin plating plant
“Uncertainty about future business is a contributing factor
A new development in the company has been the
to this reluctance, but just as relevant is the fact that the
installation of a tin plating plant. The bath, which is two and
successful companies, especially manufacturers, have learnt to
half metres long by one metre wide and was designed and
embrace new technologies.”
manufactured locally, carries out barrel plating for the smaller
“Equally you have to do more with the resources that you
components and hanging plating for the larger components.
have. For the most part, we have accomplished this by having
It is envisaged that the company will add nickel plating in the
our employees work smarter, not harder. This has enabled us
future.
to increase capacity and increase turnover while not increasing
our staff compliment.”
New development — 3D printer
Wam Metals has been an ISO 9001:2000 listed company
“Production jobs for additive manufacturing have been slow
since 2006 and, having started as a manufacturer of
to come to the shop in South Africa, in part because customers
non-ferrous products, steel and plastic components have now
are not yet familiar enough with the capability to design
been added to the company’s list of products and components
components with additive manufacturing in mind,” says
manufactured. The range of capabilities includes design,
Production Director Gavin Homan.
castings, aluminium die casting, extrusion, forging, machining,
“To many, additive technology is practically synonymous
plastic injection moulding, steel fabrication, finishing, assembly
with rapid prototyping. An additive process such as 3D printing
and packaging.
in which CAD data is used to effortlessly generate a detailed
The company is also able to manufacture and alloy any
and tangible physical model by building it in layers would seem
brass, copper or aluminium material, and they analyse all
to offer the ideal way to obtain a prototype part, but customers
material using their spectrometers so as to ensure all
are hesitant,” Homan continued.
material conforms to international material standards or
“We see 3D printing as being essential to a company’s sercustomer requirements.
vices, especially for a company like ours that dedicates numerWam Metals currently employs 112 staff.
ous hours to product development. For this company, 3D printFor further details contact Wam Metals on
ing now provides the starting point for practically every new job
TEL: 011 748 7420 or visit www.wammetals.co.za
Clearly demarcated areas include
a small sand foundry
14 METALWORKING NEWS
v 14. 2
Other capabilities of Wam Metals include a
continuous casting foundry, a pressure die
casting machine, an extrusion press operation
that is robotically loaded, a forging and
clipping area, a heat treatment area, a
cleaning and fettling area that includes shot
blasting equipment and polishing bowls,
plastic injection moulding and tin plating
May 2015
The company also has
two Everising NC saws and
five Everising bandsaws
W.D. Hearn sign up
with Japanese high end manufacturer
Kitamura Machinery
Kitamura Machinery has announced its partnership with W.D. Hearn as the new exclusive
distributor for the sales and service of Kitamura products in South Africa.
F
amily owned and operated, Kitamura Machinery has been
developing state-of-the-art machine tools since 1933.
Machining centre manufacture became the company’s
mainstay in 1971 as the company saw growth in this segment
for future generations. Today, as a result of Kitamura’s original
technologies and a reputation for high reliability, Kitamura has
a full line of CNC vertical, horizontal and 5-Axis machining
centres sold to a customer base in 52 countries worldwide.
Kitamura’s commitment to Research and Development
has led to industrial growth with the procurement of over 200
patents and patents pending in machining center design.
These include Kitamura’s own CNC control system platform.
The company also boasts that it has the world's fastest rapid
feedrates of 60mpm on solid box ways.
"We felt that the Kitamura machines were the perfect
fit for our customer's requirements in the range of products
offered," said Ray Cooper, MD of W.D Hearn.
"Kitamura has a broad line of horizontal machining centres
(from 250mm pallet to one metre) that can each be equipped
with live hydraulic fixtures if desired. In addition Kitamura
manufactures several models of pallet changing vertical
machining centres that are great products for our production
machining customers," continued Cooper.
"Since the company was established in 1937, W.D. Hearn
has been providing high quality machine tools and automation
solutions for the metalworking industry. In 1987 we sold our
first CNC machining centre and have since installed over
1000 machines countrywide.”
“Besides machining centres Kitamura also manufactures
a range of CNC bridge mills and jig borers. Kitamura also
offers a variety of systems and cells tailored to fit any
type of machining application.”
A recent introduction by the company has been
the Kitamura Mycenter 4XT 5-axis machining
centre with an integrated trunnion table. Featuring
a work envelope of 800 by 610 by 510mm in X,
Y and Z, an A-axis tilt travel of
-42 to +120°, and a 0 to 260° rotational
C-axis, the Mycenter 4XT features a solid
box guideway configuration that
incorporates a four-slideway base
construction design.
The machine features a dual contact
spindle (BT40) with a speed range from
20 to 15,000 rpm and 26 kW power
output.
Rapids of 36 m/min operate in the X,
Y and Z axes, with cutting feed rates of
10 m/min. This speed is possible for
4+1 axis machining with a rapid feed on the
A and C axes of 4,800 and 8,000 deg/min
respectively. The 30-tool ATC can change
16 METALWORKING NEWS
v 14. 2
May 2015
tools in 2.5 seconds.
W.D Hearn provides installation, training, applications,
warranty and after warranty service on machine tools of all
kinds. W.D Hearn offers single source manufacturing solutions
for a wide range of industries including high speed machining
for the die mould industry, automotive, production machining
and provides tool room equipment sales.
In the past 12 months W.D Hearn has officially signed
agreements with Tornos who have a niche of Swiss type lathes
and multi spindle machines, Starrett who manufacture
precision measuring tools and equipment, Sisma who
provide laser sources and systems for welding, marking,
3-D and cutting, Nikon Metrology who supply portable
measuring and articulated arms amongst other optical
inspection and mechanical 3D metrology solutions
complemented with vision measuring instruments, Flow
waterjet systems for the Eastern and Western Cape, Renishaw
and recently Mitsubishi EDM and WEDM.
W.D Hearn has fully fledged branches in Johannesburg,
Durban, Port Elizabeth and Cape Town that are able to offer
virtually the full spectrum of technology involved in metal
removal, from high end equipment to accommodating those
companies that prefer to be more cautious in their capital
spend.
For further details contact W.D. Hearn on
TEL: 021 534 5351 or visit www.wdhearn.co.za
Atlantis Foundries sold
by Daimler/Mercedes Benz
South Africa
G
erman metal casting group Neue Halberg
Guss has acquired engine block castings
specialist Atlantis Foundries (the old
Atlantis Diesel Engines) from automotive giant
Daimler/ Mercedes Benz South Africa.
A letter sent out by Atlantis Foundries staff
said the change of ownership was scheduled for
May 1. Daimler/ Mercedes Benz South Africa
took control of Atlantis Foundries in 1999, and
achieved record production of 60 000 tons cast
in 2012. Atlantis Foundries produces automotive
castings for both the passenger and commercial
vehicle industries. In addition, the company
machines cylinder blocks and crankshafts for
automotive applications.
The letter said the deal would result in the
formation of one of the largest foundry networks
for engine parts in the world. Atlantis Foundries
interim MD Tobias Hobbach, who was appointed
as a result of the departure of Felix Homburg,
said the change of ownership was positive and
represented an opportunity for growth in the company. An
announcement about the new MD will be made in May 2015.
Atlantis Foundries staff have been guaranteed one year of
employment, even though Halberg Guss recently entered into
cylinder blocks, crankshafts and rear axle casings for
automobile and engine manufacturers in Europe. Its
products/services include cylinder blocks for passenger
vehicles and trucks, cylinder heads for trucks, crankshafts for
passenger vehicles and power train units and other cast
Halberg Guss supplies leading car manufacturers
such as Volkswagen and Daimler. The company maintains production sites
in Saarbrücken and Leipzig, Germany and currently has a workforce
of around 2,100 employees
a seven-year agreement with Daimler/ Mercedes Benz South
Africa to supply engine blocks to the German and US markets.
Neue Halberg Guss GmbH develops and produces cast iron
18 METALWORKING NEWS
v 14. 2
May 2015
components. The company was founded in 1988 and is based
in Saarbrücken, Germany.
As of May 2011, Halberg Guss GmbH has operated as a
subsidiary of Neue Halberg Guss GmbH, a company formed
by the Dutch HTP Group. HTP specialises in the acquisition
and restructuring of companies and has among others the
Bavarian caravan builder Knaus Tabbert and the automotive
supplier Geiger and Reum under its wing.
Halberg Guss supplies leading car manufacturers such as
Volkswagen and Daimler. The company maintains production
sites in Saarbrücken and Leipzig, Germany and currently has a
workforce of around 2,100 employees.
This is not the first time Halberg Guss has bought into
South African foundry capacity. In 2007 the company bought
foundry plants in Port Elizabeth and Brits from engineering
and construction giant Murray & Roberts - a short-lived
arrangement as the German company ran into financial
problems. The company was renamed Autocast South Africa.
Last year Standard Bank took control of the company.
For more information visit www.atlantisfoundries.com
Wispeco purchases majority shareholding
in Pressure Die Castings
No purchase price disclosed in deal which becomes effective 1st July 2015.
W
ispeco Holdings (Pty) Ltd — Group of Companies
is continuing with its expansion strategy with the
announcement of a further acquisition. The statement
from the company says that it has agreed to purchase a
majority shareholding in Pressure Die Castings (Pty) Ltd (PDC),
a Pietermaritzburg, KwaZulu Natal based die casting foundry
that specialises in manufacturing brass, aluminium and zinc
castings. The purchase price was not disclosed. The sale of
the shares will be effective from the 1st July 2015 subject to
Competition Commission approval.
“PDC have built the company customer by customer.
Their approach being to start from a customer’s need
exploring various design options until the best process solution
is identified. This approach is valued by their customers who
are then confident that the process designed will best meet
their requirements,” said Hermann Rolfes, Managing Director
of Wispeco Holdings.
The new shareholders believe in the PDC business model
and would like to support further growth of the business.
The current directors of PDC Mike Wolhuter, Lance Deysel and
Graham Smith will continue to lead the PDC team.
“The business will continue to operate on a stand alone
basis and retain its entrepreneurial spirit. We welcome
PDC and its employees to the Wispeco Group,” said Hermann
Rolfes.
PDC is an innovative supplier of brass, aluminium and zinc
castings to the South African and international markets.
As a specialist die caster, which has been in business since
1952, they currently manufacture more than 100 different
components for a number of diverse industries. The primary
industries include the building hardware industry, the fire
22 METALWORKING NEWS
v 14. 2
May 2015
Hermann Rolfes and Mike Wolhuter
sprinklers industry, the electrification/powerline
sub-assemblies industry, the automotive sub-assemblies
industry, the plumbing/geyser components industry and the
electrical illumination industry. More than fifty percent of
production is exported.
The company was awarded Business of the Year in the
Nedbank sponsored Pietermaritzburg Chamber of Business
(PCB) Business of The Year for 2014, in the manufacturing
sector.
Wispeco Holdings is a leading aluminium extrusion
company in South Africa and offers a one-stop-shop in the
supply of mill finish, powder coated and anodised aluminium
extrusions for various applications in a variety of industries.
These include the building and construction, transport, energy,
agricultural, general engineering and automotive industries.
The company consists of four
main operating units — billet
casting, aluminium extrusion
(with in-house die manufacturing),
surface finishing and aluminium
systems distributor outlets
country-wide. “Being part of the
Wispeco Group will allow us to
continue our growth in our six
market segments. Our
expectations for the business
continue to be high. We are
confident that both our
customers and our shareholders
will realise major benefits
going forward as we drive for
cost reductions and market
share gains," commented Mike
Wolhuter, Managing Director of
PDC.
For further details contact
Pressure Die Casting on
TEL: 033 397 5500 or
visit www.pdc.co.za
Challenging new role for
Toyota South Africa's
President and CEO
F
ollowing structural
changes within the
global Toyota Motor
Corporation (TMC)
Management team,
Toyota South Africa's
President and CEO
Dr Johan van Zyl's
portfolio has been
expanded to now also
include Toyota Europe.
Added to his
existing responsibility
as Chief Executive
Officer: Africa Region,
Dr van Zyl will now
also be Chief Executive
Officer: Europe Region.
He remains President
and CEO of TSAM and
also becomes President
and CEO of Toyota Motors Europe.
"This is a fantastic career opportunity and I am very
excited about this new challenge. However, I want to reiterate
that my home will always be South Africa and I remain
committed to the development of the industry in this country,"
says Dr van Zyl.
The new role will see Dr van Zyl leading the Toyota brands
in both the African and European regions, with focus on
continuous improvement of production, supply and sales.
"The European market is a very competitive market and can at
best be described as a recovering market, showing increase
in automobile sales for the first time in 6 years during 2014.
Having said that, it is a dynamic market with a strong
automotive industry."
Dr Johan van Zyl joined Toyota South Africa in 1993 as
Director: Vehicles Sales and Dealer Network, after earning
a Doctorate in Business Economics from the University of
Potchefstroom, where he subsequently worked as Professor at
the Post-Graduate Business Management School until joining
Toyota.
Dr Van Zyl was appointed Group Marketing Director in
March 1995, and was promoted to Managing Director: Vehicle
Marketing in 1996. He took up the post of Managing Director:
Toyota (SA) Marketing, a year later.
In January 2002, he was promoted to the position of
President and Chief Operating Officer and became President
and CEO of Toyota SA Motors (TSAM) in August 2002. In June
2009 Dr Van Zyl was appointed to the position of Managing
Officer (TMC) responsible for Africa. In April 2011 Dr van Zyl
was appointed to the position of Deputy Chief Officer: Middle
East, Africa and Latin American operations group, and in
March 2013 he took up the position of Chief Executive Officer
for Toyota Africa, while retaining his responsibilities
as President and CEO of TSAM.
Dr van Zyl will resume his new responsibilities effective
1 April 2015 and he will be based in Brussels and Sandton.
New automotive centre set to transform economy
The new Automotive Incubation Centre at Nissan, which was launched in March 2015,
is expected to radically transform the economy.
“E
stablished automotive companies are extremely
important to our drive to radically transform our
economy and foster increased participation by women,
youth and black people,” Gauteng Premier David Makhura said.
The centre, the second in South Africa, is aimed at
establishing and nurturing small- and medium-sized enterprises
that can supply components to Nissan South Africa's production
line, while they receive training on meeting international
standards for automotive parts and components.
"We must view this initiative within the broader context of
the need to re-industrialise our economy and increase local
production on a grand scale," Makhura said.
Only 35% of the components and parts used to make
vehicles in South Africa are produced locally, the balance are
imported. Gauteng's automotive manufacturers spend nearly
R8 billion a year on imports for automotive parts, components
and accessories.
Job creation
The automotive industry is one of the sectors earmarked
by Gauteng government for inclusive growth and job creation.
The first Automotive Incubation Centre was launched in 2011 at
Ford Motor Company of Southern Africa's manufacturing plant
in Silverton, also in Tshwane.
The incubation centre was established by the Automotive
Industry Development Centre (AIDC), a subsidiary of the
Gauteng Growth and Development Agency (GGDA), itself a unit
of the Gauteng department of economic development.
MEC Maile said government was eager to participate in
such partnerships to increase the participation of black owned
businesses through incubation, technical production training
while giving them a foothold in the supplier markets.
“This initiative demonstrates the automotive industry’s
commitment to our strategic goals and is a sign of
confidence in future prospects for this sector in Gauteng,” he
said.
Nissan South Africa MD Mike Whitfield pointed out that
the facility supported the vehicle manufacturer's planned
production of a new one-ton pickup model later this year.
He explained that the centre would deepen the local supply
chain, while advancing transformation in the automotive sector.
"Only 5% of suppliers are equity owned and we need to find a
way to accelerate that."
He added that the centre was not for the exclusive use of
Nissan, but that manufacturers such as BMW, Iveco and others
in the area could also use it. "We encourage them to use this
facility."
Job Funds head Najwa Allie-Edries noted that the incubation
centre would lead to the creation of 3 861 new jobs and 4 985
training opportunities.
Allie-Edries highlighted that, through other partnerships
with the AIDC, 7 782 individuals would benefit from training
interventions.
She added that R202 million in grant funding was allocated
to four AIDC partnership projects, potentially leveraging an
additional R183 million from project partners.
It was estimated that this would result in 4 332 new
permanent jobs and 3 279 temporary jobs.
The automotive industry is one of the sectors earmarked by
Gauteng government for inclusive growth and job creation.
Evraz Steel unit
seeks bankruptcy protection
E
vraz’s South African steelmaker plans to apply for the
local equivalent of bankruptcy protection as a slump in
demand for the metal left it with insufficient funds.
Evraz Highveld Steel and Vanadium’s board filed a
resolution to begin so-called business-rescue proceedings
with the country’s companies
regulator, the unit said in a
statement. Highveld appointed
business-rescue officials, it said
recently.
Evraz, partly controlled by
billionaire Roman Abramovich,
bought a quarter of Highveld
from Anglo American in 2006.
It raised the stake to 85 percent
the following year, paying more
than a combined $678 million
for the transactions.
Moscow-based Evraz sought
to sell the business in 2013 but
failed to find a buyer as metals
24 METALWORKING NEWS
v 14. 2
May 2015
prices sank. The unit was hit by “weakened global steel and
vanadium markets and a severe reduction of domestic steel
demand”, Highveld said. Vanadium and steel fell more than
20 percent in the past year.
Evraz said in August it had found a partner - Macrovest
147 Proprietary Ltd, led
by Barend Petersen,
executive chairman of De Beers
Consolidated Mines - to buy
34 percent of Highveld for
R289 million, and help develop
the business.
That agreement has
lapsed, the unit said in its
statement. Evraz confirmed in
a separate statement the
proposed sale won’t be
completed. Its press service in
Moscow wasn’t immediately
able to comment beyond the
statement.
Component export sales dropped 30% in 2014
E
xport sales of South African-made components by
companies that are members of the National Association
of Automotive Component and Allied Manufacturers
(Naacam), had decreased 30%, from R8.4 billion, in 2013,
to R5.9 billion in 2014, said (Naacam) executive director
Robert Houdet in a recent interview.
“This drop may be the result of a lack of competitiveness
of the local component manufacturers, as well as the impact
of the labour unrest on the attractiveness of sourcing from
South Africa.”
Houdet says the impact of a number of crippling strikes
affecting the automotive industry over the last 24 months is
only now starting to trickle through the system.
“When the strike is over, everyone gets back to work, and
business is brisk as companies work to catch up on orders.
However, during these strikes, purchasing people abroad, who
have to ensure continuity of supply of components to assembly
plants, are sweating and having sleepless nights, and
South Africa becomes rerated as red.
“Supply contracts can’t be cancelled immediately, but,
vehicle manufacturers, over time, seek alternative parts
suppliers elsewhere, and contracts with South African
suppliers are not renewed.”
The South African automotive industry can still do much to
improve its effectiveness and productivity, but the labour issue
remains the most important challenge, he adds.
Total annual component sales for Naacam members
(around 140 companies) reached R50 billion in 2014,
compared with 2013’s R53 billion. Sales to vehicle assemblers
(for assembly purposes) reached R14.2 billion, up from the
R13.1 billion recorded in 2013. Houdet attributes the increase
to the seven-week strike in the automotive industry in 2013.
Parts and accessories sales to vehicle manufacturers were
at R2.4 billion, up from R1.8 billion, while independent
aftermarket sales were down to R3.8 billion, from the
R4.1 billion recorded in 2013.
Sales to other Naacam members remained static, at
R1.5 billion. Sales of catalytic converters reached
R21.3 billion. Looking outside Naacam, South African tyre
manufacturers recorded sales of R10.2 billion in 2014. The
estimated employment at Naacam members shrunk in 2014,
to 49 261 people, down from 51 894 in 2013.
Houdet attributes this to increased mechanisation in an
attempt to improve cost competitiveness and minimise the
negative impact of labour unrest.
Employment at tyre manufacturers fell significantly, to
5 469 people, compared with 6 450 in 2013. Houdet believes
the decline is largely owing to the closure of the Apollo factory
in Durban. Catalytic converter manufacturers also shrunk
employment, to 3 900 people, down from 5 015 in 2013.
Tier two, three ignored
Tier two and three component manufacturers, supplying
parts to tier one suppliers, which, in turn, supply vehicle
manufacturers, are “completely ignored” by South African
policy makers, says Houdet.
“They are the labour intensive businesses, able to increase
employment in the sector. “The average age of the owners of
these businesses is about 60 years old.”
“These businesses are going to disappear from the
South African landscape, if we don’t act soon.”
Houdet believes this sector of the local automotive
industry is best suited to black empowerment initiatives,
especially as these suppliers are not multinational entities,
as is the case with many tier one suppliers, and all
vehicle assemblers. Another way of boosting the localisation
of components is through the implementation of a significant
tooling subsidy in government’s Automotive Production and
Development Programme, says Houdet. The support scheme is
currently the subject of a government review.
“We have asked for a 75% tooling subsidy from government
in order to compensate the relatively low production levels
faced by local component manufacturers,” notes Houdet.
“This will hopefully boost the component manufacturing
industry, as well as the local tooling industry, which is in
desperate need of revival.”
New Executive
Director appointed
at Southern African
Institute of Welding
S
ean Blake, the current Operations Manager at the
Southern African Institute of Welding (SAIW) has been
appointed SAIW Executive Director as of April 2015.
