c AN ADI AN WWW.CANADIANMETALWORKING.COM METALWORKING SERVING THE CANADIAN METALWORKING INDUSTRY SINCE 1905 enc Ley Dee ey Aa Exploring the soaring highs Bringing machined pieces Coe ec) tence) EO acer) Cr Bc eet Co) AEROSPACE « DEFENCEMetal? Just ike ourtagline Dan} HURCO’ mind aver metal rograrnnin Motion Technology See how Hurco gets rid of the stuff that gets in between you and making chips. WATCH THE VIDEO HURC® mind over metal’ Scan to watch video ELLIOTT-MATSUURA CANADA INC. © ww a lliottmachinery.com + 905.829.2211The Door Opener yg Machining, Se sae Bee er ‘edge clearance allows higher ramping tiene] Ceo oe rd 1 Secure stable pocket desion wth IRE UAAMMILIL, + Groce pten cuter tor tigh TERRE. productivity with better chip Bee eR PTE eet Bt Reis pte = perience SUS aka Hav Snes GO eee LOTTI Carrey eer eh eel) tee) Solutions See Peon ee Pea ee een ed a Tis} erates en rte eeeCoroCut® QD Reliable parting and grooving When you need to machine deep grooves or part off in long overhangs, CoroCut® QD is the safest choice. All tools have over- and under coolant for best performance and chip control. Add the support from plug and play coolant adaptors and a stable, user-friendly clamping mechanism and you get CoroCut QD —a system to rely on! Teenie 4 rT. " te CetFORM 30 iRTC +GF us The Perfect Applicant. Striking out on finding the skilled machinists you need te further expand your business? It's time to stop limiting yourself to human applicants. The FORM 30, iRTC [Integrated Rotary Tool Changer) packages impeccable Swiss technology with user-friendly automation, all with an excellent price-to-performance ratio. Featuring a fast and efficient 26-position rotary tool changer and some of CeCe Sete ee eee ane See sate atc eae eee Bae ee neem nd Pree c) Seen FOR ET ee Pa rete ce ecranrii DCC oo SRT ene Re ae (Al Lee asa Milling | EDM | Laser Texturing | Automation | Uptime+ Ce nin Kereta}METALWORKING Fae any at ccaiaieldrotngcom FEATURES SOARING HIGHS AND TURBULENT LOWS — 34 Aerospace machining KEEP ON SPINNING — 38 How to care for and maintain long spindle le BUILDING ON THE STRENGTH OF COVER STORY — 28 ITS OWNERS — 44 ‘AEROSPACE AND DEFENCE SECTOR TAKES OFF D&D Precision In. Mississauga, ON ‘The state of the industry in Canada METAL FINISHING: ‘A COMPLEMENTARY PROCESS — 58 Bringing machined pieces to completion THE “IN” METAL FOR MANUFACTURERS — Challenges with cutting Titanium CLEARING THE AIR — 74 Ar quality concerns for welding GAS UP THE LASER — 80 CO: laser systems have a lot to offer aareanadaametatwarn sam FEBRUARY ST?FEBRUARY 2015 = VOL. 110 = NO. 01 ‘www.canadianmetalwarking,com eS FEATURES (CONT.) UNWINDING STEEL COILS — 86 Canadian company sels coll handling machinery to the word METAL STAMPING BUSINESS SEES THE LIGHT — 90 Tripar Inc., Montreal, OG NEW MARKETS, IMPROVED ATTITUDES — 94 Grant Metal Products Ltd, Rocky View, AB FINE DETAILS OF ‘SURFACE ROUGHNESS — 98 To contactor nat to contact DEPARTMENTS VIEW FROM THE FLOOR — 10 teem iS Oe NEWS — 12 We are also pleased to announce the keynote speaker for our Winnipeg BUSINESS MANAGEMENT — 24 Metalworking Manufacturing & Production (MMP) EXPO, Don Boitson, Vice President/General Manager of Magellan Aerospace, Winnipeg. This event TOOL TECH — 49, will take place on April 7, 2015, For more information or hw to register, check out page 14. KEN HURWITZ ON FINANCE — 101 Coming up in March, Canadian Metalworking wil feature the Mold, Tool BY THE NUMBERS — 106 & Die industry, Topics include machining molds, punching machines, along with surface finishing, tool room quality control, and more, For extended coverage of what's happening in Canada’s metalworking Industry visit our website, vwvw.canadianmetalworking.com. Check cout our “Productivity Centre” on the homepage forthe latest articles, case studies, products, and more to help enhance productivity on the shop floor. Ei i FRU Te nana So@mava iyi the sereiierd aL e NiCad continuously innovate keeps us ahead of our competitors.” eee ad Incegrated Metal Products Integrated Metal Products Retains Their Leadership Position by Partnering with Amada. Located in Guelph, Ontario, Canada, ‘Amada’s Networked Solution Provides: + Maximum Productivity (High by ex MLK combines + Maximum Flexibility (The FOMZ provides high peed procesing for a wide variety of material ypes dcknesses. The EMLK provides the abityt top nd cut on th ine) est hit rates with Cee ea + Accuracy and Reliability (The EMIK's highspeed roten sytem eto .0003° ensuring aca cee ees tate parts everytime. For mere than 10 years, the FO series hs a proven reputation for unparalled accuracy Amada Canada, Led. cand reliably. As the lotest generation, the FOM2 cont. 1 new standards for precision and perfermanc). Certo Corer iter ee ty IMP’ Gener Manages, Brian Hein sao impressed by Eersar rs) Amode’s serie and suport. Hains states, "Our Amada service Pees engineer gave us his direct contac information and an one oc: na ey came nat 10pm an a Seturdy night to ensure aur Wee jase, : eet cine citing trough the night's great to werk with «company that's committed to our succes." SELLYVIEW FROM THE FLOOR 110 YEARS AND GOING STRONG History is a great teacher. it's enriching to look back and reflect on progress we've made and how history often repeats, Please feel free to share your insights with me at the email address below. he beginning of 2015 has hit Canada like punch in the stomach. First our oil patch is reeling from sub-$50 a barrel prices, Ieading major players to begin slashing their capital expenditure budgets for the year ahead. I's at the point where Alberta is ‘actually considering a sales tax, and the Feds are delaying their budget to adjust for the oil revenue well running dry. And as a result our Loonie has tumbled compared with the U.S. greenback. And then Target gives up on Canada, leaving without hardly getting to know us. Creating a lot of vacant retail space and workers out of a job Yet, there are the positive effects of low oil prices. Drivers are happy at the pumps, and this comes after a record year for auto sales in this country with a forecast for even more cars in 2015. And for manufacturers who ‘export, our low dollar once again provides a competitive advantage. ‘This year marks the 110th year this pub. lication has been chronicling the ups and downs of this nation and this industry, and when we look back, i’s interesting to see how far we've come. In 1905, this publication's launch year, Ford. introduced its first luxury ear, the Model F, a larger, more modern four-seater with running boards. Priced at $2,000, produc. ion started in 1905 and ended in 1906 after about 1,000 were made. METALWORKING It was in 1906 that Albert Einstein intro duced his theory of relativity, which likely had no newsworthiness then, but has served fas a foundation for modern astrophysics. ‘And the world of aerospace, our cover story topic this issue, made a giant leap forward in 1905 when the Wright brothers launched their Flyer III with an upgraded engine and slightly larger cylinders, After crashing its first flight, the brothers made some radical changes to the design that influenced all future aircraft. And a flight, later that year covered 38 kilometers and lasted almost 40 minutes, until the plane's three-gallon gas tank ran out, Days later the brothers wrote to the U.S. Secretary of War, offering to sell the world’s first practical airplane. ‘And closer to home, in 1905 both Alberta and Saskatchewan (my home province) Joined confederation becoming the ath and 9th Canadian provinces. Through the good and bad, our energy and resources sector wouldn't be the same without them, ‘So while no one can predict what else 2015, will bring, we can promise that our nation and this industry will experience more ups and downs, and we'll be here to share the news with all of you. DOUG PICKLYK, EDITOR ‘ipickiyk@canadianmetalworking.com ‘2 sts-siemprtocaasameamne cn ITEPUBLISHER 08 4 ‘e522 el 725045 = anne ting "2 84 rode esog som {estate decanting ASSocATE/WEB TOR LNBs LOS "2 84 «mere cm Anrowecron stems TOMS ‘Ne-uasioo crs snamwobnsin ck ‘eez sundaes nunca ca ‘astasis- boutahtiptepct 8442786 putewunce Pee ages ‘nf ace ss omg Sato Dre ON 820 Prom soet2S600¢Fe SDS eth pes 9 me pyr ogee on ae Bs gy Lt umscnprinn nares ad 55.09, ew Cen 5900005 er ge Cory Canta $0. RETURN DELIVERABLE TO CLAN OPAATHENT ‘Otateyous bv Ts uO gree Ps ara. Te ce of e peton ‘yeti ss ny eve we. ‘ule awa arse mi ew ost {rte cmon hay aroun pee ad Inara aarp mt ort Cos a2 eas atone or 6 Feng Compr a terns em Cues bee ‘ees porn ebm ‘kien aes ah ep ap esa aay cams aay eaorsevcteites aese ‘SELAME hs aaroposs co Thabane pet once prin ae tio “eterno grr an ov ‘olan fomsion cards estar ho ey Smrcseurcckin gaits egress PRAY NOTE at tee ke arp et lave sen compe snr eae ce emai Pom 1200668294 F na fresno at ya ees oe, ae M8252 case Pate agen n6240 ‘nexus Dn trac gta ne doen lca Pot ‘eCauaPeical etter Cow Canadit Miss. © a ROOTS Ter naan aDynamics at their peak The economical way to mill grooves. Our earbide circular milling tools are used for groove milling, seating, and optimized geometries and grades ensure controlled chip evacuation, reliable processing and low manufacturing costs. www.hornusa.com worn exceisence w recnnoroer (fli HORN fill) GROOVING PARTING OFF GROOVE MILLING SROACHING PROFILE MILLING REAMINGIN THE NEWS CANADIAN AUTO SALES TO GAIN ‘Auto sales in Ganada saw record breaking numbers in 2014 and this pace is expected to continue through the next year, According to sales data compiled by DesRosiers Automotive Consultants, automakers sold a total of 1,851,373 new vehicles in Canada last year, up from just more than 1.7 million in 2013, Scotiabank analyst Carlos Gomes in Scotiabank’s Global Auto Report (Jan 2015) predicts that North America and Asia will lead the global gains. In the next couple of years, China is expected to be the driving force behind global auto sales growth Demand is forecasted to grow by seven per cent, totaling 19.5 million vehicles sold. “Purchases will be buoyed by strengthening labour markets, ongo- ing low short- and long-term in! rates and monetary expansion, as the ‘Bank of Japan and the ECB take over from the Federal Reserve and the Bank of England as the main liquid. ity providers. Sales will also get a boost from rising household purchas- ing power due to the sharp decline in oil prices,” according to Gomes. “Looking ahead to 2015...there is still room for further improvement in the U.S. while Canadian sales are likely to fi remain elevated,” says Nathan Janzen in a RBG report Ganada and US. Auto Sales, October 2014 Canada is expected to sell more than 1.86 million vehicles, with global sales totaling approximately 74 million in 2015. American sales figures totaled 16.4 million vel last year with an expected 17 million to be sold in 2015. This would mark the highest level seen since 2001 According to the Scotiabank report, over the coming year, combined vehi cle sales and production in Canada, Mexico and the United States are icles expected to surpass the 2000 peak. Sales totalled 19.8 million units and assemblies topped 17.6 million. Mexico and Canada will henefit from astrengthened U.S. demand, driving exports, especially seeing that “nearly 40 per cent of the vehicles on the road in the U.S. are now at least 12 years old, setting the stage for an extended replacement cycle,” says Gomes ‘There are several indicators of a record year. These trends are fueled by one of the strongest economic growths in the last decade, This is marked by employment growth; the level of employment returned to pre-recession levels in January 2011 “The strengthening in employ. MOMENTUM IN 2015 te eee ment growth is a key component of the forecast that Canadian motor vehicle sales will, on balance, post a record sales gain in 2014 with min imal moderation expected in 2015,” explains Janzen Affordability is also a key determi- nant for strong growth in the coming year. With the replacement cycle in place and unemployment down, more people are able to afford anew vehicle, and with available for purchase, consumers are forced to buy new. Approximately 14 automakers posted new sales records in 2014, Ford Motor Company of Canada Ld. posted its best year since 1997, making it the top-selling auto maker in Canada; Chrysler sold 290,004 cars and trucks for the year, up 12 per cent; General Motors of Canada was third among the North American automakers as its sales for 2014 totaled 249,800 vehicles. 2015 is shaping up to be a very suc cessful year for automakers, Overall, the Canadian auto industry is prov ing its strength through vehicle sales and production capabilities. If the next year is anything like the pre- vious, Canadian automakers should expect great things, fer used vehicles ERRORS ‘er nadernet aBringing the Best Machine Tools to North America GROB www.grobgroup.com na UNIVERSAL 5 AXIS MILLING MACHINES PIBTRO( ctl @G@Re | GURUTZPE | © LANBI Pe eniamenens =a Gantries and Gylindrical, Surface, Rotary, : Heavy Duty Special-Purpose Vertical Baring Mils and Vertical Grinders Mil, rg Wace CNC Lathes Machines ——— ti : _ Fifa My a al ally ' ‘wget com ‘ww. pevocamagh cam ‘wun guupe com vw anbcom eg a cee aN eRe) om DiPAOLO SNe eer meee tee Cera Pa Ce ea Ren p> tH CRY wre iscoIN THE NEWS AEROSPACE EXPERT TO KEYNOTE WINNIPEG EXPO Canadian Metalworking magazine has always had great success with its Metalworking Manufacturing and Production (MMP) Expo. And we are expecting that this year will be no different. After positive feedback, the MMP Expo will return to Vancouver for the third time on May 5. After much consideration, the MMP Expo will bbe heading to Winnipeg in order to show continued support to the Western Canadian market. (On April 7, we will be hosting a one-day tabletop show at the Victoria Inn Hotel & Convention Centre in Winnipeg. The show will bbe open from 10 a.m. to 4 p.m and attendees will have access to the latest in machine tools, cutting tools, fabricating and welding technol ogies, production software, and metrology. And it’s completely free! Don't miss out on the chance to hear a keynote address from leading aerospace professional, Don Boitson. “We are extremely excited to have Don Boitson on hoard as our keynote speaker this year” Explains Rob Swan, ‘Associate Publisher of Canadian ‘Metalworking magazine. “This is the first year we will be bringing aur expo to Winnipeg, and with a strong focus ‘on Aerospace, Don will provide a very relevant and engaging presentation, ‘on the industry in Manitoba. We look forward to bringing our event to Winnipeg on April 70" The Winnipeg MMP Expo will offer guests a chance to hear Boitson, the vice president and general manager for Magellan Aerospace, Winnipeg, speak to the needs of the industry. Magellan Aerospace is a global enterprise that provides complex assemblies and pro- prictary products to commercial and defence aerospace markets worldwide. Boitson, with more than 25 years in aerospace manufacturing, will pro- vide a market overview of the aero. space industry and the local Manitoba aerospace manufacturing capabilities Highlighting manufacturing and technology trends that are impacting the industzy, aerospace is seeing an unprecedented acceleration in the speed to market for new products. Hear about how Magellan is adopting new processes and technologies in this dynamic and booming marketplace, ‘The MMP Expo offers regional bu ing influencers from manufacturers, Job shops, maintenance, tool rooms, ‘automotive, aerospace, energy and resources, medical manufacturing, transportation and tool-die mold making, So, no matter what industry you are in, the MMP Expo will have what you are looking for. ‘This year's event will be co-located with Canadian Metalworking’s sister publication, Design Engineering ‘The Winnipeg MMEP Expo is spon- sored by Sandvik Coromant, Mazale Canada, Elliott Matsuura Canada, ‘TRUMP, and Renishaw. For more information about the Winnipeg show or our upcoming events, visit wwwanmpshow.com, GULLCO Peer Pe Poros TERRORS ‘er nadernet aWITH SO MUCH MORE SPEED, POWER AND FLEXIBILITY. THERE'S JUST NO LIMIT TO YOUR ABILITY TO MAKE WHAT MATTERS. The Makino PS-S additional capabilities you simply won't find on your current VMCs. Like spindle speed, power and ‘torque to handle aggressive cuts waka cones QO WHEN YOU MAKE WHAT MATTERS MAKINOIN THE NEWS PRATT & WHITNEY CANADA INVESTING IN R&D Pratt & Whitney Canada [P&WC) is | in Alberta, Ontario, Quebec and Nova investing over $1 billion in research Scotia,” explains John Saabas, pre and development (R&D) at both its dent, Pratt & Whitney Canada. Longueuil (Quebec) and Mississauga | PSC is developing the advanced (Ontario) facilities. Over the next 4.5 propulsion technologies, which years, the money will go to develop-__ will be leveraged across the compa ing the next generation of high-per- | ny's product families for new and formance aircraft engines. existing turbofan, turboprop and ‘The federal government has also | turboshaft engines in business, agreed to contribute a repayable sum | regional and general aviation and of $300 million. “This investment will support helicopter applications. “Our latest RED programs include nearly 1,500 high-paying Canadian _ cutting-edge materials such as jobs and countless others across Canada,” says James Moore, Industzy Minister. the Government of Canada’s investment enables PEWC to composites and advanced alloys to improve engine weight, a high-ef ficiency compressor technology to _| technologies and upgrades to its enhance engine performance and _| facilities. reduce fuel consumption, and further | Pratt & Whitney Canada was estab: invest over $1 billion to pursue its improvements to our combustion lished in Canada more than 85 years long-standing legacy of innovation _systems to reduce engine emissions,” | ago. PSWC has a long-standing his- and sustain its engineering and explains Saabas, tory working with major universities manufacturing centres of excellence | P6WG is currently investing $275 | and suppliers across Canada. million over PSWC employs 6,000 people across 800-421-8065 een peter) structural components up to 30 feet in length. wvieet00.com five years in | the country and has invested more Tem annul cutting-edge | than $10.6 billion in RED since 1982 ICRO 100 EEE KOSS AEROSPACE AWARDED $5 MILLION IN FUNDING Koss Aerospace has been awarded nearly $5 million in federal funding, The Government of Canada’s repayable contribution is through FedDev Ontario's Investing in Business Growth and Productivity initiative. “Our Government is proud to support companies such as Koss Aerospace, who help create highly skilled jobs and strengthen the Canad space manufacturing sector.” said the Honourable Gary Goodyear, Minister of FedDev Ontario. ‘The Mississauga-based company says the money ‘will go towards purchasing new machinery or equipment that will help strengthen its aerospace production capabilities, The new equipment at Koss Acrospa e will enable the company to manufacture ‘Koss anticipates creating 25 new full-time highly skilled positions. 208-888-7310 RUS ‘er nadernet aHEAVY DUTY MACHINING MP-2620 (U) Gee TUM CEC * X-axis travel (table longitudinal direction) PW + Y-axis travel (spindle head crosswise direction) 3,400 mm. Sr NCU eR cto 800 mm ORCC Ee) 1,000 mm Deer Maco) +360 Caen ECs PAD Orne nC 10,000 kg * Spindle speed 40~10,000 min SST Ce Lean TUE Series at S200} TUE-150 Bee Pn ee Ses Pe Px Sa es ce 1,550 mm Sead 15,000 kg Exes See eC On Bey een Pare ae ae ea ea TOSHIBA Nee TOSHIBA MACHINE COMPANY CANADA LTD. Te eee UMC eS aC eye vee Meee EEL) Cees eae ere SSC ne ee a)IN THE NEWS ALCOA UNVEILS BREAKTHROUGH MANUFACTURING TECHNOLOGY Aleoa’s focus has been on light- ‘weight metals technology, engineer- ing and manufacturing, And it has been successful. The company has announced a new manufacturing technology that they are calling a breakthrough when it comes to manufacturing advanced aluminum sheets. The technology is called the ‘Alcoa Micromill, ‘The company is hoping that this technology will help them eapitalize ‘on the growing demand for next gener- ation automotive aluminum products. What does the Micromill technology involve? The process dramatically changes the microstructure of the metal, This allows the aluminum alloy to have 40 per cent greater formability and 30 per cent greater MULTICYL POWER TO PUNCH WITH b ‘The best press alternative on the market for unitized tools and small die sets. MULTICYL INC {640 Hardie oa, Unit 1, Bote, ON, Canada L7E SR Tel: 905-951-0670 US. Tol Free 1-900-188-6959 - Fax: 905-951-0672 unchemutiey.com ley om strength than current aluminum used today. The automotive applications for this new process are great as it ‘meets the stringent automotive sur face quality requirements, ‘What is more, automotive parts made with Micromill material will be twice as formable and at least 30 percent lighter than parts made from high strength steel. The Micromill alloy has formability characteristics comparable to mild steels, “Alcoa Micromill represents a major breakthrough in aluminum materi- als," said Alcoa Chairman and Chief Executive Officer Klaus Kleinfeld, “This technology will unlock the rnoxt generation of automotive prod- ucts with strength, formability and surface quality combinations never before possible. Iwill allow to redefine the boundaries of vehicle design, supporting, the creation of Lighter, more fuel efficient, safer and more stylish vehicles for the future. The break through tech- nology allows for aluminum sheets to be shaped into intricate forms easily. One of the applications for this process would be in the use of inside panels of automobile doors and external fenders. The aluminum offers improved dent resistance. ‘Traditionally these parts would have been made with steel. However, using this process will allow for automakers to benefit from reduced system cost by streamlining the number of aluminum alloys used in their manufacturing process ‘The Micromill will also be extremely fast and highly productive ‘when it comes to aluminum cast. ing and rolling systems. A tradi- tional rolling mill takes around 20 days to turn molten metal into coil, ‘Micromill does it in just 20 minutes, eee aR ‘er nadernet aHigher volumes, shorter production periods and an ever-growing pressure to keep costs low. In today’s aerospace industry, suppliers are encountering ever-increasing demands, Fortunately, with Walter Valente, Walter Titex and Walter Prototyp, a solution's at hand. As professional high-tech tools and operating solutions developed by competence leaders, they yield valuable results throughout the complete machining process. From an increase in productivity of up to 100%, highest machining reliability and extremely long service lives to an innovative chipping process, minimal component costs and a broad range of applications - tailored to the specific needs of your business, of caurse. Ths Is haw we define efficiency ~ fully integrated into our client's processes. me ore Ceara ee towtd Pore EScatey peso eee Denn ec meer —|wacrer —|weurer Seen eee ma Tet) every aera tenaIN THE NEWS CHRYSLER PLANS $2 BILLION UPGRADE IN WINDSOR Chrysler is investing $2 billion in its Windsor minivan plant, The auto maker is committed to growing its Ontario operations and was welcomed by the union and the auto industry. “with this announcement, Chrysler is recognizing that the plant where it launched the minivan is the ideal place to bring the vehicle into the modern era,” says Jerry Dias, Unifor national president, Fiat Chrysler CEO Sergio Marchionne ‘made the announcement at the Detroit Auto Show, noting a hybrid minivan will be built at the plant, Dias said the announcement will have ripple effects throughout the economy, citing studies that have shown that every job in a major auto plant creates nine others throughout the economy, in auto parts manufac turing and other industries. With this massive retooling project ‘comes the need for skilled tradespeo. ple, It is estimated that there will be hundreds of electrician jobs opening. The provincial and federal gov. ‘ernments will need to work with labour and industry to develop an auto strategy so Canada can build on the spate of recent investment announcements. MAGELLAN AEROSPACE SIGNS $250M AGREEMENT ‘Magellan Aerospace has signed a 10-year agreement with Pratt & ‘Whitney Canada (P&WC), Magellan will supply complex magnesium and aluminum castings for P&WC. This agreement is expected to bring over, The QLC family of chucks is an enviable combination 0! proven mechanisms, innovative design, highest quality materials and advanced manufacturing techniques. Their lighter weight, high clamping force and long, reliable service life makes them perfect for practically all turning applications. 