AMT February 2010
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Lead story:
 Manufacturing in 2010: challenges and opportunities
By Nina Hendy
The weak world economy, a modest improvement in the domestic market and the Australian dollar still at high levels are still dampening the manufacturing sector. Many hope manufacturing will again show that it can adapt, build on existing strengths and develop new ones. Featured here are outlines of various assistance schemes including the Government’s Re-tooling for climate change program; the Automotive Australia 2020 project (Victorian Automotive Manufacturing Action Plan); Commercialisation Australia (a simpler form of assistance to companies seeking to take their ideas to market); R&D Tax Concession (simplification and enhancement) - the biggest reform to business innovation support for more than a decade; the Small Business Support Line (providing a single point of contact to access information that assists small businesses on a wide range of subjects); export promotion: the Automotive Market Access Program; AMTIL’s clustering model of export clubs (to help companies work together to access potentially lucrative export markets). An overview of credit agency support includes the Export Finance and Insurance Corporation’s assistance; Industry Capability Network’s list of major projects coming online (representing $60bn worth of contracts) – the projects listed are oil/gas: Ichthys; telecommunication: NBN; Nation Building Economic Stimulus Plan; Giant Magellan Telescope; and Defence: (One of the largest defence projects ever undertaken in Australia is the design, development and delivery of three Hobart Class Air Warfare Destroyers to the Navy.) A realistic look at the challenges ahead is presented; these include the rising costs of electricity; the lack of local raw resources; the exchange rate; skills/training; labour supply; challenging international relations; allegations of dumping onto the Australian market; and an ongoing lag in capital investment. Included also is data from the ACCI-Westpac Survey of Industrial Trends, comments from Heather Ridout: (CEO, Ai-Group); Sen Kim Carr, Minister for Innovation, Industry, Science and Research,; Shane Infanti (CEO, AMTIL); Mike Ramsay of Lovitt Technologies; Peter Nicholls, MD of Production Parts; and Graeme Billings of PricewaterhouseCoopers …
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Congratulations to AMTIL on its tenth anniversary
From Senator Kim Carr …
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Global Engagement Program needed to drive growth
Shane Infanti AMTIL’s CEO stresses the need for the federal government to develop this quickly …
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Ausplas, Austech and NMW exhibitions join forces
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Manufacturing eases in December
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Mori Seiki acquires measuring systems business
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Quickstep appoints former Boeing executive
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Amalgamated renamed
Global Tools & Machines has purchased the Amalgamated Diemould DME business and changed the name and branding to Die Mould Equipment Pty Ltd.
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60 years of Headland
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Monash University wins Formula SAE-A
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Jacinta Allan takes on industry and trade
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Government news:
Commercialisation Australia open for applications
Commercialisation Australia – the Rudd government’s $196m radical new support initiative for home-grown innovation – is open to receive applications. This program will assist researchers, entrepreneurs and innovative firms to commercialise their ideas …
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Company Focus: No tooling around
By Barbara Schulz
Located in Cudlee Creek, (South Australia), F.M. Tool & Gauge started manufacturing tools when the first turret punch machines arrived in Australia – and developed to become one of Australia’s finest high-precision tooling manufacturers today. In order to diversify, the company invested in high-precision machining equipment unique to Australia (the Gildemeister GMX 400 5-axis turn-mill centre), according to Managing Director Michael Kunst ...
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The new light – 50 years of the laser : Eugene Watson
In the 1950s, American laser pioneer Eugene Watson began a love affair with science and technology that continues today. A retrospective look at such personalities as Earl Bell while working at Varian who co-founded Spectra-Physics and was the one who discovered the ion laser and Mr Watson’s commercialisation of the first CO2 laser …
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2010 Product Review
What’s new for 2010?
Despite difficult economic conditions, companies continued to develop new technologies and explore new areas in 2009. AMT wanted to ascertain what products will be hot in 2010. The preview here includes the latest technology, tools, and accessories from Ronson Gears; Techni Waterjet; Camplex; Westgate; Complete Machine Tool Services; ABB Australia; Rockwell Automation; LMC Laser; Dormer Australia; Finlease; Russell Fraser Sales; Turck Australia; Specialised Force P/L; Bestech Australia; Momentum Energy; CNC Design; Capital Equipment; SPLat Controls; Sandvik; Walter; Taegutec; MD Production Technology; John Hart; Sutton Tools; SI Instruments; Australian Warehouse Solutions; Sarix; Fluke Australia ..