Blake takes over from Jim Guild, who has been Executive
Director since December 2000.
The SAIW is a non-profit technical organisation
dedicated to furthering standards in welding-fabrication and
related technologies. Established in 1948, it is a founder
member of the International Institute of Welding (IIW).
The SAIW provides training programmes, consultancy
and industry support services and is based in
Johannesburg, with branches in Cape Town and Durban.
The SAIW offers a wide range of courses in welding
technology and non destructive testing (NDT) at its
Johannesburg training school and also conducts training at
venues around South Africa and in other countries.
SAIW courses are developed and maintained under the
guidance of industry-based committees and presented by
qualified and experienced lecturers. All courses comply with
international standards.
Training facilities include a practical welding school
with individual state of the art welding bays, modern and
fully equipped classrooms and NDT laboratories. SAIW
Training Services is an International Institute of Welding ATB
(Approved Training Body).
The SAIW runs the Young Welder of the Year
competition. This biennial event has become the premier
welding competition in South Africa attracting young welders
from all over the country. The winner represents South Africa
at the WorldSkills competition.
For further details contact the SAIW on
TEL: 011 298 2100 or visit www.saiw.co.za
METALWORKING NEWS
v 14. 2
May 2015
25
AfriMold acquisition boosts Indutec 2015 expo
Fifth edition of event will run alongside Pumps Valves & Pipes
Africa and is now endorsed by NAACAM and TASA.
I
t has been announced that Exhibition Management Services
(EMS) has acquired the well-established AfriMold exhibition
brand, which becomes a component show of the comprehensive
South African Industry and Technology Fair Indutec.
The 12-in-1 Indutec event is the co-location of several
individual long-running EMS-staged industrial shows, all under
one umbrella banner. AfriMold will now take place alongside
11 other Indutec exhibitions at Gallagher Convention Centre,
Midrand, Gauteng from 20-22 May 2015.
Indutec 2015 is a synergistic mix of ten events targeting
manufacturing, engineering, water, petrochemical, plastics, and
energy sectors.
The umbrella event incorporates individual events such
as Pumps Valves & Pipes Africa, Afriplast Expo, Manutec Africa,
Smart Automation Africa, e.Greentec, Africa Energex, Africa
Watertec Africa, and now AfriMold.
AfriMold
“We added the AfriMold Expo to the Indutec Fair
because it is a perfect fit with the event’s other industrial and
technological sectors,” says John Thomson of show organisers
EMS. “AfriMold is a vital networking hub for showcasing
innovations and solutions in all stages of product development
by local and international exhibitors.”
Exhibitors will showcase equipment and services for functions
such as design, material selection, simulation, visualisation,
computer-aided design, engineering and manufacturing, rapid
prototyping and tooling, patternmaking, precision machining,
mould-making, machine tools, automation, processing and
finishing. This fifth edition of AfriMold will also highlight the
huge advances in 3D printing and additive manufacturing.
“3D printing, or additive manufacturing, has advanced
significantly since it was first developed,” says Ron Maclarty,
EMS organiser of AfriMold. “Originally, only plastic prototypes
could be printed, but these machines can now handle
materials like titanium and human cartilage, and produce
almost any fully functional complex mechanism, with greater
precision, at a faster rate, and at lower cost.”
With AfriMold joining the Indutec umbrella, visitors
and exhibitors can now interact through a wider variety of
industries such as plastics, electrical, automation, design,
petrochemical and energy, with companies from Italy, Germany,
England, Nigeria, India, Turkey and China at the show.
“Tooling and precision machining is used in all
industries, and this multi-show format radically increases
business-to-business networking and cross-sector opportunities
for visitors and exhibitors. AfriMold connects them, from design
through to finished product,” adds Maclarty.
“AfriMold exhibitors are definitely looking at doing
business in Africa. As South African and American
supermarket chains move into Africa, they exert a pull-effect
on infrastructure projects which boost manufacturing demand,
creating huge business opportunities.”
Huge potential in Africa
“Africa’s economy is growing fast and the need for more
new infrastructure is rising,” says Thomson. “According to
PricewaterhouseCoopers, sub-Saharan Africa is predicted to
spend $180 billion a year on infrastructure by 2025. This
26 METALWORKING NEWS
v 14. 2
May 2015
is double the amount
projected by the World
Bank.”
Blackstone, from
America, and Dangote
Industries, from Nigeria,
have just invested
$5 billion in energy
infrastructure projects
across Sub-Saharan
Africa, particularly focussing on power, transmission and
pipeline projects over the next five years.
The Cenpower Generation Company Ltd has implemented
its $900 million Kpone Independent Power Project in Ghana,
for a 350 megawatt combined cycle gas turbine power plant, a
161kV substation, liquid fuel storage facility, and delivery and
supply infrastructure.
“The infrastructure and engineering industry is currently
booming in Africa with many of these types of projects taking off,”
says Thomson. “Companies in the design, precision engineering
and machining, tooling, tool making and production industry
will definitely find business leads at INDUTEC, especially from
African companies that are starting new projects.”
Automotive sector benefits from SA Industry and
Technology Fair and AfriMold 2015
High-profile motor industry association NAACAM is the
latest entity to endorse the SA Industry and Technology Fair
and AfriMold 2015. Members of the National Association of
Automotive Component and Allied Manufacturers are major
contributors to the South African automotive manufacturing
and component sector.
In the joint announcement it was revealed that the
Toolmaking Association of South Africa (TASA) has joined
NAACAM in support of AfriMold 2015.
“NAACAM provides companies with a dynamic forum to
formulate policies and take actions that benefit the industry as a
whole,” explains Robert Houdet, Chief Executive of NAACAM. “This
exhibition helps strengthen the manufacturing sector by providing
a strong platform for networking across all sectors of industry,
in which the automotive industry is a very prominent player.”
The capital expenditure of the seven major vehicle
manufacturers and truck producers in South Africa reached
R6.9 billion last year.
About AfriMold 2015
AfriMold is the leading exhibition for precision machining,
tooling, mould-making, design and application development
in Africa. AfriMold is endorsed by Manufacturing Circle, The
South African Institute of Foundrymen, Plastics SA, Aluminium
Federation South Africa, The Southern Africa Stainless Steel
Development Association, National Foundry Technology Network
and the Department of Trade and Industry South Africa and
now the National Association of Automotive Component and
Allied Manufacturers, as well as the Toolmaking Association of
South Africa.
For more information contact Exhibition Management Services
on TEL: 011 783 7250, email marketing@exhibitionsafrica.com
or visit www.exhibitionsafrica.com
Paramount Group ramps up production capacity
by acquiring industrial assets of DCD Protected Mobility
T
he announcement follows an increasing demand for
Paramount’s world-class range of military and internal
security vehicles from discerning defence and police
forces across the world.
John Craig, CEO of Paramount Industrial Holdings said:
“It has always been Paramount Group’s vision to develop
equipment that can be produced in customer countries, while
maintaining high value jobs in design, research & development
and production in South Africa. In anticipation of significant
growth in our order book, we have been investigating the
prospects of greatly increasing our production capability in
South Africa.”
“To this end, we explored a number of ways of doing so,
and are now pleased to announce that we concluded the
transaction to secure the manufacturing facilities, certain
assets and selected personnel of DCD Protected Mobility, a
Division of the DCD Group (Pty) Ltd.”
Executive Chairman of Paramount Group, Ivor Ichikowitz
said: “It has always been my personal ambition to make
decisions around Paramount Group’s growth which will
support the development of the South African aerospace and
defence industry at large. At Paramount Group we have always
believed that the technologies which we develop, and the
products which we manufacture, are competencies that
belong to the African continent. We are firmly committed to
continuing the development, design, research and
manufacturing capability on the African Continent.”
Ichikowitz added: “Once fully operational, this facility will
be one of the largest armoured vehicle and land forces
manufacturing facilities anywhere in the world, with a capacity
28 METALWORKING NEWS
v 14. 2
May 2015
to scale production to more than 400 units per annum. This
will have a significant impact on the supplier base and for the
South African economy at large.”
Ben Jansen, CEO of Paramount Combat Systems said
“We have been exploring opportunities to complement the
capabilities and resources of our Combat Systems Business
Unit which has been experiencing rapid growth due to major
contracts signed in recent months.
“The capabilities that existed in DCD Protected Mobility’s
manufacturing facilities will be integrated with Paramount
Combat Systems, enabling us to bolster the strength and
diversity of our production, leading to increased business
opportunities, innovation, new product development and R&D.”
Ichikowitz concluded: “Paramount Group constantly strives
to attract and develop the best talent and technologies in
the industry ensuring that we have the optimum skills and
technological base in our organisation to meet the future
demands of customers, including the capability to deliver large
scale vehicle programmes across the world.”
MTool to offer
industrial robotic systems
and solutions
Appointed agents for Tiesse Robot, an industrial robotic systems and solutions provider,
that has Japanese robot manufacturer Kawasaki as a partner.
“I
ndustrial robotics systems
are becoming increasingly
important to shops of all
sizes for their potential to help
to do more with less. Automation
enables businesses to perform
unattended and lights-out
operations, free personnel from
repetitive tasks, and more.
Everything from robotic arms to
machine-tending systems to
completely automated cells, in
order to boost productivity and
take advantage of robotics
technologies are rapidly on the
rise,” says Corrie Danielis of
MTool, a well established
South African importer and
supplier of a range of machinery
to cater for the general
engineering and fabrication
industries. The equipment
includes CNC and conventional
machines that are at home in the
machine shop or metal forming service centre.
“Lower costs and increased ease of use will spur
significant growth in industrial robotics over the next decade.
Forecasts indicate that the transportation equipment,
computers and electronics, electrical equipment and
machinery industries are expected to account for around
75 percent of advanced robotics installations through 2025.
By then, robots should be able to handle 30 to 40 percent of
30 METALWORKING NEWS
v 14. 2
May 2015
automatable tasks in these industries,” continued Danielis.
It is not just about the robot!
“As a pioneer with 40 years of experience in industrial
robot automation, we can offer a wide range of robot
applications in various industries. Our expertise includes spot
and arc welding, handling, assembling, palletising, packaging,
machine tending, loading and unloading, press tending,
painting, sealing, gluing, deburring, grinding, polishing,
washing, wafer handling and clean room applications, to name
a few,” explains Stefano Molinari, Commercial Manager of
Tiesse Robot S.P.A. based in Visano, Brescia, Italy.
“To date, Tiesse Robot has a portfolio of more than
5 000 clients operating in various sectors from welding
manipulation and enslavement of machine tools, from food
to automotive and in the pharmaceutical and medical
environments worldwide,” continued Molinari.
“But it not just about the robot, either in a singular
situation or a cell. The robot interface with the application
includes many parameters. It includes design, software,
setup, accessories such as grippers, sensors and many other
unknown factors that a business owner would not normally
think of. Through our experience we are aware of all these
various factors.”
“Recent advancements have seen robotic arms wielding
live cutting tools such as end mills or face mills in a machining
situation. The applications are endless but the core
functionality of the interface
consists of three main steps:
programming, simulation (including
analysis) and creation of the robot
programs. The interface is then
used to simulate the operation and
to control the robot’s movements
through different variables, such as
axis limits, axis priorities and
workplane constraints.”
“In short we offer a complete
service to our customers including
presales support, design,
production, installation and
after-sales service,” said Molinari.
“However, the primary
objective is one of automation to
lower the cost per component or product. But it can also be
one of deploying skilled staff elsewhere where operations are
repetitive and boring and do not require skill but still need
to achieve levels of precision and production. This is true in
many applications across many industries.”
“Since 1992 Tiesse Robot’s has had a long-standing
relationship with the Japanese multinational group Kawasaki
Robotics, a world leader in the development, manufacture
and supply of industrial robots since 1969 to manufacturers,
OEMs and automation system integrators.”
“Kawasaki Robotics can provide a robot for most handling
or assembly requirements with
payload capacities extending from
a two kilogram payload, for the
ultra high speed Y-Series Delta
Arm, to the heavyweight
700 kilogram payload M-Series.”
“Tiesse Robot’s has operations
in Italy (headquarters), Brazil,
Germany, the Czech Republic and
a new operating facility in India.
We also have technical and sales
collaboration agreements in many
of the industrialised countries,
and are always looking to expand
our export penetration in
emerging economies such as
South Africa. This is why we
have signed an agreement with MTool.”
“Automation, significantly improved uptime, improved
productivity and improved consistency are some of the
benefits of implementing robots in a shop. Even though a
shop robot might not have much of a personality, you will
more than likely enjoy watching the robot fulfill its tasks
efficiently, cost effectively and with precision,” concluded
Molinari.
For further details contact MTool on TEL: 011 894 8365
or visit www.mtool.co.za or www.tisserobot.it or
www.robotics.kawasaki.com
Denel Technical
Academy
grows into national
hub for artisan training
“A
rtisan training provided by Denel SOC at its campus
in Ekurhuleni is helping to meet South Africa’s huge
demand for skilled human resources in technical
fields”, says the Chief Executive of Denel Aviation, Mike Kgobe.
Kgobe was speaking at an event to celebrate the
achievements of students who were trained at the Denel
Technical Academy (DTA).
A total of 235 students have completed their first year of
training at the DTA and will now serve apprenticeships at
various companies and organisations before returning to Denel
for the completion of their studies and qualification.
Kgobe says the country’s tertiary institutions must train
at least 30 000 artisans per year to ensure a healthy
economic growth rate and support the expansion of strategic
infrastructure.
“This is the target to be achieved by 2030, according to
the recommendations contained in the National Development
Plan,” says Kgobe.
Located next to the OR Tambo International Airport, the
DTA has built a solid reputation for the quality of artisans and
Inside the Denel Technical Academy
skilled technicians it delivers to serve the aviation industry.
In recent months the Academy has expanded the scope of
courses it offers to include other engineering and technical
sectors.
Kgobe says Denel is committed to playing a leading role
in the training of skilled engineers, artisans and technicians.
The Denel Group allocates more than R64 million a year to
its “Talent Pipeline Model” that starts with mathematics and
science programmes for high school learners, and continues
through bursaries for tertiary studies, internships and
mentoring programmes.
“For our country to achieve high levels of economic growth
and address our social challenges of poverty, unemployment
and inequality, we must work together to invest in education,
training and skills development to achieve our vision of a skilled
and capable workforce,” says Kgobe.
METALWORKING NEWS
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May 2015
31
Auto components crucial
for aluminium industry
S
outh Africa’s automotive sector is currently one of the
key drivers of aluminium demand in the country,
which stakeholders attribute to the global trend of
manufacturers using an increasing amount of
aluminium for vehicle components, particularly for
passenger vehicles.
As a result, aluminium foundries are starting to
pursue advanced technologies and techniques in
their processes, says aluminium industry
representative organisation the Aluminium Federation
of South Africa (AFSA).
“Aluminium weighs a third of the weight of steel;
it is extremely corrosion-resistant and can be made
as strong as steel with advanced foundry techniques,”
explains AFSA executive director Mark Krieg, noting
that Germany-based car manufacturer Mercedes Benz’s
C-Class was the first car built in South Africa using
aluminium body panels.
Citing a survey of vehicle manufacturers conducted
by US-based consulting and research firm Ducker Worldwide,
Krieg adds that there will be a 20-fold increase in
the use of aluminium for vehicle body panels by
2025.
He says that, while the local focus is currently on
manufacturing aluminium castings, many of which are
high-pressure die-castings used in the automotive sector,
production of these in South Africa is “on a downward
trend”.
South
Africa
are exported
— mostly to the
European Union,
the US, Africa, Australia and Japan.
“The low local sales figures can be attributed to a fairly
small domestic market,” says Krieg.
“The assistance provided by government to the
“Aluminium weighs a third of the weight of steel;
it is extremely corrosion-resistant and can be made as strong as steel
with advanced foundry techniques,”
explains AFSA executive director Mark Krieg, noting that Germany-based
car manufacturer Mercedes Benz’s C-Class was the first car built
in South Africa using aluminium body panels
This problem originates from large-vehicle originalequipment manufacturers (OEMs) that source parts and
materials from the global market, states Krieg. “These OEMs
search for the best deal and then secure the contract, usually
for the length of the new model run.”
Meanwhile, foundry industry body the South African
Institute of Foundrymen CEO John Davies says the economies
of scale are not favourable for the manufacturing of vehicles
in South Africa.
“For local vehicle production to be sustainable, each
OEM needs to manufacture between 300 000 and
400 000 vehicles yearly,” says Davies, adding that
South Africa’s total domestic market is about 650 000
vehicles a year.
Krieg notes that only 0.6% of global vehicle
manufacturing originates from South African facilities,
while Davies adds that about 70% of vehicles produced in
32 METALWORKING NEWS
v 14. 2
May 2015
automotive sector has not resulted in increasing the local
content above 40% by value on average, but has resulted
in a decline in the volume of local iron and aluminium
castings being sourced locally,” says Davies.
Krieg says government incentives are required for
localisation of the automotive sector to be feasible.
He cites the local automotive industry’s Motor Industry
Development Programme (MIDP), which he believes has
achieved success in certain areas.
“South Africa has increased the volume of cars built
locally since the programme was initiated in 1995 and ended
in 2012. However, the MIDP was an export-based scheme,
which resulted in a decline in demand for local castings,” he
says, adding that the Automotive Production and Development
Plan was subsequently introduced in January 2013, in part, to
counter the localisation shortcomings of the MIDP, which
it replaced.
Increased production of Airbus A320
signals good news for local partners
A
irbus has decided to further increase the production
rate for its very successful A320 Family to 50 aircraft
per month from Q1 2017, matching market demand.
Additionally, Airbus is adjusting the A330 production rate to six
a month from Q1 2016 as it transitions towards the A330neo.
“As an aircraft manufacturer, it is our role, for our
employees, partners, customers and investors to anticipate
market demands whilst delivering on orders and managing
revenues,” said Didier Evrard, Executive Vice President
Programmes. “Given the success of the A320 Family, both CEO
and NEO, we work closely with our supply chain, assess our
manufacturing capabilities and decide on the most appropriate
rate. On widebodies we are adjusting A330 production in
preparation for transition to NEO, while in parallel the
A350 XWB is on a steep ramp-up.”
With over 11,500 Airbus single aisle aircraft sold and more
than 6,400 delivered to 317 operators, the A320 family which
includes the A319, A320 and A321, is the world’s best-selling
and most modern single aisle family.
Airbus has the most modern and comprehensive widebody
product line. It includes the versatile A330, the larger A350 XWB
and the double deck A380. Together, the aircraft efficiently
cover all airline widebody requirements for regional, medium and
long haul operations, seating from 250 to over 500 passengers
and sharing unique levels of operational commonality.
The announcement is good news for South African exports
by Airbus’s South African suppliers, Aerosud, Cobham South
Africa, their supply chains and other manufacturers of items
that are incorporated into these aircraft.
Aerosud, the Centurion-based aerostructures business,
makes the avionics bay racks, wing flap track cans and cabin
Inside the Aerosud manufacturing plant
interior parts for the A320 Family of 120-180 seat
short/medium-range airliners.
Cape Town-based Cobham South Africa makes the satellite
communications antennae and underlying components for all
models of Airbus commercial jetliners.
Companies such as AAT Composites in Somerset-West, near
Cape Town, which is one of the world’s major fabricators of
composite-material parts for aircraft seats and baggage
stowage bins, also stand to benefit as Airbus steps up its
delivery tempo to meet increased demand from airlines.
At the end of last month, Airbus had a future order book for
5,099 A320 Family jetliners and 313 A330s. It also has orders
for 779 A350s and 164 A380 super jumbos.
Nordex awarded 111MW project
in South Africa
N
ordex SE is broadening its market position in South Africa
with the award of a financed order for a total of 111MW.
The turn-key project located in the south of the country
will have 37 N117/3000
turbines, making it the first
one in South Africa to be
fitted with Generation Delta
turbines.
With wind speeds
averaging around 8 m/s at the
site, the turbines will be able
to produce 424 GWh of clean
electricity after being installed.
Accordingly, the wind farm
will achieve an above-average
capacity factor of more than
43%.
“The establishment of
a local company in 2012
marked an important strategic
34 METALWORKING NEWS
v 14. 2
May 2015
step forward in our efforts to position ourselves in the emerging
South African market. In this way, we are able to handle local
projects more swiftly and competently,” explains Lars Bondo
Krogsgaard, a member of
Nordex SE’s Management
Board.
In the first round of
bidding, Nordex Energy
South Africa had been
awarded the 100 MW
“Dorper” project, the 80MW
“Kouga” project and the
134.4 MW “Amakhala”
project. Including the project
it has announced, Nordex
has secured a total of
425.4 MW, equivalent to
around 20% of the total of
1,983 MW allocated in the
first three auctions.
Shift in product focus
will not threaten jobs, says GMSA
P
otential product plans at General Motors SA (GMSA)
pose no threat to jobs, suppliers or investment at its
Struandale assembly plant in Port Elizabeth, operations
vice-president Ian Nicholls said.