800-544-9823 salos@forkardtus $250 million in revenue for Magellan through 2023, ‘The castings will he produced pri marily by Magellan's Haley, Ontario division. For the past 60 years, PEW has been a customer of Magellan Aerospace, ‘This new long-term agreement pro- vides the framework for a new level of strategic alignment with PW. “This 10-year agreement demon. strates PEWC's confidence in Magellan's ability to produce some of the most complex sand cast geom etwies in the industry. Magellan has invested in innovative new technol- ogies such as robotics and 3D sand printing to meet its commitment to achieve the highest standard of product and performance,” explains Phillip Underwood, Magellan's presi- dent and chief executive officer. In addition to the legacy casting programs for P6WC's current engine platforms, the agreement includes the production of castings for Pratt & Whitney's PurePower engine fam- ily which encompasses the Airbus A320ne0, Mitsubishi Regional Jet, and Bombardier CSeries programs. In addition to PEWC and P&W engines, Magellan castings are used on civil and defence, fixed-wing and rotorcraft programs across the globe, TFEERURV OTS ‘er nadernet aDISCOVER WITH MAZAK Visit your nearby Mazak Technology Center or mazakusa.com to learn more. MAZAK CORPORATION | 8025 Production Drive | Florence, KY #1042 | (859) 342-1700 | mazakusa.com Mazak Coad Tectrlogy Cente Machin Tawar, ne. AW. iar 0 Cormece Cou 803 ath rene al Pita Cambrdge, taro NC 4P7 dmortn, bra TR 25, ‘Laue, dba HS 172 aon e6e-sui9 00 426.2062 jd) 02.8178IN THE NEWS SME NAMES KRAUSE AS NEW CEO Congratulations to Jeffrey M. Krause, who was appointed as executive director and chief exec. utive officer by the SME board of directors. Krause officially took his new position on December 15, 2014. “We are thrilled to announce that Jeff will be joining SME to lead the business and drive the organiza tion's mission to inspire, prepare and support our stakeholders in the advancement of manufacturing, said SME's interim CEO and 2015 president Wayne F. Frost. "Krause’s strong background positions him to support SME in its goals of advanc ing manufacturing and attracting future generations.” LINAMAR GETS FUNDING TO HELP CREATE JOBS ‘The federal and Ontario provin cial governments have partnered to provide the auto industry with just over $100 million, greatly benefiting Ontario-hased Linamar Corp. ‘The Minister of ‘Transport, Lisa Raitt, announced the federal gov- ernment's plan to invest $50.7 million, while Ontario Premier Kathleen Wynn promised support in the way of $60.25 million to Linamar, “Canada is a great place to build cars. Canada has much to offer automakers and parts mamufac- turers: our Automotive Innovation Fund, the new Windsor-Detroit bridge, support for automotive R&D, a stable economy, a low corporate income tax rate, a highly skilled and productive workforce, well-devel oped infrastructure and access to markets," says Raitt ‘The money will go towards produe- ing the next generation of automotive transmissions. The investment is expected to result in the ereation of 1,200 new high-quality jobs and the company will maintain a minimum of 6,870 jobs at its Ontario facilities “Linamar is a true Ontario success story. By partnering with companies ike Linamar, we are positioning the province for growth now, and for years to come,” explains Wynne. Linamar Corporation is one of Canada’s largest manufacturers of automobile parts. Based in Guelph, ON, the company focuses on preci- sion metallic components and drive line systems designed for passenger vehicles “We are thrilled with the support shown by both the Ontario and federal governments through this investment in our Ontario plants,’ says Linda Hasenfratz, chief execu tive officer of Linamar Corporation, “Our Canadian plants are our company's most productive glob- ally thanks to a talented, skilled workforce with an amazing work ethic and a dedication to process and product innovation,” she says, adding “that combination of innova tion and efficiency is what makes us competitive on a global scale. Ivis critical for our governments to create a competitive environment for companies to invest. They certainly have done so today with this funding.” Linamar’s own investment in the Ontario automotive industry totals $507 million, APMA PARTNERS The Automotive Parts Manufacturers’ Association (APMA) and Canadian Association of Mold Makers (CAM) have joined forces, so to speak. ‘The organizations entered a collab- orative relationship as of January 1, 2018. They will share in common industry initiatives such as advo. cacy, events and trade missions. “APMA welcomes the opportunity to work with CAMM and its members fas we seek to strengthen the voice of the automotive supplier representa- tion in industry,” says Flavio Volpe, president of the APMA. ‘ach organization will continue to operate independently and maintain its own membership roster. This collaborative relationship will allow members from each organization to have access to membership henefits in the other association and vice versa, "This collaborative working rela- tionship will help to strengthen our industry both locally and globally,” says Diane Deslippe, executive director of CAMM. Seen annoy FERRO OOS ‘er nadernet aVOLUME FLUID SORAP LOAD: ALLIN-ONE, REDUCTION RECYCLING TRANSFER our Js a com | 1.800.968.7722 ‘See how to increase your scrap value: prab.com/modlularchipsystems siMGhobol nv)BUSINESS MANAGEMENT PLANNING TIPS FOR SMALL SHOPS BY ALMA JOHNS Arcs ssaioyeoeiie eo geier your buses? Rosomthing weber all Hard and while MEIER EEE ss lee ASFA LEDS G A APLEG STASI Tescebis wie abit ncn pS cio LOSE ORGGLES cording to seen BDC/Milen stro coi on 119 eal ed reise eevee a tcroos Cana, over OW of ae most Peat Nels el sk a Si ioe aKa id hed a ondnap for growth” Most Aa MERA IE eA Neo ost om otal een groth and poe Sul Sees Corks Foe RA Saeeearaee ue LEGIEE EEL ETEU ELE, oe ag vrs tng Aiea asso Ciel sees ‘Some owners think that because their business is small, there are ‘minimal variations in the day-to-day processes, they have been servicing the same customers fora number of years, and the only things they need tobe great at are fulfilling orders, timely collection of receivables and acquiring more customers. ‘When owners are asked what they ‘want for their business, they almost unanimously agree; they want to grow their business. But without an adequate strategic plan and a road ‘map, growth for small businesses becomes increasingly challenging due to external forces including the introduction of new environmental regulations, arrival of disruptive technologies, and low cost global producers breaking into the market. ‘The bottom line is you can't get to where you want to be without know- ing how to get there. The following steps will help in creating a simple but workable plan- ning process for amature business, Analyze the current state of the company, including annual sales and ‘estimated mazket share and whether these variables are growing or sinle ing. Also examine production capac ity and whether operating processes and methodologies are up to date by industry standards, Find out what ‘makes your products and services superior or inferior compared to competitors. Finally, look at industry trends and anticipated challenges over a short term and long term horizon. One simple and commonly used method of assessing the cur- rent state of a company is a SWOT Analysis (Strengths, Weaknesses, Opportunities and Threats}. Determine your goals and objectives aver the next 12 months to five years. Should the company expand over- seas, acquire a competitor, or grow organically? What level of revenue and cumulative growth rate do the ‘management want to achieve? What will the balance sheet look like? In conjunction, create financial projec tions based on these specific goals and assumptions. ‘Take an inventory of the financial and non-financial resources the company currently has and what additional resources are needed to achieve these goals and objectives aTFEERORY OTS ‘er naan aSol ea ey dade a Se TRUST BLUE Restrictions in some channels of the aircraft industry, among others, require silicon carbide rather ‘than aluminum oxide or ceramic fibre discs. Now, COMBICLICK®, PFERD’s innovative quick-change fibre disc system, is expanded to include silicon carbide discs. econ MU ome Mina ce mR Rina Kec ted Achieve Longer service life, faster removal, cooler grinding and faster disc change-ups If your job calls for silicon carbide, contact PFERD today or call your local PFERD distributor to learn more about COMBICLICK® silicon PFERD eee ema Rass ON ee aN Co your productivity! eae oe lear eer a ieee? www.pferd.com Seems Cree)BUSINESS MANAGEMENT Decide on how to achieve the plan and most importantly how to exe. cute, Without putting the plan in writing, communicating it to mid- cle managers and employees and persuading them to take action it can become very challenging and lead to a failed execution. Identify activities and courses of action that the company needs to ‘embark on to accomplish these objec- tives. These may involve building a stronger management team, invest- ments in new products and R&D, or securing additional financing to support the planned revenue growth. “Complexity is the enemy of execu. tion” is one of my favourite business ‘quotes, This notion holds true for any size of business, even more so for smaller husinesses. Therefore, tis absolutely essential to create a plan that is simple and actionable, espe cially for companies that have not previously gone through this exercise. ‘Aplan with few variables provides otter clarity and has more impact, providing each stakeholder the ability to focus and execute seamlessly. Establish key performance indicators (KPI) to quantifiably ‘measure the company's perfor- ‘mance against specific activities that management has identified or against key success factors in the industry. For manufacturing compa- nies, common KPIs include capac- ity utilization and manufacturing cost as percentage of revenue. My personal point of view is to identify ‘one or two KPIs across the compa. y's value chain that are crucial to achieving the company's objectives: Perhaps limit it to a total of six actionable KPIs, Tt is often realistic to stick to six KPIs that the com- pany can excel at than to 12 which could lead to a mediocre perfor- @FILTERMIST Number One Choice For Ot Mist Removal Compact | Quiet | Efficient Filtermist units efficiently remave oil & coolant mist, fume and steam in thousands of manufacturing operations around the world. ‘Post hau lms tom Being inhale 1 Rete sextet ks om spay sues Mina fe hazard caused by enrazed systems Mt ent ebod to colt a mit Desig niet wth he ides possible range of machine ol + bompct constr mines se &welgh ‘AMT Machine Tote La. 73Gaeny ete Une 11,17, extn, Ont MBWSTA COC) mance. Further to this, over-anal. ysis of the current situation and future direction of the company can become counterproductive, In my nearly two decades of bank ing experience, I've seen businesses, that after several years of treading ‘water, one day became extremely successful. They come asking for a significantly larger credit facility. When asked about the drastic surge in purchase orders and projected revenues, [often hear, “we hired a marketing consultant” or an advi sor, who helped them realize what, they've heen doing wrong, With the abundance of "b demands pulling managers in many different directions, the task of busi- ness planning can he overwhelming, In such scenarios, I strongly recom. ‘mend that managers consider engag.- ing an external consultant to achieve short term goals and an Advisory Board for long term goals. Both will have entirely distinet views and will halp objectively create a roadmap for the company. That way, managers can keep their eye on the ball and. focus on what they're really great at while competent advisors facilitate the execution of their plan. Review performance and accom- flishinintsagutnet the plain x ain ‘on-going, hasis and do not hesitate to pivot if necessary, For most shop doin, Chere toy mat be ere, solution to all challenges or aflaw- less strategy for every single initia. tive, but the most affective eption ta often at their disposal Some businesses with very long ‘hlarind sometfine fil boomtia they failed to change with the times. With myriad of changes impacting husi- nesses today, complacency and status «quo are no longer effective. Alma Johns is President of Bench Capital Advisory Inc., an indepen- dent corporate finance and debt advisory firm based in Toronto. ‘She can be reached at alma.johms@benchcapital.ca or wwwbencheapital.ca. TFEERURY OOS ‘er naan aith a large, ite count for elped an aerospace company over 27 days of production while the cost per part by nearly Se eer eee oe ee Cee ror est emer ey ee ee ec ee et www.sgstool.com Pane 330-686-5700 Manufactured in the USA™ AEROSPACE AND BY NATE HENDLEY 1's been a busy year for the Aerospace Industries Association of Canada (ATAC), ‘the Ottawa-based trade association for over 700 acrospace firms, In 2014, AIAC held Week, two "Day on the Hill” events hosting ‘meetings between aerospace reps, ‘MPs and senators. The Association also hosted its annual Canadian Aerospace Summit in Ottawa from ‘November 18-19. “We had 1,200 delegates, 100 exhibitors and somewhere hetween 400-500 B2B ‘meetings. We had a ros- ter of 85 speakers, all high-level people who are thought leaders in the aerospace, defence and space industries around the world,” says AIAC president/GEO Jim Quick, of the Summit. ‘The Summit theme was “One World: Delivering Results in a Global Market” Underlying this theme wa: of buoyant optimism, “On the aviation side,..the next 20 years look very, very good,” says Quick. Indeed, Global Market Forecast 2014-2033, a report from French aerospace manufac- uring giant Aizbus, predicts there will be global demand for 31,858 new planes through to 2033, with a market value of $4.6 twillion, The Asia-Pacific region will lead in demand, states Airbus, Ba FEERURY OOSDEFENCE SECTORS HIGH followed by Europe, then North America, Airbus itself says i's taken 1,080 gross plane orders in 2014 (up to October 31), an increase from 2012 when it took 914 gross orders. ‘Rival manufacturer Boeing, headquar- tered in Chicago, has a forecast that’s even rosier. The company predicts a global need for 36,770 new planes from 2014 through to 2033, for a total market value of $5.2 trillion. For its part, Boeing reports gro: 1,242 planes through to November 11, 2014, down from the previous year when 1,531 gross orders came in, Canada’s aerospace industry—from OEMs and manufacturers to tier-level suppliers — stands to benefit enormously from global aircraft demand orders for Of course, any windfall must be balanced against government fumbles, particularly the Joint Strike Fighter USF) program and Maritime Helicopter Project (MHP). Both of these initiatives have heen plagued with production delays and cost overruns, On the more positive side of the ledger, Ovtawa recently launched a new initiative to fund ‘aerospace RED. Canada currently has the fifth largest aerospace industry in the world, The aero- space sector contributes nearly $28 billion to the Canadian economy in terms of GDP and employs some 172,000 people. The related space industry generates $3.4 billion in annual GDP and employs #,000 people, Manufacturing accounts for 70 per cent of the aerospace sector ‘with MRO (maintenance, repair, overhaul) accounting for the remaining 20 per cent ‘The recovering U.S. economy and rela tively weak Canadian dollar both benefit the national industry. American firms are buy- ing more planes and products, and Canadian companies that supply these firms earn an automatic bonus when paid in U.S. funds. ‘The aerospace industry is more evenly spread out than one may think, While Ontario and Quebec dominate aerospace manufacturing—nearly 80 per cent of man- lufacturing activity takes place in these two provinces—the west boasts a very strong, ‘MRO presence. Western Canada accounted for 41 per cent of GDP in MRO in 2013 wl Ontario had a 29 per cent share, According to ALAC projections, 65 per cent of Canadian aerospace manufacturing in 2014 will consist of making business jets. Regional aircraft will account for 23 per cent of manufacturing, rotoreraft will account for n Maen 2008 2009 2010 2011 2012 2013 [AEROSPACE MANUFACTURING 100% 111% 123% 18195 139% 137% TOTAL MANUFACTURING 100% 101% 94% 95% 8% 05% ‘Dinners Rey nana Canada Rerun Agen CE mr eel obertons 234 ‘arcanadaamcatwaring sam FEBRUARY 2075 25nine per cent with general aviation account- ing for three per cent. Needless to say, the federal government is determined to keep the aerospace sector hoalthy and wealthy. To this end, Otawa Inunched an Aerospace Review in February 2012 to determine challenges and oppor. tunities facing the sector and policies to address these issu The Review was led by David Emerson, a former Liberal turned Conservative MP who served as Minister of Industry, among other cabinet positions. Emerson submitted his final report to Christian Paradis, Minister of Industry, on November 29, 2012 ‘ne particularly note-worthy paragraph in the Aerospace Review report {also called “The Emerson Report") touches upon the impact of environmentalism, climate change and security concerns: “The market for fuel-efficient air- craft that address environmental and commercial concerns is strong. As the north opens to more transportation and resource extraction, there is a need for aircraft that can fly long distances in harsh and frigid conditions to help locate and develop natural resources, support environ mental stewardship, supply communities and facilities far removed from southern popula- tion centres, and respond to emergencies. And, 4s security concerns shift to non-conventional threats, there is demand for airborne technol- ogy that can provide ever more sophisticated surveillance and the capability to strike with surgical precision,” reads the report. ‘The goal of fuel efficiency and tighter pollution controls are driving the current trend towards "lightweighting” aircraft, says Jayson Myers, president and CEO of Canadian Manufacturers & Exporters (CME), which has its national office in Ottawa. “The use of lightweight materials—reg- ulatory requirements in terms of em: sion reduction are going to be key here. Performance, lightweight composites, better ‘and more efficient propulsion or energy systems, all of that is going to be very important,” states Myers. ‘Montreal-based Bombardier, which is Canada’s biggest aerospace company (and the third largest commercial aircraft manufac- turer in the world), is addressing the issue of fuel-efficiency with its ¢ Series of planes. ‘The much-hyped C Series, first announced a decade ago, consists of 100- to 149-seat, single aisle jetliners. Through the use of new technology and new materials (including composites), the G Series is designed to burn 20 per cent less fuel than similar planes, boasts Bombardier. Impressive as the jet may be, the C Series has suffered continuous production delays, Bombardier says the C Series won't enter into service until the second half of 2016 at the earliest. In spite of these delays, Bombardier has orders and commitments for 563 C Series planes. In September 2014, for example, Bombardier announced a purchase agree. ment with Macquarie AirFinance of Australia, pledging to purchase some 40 €8300 jets with an option for 10 more, with delivery scheduled between 2017 and 2019 While off shoring has been a major fac- tor in automotive manufacturing for years, it’s been far less common in the aerospace sector. Aerospace ORMs want their suppliers nearby so any mechanical problems with parts or services can be addressed quickly. Then, there's the reliability issue: airplanes have to function perfectly. Once in the air, pilots can't pull over to the side of the road if something goes wrong. When accidents occur, no airline wants to be in the position of having to explain why they chose a low- cost, low-skill, overseas supplier to make a vital component over a pricier, but more competent, domestic supplier “Companies that are just competing on cost in aerospace are probably not going to sur- vive for long,” notes Myers. Avoiding aerospace policy disasters is another matter, and the likely motivation behind Ottawa's decision to introduce a new Defence Procurement Strategy. Launched February 2014, the Strategy is designed to streamline govern- ment purchases of military equipment, At the time of the announcement, Quick described the Strategy as “excellent news for the aerospace industry, our armed forces and, Canadian taxpayers” ‘While that may be the case, the Strategy was launched in the wake of two high-profile aviation misfires—the Maritime Helicopter Project and the Joint Strike Fighter program. ‘The Maritime Helicopter Project involves the purchase of 28 state-of-the-art combat-ready CH-148 Cyclone helicopters, to replace the Sa FEERURY OTSMY AFFORDABLE (fj Winoustay Des rs EXCELLENCE. MY BUDGET. Okuma—Get The Best In The Industry On A Budget Ifyou thought the excellence of Okuma was outside your grasp, it's time to reach for the stars. Breakthrough innovation, high performance, and legendary quality are now at prices below what you might have imagined. Check out these top of the line lathes and machining centers that are priced to be right in line with your budget. My Okuma means My Affordable Excellence. My Okuma: Maximizing Productivity. Powering Business. Sharing Innovation VISIT WWW.OKUMA.COM/AFFORDABLE-EXCELLENCE-PRODUCTS TO OKUMA LEARN MORE ABOUT OKUMA’S MONEY-SAVING OPPORTUNITIES EMEC Machine Tools, Inc. EMECMachine Tools, In. Thomas Skinner & Son ‘Thomas skier Son Thomas inner &Son Bis Adm Ba fue wars 10 vuln Way ‘eansahAvenvese SADT Sit avenue sissouga Ona Vest auren, @¢ fchmand rs Columbia Cage Abeta Eementon, bers suesee3500 slerssaee euezreni3t vaseatsa01 reoeas2e‘The original deal with Sikorsky Aircraft of Stratford, Connecticut, announced November 2004, cost 55 billion. Delivery of the first helicop- ters was slated for November 2008. A series of produc tion problems and technical glitches has arastically pushed back the expected aelivery date. Ottawa is now looking at receiving the CH.148 choppers in 2018 It's the same story ‘with the Joint Strike Fighter JSF) pro- gram. The J tive is a multi-billion dollar, multi-decade, multi-national effort to build a cutting edge F-36 combat airplane. Canada has been a partner in the program since 1997. In 2010, Ottawa announced plans to pur- chase 65 F-35s, with an initial purchase and services price tag around $16 billion over 20 years, The planes were supposed to start arriving in 2017 to replace Canada's current war planes, the GF-18, acquired in the 80s. ‘As production delays and technical glitches ‘mounted, the F-35 price tag increased. An independent audit by KPMG pegged the purchase and maintenance price of 65 F-35s ‘at $45.8 billion, over 42 years (the projected Iifespan of the F-35) Delays and overruns were such that Ottawa seriously considered scrapping the contract in late 2012. The government now says it will make a final decision regarding purchasing the F-25s after a new review. The aging CF-18s ‘meanwhile, are being used in the Middle-East for combat operations. The #-35 isn't expected to enter service in Canada until at least 2018. ‘Myers refuses to look at the JSF project as a white elephant, Because Canada is a partner with the program, Canadian suppliers can bid for JSF contracts, he points out, As of early 2014, some 22 Canadian compa- nies had active contracts with the F-35 pro- gram. Canadian firms have secured a total of 'US$597 million in JSF-related work, in areas such as the airframe, propulsion, tooling, software and mission systems. “I still think there's an awful lot of inno- vation and a lot of development work that Canadian companies can benefit from...1 think Canadian companies have gained a lot already from working on this project,” says Myers He has advice to shops and manufacturers looking to pick up aerospace work in general “The first thing I would say, don't look at your business as getting your product out the door, Look at it as providing a solution based on your capabilities. If you look at it that way, there are an awful lot of capa. bilities out there in manufacturing, for small companies down the supply chain. Maybe you're manufacturing currently for the automotive industry, energy industry or maritime industry. Take a look at your capabilities and think of how they could be applied to aerospace. You have to go to aero. space conferences, talk to people, figure out how some of your technologies or products or capabilities can fit into the requirements of aerospace...aerospace has probably a wider supply chain than even the automotive industry in Canada,” states Myers, Funding innovation is one of the keys to keeping the aerospace sector progressive and prosperous, he adds. Industry Canada seems to agree, which is why it launched the Consortium for Aerospace Research and Innovation in Canada (CARIC) in April 2014. This Montreal. based non-profit group is charged with facilitating communication and collabora- tion hetween aerospace companies, research centers and academia. To this end, CARIC has been funded by Industry Canada to the tune of $30 million over five years. Of this total, GARIC will dole out $4 million annu- ally for applied research projects. *[Our] mission revolves around supporting research and development projects leading to innovative solutions. It's not just research for the sake of RED," says CARIC CEO/president Denis Faubert. In addition to funding applied research, CARIC plans to host a national forum every two years, with the next forum scheduled for 2016. The Consortium will also open regional offices across the country, in Vancouver, ‘Montreal, Winnipeg, Toronto and possibly, Halifax. Of course, CARIC will work