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Complete machining of turbochargers
By Hermann Steidle
Innovative tool solutions and machining methods are the cornerstones to efficiently manufacture turbochargers. Mapal has considerable experience in machining demanding workpiece geometries with difficult material properties. In conjunction with a very varied tool program in almost all areas of machining, Mapal has developed a cost-effective method for the complete machining of turbocharger components. This method makes it possible, for instance, to machine all the features for the main bore in the turbine housing in only four steps. ISO combination tools with tangential technology master the machining requirements for the turbine housing. The Mapal interpolation turning tool reduces the cycle time by 60% compared to a chamfering milling cutter and at the same time increases the tool life by 40%. I t was often necessary to also use a lathe in the conventional machining process. Mapal is replacing this time-consuming and expensive machining process using Tooltronic, a mechatronic tool system for machining centres. A PCD combination tool for machining the main bore in a compressor housing made of AlSi8 impresses in practice due to the combination of several machining steps. For the complete machining of this compressor housing, a total of 11 tools are required..…
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Breaking new ground in the treatment of broken bones
By James Rehfisch
When producing surgical implants there is no room for error or compromise. Hence, Adelaide-based medical technology company Austofix invested in a Mazak Variaxis 500-5X II multi-tasking machining centre with Mazatrol Matrix controller and Hyper-Mill CAM software.. Established in 1993 by Dr Tony Ingman, Austofix has grown rapidly from a small family run business with limited facilities, to a publicly listed company that boasts its own state-of-the-art manufacturing facility. One of the latest in a new range of products developed by the company is the Volar Radius Plate. The company did not have the 5-axis machining capability required for this kind of work, and after considering various options, chose Mazak Variaxis 500-5X II. The table can move 150° in the a-axis (movement in the cradle) and 360° in the c-axis (table rotation), thanks to the full cradle design built into the machine’s structure. Within weeks, Austofix was manufacturing complex parts thanks also to the ease with which their designers were able to integrate the HyperMill software into their models and the excellent training, speed of delivery and installation, the level of service and support provided by John Hart …
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Producing high quality threads
By Ute Gutmann
The production of female threads is among the most time-consuming and therefore expensive individual operations. A high level of process reliability is required, as thread production is the final stage of a job, which gives it a certain volatility – if anything goes wrong, the whole workpiece can be at stake. This scenario can be avoided using the right tool combinations and cutting data. “Perfect threads require perfect holes,” say the thread specialists at Walter AG of Tübingen. The merger of the brands Walter, Walter Prototyp and Walter Titex, has brought together all the expertise needed for metalworking under one roof, including all technologies related to the production of female threads. “As thread cutting comprises two separate processes, we want to offer the best tools for both in the form of a complete solution.” Says Timo Mager Threading Product Manager at Walter, and this is it: a Walter Titex Xtreme Plus core-hole drill – with a Walter Prototyp Paradur/Prototex Eco-HT tap. The Xtreme Plus solid carbide drill and the Eco-HT tap represent a benchmark pair for the production of female threads,” says Mr Mager.” In comparison with standard tools they reduce processing times by up to 50%. Most female threads are still produced by thread cutting, but the alternative methods of thread milling and thread forming are gaining ground. This is confirmed, for example, by the Prototyp solid carbide orbital thread mill for threads from M1.6 to M8. In addition to the rotary motion, these tools also work in an axial motion (hence “orbital”). Expert advice is another crucial factor for manufacturers. Walter’s TEC/CCS software represents a comprehensive information pool for both technological and commercial questions. Based on this interconnection, users can not only find the perfect combination of drilling and threading tools, but are also given the costs per thread …
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Machining hard materials
By Moshe Goldberg
The process of machining hard materials has always presented a challenge of selecting a cutting tool insert that facilitates a durable cutting edge and satisfyingly performs, even in tough cutting conditions. In the last two decades, Iscar has developed advanced cutting tool materials for applications such as interrupted cutting (milling, parting and drilling) and continuous cutting operations (turning and threading) for hard materials. Iscar took the challenge one step further and added extra features such as unique geometries and chipbreakers, resulting in the generation of high quality surface finish, which can easily eliminate the grinding process. Here we explore which cutting tool grades provide the best solution for different applications (CBN - IB90, IB85 and IB27; Ceramics - grade IN22; Submicron substrates - Sumo grade IC807, IC903, IC908 …)
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Trends in drilling with spiral drills
The new Mapal-Mega-Speed-Drill permits cutting speeds of approx. 200m/min without a reduction in the tool life or the bore quality when machining steel. At the same time, Mapal claims, the feed can also be increased by around 25%...