He was reacting to a Business Day report that GMSA
planned to halt assembly of the Chevrolet Utility bakkie and
Spark car after the existing models reach the end of their
lifecycles, and concentrate on high-volume manufacture
of the Isuzu KB one-ton bakkie.
The latest Utility is due to end in 2018 and the Spark
in 2019. The current Isuzu KB was launched in 2013
as the final step in a R1 billion investment in the three
vehicles.
The company also builds Isuzu heavy trucks at its original
Kempston Road premises.
While confirming that "a longer-term manufacturing
footprint is under development for GMSA", Mr Nicholls
added that it is "premature at this stage to speculate about
which products would form part of our future manufacturing
portfolio".
The Business Day report observed that an Isuzu-only
plant would allow GMSA to enjoy the full benefits of the
incentive-driven Automotive Production and Development
Programme (APDP), which discourages multi-product
assembly. It would offer more security to South African
suppliers as higher volumes of vehicle-specific components
would lower unit costs and encourage local content.
By the same token, more efficient manufacture and
higher volumes would enhance job security at the Struandale
plant.
The APDP is due to run until 2020 but some incentives —
which include investment rebates of up to 30% — are
expected to extend beyond then.
"Our objective remains to grow our locally assembled
vehicle production for both the domestic and export markets.
This will allow us to continue to contribute towards the local
economy, as we have done since 1926," Mr Nicholls said.
He said Isuzu KB volumes grew 8% last year and that,
together with the Utility, GMSA accounted for 19% of SA’s light
commercial vehicle market.
Besides local sales, GMSA hopes to turn Isuzu into a
major export product.
GMSA also boasted a 36% rise in Opel sales last year
after refreshing the imported brand locally.
"As we enter the next phase of capital investment,
we will be looking to undertake further upgrades to our
manufacturing operations and investment in next-generation
programmes," Mr Nicholls said.
The Chevrolet Utility bakkie
36 METALWORKING NEWS
v 14. 2
May 2015
Vehicle manufacturers forecast to invest
another R7.5 billion in South Africa this year
according to Naamsa report
C
ontinued spending in South Africa by multinational
motor companies shows that the global vehicle
industry still sees South Africa as a safe investment
destination, says the MD of BMW SA, Tim Abbott in a recent
report. The government must stick to the principles of the
2013-20 Automotive Production and Development Programme
(APDP), to retain that confidence, he says.
His statement follows the National Association of
Automobile Manufacturers of South Africa (Naamsa) 2014
fourth quarter business review where it is projected capital
expenditure in the South African automotive assembly
industry should reach a record R7.48 billion this year.
Capex by the country’s seven major vehicle manufacturers
and various truck producers reached R6.91 billion in 2014,
and R4.34 billion in 2013. Last year’s capex already
represented a record reported Naamsa.
“Relatively high levels in capex in recent, and particularly
future years, may be attributed to investment projects by
manufacturers in terms of the Automotive Production and
Development Programme.”
BMW SA previously invested R2.2 billion to build the
current 3-Series sedan at its Rosslyn assembly plant, near
Pretoria. Though production began in 2012, before the
APDP, former MD Bodo Donauer extracted government
guarantees that the company would receive the full incentive
package — allowing the company to claim back about
R500 million.
The next generation 3-Series is due in about 2019, so
38 METALWORKING NEWS
v 14. 2
May 2015
BMW Germany will soon start seeking future policy
assurances from the South African government. Mr Abbott,
who replaced Mr Donauer late last year, hopes an APDP
review, due this year, will not recommend significant
changes.
BMW SA needs production certainty. Alongside
Mercedes-Benz SA (MBSA), it is South Africa’s most
export-focused vehicle manufacturer, shipping more than
80% of 3-Series production to markets as diverse as the US,
Japan, Australia, China, Japan, New Zealand and South Korea.
Of the 68,000 cars built at Rosslyn last year, 61,000 were
for overseas customers. Mr Abbott expects production to
increase in 2015; even a 3-Series midlife update this year
will not affect operations, he says.
Naamsa also reported that employment in the automotive
assembly industry had grown to 30 466 people in the fourth
quarter of last year, which was an increase of 1 478 jobs, or
5.1%, compared with the industry headcount at the end of the
third quarter of 2014.
The association believed the “substantial increase” in the
industry headcount was related to higher levels of vehicle
production during the fourth quarter, as well as anticipated
growth in vehicle output in 2015.
South African new vehicle production increased
marginally to 566 083 vehicles in 2014, up from
545 913 units in 2013.
Naamsa expected 2015 production to grow 10%, to
625 000 units.
shopfront
focus
Let there be light…
I
t is an old cliché but in the
case of Lighting Innovations,
a Port Elizabeth, Eastern Cape
based manufacturer that has
recently made a multi-million
Rand investment in a new
manufacturing facility situated
on Cape Road in Greenbushes
Industrial area, the glare of
South Africa’s power crisis could
not shine more on this
company’s products.
The role of the traditional
office and public space is
changing, and lighting has an
important role to play as
standard designs evolve to
accommodate modern ways of
working, to meet changing needs
and to reflect an organisation’s
values.
The office has gained
somewhat of a dull reputation
over the years, with the common
perception that it is a conforming, homogenous and somewhat
soulless environment more likely to crush the spirit than to
inspire its occupants.
While such a bleak view of the office might have had a
place in the past, current trends are encouraging a far more
vibrant and inspiring approach to the design of the modern
workplace.
New trends are emerging as a result of the changing role
of the workplace. There are three main factors influencing new
office design. These can be summarised as new ways of
working, workplace diversity and the emerging role of the office
as a brand experience. These factors contribute to shape the
office of the future, turning it into a more enjoyable and
Lighting Innovations showroom
stimulating place in which to spend the working day.
Almost as a reaction to the conventionality of the past,
architects and designers now recognise that all work in the
office is not necessarily best achieved while occupying the
same desk. The new approach to work embraces the fact that
a diverse range of working environments better enables
different tasks. At its simplest form, this concept might
encompass meeting rooms to facilitate collective working
practices, but this concept goes even further.
More relaxed working areas furnished with couches may
better suit informal meetings while standing tables may
promote more dynamic interaction between employees. Equally,
areas with whiteboards or flipcharts can provide an
environment more conducive to brainstorming and
group think-tanks. Employees can relate better to
various assignments in a selection of settings.
Moving to a work area away from the traditional
“desk-and-monitor” space can help the employee
refocus his or her mind on new tasks at hand.
Naturally, lighting design has an enormous part
to play in these office design trends, especially as
lighting can be adjusted more easily than furniture or
décor.
Lighting has three roles to play here, and these
can be achieved through a combination of intensity,
colour and positioning. Firstly, light should provide the
required conditions for the work at hand.
Secondly, lighting can help create atmosphere
and influence ambience. It can also affect the energy
levels of the occupants, making them either more
alert or relaxed. The challenge is to work with
Most of the company’s sheet metal requirements are made up
customers to evaluate how they wish to use their
of mild steel but it also processes stainless steel and aluminium. Not all of the
space, and then to design the lighting to enable and
metal fabricated is sheet metal though. In the case of the roll-forming line
enhance this function. The practice of applying a
metal is fed from coil, as are the two Multipress presses
40 METALWORKING NEWS
v 14. 2
May 2015
standard lighting design to a range of different offices is now
replaced by the understanding that every space and every
application is unique.
Lighting innovations such as LED technology and luminous
fabrics are creating more opportunities to design outcomes,
which are better matched to the requirements of each area.
In essence, these new technologies are equipping the
lighting designer with more tools to achieve better, less
obtrusive effects. The entire ceiling can, for example, now be
used as a light source and lighting can be integrated
seamlessly into walls and furniture.
Many of these concepts have been explored for more
creative applications such as in the hospitality industry, but now
that the cost of these technologies is reducing, they are becoming
increasingly accessible for the mainstream market and their
use for office applications is likely to increase in the future.
Green Building (also known as green construction or
sustainable building) refers to a structure and using process
that is environmentally responsible and resource-efficient
throughout a building's lifecycle: from siting to design, construction,
operation, maintenance, renovation, and demolition. In other
words, green building design involves finding the balance
between building and the sustainable environment. This
requires close cooperation of the design team, the architects,
the engineers, and the client at all project stages. The Green
Building practice expands and complements the classical building
design concerns of economy, utility, durability, and comfort.
Lighting and power consumption thereof plays an important
role in the Green Building environment and manufacturers are
no longer your cut, bend and assemble operation — they
play an integral part throughout the process.

A closer look at the roll-forming line
METALWORKING NEWS
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May 2015
41
This is recognisable
and carried through to all
in Lighting Innovations
the spaces, from the
approach to its new
exterior clip-on component
state-of-the-art R60 million
with its angular cut-out
lighting manufacturing
form, to the volumetric
facility that it now occupies.
shapes and colours of the
The investment is part of
furniture and lighting
the relocation of the
fixtures. The strong
factory and office
collaboration between the
component of Lighting
architect and the client is
Innovations from Wynberg,
evident, with custom light
Gauteng to Greenbushes.
fittings designed especially
What began as any
for the various spaces and
normal client/architect
in line with the concept,
relationship between
which were then resolved
architects and client,
technically in terms of the
quickly developed into a
quality of the illumination
collaborative relationship
by the technical team
Lighting Innovations has invested in two wiring robot stations
that pushed the boundaries
at Lighting Innovations.
with the latest generation of wiring tools
of what can be achieved
The concept is further
when technical knowledge and design expertise is combined.
reflected in the design of feature pieces, such as the reception
The company’s first priority was to establish its factory
desk, steel benches, comic-strip-covered angular coffee lounge
and ensure that production lines were installed. This process,
chairs, 3D wall panels in the boardroom, and custom-designed
together with new state-of-the-art CNC and robotic technology,
3D artwork in the passageway. The introduction of quirky humour
had to be completed first. Next was the office component and
in vinyl decals on glazed panels adds to the interest and
photometric laboratory with the Goniometer and Integrated
individuality of the work environment for clients and staff. In
Sphere. With its cutting-edge lighting technology being utilised,
terms of design, the result of this collaboration between architect
Lighting Innovations (which also has offices in other parts of the
and client is that Lighting Innovations is able to stand up to its
country), was able to drastically reduce electricity consumption
name of “Innovation” in its ability to manufacture custom cutand play its part in helping to preserve the environment.
steel light fittings. Through this technology it also demonstrated
The brief called for offices that would represent the
its ability to bridge the gap between simple mass-produced light
company’s philosophy and advancements in terms of lighting
manufacturing and producing custom lighting solutions.
manufacturing and development. Furthermore, it called for
the architects to capture the identity of the company within
History
the space as a showcase of Lighting Innovations’ capabilities.
Founded in 1989, Lighting Innovations grew from the
Discussions led to the conclusion that the offices and
dream of bringing the best lighting in the world to South Africa.
integrated spaces be developed to include a future proposal of
Originally located in Wynberg, which is now the company’s
a standalone showroom pavilion.
Gauteng showroom, Lighting Innovations made the bold move
With this specific brief in mind, Adendorff Architects &
to the Eastern Cape because of the necessity of a larger
Interiors began developing the concept for the office
manufacturing facility.
component by drawing inspiration from the fundamentals of
The company is a complete lighting solutions provider of
light transmission as seen through a triangular prism. Visible
products including architectural and customised luminaires,
light — often referred to as “white light”, is made up of
LED luminaires, floodlighting and trunking, and completes
component colours. These colours can be observed during
in-house design and manufacture of custom lighting solutions,
passage through a triangular prism. When transmitted, the
specification, supply and commissioning of the world's best
white light is separated into its component colours — red,
lighting brands. Their track record in major projects is as strong
orange, yellow, green, blue, indigo and violet.
as their ability to accommodate small, individual applications
Thus, derived from the angular characteristic of the
where the right application of light could make all the

triangular prism, the concept was dominant in design decisions
difference to a project's success or failure.
Lighting Innovations has its own painting facility
42 METALWORKING NEWS
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May 2015
The busy assembly floor
panel bender and the P2 is now a
key part of the company’s sheet
metal fabrication capabilities.
Set up in a cell with the
Salvagnini L5 fiber laser, which
is also a first for the company,
the P2 offers the heightened
level of versatility that the
company was looking for.
Existing fabrication equipment,
such as Trumpf turret punch
presses and press brakes and
Amada press brakes, was
relocated to the new facility from
Wynberg.
“Lighting requires a huge
amount of fabrication especially
when you consider the volumes
that we are processing. The
Salvagninis, the robotic wiring
cell and all the other equipment
has increased our efficiencies
beyond our expectations,” said
Lighting Innovations have installed a Salvagnini L5 high dynamic fibre laser in their new facility.
Craig Waddell, a Director and
The machine was supplied by Potgieter Industrial Machinery
son of the founder Bruce Waddell.
“Working with sheet metal in
New Salvagnini P2 panel bender and L5 fibre laser
the thin-gauge range needs attention and accuracy. We would
The company’s commitment to the environment has
not have been able to invest in the robotic wiring cell if we did
been proven through the pioneering work they do in energy
not have the accuracy further up the line. The robots will just
efficient lighting. To achieve this their new 8000m² facility in
shut down if the bends or holes are not in spec,” continued
Greenbushes contains some of the very latest, most advanced
Craig.
equipment available in the manufacture of lighting products.
Most of the company’s sheet metal requirements are
This includes an automatic robotic wiring cell, precision
made up of mild steel but it also processes stainless steel
CNC press brakes, a fibre laser, a panel bending machine and
and aluminium. Not all of the metal fabricated is sheet metal
turret punch presses, a roll-forming line, a fully automated
though. In the case of the roll-forming line metal is fed from
powder coating plant, a dedicated cabling cell and an assembly
coil, as are the two Multipress presses.
division.
Pride of place are the new fully automated Salvagnini P2
panel bender and a Salvagnini L5 high dynamic fibre laser.
The machines embrace the company’s reduction in energy
consumption philosophy and the fibre laser, in particular,
is said to reduce energy costs by more than 70 percent as
compared to a CO2 laser. Both machines were supplied by
Potgieter Industrial Machinery.
This is the first time that the company has invested in a
The Salvagnini P2 panel bender provides versatility in
Lighting Innovations production capabilities
The Salvagnini P2 panel bender is a key part of the company’s
sheet metal fabrication capabilities
44 METALWORKING NEWS
v 14. 2
May 2015
Within their photometric laboratory, a light's
efficiency may be measured by shining it on carefully
positioned receptacles that measure its lighting
output.
Lighting Innovations is able to determine for
clients how much light is needed for their purposes,
and to further recommend how to achieve this using
the minimum number of light fittings. Some projects
can require over a 100 hours of initial development
and design.

The interaction
this. Included in the
between modern tubes,
projects were office
electronic as opposed to
lighting, bathroom
magnetic mechanisms,
lighting, main entrance
and optimally designed
lighting, other inside
luminaires is what sees
lighting such as the
Lighting Innovations
atriums and skylights,
able to supply systems
as well as the outside
which offer a short
gable wall lighting.
pay-back period, and
The company also
which guarantee
boasts that it was
reduced energy
one of the major
consumption and
contractors for the
air conditioning
2010 World Cup
(previously necessary
Stadiums having
as a result of the
been involved with
heat created by
four of the 10
excess lighting).
stadiums.
Lighting innovations such as LED technology and luminous fabrics are
Technical support
Today the company
creating more opportunities to design outcomes, which are better matched
from overseas partners
employs
150 staff in
to the requirements of each area. In essence, these new technologies are
allows Lighting Innovations
Greenbushes and 200 in
equipping the lighting designer with more tools to achieve better,
to produce solutions that
total countrywide. Staff
less obtrusive effects. The entire ceiling can, for example, now be used as a
are in touch with
are constantly reminded
light source and lighting can be integrated seamlessly into walls and furniture
worldwide trends, and
of the company’s
the company maintains close ties with leading designers,
philosophy via the quirky humour in vinyl decals on
innovators and manufacturers in the lighting world. In addition
glazed panels that separate the offices with quotations such
to on-going knowledge transfer and the identification of global
as “We work hard” and “We work even harder here”.
trends, this partnership affords South African buyers access to
Chief Executive Bruce Waddell concluded with:
the best, most efficient lighting products available today.
“The lighting industry is pivotal to the South African
Whether it is retail, property development or housing
economy and, as with all products, systems and services,
Lighting Innovations is able to provide a modern day
what you put in is what you get out. We have made
solution.
large investments in our production lines, machinery,
Some notable projects have seen Lighting Innovations
tooling, laboratories, software and people skills, while
contribute to the impressive skyline of the Sandton Central
our showrooms compare well with those of any global
Business District, possibly the most sought after business
manufacturers.”
address in the country. 115 West Street, which houses
For further details contact Lighting Innovations on
Alexander Forbes and the new EY building are two examples of
TEL: 041 819 7598 or visit www.lightinginnovations.co.za
The company has a
number of Amada press brakes
on its production floor
Existing fabrication equipment, such as the Trumpf turret punch presses and press brakes,
was relocated to the new facility from Wynberg
46 METALWORKING NEWS
v 14. 2
May 2015
Finishing stainless steel blanks,
tube and pipe efficiently
I
f you think about fabricating steps in
order of process, you probably think
about finishing as the last stage.
Short of a final inspection and
packaging, it is last. Furthermore, in many
shops, finishing is an entry-level position,
and although the process isn’t quite an
afterthought, a nice appearance usually
isn’t as critical as everything else that
goes into a successful product — research,
design, prototyping, testing, and so on.
On the other hand, if you told
Jose Mao-Cheia you thought about
finishing last, he might just tell you that
you’re thinking it through backward.
Jose Mao-Cheia is the owner of
Stainless Accessories. Established in
1998, the company head office and
factory is located in Nelson Mandela Bay,
providing logistical access to other major
Southern African centres by road, as well
as to export markets by air and sea.
Historically Stainless Accessories was
a manufacturer of automotive accessories
Stainless Design has developed a concept of reinforcing tubing to exceed the strength
for the export market. All customers were
of the equivalent diameter solid stainless steel bar, resulting in a better quality product
in the aftermarket sector and exports were
at a significantly lower cost. Various features of these developments
are now protected internationally by patents and patent applications, as well as the
done to the USA, Canada, United Kingdom,
features of the design and construction
the Scandinavian Peninsula and Israel.
Mirror finished stainless steel exhaust tips
formed the bulk of the product range and
101.6mm and were made up to 610mm in length.
were manufactured using automated equipment designed and
Due to the volatility of our South African currency
built in-house, as well as specialised buffing techniques. These
management started investigating alternative markets and
products have been displayed at various automotive speciality
products where their existing expertise in stainless steel
products trade events around the world, most notably SEMA.
fabrication and equipment could be utilised.
After two years of business the scope of manufacture was
Over the next few years the company’s core business
increased to include the tubes required for the production of
shifted to the manufacture of catalytic converter shells and they
exhaust tips. These tubes varied in diameter from 76.2mm to
gradually pulled out of the export market.
Stainless Accessories’ first catalytic converter shell was
manufactured in December 2004 as a result of securing a
contract with the Port Elizabeth facility of Faurecia, one of the
world's leading automotive component suppliers for emission
control technology. This contract was followed up with another
contract with exhaust technology company Eberspächer, in
September 2005.
ISO 9001/2000 accreditation was achieved by the
company in the same year (2005) and by April 2006 the
company was manufacturing one million components per
annum. This figure rose to two million in 2007, three million in
2008 and six million by November 2011. Currently the company
manufactures 7,2 million catalytic converter shell components
per annum, and besides Faurecia and Eberspächer now boasts
Tenneco, VWSA and Bentler as clients.
2006 also saw the company achieve ISO/TS 16949
accreditation, an important quality management system in the
Stainless Accessories’ dedication to investing in technology is
automotive industry.
evident across the shop floor. A case in point is blanking.
The company does a lot of blanking work with a production
capacity of 530 000 per month. It is estimated that capacity of the
existing facility could be increased to one million per month
48 METALWORKING NEWS
v 14. 2
May 2015
The establishment of Stainless Design
From 2005 onwards, the company’s core business had
shifted to the manufacture of catalytic
methods that address health, safety, and
converter shells. However during this time,
environmental concerns,” explained
the experience gained in the fabrication
Mao-Cheia.
and mirror finishing of stainless steel
“As the use of stainless steel has
products was used in the design and
expanded into new applications, many
development of a self locking balustrade
tube fabricators are finishing stainless
system. Initial design and prototype
steel for the first time. Some are just
development commenced in 2007, with
experiencing its hard, unforgiving nature,
2008 and 2009 focusing on aesthetic
while also discovering how readily it is
improvements, simplification of assembly
scratched and blemished. In addition,
and automation of production. During the
because stainless steel is priced higher
period Stainless Design, a company formed
than carbon steel and aluminium, material
to manufacture and market the self
cost concerns are magnified.”
locking balustrade system, along with their
“Even those already familiar with
development partners, completed several
stainless steel's unique properties are
commercial and residential developments
encountering challenges because of
while refining the product and installation
variations in the metal's metallurgy.”
methods.