closely ‘with existing aerospace groups such as AIAG. Faubert is downright giddy about the task ahead of him. ‘When it comes to aerospace, “Canada is really punching above its weight,” he notes. E STEERS ‘er naan aMMT MITCHAM Productive Solutions with Local Service and Support 21 Tarragona Bivd., Toronto, ON. MBN Tel: 416 458 7994 email: sales@mitchammachinetools.com MACHINE TOOLS More operations. Less handling. Tum, mil, drill, grind, hob, tap, groove and more: ina Single setup. Even 6-sided machining, More precision. uracies to microns ~ best possible turned surface finishes More profit for you. With our precision turning solutions, you ean cut your cycle times dramatically, Up to 60% or more Less really is more Less time in the machine, complex parts finished complete, means less cost per piece, better part quality HM Test us. We are ready to prove it on your parts. Precision turning solutions for people who think, INDEX MS22-8 Multispindle CNC Lathe — Outproduces 8 NC lathes! High-Volume production of turned/milled parts to 22 mm, short set-up times 8 independent CNC spindles, www. indextraub com AGENC tool cartiers Also available: MS52, MS40, MS16 info@indextraubcom ENG Multispindle Lathes | Swiss Turning Machines | Turn-mill Centers | Automatic Lathes:VIE BY NATE HENDLEY Nee eee ‘and Rombardier forecast enormous global demand for new planes over the next two decades, There is particular interest in airplanes that have lighter frames, more efficient engines and use less fuel. So, how will these developments impact aerospace machining? ‘We ran some questions by a group of experts to find out, Here's what they had to say: IS FIVE-AXIS ALWAYS THE BEST WAY TO GO WHEN DOING AEROSPACE MACHINING? “There are large numbers of simple parts that go into an airplane and into other aerospace applications where a three-axis ‘machine can more than adequately satisfy the requirement, That being said, a simpler machine limits manufacturers’ ability to do a variety of parts, of which some may need five-axis, A five-axis machine can do three- axis parts but unfortunately not the con- verse,” says Tom Dolan, vice-president sales and marketing at Mistui Seiki in Franklin Lakes, New Jersey. “If Twas going to go into business on my own and start a company doing aerospace work, yes, I would absolutely have a five- axis machine, People say ‘five-axis’ and their ‘mind goes immediately to very complicated contouring work...the majority of aerospace parts do have five-axis contouring work on them, but that's usually the finishing opera tion, .to get there, there's a lot of three axis or three plus two axis work that are rough- ing operations only,” adds Wade Anderson, technical centers and product specialist ‘manager, Okuma America Corporation, based in Charlotte, North Carolina “Really, the selection of machine is based on the parts to be produced. For many struc. tural components, a three-axis solution is adequate. However, today parts are becoming increasingly complex and many times a five axis solution is the only way to process the part efficiently and within tolerance,” echoes Ray Buxton, general manager at Mazak Corporation Canada, based in Cambridge, ON. “ive-axis machining can eliminate multiple set-ups for the machining of multi-sided parts, thereby improving efficiency and reducing cyele time. Five-axis machining can also improve quality since the part stays in the fixture from start to finish which eliminates alignment issues associated with multiple set- ups,” notes Adrien Roubenne, North American sales director for Fives Liné Machines Inc,, in Granby, Quebec which in turn is part of Fives ‘Machining Systems of Hebron, Kentucky ‘ARE HIGH TOLERANCES ALWAYS A PREREQUISITE WHEN MACHINING AEROSPACE PARTS? "No, absolutely not...there are many, many aircraft components that require extremely Sa TFEERURY OTS ‘er nadernet omtight tolerances and there are many, many aircraft components that do not,” says Dolan, “Aerospace parts in the manufacturing ‘world are very diverse. You can have simple low tolerance brackets all the way to very high tolerance components for geared turbo- fans," adds Buxton. WHAT IMPACT WILL ADDITIVE MACHINING HAVE ON AEROSPACE MANUFACTURING? “This will continue to grow and grow in new ways as technology changes, Ihelieve ‘one impact of any change in technology is it opens up new areas of business for companies and entrepreneurs alike,” says Anderson. “At the JIMTOF [Japan International ‘Machine Tool Fairl in Japan last year Mazak demonstrated our new i400AM combination additive/reductive machine, Mazak is work- ing at the forefront of this emerging technol- ‘ogy and we feel that it will eventually have a major impact on manufacturing not only in aerospace but also in automotive, oil and gas etc.” says Buxton. “Additive technologies will deeply change [the aerospace maintenance, repair, overhaul] sector in the next few years...replacing worn out parts with a new ones using additive technologies,” suggests Roubenne. “at some point in time, will there no longer be a need for machining? Fortunately, for people of our industry, I don't think that’s going to be the ca: in the long-term, the honest answer is, ‘Who knows'?” says Dolan, “If Lwas going to make a prediction, I ‘would say the strengths and lightening characteristics of material is one area where Ithink additive manufacturing gives pos- sibilities. I think [additive machiningl will produce a lot more weight-effective compo- nents,” says Anderson. ia the short-term. But ‘SPEAKING OF WEIGHT-EFFECTIVE COMPONENTS, WHAT IMPACT WILL THE ‘TREND TOWARDS LIGHTWEIGHTING HAVE ON AEROSPACE MACHINING? “I's not just aerospace, it's automotive too. All the innovations that we're seeing both in aerospace and automotive are driven by the demand for performance and fuel efficienc: says Anderson, “If you look at commercial airlines, the biggest single cost today is fuel. Fuel price is driving more efficient or effective aerody- namie shapes of aircrafl, lighter weight and ‘more efficient aireraft engine technology lighter weight or more [efficient] engines that use less fuel [means] the ability to carry more Passengers or more cargo. All that is driving new technology in materials, shapes and con- figurations and electronics," says Dolan, DO YOU SEE ANY OTHER TECHNICAL TRENDS FOR AEROSPACE MACHINING IN THE FUTURE? ‘People have to start seriously embracing ‘automation. Automation doesn’t necessar ily mean robots and sophisticated flexible manufacturing systems, It means being able to automate a manufacturing process even for small lot manufacturing which is typically ‘what the aerospace industry does. Looking at automating processes means taking the most advantage of the machine capability as possi- ble, to reduce manufacturing costs and reduce the effective capital cost on the workpiece itself,” says Dolan. “The materials in aerospace are getting more and more exotie...there's new material com- ing out all the time, different alloys, different ‘mixes...nevrer, lighter weight, stronger, tougher materials. As materials get more exotic, they tend to get harder to machino,” says Anderson, ieee anreanadaameatwarng cam FEBRUARY 207535‘ONE OF THOSE “EXOTIC” MATERIALS IS ‘TITANIUM. WHILE TITANIUM IS BECOMING INCREASINGLY POPULAR IN AEROSPACE MANUFACTURING, IT IS REGARDED AS ‘SOMEWHAT DIFFICULT TO WORK WITH? “Generally, titanium machining demands avery rigid machine with high torque and horsepower. Mazak designs all of our machines with a very high level of rigidit For most of our models we also have high torque spindles as an option that success. fully address the needs of the more demand- ing user,” says Buxton, OKUMA'S AEROSPACE CENTER OF EXCELLENCE fee Ne tae Cee esse ee ty ec ego ee me Chariotte, North Carolina. Aerospace manufacturers can use the Me ae reece ee as Ser Cte ete eee don't have—time, equipment and resources,” explains Wade Anderson, technical centers and product specialist manager with Okuma, ret OCs mee ecg Cee ole ee eee ery room and a conference roam. Two Okuma application engineers (AEs) are posted full-time to the Genter o assist with R&D. Leese eum eee teeta eee ee edge ene eee ete att) Renn geen ee aa eee mete Seog et ae nad One te Cee re ete ee eee the fact there's going to be some risk involved,” he states. Sry “The majority of manufacturing is just now getting into titanium machining. We design our machines to be very rigid, with a lot of dampening and thermal ability characteris. ties,” echoes Anderson, COMPOSITE MATERIAL IS ALSO BECOMING MORE ‘COMMON IN AEROSPACE. DO YOU HAVE ANY TIPS ‘ON MACHINING COMPOSITES? “optional high speed spindles are the sity for this material along with special con. siderations for dust control,” says Buxton, DO YOU THINK THE USE OF TITANIUM AND COMPOSITE MATERIAL IN AEROSPACE MANUFACTURING WILL INCREASE IN ‘THE NEAR-FUTURE? ‘Not a whole lot more than what's being required as a pes going forward. However, the volume of these materials will definitely increase as more aircraft are (being built). At any of the major aircraft OF} quite significant, If you look at the compo. nents that are required on an airplane for both aero-structure volume of titanium is definitely going up if you consider that Boeing and Airbus are each moving towards 60 commercial aircraft a month, the volume and mix of products they expect to deliver to their cus. tomers, the requirement for titanium com- ponents is going to increase dramatically ‘centage of each aireraft s, the projection numbe ind propulsion, the over the next couple years. The same applies to composites,” says Dolan, DO YOU HAVE ANY ADVICE FOR AEROSPACE SUPPLIERS ON HOW TO GET MACHINING CON- ‘TRACTS FOR THE LIKES OF BOMBARDIER, PRATT ‘& WHITNEY, BOEING, AIRBUS, ETC.? ‘Smaller companies will require more multi-axis capability—tfive axis machining, Although they may still have a wide variety of simple parts to make, they will not want to refuse work for five-axis that comes as part of a complete package, So machine versatility will be an important change or shift [for smaller manufacturersl ... the major aerospace contracts that are being awarded now are for longer-term projects Therefore, the ability of smaller companies to understand differences in machine tools, differences in machining requirements, is going to be of paramount importance, says Dolan. “Be capable, Have the equipment and pro- cesses capable of delivering more than you can promise,’ adds Andaracn Se ERROR OOSOur Latest Innovative Solutions Set New Standards For Manufact Ree enh ae eran set pe mem lia lett Consistently on the leading-edge of innovation, Star CNC's two new models ee eee ee ee eed eee Cc eee eee uring Sa eee Rae nRrMNEANE —— Pea acta irene eee Uae Se ee Ere ert “Guide Bushing" and "Non Guide Bushing”. With full axis with ct ee naa ee eke ee eae ‘Two sophisticated machining solutions can play a big role Cee es rere TY SC) an ti ad e TRC) eae ce TeL416575-7700 + F416 676-4088 PC Ce ped pronKEEP ON SPINNING Gare and preventive maintenance options for increased spindle life BY LINDSAY LUMINOSO MQ) wot sig ou ot mind Wheat ings fe morécomen than Stowe, rn amufectrers taketh appreeeh, they ea often id hemslves wt opade eee eee Cretolng (in erlea coer an arivetoitiouundorendng the peli Ieeaes and weds of the vite Wy nou I oplodet Meny operators wl arn onthe ie edo pcatgnon iniag caeeeenite can iabaleaen ite interning anal lace tad etal uling preventive maintenance can ensure long spindle life and increase productivity. ‘The spindle really is the heart of the machine and is designed with the application and user specifications in mind. Regardless of what type of machine you are running, the spindle allows the machine to function. “Typically, when someone purchases say for example, a large milling centre, the spindle is so buried, but it’s the heart of the machine, You can build the most rigid machine in the world but you have to have a good spindle ‘motor in there,” says Gary Quirion, corporate president of GMN USA. Because the spindle is often hidden, itis sometimes forgotten about when the opera tor does machine checks and worse, can be unknowingly pushed beyond capabilities This is why itis so important to understand the features and specification of this critical component, ‘The omus is on the owners and operators to keep their spindles in good working condition in order to maintain longevity. End-users need an education on the [specifications] of the machine. I's not just plug-and-play for all its life." explains Alexandre Maurais, presi- dent of MEC PRECISION. Maintaining proper ‘machining practices and inspection of parts can mean the difference hetween a seized spindle and a spindle that lasts, “The spindle life can be infinite, but only if it doesn't crash,” says Gus Gustafson, service manager for Thomas Skinner & Son Ltd. Crashes occur when the operator pushes the machine to do something that it isn’t SS TFEERURY OOS ‘er nadernet aTIEIN|D|O' ES De ena ao UL ee Re ue Cua a) MAGNOS Magnetic clamping technology Rae Rte corned ROM CR mur em Oe eu c BY wvow.ca.schunk.comimachine-potential prmextroabennt SCHUNKnormally supposed to do; this can cause the spindle to stall and halt operations. Unfortunately, this is a common occurrence ‘on the shop floor. The spindle life really dopends on how the operator treats it and how they run the machine. “The spindle life really varies, They can last 10-15 years under normal use. But if someone crashes it on a regular basis, it could last only a year or less," continues Gustafson. SIGNS OF A PROBLEM ‘There are some clear indicators that your machine's spindle is in need of inspection or repair. Obviously, if the machine is no longer rotating, this could mean that the spindle has failed. The spindle itself is a highly sensi- tive component with many intricate parts, Rotating parts like the chucks, drawbars, quills, rotors, shafts, etc., should be handled with care to ensure that they are never hit, ‘and jarred, which can cause serious damage to the overall spindle abilities. Tolerances for ‘the rotating parts are so tight that even the smallest push can cause failure. Howaver, a spindle may not stall entirely, but there are some factors that can point to SRP TT RSC aT ETT Ce COTY ae a future spindle failure, "Old school, if t's noisy, or if you have part finish issues, or the spindle is running hot, those are good indi. cators,” says Quirion ‘The experts agree that uncharacteristic noise is one of the key signs that there is a problem. Monitoring the spindle from the install and confirming that there are no abnormal or different noises is one way to koop the spindle spinning, say Maurais. Cracking, humming or banging noises should bea clear indication for the operator to con- tact the maintenance department or spindle repair service to diagnose the problem, ‘Apart finish can easily determine a problem with the spindle, Oftentimes, you can clearly see ifa part has too much or too little material ‘removed, or the workpiece finish is not correct. Slight variances in the tolerances can catise a part to fail inspection, and if several parts are constantly failing to pass quality inspection, then this can point to a spindle problem, ‘Temperature can also point to a significant problem. When the spindle runs hot, abnor- ‘mally hot, the operator should stop running the machine hefore further damage is done. ‘The complex interior components of a spin- dle can vary significantly depending on the ‘manufacturer or application. However, if the spindle is running above the average tem. perature, this can be an early indicator of ‘a future problem, There are many ways to measure the temperature, including spindle temperature sensors that are often placed at the top and the bottom of the spindle provid. ing live temperature feedback. Gustafson says that another option for measuring spindle temperature is a heat gun. The operator can measure the temperature themselves and compare against baselines set at that facility. TIPS FOR OPERATORS Enhancing spindle life is a fine balance between proper care and proper understand ing of this high-precision component, The operator should know the ing and outs of the spindle as well as the machining applications. For example, machining titanium with low speeds and heavy loads can put alot of stress. ona spindle, while light grinding applications and lower speeds can extend spindle life. Atypical spindle is designed with the application in mind but the external design is very similar. Internal components, like the angle of the bearings, the number of bear- ings, the preload, etc., that are developed for each machining application. This is why very important to read the manual and spec: TERROR OOS ‘er nadernet afications for the spindle, especially because the spindle is tucked away in the machine and most operators generally don't access it, One of the most important tips Quirion has for extending spindle life is be safe. “I've seen many things over the years, I always say read the manual. You'd be surprised how many peo: pple call and ask a question, and I ask, ‘Did you see the manual on page stich and such?’ and they don't even have a manual,” he explains, Speaking to the spindle manufacturer before ‘operation can ensure proper use of the spit dle, The manufacturer ean provide guidel ‘that you might not even be aware of, ‘One of the first things the operator ean do is runa spindle warm-up program every shift, says Gustafson, As previously men- tioned, increased temperature is an indicator of spindle issues. Measuring the temperature the spindle runs at after the warm up cycle is important for establishing a baseline. Once the baseline is set, the operator can determine normal function of the spindle, If itis running hot, “then you know it is point- ing towards a problem,” he explains Checking the cooling system to make sure it's functional is also important. Whether the spindle is cooled through compressed air, liquid, or fan, itis important to make sure ‘that the cooling mechanisms are running smoothly. In most eases, grinding and milling spindles will be liquid cooled. If you are able, it is always a good idea to observe the tem. perature of the bearings on the front housing, ‘Maurais also points out that there are quite 1 faw spindles that have a positive pressure around the nose. “There is air that is blown all the time so the coolant doesn't go near the spindle or bearings. The air will stop blow- ing if the airline is dirty or cracked. (This) will contaminate the bearings quickly and ‘the spindle won't last long, We are telling 's to watch [out for this]. Make sure there is pressure of air around the bearings at the spindle nose,” he continues. Experts agree that you must tse caution ‘when working with longer tools, as they may alter the rotor dynamics if not careful. For ‘example, Quirion explains, “a spindle might run 60,000 rpm as advertised, but if'a long grinding quill is put in it, the speed will be limited. And if the [operator] exceeds that, twofold, you will damage the spindl 1 safety factor and someone can be injured.” ‘custom and it's GMNusa New Spindle Sales and Repair Service High Speed + GMN USA has it all! High Torque * High Quality dies for OEM & retrofit applications. RepairiService for GMN & most other makes and models: Spindle support systems. Manufacturing & servicing spindles for over 85 years GMNusa 1784 New Britain Avenue + Farmington, CT 06032 800-686-1679 + info@gmnusa.com + ww.gmnusa.cam ‘aanrcanadanmetatwarng sam FEBRUARY OTE ATEnsuring that you are using the proper toolholder and appropriate concentricity of the taper to meet the manufacturer's spec ifications is key. The toolholder’s tapered shank must fit perfectly in the spindle taper every time itis inserted. “There should be 100 per cent surface contact of the tool holder” explains Maurais, This will keep the tool on the centre line of the spindle and allow for accurate and proper use. Examining the contact surface of the taper can also be helpful. You want the contact to be at 100 per cent. Cleaning the toolhold. ers and spindle can help maintain preci sion and prolong the life of the spindle and ancillary tools. Chips and coolant can often get caught between the tool and the taper interface, damaging both the spindle and the tool holder. Spindle cleaners are quality control products that can be used regularly to remove residual particles that can affect ‘machining capabilities. Another way to prevent a spindle failure is by making sure the load on the controller is normal, In many cases, the spindle load condition can be defined for particular tools, whereby the machine stops if it reaches this limit, However, verifying the proper set ngs ensures that an overload won't occur. ‘As mentioned, machining something like titanium with heavy loads can put a lot of stress on a spindle, Make sure the spindle is qualified to perform such operations Proper care is really dictated by the type of spindle and application. For an oil-air system you have to make sure that all the settings are adjusted. Quirion explains, “You have to adjust the air and the oil flow rate, The drive unit has to be correct, the tool clamp- ing for automatic tool change spindles have to be monitored, the tool retention should be checked and all the operating parameters with tool/without tool, those safeties should be checked.” Day-to-day care can mean all the difference when it comes to spindle life. The operator should be aware of the spindle specifeations and run the machine accordingly. ‘SCHEDULING PREVENTIVE MAINTENANCE Aside from operator control, manufactur ers can schedule Preventive Maintenance appointments with expert technicians who can come into the facility and run diagnos- tics on the spindles, providing data to allow for trending and extend general lifespan of the parts and spindle. Experts agree that setting a Preventive Maintenance schedule at 3-, 6-, or 12-month intervals, can ensure spindle longevity. ‘There are many diagnostic tests that should be conducted on a regular basis. Having a thorough history or tending the machine and spindle function allows for manufactur ers to plan ahead when it comes to a rebuild, With Preventive Maintenance, “what we can do is tell you that ‘hey, your spindle proba- bly has about six months left in it before it's ‘going to fail’ And we can order the part and change it out fora customer hefore it even fails,” explains Gustafson. This allows for machine owners to anticipate future failures, ‘which can be extremely costly, especially when it comes to unexpected breakdowns. Not all spindle manufacturers have all parts on the shelf and with new models, parts are not always readily available. Preventive Maintenance tests can give a good indication when the spindle will need to be rebuilt, so parts can be pre-ordered, without expensive next-day delivery charges and production lags due to shipping times. “The customers have a machine that cannot be down, cannot be in breakdown situa- tions. The more we are able to prevent that, the more money everyone will make and the Jess emergency situations everyone will go through,” says Maurais, ‘There are 4-5 general Preventive Maintenance tests, including vibration test, checking the bearings, testing the pull force of the drawbar, and temperature checks. Understanding how the spindle functions in the machine and the appropriate machining applications for the spindle can make all the difference when it comes to spindle longevity. Scheduling Preventive Maintenance appoint. ‘ments partnered with proper day-to-day operating techniques, can ensure the spindle keeps on spinning for as long as you need. OD EER OOS ‘er nadernet aapply innovation™ Renishaw’s laser metting system is a pioneering process capable of praducing fully dense ‘metal parts direct from 3D CAD, which has the power to unlock the potential for additive ‘manufacturing, From tooling inserts featuring conformal cooling, to lightweight structures for aerospace and high technology applications, laser melting gives designers more freedom, resulting In structures and shapes that would otherwise be constrained by conventional processes cr the tooling requirements of volume production. Itis also complementary to conventional ‘machining technologies, and directly contributes fo reduced lead times, tooling costs and material waste. + Shorten development timescales - be first io market + Reduce waste product and cost - build only what you need: | lta + Enjoy increased design freedom « create complex structures and hidden features Renishaw (Canada) Limited 2196 Dunsin Drive, Misssssuga, Ontarlo LSL 1G7 Canada bbenD&D Precision Inc., Mississauga, ON BY DOUG PICKLYK. [sz stemonn:fors a eee bee chara ‘the two owners of D&D Precision, a small machining shop in Mississauga, are preparing to go make some vis- its—dropping in on thei holiday cheer and express their appreciation for another year of living the dream. Located in a small industrial park minutes from ‘Toronto's Pearson airport, D&D Procision's narrow 2,000 sq.ft, unit has a small office space in front and the back is a long corridor lined on both sides with machines and tools of the trade. Tony Desousa and Mike De Acetis, the D&D, started their business eight years ago and have ‘worked together to build a successful operation by con, tinuing to invest and grow the business while adapting to the fast-changing manufacturing industry. Both