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The new light turns 50
By Holger Kapp
In May 1960, Theodore Maiman ignited the first laser flash. In December, laser pioneer Charles Townes received the Nobel Prize. The new era that was promised was a long time in coming. The article takes us on a historical journey exploring the laser’s milestones and key personalities: (Charles H. Townes, James P. Gordon, Carl Haas, Ali Javan Donald Herriott, Arthur L. Schawlow, Dr. Hans-Josef Haepp, Jürgen Held, Prof. Berthold Leibinger, the ruby laser, the helium neon laser, semiconductor laser, Messer Griesheim, Coherent, the Welding Institute, Trumpf, the copy nibbler, the NC machine, Held Systems, the First laser cutter on show at IMTS, Strippit, Siemens, Autz + Hermann)…
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Staying ahead of the game
By Philip Talbot
When Sydney-based FJP Manufacturing decided to improve its bending capabilities, Manufacturing Director Colin Johnsen turned to Amada and installed a HDS 1303-NT Hybrid Drive press brake The HDS features hybrid drive technology, a blue toothed digital protractor and digital calliper, as well as a bar code reader. “The digital protractor and digital calliper have to be seen in action,” Colin Johnsen (Director) says. “With them the operators can do a quick set-up and then measure the first bend, and if it’s not on the money, the information is sent to the controller that makes any required adjustments automatically.” …
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Cost-efficient laser cutting
From Trumpf: A special feature of the TruLaser 1030 is that the user can choose between a beginner’s and a professional level. As a result, people without laser cutting experience can operate the machine. It can also be used as an inexpensive training machine…
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CAM software aids move to 5-axis machining
Messier-Bugatti, a leading provider of aircraft braking systems, France, has switched to Delcam’s PowerMill CAM system to support its move into 5-axis machining, saving programming time and avoiding programming errors by reducing the number of manual operations …
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New methodology to reduce emissions
Autodesk has developed a new and more rigorous methodology for corporate greenhouse gas (GHG) target setting, by developing the Corporate Finance Approach to Climate-Stabilising Targets (C-Fact) to align its own GHG reduction targets with global scientific and policy climate stabilisation targets. Autodesk has committed to C-Fact through to 2020, as well as performance reports against the stated target at the close of each fiscal year (FY). Using the new methodology calculation to set targets for FY10, Autodesk will reportedly aim to reduce its absolute emissions by 4.52% compared to FY09, translating to 3756 metric tons of GHG.
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Oldfields streamlines business processes
By Gillian Yeap
Oldfields’ challenge is to meet expectations when running a business with multiple divisions, thousands of product lines, and a diverse set of clients and suppliers spread across Australia and overseas. At the heart of Oldfields’ business is Pronto-Xi, enterprise resource planning software that features a comprehensive set of tools to manage the company’s business processes, including financials, sales, manufacturing and supply chain management. Using a solution that incorporates Pronto-Xi Mobile Sales, Oldfields’ sales team can go to the customer site, scan in the stock items directly from the shelf, talk to the customer to agree and finalise the order, and have it wirelessly dispatched to the warehouse where a picking slip is printed out. “The removal of the drudgery allows the sales person to use the time to discuss matters with the customer that enhances the relationship and offer the potential to increase sales of existing or new products,” says Paul Camillos of Oldfields …
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3D modelling broadens design services
Brisbane-based company Jaws has improved its parts design productivity by up to 40% since switching to 3D computer aided design and manufacturing software SolidWorks through Intercad ...
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AMTIL FORUM
Strategies: Global competitiveness – manufacturing & sourcing overseas
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Law: Major reform under the Fair Work Act
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OHS: New work health & safety regulation on the horizon
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Tax: Federal government R&D tax incentives
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60 years with men and machines
By Fred Colvin (1867-1965)
AMT presents part 1 of a regular series of instalments from the book “60 years with men and machines” – the autobiography of US machinist and author Fred Herbert Colvin (1867-1965). Mr Colvin, who wrote the book in 1947, will take us on a journey starting as a 15 year-old apprentice in a Philadelphia machine shop in 1883, up until 1950, the peak decades of the machine age. His firsthand experiences in the 19th to mid-20th century machine tool industry are sure to give us unique and fascinating insights into a bygone era which laid the foundations of the industry today…
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AMTIL INSIDE
Editor’s, Ministers’ and President’s messages
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10 years of AMTIL – Past to present
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AMTIL news
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Member Profile – High Speed Engineering
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