“Expectations for the finish quality
As of July 2009, the patented
have grown more demanding, industry
balustrade systems were ready for broad
leaders say, in part because the use of
marketing and Stainless Design began
stainless steel is growing in the food,
developing a network of installers.
pharmaceutical, and chemical processing
Stainless Accessories currently has
Today Stainless Design can showcase
industries, in which tube interiors are
four blanking lines, three of which are
commercial and residential installations
often required to have a mirror finish.”
dedicated to shell blanking
around the globe and has sales distribution
“Also, because stainless steel is rarely
and installation centres throughout South
coated or painted, it is, by its very nature,
Africa, South America (Brazil), Mauritius and Europe (Sweden).
an appearance metal. Therefore, expectations for the final
“One big challenge in stainless steel tube finishing is the
finish are high.”
growing expectations about the surface finish. Tools and
“Demand has surfaced for the ability to achieve a
abrasives have improved to achieve better surface quality in
high-quality finish on tube after it has been bent and
less time. At the same time, fabricators require finishing
fabricated.”

METALWORKING NEWS
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May 2015
49
The fourth blanking line, which was recently commissioned,
can accommodate coils up to 800mm wide
Once the coil is processed through the blanking lines it then moves
onto 25 different welding and finishing stations before moving on to
final checking, packaging and dispatch. Each welding station has its
own dedicated welding configuration, which have been built in house
“As with all types of manufacturing, tube fabricators are
pressured to find ways to decrease downtime, look for lean
efficiencies at every turn, and shorten the manufacturing
process overall to reduce costs.”
Stainless steel balustrades
“Stainless Design specialises in manufacturing and
installing unique modular systems for industrial and residential
applications. We currently hold several patents on a range of
railing products that utilises interference fit technology to create
a modern aesthetic system that is rigid, robust and structurally
sound, and requires no welding in the production, assembly
and installation.”
High expectations
“Because stainless steel is inherently corrosion-resistant,
no additional coatings or finishes are needed. There is however
a misconception that stainless steel is maintenance free.
The amount of maintenance required, if any, is dependent of
the grade of stainless steel used, the consciousness of the
environment in which it is installed and the surface finish
of the product.
Virtually all stainless steel balustrade installations
done inland have a brushed surface finish and use
Grade 30L SS.
In a highly corrosive environment such as external
installations in coastal regions grade 316 stainless steel is
used, but more importantly the product surface is of a
polished finished.
Stainless Design utilises automated machinery that
was designed and manufactured in house to attain a
perfect mirror finish on its modular balustrade system,
radically reducing the maintenance required in corrosive
environments.
The latest acquisition, installed earlier this year, is a Samsung
Machine Tools PL2000SY CNC turning center which has a maximum
turning diametre of 360mm, turning length of 520mm, a Y-axis travel
of ±50mm and bar-work capacity of Ø65mm. The machine has a
subspindle and driven tools with through tool coolant
50 METALWORKING NEWS
v 14. 2
May 2015
Structural elements
Stainless Design has developed a concept of reinforcing
tubing to exceed the strength of the equivalent diameter solid
stainless steel bar, resulting in a better quality product at a
significantly lower cost. Various features of these developments
are now protected internationally by patents and patent
applications, as well as the features of the design and
construction.
Equipment
Stainless Accessories’ dedication to investing in technology
is evident across the shop floor. A case in point is blanking. The
company does a lot of blanking work with a production capacity
of 530 000 per month. It is estimated that capacity of the
existing facility could be increased to one million per month.
Stainless Accessories currently has four blanking lines
The company manufactures and maintains its own dies
Installed last year was a C-Tek CNC milling machine, a
C-Tek spark-eroding machine and an Akira-Seiki Performa V5.5 CNC
machining centre, all supplied by MJH Machine Tools through their
agent in Port Elizabeth Wam Engineering
three of which are dedicated to shell blanking. These lines
exceed the output of the factory and comfortably run a
single shift. This contingency of having three lines facilitates
production in the event of a breakdown.
The fourth blanking line, which was recently commissioned,
can accommodate coils up to 800mm wide.
“This enables us to blank much larger shell blanks in house
without having to outsource this process thereby reducing
our costs. This also enables us to process coil for large
diameter shells of varying lengths with a single blanking tool,”
The C-Tek spark-eroding machine
commented Mao-Cheia.
Once the coil is processed through the blanking lines it then
moves onto 25 different welding and finishing stations before
moving on to final checking, packaging and dispatch. Each
welding station has its own dedicated welding configuration,
which have been built in house.
Until recently Stainless Accessories was running two tube
mills with the capability of producing tubing from 12.75 diametre
up to and including 50.8 diametre. A further three tube mills
arrived in January 2014, two of which are identical to the

METALWORKING NEWS
v 14. 2
May 2015
51
existing machines,
machine from solid,
and the third is able to
buy in investment
process tubing up to
castings that are then
76mm diametre.
further processed,
Both Austenitic and
or cut and machine to
ferritic steels from
size. All of this is
1mm to 2mm thick
done for our own
can be accommodated.
consumption and we
Stainless Accessories
do not look for outside
also produces perforated
work on the machining
tubing. This tubing is
side, except if we have
manufactured by
a special request from
processing coil through
one of our existing
the blanking line and
clients.”
punching holes in
Installed last year
different configurations
was a C-Tek CNC milling
and patterns as per the
machine, a C-Tek
customer requirements.
spark-eroding machine
Some of the team at Stainless Accessories / Stainless Design
The coil is then
and an Akira-Seiki
from left to right Fredrick Basson, Jose Mao-Cheia, Faisal Lagardien,
transferred to the
Performa V5.5 CNC
Carlo Dashwood, Craig Sauls and George van Wyk
tube mills and processed
machining centre,
into perforated tubing as per the process of regular
all supplied by MJH Machine Tools through their agent in
tubing.
Port Elizabeth Wam Engineering.
A finishing process for full-length mirror finishes up to
6,1 metres, has recently been designed, built and
The latest acquisition, installed earlier this year, is a
commissioned by the company.
Samsung Machine Tools
Currently all mirror polished automated tubing in South
PL2000SY CNC turning center which has a maximum turning
Africa is imported. Stainless Design will now be the only
diametre of 360mm, turning length of 520mm, a Y-axis travel
company in South Africa offering locally produced mirror
of ±50mm and bar-work capacity of Ø65mm. The machine has
automated tubing manufactured from locally manufactured
a subspindle and driven tools with through tool coolant.
SS coil purchased from Columbus Stainless Steel.
Additionally the company has purchased the SprutCam
software to run the machining section.
Toolroom equipment
“You can see from the equipment in the toolroom that we
Even though the Stainless Accessories company accounts
do not have a long run production setup but we can do small
for 90% of production, Mao-Cheia believes in building up the
production runs, which are required for some of our components.
Stainless Design side. One way of doing this is by developing
We have a mix of machines that suit us and where necessary
new products and concepts, as well as manufacturing most of
we can also machine the various plastic components that we
the components in house, that are required for the
employ in our balustrading system. Most of these components
manufacture of the modular balustrading system.
are outsourced, and again we are constantly developing new
“We have always had a toolroom to maintain our dies and
and efficient designs in this area.”
fixtures for the blanking presses and tube mills. Since the
“The mix of machines also allows us versatility and the
development of the modular balustrading system we realised
ability to carry out our own development.”
that we would have to develop our toolroom further because
Overall the two companies employ 250 staff and occupy
there are many different components that make up the system.”
5 500m² of space in Struandale, Port Elizabeth.
“We like to manufacture most of these components
For further details contact Stainless Accessories / Stainless
in-house so as to control costs, while at the same time
Design on TEL: 041 452 3529 or visit
keeping any of our developments under wraps. We either
www.stailesssteelbalustrades.net
Stainless Design now machines most of its components
for the stainless steel ballustrades
52 METALWORKING NEWS
v 14. 2
May 2015
Different components manufactured
by the company
Acquiring new business,
machining bigger components
and workpieces
Cannon Precision Engineering proves you can start in a garage!
M
achining bigger components was always on the
horizon when Juan le Roux embarked on his own
venture 20 years ago. But getting to that stage was
not always an easy ride for this hands-on jobbing shop owner.
However, Le Roux owes more than open capacity and capable
equipment for his ability to transition. In addition to pushing
the size of its work envelope, the shop had also pushed its
way into other capabilities and disciplines that have ultimately
made it well-prepared to serve different markets.
“Running your own business is always a challenge, and
even more so if you are not based in the heart of an industrial
metropolis or one of the main centres,” said this Uitenhage,
Eastern Cape based engineer/entrepreneur.
“I am not saying that Uitenhage is in the middle of the
bush or in some remote corner of South Africa, but it is just
sufficiently ‘out of town’ to present obstacles which require
more than the usual forward planning. But this has not
deterred us, and in fact it has forced us to become more
focused,” continued Le Roux.
Life in the metal working engineering world began shortly
after Le Roux left school. One of the largest automotive
OEMs in South Africa based in Port Elizabeth, 35 kilometres
away from Uitenhage, employed Le Roux as an apprentice.
“VWSA took me on as a trainee press toolmaker which I
thoroughly enjoyed. The trade gave me an insight into
machining, which has subsequently become my business life.
Once qualified, I moved on because at that time there was an
excess of qualified apprentices at VWSA, and in the region.
How we would love to say that today!”
“My father Vic, who is still involved in the business on
the design side, had a small conventional lathe and a milling
machine in his garage at home. This motivated me to start
from scratch as a one-man operation.”
“Initially I started machining components for SKF, but I
Cannon Precision Engineering has recently installed a
Hartford HSA536 CNC double column bridge type machining
centre, also with a multi-angular milling head, supplied by
Redman Engineering Supplies. The machine has a working surface
of 5000 x 3600mm and can take a load of up to 21 000 kilograms.
The XYZ travels are 5000 x 3600 x 1500mm
Juan Le Roux, owner of Cannon Precision Engineering
54 METALWORKING NEWS
v 14. 2
May 2015
soon realised that if I wanted to grow I would have to obtain
bigger machines and possibly go the CNC route. This
presented another obstacle — the garage did not have
3-phase electricity supply. After organising a loan to install the
necessary electricity I then drove up to Johannesburg to look
at a machine I was interested in.”
“This was not a pleasant experience. I found a 1972
Deckel FP3 universal tool room milling machine and
treasure chest of milling tools. I organised for the machine
to be shipped to Uitenhage and loaded up my car with all the
tooling. Unfortunately the car and all the tooling were stolen 
The new Hartford HSA536 CNC double
column bridge type machining centre allows
Cannon Precision Engineering to machine
large components up to 21 tons
The second large machine Cannon Precision Engineering purchased was a
Hartford HSA326 CNC double column bridge type machining centre with a
multi-angular milling head from Redman Engineering Supplies. The machine has a
working surface of 3000 x 2600mm and can take a load of 8000 kilograms.
The XYZ travels are 3000 x 2600 x 1200mm
before I even left Johannesburg, and before I had even had
time to insure everything.”
“This set me back but I was determined to succeed. Two
years after I started my business I was able to move from
my father’s garage into a factory in the heart of Uitenhage's
industrial area, which I subsequently purchased. I increased
the under roof area by another 600m² three years ago.”
“The machine opened up doors for me at the automotive
OEMs and with the component manufacturers situated in the
Port Elizabeth area. The 43 year old Deckel is still a
workhorse on the floor for specific operations.”
“The increased workload presented new problems, but
problems that I was happy to encounter and could quickly find
solutions for. Realising the advantages that CNC
machining technology offered it led to me purchasing my first
The new Hartford HSA536 CNC double
column bridge type machining centre has
a multi-angular milling head fitted
CNC machine in 1999, a C-Tek Cinch Mill from MJH Machine
Tools.”
“I have subsequently purchased a new CNC machine on
virtually a yearly basis, and I now have a broad selection of
Cannon Precision Engineering can now
machine components and workpieces
such as large platens and bases for
presses and press tools, structures for
overhead robot systems, large moulds
and mould bases and large welded
structures for the shipping, earth moving,
construction and automotive industries
Other large components that Cannon Precision Engineering can machine
are gear box housings and wind turbine housings
56 METALWORKING NEWS
v 14. 2
May 2015
lathes, machining centres and milling
machines. We have even diversified
our service offerings and now have
three EDM machines as part of our
mix. The latest EDM machine, which
was purchased from EDM Shop and
was installed last year, is an
Accutex AU-600iA. The machine
caters for a maximum work piece size
of L x W x H - 990 x 620 x 295mm, 
some of these tools. Serving
as a one-stop resource for
machining in this way would
make the shop a logical choice
for assembling those
components as well.”
“You obviously also have a
competitive advantage when
you can machine components
that others can’t. A big
machine tool gives the shop
that owns it more flexibility
than a small machine does.
You can run a small part on
a big machine, but you can’t
run a big part on a small
machine,” said Le Roux plainly.
“Thus, when we purchased
our first big machining centre,
the shop did more than just
expand its envelope - it also
expanded its range of
services.”
“However, making this
change took more than
installing a new machine.
Cannon Precision Engineering purchases a new CNC machine on virtually a yearly basis, and now
has a broad selection of lathes, machining centres and milling machines. They have even diversified
Anyone can buy a big machine
their service offerings and now have three EDM machines as part of the mix. The latest EDM machine,
tool and machine large
which was purchased from EDM Shop and was installed last year, is an Accutex AU-600iA
components. The challenge
was assuring the quality of
a maximum work piece weight of 600 kilograms and a
those components. When
XY stroke of 600 x 400mm.”
machining large components, it’s not just turnaround time
that’s important. Delivering an accurate component or
Bigger machines, bigger components and workpieces
workpiece to the customer is equally important.”
“Our customers were looking for companies with
“In 2004 we purchased our first large machine, a
large-machining capacity. To satisfy their demands and our
Microcut Challenger MCV 2000 double column machining
needs we needed machines with not only component size
centre from MJH Machine Tools. We already had five
capacity, but also flexibility and the capability to reach all of a
C-Tek CNC milling machines on the floor which we had
large component’s surfaces that need to be machined, using
purchased from MJH Machine Tools, and we were very happy
the least amount of machine setups to do so.”
with their backup service so it made sense to approach them.”
“Machining bigger components has always been an
“The machine has a capacity of XYZ stroke axis of
ambition of mine. This would allow us to do more than just
2000 x 1200 x 800mm, a table size of 2400 x 900mm and
take on a broader range of machining work. Machining the
can take a workpiece load of maximum 4000 kilograms.
larger components would let the shop go from making some
of the components for OEM and component suppliers, as well
Hartford invasion
as the tooling, to making all of the machined components for
“However, we soon realised that we needed bigger

Cannon Precision Engineering specialises in the manufacture
of precision complex parts, tooling, jigs and fixtures and is able to
offer milling, turning and grinding, machining with EdgeCam and
FutureCam, as well as welded construction
58 METALWORKING NEWS
v 14. 2
May 2015
The mix of metals includes aluminium
Cannon Precision Engineering’s CNC lathe inventory
includes a Doosan Puma 280 CNC turning centre purchased
from Puma Machine Tools
In 2004 Cannon Precision Engineering purchased its first
large machine, a Microcut Challenger MCV 2000 double column
machining centre from MJH Machine Tools
machines if we really wanted to participate in the large
component machining arena. This led to us purchasing a new
Hartford HSA326 CNC double column bridge type machining
centre with a multi-angular milling head from Redman
Engineering Supplies. The machine has a working surface of
3000 x 2600mm and can take a load of 8000 kilograms.
The XYZ travels are 3000 x 2600 x 1200mm.”
“We could now machine components and workpieces such
as large platens and bases for presses and press tools,
structures for overhead robot systems, large moulds and
mould bases and large welded structures for the shipping,
earth moving, construction and automotive industries.”
“These are just some examples and we are not limited
to them. Gear box housings and wind turbine housings are
others that I can mention.”
“The news that we had larger capacity soon spread and
last year we purchased our second Hartford machine from
Redmans. We went even bigger on this one. It is a Hartford
HSA536 CNC double column bridge type machining centre,
also with a multi-angular milling head. The machine has a
working surface of 5000 x 3600mm and can take a
load of up to 21 000 kilograms. The XYZ travels are
5000 x 3600 x 1500mm.”
“We understand that these are not ‘monster’ machines
but they do give us capabilities that many shops in the area
do not have. For example one of our clients Xmeco has large
machining capacity but even they are limited in certain times.
They recently had to send a three metre diametre pump
casing to us for machining, so yes we will work with other
shops in the area.”
Today Cannon Precision Engineering can boast about having
Jendamark, Faurecia, Ford, VW Motor Sport, Xmeco, MA Automotive
Tool and Die, Transwerk and Tenneco on their books
Cannon Precision Engineering is not limited
to large components. The company also machines a variety of
smaller components
60 METALWORKING NEWS
v 14. 2
May 2015
From one-offs to high-precision production
Today, Cannon Precision Engineering boasts highperformance vertical machining centres, both large and
medium sized, CNC lathes, EDM capabilities and milling
operations. The company specialises in the manufacture of
precision complex parts, tooling, jigs and fixtures and is able
to offer milling, turning and grinding, machining with
EdgeCam and FutureCam, as well as welded construction.
Design facilities are offered and Le Roux’s father Vic, a
self-taught high-end propriety software user, takes care of
this aspect. The company has been ISO 9001 certified since
2005, employs 34 staff and mostly has a double shift working.
Today the company can boast about having Jendamark,
Faurecia, Ford, VW Motor Sport, Xmeco, MA Automotive Tool
and Die, Transwerk and Tenneco on their books. Notable
projects include manufacturing the tooling for the Maserati
sunroof, amongst others.
Le Roux takes staff training seriously and over the years
has mentored and qualified 16 apprentices.
For further details contact Cannon Precision Engineering
on TEL: 041 992 3700
Oak Engineering —
Building on strengths
established from
a work-hard ethic
In 1981, with great anticipation, Brian Gardner
opened Oak Engineering in a small room at the back
of a café in Germiston, Gauteng, with only a
single second hand conventional Colchester lathe
and a Bridgeport mill.
N
ow, 34 years later Oak Engineering occupies a 1300m²
factory in Greenhills Industrial Estate, Tunney Ext 6,
Germiston, Gauteng, employs 29 staff and has a
shopfloor that is occupied by six high end Okuma CNC machine
tools.
“I had limited knowledge in the machining arena when I
started. I had only completed a couple of years as a turning
and machining apprentice at a large multi-disciplined company
when the urge came that I must do something on my own,” said
Brian with a little smile on his face.
“In the beginning anything and everything would be
tackled, and that even continued when my brother Richard
joined me in 1983. We were at the bottom of the food chain
and had to build up a reputation. We were a desperate
jobbing shop but we had a will to succeed,” continued Brian.
“We had a simple plan: Cast a wide net and something was
bound to stick.”
Today the company is not quite the jobbing shop that it
started out as. In fact it is worlds apart. The business operates
as a disciplined entity, building on the strengths established
Oak Engineering installed an Okuma MB 66-VA CNC
vertical milling machine last year, supplied by F&H Machine Tools.
CNC vertical milling provides the possibility to mill various
configurations and shapes, including 3D forms. CNC milling machines
are used for the production of simple parts with some holes, as well
as for complicated 3D form milling. This technology is also used
to carry out final treatment of the welded steel structures
in order to mill surfaces or drill precise holes
62 METALWORKING NEWS
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May 2015
Brothers Richard and Brian Gardner of Oak Engineering
from success and a work-hard ethic that the brothers have put
into the company.
“Our goal now is to secure more business in market sectors
that demand the same precision and production efficiencies
that our customers have become accustomed to,” continued
Brian.
“We can’t say that we have been successful because we
have had a high volume simple-to-machine components
strategy, or even one where we have pursued complex jobs
involving complicated processes done on single components
machine, for the reason that we are neither.”
“We have rather invested in our equipment but not in any
particular direction. We have a range of CNC machining centres
and lathes, while at the same time we have a decent
compliment of conventional equipment. This gives us flexibility
and the comfort to know that we will not waste a huge amount
of expensive machining time on one of our CNCs when an
uncomplicated job can be done on a conventional machine.”
“A good example of this is the large size shafts, lengthwise
up to five metres, that we machine. The volumes don’t justify
buying a turning centre with big capabilities so they are done on
the conventional centre lathe. Conversely all of the small shafts
up to 1500mm in length by 500mm diametre are done on the
CNC machines.”
“Shops can’t afford to only do one thing anymore. You have
to be able to do a mix of things. Shops have to be ready to do
just-in-time for customers, stock parts for them and even carry
out some assembly. We separate ourselves from the competition
by offering a mix of machining technologies along with valueadded engineering. We even take complete responsibility for
processing customer jobs, including outside services where
necessary, to ensure they can purchase a complete assembly.”
“We are not big on the fabrication side and do not intend to
be, but we will not turn away any requests. It is all about being
service orientated and taking care of the extended needs of 
The Okuma MB 66-VA is equipped with a Kitagawa TRX 320 heavy-duty rotary table
that gives the machine integrated 4th axis capabilities. This now allows the company to
machine many different components in a ‘done-in-one’ operation
our current customer base.”
Taking the CNC plunge
When CNC machine technology was gaining popularity
in the 1980s the brothers did not think they would be
acquiring one in the near future, even though they saw
tremendous potential in CNC machines.