from the Greater Toronto area, Desousa and De Acetis met while working as mold makers for Ryka Blow ‘Molds, a shop that was located around the corner from where they are now. De Acetis was running machines loyal customers to share some and managing a testing facility, while Desousa, after fin ishing his apprenticeship on the shop floor, took on more business and administrative roles in the office. ‘The two often worked together and were frequently mis- taken as brothers, Sensing a strong compatibility, their conversations led to talk about starting up a business, “Thank you Michael Ryan (original founder of Ryka Blow Molds) for the tools and knowledge we acquired at Ryka,” says Desousa, ‘Through a family friend of De Acetis, the two were able to secure a walled-in 10- x 10-foot space on the floor of a plastics factory, squeezing in a small lathe and a manual tilling machine, At the heginning both were still employed. They would often work a full shift and race to the other shop staying up until the middle of the night, only to get up and do it all over again, A little more than a year into the project they took the leap, leaving their well-paying jobs to break out on, their own. "We took a hig chance. Everyone told us we were crazy, and we're still getting that today,” laughs De TEERRVIOS ‘er nadernet aAcetis. “The thing is, both ‘Tony and I, we love what we do.” It was 2006 when DBD Precision was born, and two years after the launch came the economic crash in 2008. "It's like some. body turned the taps off,” recalls De Acetis. The partners went four months without drawing a salary, yet at the tail end of 2008 they went out and bought a small used CNC . lathe. As De Acetis remem hors, the machine sat silent on their floor for the first month, but it’s been going non-stop ever since. Taking chances and not being afraid, that’s part of business,” says De Acetis, ‘And it’s been their strategic moves that have kept them rolling, "Machine shops have got to be smarter, leaner, and faster.” he insisting that business ‘owners need to keep up with the changing times. It’ not a guarantee that you will be successful by just adding new equipment. For us, I believe it’s been the combination of our skill sets. Tony selle it, and I make it run. ‘Their space on that factory floor grew to 800 sq, ft., but as jobs began piling up they became restricted by their cays, technology—material had to wait for a spindle to free up. ‘They were in need of another, larger, mill and ultimately found a used machine at a local aerospace company. "It ‘was a perfect fit for us, and that’s what led to the move to our current facility lin April 20131,” explains Desousa. ‘The larger envelope of the new mill led to a greater range of work possibilities, and soon the business was rowing again. Now work began piling up on their lathe, which led to researching new turning machines. And based on their history they knew they were hetter off going with something bigger. “We always overkill our homework, and it’s helped us along the way.” says De Acetis. They ended up going with a new Okuma LB4000 EX twvo-axis lathe with live tooling. “It ‘was a calculated move and we have no regrets,” he says, Purchased from EMEC Machine Tools in Mississauga the new machine has a maximum machining diameter of 18.9 inches and length of 60 inches between centers. The BUSINESS PROFILE: MACHINING live tooling option also allows them to perform a combi nation of processes from one set up. ‘I'm surprised at how easy it was to program and dive "says De Acetis. “And EMEC has been phenomenal. I's the first product we've bought from them and likely not the last, considering the way they've treated us.” into operating the machin “IT’S NOT A GUARANTEE THAT YOU WILL BE SUCCESSFUL JUST BY ADDING NEW EQUIPMENT. FOR US | BELIEVE IT’S BEEN THE COMBINATION OF OUR SKILL SETS. TONY SELLS IT, AND | MAKE IT RUN.” — MIKE DE ACETIS DED has be en taking on jobs from a variety of indus tries: aerospace, material handling, freight elevators ‘and military. “Anything that can fit on our equipment we can do, and we don't shy away from tolerancing since our machines are capable of holding accuracy | FEBRUARY 2075BUSINESS PROFILE: MACHINING and repeatability," says Desousa. "I ‘would classify us as a medium-sized shop now. But we have that big shop capability.” ‘The partners are hoping to position the company correctly over the next five to 10 years, and as experienced machinists they are optimistic that the machining industry will climb its way back to the place it belongs “at the top of the trades" “Tf all goes well, we will he right there," says Desousa, ‘The Okuma was installed in the summer of 2014 and it's been run. ning non-stop. The challenge now for DED is keeping up with the business and managing their workflow. ‘They ty to maximize machine time with intelligent set ups, but they are actively seeking additional hands to been actively promoting their new capabilities, hoping to find a couple more people to alleviate the work- load hefore they start pushing for more work. "The business is heading in the right direction, that’s for sure. But ‘we still have to watch what we spend land be selective on the type of busi ness that we choose, because now we've got the range, but you ean still bury yourself by selecting the wrong type of work,” says De Acetis. In 2015 it’s about optimizing their workflow through the shop, make ing sure the work they're doing is profitable, One aspect of the industry today that Desousa finds challenging are the short lead times (lean manufac turing), or justin time delivery and ‘work the machines—and that's proving to be difficult, | lack of long term project commitments. In busy periods they have hired operators on a contract | “We're lucky though, from day one our customers have hhasis, but the challenge has been finding someone reli. | eon awesome,” admits De Acetis. “Of course without able and passionate about the work. ‘them none of this would be possible, They have had the De Acetis is 40, and he's concerned about lack of next confidence and faith in us and have stuck with us. generation machinists coming up after him. “When I But Desousa and De Acetis are not shy to give themselves started there were people eagerly interested in pursuing credit as well. They put Precision in their name for a rea. a career in this field. I don’t see that now," he says. son, “You have to hold yourself to a standard, anyone who Both partners see the problem coming with this skills doesn’t won't be around for long,” says De Acetis. gap in the workforce. In fact, until now they haven't With the business running smoothly, the partners are content, but they do have goals, including the possibility of one day designing, developing and produe- ing products of their own—they already have ideas and concepts in the works. "To me that is an ultimate goal, says Desousa. “At that point you become global. You go from having, 10 customers to 10 million potential customers. For now though, the owners of D&D Precision are happy to keep their machines humming, enjoying work and life, “We've always said, it's a tough business, but let's have fun. We take our work very seriously, but ‘we have fun,” laughs De Acetis. Latoreo er nt, partes) FEERUARY 2075 ‘er nadernet aYESTERDAYS CRIAFTSMANSHIP TOMORROW’S TECHNOLOGY CUTTING TOOL TRIFECTA BOSC. wa Pee www.HeritageCutter.com bee Rena ORO RM RUS Rr Ce ALU ee eae oUeue mC el AeA RCOM MCR ACR H Smale ee) BU oR ce Moke Ho Re RUC ULUeU ERO LMY ULCWE KNOW what its like, We'te MACHINISTS, too, We CUT METAL every day. That's why we're driven to make sure that every CNC machine is trustworthy, affordable, and always backed by the industry's bes! service. Find your local Canadian Haas Factory Outlet find them onlin faasCNC.cor the Stewart-HaaTOOL TECH EFFECTIVE MACHINING OF EXOTIC MATERIALS BY RAFI RAVOACH Ne chromium based superal loys are oxida- tion and corre- sion resistant materials, well suited for ser- vice in extreme environments subjected to pressure, heat and kinetic energy. ‘When heated these alloys, such as Inconel and Waspaloy, form a thick, stable, passivating oxide layer protecting the surface from further attack, causing challenges for effec- tive machining. Because these materials are able to retain strength over a wide tempera ture range, typical applications are ‘within the global aerospace industry for components located in the hot section of the engine In the oil and gas industry it fills the need of a high strength alloy with good corrosion resistance for downhole equipment, and the need for completing high-pressure gas ‘wells to gas containing high CO2 and 12S for completion equipment. ‘The major problems encountered when machining nickel chromium based superalloys are character ized by the generation of very high temperatures on the cutting edge of the insert, This is due largely to the abrasive elements in the material's composition (high nickel content of 44.2-70% and chrome 14-30%), which cause high wear rates, chip ping, notching and insert breakage. ‘These factors contribute to reduced tool life, deformation of the cutting edge, even at low cutting speeds, and increased down-time, Another problem associated with the machining of nickel chromium. based superalloys is its tendency to malform due to its metallurgical sensitivity to residual stresses and self-hardening effects during the ‘cutting operation. ‘To help overcome these multiple dif- ficulties and to enable the effective ‘machining of this challenging mate- rial, cutting tool manufacturer ISCAR has developed 1C806, a submicron grade insert with a PVD TIAIN nano: layer coating. The hard substrate of 1C806, its coating and additional post ‘coating treatment together deliver longer tool life, improved reliability and greater resistance against flak- ing and chipping, By combining two major compon tents, grade and chipformers FIM & MM, optimum results in machining superalloys is achieved ‘The main advantage of the 1C806 is the ability to machine superalloys such as Inconel and Waspaloy at very high cutting speed (more than double) ‘when compared to existing grades, ‘The average cutting speed with the standard current grades for machining these superalloys is between 25 to 30M/min. The new 1C#06 can run up to 80m/min, increasing productivity while also achieving improved tool life. In extensive trials [C206 was proven to exhibit superior wear resistant properties, excellent machining results and deliver bath praductiv ry gains and cost reductions. Ed) By Rafi Ravoach, 180 Turning product manager, based at Iscar Global Head Quarters in Tefen, israel. anceanadaamatatwartng sam FEERURAY 20STOOL TALK EMEC MACHINE TOOLS IS EXPANDING EMEC Machine ‘Tools is expand. ing its product offerings with the announcement of a new distribution agroement. The Mississauga-based company will now be the exclusive end-user distributor of the full line of Modig products in Eastern Canada and will provide installation and warranty services for customers in this area. “EMEC and Modig are both known, for quiick response and professional services,” says Modig U.S. president David J. Waldron. “Modig's innova. tive technology, optimized for the aircraft industry, is recognized for dramatic reduction in produetion time, leading to lower manufacturing costs...Coupled with EMEC's solid veputation built over 20 years of providing highest quality products and support, we can now hring an outstanding value proposition to our Canadian customer base. Bill Mara, prosident of EMEC adds, “Modig builds some of the finest ‘machining tools we've seen. Our mutual ability to address customer challenges in component manufac ‘turing for aluminum and composites is key to contributing to customers’ - eee ced r Caen ere success. Modig’s approach of build ing long term relationships mirrors ours, and Iam confident our custom ers will enthusiastically welcome this extensive addition to the prod- ucts we represent, EMEC Machine Tools is also expanding its operations in order to otter assist its customers. In November 2014, the company hosted a two-day grand opening event at its new facility in Montreal, ‘The company has been in Montreal et for 20 years and moved into its larger space, located at 7929 boul. Henri Bourassa Ouest, on August 1, 2014 This expanded location features an operating showroom. At tthe open house the experienced technicians at EMEC Montreal were running live demon. strations on an Okuma LB3000 EXIT horizontal lathe, Okuma M560 verti- cal machining centre and TSUGAMI $8327-5AX lathe. Is nice to have the new building and showroom, but it's having the cor rect personnel to servi ers, that's where the big investment has heen,” said Mara at the event. ‘The two-day open house also fea. tured additional support from sup. pliers including Sandvik, Kitagawa, Hardinge, WTO, Renishaw and Blaser. HYDROMAT PARTNERS WITH WITZIG & FRANK ‘The Witzig & Frank brand has renewed its partnership with Hydromat. Hoth companies are com- bining their matching portfolios of high volume metal cutting solutions for the automotive, communications, medical, aerospace, plumbing, and general machining industries. Witzig & Frank is a manufacturer of highly integrated machin. ing solutions for high volume applications based in Offenburg, Germany, The companies have had close ties for more than 25 years when Hydromat president and CEO, Bruno Schmitter, co-founded a joint venture with Witzig © Frank, Hydromat’s chief sales officer, Matthias Walter, started his career at Witaig & Frank and later took over its U.S. entity, Turmatic systems. "We have acts Hy sold, installed and serviced more than 160 Witzig & Frank machines in the U.S,, so we're very experienced in the field and know the players,” said Walter. According to Pascal Schnebelt, sales director at Witzig & Frank, the demand for their products in the Northern American market is strong, here is a variety of industries in the growing American manufacturing, industry and also existing German customers setting up production in the U.S....With the proven part nership of Hydromat we have the expertise on site and we can guarantee a top service for our customers. Hydromat’s contract with Witzig & Frank includes sales, service, spare parts supply and retrofits, FEROS ‘er nadanrnatwrtg om(talon No Time for'Look Alikes! Don't Settle for Less Use ISCAR's Innovative Products ate Insert Clamping Guarantees Supreme Tool Lif JET HIGH PRESS 350 LINE Jet Pressure with Unique Free Unobstructed Chipbreakers for Ultimate _ Chip Flow for Ultimate Insert Life < Blade Life Machining Inteligenty esaz www.iscar.caTOOL TALK DMG MORI OPENED ITS DOORS AT NEW MISSISSAUGA LOCATION On November 18, DMG MORT ‘Walking into the building, we were | The event offered a wide range of kkicked off its grand opening event, quickly greeted by DMG MORI staff | products and services for all your celebrating the opening of the members who directed us towards | machining needs. Mississauga location, Located on _the showroom floor. The brightly The chips were flying and the Ambassador Road, DMG MORI's new | lit room offer guests a chance to coolant was spraying on many of facility offers a pristine Technology see a wide variety of machines in _| the live demonstrations. The com. Centre that houses some spectacular | action as well as learn about them | pany highlighted 12 of its machines, machines. through interactive info guides and | seven of which are Canadian mieres. The sleek new design was, hard to miss, highlighting the black ‘and white options, as well as the new CELOS interface that demon- the expert staff that are there to assist, Representatives from com panies like Renishaw and In-House Solutions, amoung many others, were on hand to speak with visitors about their products and offerings. strates DMG MORI's commitment to user-friendliness and functionality. Looking to Grow Your Customer Base? We'll Help You Get Started CONTACT Lists ON-DEMAND EMAIL MARKETING SERVICE DATA SERVICES Ren PCa aR Lol es eca) Pee ee ey Ft tener eetny PSs SERRE ‘ee SanaanaaterAa SoTOOL TALK HEXAGON METROLOGY M&H PRODUCT LINE AND KOMA PRECISION FORM A STRATEGIC ALLIANCE ‘There is a new strategie alliance Metrology MBH product line and Koma Precision Inc for the North American market Starting January 1st, 2015, Koma Precision will be fulfilling tasks as the master importer and system inte grator. This agreement allows both ‘companies to join forces to support existing and new customers ‘M6 initially ventured into North America with their office in Ontario, Canada in early 2004. Upon becoming part of Hexagon Metrology, the com- pany transitioned its operations to the current location of Wixom, Michigan, between He Aes Sy pie h Ni} pe Koma Precision has been suecess- | and Mexico will allow faster response fully involved for decades in the needs of customers The new alliance has four service! integration sites as well as eight sales offices North American machine tool market Koma Precision’s regional sales and service branches in the US., Canada, When something exceptional develops between us: That's the MAPAL effec. Yo Poni solutions so becomes more e ise tl and see alos now at re you sues sewsmepl co |Your tea perme fr FEERURAY 205TOOL TALK PCT BS i GROB SYSTEMS PARTNERS 7 WITH DIPAOLO MACHINE TOOLS Back Spotfacing & : ROH Systems announces a new partnership with DiPuolo Machine Counterboring Tool ig ANd Gide y The BSE tool back DiPaoto will assume sales and service for the GROB line of S-axis unk versal machining centers, high-volume production systems, and assei Spotfases or back Hy csid testing efulpant in Ontarln, use and New Brunvwrick counterbores in one peas bores, GROB Systems will continue its direct support of automotive OEMs operation without with dedicated account managers, a strategy which has earned the turning the workpiece company multiple supplier awards in recent years. “The partnership with GROB brings several advantages, The design Etat Secs iach fe gue in ea abr alloGtng exseptanal flexibility and creativity tn tho process” says Nelaoh Martins, prow ident of DiPaolo Machine Tools. “Equally important is that GROB is manufacturing hundreds of machines in Ohio each year, 0 service and Counterbores Up to 2 all replacement parts are close to our customers," he says, Bill Vejnovic, Vice President of Sales at GROB Systems, says he was impressed by DiPaolo’s heritage first as a manufacturing and service company. "The background of this organization shows an appr for high-quality machine design and construction, and a full-service commitment to the customer. That's right in line with the philosophy of GROB Systems.” According to Vejnovic, new machine installations, technical support and replacement parts will remain the direct responsibility of GROR Systems. "The DiPaolo team will be an additional resource for new cus. tomers,” he said. To ensure fast service response, DiPaolo’s staff from Toronto and Quebec will be trained at the 290,000 square foot GROR ation Systems factory in Bluffton, Ohio, For more information, visit www.dipaolocne.com. tery Inc. Is pleased to ann thea . Tete re eee eh eee eee) Beene err et acne as roi Pret) wrt Sree ey Dee ree Peat ssagt ere eee eet ee aed ee ee eee) Se ee Pett cee ET FESRUAR OOS ‘ee SanaanaaterAa SoSoftware automatically generates part programs for inspection Mitutoyo Canada is announcing a development for current and future Mitutoyo. ‘CNC CMM users. Mitutoyo's MiCAT Planner is a sophisti- cated software program ‘which automatically ‘generates part pro- ‘grams for inspection. The software enables programming time to be reduced by up to 959% com- pared with programming using gen- cral-purpose software, fora significant potential increase in the efficiency of ‘measuroment work. The users simply upload thelr CAD file data with PMI (@D&qT), as well ‘as CMM system configuration data land the softwar then instantly and automatically creates a measurement program in a single click! MICAT Planner identifies tolerance informa- tion included in 30 models, defines the location for measurement and creates a measurement program automatically. Through its optimiza- Power chucks designed for the pipe threading industry ‘Samchully Workholding introduces its seties of Mega Bore Air Chucks, ‘model PAC. These pneumatic power chucks are designed forthe pipe threading industry and large through hole applications. The ar chucks range in size trom 18.5" with a 7.5 through hole (PAC-470/181) to 99.3" with a 22 through hole (PAC-1000/560). The full range of Samechully Mega Bore PAC chucks includes through hole, in adltion tothe two sizes shown above, ‘of 9" 230 mm), 10.8" 275 mmm), 12.79" (@25 mm) and 1476" 975 mmm), All of the PAC air chucks are extended stroke versions with total jaw strokes up to 1" (25.4 mm) ‘Samchuily offers front mount or front and rear mount chucks. worwsamchully.com ——_— tion function, MICAT planner creates program that enables measure- TOOL TALK editor, provides the ability to create programs which use the same param- ‘ment in the shortest possible time with the minimum number of probe re-positionings eters each and every time, preventing variation in measurement quality due to traditional program creators. MiCAT Planner will be avallable for release in and tool changes. early 2015. Utlization of the user For more information, visit customizable rule ‘www.mitutoyo.ca. CA5 RSS eee relay P Series Ghipbreakers Cope on) In comparison tests, KYOOERA'S new CAS-Series stad tuning inserts combined withthe PP, PO, and PG smart chipbreaker lineup have consistently outperionmed the competition, Don't take our word fr. for yoursal Contact your local KYOCERA Sales Enginoer or iit KyoceraPrecisionTools.com/CAS ‘o request a FREE SAMPLE. fF SPECIAL OFFER mt BUY 20 INSERTS, GET 10 FREE More information at KyoceraPrecisionTé iad <8) f=) aoe FEBRUARY 2075 35TOOL TALK Rigid and stable turning bars ‘Seco Tools adds turning bars to the line of damped ant-vibration tooling for tong overhang machining operations. These turning bars reduce vibrations in extreme culting conditions. This is dione by a “dynamic passive system’ inside the holder body where a heavy ‘metal mass counteracts vibrations created by the holders flex. ‘The GL connection has a polviobe taper-interface with two 180-degree positions that orient the too!’ cutting edges either face up or face down. ‘The connection also has fast lock- ing capability via a single integrated clamping ring that draws inthe tool head. Once a turning bar Is set it becomes possible to ‘mount and remount tooting heads without having to reset the system, ‘www secotools.com/us Improved speed, lower electrode wear and more uniform finishes Makino announces its new HS-Rib high-speed Z-axis technology for large sinker EDM processes, Makino's new technology has a jump rate four times faster and Z-axis acceleration rate 20 times faster over previous technologies. “The new high-speed Z-ax's technology is available on all Makino EONC-Series sinker EDM machines, and is designed for use in large workpiece applications requiring high accuracy and fine surface finishes. tts design offers highly tlexible processing capabilities, Including a jump rate of 20 m per minute with 1.5-G. ‘acceleration, Z-axis strokes ranging from {500 to 800 mm, and programming of corbital machining patterns with no amper- age limitations. The use of direct-crive motor technology and liquid cooling within the Z-axis structure ensures sustained ther- ‘mal stability and precise depth control, and supports electrode weights of up to 220 Ibs. ‘These machines combine rigid and precise construction, simple programming and advanced performance features for accurate EDMing of large workpieces, ‘Automatic tool change and adaptive controls enable high levels of unattended ‘machining without the need for operator intervention, and is further supported with advanced automatic jump machining controls to optimize debris removal ‘without the need for external flushing ‘wwv.makino.com Tc Sa Es Deco) Pe aoe y Dao ATTHE WORKPIECE INFRARED PROBES. RADIGWAVE PROBES. LASER TOOLSETTERS: mh MEASURING SOFTWARE Ba FEERURY DOTS ‘er nadanrnatwrtg omTOOL TALK Thinnest pneumatic quick-change pallet module With a module height of 20 mm, the VERO-S NSE mini ‘module from SCHUNK provides ideal conditions for retrofit: ting existing machines, making full use of the engine room, and direct clamping of small workpieces The patented drive concept consists of a fast stoke and a clamping stroke, ensuring that the compact modula has a Fighly compact parformanca. At a module diameter of 90 ‘mm, and a clamping pin diameter of only 20 mn, the NSE ‘mini also has an integrated turbo function and enormous pullin forces up to 1500 N. Locking is done mechanically via spring - force. The large contact = surfaces between clamping siide and pin minimize the surface pressure in tunclamped coni- tion, and the wear ofthe module. Even small workpieces can be directly clamped, and are completely machined from fve sides without restricting accessibilty. This is done by screwing the clamping pins of ‘he Quick-Change Pallet Systems directly into the workpiece, wow schunk.com Flexible machine configurations INDEX Corporation offers the MS400 fully CNC multisp- indle for nearly unlimited operations on small workpioces from bar up to 40mm (1.57 in) diameter or for chucking up to 120mm (47 in). Several innovative features make the MS40C quicker, mote precise, and mote energy efficient than competitive machines. With six fully Independent liquid-cooled, hollow-shaft CNC spindle drives each capable of up to 7000 rpm, the ‘M40 includes a main spindle rive with increased stiffness, and hydrostatic guide bush- Ings on each cartier slide which eliminate wear and the transmission of vibration to the tool. Designed as a modular system, the range of MS40C multispindles includes flexible machine con- ‘figurations. Across the range, the MS40C can be equipped with up to 35 axes, 12 identical CNC tool carriers with 1 or 2 axes, plus one or two 10,000-rpm synchronized spindles with 150 mm travel InZ, and up to six tools for backworking. Two tool slides approach each spindle, permitting two tools to be simulta ‘neously in the cut on each part. www.indextraub.com PRECISION THE CANADIAN LEADER IN SPINDLE REPAIRS its} Nath evan FRINERESSLER spins Jor HURON ON act, SOLUTIONS FOR ALL YOUR NEEDS 1 Fully vained technicians cetitiod by spindle manufacturers t= Compete in-house aching cer and Dynan Balancing f= Compe entngberchox i simulate yo CNC sind egurasons = One ear waranty or pas = Complete tam of technicians sericing Canada 1 Preventive maintoneree ar vibration analysis 1 Onsite tpe ging « BENZ HEXAGON aacanadaamtatmarng sam FEBRUARY 2075 57Metal finishing brings machined pieces to completion BY LINDSAY LUMINOSO jhe metal finishing industry is inextrica- bly Linked to the metalworking industry, as almost every metallic part must be fin ished in one way or another. The Canadian Association of Surface Finishing (CASF} rep- resents the wide range of companies dedi cated to various surface finishing processes, ‘and although surface finishing is not spe- cific to metal alone the association primarily deals with metal finishing, concentrating on electroplating, anodizing, and coating. ‘We spoke with Mike Kuntz, vice-chair of CASF and vice president of sales and mar- keting of Kuntz Electroplating Inc. (KEN), located in Kitchener, Ontario, to gain a better understanding of the depth and reach of the metal finishing industry in Canada, HOW DOES THE CANADIAN ASSOCIATION OF ‘SURFACE FINISHING (CASF) FUNCTION WITHIN THE INDUSTRY? ‘When it comes to the association, the CASF has been going on since the 1980s. It really is here to represent the surface finishing industry. The CASF used to be the Canadian Association of Metal Finishing and in the “90s that was changed to broaden the scope and open it up to finishing in general. It still hasn't broken out of its original mold, specifically metal finishing...