The turning point for the company came when they noticed
that their first client Copalcor had a CNC that was very under
utilised.
“That was back in 1989 and it would be our first
encounter with Okuma machines. We struck up an agreement
with them and before we knew it we had the LC 1500
on our floor. We were into this less downtime, interpolation,
contouring, finishes and high precision, all traits that are
attributed to the CNC machining concept,” explained Richard.
“We had moved into a bigger factory in Premier Park,
Germiston South, by that stage so space was not a problem,”
continued Richard.
“The machine opened up a whole new world and set the
course for the company's future machine tool acquisitions.
By 1994 we had purchased two more CNCs but this time we
went the new route. Both of them were Okuma LB 15s. We are
very loyal to our suppliers and that is why we have stuck to
the Okuma brand. Besides, we don’t believe in purchasing a
Oak Engineering can machine shafts up to five metres in length
on their conventional lathes
64 METALWORKING NEWS
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May 2015
Shafts that have been machined
in a ‘done-in-one’ operation
machine that will have to be replaced in two years. We look for
a minimum of 10 years lifespan.”
Once the company invested in these high integrity
CNC machines, the machines drove the business to find more
complex and high precision work. For the Oak Engineering
team, it’s critical to invest in the latest equipment in order to
keep up with competition and customer demands.
New Okuma MB 66-VA CNC vertical milling machine
This is exemplified with the addition of an
Okuma MB 66-VA CNC vertical milling machine last year.
“CNC vertical milling provides the possibility to mill various
configurations and shapes, including 3D forms. CNC milling
machines are used for the production of simple parts with
some holes, as well as for complicated 3D form milling.
This technology is also used to carry out final treatment
of the welded steel structures in order to mill surfaces
or drill precise holes,”
The Okuma MB 66-VA has a milling length (X axis) of up to
1500mm, a milling width (Y axis) of up to 660mm and a
maximum spindle speed of 15000 rpm.
Oak Engineering has also equipped the Okuma MB 66-VA
with a Kitagawa TRX 320 heavy-duty rotary table that gives the
machine integrated 4th axis capabilities. This now allows the
company to machine many different components in a

Some larger shafts that have been CNC machined
at Oak Engineering
Oak Engineering has standardised on
Okuma CNC equipment for their machine shop
Included amongst the Okuma lineup is a Space Turn LB4000 EX CNC
turning centre, which is built on Okuma's Thermo-Friendly Concept to
ensure minimal thermal growth, also supplied by F&H Machine Tools
‘done-in-one’ operation.
"Flexibility is a key requirement for our production mix and
we gain a processing choice with this machine. We can run
one job complete or we can run two different parts through the
machine. Coupled with our mill/turn and conventional two-axis
turning centers, we can pick the best combination of turning
and milling operations for the work we have, rather than trying
to fit the work to a limited process capability."
“We love the machine not only for its operational
efficiencies and the versatility that it offers, but also because of
the OSP control. We are biased because we have a floor full of
Okumas, however we believe they are one of the best machines
on the market,” said Richard.
Controlling every aspect of the manufacturing process is
also the key to the shop’s ability to be both competitive and
profitable. Both Brian and Richard fully understand that the
shop must continually find ways to machine parts “better, faster
and cheaper.”
Oak Engineering cuts a variety of materials, including steel,
aluminium, stainless steel, copper and brass and is not scared
to tackle those difficult to machine requests.
The owners of Oak Engineering also believe that in today's
manufacturing environment, many customers equate shop
cleanliness with quality.
"If a customer visits our operation and sees the
environment in which we manufacture, it's a plus for getting the
order," says Brian. "Our shop is a sales tool. Of course we must
do the job correctly but the first impression customers get when
they see us helps give us a time to explain our manufacturing
capabilities," said Brian.
There are other advantages that Oak Engineering has
reaped from its clean, well-lit and spacious shop environment in
Greenhills Industrial Park, Tunney, Germiston, which they
custom built six years ago.
“Finding and keeping good people has been easier with an
orderly shop. To maintain a competitive business in an industry
that is fighting to keep jobs from being outsourced to China and
India, you need to be on top of your game and take advantage
of any aspect that you can control,” said Brian.
The brothers have also kept the business in the family.
Both their wives work in the administration department, and
Richard’s daughter has recently joined to take care of the
social responsibility aspects of the business.
“There are a myriad of rules and regulations that are thrown
at us these days, which we understand have to be taken care
of. However these are going to be to the detriment of many
SMMEs in this country. We are fortunate that we can afford to
employ a dedicated staff member but many small businesses
will not be able to do so,” said Brian.
“Moving into the future Oak Engineering must preserve its
assets (Staff) and remain competitive in a new global engineering
world. As far as we can see engineered products in South
Africa are mostly of a high international standard, so at Oak
Engineering we remain positive for the future,” concluded Brian.
For further details contact Oak Engineering on
TEL: 011 822 2555
A view of the conventional machine section
at Oak Engineering
Oak Engineering cuts a variety of materials, including steel,
aluminium, stainless steel, copper and brass and is not scared to
tackle those difficult to machine requests
66 METALWORKING NEWS
v 14. 2
May 2015
b etter
pro d u c tion
Treat your machine tool
as if it was your car
H
ave you ever had a machine down
because of a $1 bolt? Or perhaps
you have needed a Torx Wrench #7,
and the only one is in Joe’s toolbox,
which is locked because he’s out?
Or you have repaired something
on a piece of cardboard on the floor
(on your knees), because the tables are
all busy? If these situations have ever
happened to you, or if this is the normal
reality in your shop, well… there are
two solutions for you: embrace 5S,
or treat your machine tool as if it was
your car. The second choice sounds
funnier, so let’s see where that
brings us!
The connection
You finally bought that Camaro ZL1,
a beautiful, high performance car.
Do you know what the most important
component is? The tyres! Tyres
connect the car to the road and the
580 horsepower from your new car needs to be released
properly through the tyres. The tyres allow you to enjoy your
car’s performance and the acceleration/deceleration G’s.
What is the tyre equivalent in machine tools? The toolholder!
It connects the cutter to the machine. The holder allows the
cutter to enjoy the machine’s power and rigidity. Unfortunately,
the effects of a toolholder in poor condition can be very
difficult to detect. For example, run-out has a big impact on the
cutter and the spindle life, but it’s not easy to spot and many
times is overlooked. Toolholders deserve the maximum care,
and they should only be in two locations: in the machine, or
in the toolholder storage with the mating surfaces protected.
Every time a holder is removed from the machine, it must be
cleaned, oiled, and put away.
The flat surfaces
If you think that a cart is a permanent storage on wheels
and a table is a permanent storage not on wheels, let me tell
you — you are wrong! What’s a pickup truck good for if its bed
is always full of stuff? Normally the bed is empty, ready to be
loaded at any moment and unloaded as soon as possible.
Carts and tables in a machine shop make our life easier and
they can only do their job if they are normally empty. Therefore,
if you use a cart for whatever reason, when you are done the
cart should be empty again, so the cycle can start over. For a
table, use the 60/40 rule: 60% of the tabletop must be free
and 40% is for the tools needed to perform the job. If you find
yourself with less than 60% free area, you have a clutter
problem. Clutter always has a negative effect on part quality.
The clean
Air does not clean, it just moves the metal
shavings somewhere else. This “somewhere else”
means corners and hard-to-reach locations between
moving parts. The result is more wear and tear on
your machine tool. How does a car wash work?
Water first, to take the dirt down to the floor where it
goes in the drain and it can be easily removed.
Then air for drying. The same should be done with
machine tools: at the end of every day, with the
wash gun, use the machine coolant to take the metal
shavings from the machine or the part down to the
chip conveyor, where they can easily be removed.
The care
How do car makers make sure your engine
and transmission stay at top performance?
Scheduled maintenance performed by a certified
68 METALWORKING NEWS
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May 2015
technician. Your machine tools have the same needs. There are
oils and filters that have to be replaced periodically and there
are inspection points to be checked. In addition, the leveling
and the accuracy have to be checked periodically. A machine
tool is made to work for many hours a day. Letting it go until
something breaks just isn’t that smart.
The cheap and the right
So, you bought that very well kept used car for almost
nothing. A deal, right? And now, your daily 30-mile commute
to work is an adventure between the car breaking down and
fixing stuff on the fly. Keep getting to work late and you may
even lose your job. Basically, what you saved by buying a cheap
used car goes to the repair shop and frustration. The same is
true with machine tools, and actually, the machine shop is the
perfect example of “you get what you pay for.” Replace “cheap”
with “right” and you are going to be fine. Buy the right machine
for your job not the cheaper one, and the right cutter not the
cheaper one. In a machine shop, as with cars, it’s all about
tomorrow, never about today. A cheap cutter that saves you a
few dollars today, will produce more scrap that will cost you
many more dollars tomorrow, if not even a customer.
The knowledge
Have you noticed that if someone wants to work on a car
it’s usually an old one? Yes, old cars are cool, but they’re also
the ones that are understood and easy to play with. Today, cars
are complicated. A lot of electronics and software is on top of
the mechanics. It’s relatively easy to play with a carburetor,
but it’s another story to play with an electronic injection. Metal
cutting is not different — it’s a science and a complicated one.
A successful part is the result of many factors: building floor
quality, machine installation and general conditions,
environmental temperature and humidity, part holding,
cutters, toolholders, coolant, process and programming.
Physics, mechanics, hydraulics, pneumatics, electronics,
software, chemistry, and material science all are involved
every single moment in metal cutting.
Intimidating, but true. Technically speaking, only engineers
should be around machine tools! In fact, an engineering
mindset is the foundation of successful machine shops.
If you still think it’s better to embrace 5S, I cannot disagree
with you. Just remember that a machine tool is a “tool” for
making parts. It’s like a brush in the hand of an artist: the best
artists use the best tools that are kept in perfect condition!
This article was written by Germano Zerbini.
Germano has been in the manufacturing industry since
1990 and has extended experience in this field. Originally from
Italy, he has a degree from B. Castelli Technical Institute in
Brescia, Italy. Germano spent his first fourteen years as a CNC
programmer and shop foreman with an Italian company, after
which he moved to the United States. In subsequent positions
he has worked as a machinist, programmer, engineering manager and plant manager. Germano joined Okuma in 2012 as an
applications engineer, and his experience with solid modeling
and programming multi-axis mills and lathes has made him a
valuable asset to the team. Always looking to improve his skills,
Germano enjoys working with complex and challenging parts.
The article first appeared as a blog post on March 4, 2015
on www.okuma.com
METALWORKING NEWS
v 14. 2
May 2015
69
international
news
Additive manufacturing debuts
at Emo Milano 2015, the world’s
number one metalworking exhibition
Italy will host the 2015 edition of EMO, the world machine tool exhibition that runs
every two years in Hannover and Milan, alternatively.
T
he 2015 EMO Milano exhibition, scheduled for October
5-10 at the Fieramilano convention center in Milan, Italy,
will be the first edition of the show to devote an area
exclusively to additive manufacturing technologies.
EMO, a biennial travelling exhibition sponsored by
CECIMO, the European Association of the Machine Tool
Industries, is considered to be the most important occasion
for the world’s manufacturing industry operators to familiarise
Exhibitors will display their products, ranging from
machine tools, robots, and automation systems to mechatronics
and auxiliary technologies, representing an industry worth
64 billion euro, on more than 345,000 square meters of
surface at the fieramilano premises. This year’s exhibition will
mark the debut of additive technologies, a fast developing
sector yet to be fully explored, which has chosen EMO as the
ideal stage to present itself to the metalworking industry.
“A special area of the exhibition has been devoted to
additive manufacturing, thus completing the 2015 world exhibition’s index
of products with one of the fastest growing technologies, whose
ground-breaking impact will be felt in the very near future.”
themselves with the latest manufacturing technologies.
The exhibition’s comprehensive offer on display has always
greatly attracted operators of all user sectors, such as
carmakers, aerospace manufacturers, engineering and
energy companies, and representatives of other sectors
including producers of household appliances, biomedical,
nanotechnologies and earthmoving machines.
70 METALWORKING NEWS
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May 2015
A special area will be exclusively devoted to additive
manufacturing. There, exhibitors will display machines along
with other products designed for the mechanical engineering
industry. A whole series of meetings, workshops and
conferences will take place during the exhibition, including
an event organized by UCIMU in cooperation with AITA and
CECIMO, aiming to highlight the competitive edge arising
from the use of additive technologies for specific
manufacturing processes and processing techniques.
All of this and much more will make up the additive
manufacturing offer at EMO MILANO 2015, a unique event
with some 1,600 exhibitors and 150,000 expected visitors
from 100 countries.
“EMO has always played a pioneering role, anticipating
market trends and presenting innovative solutions both in the
machinery sector as well as in the fields of accessories and
auxiliary technologies, with a particular focus on unexplored
sectors”, says Pier Luigi Streparava, General Commissioner of
EMO Milano 2015.
“For these reasons” - he continues - “a special area of the
exhibition has been devoted to additive manufacturing, thus
completing the 2015 world exhibition’s index of products
with one of the fastest growing technologies, whose
ground-breaking impact will be felt in the very near future”.
For up-to-date information and ad-hoc services for
exhibitors and visitors visit www.emo-milano.com.
Trade Fair Travel and Metalworking News tour to
EMO Milano 2015
Trade Fair Travel, a specialist travel agency for trade fairs
internationally, have put together a very reasonable tour
package to visit this exhibition. The tour includes return
airfare Johannesburg/Milan, airport taxes, airport/hotel
transfer, accommodation, full breakfast daily and medical
and travel insurance.
For a booking form contact Trade Fair Travel on
TEL: 031 916 1414, Fax: 031 916 5674, or email
peter@tradefairtravel.co.za or visit www.tradefairtours.com
For further details on EMO Milano 2015
visit www.emo-milano.com
Messe Düsseldorf
launches portal for
metalworking industries
M
esse Düsseldorf GmbH, Düsseldorf, Germany,
has launched the new sector portal Metsearch,
offering a comprehensive product and company
database for the various metalworking sectors, at
www.metsearch.net.
The portal, presented in German and English,
features sector and company news, background
information on the industrial segments of national and
international trade fairs, and highlights of key topics
that change monthly. Users can access a
comprehensive database containing products,
companies, and sector and company news. Users also
can search for companies exhibiting at specific trade
fairs.
Sector and company news along with background
information on the industrial sectors of the national and
international trade fairs covering the areas of foundry
technology, metallurgy, cast products, thermal process
technology, industrial fittings, pipes/tubes along with
wire and cable, round off the range of services.
For further details visit www.metsearch.net
3D Systems acquires Cimatron
The $97 million deal strengthens 3DS’ position in 3D-printing-centric manufacturing through a
seamless digital workflow between design and traditional and additive manufacturing processes.
3
D Systems, Inc. has announced that it has completed
its acquisition of all shares of Israel’s Cimatron Ltd. for
approximately $97 million, inclusive of Cimatron’s net
cash. The integration of Cimatron software products into the
company’s portfolio strengthens 3DS’ leadership position in
3D-printing-centric advanced manufacturing by enabling a
seamless digital workflow between design and traditional and
additive manufacturing processes.
The transaction adds complementary technology, extends
3DS sales coverage globally, multiplexes cross-selling
opportunities and is expected to be accretive to the company’s
cash generation and non-GAAP earnings per share for the full
year 2015.
“Cimatron represents a perfect strategic fit for our business
by providing expanded capabilities in product development,
sales coverage and complementary technology. We believe
that this combination offers unique synergies with significant
long-term customer benefits and shareholder value. We are
delighted to welcome Danny Haran and his entire global team
to 3DS as we complete the digital thread from design to digital
fabrication,” commented Avi Reichental, the president and
chief executive officer of 3DS.
Cimatron is a provider of integrated 3D digital fabrication
software for manufacturing, with products used by a growing
number of companies worldwide for their 3D production molds,
tools and dies in a wide variety of functional end-use
manufacturing applications. Two of the company’s products,
CimatronE and GibbsCAM® provide digital fabrication tools for
key manufacturing operations.
CimatronE is an integrated CAD/CAM solution for
toolmakers and manufacturers of discrete parts, which
provides full associativity across the manufacturing process
from quoting, through design and up to delivery. GibbsCAM
offers powerful yet simple-to-use solutions for programming any
type of CNC machine tools, from simple mills and lathes, to the
most complex multi-axis multi-tasking machines.
“With a 30-year track record of providing comprehensive,
cost-effective solutions that streamline manufacturing cycles and
shorten product delivery time, it is the perfect time to become
part of 3DS where we can substantially accelerate our progress
and extend our reach and impact,” said Haran, the former chief
executive officer of Cimatron who was named executive vice
president and chief operating officer of software at 3DS.
Cimatron shareholders will receive $8.97 in cash for each
ordinary share held by them as of the effective time of the
merger. As a result of the completion of the merger, the
ordinary shares of Cimatron will be delisted from the NASDAQ
Stock Market and deregistered under the Securities Exchange
Act of 1934, or the Exchange Act. Cimatron will cease filing
reports pursuant to the Exchange Act, and trading in its
ordinary shares was halted before the opening of business on
February 9, 2015.
Gleason launches new
manufacturing facility in India
G
leason Corporation recently
announced that it is to build a
new manufacturing facility in the
Bengalaru Aerospace Park Industrial Area
located in Bangalore, India to
accommodate Gleason’s expanding
product offerings and capabilities in India.
Gleason had a presence in the Indian
market for years, first through
representatives and then through Gleason
Works (India) Private Limited, established
in 1995. Gleason Works India has machine
and cutting tool manufacturing operations
in Bangalore, a cutting tools service center
in Chennai, and sales and service offices
in Delhi, Jamshedpur, Mumbai and Pune.
“We continue our belief that the Indian
market offers significant near-term and
long-term growth opportunities, and we
are pleased and excited to take the next
step to position Gleason to better serve the
Indian market,” said John J. Perrotti, president and chief
executive officer of Gleason Corporation.
72 METALWORKING NEWS
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May 2015
The Bengalaru Aerospace Park is
home to many companies serving the
aerospace industry. The Gleason facility
will produce products and services for
aerospace customers as well as markets
including automotive, heavy truck,
construction, agricultural equipment,
energy and others. Phase 1 of the new
Gleason Works India facility is planned for
completion in the second half of 2016,
and includes 4650m² of space for
manufacturing, sales, service and
administration.
The facility will continue the
manufacture of Gleason Genesis gear
hobbing machines, gear cutting tools,
workholding equipment, and aftermarket
products and services, and will provide
the space needed for continued
expansion for other products.
For further details contact
F & H Machine Tools on TEL: 011 397 4050 or visit
www.fandhmachinetools.co.za or www.gleason.com
Air Products supports emerging
3D metal printing market
Company helps additive manufacturers optimise use of critical industrial gases.
A
ir Products has launched a new website designed to guide
additive manufacturers in the proper selection, supply
mode, and purity of industrial gases used to improve part
processing in the fast-growing 3D metal printing market. The new
website provides technical information, online tools, gas supply
options and more to help additive manufacturers optimise the
industrial gases used in their 3D metal printing processes.
3D metal printing is a revolutionary production method ideal
for prototyping and manufacturing high-quality components.
The biggest challenge for additive manufacturers is building
components in a controlled environment with minimal impurities.
Maintaining the proper gas atmosphere by using gases such as
argon and nitrogen helps to produce quality parts that meet the
high-tolerance standards required in 3D printing.
Air Products has extensive applications knowledge in
surface/bulk treatment of metals. "Our range of industrial gases
and purity levels will enable companies to experiment and grow
with 3D printing technology, whether they are in start-up or full
production," said Justin Rabe, Industry Marketing Specialist for
Air Products.
Air Products recently worked with Turbocam International,
a world leading manufacturer of precision metal parts for aero-
space, automotive, and industrial applications. Turbocam uses
high-purity argon in their 3D printing process, which they have
found keeps out more impurities, particularly nitrides, and
enables them to deliver a better end product to their customers.
Following multiple site visits to gain an understanding of
Turbocam's overall process, Air Products installed a bulk supply
system properly sized to meet Turbocam's current business
requirements, yet scalable to meet future growth projections.
"Air Products has helped us improve our 3D printing on both
an environmental basis and a day-to-day operational basis.
We previously used cylinders and always had to check purity
levels, leaks, and whether we had enough gas to complete the
build. With Air Products' bulk system, now we have consistent
purity levels and consistent delivery of gas for long builds," said
Jonathan Bicknell, general manager at Turbocam
In addition, Turbocam uses Air Products' Telalert® telemetry
system, which enables Air Products to remotely monitor their
gas supply and schedule product deliveries when they are
needed without any interruption to Turbocam's gas supply.
To learn more about how Air Products can help additive
manufacturers optimize their 3D printing processes, visit the
company's new website at www.airproducts.com/3d.
METALWORKING NEWS
v 14. 2
May 2015
73
MMC Hardmetal opens
Engineering Centre in Thailand
M
MC Hardmetal (Thailand) Co.
Ltd., a subsidiary of Mitsubishi
Materials Corporation (MMC)
has announced the opening of the
MMC Hardmetal Thailand Engineering
Centre (MTEC), which is located in
Amata Nakorn, Thailand.
The new centre complements the
company’s four existing Engineering
Centres` that are located in Japan
(Omiya), China (Tianjin), Spain
(Valencia) and the USA (Chicago).
The MTEC is located in the heart of
Thailand’s industrial sector and it will
provide MMC Hardmetal customers in
the metal cutting tools industry with
various services that include
machining tests and education and
training opportunities.
The latest machine tools,
equipment and software are used at
MTEC to provide cutting solutions. The
well-equipped demonstration room
is equipped with the latest machine
tools, including a vertical machining
center and a CNC turning lathe, and
the latest in software, measuring and analysis equipment
enabling periodic seminars, product demonstrations and
training sessions to be held. The use of the latest measuring
equipment enables trouble shooting and rapid
evaluation of problems. An E-learning system
can be utilised for pre-or post-training
purposes. Training materials covering the basic
aspects of metal cutting is available in Thai,
English and Japanese.
MMC Hardmetal encourages and welcomes
customers to utilise the new facilities that also
includes hi-tech video recording equipment
that’s used to record tool performance and
demonstrations for customers’ requirements
from all around the world.
For further information please contact
Multitrade Distributors on TEL: 011 453 8034
or visit www.multicarb.com
Mitsubishi Heavy Industries, Siemens launch joint venture
T
he new metals company will serve customers
across Asia, Europe, Russia, Africa and the
Americas.
Mitsubishi Heavy Industries (MHI, Tokyo, Japan) and
Siemens AG (Munich, Germany) have established
Primetals Technologies Ltd., a joint-venture company
for the metals industry headquartered in London, United
Kingdom. The venture is intended as a globally operating,
complete provider for plants, products and services
74 METALWORKING NEWS
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May 2015
related to the iron, steel and aluminium industry.
Mitsubishi-Hitachi Metals Machinery Inc., an MHI consolidated
group company with equity participation by Hitachi Ltd.
and IHI Corp., holds a 51 percent stake in the joint
venture, while Siemens holds 49 percent. The unit will
start operations with 9,000 employees coming from both
partners.
For more information on Primetals Technologies Ltd.
visit www.primetals.com
Prima Power Laserdyne technology
centre in Suzhou, China
P
rima Power Laserdyne, which manufactures multi-axis
laser cutting, welding, and drilling systems, plans to install
a Laserdyne 430BD system at the new Prima Power
Technology Centre in Suzhou, China. The centre will provide
laser process development for Asian customers seeking
solutions to a wide range of fabricating challenges. The six-axis
laser system will be equipped with a 15kW quasi-continuouswave (QCW) fiber laser for the demonstration of precision
cutting, welding, and drilling in a wide range of materials.
"Installation of a Laserdyne system in the new Technology
Centre is in response to recent orders received from Chinese
customers for the 430BD system and increasing interest in this
system," explains Mark Barry, VP of sales and marketing.
"This new laser system is an example of technology in a
combination of cost and capability that has not been available
to the Chinese market or anywhere else, for that matter. Long
served with earlier Laserdyne multi-axis systems, Chinese and
Asian manufacturers have found it advantageous to invest in
the newest and best manufacturing technology available. The
Laserdyne product line was one of the first to be offered with
high-power fiber laser technology."
The 430BD has utility in precision cutting, welding, and
drilling of 2D and 3D components. The system operates at
speeds up to 20 m/min (800 inch/min) in the X, Y, and Z
axes with bi-directional accuracy of 12.7µm. This accuracy is
throughout the system's 585 × 408 × 508mm work envelope,
making it ideal for laser processing a broad range of
components in many materials. An optional, fully integrated
and interpolated six-axis rotary table extends the size of
components that can be processed in the system.
For further details contact Talmac Machine Tools on
TEL: 011 827 6539 or visit www.talmac.co.za
Tongtai Group acquires French firm
T
he Tongtai Group, one of Taiwan’s leading machine tool
makers has said that it has completed an acquisition of a
100-percent stake in French-based PCI-SCEMM as part of
its efforts to boost its visibility in the global market.
Before the acquisition, PCI-SCEMM served as a designer
and manufacturer of machining systems under French
automaker PSA Peugeot Citroen.
At the end of March, Tongtai and PCI-SCEMM signed an
agreement on the acquisition of the headquarters of PSA
Peugeot Citroen located in Paris, and was witnessed by
attorneys from both sides.
Before the deal was signed, Tongtai and PCI-SCEMM had
76 METALWORKING NEWS
v 14. 2
May 2015
gone through negotiations for about one year. After wrapping
up the talks, Tongtai agreed to spend about 5.5 million euros
(US$5.89 million) to acquire the French firm.
Following the signing ceremony, Tongtai’s executives went to
the headquarters of PCI-SCEMM in Saint-Etienne for a meeting
which focused on the operations of the French firm after the
acquisition. The Taiwanese suitor has started the process of
taking over PCI-SCEMM’s projects.
On April 3, Tongtai and PCI-SCEMM held a news conference
in the French firm’s headquarters to brief 150 attendees,
including representatives from the Saint-Etienne city
government, about the newly signed acquisition agreement.
After the buy-in deal, Tongtai Chairman Yen Jui-Hsiung has
become the chairman of PCI-SCEMM, while Huang Ying-chun,
the head of Tongtai’s operations division, has served as the
president of the France-based firm. Tongtai said that Huang has
been in charge of integrating the resources of the Taiwanese
firm and its new French unit.
In 2014, PCI-SCEMM posted about NT$1 billion
(US$31.95 million) in sales, slightly higher from a year earlier,
Tongtai said, adding that the French subsidiary has set a goal
to double its sales by 2020.
Tongtai said that the acquisition is expected to strengthen
the group’s production capacity in rolling out auto products.
The group said that the deal is expected not only to cater to the
European auto market but also to penetrate the growing China
car market.
For further details contact PBS Machine Tools on
TEL: 011 914 3360 or visit www.pbsmt.co.za
Laser World of Photonics — don’t miss it
Exhibition and conference takes place in Munich, Germany from June 22-25.
E
very two years, Munich hosts an
inspiring international trade fair
and technical conferences that
together draw over 1100 exhibitors
and 25 000 researchers and
professionals in lasers and optics the Laser World of Photonics exhibition
and the World of Photonics Congress.
From fundamental and applicationbased scientific topics to the latest
laser and photonics applications in
industry and medicine, all sides of
photonics are presented in five large
halls and in the Congress center at Messe München.
Here’s a brief introduction to what you will find at the
trade fair from June 22-25. There’s much more on the trade
fair website: www.world-of-photonics.com.
The exhibition is very
large and comprehensive,
with halls or parts of halls
focused exclusively on
seven different
application areas:
• Laser systems for production
engineering
• Imaging
• Sensors, test and measurement/
optical
measurement
systems
• Optics/
manufacturing
•
•
technology for optics
Optical information and communication
Lasers and optoelectronics
World of Photonics Congress
The technical conferences at the
World of Photonics Congress reflect the
close relationship between research
and industry, and focus on photonics
applications in the industrial and
medical sectors.
The hottest topics in 2015,
representing about 50% of the 200 submitted abstracts
are on additive manufacturing and joining in the
sub-conference on macro-processing and ablation, drilling,
and micro-cutting in the sub-conference on micro-processing
with an emphasis on
surface functionalisation.
Additionally, fundamentals,
diagnostics and
control, and system
engineering will also
be discussed
with numerous
presentations.
For extended networking,
the registration to the
LiM 2015 includes an
evening reception at
the Augustiner Keller
in Munich.
For further
details visit
www.world-of-photonics.com
Fair Friend Group opens flagship facility
The FFG Machine Tools Division is aiming to ramp up production over the next seven years.
T
he Fair Friend Group (FFG) Machine Tools Division
has set a goal of producing 30,000 sets of machine
tools per year by 2022. As a step toward reaching
this goal, FFG has opened a flagship factory in Taichung,
Taiwan. Construction began on the building in 2013 and
was completed this past March. With 22,560 square
meters of production space, the facility can produce
as many as 150 sets of CNC machines per month,
the company says. The new facility is one of the
division’s 40 plants located in Taiwan, China and
elsewhere overseas.
The Machine Tools Division, which accounts for
78 METALWORKING NEWS
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May 2015
50 percent of FFG’s revenue, was established in 1985 as
a producer of traditional belt saw machines and grinders.
That same year, FFG began developing CNC machines and
selling them globally under the Feeler brand name. Today,
the division produces vertical and horizontal machining
centers, vertical and horizontal turning
centers, double-column machining centers, large CNC boring and milling centers, floor-type boring centers,
five-axis machining centers, double-column CNC grinders,
and other machines sold under 26 brand names.
For further details on the Fair Friend Group visit
fairfriend.com.tw
Yaskawa celebrates
100 Years
Y
askawa Electric Corporation headquartered in Kitakyushu,
Japan commemorates their 100th anniversary during
2015 across all global locations in 28 countries. In
addition to the centenary celebration, the company will renew
its corporate logo and identity as a symbol of evolution and
future growth.
Yaskawa started in 1915 as a producer of coal mining
equipment by Daigoro Yasukawa, known today as the founder.
During the 20th century, the company developed technology
innovations such as the super synchronous motor, minertia
motor and Motoman® L10 robot. Today, Yaskawa is a leader in
developing and manufacturing robotics and automation
solutions, with approximately $3 billion in annual revenue and
over 14,000 global employees.
“Celebrating our 100-year anniversary provides an
opportunity to reflect on the values that have made us
successful,” stated Junji Tsuda, representative director,
chairman and the president of Yaskawa. “Our ability to develop
products that help society progress will ensure a prosperous
future for us and our customers.”
“For any organisation, company or brand, the ability to
stay relevant and provide value to customers for a century is
an extraordinary accomplishment. For us, we feel fortunate
to provide
products and
solutions that
help advance
society and
alleviate
people from
jobs that are
dirty,
dangerous or
dull.”
“We are
a very
customercentric
organisation.
We have and
will continue
to invest in
people, products and technology that prioritise customers, and
their satisfaction, to the highest level.”
For further details contact Yaskawa South Africa on
TEL: 011 608 3182 or visit www.yaskawa.za.com
METALWORKING NEWS
v 14. 2
May 2015
79
C-Class wins
World Car of the Year
xx
T
he Mercedes-Benz C-Class, which narrowly lost out
to the Porsche Macan in this year's Wesbank SAGMJ
South African Car of the Year competition, has won the
World Car of the Year award.
Mercedes-Benz also took top honours in the World
Luxury Car and Performance Car categories with the S-Class
Coupé and AMG GT respectively, while the Citroën C4 scooped
the design award and the BMW i8 was deemed the best
'green' car.
On why the C-Class took overall honours, the World Car
Awards statement explained it like this: "Taking its design and
technological cues from the S-Class, the C-Class employs an
all-new aluminium/steel hybrid platform and updated
rear-drive powertrains that delivers levels of refinement,
luxury, safety, ride and handling that challenge
best-in-class."
The finalists for the competition are selected by and voted
on by 75 'top-level' motoring journalists from around the globe
and the ballots are tabulated by KPMG.
2015 category winners were:
• World Luxury Car - Mercedes-Benz S-Class Coupé
• World Performance Car - Mercedes-AMG GT
• World Car Design of the Year - Citroën C4 Cactus
• World Green Car - BMW i8
Mahr acquires MWF Roland Friedrich
E
ffective from January of this year, MWF Roland
Friedrich GmbH (Grossostheim, Germany), was
added to the Mahr Group. MFW offers custom
measurement and testing solutions for automotive and
other industry applications. Solutions range from simple
hand-held measuring stations to fully automatic measuring
units for 100 percent control in production.
“By joining the Mahr Group, we guarantee to fulfill
our customer commitments and benefit from their
good reputation,” says managing director Roland
Friedrich.
80 METALWORKING NEWS
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May 2015
Stephan Gais, the managing partner of the Mahr Group,
sees the acquisition “as a reinforcement of our own activities
in customer specific measurement solutions and as a logical
step for further revenue growth.”
With the merger of the two companies, special
measurement and test solutions from MWF Roland Friedrich,
supplemented by building blocks of Mahr measurement
technology, will be offered through the Mahr Group global
sales and service network. This will further expand the
custom design and build capabilities that Mahr Federal
provides to its customers.
New 3D printing technique
A
brand new 3D printing technique working 100 times
faster than conventional 3D printing and making objects
within minutes by simply lifting them out of a pool of
resin, has been created by scientists from the University of
North Carolina. The technique, which could transform 3D
printing, works up to 100 times faster than current methods
and produces objects that are considerably stronger.
And if the machine looks like the product of a science
fiction author’s imagination, it may be because its inventors
were inspired by the Terminator 2 killer robot, T-1000, that
rises menacingly from a puddle of molten metal in the film.
“We were inspired by the Terminator 2 scene,” said Joseph
DeSimone, a professor of chemistry at the University of North
Carolina and a founder of the company, Carbon3D. “Why
couldn’t you have an object rise out of a puddle in real time
with essentially no waste?”
The new technique, called continuous liquid interface
production (Clip), features a moving platform that lifts printed
objects gently out of a reservoir of liquid resin. The technique
combines pulses of light, which solidify the resin, and oxygen,
which prevents it from solidifying, to craft intricate threedimensional objects. Crucially, it works continually, unlike current
printers that construct objects by building layer upon layer.
“3D printing is actually a misnomer; it is actually 2D
printing over and over again,” DeSimone said. “There are
mushrooms that grow faster than 3D printed parts.” In a
demonstration, it took the Clip printer seven minutes to
produce a hollow geometric ball — a task which would have
taken about 10 hours with a conventional 3D printer.
Printing finished parts at speeds competitive with current
manufacturing processes is “a game changer”, said DeSimone.
In a study, published in the journal Science, DeSimone and
colleagues describe how their technique combines the
manipulation of oxygen and light. At the base of the liquid resin
reservoir, is an oxygen permeable window — similar to a contact
lens — which leads to an oxygen rich “dead zone”, less than
1mm thick, at the bottom of the tank. Oxygen stops the resin
from solidifying, even when light is projected through it,
meaning that the solidification happens just above the dead
zone. The precise shape that solidifies is controlled by light
projections through the permeable window. Since the liquid
layer is always present beneath the slowly-forming object, there
is no need to wait for new resin to flow in and the object can be
pulled upwards steadily.
The continuity of the process also means that Clip produces
much stronger objects than the slate-like structure of objects
printed in layers, which can be sturdy in one direction, but
will shatter under force in the other. The 3D-printed gun may
have made the headlines, but it would have been useless at
withstanding an explosion in practice. Jonathan Rowley, of
Digits2Widgets, a 3D printing company in London, said the
strength factor was even more impressive than the new
technique’s speed. “At the moment most 3D printers produce
crap slowly and I don’t need crap fast. If you add the
speed of this technology to the extra strength it provides it
means you could produce parts that start to compete with
traditional manufacturing. It’s probably something of a big
deal.”
DMG Mori Seiki Co share tender offer for partner passes 50%
J
apanese machine tool maker DMG Mori Seiki Co's
shareholding in German machine tool maker and partner
DMG Mori Seiki AG has passed the 50% mark, following its
share tender offer that expired on 25 March.
The Japanese firm said in an announcement dated
31 March 2015: "Conditional upon the approvals of the
antitrust law and anti-competition law authorities, the
settlement of the tender offer will occur, causing AG (DMG Mori
Seiki AG) to become one of the Company's (DMG Mori Seiki Co)
consolidated companies."
DMG Mori Seiki's actual shareholding now stands at
50.81%, or 50% plus one share. The cost to acquire those
shares at €30/share has been put previously by DMG Mori
Seiki Co at €272 million.
This result has triggered an additional tender offer
period that commenced on 31 March 2015 and lasted until
82 METALWORKING NEWS
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May 2015
13 April 2015, with the results of that to be announced shortly.
The two companies started to co-operate in 2009 as
Mori Seiki Co and Gildemeister AG, with a cross-shareholding
of 5% established by each at that time. The two sell globally
through the DMG Mori Seiki network of operations that are also
jointly owned.
Estimated turnover for DMG Mori Seiki AG is €2.2 billion
for 2014, with DMG Mori Seiki Co's estimated figure for its
2014/15 year put at €1.35 billion. Once consolidated into a
single reporting organisation, these combined figures would
appear to make the company the largest machine tool maker in
the world, according to The Machine Tool Scoreboard, published
by Gardner Business Media, nudging Germany's Trumpf off the
top spot (€3.25 billion for 2013/14).
For further details contact Retecon Machine Tools on
TEL: 011 976 8600 or visit www.retecon.co.za
3D printer pricing now publicly available
in Senvol Database
T
he Senvol Database, which is the first and most
comprehensive 3D printing database for industrial
additive manufacturing machines and materials, has
expanded to include machine pricing information. In addition
to being able to search by machine build size, material type, or
material tensile strength, for example, users can now search by
machine price as well.
“We’re very excited to announce the addition of pricing
information to the Senvol Database,” Senvol President Zach
Simkin said. “It was something that a lot of people in the
industry had asked us for. We’re pleased to continue to provide
more and more information — information that companies need
in order to make informed decisions about implementing
additive manufacturing into their supply chain.”
3D Printing Industry writer Andrew Wheeler recently
weighed in on the Senvol Database’s progress, noting,
“Senvol has responded to the attention by doing what makes
[them] such a standout in the first place: they’ve added more
information and clarity to the whole 3D printing industry.”
Senvol President Annie Wang commented, “We work in
close collaboration with the machine manufacturers. The price
ranges in the Senvol Database reflect the fact that specific
machine pricing can vary by location and by distribution
channel.”
The Senvol Database is online and free to access
(http://www.senvol.com/database) and currently contains
detailed information on over 350 machines and 500 materials.
Users are able to search the database by over 30 fields. For
example, a user can search for a machine that is compatible
with steel, has a build envelope of at least 6x6x6 inches, and is
priced below $500,000.
Feedback from its global user community is instrumental
in helping Senvol to continually expand and improve the Senvol
Database. Anytime users have a comment, suggestion, or idea,
they are encouraged to email database@senvol.com.
About Senvol
Senvol is a services firm that conducts analytics
exclusively for the additive manufacturing industry. Senvol
has worked with a variety of Fortune 500 companies and
government agencies in industries such as aerospace,
oil & gas, consumer products, and automotive. Senvol’s
founders have been published in various additive
manufacturing industry journals, such as the Wohlers Report,
and have been featured speakers at numerous industry trade
shows and conferences.
To check out the Senvol Database and start your search,
visit http://www.senvol.com/database.
METALWORKING NEWS
v 14. 2
May 2015
83
pro d u c t
review
New Hypertherm Powermax30 AIR
delivers portability, with the added
convenience of an internal
air compressor for on the go cutting
Expands patented True Hole technology to include
more thickness, amperage and consumable options.
H
ypertherm, a manufacturer of plasma, laser and
waterjet cutting systems, has announced the
introduction of the Powermax30® AIR, a new
portable air plasma system and internal compressor
in one.
With the built in compressor and the ability to
operate on both 120 or 240 volt lines, the
Powermax30 AIR is a highly versatile system that
enables metal cutting just about anywhere. Weighing
only 13.5 kg the Powermax30 AIR provides 30 amps
of output giving it the highest power to weight ratio
of any system in its class.
“Hypertherm is setting new performance and
portability standards with this new model,” explains
Harry Mellott, a Hypertherm Powermax specialist.
“With a recommended cut capacity of 8mm and a
severance capacity of 16mm, the system can easily
and quickly cut a variety of metal types and
thicknesses making it a great entry level cutting tool
for a variety of professions, as well as home users.”
This high power to weight ratio is due in part to several
engineering advances including an all -new patent-pending
consumable design that optimizes air flow from the compact
internal compressor. This design directly contributes to the
efficiency of the system and delivers consistent cut
performance.
Hypertherm expands patented True Hole technology to
include more thickness, amperage and consumable options
For the first time, customers can use the True Hole process
to cut 8 mm mild steel at 80 amps, in addition to the existing
130 amp power level. Though cutting at 80 amps is slower,
this slower speed could benefit customers who have tables
with lower
acceleration
capabilities. It
provides more
options based
on application
needs.
In
addition,
customers
can now use
the 200 amp
bevel
process to cut
10mm, 12mm
and 16mm
mild steel.
84 METALWORKING NEWS
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May 2015
Previously, 200 amp True Hole cutting required the use of
standard HyPerformance® HPRXD® consumables, rather than
bevel consumables. With more customers performing bevel
cutting on the plasma system, adding True Hole to the
200 amp bevel process fills an important market need.
Hypertherm’s patented True Hole technology greatly
improves the capability of HyDefinition® plasma to cut high
quality, bolt ready holes. The technology uses a specific
combination of cutting parameters optimized for mild steel
applications. The end result, demonstrated in both internal and
customer testing, shows an up to 50 percent improvement in
the shape of the hole. At the same time, taper and dings are
virtually eliminated on holes with an equal diameter to
thickness ratio.
“The introduction of True Hole technology more than
5 years ago, along with True Bevel® technology, significantly
simplified production for many of our customers by
allowing them to create bolt-ready holes and beveled edges
in one step,” explained Phillip Parker, product manager for
Hypertherm’s Mechanized Plasma team. “Though other plasma
manufacturers claim to offer True Hole technology, in fact the
technology remains a patented process in which Hypertherm
continues to invest.”