[ Uhink there is a long term goal to include painting, which is source of finishing. The primary mode of fin- ishing, certainly on metal parts and equally on plastics, is the electroplating process. Outside of meval finishing and electroplat- exs, you have the suppliers, and the profes- sionals like environmental engineers and consultants, that are all involved. The chem- ical suppliers are a huge part of the industry and associations. In the last three years there has been a revival to reach out and provide a resource to the industry because it still employs tens of thousands of people across the nation. The CASF] launched a new website last year, and every year there are networking events, technical/environmental forums, and social networking events to bring people together to talk about the industry. ‘WHY IS METAL FINISHING SO IMPORTANT? Without it, parts can fail prematurely and there are safety issues, A lot of finishing hap. pens in the aerospace industry, for example. TERROR OOS ‘er nadernet a‘There is some very technical finishing that happens on landing gear, of say a [Boeing] 747 for example, that if you don’t do it your plane @oesn't land. Automotive, aerospace, and mining and gas exploration all have a fairly healthy finish- ing industry that support them. When you see Harley Davidson, for example, {the metal finishing] sorves two purposes. It provides corrosion protection because you have parts that are exposed to the environment; it also has the aesthetic, jewelry-type look. That's a traditional nickel plated part. I's a huge industry in North America that accounts for somewhere between $500 million to $1 billion just for the decorative plating, and it’s not just metal parts that get finished but also plastics and composites. ‘The electronics industry is also quite large, like printed circuit boards, and it has a num. ber of different surface finishing processes that apply. Specialty metals and copper are what let the electricity run through the components, and you are plating conductive ‘metal on to non-conductive materials that allows current to run through them, WHAT ARE SOME OF THE CHALLENGES FACING ‘THE SURFACE FINISHING INDUSTRY IN CANADA? I's a shrinking industry in Canada, but it's an essential part of the industry. The sur face finishing industry is faced with the same struggles and challenges as any other traditional manufacturing sector in Canada. We are struggling just like anybody else with the high labour rates here, Our customers require us to he globally competitive. Alot of the finishing that used to happen in Canada or the U.S, has gone to China or Mexico, ‘The shops that are left are the ones that are specialized, What we would consider advanced manufacturing, where there are real technical/specifie technologies required, or specific manufacturing processes that cannot be easily repeated somewhere else, ‘especially in low-labouz-cost countries. Those are the ones that are thriving It's cyclical too, [Kuntz Electroplating is] an automotive company for the most part, and we kind of live and die by automotive volumes. Same goes with aerospace suppli ers. They are experiencing a hoom right now due to resurgence in aerospace manufactur ing. But it’s eyelical; the ones that are doing ‘well are the ones that specialize, or have embraced lean manufacturing, technology and automation, and focus on responsive, flexible supply chains WHAT ABOUT ENVIRONMENTAL REGULATIONS, HOW DO THEY AFFECT THE SURFACE FINISH INDUSTRY? ‘The regulatory environment is changing so quickly. We are probably one of the most heavily regulated industries in Canada, with 1 few minor exceptions. There are an extreme number of envizonmental regulations, from municipal, provincial and right up to the fed eral level, and for goad reason, It's a chemi cal intensive process and industry; you can’t afford to have a mistake. That doesn't change the fact that it becomes a heavy burden to make sure that you are in line with all the aifferent changing regulations. [At Kuntz Electroplating], we have 15 full time environmental people at our com pany that take care of th ity program, all of our waste streams, recy- cling, energy, water, and air. We are proud of that, and we are always trying to stay ahead of the curve with environmental technology. 11's still a cost burden; it’s part of the cost of doing business in this industry. entire sustainabil: IS THERE A SPECIFIC REGION IN CANADA THAT YOU SEE A CONCENTRATION OF METAL FINISHING COMPANIES? ‘The majority of finishers reside in Ontario and Quebec. There is a fairly healthy fin- ishing industry in the West as well that is associated with the ofl and gas and mining industry. Those are functional type finish- rs, very specialized. You've got very large mining equipment and oil and gas services require specialized equipment under very harsh conditions, so there are some very large, healthy finishers that are again spe cialized for servicing a specific industry and sticking close to that industry. For the short responsive supply chains, they are important, to compete today. aareanadaametatwarn sam FEBRUARY 2075] 55WE ARE SEEING A TREND IN OTHER INDUSTRIES WHERE OEMS ARE IN-SOURCING OR MOVING ANGILLARY PROCESSES IN-HOUSE, IS THIS THE ‘CASE FOR SURFACE FINISHING? ‘The trend is actually the opposite in the fin- ishing industry. It is such a specialized func. tion of the manufacturing process. 4 lot of the ‘OEMs are saying “this isn’t our core compe- tency, s0 why are we doing it" The finishing business is a high fixed-cost business, there are barriers to entry, and there are extreme ‘environmental requirements and restrictions. ‘There are a lot of heavy chemicals used and itrequires a lot of due diligence to make sure those are managed properly. ‘The big OFM are outsourc ing more. Harley Davidson is a good example of that. ‘They were huge into doing electro- plating, the dec orative nickel-chrome plating, that bling that you see on their matoreycles. They did a lot of that in-house. Five to six years ago they made the conscious decision that they couldn't compete anymore, They now out- source all of their electroplating needs. Some painting is done in house, but the more specialized electroplating they decided to outsource, and that is a fairly common trend ‘we are seeing which presents opportunity for those that are competitive in that space. ‘There is certainly a lot of consolidation though. The last recession took a big bite out of the industry. A lot of the smaller, less ‘competitive finishers in the industry just couldn't compete. They were already sort of hanging on and if they didn't commit to lean processes and right sizing their business, they weren't able to survive the storm. IS IT COMMON FOR A SURFACE FINISHING ‘COMPANY TO SPECIALIZE IN ONLY ONE TYPE OF PROCESS? It's kind of split. There are many finishers that offer a broad range of finishing ser- vices. There is hard chrome plating, anod. izing, and dozens of electroplating finishes that you can provide. It depends on how specialized each company wants to become. For example, [KEI] used to provide dozens of different kinds of finishes. Then we saw there was an opportunity in high-volume decorative nickel chrome on metal sub- strates like steel and aluminum. We decided to specialize and carve out our niche. That was a good decision, as there weren't and still aren't many companies today that can provide the level of cosmetic quality and functional quality at the same time at the volumes that the motorcycle and automotive industries require. ‘There are others that are more diversified though. In some other spaces, like functional finishes, itis a little more competitive and commoditized. Like when you are doing fas teners for example, you are doing millions, and hundreds of millions of nuts and bolts per year. Isa mixture really. ANY FINAL THOUGHTS? ‘The metalworking and metal surface finishing industries are complementary toeach other. Many of the parts that are sur- face finisiod have to he metal worked firs, they need to he machined and have exact tolerances built into them, What's interest- ing is alot of times the finishing needs to be factored into the matalworking, becnase with finishing you are building up surfaces. So if you don't take into consideration a couple of thousandths of motal thickness building up on a metal finished part, then things just don’t fit. Many of the metalworkers who work with metal finishers understand through the OBM designs that those tunings need to work together. Many of the metal finishers will work closely with the machine shops to make sure that the quality is in syne ond unison, TERROR OOS ‘er nadernet aoa Ah/18V battery — | hp I emo Fy ee) Pat) SUE Celi) Ae Lie | ae ut} 4 rar Coen “2 The Ce nC ] unr or a ss Cena (On aera Naas 7 2 i enn LeerThe ‘in’ metal for manufacturers BY NATE HENDLEY Keren by te symbol, sania i a increasingly popular ‘go-to’ metal for manufacturers “Titanium is both strong and lightweight— as strong as steel but weighing only 56 per cent as much as steel. That gives it the high- fest strength-to-weight ratio of any of today’s structural metals. To produce structures of the same strength, far less titanium is required than other metals," reads infor- mation from the International Titanium Association (ITA), a non-profit trade group based in Northglenn, Colorado. Heat and corrosion resistant, titanium is highly regarded by people who make air planes and airplane parts “The commercial aerospace industry is the ~ — single largest market for titanium products primarily due to the exceptional strength to.weight ratio, elevated temperature perfor ‘mance and corrosion resistance,” states the TTA. “Titanium applications are most signif. icant in jet engine and airframe components that are subject to temperatures up to 1100°F (599°C) and for other critical structural parts, fas new titanium products, alloys and manufac turing methods are employed by the aircraft industry, the use of titanium will expand.” Indeed, titanium is also finding its way into the medical parts sector and world of oil and gas. For all its advantages, however, titanium has a reputation for being difficult to cut. Tt doesn't like to be bullied,” is how Brian Hamil, product engineering manager, SGS Tool Company, in Munroe Falls, Ohio puts it With that in mind, what’s the best way to cut this metal? ‘We asked some experts, and here's what they had to say: "Probably the biggest problem people report is heat build-up at the cutting edge, because titanium is a poor conductor of heat,” says Don Graham, manager of education and tech nical services, Seco Tools, in Troy, Michigan. “Titanium is regarded as a heat-resistant super alloy (HRSA). One of the biggest chal lenges lin cutting itl is chip control," adds Brian Sedesky, applications/sales engineer, Horn USA, in Franklin, Tennessee. “Chip con trol is difficult because the titanium alloys SEERA IOS ‘er nadernet a{ PVA Lg SMALLER Inserts with Superior Durability and the SAME THICKNESS as ISO inserts ‘* Same thicknes as 1/2"1,C. turning inserts at 20-25% lower cost! * Inserts feature a 3/8 |.C. and are available in 4 shapes (CNMG, DNMG, SNMG, TNNG) Unique damping system provides fast indexing and excellent stability © 12 external holder styles {including quick change) & 6 boring bar styles + Cutting depths up to 175" per side +12 grades and 11 geometries nge. Cutting Tools Rn ate ae ae ee eee Re oe eewill retain their strength at high tempera tures, Titanium does not soften and flow into the chip form of the cutting tool like steels do. The requirements of the cutting tools are also demanding when machining titanium. The cutting tools must have a sharp enough edge to shear the material in the cutting zone but be strong enough to withstand the repeated cutting forces of the material.” / ‘wore: indexingtechnolagies.com Z o' TT ice 1-888-88-NOEX mons TECHNOLOGIES INC. TOOLING COMPANY INC Heavy Duty, Large “| ug & Manual indexing Tables. For Machining, Assembly and Inspection applications + Seif Contained: Easy to install ~ Easy to operate ~ HIRTH Coupling for Accuracy, Repeatability & Rigidity ~ Bi-Directional Rotation - Ideal, Safe Solution for Handling Large! Heavy Piece Parts / MBT Series ‘Sizes from 18 ~ 98° square mt houstex" Febru 2015 Booth 133 BMT Tool Holders Driven & Static Talon Sik size! 40" Cawrae see, 7985" igh Torque, High Pressure Coolant + Muttiple Outputs [Quick Change Systeme, SReedily Available. cain P ON THE CUTTING Typically the heat build-up from ‘machining is controlled with coolant and by using an appropriate cutting tool that minimizes the heat generated during cutting,” says Kurt Ludeking, product manager for turning, Walter USA, Waukesha, Wisconsin. "A sharp cutting edge and appropriate chipform geometry can help quite a bit in con- twolling the heat.” ‘According to Brian MacNeil, milling products and application specialist at Sandvik Canada in Mississauga, Ontario the pai heat are, in order of biggest impact: 1) Ve cutting speed, m/min (ft/min) 2) ae cutting width, mm (inch) 3) fe feod per tooth, mm/tooth finch/tooth) 4) ap cutting depth, mm (inch) After setting appropriate param. the next thing we ean do is introduce high precision coolant at the highest available pressure,” says MacNeil, "Grades and geometries can also play a part in reducing heat by using sharp ground geometries and thin PVD coatings that pre- vent edge rounding of the geometry itself, Programming techniques can also help to reduce heat.” meters that affect eters, THE SANDV ‘Titanium is a very high strength material but has a low modulus of elasticity. This causes the mate rial to want to move away from the cetting tool. Or causes the tool to deflect,” says MacNeil. “You want to SERRATE ‘er nadernet ause very positive tools with sharp edges to overcome this challenge. ‘AS A RULE OF THUMB, IS IT A GOOD IDEA TO USE LOTS OF COOLANT WHEN CUTTING TITANIUM? IS IT POSSIBLE TO CUT TITANIUM WITH MINIMAL COOLANT? “Ido know that people are researching Cryogenic machining and Minimal Quantity Lubricant (MOL) machining. Sandvik is heavily involved globally in this type of research as ‘well with a number of universities here in Canada. These [applications] are not mainstream or readily available yet. Until then the best and most produe- tive results will always be with precise delivery of coolant under the highest possible pressure,” says MacNeil HAVE MORE OF YOUR CUSTOMERS BEEN ASKING ABOUT TITANIUM? “Yes, we see it more and more. It used to be just the big aircraft com panies or their first-tier suppliers [that used titanium), but now it’s get- ting into some of the smaller shops 100. A lot of them don’t have much experience with titanium or some of the high temp alloys...if you're a small shop, you want a tooling supplier that has experience with titanium, since [small shops) gener- ally don’t have in-house [titanium coxperts},” says Ludeking. ‘SOME EXPERTS RECOMMEND THE FOLLOWING CUTTING SPEEDS FOR TITANIUM: 60 M/MIN FOR ROUGHING AND THREE TO FOUR TIMES THAT WHEN FINISHING. WOULD YOU AGREE? “Yes, would agree if we are cutting ‘TiGALAV which is an Alpha/Beta tita- nium, We tend to use it as the bench. ‘mark for speed and factor speed for other material from it. For example ‘T1-5859 which is a Beta Ti, we would use half Tisalay," 12 speed as we would for says MacNeil. TITANIUM IS VERY POPULAR IN THE AEROSPACE INDUSTRY. DO YOU EXPECT ‘THE USE OF TITANIUM TO INCREASE FOR CIVILIAN AND MILITARY AIRCRAFT? “absolutely. ‘Titanium’s combination of properties makes it highly desir. able for the demanding applications of aircraft. Use will almost certainly inerease in the future...titanium] applications are expanding. Its corrosion resistance brings it into some other areas that are not typical aerospace,” says Ludeking. ‘These other areas include automotive, med. ical parts and oil and gas drilling. ‘SOME EXPERTS SAY TROCHOIDAL MILLING (IN WHICH THE CUTTER IS PROGRAMMED TO MOVE IN. ‘ACIRCULAR PATTERN) IS THE BEST MILLING ‘SOLUTION FOR TITANIUM. WHAT'S YOUR OPINION? “This is a very secure and efficient method of milling in HRSA. The low engagement (usu- Tap the Toughest Materials With 3 NEW Emuge Technologie: Z-TAPS Introducing 3 NEW Ranges of Emuge Taps with atvanced geometries and coatings, each designed to tackle today's most challenging materials. “2-Taps" with GLT-1 coating fr Stainless, VHC Technology for Nickel alloys and HRG Technology for taium, ‘Dramatically increase your productivity, process security and too! life today! — 4MUGE HIGH PERFORMANCE TOOLS 800-323-3013 ‘veww.emuge.com Lear more at www.emuge.com Aull Line of High, Performance Cutting Tools aareanadaametatwarn sam FEBRUARY 2075 65DUSSELDORF/GERMANY 16-20 JUNE 201% WZ dhe at wes of Metals Be eee oe Seti oe ee nud eee ete cece ete of Europe generate synergies in regard to foundry, Pree eer) os ee rd s top class technology forums dealing ie erent es ee ee Sang eee aoa eee eee ape me Messe Dusseldorf ally less than 10 per cent of the tool diameter) allows us to increase our feed and the short contact time in cut, allows us to increase the speed,” says MacNeil ‘Trochoidal milling is one of the machining tech. niques (that) can be advantageous if it is applied cor rectly and uses the right cutting tool," says Tom Hagan, milling product manager at Iscar Tools in Oakville, Ontario, "In many cases this technique does indeed sig. nificantly improve the situation, Material is machined by producing thin chips with high sfm. The tool must have the necessary cutting geometry and coatings but, ‘also must have the correct helix angle for smooth and, stable cutting for titanium material.” IN YOUR OPINION, ARE CARBIDE TOOLS THE BEST CHOICE FOR CUTTING TITANIUM? “With regards to finish and rough milling, in my opinion, no doubt, yes,” says Hagan. “Finish machining allowance (material to be removed per pass) is small, chips are thin and the heat does not affect the tool dramatically. In rough milling, low heat conductiv ity of titanium is a key factor and heat resistance of a tool material is very important, ‘Tungsten carbide has higher heat resistance compared with high speed steel (HSS), even with rich cobalt (Co) content and coatings. Sa ESRD OOSHowever, the thermal shock resistance of HSS is greater than carbide...as a result, HSS and HSCo (high speed cobalt) milling tools continue to be widespread in industry.” DO YOU HAVE ANY TIPS FOR OPTIMAL MACHINE TOOL SET-UP WHEN CUTTING TITANIUM? SHOULD YOU ONLY USE RIGID EQUIPMENT? “overall rigidity is key, as well as part fixturing,” says Matthieu Guillon, global segment manager, aerospace and defence, Kennametal, in Latrobe, Pennsylvania, “That is a Catch-22 question. Most of the parts in the aerospace indus- ry are very complicated shapes that vequire large clearance in overhangs of the tooling. As for rigidity, rigid equipment is always preferable. However, in many cases we will ‘machine non-rigid work pieces or have to deal with insufficient stiff: ness (poor work and/or tool holding, high overhang), or the machine tool is, not in the best condition,” says Hagan. WHAT ARE THE MOST COMMON TYPES OF TOOL WEAR EXPERIENCED WHEN CUTTING TITANIUM? Thermal cracks, edge breaking and chipping of the cutting edge," says Hagan. “Build-up and erater wear along with chipping are usually the pri- mary wear mechanisms in titanium machining,” notes Ludeking, “To com- bbat these and get the best tool life, {you need a cutting edge and chipform geometry suited to titanium...to get the sharpest edge and avoid build-up, ‘many manufacturers use uncoated carbide for titanium applications.” DO YOU HAVE ANY TIPS FOR TAPPING TITANIUM ALLOYS? “Tapping titanium alloys such a3 TIGALAV is more difficult than tapping most alloyed materials, but certainly doable with the appropri. ate taps and techniques...tapping speed is critical for cutting threads in titanium alloys and will result in tap failure and/or shortened tap life if not followed. We recommend a tapping speed of 10-13 sfm both turning into the tapped hole and exiting ont of the tapped hole,” says Mark Hatch, prod- ‘uct director at Emuge Corporation in West Boylston, Massachusetts ANY FINAL THOUGHTS ABOUT TITANIUM? “Rost machining practices are critical to use when cutting titanium or any HRSA," says ‘MacNeil, “Simple habits such as rolling into cut, keeping tools in cut and relling around corners are often overlooked and can give you a benefit in terms of tool life.” ‘And finally: "Don't be afraid of it. Understand it, It's not a black hole. We tool guys understand titanium and know how to deal with it," says Hamil. SAMCHULLY wwsamchullycom | 1977-75047 |infoasamchuilyworkhldingcom aareanadaametatwarn sam FEBRUARY 2075 67FABRICATING & WELDING NEWS CWA FOUNDATION’S “WEEK OF WELDING” he Canadian Welding Association (CWA) Foundation hosted a week of welding recently that included robotics and welding students from various schools within the Halton District School Board and technology educators from both the Halton District and the Catholic District School Boards. “It was a great time. All of the stu- dents and educators really enjoyed their experience learning about the ‘welding profession and having the opportunity to actually put the skills to the test and weld final proj ects,” said Deborah Mates, Executive Director of the CWA Foundation “Seeing the students’ interest in welding and how they worked as @ team clearly showed that if students are exposed to the welding profes sion ina safe environment, they really take hold and enjoy it.” From December 1-3, 2014, female robotics students from M.M. Robinson High School, Burlington Central High School, Garth Webb Secondary School, Craig Kielburger Secondary School, Milton District High School and Georgetown District High School learned all about MIG ‘welding safety, proper welding tech. niques and they even tried the vir. tual welding simulator and welded a decorative Christmas bell. acne on eee rere ne pea eer er ate Peon oe Lee een pene rtrry ier eee Brea satanic “Tloved it, it was a lot of fun,” said Heather Tarnawski, 17, a Grade 12 robotics student from M.M Robinson High School about her experiences welding at the Canadian Welding Bureau (CWB) Group's headquar. ters in Milton, Ontario. “like the ares and sparks and fusing metals together and seeing how it all works out when the project is completed.” On hand to educate the students on all safety measures, proper welding techniques and ensure the envi ronment was safe was Canadian Welding Association's Manager for Western Canada Ken McKen, along with Kim Kovaks and Tony Pisano, hoth CWE Certification Service Representatives, and Jamie ‘MeMillan, a female ironworker. “te was a lot of fun,” McKen said. "They quickly learned the basics of ‘MIG welding and were eager to see the arcs and sparks. The projects turned out great and by the team. ‘work and enthusiasm displayed, they can all become wonderful welders. MoKen and his team not only assisted the robotics students, but on December 4, the CWA Foundation hosted a "Train the sion for manufacturing educators throughout the Halton District School Board. The basics of TIG and MIG welding fundamentals, safety and introduction to the latest weld- ing technologies were covered. After the crash course, the educators were tasked to TIG weld an aluminum bird house as their final project. “PIG welding is a complicated and delicate welding process. It takes a lot of practice to master it, but the educators did a great job grasping the concept and their final projects were welded quite well,” said McKen. ‘The final day of the week, the CWA Foundation wel comed stu dents from Robert Bateman High School in Burlington, Ontario and wo manufacturing educators from the Toronto Cathol ‘They all got the chance to learn School Board. about welding and they fabricated @ similar project as the other students earlier in the week Every one of them had a great time,” said Yvan Poulin, Program Lead SHSM Welding/Manufacturing fat Robert Bateman High School. “The CWA Foundation always helps out. our students and the relationship is wonderful. It's exciting to have an organization that promotes weld ing education, safety and the entire welding profession in our backyard. Poulin also participated in the ‘Train the Trainer session the previ ous day where he received hands on training in TIG welding. “The experience was great,” he said. “TIG welding is a high-end welding process and heing able to get an educational session on that process and then apply that training to the more practical side and TIG weld a project was a lot of fun. I'm looking forward to further working with the CWA Foundation.” ‘The CWA Foundation invites other schools and educators to contact the Foundation and find out more information about bringing these initiatives to high schools in their provinces and communities. SERRE ‘er naan a7A oe OM ttt ate with Et iue Ue Tae PY ae AAC eve ORs a eur 1d Le See ne Oe een Ota ae acct) ‘welding fumes in your workplace, improve preductivity and quality.FABRICATING & WELDING NEWS ‘The turnout for the Canadian Welding Associ Newfoundland and Labrador chapter's inaugural event was a huge success, as nearly 70 attend. ees gathered at Manuals River Interpretation Centre on November 18, 2014, “Personally, as Chapter Chair, and as an executive, we are very pleased with our first event,” said CWA Newfoundland and Labrador Chair Brad Forsey. "This is our sec- ond attempt in the province to try and establish a Chapter, so to have this kind of turnout for our first event was very reassuring and is a clear indictor that the chapter can succeed.” Forsey said the chapter is focus. ing on getting industry involved fas much as possible because it will help industry disseminate their ‘message while boosting appeal to attendees, “We're going to work collabora- tively with industry and leverage the great things they're doing in the welding landscape here in the province while getting the chap- ter's word out and promoting the benefits of becoming a CWA mem: ber,” he said, “So far we have had A SUCCESSFUL CWA NEWFOUNDLAND AND LABRADOR CHAPTER INAUGURAL EVENT positive feedback from our first event and I'm excited to see this chapter grow over time.” Guest speakers for the event included: Rod Bursey, PEng., who focused on the latest revisions to SA W59-13, Greg Saunders, P-Eng., discussed fixed steel offshore structures ~ CSA W59-13 Annex U vs, $473 and Stig Skarborn, PEng., who presented on Quality: The Welder's Responsibility. “Having distinguished speakers attend the event was a great hon. our," he said. "They did an amazing job and the attendees were very pleased. All of the topics are very timely.” “Lam very confident on the chapter's future success,” said Forsey. Local industry is at a place right now where the CWA can pro- vide a lot of value and I don't see that changing for the foreseeable fuvure. The CWA is very important to industry here for educational seminars, new technological infor- mation, networking and the overall presence it has with regards to the welding industry.” Although the chapter's first event recently concluded, Forsey said the executive is working hard prepar- ing for future events, “We're working on two high impact events for the new year as a chapter, as well as work with the Canadian Welding Association (CWA) Foundation to host a Mind over Metal welding summer camp for students and work with indus. try to promote the 2015 CWA. CanWeld Conference that will be sight here in St, John’s from ‘September 12-15. Dan Tadic, Executive Director of the CWA, said it's great that the ‘Newfoundland and Labrador chap- ter had such a successful event. “Tis wonderful news—I'm very pleased with the hard work by every. cone to really make this a success,” he said, “It truly indicates the commitment by Brad and all the chapter committee members. There's alot of activity in the province right now and I'm looking forward to see- ing this chapter successfully grow.” For more information about the Canadian Welding Association and becoming a member please visit their website at www.cwa-aes.org. LINCOLN ELECTRIC ACQUIRES REALWELD SYSTEMS, INC. Lincoln Electric is expanding its ‘educational and training capabilities with its latest acquisition, ‘The company has acquired the ‘assets of the privately held live are welding training system manufac- ‘turer, RealWeld Systems, Inc, and the associated intellectual property from EWI, “RoalWeld Systems’ RealWeld ‘Trainer solution offers hands-on are ‘welding training and evaluation, ‘which complements our existing edu. cational offering and strengthens our position as a maxket leader in welding ‘education in North America,” sai ae] Mintun, Senior Vice President, ‘North America Sales & Marketing. “EWI developed RealWeld’s tech nology to advance welding training and help establish industzy-accepted credentials for welders,” said Henry Gialone, President of EWT. “We are thrilled that Lincoln Electric shares our vision for the RealWeld Trainer in its ability to educate and deliver skilled, production-ready welders for the manufacturing workforce, ‘The terms of the transaction were not released, Ta FEERORV OTS ‘er naan aFABRICATING & WELDING NEWS ELLIOTT TO DISTRIBUTE LVD STRIPPIT IN CANADA Elliott Matsuura Canada has Strippit has a bright future. The LVD Strippit Sales and Marketing rippit product line together with LVD now product demanding requirements of the ippit to pa ages their excellent reputation for .g market presence, industry awledge Canada. The new relationship brings xr resources and a broader plan rtively support and increase metal fabricating industry in Canada, The LVD Group is a leading man. ufacturer of a comprehensive range of sheet metal/plate working machine tools and software d customer service in solutions, including laser our business in Canada. We beliove cutting systems, punch presses, press brakes, our current and fuvure customers, Elliott and LVD Strippit will ben efit greatly from this, guillotine shears and mid level automation systems, integrated and supported partnership. hy its CADMAN PG based 4 Visit the Elliott show Windows compatible y? room in Oakville, software, Ontario and check out ‘We are confident that the rela their full range of metal tionship between Elliott and LVD ‘ working machinery One Machine Does It All Plasma Cutting « Oxy Fuel Cutting * Beveling Drilling * Tapping » Counterboring ¢ Milling * Marking rN www.kineticusa.com 800-606-2954 sales@kineticusa.com ‘sareanadaamtarwarng sam FEERUAAY OUTSTFABRICATING & WELDING NEWS AN APP DESIGNED TO HELP DETERMINE APPROPRIATE FILLER METAL Check out the latest Hobart app, available for iPhone and iPad. This new free app can be downloaded at the Apple App Store. "The Hobart Filler Metal Selector and Calculator app is a quick ref erence tool designed to help users determine how much filler metal is needed for a job, and it provides filler metal recommendations for ‘welding various materials. It also includes a heat input calculator and a hardfacing product cross reference function. ‘To determine the volume of filler motal required for a job via the app, users simply select a weld joint type and enter the dimensions of the weld size, The app alsa requests the user to input the total weld length, mate- rial and transfer modes, resulting Portability, durability, and performance in extreme-use applications Twoco's ArcMaster 4O1MST (MIG-Stick-Lit TIG) and ArcMaster 4018 (Stick-Lift 1G) power sources offer best-of-class perfor. ‘mance in on-site and portable welding applications. These units have a 10- to 400-amp output and provide ‘superior welding performance, especially with cellulose 6010 electrodes and MIG and flux cored wires (401MST). A rugged case protects the units from a 3-ft. drop and take up 60% less space than welders with similar outputs; the units measure 16.5" x 8.3" x 17.7". The ArcMaster 401MST weighs 54 Ibs. and the ArcMaster 4018 weighs 46 lbs., both about 403% less than competitive welders. Automatic primary voltage selection with no mechani cal changeover enables the unit to operate off single- or three-phase power, 208-230/400/460 VAC. Combined with 20% better eneray efficiency and strong performance when ‘connectad to generator power, the ArcMaster 401MST and 4018 are ideally suited for use in the following markets: Industrial fabrication, power generation, pipe fabrication, shipboard instal- lation and repair, petrochemical ‘fabrication, maintenance and repair and rental. ‘The 401MST works with all ‘common wire feeder platforms. CUSEMIGNESIEEL. BEES ENO ORE oe steel MIG and flux-cored welding —s ‘The heat input calculator in the Scenic Hobart Filler Metal Selector and A vopstencntaeesl voltage, amperage and travel speed variables to determine heat input, for a given application, while the filler metal selector option provides recommendations for Hobart filler metals. The Hobart filler metal results list the appropriate American, ‘Welding Society (AWS) classification for the recommended products. Ahardfacing product cross ref erence function in the new app allows the user to determine the Hobart filler metal equivalent to competitive manufacturers’ products The laser solution at your finger Gravotech’s Energy 8 is an economical CO» laser engraver designed for low-output marking neods in the workshop, store or office. Its compact size, low running cost and Included software make it highly effective solution. Energy 8 features ergonomic functionalities namely, the ‘ront loading concept, user control ofthe laser via the Interactive machine instrument panel, integrated storage capabilities and automatic focus adjustment. For occasional users whose activ- ity does not involve intonsive marking, this offer represents the answer to a vari ety of demands, be it {or fat or cylindrical engraving, or engraving on objects. ‘Compact in size (775 x 725 x 460 mm), Energy 6 fits easily into a small workshop and makes it possible to perform immediate engraving operations, The customer can chose, on the spot, the material he wishes to mark, from the exten- sive range oftered by Gravotech Energy 8 is supplied as standard with GravoStyle Discovery, which offers both the secunty of reliable software and the flexbilly of saved settings according to materials. wwrw.gravotech.com FT FEERORV OTS ‘er naan aNew high performance abrasive blend Norton Abrasives has introduced a major upgrade of thelr BESTir depressed center wheels forrignt angle grinding applica- tions. Norton NorZon Plus wheels now utilize a proprietary blend of Norton's patented, newest gen- eration SG ceramic alumina and Norton BlueFireTM zirconia alumina abrasives, combined with @ new high performance bond system for significantly improved grain micro-fracturing The new Norton NotZon Plus line has also been expanded with the introduction of Norton NorZon Plus Fast Cut Depressed Center Wheels. Norton NovZon Pus’ improved micro-fracturing capabil- ity provides a continual supply of serrated cutting edges, enabling unparalleled productivity, wheel life and overall cost effectiveness across a broad spectrum of right angle grinding applications. NorZon Plus Fast Cut provides a 15-30 per cent improved cut rate over standard NorZon Plus wheels. NorZon Plus wheels offer a fast cutting, long lasting, ow total cost solution, NorZon Plus is idea! for steel, stainless steel and ferrous metals. Wheels are avalabla in sizes 4-9" in "thickness. \wwrw.nortonindustial.com FABRICATING & WELDING NEWS High performance abrasive flap dises Weller introduces Tiger Paw abrasive flap discs, designed for aggressive performance and longer life in heavy-duty applications such as edge grinding. ‘The 100 per cent zirconium grain on the Tiger Paw is designed to last up o 40 per cent longer than other standard zirconium flap cscs. That durability comes from a high-per- ‘formance grain and special poly-cotton backing that provides superior grain retention. This is ideal for applications such as pipe beveling, weld blending, grinding, stock removal, edge chamfering and surface frishing and blending, ‘The multiple layers of coated abrasive mate- rial on the Tiger Paw flap discs expose sharp, fresh grains as they slowly wear away, and the poly-cotton backing prevents premature grain shedding on aggressive applications, Tiger Paw flap dises are avalabl in 4-inch, 4 1/2"-ineh, 5-Inch and 7-inch sizes that come wth cor without a 6/-inch 11 nut. Al sizes come in standard Type 27 syle, for smooth action, and standard Type 29 style, for the most aggrossive applications. The 4 1/2".inch and 7-Inch sizes also come in a Type 27 super high-density contig- ration, which contains 35 to 40 per cent more flaps for increased flexiitty, extended lf and lower operator fatigue wwvu.welercorp.com eM G ULL aN G9 Al indusis hove rules or the post 85 years the Teens cue os uphold the requirement of ih Canadian end eee oer eens Se ee PaO aU PESO THE OFFICE OF FEBRUARY O06 73Air quality is a cot BY NESTOR GULA hhe days of grimy smoke-filled manufac. turing plants are long gone. There is an ‘ongoing push to make the work place health- ier, and to this end there are more regula tions coming that will mandate the reduction of allowable exposure to the harmful fumes that are created during the welding process, “Hexavalent chromium [Cr(XD)l and manga nese [Mnl are among these materials,” says Kevin A. Lyttle, senior development scientist, ‘at Praxair, Inc. in a paper he presented at the Canadian Welding Association's Conference in October 2013. "The recent significant lowering of suggested exposures to these ‘materials makes it imperative that the weld- ing community have a better understanding of what can be done to reduce the amount of these and other potentially harmful constit. uents found in the workplace environment. ‘The challenges of controlling fume genera tion are significant, but they can be met by careful selection of consumables and weld ing processes, and proper use of ventilation, ‘While some may bemoan the introduction of new stringent regulations covering the workplace as an unnecessary intrusion by the government into the affairs of private business, the aim is to create a healthy work and regulators nd an even playing field for ssses. “Foremost is 1 3 protection as it applies loyer's responsibility to create a ‘working environment for employees,” says Peter Flleman, director of FHS at ESAB Welding & Cutting Products. “Employers ‘must obtain and apply the expertise to eval- uate worker exposures against the evolving regulatory and scientific exposure limits.” ‘Complying with any new air quality stan- dards will bring costs to the business. For Blleman, one single assessment is not sufficient for determining air quality and fume exposure. Welding is performed in a variety of scenarios; one of the only effective and accurate ways to evaluate worker exposure is through air sampling over the course of a shift or other respective period. One important factor when ‘measuring against new regulatory standards is using a “representative period of time that, encompasses the peake and valleys of fume generation at a particular job. This industrial hygiene assessment is not a skill set of most employers, so it adds to the cost of business when an external expert is retained for this purpose. It may be a case of proving the neg. ative, but one must make decisions based on the data from sampling rather than trusting assumptions or inference,” says Elleman. a FEBRURRY 7 ‘er nadernet aDTA aia INSPECTION COURSES TO TAKE YOUR SKILLS TO THE TOP LEVEL ORC cM ORE Coc) This course is designed to introduce inspectors, engineers, supervisors and other non-welding personnel to the theory and practical application of welding inspection tools and destructive testing of welds. The course begins in the classroom with the theory and fundamentals of common welding and cutting processes leading into the weld lab where attendees will learn the setup, application and techniques required to work using stick MIG, TIG and other common welding and cutting processes. After making welds, attendees will be given instruction on the use of Peer ie eee oa eat net ceed gages to asses weld discontinuities. Welds will then be subject to destructive inspection methods like fillet break, macro-etch and guided bend testing with additional discussions on other ee tea U RC eke eee ee eR On Lun eg ace eae ea This self-study course is ideal for individuals seeking certification to CSA W178.2, Certification of welding inspectors, Level 1, who want exposure to the course material prior to taking the ee ee a re ake en cL study material and quizzes to test the candidate's knowledge and retention of the material. The key purpose of the course is to prepare the individual for the classroom course and increase their Cee ete eae katate ete ee Pee eect SMCs ate etree ee tet a Pee Cn aac ear Cmte will practice to correctly identify discontinuities using 3D ete ecto Cnc Le et cy of discontinuities. This course is ideal for Welding inspectors, individuals seeking certification to CSA W178.2 and engineers with an interest in welding. Non-welders looking to have a career in inspection, entry level welders with little welding backgrounds.er storeys The hi of the reasons for companies to invest in a healthy work environment, “An increasing number of companies are preparing to purchase or already implementing steps, stich as source capture, to create a cleaner, safer welding environment,” says Allan Hilbert, fume extraction product specialist, Miller Electric ealth of the worker is but on Mfg. Co. "Additionally, insurance carriers are heginning to place more requirements ‘on companies to create a viable weld fume management program, making companies take action sooner.” Liability, from an insurance point of view, can extend beyond just the health of the ‘workers. Elleman explains that a second con. cern is the potential for product liability. "By design, welding consumables can generate hazardous decomposition products during use, Manufacturers must clearly communi cate the risks and uncertainties to the prod- uct purchaser and then trust that the user will use due care with the products, Welding fumes rise from the weld arc and are largely caused by the melting and vapor: ization of the consumable electrode. The fume will contain such elements as manga nose and copper, but the specific chemical compounds present in the welding fume depends on the composition of the consum able electrode alloy, the base metals being welded among ather factors. “Some specific compounds in welding fume have occupational airborne its,” says Lyttle. “While in some instances there may be an exposure limit for total welding fume, the exposure limit for a given individual compound in the fume may he many orders of magnitude lower. Therefore, certain compounds of environmental health significance can effectively drive the need to limit total welding fume exposure to very low levels. These compounds typi cally include forms of cadmium, chromium, cobalt, capper, manganese, and nickel.” As more research is being done on the effects of various organic and inorganic com- pounds on the human body, exposure limits exposure lim. and exposure guidelines for welding fumes continue to be modified and manufacturers should pay attention to how these can affect the business. “In 2006 (compliance by 2010), a change was made in the Permissible Exposure Limit @ for hexavalent chromium,” notes Lyttle. “This material is found in varying quantities in the fume generated by stainless st in the || welding electrodes and wires, This limit, set at 0.005 mg/m3 for any form of Cx(VI), proved challenging but not impos- sible to meet through the use of engineering controls and ventilation,” he says. "In early 2013, a new Threshold Limit Value (TLV) was published by ACGIH (American Conference of Governmental Industrial Hygienists) for exposure to manganese in both respirable Te FERUARY DOTS ‘er nadernet aand inhalable forms. This new guideline is 0.02 mg/m3—a reduction from the previous ‘TLV by a factor of 10. While this is a guide- line exposure number and does not have any regulatory impact, many in industry do seek to limit personal exposures to materials in the work environment to levels at or near recommended TLVs. Itis important to note that the ACGIH. makes recommendations as opposed to standards. “Implementing the CCOHS Hierarchy of Controls is the best step toward meeting them. This hierarchy pro. vides feasible options for reducing worker exposure to weld fume and includes four guidelines,” says Hilbert, "There are some steps that can he taken to ensure reduction of overall exposure, Miller Electric outlines four ways: (1) elimination or substitution; (2) engineering controls; administrative controls; personal protective equipment (PPE). “Elimination or substitution uses Jow-manganese filler metals or changing the shielding gas to an argon mix to reduce overall fume gen. eration rates. Engineering controls adds portable source fume extraction ‘equipment or centralized filtration systems. Administrative Controls ‘makes behavioral changes (e.g. proper hody positioning). Personal Protective Equipment (PPE) includes respira tory protection such as half masks, powered air purifying respirators or supplied air respirators. ‘There are many ways that aman- wfacturer can comply with these new regulations and guidelines. For some, it may require a change in pro- cess, consumables or fume capture at source or a combination of any of these three methods. “Lbelieve that our industry is doing its hest to comply with these new regulations,” says Dan Tadic, Ee eel executive director of the Canadian — Welding Association. “Some compa- — increased use of ftme captire at ‘=> source, use of welding respirators, a3 _ sare change in welding consumables, or simply though a process change. An aaa a FEBRUARY O05 77Welding wire for reduced manganese emissions Developed for hand-held, automaic and robotic welding in the automotive industry, as well as ral car manufacturing, structural ‘welding and other similar applications, this low manganese emission ‘metal-cored welding wire also addresses the new ACGIH guidelines, Coreweld C6 has more than 50 ‘per cent lower manganese content and is designed to provide improved operating ualiies while reducing manganese levels in the welding fumes when com- pared to standard met- ai-cored electrodes ofthe same classification. vwwva.esab.ca Welding gun sucks fumes away Lighter and smaller han many standard fume ‘extraction guns, the redosianed Clean Air Fume Extraction Gun from Bernard (a dition of Miler Electric Mig. Co), provides welding ‘operators wth a mora comrortabla option for reciicing weld fume and smoke, The gun is neary the same dimensions asa regular Bemara Ser\- ‘Automatic MIG Gun ands suitable or armost any ‘mocium- te heavy-duty sol or fux-cored welding application. features afour postion nozzie shroud that optimizes weld fume capture, gas ow and wold access. Tha small sia offers qood int ‘access and visibly, while a 960-dogree vacuum hose swivel on te rar ofthe handle mproves fxi- bilty and reduces wrist etigue comes in 400-500: ‘and 600-amp mocils witha 45- or 60-dogroe mock bend to maximize wie feeding, wwrw.bernardvelds.com Portable at source fume captu The Mobifiex 200-M from Lincoln Electric is a ow vacuum system for welding fume extraction and filtration. Suitable for smaller manufacturing facilities that require light to medium duty weld- ing fume extraction in variable locations, thas ‘one of the largest disposable filter cartridges in its class. It comes standard with @ collulose/polyester ftar and has after status indicator located on the front. A washable aluminum ppre-fiter protects and extends the life of the fiter by removing larger-sized particulate and pro- viding spark entrapment. wwwlincolnelectric.com example could be the use of the Gas Metal Are Welding (GMAW) or Submerged Are ‘Welding (SAW) processes.” ‘While shielded-metal arc (SMAW), pas-metal arc (GMAW), and flux-cored are (PCAW) weld- ing processes are responsible for generating a significant portion of the fume particles found in the welding environment, “gas-tung- ston are (GTAW) and submerged arc (SAW) welding processes