The Powermax30 AIR, like all Hypertherm Powermax
systems, is rugged and reliable with Hypertherm CertifiedTM
reliability to perform in the most demanding environments. It is
available from authorized Hypertherm partners around the world.
To get in touch with a Hypertherm sales representative, feel
free to visit the Where to Buy section on www.Hypertherm.com
For further details contact Craig Sterley of Hypertherm
on email craig.sterley@hypertherm.com
Tongtai TMT2000 Series has twin spindles
and two individual machining areas
Mass production turning centres introduced in an attractive and modern design.
T
ongtai's CNC Lathes have been widely popular because of
their high reliability and high cost-performance rate. Now,
Tongtai has launched a new CNC Lathe series - TMT 2000
Series — that has twin spindles and two individual machining
areas. The turrets and spindles are designed in parallel to each
other. This design allows components, which need two
machining processes, to be finished on one machine.
Moreover, by adding a gantry type robot on this model it
not only improves the utilisation of the floor space but also
decreases labour costs. Depending on the cycle time required
(mostly, the cycle time of turning processes of automotive small
parts is within 60 sec), a single robot arm or twin robot arms
can be added to increase automatic production efficiency.
The Tongtai TMT 2000 Series are state-of-the-art,
high-precision CNC turning centers cast from Meehanite iron.
They are loaded with high tech features not found on any
comparable machines. Features such as a 75 degree
mono-block slant bed for excellent rigidity, chip flow and
unparalleled ergonomics are included.
In addition, the optional true linear
(perpendicular) Y-axis leads to simplified
programming while high power synchronised
spindles provide superior acceleration and
deceleration times. Two servo driven turrets
provide high speed indexing. The optional live
turret with the rigid BMT-65 tool system with
available Y-axis on the upper turret adds
productivity and reduces cycle times.
Both precision spindles are built using
precision double row roller bearings in
conjunction with angular contact ball bearings
for high rigidity and accuracy. The spindle quill inner and outer
linings are precision ground for fit with the spindle, thus
ensuring extreme
concentricity and
accuracy.
The main
4500 rpm spindle
with 64mm bar
capacity is driven
by a 15kW high
torque motor which
provides power and
unsurpassed
acceleration while
the synchronous
sub-spindle has
18,5kW,
6000 rpm and a
50mm bar capacity.
Both spindles
feature an
optional full contouring Cs axis.
Other machine specifications
include a pitch of the two spindles
of 440mm, maximum swing
diametre of 210mm, maximum
turning diametre of 210mm and
turning length of 145mm.
For further details contact
PBS Machine Tools on
TEL: 011 914 3360 or visit www.pbsmt.co.za
Fibre laser cutting machine incorporates
patented compass head positioner
T
he 2015 Salvagnini L5 fibre laser cutting machine
incorporates the patented, rotary motor-driven compass
head positioner. According to the manufacturer, the
positioner allows for improved speed, accuracy, reliability,
energy conservation, and performance.
Available in 2, 3 and 4kW versions, the machine comes
fitted with a new, all-electric pallet changer. The processed
piece always passes beneath the worktable, eliminating any
risk of cut parts or scrap falling onto the incoming blank.
An automation package is available that includes the
manufacturer’s MCL automated Cartesian sorter/manipulator
for laser cutting systems. This floor-mounted gantry uses a
single suction cup gripper to pick up parts as small as
200 by 100mm and uses two grippers to pick up parts as
large as 4000mm and weighing as much as 130 kilograms.
Guided by a software program that automatically positions
the sorter over parts to be retrieved and runs an efficient
86 METALWORKING NEWS
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May 2015
unloading and placement cycle, the system can extend kit
production and single-piece part flow to automated laser cutting.
For further details contact Potgieter Industrial Machinery
on TEL: 011 022 4648 or visit www.industrialmachinery.co.za
New Harrison Alpha XS combination lathes
fulfill heavyweight turning demands
A
s part of their comprehensive new product development
programme, 600 UK are bringing two new heavyweight
additions to the hugely successful Harrison Alpha
XS Manual / CNC lathe range.
The heavy duty Harrison Alpha 1660XS and 1760XS models
have been specifically designed in response to increased
customer demand for turning larger diameter components
accurately, efficiently and more cost effectively. These new
Alpha 1660XS and 1760XS large capacity lathes are designed
to fit perfectly into the existing range, offering customers even
more choice when choosing the best selling combination
lathe in the world and perfectly compliment the hugely
successful Alpha 1350XS, 1400XS, 1460XS, 1550XS and
88 METALWORKING NEWS
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May 2015
super heavyweight Alpha 2800XS.
Both the Alpha 1660XS and 1760XS machines offer a
high powered 18.5kW motor with 105 mm spindle bores
(1760XS model has an optional bore of 155mm), outputting
a spindle speed of 2000 and 1400 rpm respectively.
Both models are of cast iron construction to give maximum
stability and can be specified with a centre distance from
1.5 metres, up to 4 metres, giving class leading heavy duty
turning performance and accuracy for even longer and
larger diameter components.
The Alpha 1660XS and 1760XS models are fitted with
the same unique Fanuc 0iTD / Harrison Alpha control
system as the rest of the range. This Alpha control offers
customers huge flexibility through the
unique Harrison control, allowing 4 ways
of working for the operator - from manual
turning through to full CNC production
incorporating Harrison’s renowned
Alpha System, which is widely
acknowledged as the most simple
and intuitive system in the world to use.
For further details contact
F & H Machine Tools on
TEL: 011 397 4050 or visit
www.fandhmachinetools.co.za
AU-1440iA Z800 submerged wire EDM from
AccuteX provides large capacity, flexibility and speed
T
he new AccuteX AU-1440iA Z800 submerged
wire EDM is engineered to process large as well
as smaller parts with accuracy, speed and
convenience. The machine’s X axis capacity of
1378mm with 787mm in Y and Z enable
it to handle workpieces up to
1712 x 1062 x 782mm in size.
The machine structure, designed
via Finite Element Analysis (FEA),
includes a Meehanite cast honeycombtype base, highly-ribbed column
mounted with oversized UVZ axis, and
a reinforced lower-arm to increase stiffness.
To maximize durability, the 148mm U and V axes are
protected in a cabinet located above the working area. All
castings are stabilized to ensure maximum strength, reliable
high precision and long durability when machining workpieces
as heavy as 7,473 kilograms. The rigid structure and 20mm
C1 Class U-V ball screws provide repeatable precision at the
high flushing pressures necessary for high-speed cutting.
A precision hardened-stainless-steel workpiece-mounting
table offers easy accessibility and is designed to function as a
standard clamping system, permitting a wide range of
workpieces to be fixtured quickly and accurately. The worktable
can also accommodate any commercial clamping system.
AccuteX’s exclusive automatic wire
threading (AWT) system enhances
machining speed by accomplishing fast
submerged rethreading at the break
point. When wire breakage occurs,
rethreading takes place without
dielectric drainage/refilling, resulting in
spark-to-spark times as low as
15 seconds. The system also includes a
scrap wire disposal unit.
A 64-bit Widows CE based PC CNC
system drives machine axes via closed
loop, direct coupled AC servomotors, with
8 millionths resolution confirmed by a
Heidenhain linear glass scale feedback system. The patented
structure of the machine’s Hiwin linear guideways reduces up
to 90 percent of friction and vibration to produce
unwavering accuracy of motion. Resulting positioning accuracy
is ±0.003mm and repeatability ±0.002mm in X & Y.
The AccuteX AU-1440iA Z800 EDM enables shops to easily
process both large and smaller parts. The machine’s strength,
speed, and accuracy assure maximum flexibility and
productivity, according to the company.
For more information contact EDM Shop on
TEL: 011 762 5231 or visit www.edmshop.co.za
METALWORKING NEWS
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89
For milling, drilling, or tapping, Widia’s Vari family
of tools delivers high performance
E
xtreme challenges are daily fare for job shops. To address
the unique needs of job shop customers and the
distributors who serve them, the Widia VariMill, VariDrill,
and VariTap are specifically engineered to be versatile, easy
to choose, easy to use, and deliver superior results in a wide
range of applications and materials.
The VariMill, VariDrill, and VariTap are designed to
conform to Widia’s theme of “Extreme
Challenges, Extreme Results”. These
tools are specifically engineered to
address the needs of the end-user,
providing a versatile tool that is
capable of attacking a varying range
of applications and work materials
with high-performance results.
“The job-shop
mentality is tackling multiple
small-lot assignments under
tight deadlines,” says Dr Tilo
Krieg, Director, Holemaking and
Solid Endmilling products at
Widia.
“Their expertise and
reputations depend on
performance, often having to
exceed past results while
leaving enough margin to make
money. They know they have to
have tools that work.”
While Widia’s VariMill,
VariDrill, and VariTap deliver
convenience and results
for the customer, the
concept behind the Vari
portfolio was conceived
with the Widia distributor
in mind. When armed
with the Vari family of
tools, Widia
distributors can meet a
variety of unique customer
needs and applications with one
drilling, milling, and tapping product
line. The portfolio is designed to cover every diameter,
length/diameter ratio, and coolant option that the end user
might need. Therefore, a limited amount of Vari tooling stock
can address a wide variety of customer needs.
By reducing the need for custom or specific drills, mills or
taps, Widia distributors are able to streamline their on-hand
inventory without sacrificing their ability to respond quickly to
a customer’s unique tooling needs. Simply put, Vari tools from
Widia are designed to offer a complete package of highperformance tooling solutions that can get the job done:
use VariDrill to drill the hole, VariMill to complete the surface
finish of the workpiece, and VariTap to finish the job.
For more information contact Widatech on
TEL: 087 150 3266 or email: info@widatech.co.za or
visit www.widatech.co.za
Feeler introduces economical FT-250SY high-performance
milling lathe with true Y-axis and sub-spindle
F
eeler has expanded its FT-series high performance CNC
turning centers line with the new FT-250SY. A unique
capability in its class, the FT-250SY features a true Y-Axis
with 100mm (+/- 50mm) of travel, which provides increased
rigidity and a more robust machining environment. Also, by
offering an 8-inch sub-spindle in addition to the primary 10-inch
spindle, the FT-250SY provides more capacity than competitive
turning centers.
For excellent vibration dampening when turning in hard
materials, including interrupted cutting, the FT-250SY features
a single-piece structure with boxways, 45-degree slant bed
and robust base. Extra rigidity from a heavy duty 12-station
turret results in high metal removal rates, superb finishes,
and ensures long term accuracy. For maximum integrity, FEA
analysis is used to ensure a solid machine base with excellent
overall structural rigidity and stability. The machine also offers
exceptional capacity with a 30 HP, 3,500 RPM 10-inch (chuck
diameter) primary spindle in addition to a 20 HP, 4,500 RPM
8-inch (chuck diameter) sub-spindle.
The FT-250SY is a valuable addition to the Feeler FT Series,
providing exceptional rigidity and capacity at an economical
price.
The Feeler FT-250SY offers an X-Axis travel of 210mm,
90 METALWORKING NEWS
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May 2015
Y-Axis travel of
100mm
and a
1050mm
Z-Axis
travel.
The
machine
comes
standard
with a
Fanuc
31i-TB CNC control.
A BMT-65 tool system features a solid interface for tool
holding. For maximum machine component longevity, a fully
enclosed CE cabinet prevents dust and fumes from
entering.
Feeler machines are manufactured by Fair Friend Group
(FFG). Established in 1979, FFG is one of the world’s largest
machine tool builders and has major manufacturing operations
in Taiwan, China, Japan and the U.S.A.
For further details contact Craft Industrial Equipment on
TEL: 011 845 2030 or www.craftmt.co.za
Neway CNC Equipment
launches four new machines
Vertical machining centres with roller type linear guides.
N
eway CNC Equipment (Suzhou) Co., Ltd now offers three
new VMCs — the LH/LD series — and a new CNC vertical
tapping/drilling centre. These machines were designed
using Finite Element Analysis (FEA) in both the static and
moving state to help ensure optimum performance. The
company says roller bearing linear guideways, 45 degree
surface contact and surface bearing load offer better load
capacity, less deformation, higher accuracy, longer working life
and better dynamic balance.
The 4-axis CNC vertical machining centre VM75LH/LD
has XYZ travels of 680 x 440 x 520mm, a table size of
750 x 420 mm, travel speeds of 40 metres per minute,
BT 40 tools, 7,5kW motor and can carry a load of 450 kilograms.
The larger 4-axis CNC vertical machining centre
VM95LH/LD has XYZ travels of 880 x 550 x 580mm, a table
size of 950 x 520 mm, travel speeds of 36/36/30 metres per
minute on the XYZ, BT 40, 11/15kW motor power and can
carry a load of 850 kilograms.
The even larger 4-axis CNC vertical machining centre
VM110LH/LD has XYZ travels of 1030 x 550 x 580mm, a table
size of 1100 x 520 mm, travel speeds of 36/36/30 metres per
minute, BT 40 tools,
11/15kW motor and
can carry a load of
850 kilograms.
The new
TP65LD
vertical
tapping/
drilling
centre
features a
Siemens
828D
control, a
work load of
350 kilograms, XYZ travels
of 510 x 400 x 350mm, travel speeds of 48/48/80 metres
per minute on the XYZ, and a 4,9kw motor with a spindle speed
of 15 000 rpm (direct drive).
For further details contact Machine Tool Promotions on
TEL: 016 931 1564 or visit www.mtpsa.co.za
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91
TruLaser 3030 fibre laser machine
with BrightLine fibre technology
B
rightLine fibre technology allows
the cutting of both thick and
thin materials on a solid-state
laser machine to equal levels of
quality and cost-efficiency, giving
manufacturers far greater flexibility
than ever before, says Trumpf.
The TruLaser 3030 fibre features
both high speed cutting and
processing flexibility, resulting in
maximum profitability. The
fibre-delivered TruDisk laser excels
not only at thin sheet cutting, but also in steel up to 3/4"
thick with peak performance, cut quality and low operating
cost. Stainless steel, aluminium and copper can also be cut
with speed and quality, giving you a full range of capabilities.
Switching between materials is fast and easy, thanks to the
automatic nozzle changer and the single cutting head. To
further expand capabilities, the TruLaser 3030 fibre may be
optionally equipped with RotoLas for tube processing.
What is BrightLine Fibre?
With typical fibre delivered lasers, the beam size is half
that of a C02. While this is great for cutting thin material, in
thick material the expulsion of the molten material is difficult
in this small kerf. This is the reason that most fibre delivered
lasers struggle with thicker materials and why the edge quality
is worse in thicker materials. With BrightLine fibre, which is only
available on a Trumpf laser, there’s the ability to change the
beam size from a small beam to a larger beam. Not only is the
edge quality better than any fibre delivered laser we have seen,
but also thicker parts can be removed from the nest with ease.
Benefits
• Higher quality edge — cut mild steel, stainless, and aluminium up to one inch thick using the wider beam, thus allowing the molten material to quickly escape the gap
• Higher processing speeds — achieve much higher
processing speeds than ever before, if you are
cutting with nitrogen you witness this remarkable
speed
• Small hole processing — small holes that would
previously have to be drilled are now easily
laser cut
• Higher piercing quality — since much less material is removed, there is much less splatter
• Easier removal of parts — with a wider beam and smoother edge quality, parts can be more easily removed from the scrap skeleton
For further details contact Retecon Machine Tools on
TEL: 011 976 8600 or visit www.retecon.co.za
Five cutting edges make Iscar’s Penta 24
threading inserts a ‘star’ performer
F
ollowing the global success of the
advanced Penta 24 inserts, Iscar
has expanded Pentacut’s application
range by adding threading options. The
new Iscar inserts feature the ability to
perform highly efficient threading
applications. Full profile inserts are now
available in ISO, UN, Whitworth and
BSPT thread standards. In addition,
partial profile inserts are available in
60o (MT) and 55o (WT) profiles.
The new Penta 24 inserts feature
multi-corner, five cutting edges, which
provide the user with an extremely
economical price per cutting edge. The
new advanced inserts benefit from the combination of a very
rigid clamping system and a robust insert design, enabling
production at very high machining parameters.
92 METALWORKING NEWS
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May 2015
Penta 24 can be used for threading
between walls to enable complete part
production on bar feeder machines,
whilst the inserts’ innovative chipformer
provides short chips, which result in
excellent accuracy and enhanced
surface quality.
The new Penta thread inserts can
be mounted on standard Penta 24 tools
and the system’s advanced design
ensures easy and fast edge indexing
from either side of the holder.
The new inserts are made from
Iscar’s very versatile PVD coated grade
IC908. Following an edge breakage, the
tool will survive and all other cutting edges still can be used.
For further details contact Iscar South Africa on
TEL: 011 997 2700 or visit www.iscar.com
TaeguTec’s TwinRush — A new large diameter drilling
solution with an interchangeable head and inserts
T
aeguTec is combining the power
of two of its popular drills into
one package. The TwinRush
takes away the worries associated
with machining large diameter holes
by assuring that the new addition to
the TaeguTec drilling line offers
excellent performance and high
productivity.
On first glance, the noticeable feature of
the TwinRush joins together a centering insert with a pair
of precise square inserts on either side in order to combine
two different drill types onto one drill body.
In order to protect the TwinRush from premature wear
or damage and extend the drill’s life, which saves on tool
cost and downtime, TaeguTec shields it with the remarkable
TT9080 PVD multi-layered coated grade.
The centering insert is TaeguTec’s revolutionary and highly
popular DrillRush indexable head — a tool that continuously
enables precision self-centered machining
for achieving hole concentricity.
Both outer inserts are the specially
designed economical 4-corner SPGX type
and are equipped with
a wiper ground area
for improved surface
roughness. When
compared to
conventional
inner/outer indexable
type drills, the
SPGX type inserts’
symmetrical
alignment offers double
the productivity.
Further benefits include an internal
through hole coolant system, a hardened
body for rigidity, and smooth surface and
wear resistance due to the drill’s
post–treatment process.
TaeguTec’s TwinRush comes in a
diameter range from 26 millimeters to
45mm and 5xD drilling depth of cut and is
available as standard items.
When it comes to drilling deep holes
and/or large hole diameter machining, the
TwinRush’s improved body rigidity,
excellent chip control, precise 4-corner
insert with wiper, double effective design
and ability to drill directly without a pilot
hole makes this the go-to tool when quality
of the manufactured part, cost reduction
and productivity are the main focus.
For more information contact
TaeguTec SA on TEL: 011 362 1500 or
visit www.taegutec.com
Okuma’s new GI-10NII internal grinding machine
provides high efficiency
O
kuma’s GI-10NII is equipped with extremely rigid,
high-speed grinding wheel spindles that produce high
performance production in automated environments.
Capable of simultaneous two-axis control, this model is
extremely flexible in handling a variety of workpiece shapes in a
simple data setting.
Centralized control of lubricating and pneumatic devices
allows for easy maintenance, while simplified programming and
the program help function allow for easy operation.
Equipped with features that enhance the automation
process, this CNC grinding machine is capable of simultaneous
dressing and loading, fixed workhead construction, and greater
X-axis travel to provide additional space for workpiece
loading/unloading.
Key features of the GI-10NII are a 6” maximum grinding ID,
NC high-speed oscillation for higher stock removal rates,
94 METALWORKING NEWS
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May 2015
5-surface hydrostatic guideway
system (Z-axis), standard Hi-G
control, high-speed
loader at a rapid
traverse of
180 m/min and a
variety of loader
patterns for easy
automation
For further
details contact
F & H Machine
Tools on
TEL: 011 397 4050
or visit
www.fandhmachinetools.co.za
Upgraded Romer Absolute Arm laser scanner
speeds up inspection
H
exagon Metrology has announced the release of RS3,
an upgrade package delivering a dramatic performance
improvement for the Romer Absolute Arm with integrated
laser scanner.
Available with all new Romer Absolute Arm SI portable
measurement systems or as an upgrade for existing customers,
the RS3 doubles the scan rate of the previous RS2 integrated
scanner, enabling users to inspect like-for-like parts in
approximately half the time. Point cloud density has also
increased, resulting in a maximum acquisition speed more than
nine-times that of the RS2 model, giving faster, more detailed
scanning without compromising on accuracy. Users also benefit from the latest RDS proprietary software, featuring SMART
technology which allows real-time monitoring of the arm and
will reduce the mean time to repair.
Combining non-contact scanning and tactile probing, the
Romer Absolute Arm with integrated scanner is a multi-purpose
portable measurement system suitable for point cloud
inspection, product benchmarking, reverse engineering, rapid
prototyping, virtual assembly and CNC milling applications.
Scanner and probe measurements can be made seamlessly in
one software session, while the RS3 scanner guarantees the
quality and ease of use customers have come to expect since
the launch of the Romer Absolute Arm in 2010.