generate significantly less fume than other techniques because of the way in which material is transferred from the consumable electrode to the weld pool, The fume generated by any of these arc welding processes depends upon a number of factors and each can have a very significant impact on fume production," says Lyttle. Fume hoods and fame control is the primary method of dealing with this noxious smoke. For Elleman, one of the best approaches is to direct fumes away from the welder at the source or through appropriate ventilation, “It's also important to consider the exposures that may arise from handling the raw con. sumables, by-products and filters that are the less obvious exposure pathways, I's wise to exercise good hygiene practices all around the ‘welding activities,” he explains. Positioning and the power of the fume extraction technology are essential. “It's important to have a system that includes the appropriate filter to capture the fume and that provides enough velocity to pull in the weld fume before it reaches the welding operator's breathing zone,” says Hilbert. "The combination of performance and cor- rect filter type maintains the best capture distance. For the welder that means the hood can be further away which means less arm movements and results in more welding.” However, a well-ventilated shop will not nec. essarily comply with the new guidelines alone. Tadic warns that General ventilation is not always practical as the fume may be inhaled before reaching an exhaust unit, This is why itis important to capture the fumes at the source. Whenever possible, use at-source fume control so that fugitive fumes are minimized, “At source fume extractors are also more effective tools for directing the fumes and air stream into the desired direction, away from the welder's breathing zone," says Elleman, "They will reduce, or possibly eliminate, the requirement to assess collat eral exposures and liabilities. Whole-plant fume capture is reasonable but is not as effective as source capture. One can use both, of course.” Fa FEERURRV OTS ‘er nadernet aIt’s the tie that binds DESIGN + DISCOVERY When people look for solutions, they turn to someone they can trust. NASA's James Webb Space Telescope wil soon allow us to see deeper into the cosmos than ever before, To make ure its tip into space isa success, testing had to happen right here on the ground. A new innovative filer metal needed to be developed to bind the alloys of is test fixture. Hobart had the solution. Find Your Solution. Today. | -a HOBART a 5 Ora sample of our vate fier etal ct PH today at HobartBrothers.comytiethatbinds. FILLER METALSeet earners cenit CO; lasers have a lot to offer BY NESTOR GULA rhen it comes to deciding on the right ype of laser cutting system, fiber lasers have heen capturing recent headlines due to their speed advantages. However, CO: lasers have been supplying much of the laser cutting capacity in North America. The fact, of the matter is CO: lasers have a strong. hold in the manufacturing industry because of their longevity. They simply have been around for a lot longer than the fiber laser systems and continue to be a popular choice for customers searching for the right system for their specific applications. “There is an install base of about $0 to 1 of C02 lasers versus fiber lasers,” says Mike Millette, laser product manager for Prima Power. One of the reasons is because GO: lasers can cut vary. ing materials and thicknesses without chal lenge—cutting up to one inch thick stainless steel. Shops that focus on custom fabrica tion, the COs laser offers the most flexibility. ‘What is the fundamental difference? When it comes to laser systems, the difference is found in the way the beam is created and the wavelength that is emitted. "CO: lasers create the beam using a gas as again medium, and the heam produced is of @ 10.6 micron wave. length,” says Brett Thompson, sales eng: for TRUMPF Inc ‘The energy represents what we commonly refer to as heat or infrared radiation, “It is transmitted from the laser to the pro- cessing head via line-of-sight copper mir rors enclosed in an external beam deliv- ery system,” explains Bob Kloczkowski, regional sales manager for Rofin-Sinar Ine, COslasers convert electric power into heat energy with approximately 10 per cent coming the actual laser beam. ‘The transportation of the beam to the focusing lens also changes a FERUARY OOS 2aSalvagnini Panel Benders Productivity Made Easy Se MG DIC Cee nin Pe eae ce sth flexible, accurate, and efficient way to form finished parts. Cornea It doesn’t get any ea: eet me ee cc) Ceca cre See ue Cane gee eu cna Steet et ere Oana eee NT AM Ce RL Cea RU Cee oe ee a RM cu eet oC aoe na RM CUNT SOE a nee ere Cente er Recueil Weeder teria g = aE CSET IT | For more information, = cers eral ll saivagnini salvagninieee aan orate aenverery) ries anpnding A Cots ae oath seme fue elds ens Seca ne Monat meh ieee opin oer nal mer cotbbiuipeondutve tals such as brass, : ys Ww variety of met. als as well as non-metal, including wood and plastic, making up for its limitations, The wavelength of a fiber laser is unable to cut these types of ‘materials, This allows for more offerings when it comes to customers’ requests, Setting aside some material exceptions, there are many advantages to choosing a CO: laser system for a manufacturing facil ity or job shop. "The primary advantage of 8 COs over a fiber laser is its ability to cut thicker stainless steel with smoother edge quality than what a fiber can do,” says Jason Hillenbrand, laser product manager for ‘Amada America Inc. From Amada's stand point the real advantage is the fact rare trl that the CO: option can cut ‘thick mild steel with a hit better edge quality as well as its speed, Solid state, fiber laser systems are best suited for up to six millimetre thick mate rial, Millette explains that this is where you get the speed differential and therefore the payback on the cost of the machines. He uses the example of a company that makes rail cars or something similar in nature, where a good edge quality is needed in half-inch, three-quarter inch or one inch material, this is where the CO: laser has the advantage "As you get into thicker material the cut speeds become closer and closer together. One thing that is a detriment to fibor is when cutting thick material, the beam is so small that itis difficult to get parts out of the skeleton. All of the time you would gain, potentially, with more speed y * inthe processing, you would lose getting the parts out of the nest,” says Millette. TERRY OOS ‘er nadernet arofin ROFIN Laser Solutions — Marking, Welding and Cutting Systems for Automotive, Aerospace and Defence ROFIN laser systems can be found providing durable, high-contrast Direct Port Marking and Unique ID traceabilly marking for aulomotive and mission-essential military ond aerospace applications; high-speed, high-power laser cutting for processing of metals and organic materiols; and loser welding for precision, contact free material joining with minimal heat distortion From high-ps reduction systems for high-volume manufacturing fo dap RAD unis when canes Hh Gul, High Sped ee Feemsolbions for Marking, Cuting L-= Think ROFIN ROFIN-BAASEL CANADA LTD 360014) Lord Rood Missssougo, Onto L5L-6AS 607-0400 for « demonstration imple WE THINK LASERScere Se aeteeete eee nraton ‘The initial investment cost of the CO: laser system tends to be lower than the fiher option, and those working with a wide variety of materials generally see this as a reasonable choies In addition, the overall performance and quality of the resulte tend to be higher ‘compared to solid-state laser cutting,” says ‘Thompson, who adds, ‘When processing stainless steel the CO: laser produces a sub stantially more cosmetically appealing edge. Processing stainlees eteel with a solid-state ‘a. laser produces a more stri- ated edge and the 8 win * stainless steel has a lower burr limit Fabricators who process high quantities of stainless steel, or who are especially con. cerned with the edge quality, would be more inclined to install a CO: laser system." Another area of concern i when purchasing a new machine comes with operat ing costs. Even if the machine investment is the right price, a high operating cost can soon eclipse the initial savings. "The electrical efficiency of the CO> is approximately 10 to 12 per cent. whereas! the electrical efficiency is 30 per cent for a fiber laser,” says Frank Arteaga, head of product marketing, NAFTA region, for Bystronic Inc. What this means is that fiber laser requires less electricity to create the laser beam than its counterpart. This can equate to averall costs savings. However, another factor in operating costs is. cutting material and thickness. When dealing with mild steols, the fiber laser has a lo operating cost, generally as low as $5-13/hour, whereas the CO: costs $9-15/hour. However, iis cutting stainless steels and aluminum e the cost differential is minimal. “They get closer together in costl because [co] use nitrogen in the cutting and with fiber you have to use more nitrogen pressure and volume to accomplish the same [result] so you would spend a bit more on the nitrogen cover gases than you would on a GOs, Both systems can be up to 25 dollars to cut alu minium or Stainless steels,” says Millette Overall, the decision to purchase or use one system over the other is predicated on ‘shop's general applications. There is no fast and hard rule for choosing one over the other. The fiber laser system, the more mod. ern of the two, offers many cost-effective solutions. However, “For a smaller job shop it is very difficult to make up a hundred grand 11 operating costs to the initial purchase price of the machine where you are only running the machine maybe 30 to 40 hours a week,” explains Mil ‘The strength of the GO: machin in its usefulness. "CO: remains the most flexible laser cutting technology,” said Colle. Being able to cut various materials and thicknesses gives this machine an advan- tage. However, having both fiber and CO. lasers in the shop ie a sure fire way to maxi mize the features of both machines, @) esate TERROR OOS ‘eonsanadaameabnerng sorMANUFACTURE THE FUTURE Ua eR I UCeaa TU Te) Viola eae Diels) Uc. 0) esl al aol od LOL] OnE CANADIAN MANUFACTURING TECHNOLOGY SHOW , Perea MMC merge cr technologies and 700+ manufacturers POPC eam! Ver Whe mp CONNECTING BRIGHT —_—_ INNOVATIVE Ree ROL itt PEOPLE Lat} TECHNOLOGY coal FIND OUT MORE AT CMTS.CA ote Sead Re a aeSTEEL COILS BY NESTOR GULA eed end of Toronto, Mecon Industries is @ privately held Canadian firm that special- izes in making coil handling equipment—the machinery that unrolls the coils and the straighteners that make the coiled steel flat so it can be worked by other machinery. ‘The company was founded in 1961 by Anthony Foscarini to manufacture press tooling, fixtures and machined parts. The company gradually expanded its product ine to include custom designed machinery, conveyors, drilling machines, inspection equipment and coil processing equipment. Today the company places its focus on two ‘main product lines, sheet metal bending tools (or brake dies) and coil handling equip. ment. These areas comprise 70 per cent of the company’s business, with the other 30 per cent including machine shop and weld- ing services, custom design and builds of specialty machines. ‘Mecon’s primary clients are associated with the automotive industry. “They tend to buy the biggest and the most,” says Jeff Norman, Canadian company sells coil handling machinery to the world vice president of Mecon Industries Limited. “But anyone who makes stamped parts from metal is our client. You can have office furni ture makers, appliance manufacturers, people that make air conditioning equipment. The plant is located in an area that used to have a lot of automotive and other man. ufecturing activity. “The GM van assembly plant was right here. We did a lot of work for them,” he says. As plants closed, Mecon moved further afield to find customers. "A lot of the plants are still here but they are not doing much. An area that is coming back is Ohio and Michigan, Norman sees no reason to join the flight of manufacturing and relocate his shop. The have a 45,000 square foot plant that employs 25 people, "We have a good spot here. We have a good building, a good facility, and there are a lot of big advantages of building in Canada, and in Toronto,” he says. "We have a well-educated workforce. We have a good and secure environment to work in, ‘There are a lot of good reasons for us to he here." With customers in the United States, Mexico and even in Europe, Norman does not see the distance to customers as a great Be ERROR OOS ‘er nadernet aobstacle, although he admits it does make sales and support more difficult Using coiled steel is beneficial for manufac. ‘turers with long production runs. “Where you are making parts in the 5,000 and up range, there are lots of savings to be had by not hav- {ng to constantly start and stop and handle sheets of metal,” says Norman, "Coil process- ing means you can set up once and then run a lot of weight of material for many, many hours without doing setup change, It means youcan do high volumes of parts with a very small amount of labour input. The stamping process is very fast as compared to some of ‘the cutting processes. With stamping you can produce parts at 60 strokes per minute.” Before using coiled steel, it must he straight- ‘ened, and this is where Mecon’s expertise lies. “You start from coil, you need to unwind it somehow, that is where we come in,” he says. “Our machine unwinds the coil, conditions it to take out the curve, and we have a machine ‘that will feed it into the next process. So if you dial 12 inches, the machine will give you exactly 12 inches within a thousandth of an inch—every time you ask for it.” ‘Mecon’s coil handlers can feed a press, laser cutter, torch, shear or any other sheet metal tool. ‘The goal of the conditioning is to get the metal sheet flat, especially if it’s producing blanks which will he stacked up. Mecon’s systems can handle coiled metal from one- inch thick to material that is about only three thicknesses of paper. There are two types of systems for unrolling coiled steel. In one the coil reel locks the coil in the centre and then rotates it like a spool. The other is a cradle system with the coil resting on rollers and the forge rotating the coil comes from the rollers. “The problem with the cradle is that you are rolling on the outside surface which is the ‘working surface, so there is a risk of contam- ination, marking or rubbing,” says Norman. ‘So itis not a good choice when things have to bbe perfectly smooth. If you are making outside car parts and they will be painted with gloss paint any mark will show, s0 you need to run the coil with a different process, something that holds the coil frem the inside and does not have a chance to mark it from the outside.” ‘The biggest challenge the coil handling industry is facing now is adapting to new stronger and lighter materials being used in the auto industry. The newer ear parts are ‘being made with steel that has more carbon and other alloying elements in them. They have much stronger mechanical properties and they act quite different, explains Norman, “We are engineers and we understand the material, and we will design the machines Gifferently to handle the hard and strong, materials, What harder and stronger means is that you have to bend it further to actually straighten it. ‘The way Mecon's straightening machine ‘works is by hending the metal back and forth as it passes over a series of rollers. “With harder material the old straighteners may not have any influence on these new mate- rials. They worked well on 1/-ineh mild steel, but now with the harder material they cannot push the 1/8-inch to a small enough radius to actually bend it," he says. "So ith the hard material you need a different straightener: aareanadaametatwarn sam FEBRUARY 2075 a7Peri eer me ee eee Coil handling equipment, especially straighteners, is not a one solution fits all system. Each system Mecon builds is cus tomized to that customer's requirement. According to Norman different details that you need to know, the material thickness, material width, the min imums and maximums, and the hardness of the material “We generally ask for the specifications and ‘we look at all the materials they run and look at our straighteners to see what is the best compromise for all that will give them the best performance," he says. there are several ‘The process is not as simple as unrolling the coil and passing the metal through some rollers to make it straight. One of the chal lenges when starting to straighten the metal is that the material characteristics can change, depending on the type of mate- rial. This means that you really need to be careful not to overwork it, especially in the straightener. “Depending on what you are trying to do with the steel after in the press, if you are making a deep draw, making a cup shape that material has got to go from a circle and get drawn into a cup, so that is deforming ener a ESRD OOS Te nana Soa lot in the forming process,” says Norman. | cut sheets from a steel service centre made “The materials must also have the properties | sense,” he says. “The high production in mak- that allows it to flow into the new shape— | ing tubing or making pipe or making auto that would he a special type of steel that is | parts is where you are trying to get 5,000 developed that would allow it to draw like | parts out of an eight hour shift and you are that. Ifwe did too much straightening and | trying to do that three times a dny, 200 days worked that material that would change the | a year. Thatis high production and that's the mechanical properties that didn't allow it | way auto parts are made. Ifyou tried doing ta flow then we have done too much aid you. | them in a different way you would never he would end up with eracking in that drav.* | able to afford the price of a car” Bd ‘As the North American and world economies slowly begin to move for ward, Norman sees a positive future. Manufacturing, especially in the auto sector, is bouncing back. "There is a point where buying coil of material and processing it into many pieces steel makes sense. There crear is a point before core that where buying Cleaners for Every Sump! Eriez offers everything from drum top vacuums to 1,000 gallon dual tank sump cleaners to remove coolant, sludge and chips from your sump, ther + Filter the sludge and chips from the coolant {Return the tered coolant tothe sump, br transports it for recycling or disposal Fluid Reeyeting Selection Guide See the whole line-up! visit Hydrotlow Eriez.com { FILTRATION SYSTEMS aaa a FEBRUARY 207568Tripar Inc., Montreal, Quebec BY DOUG PICKLYK ver four days in early November 2014, Montreal based Tripar Inc. opened its doors to customers and suppliers to o: 65th anniversary. This event was made doubly special lebrate the metal stamping company's ‘when 91-year-old Ben Sevack, the company's founder and chairman, made an appearance ‘The well-attended open house was symbolic of the com, pany’s core strength of building long-term relationships ‘with its customers, one dating back since its inception, all ingness to share the expertise the company has acquired over three generations. ‘Tripar’s specialty lies in metal stamping (mainly pro- gressive, draw & deep draw), with an international rep. utation for its work in the commercial and architectural lighting industry. The business originally started in 1949 by three partners, thus the Tripar name. It was brothers Ben and David Sevack, who from England following. the Second World War, and local man while also maintaining strong family values and a nected to the die making trade, Before long it was just the Sevack brothers ‘who were running the metal stamping business, but the Tripar name stuck. Initially located ina 4,500 sq. ft. building on Hays Avenue in Montreal, the company moved to 4 10,000 sq, ft. space in northeast end of Montreal Island after its 10th anni. versary in 1960. Now aft Tripar occupies a 65,000 sq. ft. plant, space for now,” says current company President, Lloyd evack, Ben's son, although he doesn't discount potential expansion in the future. ‘An engineer by training, Lloyd worked for two compa nies over 15 years prior to joining the family business as president in 2001 after his uncle had retired. days Tripar has been well known to the lighting fixture industry. Lloyd notes that today around 80 per cent of its business comes from lighting OEMs. “We're very responsive to that market. We can modify tooling, often giving customers exactly what they want with little or no tooling cost,” he says. ‘Tripar does resists competing in the high-volume, low- end, residential lighting space, the products typically found in the big box hardware stores where deals like & six-pack of recessed lights run for $50, with light bulbs included. “I's all made in China and of terrible quality four rounds of expansion ‘We have enough since its Ba ERDASsays Lloyd. “But that’s not our market, That's practically a throw-away market ‘Metal stamping in North America is a challenging business and a lot of work has moved overseas, but Lloyd does see some work coming back. “It's not a tidal ‘wave, but it is happening. Laure Sevack, Lloyd's daugh er, joined the asales and marketing role in 2013. She relates the story of one local customer who had shifted its manufacturing to China years ago and recently rediscovered Tripar. “Th ‘we were always there to help them,” she says. ‘Tripar was able to quickly turn around their request, and Li up by asking for the opportunity to quote on the bulk of their close we were to the pricing from China. I know we are competitive, and we're constantly innovating, “Well, their mouths were on the floor when we quoted, and they said, you've won our business back, It's a combination of being local and a focus on quality that works in their favour. "Phe reason we got the eppor- tunity to regain their business was because they had ordered a thousand parts from China and more than half were scrap," ‘The company is not only winning hack business from local customers but is also growing its relationships with European lighting clients. “We have customers from France, England and Belgium and we're in discussions with firms in Denmark and Germany. All for the same reason, they're eyeing the North American market,” says Lauren. As the European economy remains stalled these OEMs see the North American market ripe for expansion. The firms find Tripar, often through referrals, and take advantage of their expertise with North American con- struction and electrical codes, and the company's ready supply of existing parts. “Initially we may he shipping components to Europe, where they assemble them and ship them ack to North Ame: European firms are setting up shop somewhere in North company in ed us because they were in a piclele and knew ren follow ork. “I wanted to see how notes Lloyd. ca, but more and mare the ‘America to assemble and deliver from here,” says Lloyd, Although modest in their Canadian way, the are convinced they are the largest firm in North America specializing in the lighting market “We get told that all of the time," says Lauren. “We don’t know if we're always safe to make that claim, but then we have customers who tell us that we're the only ones who do what we do.” ‘T know of a few others that do other aspects of light. ing, but we're the biggest,” says Lloyd. And with 65 years in operation the company’s knowledge is valued. Sevacks "The number one feedback I get from our customers is that they love our expertise,” says Lauren. “They know that at any point they can come down, sit with our team of engineers and work out their problems. We care about finding solutions, and for the lowest possible cost. ‘As much as we try to diversify out of lighting—which we do—we still continue to get more customers within, lighting,” says Lloyd, “particularly now with the evo. lution of LED lighting which has taken place with such rapid speed over the last three to four years. New compa: nies keep popping up.” The company certainly handles jobs outside of lighting as well, listing off projects including air purifiers, gar dening tools, and project supplies such as xylophone kits and blind shelf supports. The company’s largest single contract was to manufacture a racking system for a mas- sive (600,000 eq, ft.) grocery chain’s automated storage & retrieval system, FEERURAY 2076 at(On the factory floor, Lloyd insists they are constantly try- ing to modernize to meet new demands and requirements. ‘The company has over 100 presses, CNC laser & press brakes, shears and metal assembly including spot welding. They do a lot of high-volume press work that start from coils, and for smaller volume jobs they have sheet metal fabrication equipment. For a lot of lighting components they work with galvanized steel, but for jobs that require a better aesthetic they use cold rolled steel that can be coated or plated. “We also work with aluminum, copper, brass, stainless stecl, and some prefinished materials, like pre-painted steels or pre-plated—both of those can be formed to a degree without flaking and if that works for the cus- tomer, it's