“The Romer Absolute Arm with integrated scanner is
already well-known
for delivering
excellent scan results
even on tricky
surfaces like carbon
fibre and steel, but
the performance
improvement of the
RS3 compared to the
previous RS2 model
is really quite
extraordinary,” said
Stephan Amann,
Product Line
Manager at Hexagon
Metrology. “Existing systems can be upgraded very quickly
without returning the arm to the factory, so customers will see
immediate benefits in terms of speed and usability.”
As of 20 April 2015, all new units of the Romer Absolute
Arm with integrated scanner will be supplied with the RS3
scanner as standard. Customers who wish to upgrade an
existing RS2 system to the RS3 integrated scanner should
contact their local Hexagon Metrology service centre.
For further details contact Retecon Machine Tools on
TEL: 011 976 8600 or visit www.retecon.co.za
METALWORKING NEWS
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95
Cut parts faster, with Vericut OptiPath
I
n the business world today it’s all about being productive;
applying lean principles such as Kaizen, continuous
improvements, 5s, one-piece flow and so on. Most of us have
heard or have first-hand knowledge of these methods and how
they can improve businesses that are on a journey to become
more effective and efficient. By reducing waste and improving
processes companies can become more competitive and more
profitable.
So it should come as no surprise that many companies
are increasingly focusing on how to reduce CNC machining
cycle times, particularly through the use of technology. Huge
advances have been made in the materials that cutting tools
are made from, the coatings applied to improve tool life, and
the use of coolants. In addition, many CNC machining centres
now feature adaptive feed control to ensure that a constant
load is being applied to the cutting tool.
As with all technologies some are very affordable and easy
to implement, others require expensive modifications to
existing machinery.
This is also true in the world of CAD/CAM where new
machining strategies are developed to improve the speed
that material is removed or to improve surface finish. The use
of adaptive feed control (AFC) is also being applied. This in
principle is great, as the end user can now rely on software to
consistently control the CNC machining centres, and thereby
reduce the cost of applying adaptive feed control across the
whole of the machining process.
However, one important element can be overlooked; how
accurately does the software-based solution represent the
actual machining process? If AFC is applied to code that has
not gone through the post processor, then the chances are
you’re not going to get the best out of the AFC.
One way to ensure that you are getting the most realistic
performance is to use a solution that actually uses the same
ISO G-code that the CNC machining centre uses. Vericut is the
world’s leading CNC simulation, verification and optimisation
solution and is at the forefront of CNC machining optimisation.
Vericut’s optimisation module, OptiPath®, automatically
modifies feed rates based on the current cutting conditions to
make your programs more efficient, while also extending tool
life and improving the quality of the finished surface.
Knowledge-based machining
Vericut is a true knowledge-based machining system:
through the simulation process it learns the exact depth,
width, and angle of each cut — and it knows exactly how much
material is removed by each cut segment. With that knowledge,
OptiPath divides the motion into smaller segments. Where
necessary, based on the amount of material removed in each
segment, it assigns the best feed rate for each cutting
condition encountered. It then outputs a new tool path,
identical to the original but with improved feed rates. It does
not alter the trajectory.
Simplified setup and use
A setup wizard prompts the user for cutter settings as the
part is machined — essentially, adding intelligence to the
cutter — and all the settings for that cutter are stored in an
optimisation library.
Every time that a cutter
is used the results can
be instantly optimised.
OptiPath also features
a ‘learn mode’ for
creating the
optimisation library
with no setup required.
For each tool, OptiPath
finds the maximum
volume removal rate
and chip thickness
and uses them to
determine the best
optimisation settings
for the tool.
Optimisation
for roughing
During roughing,
the goal is to remove
as much material as
96 METALWORKING NEWS
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May 2015
quickly as possible. OptiPath keeps the cutter at its maximum
safe rate-of-advance into material for the varying cutting
conditions. For example, during planar roughing of an
aluminium aerospace structural component, material may be
removed at a constant axial depth, but the radial width of cut
could differ greatly from cut to cut. OptiPath modifies the feed
rates to maintain a constant volume removal rate.
Optimisation for finishing
Chip loads typically vary widely as the tool profiles through
the material left behind during roughing cuts and over the
contours of the workpiece to near net shape. OptiPath adjusts
defeat the goal of reducing machining time. Cutting at greater
depths removes material more efficiently. But, the cutter may
encounter an overloaded condition causing it to break or
exceed the machine’s spindle power. Since OptiPath knows the
amount of material removed, it adjusts feed rates accordingly
and maintains a consistent chip thickness. This provides more
efficient machining while protecting the machine and cutter.
As a general guide, by using Vericut OptiPath end users can
expect to reduce their CNC milling times by between 25 – 50%
when cutting aluminium or similar materials, 10 -20% when
cutting steal and other hard materials and between 5 – 15%
when cutting titanium and other exotic materials.
OptiPath automatically calculates and inserts improved feed rates
where necessary. Without changing the trajectory, OptiPath writes
the updated feed rates to a new NC program
the feed rates to maintain a constant chip load. (Consistent
chip loads are recommended by cutting tool makers to reduce
‘chip thinning’.) The results are improved tool life and better
finish. This is especially critical when tip cutting with a ball
end mill or contouring a surface with a small step-over, such
as semi-finishing or finishing in a tool steel mould cavity, for
example.
How it works...
As the cutting tool encounters more material, feed rates
decrease; as less material is removed, the feed rates speed
up accordingly. Based on the amount of
material removed by each cut segment.
OptiPath automatically calculates and
inserts improved feed rates where necessary.
Without changing the trajectory, OptiPath
writes the updated feed rates to a new
NC program. An additional benefit of using
OptiPath is that any fresh air cuts encountered
are converted into maximum linear feed rates.
This alone can reduce a CNC cycle time by as
much as 10%. With more time available on
the machine, planned preventative
maintenance can be implemented.
Imagine having an extra 50% machining capacity available.
Planned capital expenditure can be reduced on the need for
new machinery to keep up with production, projects can be
delivered on time more often, direct overheads like shift
premiums can be reduced and cutting tools expenditure can be
reduced. All these additional benefits will have a direct impact
on any company’s profit margins.
For further details contact TDM Solutions on
TEL: 011 234 6019, email sales@tdmsolutions.co.za or visit
www.tdmsolutions.co.za
High speed vs. high efficiency machining
The traditional method of high-speed
machining, cutting at high feed rates with very
shallow cuts and small step over can actually
METALWORKING NEWS
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97
Yamazaki Mazak previews new
graphical user interface and control
Y
amazaki Mazak’s Smooth Technology
incorporates a new Mazatrol SmoothX
CNC control alongside new machine
hardware and servo systems to deliver an
improved operator experience, faster
machining times and further integrate CNC
into the overall factory management system.
The interface is operated intuitively in a
similar way to smartphones and tablets.
SmoothX features new Smooth Graphical
User Interface with five new process home
screens that present critical data in a single
page view, whilst simplifying the key
operational stages: from part programming,
management of tool data and set-up, through
to the actual machining cycle and machine
maintenance.
The new Quick Mazatrol interface
dramatically reduces the process time and number of
keystrokes required to enter a conversational program by 38%
compared to its predecessor. This is achieved by the use of
touch screen technology and real-time processing of the 3D
part shape in simultaneous view as the program is compiled.
Editing is made simple by touching the displayed 3D part to
reach the feature in the program. SmoothX also features a new
3D assist function to enable the import of 3D CAD to the CNC,
further reducing programming time.
Mazatrol SmoothX also includes a range of new Mazatrol
programming functions such as intelligent pocket milling that
can reduce machining time by up to 60%
compared to conventional offset tool paths.
Fine increment programs such as
simultaneous 5-axis machining and
free-form die-mold machining also benefit
from new functions such as Seamless
Corner Control, Variable Acceleration
Control and Smooth Machining Control to
reduce cycle times.
SmoothX is capable of ultra-fast
processing speeds up to four times faster
than its predecessor, enabling it to respond
to the demands of the latest generation of
servo motors employed.
SmoothX can also play a key role in
factory management operations through its
ability to manage data and production
systems on one platform and with an open
interface, enabling automation equipment to be connected
and managed from the CNC.
Marcus Burton, European Group Managing Director for
Yamazaki Mazak, commented: "SmoothX marks a leap in
technology equivalent to the jump from desktop to tablet
computing with all the associated benefits, from user interface
via the touch screen, through to the integration of new
intelligent control technologies, component visualisation and
factory connectivity."
For further details contact Hi-Tech Machine Tools on
TEL: 011 608 0088
Ficep’s CNC drilling line is Rapid
T
he Rapid from Ficep is a new CNC high speed drilling line
for angles and flats offering high productivity, quality,
flexibility, accuracy and lower production costs. The
machine has the option of using indexable carbide drilling
tools.
The CNC materials handling system loads the angles on
to the conveyor track which then automatically clamps the
workpiece in position, and every process then takes place
sequentially.
The two drilling heads are equipped with direct drive
spindles, each of which has an automatic, six-position tool.
The CNC
system
controls
spindle
positioning and
feed rates and
linear guides
with controlled
servomotors
and ball screws
ensure
maximum
precision on
every axis. A
98 METALWORKING NEWS
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May 2015
new additional auxiliary axis of 200mm allows independent
control of the two spindles in the length (X) axis.
The Rapid CNC drilling lines are also modular and can
therefore incorporate scribing, hard stamp marking, single or
double shearing or alternatively, high speed circular carbide
saw.
The processed angles, scrap or swarf can be automatically
offloaded at predetermined or selectable positions along the
unloading area to reduce manual handling and sorting.
For further details contact Retecon Machine Tools on
TEL: 011 976 8600 or visit www.retecon.co.za
BLM Group model LT8 laser tube
cutting system enhances processing
of large tube diametres
T
he system provides flexibility and operator ease for up to
220mm diametre tube cutting in production
environments.
BLM Group has announced the introduction of the flexible
Model LT8 laser tube cutting system. The LT8 is a three
dimensional CO2 laser tube cutting machine that provides
excellent flexibility and user-friendliness for extremely precise
laser cutting on tube diametres up to 220mm and a bar weight
up to 450 kilograms.
The unit, equipped with a tilting, ±45° head, provides for
three dimensional, five axis cutting and ultra high-speed
piercing allowing for complex cutting on most tube profiles.
The LT8 incorporates Active Focus, a technology that
adjusts beam focal position. With Active Focus pierce times
can also be reduced up to 30% and this improves the tilt
cutting speed. The LT8 has up to 12,1 metres loading
capabilities, clean tube technology for processing of stainless
steel, and other features that allow for a comprehensive laser
tube cutting system.
The unit features an automatic loading system
combined
with a unique
unload
operation,
increasing the
productivity of
most
operations.
Complex
operations
such as
nesting
multiple part
numbers on the same bar and changing to different profiles,
are managed automatically.
The LT8 is available in multiple load and unload
configurations including an automatic bundle loader
(capacity 3990 kilograms), automatic step loader and/or a
manual single bar loader. It is ideal for large and/or
thick tubes requiring a high degree of accuracy.
Also standard with the LT8 is Artube, a complete, three
dimensional CAD/CAM software package that provides for
quick programming in simple to complex tube processing
operations.
The LT8 takes full advantage of the BLM Group Enterprise
Software solution that incorporates full management of
lasers, tube benders, end machining, and cold saws to
manage production with real time production feedback.
This optional package incorporated with Artube allows for
seamless programming and production management.
For more information contact First Cut (Pty) Ltd on
TEL: 011 614 1112 or visit www.firstcut.co.za
Bystronic CNC interface designed for press brakes
B
ystronic offers the
ByVision Bending CNC
interface for press
brakes. It features a 22-in.
touchscreen to help simplify
setup and operation.
The operator is guided
through the programming
and manufacturing process.
Bending sequences can be
modified on-the-fly by the
operator, even if the program
was developed offline. The
interface operates within the
Windows® 7 platform. Program data transmissions are
transferred between the interface and the CNC using
high-speed network communications.
For complete process integration, the Bysoft 7 programming
100 METALWORKING NEWS
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May 2015
software offers users
synchronization of press
brake, laser, and waterjet
processes. Bybend, an
integrated Bysoft software
module, provides offline
programming capabilities,
including automatic bend
deductions, bend reliefs,
bending sequences, and
backgauge placements, for
press brake users.
With a 3-D simulation
feature, visualization of the
bending sequences and automatic collision detection are
performed before the part is sent to the operator for processing.
For more information contact First Cut (Pty) Ltd on
TEL: 011 614 1112 or visit www.firstcut.co.za
Hurco expands large machining centre range
H
aving introduced a pair of twin-column, bridge-type,
vertical-spindle machining centres in 2009, Hurco
Europe has now added a third, much larger model, the
DCX42i. The 51 ton machine has a 4.2 metre X-axis travel,
plus 2.6 metres in Y and 1.1 metres in Z, providing a
working volume nearly double that of the next model down,
the DCX32i, and more than four times that of the DCX 22i.
A major advantage of the design over a traditional C-frame
is that a much larger Y-axis travel can be achieved without the
loss of rigidity. It also offers superior thermal stability for
higher accuracy machining and allows heavier table loads, so
large components can be produced to tight tolerances.
A single component of up to 16 tons can be carried on the
table of the DCX 42i. The massive cast-iron structure was
designed using finite element
analysis, ensuring that
there is sufficient weight
and strength to take the
heaviest of cuts.
The 60 kW spindle,
mounted in a vertical
ram of box-construction,
can be supplied with
a maximum speed of
either 6,000 or
10,000 rpm. It is
oil / air cooled and can deliver up to 570 Nm of torque.
The tool magazine has 40 stations for BT50 tool holders
and a swing-arm tool changer that keeps the carousel clear of
swarf and maximises the working envelope.
All DCX machines are fitted with the Hurco WinMax
twin-screen control. Standard features include simple
conversational programming, full industry standard
NC capabilities and a 64 GB hard drive. Ultimotion
high-speed profiling software reduces cycle times by up
to 30 per cent.
The flexibility of the control is a major factor in ensuring
that any job, no matter how complex or simple,
can be programmed in the shortest
possible time with the least effort.
Options include Ultimonitor
web-based networking to
allow remote machine
surveillance and
Extended Shop Floor
for diagnostics.
For further
details contact
Hurco South Africa
on TEL: 011 849
5600 or visit
www.HURCO.com
METALWORKING NEWS
v 14. 2
May 2015
101
ExOne debuts Exerial™ 3D printing system
designed for industrial series production
T
he ExOne Company, a global provider of three-dimensional
printing machines and printed products to industrial
customers will debut its largest 3D printing system,
the Exerial™, at the GIFA International Foundry Trade Fair in
Düsseldorf, Germany, which takes place June 16-20.
The Exerial system demonstrates a considerable evolution
in ExOne’s machine portfolio as the new printer allows
customers to engage with the indirect printing technology for
industrial series production, beyond the rapid prototyping and
small batch production for which the company’s other systems
are currently being used.
“ExOne’s industrial customers are pressing for latter stage
technology to address their production needs with a 3D printing
system that supports higher volumes and automation for the
industrial production environment,” said S. Kent Rockwell,
Chairman and Chief Executive Officer for The ExOne Company.
“The Exerial system, which we see as our flagship for the
coming years, fully meets all of our clients’ demands. When the
Exerial system rolls out this year, ExOne will have addressed the
industrial-level solution, further
separating binder-jetting as a
more cost effective technology
than other 3D printing
solutions.”
The Exerial is unique
compared to ExOne’s other
indirect printing systems in that
it contains multiple industrial
stations that allow for
continuous production and
simultaneous processing. The
Exerial is distinctly equipped
with two job boxes, each
A component manufactured
1.5 times larger than the single
on the new ExOne Exerial™
3D printing system
job box in ExOne’s next largest
The ExOne Exerial™3D printing system
designed for industrial series production will debut at GIFA 2015
model, the S-Max. Notably, the Exerial system offers a total
build platform of 3,168 litres and is expected to be capable of
printing output rates nearly four times faster than the S-Max.
The anticipated Exerial utilises a new re-coater system, bigger
print head and automation controls. As part of the development
of the Exerial, the company has filed five patents related to
machine design elements.
“While our machine R&D focus in 2014 concentrated more
intently on this type of customer base, ExOne continues to
address the growing needs of our rapid prototyping and low
volume production customers with further improvements in our
existing machine portfolio platforms — the S-Max™, S-Print™
and M-Flex™,” Rockwell concludes.
For further details contact Andreas Fischer of
ExOne Europe on TEL: +49 (0) 821 65063 123, email
andreas.fischer@exone.com or visit www.exone.com
New plug-and-play
milling cutters from Walter
M
illed mating faces are almost always a feature
of cast parts. But it is only when the
machining process has succeeded in
conferring perfectly flat faces that they are able to
ensure that, for example, an engine or transmission
can run reliably for years to come. Walter's new
M2025 and M2026 finishing face mills are ideally
suited to this, combining maximum precision with cost
effectiveness.
Machining large quantities of cast parts, such
as for the automotive and utility vehicle industries,
requires tools that meet specific requirements. For
example, high cutting outputs are required to reduce
the machining times when milling the joining faces of
cylinder heads or crankcases and gearbox cases. A
single operation must be sufficient to fulfil the most
102 METALWORKING NEWS
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May 2015
stringent quality standards. Walter AG's
new finishing face mills go that little bit
further. Its easy handling also
noticeably reduces the set-up and
take-down times.
For further details contact
Gerald Green, Walter’s
Application Engineer for
South Africa on
TEL: 071 688 3266, email
gerald.green@walter-tools.com or
visit www.walter-tools.com,
or contact Spectra Carbide Tooling
Technology on TEL: 0860 23 23 23 or
email spectra@spectra-sa.co.za or
visit www.spectra-sa.co.za
Asymmetric boring bar from Kennametal
drives productivity
K
ennametal´s new asymmetric line-boring solution
increases machining robustness, process speeds, and
bore quality, and reduces tool maintenance and
handling.
Precision boring is a vital process in
manufacturing many critical
components. The accuracy and
finish of a multi-journal crank bore
in an engine block relates directly
to power and fuel efficiency, and
the time it takes relates directly to
the engine company’s profits. Precision
bores in numerous engineered components
are essential to critical performance metrics. Such bores must
meet critical tolerances; but the downside is that precision
boring can be costly and time-consuming, with a small
mistake or error resulting in the scrapping of expensive parts.
The response from Kennametal is a geometric and asymmetric
line boring bar solution being termed a revolution in the
process by delighted users.
By definition, boring, as opposed to drilling, is a machining
process in which internal diameters are made in true relation
to the spindle centerline. This process is most commonly
performed with the workpiece held stationary and the cutting
tool both rotating and advancing into the workpiece, although
boring is also done with the cutting tool and the workpiece
being adjustable.
Common applications for boring include
the enlarging or finishing of cored, pierced,
or drilled holes and contoured internal
surfaces. Related operations sometimes
performed simultaneously with boring include
turning, facing, chamfering, grooving, and
threading.
Kennametal has released an asymmetric line boring solution
that is said to accentuate the advantages of reaming and line
boring, while virtually eliminating the disadvantages of both.
The Kennametal solution is set-up similar to a typical guide
pad reamer, but the guide pad, normally located at 180° to the
cutting edge, has been rotated. The resulting design provides
sufficient freedom to enter and exit the guide part.
In short, this geometry means the bar can be fed through
raw bores on an eccentric path. Kennametal says the solution
retains all the advantages of previous line boring products,
such as precision bore creation and support on both ends of
the tool, but requires no expensive lift functions, obstructive
counter-bearings or critical mechanisms inside the tool. The
company also adds that complete feed-in and feed-out moves
can be done at increased feed rates on conventional machining
centres.
For further details contact Kennametal South Africa on
TEL: 011 748 9300 or visit www.kennametal.com
Portable arm-based CMM scanning solution
with MCAx articulated arm and MMDx scanners —
Nikon Metrology
N
ikon Metrology’s MCAx manual coordinate measuring
arm is a precise, reliable and easy-to-use portable
7-axis measuring arm. It is the perfect partner for the
ModelMaker MMDx/MMCx digital handheld laser scanners and
Focus 10 handheld scanning and inspection software. This
total solution’s accuracy, capability and portability make it feel
perfectly at home in the metrology lab, on the shop floor and
in-the-field. The MCAx arm can be equipped with a wide
range of probing systems for laser scanning, touch-trigger
measurements and continuous scanning. The new 7-axis MCAx
range of articulated arms is available with a measurement
volume ranging from two and 4.5 metre diameter.
Already known for its industry-leading data capture of
almost any material (ESP3), the arm and scanner now offer
improved total solution accuracy. It offers compactness in
packaging and an unprecedented seamless transition between
probing and scanning. This high-precision portable scanning
solution reaches better than 50µm of measurement accuracy
while encased in an enhanced ergonomic design. Applications
such as automotive R&D, quality labs and contract inspection
facilities will benefit from a shortened learning curve due to the
ease of use, while delivering measurement data faster and with
greater confidence in the results.
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May 2015
Specifications
for these 7-axis
arms range from
2 to 4.5 metres and
include infinite
rotation of the
principle axes.
Absolute encoders
are standard as is
the locking
counterbalance
feature. Base
options include
bolt-down base
plates or a magnetic
base, WiFi, battery
and probes.
For further
details contact
W.D. Hearn on
TEL: 021
534 5351 or visit
www.wdhearn.co.za