way more cost competitive than post finishing (painting or plating)” says Lloyd, Shortly after the economic collapse in the fall of 2008, ‘Tripar installed its Amada LC 1212 C02 laser cutter. “We ‘were responding to what customers were telling us," says Lloyd. “I was the one who resisted it for the longest time.” He adds that the laser has allowed the company to start small with a lot of new and even existing customers “Customers told us, ‘When we have high volume and can justify tooling you guys are great. If we don't have high volume and you can modify an existing die, you guys are pretty good. But for lower volume you don’t have any option and we have to go somewhere else.” So Tripar will often start out with the laser option with new clients or projects that are in their infancy and may need to he market proven before moving to larger runs, “The difference with us is, unlike a laser-only shop, once a customers’ volumes increase we'll he the first to say, ‘You're tying up our laser doing high-volume work, so instead of paying $4 part, if you spend x-thousand dollars on tooling, your price will drop to $2 per part.” And the numbers speak for themselves,” explains Lloyd. “That takes the load off our laser and keeps it available to do what it's really best at which is our lower run work." Last year Tripar installed its newest stamping press, 4 200-ton Minster press, up from the 160-ton which was their previous top end, “Since installation in late 2014, ‘we have several jobs that we had won, the dies of which are being designed and would have been difficult to put ona 150-ton press,” says Lloyd, ‘The company is very vertically integrated, with all of its tooling done in-house. "Lately our tool room has been, working overtime, 60 to 60 hours a week for the past three months because we have won orders for many nev dies,” says Lloyd, adding the company has over 1,500 dies in stock. “The only process we subcontract is wire cutting and NG profiling, the whole die design and build cycle is, done in house,” says Lloyd, "The next project we're going to be evaluating is whether or not it makes sense to actire CNC milling capability to speed up the machin. ing of various blocks that we have to make for the dies.” He explains that it would possibly speed up the tooling process, but it wouldn't be a big change to the busi ness, explaining, “Our objective is to make profit on the stamped parts, not the tooling.” ‘As the company enters its 66th year, the benefits of experience and staying responsive to the market are propelling it ahead. “It’s no walk in the park,” says Lloyd. “Yes we have our reputation and yes we have customers coming to us, but Asia is out there, it's a reality. We have lost some business to people who say they have to save ‘money and move their manufacturing to China; some of them have come back to us. ‘It's two steps forward, and 1.5 steps backward, and we slowly progress. We quote on a lot of things and we don't win them all, but we win enough to keep moving, forward.” ST EERURY OOS ‘er nadernet aEdmontonEAro \Gentres = Bc aa ae 7. = am To reserve your booth or register visit wmts.ca sme" Official Media Partners cae PLANT WEST — WvANUFaxTURINGNEW MARKETS, IMPROVED ATTITUDES Grant Metal Products Ltd., Rocky View, Alberta (COURTESY OF PRIMA POWER. fastest growing city in Canada. But geography alone only begins to tell part of the story of the company’s success ‘Three main rules for success in the real estate market, Grant Metal Products was founded by Bill Grant and are: location, location, location. And that same maxim his wife Joan in 1980. Through the years, the com. could also apply to the dramatic success of Grant Metal _pany has evolved to become the supplier of choice for Products Ltd. in Rocky View, Alberta, a custom manu- a growing list of customers who require high quality, facturer of sheet metal products for the construction, consistent precision-made sheet metal components in lazing, and signage industries. which found itself inthe | British Columbia, Alberta, Saskatchewan, Manitoba, middle of the Calgary's recent construction boom—it’s the | and customers who supply products around the world. During this time, the company has grown from three to 34 employees. and today is housed in a facility that provides 85,000 square feet for pro: duction, operations, storage, project management, and shipping. Grant ‘Metal Products fabricates mainly light gauge material for its custom ers—everything from 26 gauge to inch in steel, aluminum, copper, brass, and stainless steel ‘The company attributes its contin. Cee creates Pee eneen er itor) Sa ERROR OTS Te nana Souued growth to its ability to respond to new business opportunities and the ‘willingness to try new things. "We have continually diversified our ser: vives," explains general manager John Reitmeier, “AL one time all we pro- duced was metal building flashing, ‘Thon we began servicing the glazing industry and then the sign industry. BUSINESS PROFILE: FABRICATING “WE'VE USED THE SHEAR GENIUS IN A LIGHTS OUT APPLICATION WHERE WE'VE LOADED IT AND GONE HOME AND IT IS READY FOR US THE NEXT MORNING. WE ARE NOW USING IT FOR REPEAT ORDERS. WE JUST PULL THE FILE AND U.S, the company looked at three types of machines, including water Jet, laser, and punch centers. After mich comparison and evaluation, Grant Metal Products purchased the Prima Power Shear Genius flexible manufacturing cell. It was installed and operational the last week of January 2006. “We decided not to buy We also supply sheet metal parts to a RUN THE JOB. THE SHEAR used or an entry-level punch center,” company that builds theater sets that GENIUS HAS IMPROVED OUR says Reitmeier. "We wanted to pur- have heen used in performances such PRODUCTION AT LEAST chase the best equipment available.” as Phantom of the Opera, Showboat, 20 PER CENT.” and others.” Today, Grant Metals has expanded its services to pravide con tract manufacturing to other OEMs in the area, While slow, steady growth has been the foundation of Grant Metal Products’ success, the realities of today’s ‘market are evident in the company’s changing philosophy. “The entire building industry is a big part of our busi- ness,” states Reitmeier. “With the explosive growth of the construction market in Western Canada, we've never been so busy." This dramatic increase in demand for higher productivity and quality, coupled with the increasingly difficult task of finding labour in Alberta, drove a search, for automation, MORE PUNCH FOR THE BUCK ‘A good example of this new emphasis on automation ‘was the company's increasing need for faster and more cost-efficient punching, For many years, Grant Metal Products had used a strip punching system to handle its punching needs. “While this system was very slow and labour intensive, punching was not a big part of our business,’ amount of punching increased so much that we had to find a more productive punching method. After attending several trade shows in Canada and the sxplains Reitmeier. “However, by 2005, the Ts neem torent erie cones PUNCH/SHEAR COMBINATION With the Shear Genius (SC) concept, the objective is to provide one machine capable of trans forming a full-sized sheet into finished parts. These parts can be moved to final production stages for imme. diate integration divectly inte final product assembly, Shear Genius requires minimal set-up times and allows for “lights out” operation, while also increasing mate rial productivity through efficient and versatile nesting programs, The level of automation can be customized through Prima Power's modular solutions for raw mate rial storage, loading, unloading, sorting and stacking, According to Reitmeier, the benefits of the Shear Genius to Grant Metal Products include increased speed and accuracy, additional product lines including more elabo- rate products and the possibility of new markets, such as small part brackets and heavier material products. “There is a definite labour saving as well, since we are xno longer having to pre-shear or go through all the pre. vious manual steps,” says Reitmeier. “We've used the SG ina lights out application where we've loaded it and gone home and it is ready for ts the next morning. We are now using it for repeat orders. We just pull the file and ran the job. The Shear Genius has improved our production at east 20 per cent. aareanadaametatwarn sam FEBRUARY 207595BUSINESS PROFILE: FABRICATING ADDITIONAL AUTOMATION Im 2009, Grant Metal Products replaced their earlier model the SG8. The company also added the Night Train Material Management System to its arsenal of fabricat, ing products. And in January of 2014, the EBe automated bender was purchased, NIGHT TRAIN ‘The Night Train Material Management System, a mate rial transporting center, allows the connection and operation of multiple flexible manufacturing units to a factory manufacturing system. The automated system provides a total solution for unmanned operation for sheet metal fabricators by controlling material flow within the system, including the supply of raw material as well as removing and storing work in process. “The Night Train is a remarkable piece of equipment with 130 bays,” explains Reitmeier, “The more we use it, the ‘more we understand everything that this system can do for us. The Night Train allows us to better control our inven- tory. It allows us to buy in bulk and store material, because ‘we have a wide variety of small jobs. For example, we might make one or two products for one company and 300 for another. So we stock a lot of that material in there. We use it for work in process with the new bender. It allows us to store the 5G parts for the automated hender with minimum space requirement, We used to store these parts on skids and racks and pulled them up when we needed it. The ‘Night Train does the work of three employees and provides better control of our inventory and our entire process.” i cee rersatle nesting programs. Tha lve AUTOMATED BENDER ‘The company's EBe servo electric Express Bender is fully automated, from the loading of flat punched parts to unloading of the finished product, ‘We purchased the EBe because we couldn't keep up with just our four press brakes,” explains Reitmeier. “The Ee is an excellent machine, The accuracy is amazing. Some of our parts have up to 16 hits, and they come out perfectly aligned every time, The savings the EBe has provided us have been huge. A number of our parts that ‘were formed on the press brake required two men and took six minutes for each man to make the part. The EBe does it in 60-90 seconds...and it is more accurate, NEW MARKETS...MPROVED ATTITUDES “This is the busiest that we have ever been," concludes Roitmeler. “The Prima Power nquipment hex allowed to sec out new customers and seek out different mar Kets, The equipment also has improved our accuracy, delivery times, the volume of our work throughput, .and some nititudes too, Our guys are now working an batter equipment, And they are happier to work with reduced manual labour and a different skillset that requires them to be computer savvy.” Be FERUARY DOTS ‘er nadernet aPT oe Tn Re aa Mitel MTEL} Corre me) Don Boitson KEYNOTE SPEAKER) TIME: 9AM - 10AM bo OCR Cm elt SNE ee Fao] ea ; pa SgA AME ticinfagelan Aerospace Lied ¢’ | MAG ELLAN Fed Cr aa oi ae a RO 5» Ac © Meee METALWORKING 1. COQUITLAM, BC! be , BC! xo CIC tele eerie Cilla Ly 2080 United Blvd. Coquitlam, BC The Metalworking Manufacturing & Production Expo will attract regional buying influences SRE w ge Mn eae cos ae U eer SR resources, medical manufacturing, transportation and tool-die moldmaking, TRUMPF Ellicstt SPONSOR: Renee TTY By maith) ele NN WN] LVR ATT (416) 510-5225 * RSwan@canadianmetalworking.comFINE DETAILS es ()- ee SURFACE ROUGHNESS To contact or not to contact BY DOUG PICKLYK. se re alworking manufacturing, the measure ment of surface finish is a complex subject with multiple standards for defining the various elements of roughness, w other parameters required for the descrip. tion of machined surfaces. For decades the use of diamond-tipped contact profilometers have been the standard tools used to mea. sure surface finish qualities, but as optical technologies have evolved the introduction of more detailed surface topography images are being made available for extremely demanding applications where surface finish readings are critical. nrc omplant inspection The typical contact surface measurement instruments come in a variety of shapes and sey sizes, including handheld portable devices and eet dedicated bench type machines, and because of their relative affordability and ease of use, these instruments continue to be the most common tools used for surface metrology. Peter Detmers, vice president sales with Mitutoyo Canada, has been involved with doing surface roughness measurements for some 25 years, He relates a long-term stan. dard used for measuring the roughness aver- age (Ra) of a component would involve using a stylus-type profile measuring device and. measuring a 0.8 mm cut-off five times, and depending on which parameter you're using, the Ra number is generated from those five different sections. Unlike the stylus on a turntable which follows a groove and converts vibrations into sound, the stylus on a profilometer moves in a linear path and moves up and down over the surface and the device calculates surface roughness or other topographical data from the variations, “Most of the standards in the industry were written around the contact-type technology, a 2D reading,” says Detmers. ‘Surface finish has an effect on many differ ent aspects of a part's functionally, Detmers suggests that- most shops in automotive, aerospace and even general machining will ‘have at least one if not many portable pro- filometers on the floor as well as dedicated bench-top units ‘These surface measuring tools are used to read surface finish on external surfaces and internal surfaces, including small bore holes. And manufacturers of stylus instruments have made tips very small to get into those types of surfaces. ‘Accylinder bore is a common example used for the importance of surface finish, Ifa piston and the bore contact each other even. tually they're going to weld together, so the bore must be able retain oil to keep a viscous layer between the cylinder and the bore. In measuring the bore, the desired surface would have low peaks and deep valleys to hold the oil, ‘The most recent developments in sty. Ius-hased measurement has inchided the integration of surface finish probes into com- mon CMM (coordinate measuring machines) Renishaw has the REVO SFPI probe, a tip-sensing probe for use on its REVO mea- suring head and probe system. Mitutoyo also has its SURFTEST probe which can be fit on the rotary head of the Renishaw PH10 system on Mitutoyo's CMM systems. And the Zeiss ROTOS is a roughness sensor that can be incorporated on a Zeiss production CMM, All Sa FEERURY OTS ‘er nadernet ameee The SURFT of these solutions eliminate having to reposition a workpiece on multi pple devices and allow one machine to compile all measurement data into one report. One challenge may be justi- ‘ying tying up an expensive CMM system when a less expensive surface measure, ‘ment tool could he used for” this process. Beyond the stylus, non-contact opti- cal solutions using light to measure the surface of components are capa ble of capturing more finite detail than the stylus tools, and perform the task much faster, ‘The data points compiled by optical Aevices are stitched together to form ‘point cloud which is digitally trans- formed into a 3D topographic image. According to Rob Johnson, prod. ‘uct manager for Carl Zeiss products, ‘with Elliott Matsuura Canada, one area of strong market demand for detailed surface finish accuracy is within the automotive powertrain sector. White light interferometry is one well established technology, proven to be very repeatable with a high degree of resolution, making it suitable as an optical profilometer. Another is the confocal microscope. Novacam Technologies of Point Claire, Quehec, manufactures fier: based optical non-contact 3D profilo- meters tsing low coherence inter ferometry. Novacam’s profilometers allow for high-speed scanning and create surface maps providing detailed roughness data. Novacom has created many small fiber-based probes that can be fed into small diameter hores or challenging environments, allowing the measure. ‘ment of both dimension and rough- ness, Along with the many advantages of the optical solutions come higher costs admits Vuk Bartulovic, presi- dent of Novacam Technologies. He says the technology is being applied in the auto industry today, for high-precision machined parts. “They are producing a lot of parts and the takt time is. quite short, so in many cases you have only seconds to do the measurement,” he says, pointing to the benefit of speed with the optical solution. Bartulovic also notes that recent require. ments from aerospace and automotive call for finer resolutions. Already Novacam’s optical solutions can deliver sub-micron resolution (0.8 micron}, and he suggests that the next generation instruments will go even further, Automatic measurement program generation software MiCAT Planner Call o book your demo today. REDUCE PROGRAMMING TIME UP TO 95%" Mitutoyo Quality on Mitutoyo Canada Inc. MiCAT Planner * Download CAD mod! data and CA cai CAT nner automaticaly creates COSMOS measurement program ‘Tule Edo Function reverts vation between program waters Capa nthpsrnnrgine grap te ‘sarcanadaameatwarng sam FEBRUARY 207555Meee Another high resolution alternative is the confocal laser scanning microscope (CLSM) like the Olympus LEXT 0154100 which has boon optimized for surface imaging, opti cal profilometry and surface roughness According to David Rideout, director of sales and marketing, industrial microscopes with Olympus, the laser is a very small spot size, and confocal removes all out-of-focus light capturing only high-resolution data and then compiles it into one 3D image. “We've sold this solution into the aerospace industzy, automotive, semiconductor, and archeology. For any industry that's look ing at surfaces at a sub-micron level it’s an appropriate instrument,” says Rideout, For the industrial market, Olympus released its 4000 model with the ability to The SFPt surtace filter the data hack down to replicate using entero a regular stylus-tipped contact profilometer. *profilometers have been around for a long time, so there's a well-established comfort level there, When you want someone to try echnology you have to make them comfortable with that new technology,” s Rideout. “One way to do that is to give them ‘what they're used to as you take them to this new level of measurement.” With the advancements of non-contact opti cal technology in the field of surface finish, the ISO 25178 standard has been developed for 2D surface metrology. ‘When comparing an interferometer with confocal, the interferometer offers a better depth of field for reading peaks and valleys, but the confocal is stronger in the xy and at reading angles, says Rideout. ‘He admits the laser confocal process is used more ina controlled environment and is thors af envanalysis tool and nottised much in production For most matalwarking machining wspll cations the fine detail of the optical tools are overkill, and because ofthe large cost differential betsvean stylus fnstriinenta and optical, only if an application demands a non-contact soliton would manufacturers select that option, *Parvof the reason is cont, another part is, where do you put this machine?" asks Detiners of Mitutoyo, who does offer optical solutions as well a tradition contact pro- filomatera: Ha axplaina that becatisa there are optics involved, vibrations can affect the measurement, and if you require a very high resolution measuring capability, you'll ned 4 suitable environment. “im the metalworking industry typically the only time somebody will ever bring up the idea of nos-enntact fn if ha serach leftbehind by the diamond dragging across the part will affect the use ofthat part.” he says. Bd Eee foie ‘00] FEBRUARY 20 ‘er snadanmawa aFINANCE es FINANCING AND YOUR BUSINESS thought it would hea good idea to reflect hack on 2014 and share some of my most fre- quently asked questions, WHY IS MY BANK NOT INTERESTED IN MY BUSINESS? Well it may not be quite that bad, but pretty much any business has some form of banking relationship, even if it’s just for deposits. A bank will look at your business and hang a number on it they feel comfortable with lend- ing. The number is the total amount of credit they are prepared to offer, and it could be a combination of, loans, operating lines or other pur- chasing lines of credit, credit cards, and secured lending. As soon as you hit that number you will be capped. It is no secret your bank will always be your lowest cost of funds, and this is for two reasons: first, the cost of funds for a deposit taking institution these days is less than 1%, maybe even less than 0.5%, and that's pretty tough to beat. For a bank to put out rates a couple of points over prime, their profit mar gin is still very good, and when you are the lowest cost in your industry you can pick and choose who and ‘where you put your dollazs. Secondly, a bank will have you secured in more ways than you probably realize. Tcannot tell you how often I tell one of my customers that even though they have no debt and all of their equipment was paid in cash, their bank still has a first charge against everything via a GSA. (General Security Agroement). A GSA provides a lender a security inter- est in a specified asset or property that is pledged as collateral. In the event that the borrower defaults, BY KEN HURWITZ, the pledged collateral can be seized and sold. It is presented and signed when an account is opened and gives the bank a first charge against all ‘current and future assets ‘As an asset-based lender, come across this often when 1 close a deal by taking a piece of eq) lateral in liew of a deposit. I inform my client I need a waiver from their bank. [almost always get “but I pai for it in cash, I didn’t use my bank to finance it.” Regardless of how banks secure you or your company, they will ensure to always be in an, ‘equity position, meaning the security is always more than the value of the credit provided and/or offered. ‘When it comes to small business Joans, in my world of equipment loans, banks will first look at the size of the transaction and whether it fits the equity box of the company. Specifically, they will look at the ‘company’s total net, or essentially cash left within the company. A bank will think the transaction fits if the net worth is twice the amount of the transaction. However, in the manufacturing industry this type of evaluation is problematic since ‘equipment is inherently very expen: sive and usually purchased when an opportunity for growth comes along, ‘The reality is a bank has a surplus, of cheap money and lots of poten- al investments, there is an excess demand for their services and there fore they can pick the most secure and risk-free investments. ment as col WHY AREN'T YOUR RATES IDENTICAL TOMY BANK? ‘When banks look at a potential transaction they evaluate their exit strategy. For example, let’s take a ‘mortgage. Most institutions will not Jend more than 70-75% of the pur- chase price, but when they do it will be at very cheap rates, maybe 3% ‘or 4%, In the event of a default the property is sold and the hank gets all its money back because they are in a full equity position, the amount, lent is less than the total value of the asset so they are only out the time it takes to get the property sold. A private non-bank leasing company gets its money from a number of ent places, butt is not a deposit taking institution and therefore has a higher cost of funds. The typical leasing company will focus on assets where they have expertise, A leasing company will look at the $100,000 transaction ‘and will expect the company to have retained earnings of $100,000. Also, a new piece of equipment will auto. matically depreciate the moment itis installed. Those two factors equate toa transaction that is riskier than a bank would accept and therefore they will not be priced identically. CAN YOU QUOTE ME A RATE? Getting a quote for financing is as simple as looking up lending rates on a website; itis the approval that actually counts. The only way for any business to got a meaningful ‘plete is once an approval haa been ued oF after enough information has changed hands that whoever is evaluating the transaction can make 2 qualified statement. I totally understand everyone wants to ensure they are getting the best deal at the lowest possible cost, but shopping for financing is as important as sourcing the right equipment. and the same care should be takin to find the right source with expertise and under standing ofthe industry. BD Ken Hurwitz is the Senior Account ‘Manager with Blue Chip Leasing Corporation, an equipment finance company in Toronto. Ken has years of experience in the machine tool industry and now works to help all types of manufacturers either source or tap into their own capital to optimize their operations. Contact Ken at (416) 614-5878 or via email at ken@bluechipleasing.com. Learn more at www.bluechipleasing.com ‘marcanadaametarwarng sam FEBRUARY 20751,